AC651 Manual - Paw-Taw
Contents
1. EMILE jm Li LI oooooooooo ooooooo SEN a 000000000000000000 3 Transterm 5 handheld terminal to single card rack PEPEEEEEPPPEPEPEPE EHE ELE et E E Copyright 1998 Paw Taw John Services Inc INTRODUCTION 4 PLC with TTL input out modules interfacing to AC651MB rack For further information please contact Paw Taw John Services Inc at 208 687 1478 Copyright 1998 Paw Taw John Services Inc INTRODUCTION 1 CONFIGURATION OPTIONS 486DX computer to AC650MB card rack TE2. vidual Temposonics probes to a standard scale This value is preset at Paw Taw John Services Inc position Minimum Limit MIN LIMIT sets the minimum allowed cylinder 3 Maximum Limit MAX LIMIT sets the maximum allowed cylinder position 4 Number of servos OF SERVOS is used to set the number of axis or servos in the system 1998 Paw Taw John Services Inc INITIAL SYSTEM SETUP 12 5 MAXVEL INC 1 TO 99 determines the amount of drive to the servo valve in the turn on portion of drive 6 MAXVEL DECREASE determines the amount of drive to the servo valve in the turn off portion of drive 7 JOG X determines if this module can be jogged ENTERING SYSTEM PARAMETERS The parameter mode is used to set up the dynamics of the servo loop Tem posonicse calibration starting offset valves or calibration of the hydraulic cylinder to the 0 of the machine and other selected functions To enter this mode do the following 1 Depress CLEAR S2 and P keys in sequence 2 Display will show the following 1998 Paw Taw John Services Inc TM INITIAL SYSTEM SETUP 13 3 To sequence through the parameter mode depress SPACE To se quence the display in reverse depress DELETE The cursor will be present at the beginning of the values that can be changed To enter a new value key in the new number on the keypad Then press the ENTER key to send the n
3. and GAIN operating parameters An example of cylinder action is demonstrated in the graph below where a target position change was made from 1 to 11 by a cylinder with a travel rate of 5 per second The graph on the next page illus trates the effects of acceleration and deceleration which are necessary to produce smooth start and stop without objectionable jerks or over shooting Refer to the Servo Output curve for the following discussion Cylinder movement begins with the servo output signal from the AC650 card controlling the servo valve by supplying an operating current The Acceleration ACCEL parameter sets the rate at which cylinder speed increases This is demonstrated by the rising part of the curve The Acceleration parameter can be set to any value be 1998 Paw Taw John Services Inc INITIAL SYSTEM SETUP 10 tween and 50 The higher the value the faster the acceleration and the quicker the cylinder will jerk to full speed b When the maximum desired operating cylinder operating speed is less than the cylinder maximum Maximum Velocity MAX VEL may be set to prevent an over speed condition The Maximum Veloc ity may be set at any number from 0 to 99 which is demonstrated by the flat part of the curve C At some point prior to reaching the new target it will be necessary to slow the cylinder to a stop gradually This is done in two stages as shown on the following edge of the curve The first stage c
4. green DTD red DRD black DRD yellow GRD blue 12VDC white DRO jump to RD DTR jump to CTS Should questions arise call Paw Taw John Services Inc Phone No 208 687 1478 Anytime Paw Taw John Services Inc TROUBLESHOOTING PROGRAM IC REMOVAL AND INSTALLATION Changes to system hardware or requirements for additional software func tions may make it necessary to change the Program Integrated Circuit IC which operates the AC651 While this may happen seldom or never we are including procedures for this change IC REMOVAL PROCEDURE l Using a small screw driver insert under bottom of Program IC be tween the IC and socket and lift up area 2 shown below Lift ap proximately 1 8 2 Position small screw driver at area 1 shown below between the IC and socket and lift up 1 8 3 Continue between areas 1 and 2 shown below lifting IC further from socket until it comes completely out NOTE This procedure prevents the pins on the program IC from getting bent INSTALLATION l Check the new Program IC to be installed has all pins straight both vertically and horizontally 2 Orient the IC matching the indent on one end to the indent on the IC socket Refer to area 1 of the below drawing Align the pins of the IC to the socket With one finger push the IC into the socket GENTLY pope CAUTION If the pins don t align up properly they can be bent during inst
5. 3 Care should be taken if the value of R18 must be changed A quali fied electronic technician should be used to perform the change or the AC651 card s may be returned to Paw Taw John Services Inc 4 Refer to the drawing and table below should it be necessary to change servo output current Note Each AC651 card must be matched to it s own servo valve 1998 Paw Taw John Services Inc INITIAL SYSTEM SETUP 3 AC651 SERVO OUTPUTS Current Adjustment Servo Valve R18 Resistor Current Required Value 39K ohm 50K ohm 82K ohm 100K ohm 180K ohm 5 Install all AC651 cards in their correct positions with the Master in the left most position Note the card connectors are keyed to prevent incorrect orientation VOLTAGE TESIS AND WIRING CHECKS Refer to figure above for the tests and checks that follow 1 Remove all AC651 cards from cardrack before applying power 1998 Paw Taw John Services Inc INITIAL SYSTEM SETUP 4 2 Apply AC power to system and verify correct DC voltages are present at power terminals on the AC651 cardrack per table below AC651 CARDRACK VOLTAGES Terminals Voltage From To Minimum Maximum 5VDC GND 4 9VDC 5 2 0 15VDC GND 14 9VDC 15 2VDC 15VDC GND 14 9VDC 15 2VDC 24VDC 24V RET 5VDC 30VDC Input Output Supply Voltage 3 Turn off AC power 4 Verify
