BCS100 Capacitive Height Controller User Manual
Contents
1. 22 PE P ccu 22 7 5 Config FIG EE 22 OscillOSCODe eddie tute tut tu t 23 Installation InstructiOhs ioter hene RR ran eee Rea E RYE re Need kun 24 Introduction to Accessories essesssessssssseseeenee eene entren enhn en tnn enn 24 Installation Size Unit mm nnne enne nenne 24 2 L Preamipliflgrz iet eeiam ten el 25 2 2 Master controller a c tee teet ee eter n a eR Een n v teens 26 Wiring INSEFUCKIONS Rm 27 3 1 Interface LayOuts 2sc c cccccciesccccaaseteceaeded cceaecedeceaecedededecedacesededededecedededecabedebecanes aed 27 3 2 Power Interface INStructiOnS ccccesseeeeeeeeneeeeeeceseeeeneceeaeeseaeeseaeeseaeeeeseeeeeaeenes 27 3 3 Servo connection and setting ccesscccsesseecesssseceesseeeesssssecesesseeeesseeeeesssseeenes 28 3 4 Description of Input and Output Interface eeeesesseeeeeeennennenne 37 3 5 Description of Sensor Interface cccccccsssccesssseceessseecesssssecesesseeeessseeeesssaeeesees 37 Deb ggihng Steps tmi i animer e abt iei isse EERE 37 Alarm process and EAQ nieto ene rio d xh d ae do Re T xx cbr n RR 39 o BCS100 Capacitive Height Controller T 1 System alarm analysis c ccccecsscccsssssecesssscecesssseecesssseecscaseceseaeeeeeseaeeeesssseeeeseseeeesenaes 39 1 1 Z Z limit enable iet entes ote recte ett ete e eter Cedere bt e2. BCS100 Capacitive Height Controller lt Schneider Lexium23D or Fuji A5 1 represents the servo of Yaskawa V or Delta ASDA series 2 represents the servo of Teco JSDEP series The principles of zero speed clamp logic of input and output signals and system control parameters are different when the servos are different Logic of limit input Set the logic of limit input port IN5 6 0 normally opened 1 normally closed Logic of General input Set the logic of universal input port IN1 4 0 normally opened 1 normally closed IO control mode If it is set to be 0 the follower will move down when INI is enabled while the follower will shut when INI is disabled If it is set to be 1 after INI become disabled the follower can move up only after setting IN3 to be enabled The parameter is ignored when using network communication 5 6 Network Settings Press to enter the interface of network settings as shown below IP Address 616 661 661 188 subnet Mask 255 255 255 006 Gateway 6146 661 61 B61 Het Enable F3 Orie SB NE I ENT ISAVE When using CypCutlaser cutting software of our company lift up by arbitrary height leapfrog segmented punching flying light path compensation and other advanced functions can be easily achieved through the network See the manual for CypCut software for details When not using CypCut software please shut down the network or start u
3. Pm 4 SPR TROR shielded wire in ci v gt 1 gt ea J re forte PA d LSS Z NIN NIN iz Hs co Role c1 o GND on L Be j op 02 z Z Epi ERR os f2 i Cso 5 CR 7 i 31 Corresponding to the wiring modes above the servo parameters are set as follows Panasonic A5 series Parameter Recommended Description No value Pr001 I Control mode It must be set speed mode Pr002 3 Real time automatic adjustment The recommended setting is vertical axis mode Pr003 17 Servo rigidity the recommended range is from Grade 14 to Grade 20 Pr302 500 Input the gain of speed command Pr315 1 Enable zero speed clamp function 9 BCS100 Capacitive Height Controller e Wiring diagram of Yaskawa servo BCS100 servo interface Yaskawa Z V servo 50 pin interface shielded wire D 1 A A A Le ls rr 93r E H rr r HH 4 35 Heee E 33 1315 HER Hg s 2 gt 41 Sc Ie ee a ar 1 rr 7 i rs He E a d ABE CHEFA COA e e Yaskawa X V series Parameter Recommended Description No value Pn000 00A0 Speed control with zero position fixation function Pn00B Set to 0100 when using single phase power Pn212 2500 Number of pulses output by the encoder per revolution The pulse parameter of corresponding BCS100 per revolution is 10 000
4. A in temperature Please preheat the amplifier for 2 to 5 minutes and then operate BCS100 controller after the sampling capacitance in the amplifier becomes stable Calibration problem The phenomenon above often appears if the follower capacitance is not calibrated again after replacing the nozzle Nozzle temperature increases abnormally above 1000C because the laser scatter to the nozzle or the blowing is abnormal and thus the capacitance of cutting head changes The follower does not hit the board in intelligent calibration and the actual following height is higher than the setting height Please do calibration after closing the intelligent check option 2 4 The follower cannot move up to the correct height If the follower cannot move up or the lift up height is incorrect users need to first observe and determine whether Z axis coordinates are normal If Z axis coordinates get less obviously it is required to first return to the origin press repeatedly FOLLOW and SHUT and then obverse whether Z axis coordinates are consistent with each other after following to the board If Z axis coordinates continue to decrease there may be a problem in the position feedback of the system The reason may be that servo motor or ball screw and coupling slide against each other resulting in coordinate offset 2 5 Validation error failed ARM upgrading when upgrading Upgrade file may be infected by computer virus 2 6 Followe
5. Dorsal view e USB e Ema L1 m Sensor Input and output Servo Net Power 3 2 Power Interface Instructions 24V OV FG To machine main etal part The machine casing is the negative electrode of the measured capacitor In order to ensure the steady operation of measured circuit it is required to reliably connect FG pin of power interface to the machine casing i e have good conduction with machine casing and preamplifier casing also must have good conduction with machine casing The specific indicator is that D C impedance is always less than 10 Q or the actual following effect may be poor o BCS100 Capacitive Height Controller lt 3 3 Servo connection and setting Baer o0 5 e m2 Q Q 15 14 13 12 11 10 9 Pin Color Signal name 1 Yellow DA with an analog output of 10 10V 2 Blue OS Zero speed clamp 3 Black A Encoder A 4 Orange B Encoder B 5 Red Z Encoder Z 6 Green SON Servo on 7 Green black CLR Clear alarm 8 Brown 24V Power output 9 Yellow black AGND Analog ground 10 Blue black OV Power ground 11 Black white Encoder A 12 Orange black Encoder B 13 Red black Z Encoder Z 14 Purple ALM Alarm signal 15 Brown black OV Power ground l 29 BCS100 Capacitive Height Controller gt Wiring diagram of Panasonic servo BCS100 servo interface Panasonic MINAS A servo 50 pin interface
