English User Manual
Contents
1. grams and want to run the machines in Auto mode 1 Choose a suitable program 2 Press ACTIVATE 3 Start the machines T1 and T2 7 SETTING T1 amp T2 STROKE UPPER LIMITS 1 On the Start up Display Page press TO SETUP The following Screen appears GO TO SETUP PAGE ENTER PASSWORD BELOW 1 6 DIGITS 0 The dashes indicate that access is prevented PUSH BUT7ON fa sve A TO SETU PARAR EA START iaj 2 Press here A Numeric Key board appears on the Screen 3 Enter the Numeric Pass word Code which you get GO TO SETUP PAGE from your Dealer Then press ENTER ENTER PASSHORD BELOW 1 6 DIGITS 0 4 Now you have access to the Setup Page Press here J nar race The Setup Page appears PUSH BUTTON TO SETUP r 7 5 If Upper Limits boxes FAR EJ ANDRAS already contain values should DO NOT MODI FY be around 200 you may not have to modify In other case set the values to approx the same as indicated in the picture to the left upper Limit T1 L34 Then go to the MANUAL JOG Screen via the Start Page er refer to pages 5 6 in this Limit T2 manual and move the spray 234 guns up to the point where pian you want to set the upper limit Then go back to this Screen to modify the values accordingly Technical section PGC Reciprocator Control and Trigger System PGC TWD RC series Connection diagram for reciprocators with incremental pulse encoders2. speed in percent of maximum speed This page displays all the parameters required to run T1 in Auto Mode Program number Upper turning point Lower turning point Speed Pause timer setting IMPORTANT The settings in a program must be ACTIVATED before they can be used Press ACTIVATE when you have finished programming Press here to go to T2 programming page when you are finished with T1 Press the surface indicated by the arrow if you want to adjust this value Press here if you want to pogram or change the value for the High Turning Point When you are satisfied with the settings for the turning points Press T2 PROG button to go to the T2 Programming display page When you have finished programming the settings for T1 and T2 Press ACTIVATE button Now press START PAGE to go back to the Start up Display page below START PAGE fa ET SYNCH INDIVIDUAL ON OFF gt MODE T1 STOP PROG ACTIVATED reo START 1 188 PROGRAM ACTI a C UATE T2 STOP a pr wekKAn ace MANUAL COPT PASTE TU SETUP UP DOUR Boao These buttons are used for starting and stopping T1 and T2 individually in AUTO Mode OBSERVE f this blinking Alarm Mes sage appears you have simply forgtten to leave the Manual Mode Just return to the Manual Display Page and give the MANUAL JOGGING Button another push 4 RUNNING T1 AND T2 SYNCHRONIZED A Push Button with which
3. A amp B channels for the vertical movement CABINET AND PLC SYSTEM COMPOSITION Cabinet outside view Explanation of numbering O O Communication Module Model TWDNOZ485D Comm Cable between PLC and HMI Base PLC Model TWD LMDA20DRT Left row 12 digital inputs Right row 2 trans outputs 6 relay outputs Module TM2AVO2HT with 2 analog outputs 0 10V for T1 and T2 Speed Control Module TM2DDO8TT with 8 trans outputs 4 are used to control T1 and T2 up down Plug in Memory Chip TWDXCPMFK64 contains the Control Program Explanation of numbering o HMl Terminal HMI STU855 with a 5 7 Touch Sensitive TFT Color Screen Stop button Causes immediate stop of T1 and T2 motions when pressed To reset Turn slightly Counter Clockwise 230VAC Main Power Breaker Can also be mounted on the Cabinet Side O T1 and or T2 Running Indicator Lamp HMI Terminal Model HMI STU 855 Power Supply ABL8REM24030 Auto Fuse Primary 230VAC Out 24VDC 3A PLC MODULES ELECTRIC CONNEXION PLC SYSTEM TWD LMDA 20DRT ELECTRIC DIAGRAM TWD LMDA 20DRT T1 amp T2 Run Lamp ej ap H Inputs Screw Tao Terminal Block Outputs Screw Terminal Block 7 Outputs Not Used Spare ee ue y z 12 Inputs 8 Outputs NEE address l0 0 10 11 Q0 0 Q0 1 2 Transistor lt 9 Q0 2 Q0 7 6 Relay O lt m u aTa m TE si l gt i a T om
4. select a program number steps 1 3 START PAGE m START SYNCH INDIVIDUAL ON OFF gt MODE dk PROG NR ACTIVATED J idiak 1 188 gt 5 PROGCEAR cS o bs 0 T2 STOP WARNING PROCRAN UP DOWN IN MANUAL MANUAL COPY To PASTE ee UP DOUN J Start here 1 Press here to select a program number The display image is now transformed into a 10 key keyboard as shown below This area shows the value you are entering Always check that the value is OK pressing the digit 1 key uia 3 Then press Enter nee Now the display again shows the start up display 49 with program nbr 1 selected as shown below START PAGE eed cee Next let us find out find out what values for the turning SYNCH INDI IDUAL 11 sro ON OFF ES Ti STOP points we should enter into i r2 START First press the button marked PROG NR ACTIVATED MANUAL UP DOWN the program 1 188 gt PROGRAM ES 4 hee 0 T2 STOP WARNING PROGRAM UP DOWN IN MANUAL MANUAL COPY To PASTE ie UP DOUN Next we will manually operate the reciprocators up and down 5 2 MANUAL JOG amp TEACH IN PROGRAMMING METHOD By manually jogging the guns up or down we will establish the digital values for the upper and lower turning points which we will enter into our program By using the TEACH IN function this procedure is very fast and easy WARNING Manual Mode starts the recipro