6. MTS Temposonics transducer connections are correct per drawing 5 Verify SERVO and SERVO lines are present at the correct termi nals per drawing 6 Verify that 150 ohm resistors are installed Between the REC REC and XMT XMT terminal pairs of the GSC 1 and GSC 2 terminal blocks TRANSTERM 5 TT5 Keyboard SETUP 1 Install the keypad cable between TransTerm 5 and KEYPAD jack face of the left most AC651 card master position 2 When power is applied the TransTerm 5 should beep three times The top line will display the AC651 firmware program name date and whether the AC651 card is a master or slave The bottom line will initialize for a moment and then display a card status message PRGMNAME 1 15 95 MASTER SYSTEM OK 3 A TransTerm 5 register check should be conducted next to make sure the TTS is set to properly communicate with AC651 cards It is nec 1998 Paw Taw John Services Inc INITIAL SYSTEM SETUP 5 essary to switch to the setup mode by entering the following key strokes S2 blue key S1 red key and S2 blue key The top line shows SR indicating the setup register mode and two se quential counts from 1 to 8 to mark data bit positions The bottom line of the display shows which of the four registers SR1 SR4 is active the data for that register and the blinking cursor at the first new data entry position Each register contain
7. These computers are interfaced to the AC651 cards via a high speed dual channel interface card PC1 mounted inside the 486DX computer and communications cable This system interface is used for more complicated system controls All setup and operational characteristics are controlled from the computer 8 PLC s These machine controllers are interfaced to the AC651 cards via a 16 point DC output module connected to a 16 point terminal strip located on the AC651MB card rack A data strobe is also required from the PLC to strobe data into the AC651 cards AC651 SERVO CONTROLLER CARD FEATURES AND Copyright 1998 Paw Taw John Services Inc INTRODUCTION 5 ELECTRICAL SPECIFICATIONS The AC651 servo control card is used for linear positioning and hydraulic servo valve control It is used with PLC s as a external servo controller A PLC can control 1 8 axes per bank FIRMWARE FEATURES e Isolated 17 inputs 5 32VDC e Non volatile memory storage so no battery backup is required e High speed RS485 RS422 SDLC serial port Baud rates of 1 2 m standard e Low speed RS 422 serial port accessible through a 6 pin phone jack Baud rates of 2400 to 19 2k e Digital interface to MTS Temposonics linear transducers e Provides 0 100 mA current output for Servo valves e Has 10vde output capability e Dip switch auto null selection e Addressable Dip switch settings for up to 8 axes per bank e Red status LED s mounted
8. With the Transterm 5 cable installed in the master AC651 phone jack depress Clear gt 1 and note the TO1 position and P position Increase the gain value in the parameter mode by 5 and enter a change in the set value from the set panel Observe the cylinder reaction and note the TOI and P readings The readings should be within 004 of each other Continue increasing the gain value until the cylinder becomes erratic or enters a condition called hunting The cylinders oscillates When the hunting condition is reached decrease the gain value until the oscillations stop While making set changes from the set panel adjust the ACCEL and DECEL values until the desired response is obtained Increase the MAX VEL INC and MAX VEL DECREASE values until the desired speed is obtained Repeat 1 through 11 for axis 2 and so on Minor adjustments might be needed for each axis after all cylinders are adjusted Using the parameter value entries stated above adjust accordingly Proceed to the Offset Calibration Procedure for alignment of the cylinders to the machine Paw Taw John Services Inc SERVO LOOP SETUP 2 OFFSET CALIBRATION PROCEDURE To adjust the OFFSET Calibrate the set system to the sizes to be cut use the following steps 1 Enter set values from the set panel for each axis Example 4 000 inches 2 Depress CLEAR 1 3 The TransTerm 5 disp
9. actual position are within 050 Check for mechanical or objects preventing the completion of the set TRANSTERM 5 TROUBLESHOOTING The TransTerm 5 is a complete terminal capable of all functions encountered on a normal personal computer system The unit can be powered using a 12 volt external power unit or powered can be applied to the D 25 connector The AC651 is usually jumpered to supply this voltage through the 6 pin telephone jack Listed below are troubles that are sometimes encountered and solutions TROUBLE SOLUTIONS Unit displays erroneous characters Check the terminal for proper configuration Unit displays cursor in upper left Check the connections between the terminal corner of display only and the AC650 With power applied the terminal The terminal is I O bounded Try another doesn t display a cursor or characters AC651 board or replace the terminal or doesn t beep three times when powering up To check the terminal for proper configuration depress S2 S1 S2 Refer to TransTerm 5 operators manual Chapter 6 page 11 TransTerm 5 set up The shift registers are as follows SR1 00000000 SR2 00000010 SR3 00001001 SR4 00000000 OPERATING MODE 001 CONTRAST 007 UNIT ADDRESS 001 TOTAL COLUMNS 024 The DB25P cable is wired per table Check connector for broken wires or other damage and repair as necessary Paw Taw John Services Inc TROUBLESHOOTING 3 TRANSTERM 5 CABLE WIRING Signal Color DTD