6. Pn300 6 00 The speed gain of corresponding height controller is 500 r v min Pn501 10000 Zero fixed value Pn50A 8100 Forward rotation is enabled Pn50B 6548 Reverse rotation is enabled 31 BCS100 Capacitive Height Controller Wiring diagram of Delta servo BCS100 servo interface Delta ASD A servo 50 pin interface shielded wire A S M GND 9 E ES w j Re ie m JSN ho ININ ofw Jor Joe N M co bo B ERU A iH Aa a e IE eR s UNE up 4 LL 1 d Hj NI eae Delta ASD A series Parameter Recommended Description No value P1 01 0002 Control mode It must be set to speed control mode P1 38 2000 Set zero speed clamp value to the maximum P1 40 5000 The speed gain of corresponding height controller is 500 r v min P2 10 101 Set DII to SON normally opened P2 11 105 Set DD to CLAMP normally opened P2 12 114 Set speed command to external analog control P2 13 115 Set speed command to external analog control P2 14 102 Set DI5 to ARST normally opened P2 22 007 Set DOS to ALRM normal close o BCS100 Capacitive Height Controller Wiring diagram of Teco servo BCS100 servo interface Teco JSDEP servo 50 pin interface s per a eal Teco JSDEP series Parameter Recommended Description No value Cn001 1 Control mode It must be set to speed c
7. The speed gain of corresponding BCS100 is 500 r v min P1 46 2500 Number of pulses output by the encoder per revolution The number of pulses of corresponding BCS100 per revolution is 10 000 35 BCS100 Capacitive Height Controller lt Wiring diagram of Fuji ALPHAS servo BCS100 servo interface Fuji ALPHAS 26 Pin interface Fuji ALPHASseries Parameter Recommended Description No value PA 101 01 Control mode It must be set to speed control mode PA 108 2500 Number of pulses output by the encoder per revolution The number of pulses of corresponding BCS100 per revolution is 10 000 PA 115 17 Servo rigidity the recommended range is from Grade 14 to Grade 20 PA 303 02 Forward rotation is enabled PA 331 6 0 The speed gain of corresponding height controller is 500 r v min o BCS100 Capacitive Height Controller Wiring diagram of SANYO R servo BCS100 servo interface SANYO R 50 Pin interface Parameter Recomme Description No nded value SY08 01 Speed control mode Gr0 00 00 Auto tune Gr8 25 5000 Speed gain The speed gain of corresponding BCS100 is 500 r v min Gr9 00 00 Motor rotate CW enable Gr9 01 00 Motor rotate CCW enable Gr9 26 00 Shut down servo gain switch GrB 13 0 GrB 14 0 GrC 05 2500 8192 Number of pulses output by the encoder per revolution The number of pulses of corresponding BCS100 per
8. eeeeseesessss 43 2 5 X Validation error failed ARM upgrading when upgrading 43 2 6 Follower moves up without contacting the board during calibration 43 eo peri BCS100 Capacitive Height Controller Chapter 1 Introduction to Product 1 Introduction BCS100 capacitive height controller hereinafter referred to as BCS100 is a high performance control device which usedclosed loop control method BCS100 also provides a unique Ethernet communication TCP IP protocol interface it can easily achieve many functions with CypCut software such as automatic tracking of height segmented piercing progressive piercing edge seek leapfrog arbitrary setting of lift up height of cutting head Its response rate is also improved greatly Especially in servo control aspects its running speed and accuracy should obviously be better than other similar products owing to dual closed loop algorithm of speed and position 2 Performance Description Sampling rate 1 000 times per second Static measurement accuracy 0 001 mm Dynamic response accuracy 0 05 mm Following range 0 25 mm The signal will not decay with strong capacity of resisting when the length of signal transmission cable is up to 100m Support network communications and U disk online upgrade Adapt to any cutting head and nozzle Support alarm while hitting the board and beyond the edge Support edge detection and automatic
9. to enter the interface of lt edge settings gt as shown below Saturation Speed Fes mm s Cut In Check mm Cut gut Check mm T ut Out Delay m Fi JHEIGHT ENT ISAVE Parameter name Description Saturation speed The max speed to follow down after head cutting out of board to prevent deep drop damage Cut in check When check the H is lower than this parameter the head start follow Cut out check If it is checked that H position is larger than cut cut out check Cut out delay and last more than cut out delay Height Through cut height Set the Z position to locate to before following 6 Test Interface On the main interface press lt F3 gt to enter the interface of lt functional test gt as shown below LCA BCS100 Capacitive Height Controller Input 1234567 Outputs 123456 keyboard ncodem direction error Users can test whether the state of keys input and output ports and the rotation direction of motor are correct After completing the installation for the first time users must enter the interface for switch jog to determine whether the rotation direction of motor and the director of encoder signal are correct If the rotation direction of motor is incorrect users need to modify the servo direction parameters in mechanical parameters and then conduct open loop jog to determine whether the direction of encoder signal is correct If it is pr
10. BCS100 Capacitive Height Controller Chapter 3 Installation Instructions 1 Introduction to Accessories Capacitance control system is composed of BCS100 controller preamplifier laser cutting head and cable as shown below m V Accessory name Number Standard type Optional type Master controller 1 BCS100 Preamplifier 1 BCL_AMP Thermostable cable 1 SPC 140 140mm SPC 180 180mm Sensor signal cable 1 HC 15 15m HC 15 20m Servo drive cable 1 C15 2 5 2 5m C15 1 5 1 5m C15 4 4m DB15 plug pin 1 DB15M DB15 plug jack 1 DBI5F Manual 1 2 Installation Size Unit mm eee 25 BCS100 Capacitive Height Controller lt 2 1 Preamplifier The appearance and installation size of preamplifier is as shown below Appearance of amplifier l l eo m 03 54 31 Installation of amplifier co BCS100 Capacitive Height Controller 2 2 Master controller The appearance and installation size of preamplifier is as shown below Front view 236 225 BCS100 V3 0 BCS100 V3 0 controller gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt gt BEES T Eq E 2 ae 4 Q o po o r ES 4 04 5 217 34 8 a Top view 5 eft view eee 27 BCS100 Capacitive Height Controller lt 3 Wiring Instructions 3 1 Interface Layout The detailed interface layout of BCS100 wiring terminal is as shown below
11. first time do servo calibration first Then return origin do capacitance calibration At last do self adjustment At the next time do capacitance calibration is enough 4 1 Servo Calibration The purpose of servo calibration is to eliminate the zero drift of servo motor Press the key lt 1 gt to enter the interface of lt servo calibration gt as shown below Please confirm the Mechanical parameter iz right Jog to the middle of z axis 2 885 258 Low ENT IBEGIN During servo calibration the motor vibrates back and forth with small amplitude so it is required to first jog the motor to the mid travel and thus prevent from exceeding the travel range while vibrating And then press lt ENT gt to begin calibration POLIO LING Servo calibrate successful ie S ENT ISAVE The system will return to the previous interface after completing the automatic LCA BCS100 Capacitive Height Controller calibration 4 2 Capacitance Calibration The purpose of follower calibration is to measure the corresponding relationship of capacitance and position between the follower and board Press lt 2 gt to enter the interface of lt follower calibration gt as shown below Please jog to approach the board feep board staticsno vibration F4 SET ENT ISTART If no setting has been conducted before press lt F4 gt to set calibrated parameters Calibrate Distance Board material F1 metalia re Re ENT Sav
12. revolution is 10 000 eo BCS100 Capacitive Height Controller 3 4 Description of Input and Output Interface RENE NEUES C aerou C 9 10 11 12 13 14 15 15 pin male input and output interface Pin Signal definition Pin Signal definition 1 24V Power output 9 IN7 General input 2 IN8 General input 10 IN9 General input 3 OUT Cutting in place 11 OUT2 Stay to position signal 4 OUT3 Alarm 12 OUT4 Punching in place 5 IN1 Cutting tracking 13 IN2 Move to aligning coordinate 6 IN3 Quick lift up 14 IN4 Stop 7 INS Upper limit 15 IN6 Lower limit 8 OV Power ground Notes 1 Output ports OUT1 OUT4 are all open drain output and they are connected with the power ground for outputting 2 Input ports IN1 INO9 are all active low level input and the input is enabled when the input ports are connected with the power ground 3 When the cutting head punches to place OUT4 will output a desired signal with a width of 200ms When the cutting lead follows to the cutting height OUTI will output continuous desired signal 3 5 Description of Sensor Interface 1 Connect with pin 1 of the cable o 2 Connect with pin 2 of the cable 3 Connect with pin 3 of the cable 4 Connect with shield of the cable 4 pin signal transmission cable of sensor can be manufactured with 3 pin shielded cable and 2 4 pin air plugs It is required to
13. Ones BCS100 Capacitive Height Controller User Manual Shanghai Friendess Electronic TechnologyCo Ltd www fscut com Ver3 22 o BCS100 Capacitive Height Controller e Thank you for using our products This Manual describes BCS100 capacitive height controller in details including system features operation installation instructions etc If you want to know more about CypCut laser cutting software that can improve the performance of height controller while using together please refer to the help documents of the software For any other information please contact us directly Please read the Manual carefully before using the controller and relevant devices so that you can make better use of it in future Along with continuous updating of product functions there may be some differences between that you received and the Manual We will apologize for any inconvenience aes 3 BCS100 Capacitive Height Controller Conten Chapter 1 1 2 Chapter 2 1 2 3 8 Chapter 3 1 2 4 Chapter 4 ts Introductiorto Product eret eere ree ERR LASATA EAn EEAS 5 TapdreTolUTodfe 1mete 5 Performance Description cc ccccsssssecessececesseseecessesecesscesesessnsensessnsesessensesessesensesanees 5 Operating Instructions ussseesesesseeeee eee eene nnne nennen eene nnn nisse eene nnnnnn s 6 Description Of KeyS nneseeetehseteetutefu LLL fe LE Ee 6 Functional Hierarchical Graph iiie ene as Rr ti
14. ameter is interpreted in Chapter 2 5 5 The alarm reason includes gt Cut out of the board There is nothing to follow below gt Board is vibrating heavily 1 12 Sample capacity large When sampled capacity is larger than the largest capacity in calibration the alarm happens The reason includes gt The spray touched the board below There is water in cutting head Connection is not fixed In the internal of cutting head the positive of capacity spray is short circle with the negative of capacity the shell of machine 1 13 Expiration of time There is no more time permitted to use this system 1 44 Battery lost lock When unpacked the battery of the unregistered controller the alarm happens User can remove the alarm by registering the controller 115 Jog nearby board When jogging the follower near the board the alarm happens 2 FAQ 2 Obvious vibration and mechanical shock in the following movement Amplifier casing or controller FG pin are poorly connected to the machine casing Machine casing is the negative electrode of the measured capacitor When the conductivity of amplifier casing and machine casing is poor the AC impedance between the positive and negative electrodes of the capacitor is large Thus the load of measured circuit varies which may lead to larger measurement error If good mechanical connection cannot be achieved users can add a wide wire copper material is better between amplifier
15. ch as 201111180100 Expiration The remaining time for BCS100 such as 30 days or unlimited Current Time BCS100 current internal date We will release a new version of the program regularly The update step is shown as below 1 Find a U disc format it to FAT FAT32 we don t support NTFS format 2 Copy the upgrade files to the root directory of the U disc do not rename the files For BCS100V2 0 there is two files named lt BCS AFM gt and BCS FFM For BCS100V3 0 there is only one file named lt BCV3 AFM gt 3 Insert the U disc to BCS100 s USB interface 4 Reboot the BCS100 Method 1 Power off then power on Method 2 Use the restart function 5 Wait until upgrade progress bar 100 finish then the buzzer beep 6 Remove the U disc Check the software version When the service time of BCS100 expires alarm information service time expires will be displayed on the main interface and key functions cannot be implemented such as following Users can press F1 to register and enter lt registration interface gt and then continue to use the height controller after inputting the correct registration code TUE BO4274G6 3HG124 PL input 28 register code ENT JCONFIRM 7 2 Alarm Information Press lt 2 gt to enter the interface of lt alarm information gt as shown below LCA BCS100 Capacitive Height Controller 7 sensor enable 84 28 B9 3 n Fi ICLEAR In this interface t
16. citance calibration is done There is a board below the head to be followed The course of adjustment is follow again and again to optimize the internal parameter The optimization result is as shown below Adjust finished Follow Down Gain Lw 26 219 ENT ISAVE Press lt ENT gt to save the parameters The meaning is as shown below Parameter Description The larger it is the faster head follows Too large level will Follow down result in large deceleration This parameter can be only set by gain lv self adjustment And follow level parameter is also set at the time after adjustment 5 Parameter Interface On the main interface press lt F2 gt to enter lt parameter interface gt as shown fees BCS100 Capacitive Height Controller below TECHHIC 5 MECHANIC SFEED 6 NETWORK ORIGIN 7 ALARM JOG 8 EDGE Users must correctly set the parameters above when using BCS100 for the first time Especially mechanical parameters should be set correctly or the system cannot work normally 5 1 Technical Parameters Press 1 to enter the interface of technical parameters and the first page is as shown below 2 Rana ock position Aaa Aa mm Mid position ABA aa mm Punching height 18 68 mm TENT INext The descriptions of parameters are as shown below Parameter Description ZRan Set Z rang Immediately stop when exceeding the travel during d running and