10. data is only for the PLCSILNG HEX program on a Rev 3 card or a Rev 4 card configured for active low inputs Paw Taw John Services Inc PLC INTERFACING 5 This system accepts inputs in binary format with input 1 being the least significant bit and input 16 being the most significant bit To make a set the first 3 inputs are used to select the axis Input 1 2 3 4416 1 Grounded 0 Ungrounded While the address is held on the buss the strobe input is pulled to ground and held there with the strobe line held low The address is removed and the set position is presented NOTE The set size is a 16 bit binary value with a resolution of 002 per step For example a set of 37 125 1 37125 2 18562 5 or 18563 2 The value 18563 is converted to binary and presented to the buss as Input 1 23456789 10 11 12 13 14 15 16 111010010001 00 10 Remember 1 Grounded 0 Ungrounded Once data is present on the buss the strobe line is ungrounded and finally the data can be removed Synopsis Present address Pull strobe low Clear address Present data Clear strobe Clear data E e m gt o gt PLC DATA INPUT TIMING NOTE when using AC651 Rev 4 cards it is possible to reconfigure the cards to respond to an active high signal This is not a common mode of operation and as Paw Taw John Services Inc TM PLC INTERFACING 6 shipped from the factory all Rev 4 cards are configured in the active low mode If your car
11. 56 512 1024 2048 4096 8192 16384 32768 PROGRAM PLC51A6 HEX j 0 XKXXX GAIN TOI6 Paw Taw John Services Inc TM PLC INTERFACING 3 2 XXXXX ZROAD 512 XX XXX ACCEL 4 1 4059 8 MAXVEL 0 TO 2047 3 XX XXX EXT TO ZERO IF 1 XX XXX MIN LIMIT XX XXX MAX LIMIT lt o O 2 16 F 3268 PROGRAM PLC51B2 HEX PARAMETERS BIT BIT WEIGHT PARAMETERS T XX GAINITO25 256 XX XXX TEMPOSCALE 2 XX XXX ZERO OFFSET ADJ 512 4 XX DECEL ITOS0 8l 16 XX XXX MIN LIMIT O C 8192 XXXXX SPARE _ O X X X XX ACCEL 1 TO 50 X X X XX MAX VEL 1 TO 99 PROGRAM PLC51D1 HEX So C 9 4 Paw Taw John Services Inc PLC INTERFACING 4 ee XX ACCEL 1 TO 50 XX DECEL 1 TO 50 Above programs PLC51A6 HEX PLC51B2 HEX amp PLC51D1 hex work with probe lengths up to 65 Above programs have 0 001 resolution PROGRAM PLCSILNG HEX Jo oo 2 1 2 XXXXX TEMPOSCALE 8 XX ACCEL ITOS0 A C UTERO 4 C C 1 E 1634 F Above program works with probe lengths up to 130 Above programs have 0 002 resolution Program PLCSILNG HEX doubles bit weights except on addressing values AC651 PLCSILNG HEX DATA ENTRY NOTE This
12. E BEER gee Edges deer dees 3 o a gt Ep o 1 osa Saat omar ase 1 S 2 a Z pd PEE DEEPEN ELE FEEEEEELE Waa aww m SUERTE me 0505000090505059000509006092500009 AC650MB cardrack Communications cable 2 486DX computer to multiple card rack system 1 WI Leen ara S23 LO aay A mum lt lt 3 Transterm 5 handheld terminal to single card rack FFFFFFFFFFFF E TEFEN HE AC651 SERVO CONTROLLER CARD The AC651 servo control card is used for linear positioning and hydraulic servo valve control It is used with PLC s as an external servo controller A PLC can control 1 8 axes per bank FIRMWARE FEATURES solated 17 inputs 5 32 VDC Non volatile memory storage so no battery backup is required High speed RS485 RS422 SDLC serial port Baud rates o
13. Enter Parameter Table Displays Axis 1 Target and Actual Position Displays Axis 2 Target and Actual Position Servo status data screen Shortly after power up of the system the TransTerm 5 will display the fol lowing PLC51D1 04 23 93 SYSTEM OK fal et m 80 5 er ra E 1 Le Ie JL 5 1 O se F7ZJFS At any time the TTS terminal may be placed in or returned to the RUN MODE by depressing the CLEAR key Refer to the above display DEFINITION OF SYSTEM PARAMETERS 1998 Paw Taw John Services Inc INITIAL SYSTEM SETUP 8 COORDINATE SYSTEM 1 Note The AC651 servo control system measures movement of the cylinder in inches The coordinate system can be set up to place the zero refer ence at any point that is most useful The direction of Increasing Po sition can also be selected The EXT TO ZERO IF 1 operating parameter establishes the direc tion of increasing cylinder position When set to one 1 the zero po sition is near the extended end of the cylinder and position increases toward the retract end of the cylinder If EXT TO ZERO IF 1 is set to any value except one the zero value will be at the retract end of the cylinder and position will increase to ward the extended end of the cylinder Temposonics probes are physically 4 5 to 5 0 longer than the actual operating length Please refer to the drawing fo
14. GSC 1 of rack 2 using the following cabling diagram COMMUNICATIONS CABLE INTERCONNECT RACK1 GSC2 RED WHT BLK PAIR GRN SHIELD ARE CONNECTED TO EARTH GROUND NOTE Usually a three pair shielded cable is used for this jumper AC651 CARD ADDRESS SETUP 1 Referring to the AC651 drawing and the DIP Switch Table below adjust the card address DIP switch positions on each AC651 card Dip Switch Area 1998 Paw Taw John Services Inc INITIAL SYSTEM SETUP 1 or or OF f E 6 ON OF ON 6 8 ON ON ON J 8 G CU 7 U s Example for single axis systems address switches 1 2 and 3 are off NOTE Axis 1 is always the MASTER 2 DIP position number 4 is auto null enable When the AC651 card supplies correct servo drive current to counter any out of null conditions the valve might have In this mode the target position and the actual position on the terminal should be within 0 001 AC651 CARD SERVO OUTPUT SETUP l The AC651 servo drive output range may require adjustment depend ing on the type of servo valve being used Refer to the servo valve manufacture s specifications to determine the amount of servo drive current required 2 The AC651 is shipped from Paw Taw John Services Inc factory preset to 30mA A 50K ohm resistor is installed in position R18
15. INSTALLATION and OPERATION MANUAL AC651 SERVO CONTROL MODULE Revised 9 4 98 Printed 11 19 98 PAW TAW JOHN SERVICES INC 18125 N RAMSEY ROAD RATHDRUM ID 83858 208 687 1478 FAX 208 687 4148 888 687 1478 E MAIL pawtaw pawtaw com C Copyright 1998 Paw Taw John Services Inc All rights reserved Paw Taw John Systems Inc AC651 SERVO CONTROL MODULE INTRODUCTION ABOUT Paw Taw John Services Inc ABOUT SERVO CONTROL SYSTEMS Paw Taw John Services Inc SERVO CONTROLLERS TYPICAL SYSTEM COMPONENTS FIRMWARE FEATURES SOFTWARE FEATURES POWER SPECIFICATIONS OPERATING TEMPERATURE CONFIGURATION OPTIONS SYSTEM INSTALLATION SERVO SYSTEM COMPONENTS MECHANICAL INSTALLATION ELECTRICAL INSTALLATION AC651MB RACK DATA INPUTS OUTPUTS AC651 INITIAL SERVO SYSTEM SETUP AC651 CARD RACK CONFIGURATION MULTIPLE CARD RACK CONFIGURATION AC651 CARD ADDRESS SETUP AC651 CARD SERVO OUTPUT SETUP VOLTAGE TESTS AND WIRING CHECKS TRANSTERM 5 SETUP TRANSTERM 5 TERMINAL OPERATION DEFINITION OF SYSTEM PARAMETERS COORDINATE SYSTEM SYSTEM RESPONSE MISCELLANEOUS PARAMETERS ENTERING SYSTEM PARAMETERS TRANSTERM DISPLAY MESSAGES SERVO LOOP DYNAMICS SETUP OFFSET CALIBRATION PROCEDURE AC651 FACE PLATE INDICATIONS PLC INTERFACING TO AC651MB RACK AC651MB RACK DATA INPUTS OUTPUTS PROGRAM DATA SPECIFICS PLC DATA INPUT TIMING TROUBLESHOOTING INITIAL SYSTEM TROUBLESHOOTING OPERATIONAL SYSTEM TROUBLESHOOTING TransTerm TT5 KEYPAD TROUBLESHOO