17. connect Pin 1 2 and 3 together and connect Pin 4 to shielding layer during the manufacturing process 4 Debugging Steps After the installation users need to debug the controller as follows Set servo parameters See servo parameters in Chapter V for details After powering on and completing the initialization enter the parameter interface o BCS100 Capacitive Height Controller hd and set mechanical parameters Go back to main interface to check whether the travel switch is enabled If it is an optoelectronic switch the interface will display upper limit is enabled when blocking the upper limit with shade it will display lower limit is enabled when blocking the lower limit Enter test interface to conduct open loop jog and check whether the rotation direction of motor is right If the direction is wrong please change the servo direction parameters And then conduct open loop jog again please change the encoder direction parameters if the encoder signal is inverse mechanical parameters Enter calibration interface and conduct servo calibration to eliminate the zero shift of servo Return to the origin manually and turn on the power on reset function on the interface of reset parameters Enter calibration interface and do capacitance calibration for the follower Modify other parameters as required after completing the steps above eo aa BCS100 Capacitive Height Controller Chapt
18. e Parameter Description Calibration It is required to record the capacitance data within the range for calibration and the default is 25mm When the travel of Z axis is too Distance short users can appropriately reduce the value Board Set the material of the following object material Press ENT to save the parameters and return to the previous interface Before calibration first fog the follower and make it close to the board larger than Imm from the board and keep the board still without vibrations Then press ENT to begin calibration Calibrating Stability Excellent Smoothness Excellent Effective value 423 ENT ISave The calibration process can be done automatically within ten seconds Users can press the lt Stop gt button to forcibly terminate the calibration After the calibration is complete there are two standards and four grades of excellent good not good and poor are respectively set for each standard The automatic calibration steps are as below SS 11 BCS100 Capacitive Height Controller lt 1 Head moves down slowly and checks if board is hit 2 After head hits the board moves up for 2mm checking the stability 3 Head moves down slowly and checks if board is hit for the second time 4 If board is hit head moves up for the calibrate range checking the smoothness and the capacitance characteristic If one of the steps is not ex
19. ecuted and there is alarm after calibration hardware or connection problem should be considered An easy way to check the problem is touch the spray by metal and see if capacitance changes If the change is low in 200 or the capacitance is always 0 hardware or connection problem is proved In addition considered to safe and static electricity factor touch the spray by hand when system is powered is not recommended The meaning of calibration result is as below Stability It reflects the static characteristics of the capacitance If the standard is not ideal after calibration the reason may be due to the vibration of the board or strong external interference Smoothness It reflects the dynamic characteristics of the changes in capacitance during calibration These two standards at least should be medium or the system may not be able to be used normally In relatively ideal conditions the two standards should be excellent or good Effective value It s difference of capacity from 0 5mm nearby board to infinity If the value is large follow precision and stability is better After pressing lt ENT gt to save the calibration results capacitance distance curve will be displayed Normal curve should be smooth as shown below If the curve is not smooth with downs or glitches the results are not ideal and re calibration is required If the results are still not ideal after repeated calibration users should reexamine t
20. elow Direction Of Servo Direction f Encoder a Servo Type a PANASONIC MITSUBISHI ENT HEXT Press lt ENT gt again Page 3 is as shown below Logic of limit input a Normal open Logic of universal input CHormal open I0 control mode a tHo lift signal ENT Save The descriptions of parameters are as shown below Parameter Description Lead screw pitch Set the travel of the transmission mechanism per revolution such as screw pitch lead In theory the greater the screw lead the faster the running of Z axis and it is recommended to use the ball screw with a lead of 5mm Max RPM rotate speed per minute Set the allowable upper limit of rotational speed of servo motor according to the characteristics of motor and load Generally it does not exceed 4 500 rev min Speed voltage gain Set the actual rotational speed corresponding to each volt The speed should be consistent with the parameters in the driver and the recommended value is 500 rev min corresponding to each volt Pulses per round Set the number of pulses fed back by the encoder of servo motor per revolution The number should be consistent with the parameters in the driver Direction of servo Set the rotation direction of servo Direction of encoder Set the direction of pulse feedback of encoder Servo type 0 represents the servo of Panasonic A5 Mitsubishi J3 series
21. en ro xia o Race cdi 7 Main Dorica oc 7 3 1 Hidden Functions of Main Interface esesssesssssseeseeeeeeee enne enne 8 Calibration Interface rre er ine Pee rre RD AR reris a ree RE RR ERES 9 4 4 Servo CalibEatlOTiz ote ente rn ete yon ar ee EXE hr ng Re E eR VENE Rus 9 4 2 Capacitance Calibration oi ie ttes tette distri ie ten Dee de es tede Uds 10 4 3 Selfadjustment uusu a endisse ece esae deae credi era ende eacus daa aate ced 12 Parameter interface isis ici cs reor de er reine ER eR ee Erde eget 12 5 1 Technical Parameters snan anaana aaa a aaea aa eaa a Aa AiE 13 5 2 Speed Parameters ete detti eed ee ee 14 5 3 Origin Parameters sssrinin annene iiaii aE 14 5 4 Jog Parameters nn e RR E REN NIMM RR ERN RA NR RR d ate 15 5 5 Mechanical Parameters ro rr ee nea ee re i edv e eene 15 5 6 Network Settings esce eiectibo etes beiet ttes intet bein tede cnet eiie eee ese eU ru 17 5 7 Alarm Settings soiirci etnisen ioiei apaiia iaka edat daban eios 18 53 Edge Settihgs one ea tur I LE 19 Test Interface cett t ER REPE Lr ERN ERE ERA NRURR vs ERE AROEN 19 Interface of Advanced Settings cccccccsssscccsssseceesssseecessseeesssseeeesseseeessseeeessseeeesees 20 7 1 Product Information esssessseseseesseeeeeee enne entente nnne entes intent 20 7 2 Alarm InformatiOnDs sciri ere YR Herr RE Re SERRE ETE E FRr ee RH 21 7 3 Restart voissa
22. er 4 Alarm process and FAQ 1 System alarm analysis 11 Z Z limit enable When system checked Z Z limit input is enabled the alarm happens The reason includes gt Z Z sensor detect something gt Z Z sensor is broken Or it is used for long time there is oil contamination and powder on the surface gt The parameter of Limit logic can be set to normal open or normal close gt The wiring is not correct 12 Out of Z range When Z moves large then range which is a parameter of system the alarm will be throw out If it is wrong alarmed take attention in the range parameter if the system returned origin and if the encoder feedback is correct 13 Z limit continue enable When system is returning origin it moves back when z sensor is enabled but can t quit the z sensor enable area the alarm happens Take attention if the sensor is broken 14 Z limit continue enable When system is returning origin it moves back to positive axis but come to the z sensor enable area the alarm happens Take attention whether the Aligning coordinate or Dock coordinate is too large 15 Servo alarm When system checked NO 14 input ALM is enabled which reflect the servo alarm status the alarm is shown on the screen The reason of servo alarm includes The servo alarms The Servo Type parameter is not correctly set Wiring is not correct Electrical system disturbs the wire VVV WV 1 6 Encoder moves abnormally When sy
23. ght output port 1 will give a constant effective signal 5 2 Speed Parameters Press lt 2 gt to enter the interface of speed parameters as shown below Moving Speed Gals mm s acceleration 4 58 G Max follow ENT ISAVE The descriptions of parameters are as shown below Parameter Description name Movi Up Down Speed of Follower The recommended setting is that the ser ovin 2 d d vo motor should run close to rated point so as to improve efficiency a spee nd ensure stable running of system Acceleration Set the acceleration of follower for following and moving The Max Following Speed It depended on Acceleration and the type Maxfollow of the nozzle The value increases with the increasing Acceleration and becomeshigher with the higher capacity sensitive nozzle 5 3 Origin Parameters Press 3 to enter the interface of Origin parameters as shown below cmi BCS100 Capacitive Height Controller n Jhen Power n Bet Dock Poss Ine er org LURK ac ios Afte Ea jno F3 lyes org Speed Tes mm Return Distance ga 5mm ENT S VvE The descriptions of parameters are as shown below Parameter Description Whether to origin after Set whether to automatically reset after power on and set power on the option to be Yes after debugging Whether to return to Set whether to go back to the set dock position after dock position completing reset Or
24. give an alarm of Out of Z Rang h locati f the foll letel ing th DockPosition Set the target location of the follower after completely processing the program Mid Position Set a coordinate mu move to the coordinate through pressing lt lt gt and lt gt gt on the main interface Puschleioht Set ihe spacing distance between the follower and board during punching movement 99 66 When the cursor selects the parameter of aligning position stopping coordinate or Z axis travel there will be one more menu for F1 And press F1 to set the current parameters by jog mode Press ENT for the following page and continue to set process parameters The second page is as shown below LCA BCS100 Capacitive Height Controller ollow F2 punch first F3 Increment Punch Delay TELE ms Punch Speed 45 8 mm s ENT ISAVE These parameters are mainly used in I O control mode These parameters will not take effect in Ethernet control mode The descriptions of the parameters are as shown below Parameter Description IN1 following When input port is effective direct following mode is used that mode is punching delay following Punching delay Delay time during punching Progressive sped Speed when progressively follow to the cutting height When dropping to the punching position output port 4 will give a 200ms of effective signal When dropping to the cutting hei
25. he hardware installation and wiring of the system In addition users can view the calibrated curve after pressing button lt 6 gt on the main interface If calibrate failed alarm is as shown below Alarm Description When calibrating if the cutting head moves down and check no board is hit in long time there will be this alarm How to check what happened First ensure the head is near the board before calibration in about 5mm Next check if the hardware and connection are right Last try to do calibration again If the head does not Hit board over time LCA BCS100 Capacitive Height Controller move when calibrating maybe the resolution ratio of analog voltage output is not enough You should try to modify the speed voltage gain less Leave board Check if the hardware and connection are right overtime Sample overtime Do calibration again Always hit board Please refer to Leave board overtime alarm Capacity changes Do calibration again Take care jog near the board at abnormally about 1 5mm before calibration 4 3 Self adjustment Press lt 3 gt to enter the interface of lt Self adjustment gt as shown below i Please confirm capacitance servo calibration and orain have been done 2 Please confirm that a board elow can be followed ENT IEEGIH Before adjustment it should be confirmed as below Servo calibration is done gt Origin is done gt Capa
26. he previous alarm events are displayed in a list The system can record as many as 20 alarm events Users can clear the alarm list after pressing lt F1 gt Users can refer the meaning of each alarm to Chapter 5 7 3 Restart Users can press lt 3 gt to restart BCS controller This operation is equal to that the system is powered down and then powered on Users can first insert USB disk to BCS when they want to upgrade the program and complete the upgrade with restart function which can avoid the trouble to power down and then power on the system 7 4 System Settings Users can press lt 4 gt for system settings and then enter the interface of lt system settings gt after inputting the password of 61259023 APPlication C203 Language Enalish User Config Poram Protect ENT JSAVE Parameter Description Application 0 plane cutting applications 1 3D cutting application Language 0 Chinese version 1 English version User er Special customization function configuration 0 Parameters are not encrypted 1 Parameters are encrypted Parameter protect Users need to enter the password if they want to modify the parameters Password 11111111 7 5 Config file Press lt 5 gt to enter config file interface is as shown below eal BCS100 Capacitive Height Controller 1 Import from USB disk 2 Export to USB disk 3 Delete boot logo The function of configuration file include