16. K OUT PROCEDURES MUST BE FOLLOWED 1 Ensure Transterm 5 is connected to the Master AC651 servo card Each AC651 card in the system must have the same parameters loaded 2 To prevent any violent movement when the hydraulics is turned on enter the parameter mode Clear gt S2 gt P and enter the following 06 GAIN XX XXX ZERO OFFSET ADJ MAKE EQUAL TO CYLINDER STROKE LENGTH 25 ACCEL 25 DECEL 00 200 DECEL MIN POS 30 MAXVEL 30 MAXVEL DECREASE X 1 OR 0 FOR STROKE DIRECTION 00 500 MIN LIMIT XX XXX MAX LIMIT ENTER MAXIMUM VALUE THAT CYLIN DERS WITHIN THE LIMITATIONS OF THE MACHINE X ENTER THE NUMBER OF AC651 CONTROLLER CARDS IN THE CARD RACK JOG 1 DEPRESS CLEAR gt S2 gt 4 AND ENTER 1 OR 0 FOR EACH AXIS THAT REQUIRES THE JOG FEATURE 3 After the Master AC651 servo card is loaded remove the cable from the phone Jack and install in the next AC651 Repeat entering the above parameter values Perform this procedure for all AC651 servo cards used Paw Taw John Services Inc TM SERVO LOOP SETUP 1 CAUTION WHEN HYDRAULICS IS TURNED ON CYLINDERS MIGHT MOVE ERRATICALLY UNTIL AIR IS BLED FROM THE CYLINDERS PERSONNEL MUST REMAIN CLEAR OF THE MA CHINE 4 10 11 12 13 14 Turn on the hydraulics and enter a position value from the set panel Exercise the cylinders by changing sets on the set panel until they move smoothly User is bleeding air from the cylinders
17. RAM PLC51LNG HEX Os XX GAIN T TO 25 1 XK XXXE TEMPOSCALE L3 2 4 J XXXXX ZEROOFFSETAD2 L3 8 EIL Above program works with probe lengths up to 130 Above programs have 0 002 resolution Program PLC51LNG gt HEX doubles bit weights except on addressing values Paw Taw John Services Inc PROGRAM DATA
18. TING PROGRAM IC REMOVAL AND INSTALLATION IC REMOVAL PROCEDURE INSTALLATION ON Oo N O N Q N N INTRODUCTION ABOUT Paw Taw John Services Inc Paw Taw John Services Inc is a designer and manufacturer of semi custom servo controller systems and associated components used in wood products and other manufacturing industries The company brings together individuals with decades of experience in systems and software design custom electrical and electronic systems manufacturing and technical sales with expertise in sawmill operation and automation Paw Taw John Services Inc specializes in systems that provide greater user flexibility lower maintenance increased productivity quicker pay back and higher yield Our systems are in use worldwide by companies wanting more intelligence with their controllers Paw Taw John Services Inc systems are easier to setup modify and use in everyday operation than most programmable controllers No special programming language must be learned and all programming may be done from a keypad terminal or 486 computer terminal Our systems also interface with most popular position and limit sensors directly or via economical interfaces boxes we can supply with systems Paw Taw John Services Inc can also control most all popular servo and proportional valves directly This offers a significant reduction in equipment suppliers required to construct y
19. allation Paw Taw John Services Inc TM Program IC 1 1 3 2 For further assistance call Paw Taw John Services Inc at 208 687 1478 Paw Taw John Services Inc Program IC AC651 PROGRAM DATA SPECIFICS The following tables indicate binary bit conversions and specific program data Please refer to this for specific data on specific programs BIT CONVERSION TABLE BIT BIT WEIGHT PROGRAM PLC51A6 HEX L0 1 XXXXX GAN 0TO16 0 8 256 XXXXX TMPADJ 52 XXXXX ACCEL O 0 0 0 0 0 3 8 XXXXX MAXVEL OTO2047 0000000 B 2048 XXXXX EXLTOZEROIF1 0 L9 4 16 XXXXX MN LMT C 5 E 7 F 32768 LC o 5 D E 6 E 4 pe i p R E i 16384 PS 805 Paw Taw John Services Inc PROGRAM DATA PROGRAM PLC51B2 HEX L1 0 XX GANG TO25 j 2 8 29 XXXXX TEMPOSCAE L3 1 JO2 XXXXX ZEROOFFSETAD 4 9 512 XX ACCEL 1 TO 50 XX DECEL 1 TO 50 6 A 1024 XXXXX DECELMIN POS _ 7 j 3 8 XX MAX VEL 1 TO 99 8 B 28 X EXITOZROI I S 9 4 X 16 XXXXX MN LMT 12 D 919 XXX SPARE o PROGRAM PLC51D1 HEX 1 2 4 16 X EXT TO ZERO IF 1 Above programs PLC51A6 HEX PLC51B2 HEX amp PLC51D1 hex work with probe lengths up to 65 Above programs have 0 001 resolution Paw Taw John Services Inc PROGRAM DATA PROG
20. alled De celeration DECEL is used to reduce speed quickly The second stage called Gain GAIN provides a more gentle speed reduction making an easy to stop without overshooting the target d DECEL may have a value between 1 and 70 The higher the value the quicker more abrupt the approach to the target e The transition from the Deceleration phase to the Gain phase is con trolled by Minimum Deceleration Position MIN DECEL POS A number between 1 and 999 determines how far from the final target this happens A larger number makes the transition occur further from the target f GAIN controls the system response while jogging the cylinder in ad dition to holding the setpoint after leaving the Deceleration mode The value can be between 1 and 25 with 5 to 10 being most com mon A high value will give quicker system response but could cause cylinder oscillations A value that is too low will cause sluggish sys tem response and large errors between actual and target position 1998 Paw Taw John Services Inc INITIAL SYSTEM SETUP 11 SERVO SYSTEM RESPONSE E 2 38 8 ow gt tc w o gt gt o 2 o Servo Output 96 Cylinder Position N x N N 2 4 Cylinder Operate Time seconds MISCELLANEOUS PARAMETERS 2 6 2 8 O gt N O OC O N CO O Cylinder Position inches l Temposonic Scaling Factor TEMPO SCALE used to adjust indi
21. an be attained through the serial communications terminal AC651 INITIAL SERVO SYSTEM SETUP HARDWARE CHECKOUT WARNING INSURE ALL LOCAL LOCKOUT PROCEDURES ARE FOL LOWED AC651 CARD RACK CONFIGURATION doom ore zc o 2z o O HPP A Refer to figure above for the following check 1 Ensure 4 Master Jumpers wires are installed near card 1 connector 2 Install if not present NOTE In multiple card rack configurations the second rack has 4 jumpers installed in the Slave locations MULTIPLE AC651 CARD RACK CONFIGURATION Refer to drawing below 1998 Paw Taw John Services Inc TM INITIAL SYSTEM SETUP 1 AE FEPER PEEPI PEPEE dio d v W 5059000000100000 pes ooo 1 Install jumper cable between GSC 2 of rack 1 and
22. ds are configured to respond to active high reverse all the following data The information as shown below applies to AC651 Rev 4 cards in the active low mode and to all earlier revisions Inputting data to AC651 cards must be sequenced by the PLC program in a special format A timing chart is provided below Remember that a low input is active Depressing S1 gt 4 on the Transterm 5 keypad will show the data entering the servo card s m J TIME PERIOD A ALLINPUTS ARE NOT ACTIVE HIGH B INPUT 1 IS PULLED LOW TO PRESENT AN ADDRESS CARD 1 THE AC651 S C THE STROBE IS PULLED LOW TO TELL THE AC651 S THAT THE FOLLOWING DATA WILL BE FOR CARD 7H D INPUT 1 IS ALLOWED TO RETURN TO IT S NORMAL HIGH CONDITION E INPUTS 2 5 AND 10 ARE PULLED LOW TO PRESENT A POSITION TO THE SELECTED CARD F THE STROBE IS ALLOWED TO RETURN TO IT S NORMAL HIGH Paw Taw John Services Inc PLC INTERFACING CONDITION THIS CLOCKS THE POSITION INTO THE CARD G INPUTS 2 5 AND 10 ARE ALLOWED TO RETURN TO THEIR NORMAL HIGH CONDITION FINISHING THE SET If needed please contact PAW TAW JOHN SERVICES INC for further programming information 208 687 1478 Paw Taw John Services Inc PLC INTERFACING 8 TROUBLESHOOTING INITIAL SYSTEM TROUBLESHOOTING Discussed below are some common problems sometimes encountered after installation of a new system TROUBLE When the hydraulics are applied the cylinder ex
23. ew number to the system 4 The following are the parameters that will be scrolled when sequenc ing through the parameters mode starting at the GAIN XX GAIN 1 TO 48 7 9972 TEMPO SCALE XX XXX ZERO OFFSET ADJ XX ACCEL 1 TO 50 XX DECEL 1 TO 50 XX XXX DECEL MIN POS XX MAXVEL INC 1 TO 99 XX MAXVEL DECREASE X EXT TO ZERO IF 1 XX XXX MIN LIMIT XX XXX MAX LIMIT X OF SERVOS 1 8 JOG 1 5 Refer to the previous section Definition of System Parameters for explanation of terms and values 6 NEW ENTRIES SHOULD BE RECORDED ON A PAPER FOR FUTURE REFERENCE 1998 Paw Taw John Services Inc TM INITIAL SYSTEM SETUP 14 7 Press the CLEAR key to exit the PARAMETER mode TRANSTERM DISPLAY MESSAGES The AC651 card status messages have the following meanings Tempo Bad Temposonics transducer system has incorrect or no input to numbered card Bad Module numbered module not communicating or work ing System OK all cards are communicating and working null Bad Null card drive to servo valve is unable to maintain This message can occur during power up or if hydraulic system is not on Overtravel axis has reached software stroke limit This completes initial setup Continue on with the Servo Loop Dynamics Setup 1998 Paw Taw John Services Inc INITIAL SYSTEM SETUP 15 SERVO LOOP DYNAMICS SETUP WARNING WHEN USING HYDRAULICS USERS SHOULD BE CLEAR OF MOVING MACHINES AND ALL LOCAL SAFETY AND LOC
24. f 1 2 m standard Low speed RS 422 serial port accessible through a 6 pin phone jack Baud rates of 2400 to 19 2k Digital interface to MTS Temposonics linear transducers Provides 0 100 mA current output for Servo valves Has 10vdc output capability Dip switch auto null selection Addressable Dip switch settings for up to 8 axes per bank Red status LED s mounted on the face of the board Uses Euro style connector for easy installation in single or multiple card racks Can be interfaced to RS 232 serial communication port through inexpensive converter SOFTWARE FEATURES Custom programs embedded on UV EPROM Programs written to interface card control through a phone jack to dummy computer terminals Programs written to interface card to PC s through high speed serial port Personal Computer PC High speed communications board PC1 available Data presented in thousandths of inches or centimeters Programs written for special applications POWER SPECIFICATIONS t5vdc 5 amps 15vdc 1 amps 15vdc 1 amps When using TransTerm 5 Computer terminal 15vdc 5 amps is required OPERATING TEMPERATURE 40 TO 150 deg F 40 to 66 deg C AC651 MOTHERBOARD The AC651 Motherboard provides housing for up to four AC651 servo controller cards as well as providing hookup location for power inputs outputs serial communications terminals servo and MTS Temposonics Multiple card racks c
25. ht 1998 Paw Taw John Services Inc INTRODUCTION 3 A typical servo system from Paw Taw John Services Inc will be constructed from one or more of the components below 1 System Control Enclosure The servo control enclosure contains a cardrack used for support and interconnection to one or more AC651 Servo Controller Cards power supplies necessary to operate the controller cards and other system components AC power switch and fuses and suitable terminal blocks for connecting external component wiring All of these parts are housed in an NEMA 12 enclosure designed for wall mount Care is taken in design to provide wire ducting so that primary AC and secondary DC may be kept separated The enclosure should be drilled for attachment of conduits during installation Temposonic Probe A linear transducer mounted inside the center of each cylinder used to measure position A magnet that moves with the piston reflects an internal square wave generated at the probe head The reflected wave is processed and provides accuracy to 0 001 inches 3 Recirculation Box The Recirculation box contains a circuit card AC700 that distributes the servo drive and Temposonics signals for a single axis A system may have one or more Recirculation boxes The card controls the number of recirculations that the position signal will make in the Temposonic probe The more recirculations the greater the resolution The AC700 also sets the p