27. igin speed Set the fast movement speed to go back to the origin Set the return distance after touching the origin switch This Return distance ND location is coordinate zero 5 4 Jog Parameters Press lt 4 gt to enter the interface of lt jog parameters gt as shown below Jog Speed Low Aas mms Jog Speed High 425 mm s Software Limit F2 off ENT ISAVE The descriptions of parameters are as shown below Parameter Description Jog speed low Set the speed of Gear L during jog movement Jog speed high Set the speed of Gear H during jog movement Determine whether or not to enable the soft limit while setting jog If used the soft limit should not jog to the position of negative Software limit coordinate or below the following height so as to avoid hitting the limit or board during jog movement Soft limit protection function only becomes effective on the main interface Only the jog function on the interface of lt test gt is open loop controlled The jog function on the functional testing interface will not be affected when encoder signal is abnormal 5 5 Mechanical Parameters Press lt 5 gt to enter the interface of lt mechanical parameters gt and Page is as shown below o Lead Screw Pitch Max RPM Speed voltage Gain Pulse Per Round BCS100 Capacitive Height Controller mim r min r min v F zd Press ENT Page 2 is as shown b
28. inspection Automatic calibration process with fast and easy operations Support leapfrog and segmented piecring Support oscilloscope functions to detect the capacitance in real time VVVV ON VVVVV VV The comparison of new and old products are shown as below Performance index BCS100 V2 0 BCS100 V3 0 MaxMoving Speed 400mm s 999mm s Max Acceleration 0 4G 2G Capacitance Mutation Restraint 5 10 Min Inflexibility Requirement SHz 2Hz DA Resolution 12 bit 16 bit DA Zerodrift 16mv 3mv DA Response Time 5ms 0 01ms Positioning Accuracy 0 05mm 0 01mm o BCS100 Capacitive Height Controller Chapter 2 Operating Instructions i Description of Keys Keyboard Function Functional EJ R29 IESU EISA oiim Achieve the functions prompted by the key interface Te E220 3 Number key 4 5 6 Decimal point 7 8 9 Backspace ou es key Used for digital input and mainly for parameter input A Arrow key eee v NT T Used for switching cursor and inching follower and the key of SHF can switch the jog speed co RERO mmm mb o dw FAST 40 1 STOP ENT d Hp REE ERA HUM SLOW 0 1 ORG ESC lt SHUT gt The cutting head will automatically rise to the stop position i i Il l Conid key while shutting the follower lt FOLLOW gt Open the following function FAST and SLOW Used for adjusting the following gain level lt 0 1 gt and lt 0 1 gt Used for adjusting
29. le i EMT HEXT Limit amp larm Enable ENT ISAVE Parameter Description name It is the maximum allowable following error of BCS100 After the cutting head is in place the controller will give an alarm for too large following error if the following error exceeds the set alarm value due to the movement beyond the plate boundary or severe vibrations of board Max follow deviation a BCS100 Capacitive Height Controller lt Set the filter time of following error alarm The greater the value Max foll i d i aah the slower the response and the stronger the ability to filter out et interference When the follower hits the board and the duration reaches the time Hit board m dela limit the follower will automatically move up for protection and d output alarm signal This parameter indicates if hit board alarm is active when the f follower is in stop state It is safer when the value equals 1 And Stop hit alarm enable when you need to adjust the center of laser by stick adhesive tape or when you do not want the controller always alarm in no plastic film it is convenient to set it to 0 When it is set to be 1 upper and lower limit alarm function will be TEF started The follower will automatically move up when Limit alarm encountering upper lower limit and then give an alarm signal When it is set to be 0 alarm function is disabled 5 8 Edge Settings Press lt 8 gt
30. metal casings to reduce AC impedance The AC impedance of single point connection is greater than that of good mechanical connection It is o BCS100 Capacitive Height Controller lt required to make the AC impedance less than 10 ohms gt Too large servo rigidity Mechanical shock and obvious vibration may be caused during the movement due to too large servo rigidity For example it is recommended that the servo rigidity of Panasonic MINAS AS series should not be above Level 19 gt Too large following speed level Vibration may be caused during the movement due to too large following speed level Level 3 to 7 are recommended gt Poor follower calibration When the data stability and smoothness of capacitance and position stored in BCS100 is poor vibration will be caused during the following movement Please do follower capacitance calibration again until the stability and smoothness becomes excellent or good gt If there is a large interference at the field users can appropriately reduce the parameter of servo gain coefficient 2 2 The follower always hits the board during in following movement gt Too small calibration range or too large Z axis speed The smaller the calibration range the smaller the deceleration distance of following movement If Z axis speed is too large and it is not reduced to 0 when the follower flows to place overshoot will be unavoidable The greater the Z axis speed is the greater the oversho
31. n cutting head gt The local capacity of the cutting head is large which is out of the check range of the preamplifier The preamplifier is broken Connection is not fixed gt In the internal of cutting head the positive of capacity spray is short circle with the negative of capacity the shell of machine gt gt 1 10 Local capacity small When local capacity changes less the alarm happens The reason includes gt Connection or some part is changed or moved You can do calibration again gt Laser shoots on the spray the temperature gets very high is short time Man s hands can t stay on the pray gt Blow leads to the change of distance of positive pole spray and negative pole shell of the machine Connection is not fixed The parameter of calibration range is low can also lead the alarm In 2D mode 15mm is recommended And 10mm is recommended in 3D mode 41 BCS100 Capacitive Height Controller A gt One of the reason is the cutting fire and electronic affects the capacity sensor when the boardmaterial is stainless steel If there is plastic film on the surface of steel remove the film first Check if the machine is connect to the ground well The following height should be large than 0 5 mm Improve the blowing pressure 1 11 Follow deviation large When system check the H height the distance between spray and board changes large in short time in follow state the alarm happens The relative par