26. it s data cable from the AC651 Typically AC651 cards provide 12 to 15 volts through their 6 pin keypad jacks The 5 terminal has two shift buttons labeled S1 and S2 S1 is Red and when first depressed activates all red characters on the keypad An example would be if a function requires T to be entered first press S1 which acti vates the Red characters then press the I key to send the command The S2 key activates the all Blue characters on the keyboard To enter a P requires first pressing the S2 key to activate Blue characters and then the P key to send the command An example is shown below z e 4 sje in It is a good practice to press the CLEAR key before beginning a command sequence to assure the TransTerm 5 is not already in the middle of a com 1998 Paw Taw John Services Inc INITIAL SYSTEM SETUP 7 mand sequence Single character or word commands in Black on the key board are direct entry commands in that they may be entered at anytime after the CLEAR key has been pressed Refer to the table below for valid AC651 commands entered from the TTS terminal AC651 COMMANDS Command Sequence Function or Action CLEAR Return system to Run mode ENTER Enter values previously typed in SPACE Scroll forward to next entry DELETE Scroll backward to previous entry 131 Data transfer information screen 2234 Enter Servo jog enables 2
27. lays the following T01 XX XXX P XX XXX S XX 12 OK 4 Depress S1 DELETE The display shows the following Paw Taw John Services Inc SERVO LOOP SETUP 10 11 To add 060 to the position of the saw enter 060 Depress EN TER Subsequently each time the ENTER key is depressed the saw will move 060 To subtract 060 from the position of the saw depress S1 F7 The minus sign appears before the offset entry area Enter 060 and de press the ENTER button Again each time the ENTER key is de pressed the saw will move back 060 To change the sign back to a positive value depress S2 F7 The plus sign will reappear before the offset entry area Press the CLEAR key to exit the OFFSET CALIBRATION mode Press 2 on the Transterm 5 keypad This shows positioning and status information for axis 2 Repeat steps 4 through 8 above for axis used in the system Return the Transterm 5 display to the run mode by depressing CLEAR NOTE When product is processed check for users desired accuracy Due to machine inaccuracies some fine adjustments will be needed Follow the procedures stated above This completes the Servo Loop adjustments Paw Taw John Services Inc SERVO LOOP SETUP 4 AC651 FACE PLATE INDICATIONS The indicators on the faceplate of the AC651 servo card provide valuable information about the status of the module The follo
28. minal and 486DX computers are used This feature makes possible on site setup changes or accommodates for mechanical component wear or replacements One final serial communications port allows several AC651s to intercommunicate making possible multiple controller systems that can work in harmony In this manner one command BYTE from a PLC control might permit separate and different actions from two or more controllers simultaneously The AC651 has 16 inputs and 1 output that can operate between 5vdc to 30vdc A 4 position dip switch located on the component side of the circuit board provides the addressing necessary in multiple card configurations and for special functions The AC651 operates from a Firmware program stored in a 28 pin memory IC The card has another memory device for storing set and servo dynamics parameters stroke limits and transducer interfacing information Both of these devices are non volatile so there data is not lost if power is removed The main I O connector opposite of the face of the card is a Euro style 32 pin dual readout This provides the card with flexibility to mount in single or multiple cardrack configurations A complete custom Paw Taw John Services Inc servo control system is built from one or more AC651 controllers Servo systems also typically include power supplies wire and cable terminating blocks suitable enclosures PLC s and custom operator panels TYPICAL SYSTEM COMPONENTS Copyrig
29. on the face of the board e Uses Euro style connector for easy installation in single or multiple card racks e Can be interfaced to RS 232 serial communication port through inexpensive converter Copyright 1998 Paw Taw John Services Inc INTRODUCTION SOFTWARE FEATURES e Custom programs embedded on UV EPROM e Programs written to interface card control through a phone jack to dummy computer terminals e Programs written to interface card to PC s through high speed serial port e Personal Computer PC High speed communications board PC1 available e Data presented in thousandths of inches or centimeters e Programs written for special applications POWER SPECIFICATIONS e 5vdc 5 amps e 15 4 1 amps e 15vdc 1 amps When using TransTerm 5 Computer terminal 15vdc 5 amps is required OPERATING TEMPERATURE 40 TO 150 deg F 40 to 66 deg C CONFIGURATION OPTIONS 1 486DX computer to AC651MB card rack Copyright 1998 Paw Taw John Services Inc INTRODUCTION 7 486DX computer WI rami Bons HHH LE F Z 2 My ay aa ZZ mmm AL AC651MB cardrack Communications cable 2 486DX computer to multiple card rack system ZZ EM