32. ocessing D Follow The follower follow the board while conduct punching and cutting operations E Origin Go back to the mechanical origin of Z axis F Jogging Manually jog Z axis G Lift up It is the process to shut the follower off and lift it to the stop position Following gain level The level of following gain ranges from 1 to 30 The large level is the smaller average error is the quicker follow acts and the stronger slope move ability is But if gain is too high there may be self oscillation It is recommended to set this parameter by self adjustment Following height The actual following height can be adjusted with a step of 0 1mm after pressing the button lt 0 1 gt and lt 0 1 gt The following mode can be changed through pressing lt SHUT gt and lt FOLLOW gt After pressing SHUT the axis will automatically raise to the stopping coordinates it defaults to the position of Z 0 the stopping coordinates can be modified after pressing lt F2 gt to enter the parameter interface In addition in the Ethernet control mode the following height is set by CypCut software Dynamic error In the following state this value reflects the real time error during following movement Distance H between follower and board surface Within the capacitance measurement range calibration range the distance between follower and board surface is following height plus dynamic error When exceeding the measuring range se
33. ompted that the direction of encoder is incorrect users need to modify the encoder direction parameters in mechanical parameters The input and output ports of the interface are defined as below Input Definition Outpu Definition port t port INI Follow to cutting height OUTI Signal for following to place IN2 Move to aligning coordinate OUT2 Stay to position signal IN3 Lift up signal OUT3 Alarm output signal IN4 Stopping signal OUT4 Punching signal IN5 Negative limit OUTS Servo clearing alarm servo signal IN6 Positive limit OUTS6 Servo enabled servo signal IN7 Servo alarm servo signal OUT7 Zero speed clamp servo signal 7 Interface of Advanced Settings On the main interface press lt F4 gt to enter the interface of lt advanced settings gt as shown below 1 PRODUCT INFO 4 SYSTEM SET 2 ALARM RECORD 5 CONFIG FILE 3 RESTART 7 1 Product Information Press 1 to enter the interface of product information as shown below aS BCS100 Capacitive Height Controller Version ID 261111156166 Expiration 2815 82 28 CurrentTime 2014 85 18 1 Users can view the following on this interface Information Description For example v3 0 3032 is program version number 2D represents Version being used for plane cutting 3D represents being used for 3D mechanical cutting ID number BCS100 global only serial number Su
34. ontrol mode Cn002 2 1 Automatic gain Note It is the parameter of the second figure of Cn002 Cn005 2500 Number of pulses output by the encoder per revolution The number of pulses of corresponding BCS100 per revolution is 10 000 Cn026 4 Rigidity Level 4 is the default n216 4000 Speed gain The speed gain of corresponding BCS100 is 400 pes 33 BCS100 Capacitive Height Controller w Wiring diagram of Mitsubishi MR J30A servo BCS100 servo interface Mitsubishi MR J30Aseries Mitsubishi MR J30A servo shielded wire Parameter Recommended Description No value PAO 2 Control mode It must be set to speed control mode PA15 10000 Number of pulses output by the encoder per revolution The number of pulses of corresponding BCS100 per revolution is 10 000 PC12 5000 Speed gain The speed gain of corresponding BCS100 is 500 r v min PC17 0 o BCS100 Capacitive Height Controller Wiring diagram of Schneider Lexium 23D BCS100 servo interface Schneider Lexium 23D 9 son Schneider Lexium 23D Parameter Recommended Description No value P2 10 101 Servo INI function SON P2 11 0 Servo IN2 function Not used P2 12 5 Servo IN2 function ZClamp P2 13 P2 17 0 Servo IN4 IN8 function Not used P1 38 400 It s 40 0RPM the zero compare value P1 01 2 Control mode It must be set to speed control mode P1 40 5000 Speed gain
35. ot is When Z axis speed is greater than 100mm s it is recommended to set the calibration range to be 15mm When Z axis speed is greater than 250mm s it is recommended to set the calibration range to be 20 to 25mm gt Too small servo rigidity Servo response may lag behind the control signals of controllers due to too small servo rigidity and thus the follower will hit the board For example it is recommended that the rigidity of Panasonic MINAS AS series should not be below Level 13 Capacitance calibration The follower will hit the board when there is a large deviation between the capacitance stored in BCS100 and actual measured capacitance For example the nozzle temperature increases a lot or the connection is not stable Users need to first find the reason and then calibrate capacitance again after solving the problem No preheating Please preheat the amplifier for 2 to 5 minutes and then operate BCS100 controller after the sampling capacitance in the amplifier becomes stable gt The locking nut of ceramic part is not connected tightly The locking nut of ceramic part is not connected tightly which may lead to instable detecting capacitance 2 3 The following height is different from the actual height No preheating Please preheat the preamplifier for 2 to 5 minutes and then operate BCS100 controller The sampling capacitance in the preamplifier may changes with the changes eee 43 BCS100 Capacitive Height Controller
36. p process will become slow When using the network functions it is recommended to directly connect PC and BCS100 by crossed wire IP address of PC should be in the same network segment with BCS100 10 1 1 xxx which cannot be same to BCS100 The gateway should be set in the same network segment and the last number should be 1 such as 10 1 1 1 As shown below BCS100 Capacitive Height Controller Internet Protocol TCP IP Properties General You can get IP settings assigned automatically if your network supports this capability Otherwise you need to ask your network administrator for the appropriate IP settings Obtain an IP address automatically Use the following IP address IP address 10 1 1 8 Subnet mask 255 0 0 0 Default gateway 104 Be wet uel Note When the computer is connected to other network equipments concurrently such as IPG fiber laser network connection mode and each equipment should be set in different network segments For example the equipments can be respectively set to be 10 1 2 x and192 168 1 x 2 After the IP of network card is reset please disable enable the network card again so as to make the IP settings of the network card to take effect 5 7 Alarm Settings Press lt 7 gt to enter the interface of lt alarm settings gt as shown below Max Follow Deviation 45 8 mm Max Follow Delay AASA ms Hit Board Delay EID mz Stop Hit Alarm Enab
37. r moves up without contacting the board during calibration Please check the follow material is set to metal or nonmetal
38. s gt Copy parameter of specify machine to all same type machines gt Make boot logo of BCS100 gt Back up BCS100 s parameter Make notice of gt Use a USB disk with FAT FAT32 format gt The configuration file s format is xxx CFG When import file from USB disk make sure there is only one CFG file at the root directory of the disk gt The file export to USB disk named EXPORT CFG If there is a file EXPORT CFG in the USB disk before exporting This file will be covered 8 Oscilloscope Oscilloscope function is one of the unique functions of BCS100 Users can enter the interface of lt capacitance oscilloscope gt after pressing lt 5 gt on the main interface The principle of the oscilloscope is to display capacitance value C in real time It also displays the maximum value MAX minimum value MIN difference between the MAX and MIN DIFP and average value AVE of the measured capacitance As shown below M HM p n imh JGI J Le cw ut T a Em Der m To p J PICT hob mz lt FILTER tis Please observe the changes of capacitance while keeping the cutting head and board stationary The greater DIF value the greater the interference or the more unstable the capacitance is Users can determine the interference size in reference with the values below Interference size DIF value 0 10 None 10 20 Very little 20 30 Little 30 50 Average 50 WE Large ca
39. sito evt eO 39 1 2 QutofZranmge o E E E E en 39 13 Z limit contin e enable ett eter ee ee re ree tan eee unn 39 14 Z limit continue enable eere enne nnne nne nnns entrent 39 I MEME OCIEmEE 39 1 6 Encoder moves abnormally ccscccccssscccessseeeesssseeeessseecesssseeessseeeeessseeeesssaeeess 39 1 7 Encoder no respornse eiie dr o op A cr Va ERA EE RE EKE 40 1 8 Encoderdeviation large ere e teretes son reste re EORR RUNS 40 1 9 Capacity iSO arenei Hess cecus e oe ebe giae aiana CREE ER Ode MAR eaa ER ERE Le AR HR eR e RR EROR 40 1 10 tocal capacity small oret rrr trigo erba E ERR ERR Ed 40 1 11 Follow deviation large nc rete tr e chen eec recent d 41 1 12 Sample capacity large ssessssssssesssseseseeeee enne nennen nnne nnne nnns entis entes 41 1 13 Expiration of time isis eceiecese ces eceb e abonar era bed aeLa aia dana cand 41 1 14 Batteryilostlockus de redo d e teintes tet 41 1 15 Jog nearby board iicet eet cn Ro eot E AREE 41 2 O 41 2 1 Obvious vibration and mechanical shock in the following movement 41 2 2 The follower always hits the board during in following movement 42 2 3 Thefollowing height is different from the actual height sussssss 42 2 4 The follower cannot move up to the correct height
40. stem keeps in stop status the encoder feedback value changed there will be this alarm The reason lead to the alarm includes gt The axis vibrates by outside force gt Wiring wrong the zero speed signal does no effect o BCS100 Capacitive Height Controller lt gt Servo rigidity is very low gt The encoder wire is disturbed The shield is needed and should be connect to the ground Add some wire magnet ring is better 1 7 Encoder no response The system try to move send out speed command as voltage but the encoder feedback value does not change at all The alarm happens The reason includes gt Wiring error gt Servo type is wrong Servo must have speed control mode gt Servo parameter is not correctly set It should be switched to speed control mode 18 Encoder deviation large When thedifference between destination position and feedback position is too large the alarm happens It reflects the servo can t follow the speed command correctly The reason includes gt Encoder feedback direction is wrong The relative parameter should be modified Wiring error or disturb make the encoder feedback wrong gt The mechanic is stuck the really position can t follow the destination position 19 Capacity is 0 When system can t check the capacity of the spray the capacity value is shown as 0 on the screen The following situation may cause the alarm gt The spray touched the board below gt There is water i
41. t following height plus dynamic error is identically equal to the calibration range Current Z axis coordinates After homing to origin a mechanical coordinate system is established at Z axis The coordinate will increase when moving down Current capacitance value C The principle of systematical sampling is to get the distance through measuring the capacitance between the follower and polar plate The closer the follower is to the board the greater the capacitance value is The capacitance will change to Zero while the follower hits the board Jog speed of Z axis lt L gt represents low jog speed and lt H gt represents high jog speed The jog speed stalls can be switched through pressing the button lt SHF gt You can press the buttons lt 1 gt and lt gt to jog 3 1 Hidden Functions of Main Interface Key Functions asl Ip BCS100 Capacitive Height Controller 3 Set follow parameters 4 Real time following error oscilloscope 5 Real time monitor oscilloscope of capacitance 6 Capacitance distance curve T Record the current capacitance 9 Start the follower of edge cutting 0 Set the current Z axis coordinates to be 0 4 Calibration Interface In the main interface press the key F1 to enter calibration interface as shown below SERVO CALIBRATION CAPACITANCE CALIBRATION SELF ADJUSTMENT After BCS100 was installed and sued as
42. the following height STOP Immediately stop all movements ORG Immediately implement the movement to go back to the origin and correct mechanical coordinates ENT Confirm the current operation ESC Cancel the operation and go back paeem BCS100 Capacitive Height Controller 2 Functional Hierarchical Graph The functional hierarchy of BCS100 is as shown below Servo calibrate Calibrate Capacitance calibrate Self adjust Technic Speed Origin Jog Mechanic z c t Alarm Edge Test Version Alarm info Advanced Restart System set 3 Main Interface It will automatically enter lt main interface gt after the system is powered on and the initialization is completed as shown below Dynamic Error Follow level 1 9 Function Current State top lv 5 Follow height EB Spr BB HBB Z coordinate gt FEES pers RO eT calibrate Current Capacity Cina22088 Parameter Jog Speed o BCS100 Capacitive Height Controller ET lt The displays on the main interface include Current status display the current motion state of the following system The motion states are as follows A Stopped Z axis is in an idle state B Decel There will be a very short transition state for slow stop after receiving a stop instruction in motion state It will change into stop state after completely stopping C Moving It is the movement of Z axis while lifting up during pr
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