30. our servo system ABOUT SERVO CONTROLLERS A servo control system when applied to positioning is an electro mechanical system that knows where it is at all times and provides for external data input whether from sensors computers or humans to act upon or produce a response to the input Most often in industrial applications the servo system is used to control a linear motion such as positioning of a saw or movement of knees on carriage Each isolated linear motion is referred to as an axis Paw Taw John Services Inc systems are used to control one or more axes Several of the axes may be interactive in multi axis systems such as moving multiple saws simultaneously while still permitting individual saw adjustment Copyright 1998 Paw Taw John Services Inc INTRODUCTION 1 A typical servo control system might consist of a hydraulic cylinder used to move a saw The hydraulic fluid power is directed by a servo valve under the control of the servo controller Some type of position sensor attached to the saw would provide positional data to the controller To make the system usable an operator console might permit the selection of several cut lengths In a real time example the operator could choose a 10 cut width by pressing the 10 button on the console This requests the servo controller via a PLC to move the saw to the 10 position The controller sends a signal to the servo valve to move the hydraulic cylinder in the correc
31. r discussions below The ZERO ADJUST is used to place the coordinate system zero ref erence where it will be most useful for the system It can be set to any value between 0 and 65 If the zero reference is best at the extended end of the cylinder EXT TO ZERO IF 1 1 a value of the probe length plus 3 will place 1998 Paw Taw John Services Inc INITIAL SYSTEM SETUP 9 the zero reference near the extended end of the cylinder tip of the probe Example The 12 probe would need a value of 15 000 to place the coordinate system zero reference near the extended end A higher value will move the zero reference beyond the end while a lower value will move the zero reference toward the retract end If the zero reference is best at the retracted end of the cylinder EXT TO ZERO IF 1 0 a ZERO OFFSET ADJUST value of 12 000 will place the zero reference near the retracted end of the cyl inder base of the probe Values greater than 12 000 will move the zero reference off the base end of the probe while a ZERO OFFSET ADJUST value less than 12 000 will move the zero reference toward the extended end of the cylinder EXT TO ZERO IF 1 and ZERO ADJUST are both set for each axis used in a multiple axis system SYSTEM RESPONSE 1 The ability of the system to respond smoothly and quickly to a target position change is set using the ACCELERATION MAXIMUM VELOCITY DECELERATION MINIMUM DECELERATION
32. robe operating frequency and triggering signal Please refer to Recirculation box manuals for setup and operation information Operator Control Panel The Operator Control Panel is the main user system operating and control interface This panel is typically custom designed and constructed to suit the requirements of the servo system An assortment of Set control lighted push button switches and other switches or joysticks for jog and cut control allow the operator to control the system This panel is connected to the System Control Enclosure via a multi conductor cable Copyright 1998 Paw Taw John Services Inc INTRODUCTION 4 5 TransTerm 5 Terminal The keypad terminal is used to display system status and adjust operating parameters axis offsets jog functions and for troubleshooting Refer to system to the System Operation section of this manual for specific operating details The TransTerm 5 terminal connects directly to the AC650 cards inside the System Control Enclosure 6 Servo Proportional Valves Servo Valves and in some systems proportional valves control the flow of hydraulic pressure to the hydraulic cylinders One valve will be associated with each axis The Servo Valves are controlled from the servo output of AC651 cards located in the System Control Enclosure Refer to the system installation section of this manual for adjustments to the AC651 that may be required by any specific valve type 7 486DX computer
33. s Bad Module Transterm 5 display shows Tempo Bad Transterm 5 display shows Overtravel Temposonics Bad indication Paw Taw John Services Inc SOLUTION Check AC651 drive LEDs for ON If ON use external drive box to check for movement of cyl If no movement check filter for blockage or replace Also check hydraulic unit for 1500 psi or greater Check wiring to servo valve Replace servo valve Does the Transterm 5 display show an Overtravel Bad module Temposonics Bad indication Repair problem Replace the AC651 card associated with the number displayed with the Bad Module indication Check the corresponding Tempo Bad indication with the AC651 card The Tempo lamp should be on constantly Troubleshoot the Temposonics loop A program software limit has been reached One of the AC651 min max parameter limits or system max limit parameters is set to high By depressing Clear 1 through 8 the appropriate servo controller will show the overtravel indication Enter the Parameter mode for that module and correct one of the parameter limits stated above If using an AC700 tempo interface card check the LED indications If POWER LED out check power on board Fix power problem If RUN LED out replace probe Follow AC700 operation manual for repair TROUBLESHOOTING 2 Push button lamp blinks Axis has not reached target position Verify target and
34. s 8 data bits that are either 1 or 0 This data determines how the TTS will work It is necessary to have the registers filled with the exact se quence of 1 s and 0 s so the terminal can talk with the AC651 The bit sequence for register SR1 should be as follows SR1 00000000 If the data displayed does not match key in 00000000 Then press the ENTER key If the data displayed does match the bit sequence just press the ENTER key to accept the data as displayed After the ENTER key is pressed in step 7 the display will automati cally increment to the next register Repeat the procedure in step seven for all four registers confirming or changing the data bits to match the following 1998 Paw Taw John Services Inc INITIAL SYSTEM SETUP 6 SR2 00000010 SR3 00001001 SR4 00000000 Hit the ENTER key after each register entry 9 When all four registers are correct press the CLEAR key to exit the setup mode Please refer to TransTerm 5 Troubleshooting if no data is displayed Also refer to the TransTerm 5 User s Manual included with the system for more detail on terminal setup Starting system parameters are loaded by Paw Taw John Services Inc at time of manufacture TRANSTERM 5 TERMINAL OPERATION The TransTerm 5 is a complete dummy terminal capable of all functions used on standard personal computer systems The TT5 may be powered us ing an external 12VDC power unit or powered via
35. t direction Information returned to the controller from the saw position sensor is compared with the operator requested position and movement of the cylinder continues until the saw position reaches 10 At that position the controller removes the signal from the servo valve and the saw stops Paw Taw John Services Inc SERVO CONTROL SYSTEMS Paw Taw John Services Inc servo controllers are semi custom systems designed and assembled from a group of standard components The heart of the system is an AC651 servo control module The AC651 is designed to accept positional information from many industry standard sensors It will output the appropriate control for most industry standard servo valves Sixteen inputs and a data strobe are provided for receiving positioning information from a PLC w jm mo ee Copyright 1998 Paw Taw John Services Inc INTRODUCTION 2 The specific operating characteristics and personality of the AC651 are a function of the firmware programming that directs the microcontroller contained within This program is created special to meet each PLC system s specific operating requirements The AC651 servo controller high speed serial communications port may be connected to a terminal or computer via a telephone style modular jack for system setups and calibration data tracking and certain operating program modifications Presently the Computerwise TransTerm 5 ter
36. tends or retracts to the maximum The ACTUAL POS Display value is jittery The cylinder is hunting when it arrives at target The cylinder overshoots or under shoots the target When power applied to the system the AC651 doesn t respond consis ently to commands The board sizes get thicker orthinner as the cylinder extends or retracts The board sizes vary out of tolerance When a set button is depressed the cylinder doesn t move Paw Taw John Services Inc TM SOLUTION Check the TransTerm parameter EXT TO ZERO value If okay switch the SERVO and SERVO cable pair Swap the TEMPO and TEMPO cable wire pairs GAIN value is too high Lower the value Adjust the ACCEL or DECEL value to correct Also check adjust the GAIN Verify the 150 ohm resistors are installed on the cardrack Refer to Innitial System Setup Step 6 Check TMP ADJUST value for linearity of cylinder stroke Check linkage for security and proper ratios Check the cylinder mounting for security and the clevis for integrity Check that PLC is addressing the correct axis Refer to data screen on Transterm 5 TROUBLESHOOTING 1 OPERATIONAL SYSTEM TROUBLESHOOTING These are common problems encountered after the system has been operating TROUBLE Cylinder moves slower and slower Cylinder stops moving Cylinder will not move AC651 drive LED on Cylinder will not move AC651 drive LED off Transterm 5 display show
37. ut 1s a 24 volt high when the target and actual position data are within 050 of each other 3 Inputs 1 2 3 amp 4 or Inputs 1 3 5 amp 7 with some programs are used for addressing each AC651 servo control card When the Strobe input goes active and any of these inputs are active as per the following tables an AC651 servo card is selected to receive data Paw Taw John Services Inc PLC INTERFACING 1 ON Active OFF Inactive The following table is applicable if the program used is PLC51D1 HEX or PLCSILNG HEX NPUTT NPUT2 NPUTS NPUTA pro r2 The following table is applicable if the program used is PLCSIB2 HEX or PLC51A6 HEX INPUT 1 INPUTS INPUT5 INPUT 7 __ BIT2 CARD 5 CARD 6 CARD 7 CARD 8 o s e U m Remember ON Active OFF lnactive Note The no of servo s entry in the Parameter mode of the Master AC651 card determines which group of the first 4 inputs is used for addressing An example is no of servo s entry 2 then inputs 1 and 2 are used Paw Taw John Services Inc PLC INTERFACING 4 Inputs 1 through 16 are all used during the position entry time There weighted values are as follows AC651 PROGRAM DATA SPECIFICS The following tables indicate binary bit conversions and specific program data Please refer to this for specific data on specific programs BIT CONVERSION TABLE BIT BIT WEIGHT 16 32 64 128 2
38. wing is a brief explana tion of each indicator 1 The Servo and LED s illuminate when the card is sending servo current to a valve The LED s will glow brighter as more current is applied to a valve Servo is one direction while Servo is the oppo site direction The Status LED will remain on while the cylinder is within 050 of the target position If not or while the cylinder is moving the LED will flash The Tempo LED must remain on at all times No blinking or inter mittent blinking is acceptable If so the Temposonics loop has a problem The RCV and TRX DATA lamps will blink most of the time in a ran dom mode 5 The Transterm 5 cable is connected at the KEYPAD area Paw Taw John Services Inc SERVO LOOP SETUP 5 PLC INTERFACING TO AC651MB RACK The following discussions encompass the AC651MB rack inputs their functions and PLC data transmission requirements AC651MB RACK DATA INPUTS OUTPUTS OOOO000000000000 e e Shown above is the connections used to interface a PLC to the 651 card rack The following is an explanation of the inputs and outputs for Axis l 1 Strobe is an input used to transfer address and data from the PLC to the AC651 servo control cards When the strobe 1 activated address information is transferred data is transferred when the strobe is deactivated 2 In Pos is an output generated by the AC651 servo control card for each axis This outp
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