5. you can switch toggle between Individual and Synchroni The Reciprocators T1 and T2 can be operated in two zed Operation Mode different Auto Modes A Label indicating which mode is selec INDIVIDUAL ted Individual or Synchronized OR SYNCHRONIZED In Individual Mode T1 and T2 START PAGE r 1 START are started and stopped indivi d dually and run with individual CYNCH INDIVIDUAL settings with regard to speed and ON OFF MODE E STOP turning points In Synchronized Mode the start of T1 also starts T2 PROG NR ACTIVATED i2 START 1 199 gt PROGRAM T2 automatically assumes the ACTI same speed and turning points YATE J TZ SIF as T1 regardless of how T2 was programmed Procran The one of T1 and T2 that reaches the upper turning point MANUAL first will automatically wait for the COPY PASTE TO UPZDOUN other one so as to start the down SETUP ward travel simultaneously NOTE When you leave the Synchronized Mode to run the machines Individually again the programmed settings for T2 will be re entered automatically to control T2 in Individual Mode 5 PAUSE TIMERS AT T1 AND T2 UPPER TURNING POINTS A Pause time can be programmed for T1 and or T2 in any program number The Reci procator will stop and hold its motion the programmed time at the Upper Turning Point before it starts its downward movement The Pause time is programmed in units of 1 10 second Thus if you enter the value 20 the
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7. 1 Select a program number which is pre programmed with the desired settings 2 Press ACTIVATE 3 Start T1 amp T2 That s all SAFETY FIRST IMPORTANT SAFETY NOTICE The reciprocators movement areas can be can be considered to constitute a potential Danger Zone Therefore never start the operation of the Reciprocators unless you are comple tely certain that no person is in or at risk of moving into that Zone Also observe that when you initiate Manual Jog Mode described on page 6 the Reciprocators will automatically perform a downward motion Also please consider the safety regulations existing in your country concerning the installation and operation of this type of equipment WE RECOMMEND CHECK THIS OUT FIRST TO RUN THE MACHINES IN AUTO MODE Before the machines can perform a reciprocating up and down motion in automatic mode the system needs to be programmed A program must contain the information of e The Upper and Lower Turning Points of the two Reciprocators referred to as T1 and T2 Two easy programming methods will be shown in this manual e The Speed of the Reciprocating Motions The speed is programmed in percent of the maxi mum speed ADDITIONAL FUNCTIONS INCORPORATED IN THE CONTROLLER Pause in the upper turning point The motion holds during the assigned time before turning into a downward motion This is repeated in every stroke cycle e The Operator can chose between Synchronize
8. I A BS gt E TER TM2 AVO2HT 2 Analog Outputs TM2 DDO 8TT 8 Transistor Outputs 24 V address Q2 0 Q2 7 7 T Q2 2 T1 up Addr Q2 3 T1down QW1 0 Q2 4 T2 up Q2 5 T2 down its The rest are Addr free AQW1 1 NEXT PAGE CONNEXION OF INCOMING CABLES FROM T1 amp T2 CONNECTIONS AT THE MAIN TERMINAL INSIDE THE ENCLOSURE Hookup with two Reciprocators plinth row version EXPLANATION Remote connexn remote control LS Limit Switch Q2 5 T2 down T1 Reciprocator 1 T2 Reciprocator 2 Q2 4 24 T2 up Q2 x Discrete PLC output 10 x Discrete PLC intput Q2 3 23 T1 down QW1 x Analog output x refers to channel nbr Q2 2 22 T1 up Q0 0 AHQAW1 1 QW 1 0 T1 spedd 0 10V FR PWR SUPPLY OVDC Black SUPPLY ANA MODULE 0VDC Black D T1 amp T2 Freq converter COM SUPPLY PLC OVDC Black D T1 amp T2 Pulse gen OV supply MATN PLC ING OVDC Brown 15 t NO FR PWR SUPPLY 24V Red p lt iN QS ER 24V SUPPLY ANA MODULE 24V Red 13 Q o T1 amp T2 Pulse gen 24V supply SUPPLY PLC 24V Red 12 M 4 24V Red 1 amp All Stop Black Stop Button in Front i Remote Start 7 10 11 LS2 2 0 10 10 e LS2 1 o 710 5 T2 LS home _ LS1 10 10 2 T1 LS home n frc Addresses A wire numbers Betraco Automation Fritsla Sweden Tel 46 320 7
9. Quick guide for PRC TWD Novo Series Reciprocator Control System Vertical stroke pattern control for 2 reciprocators also available with Trigger Functions option THE PRC TWD Novo CONTROLLER Copyright 2000 2015 Betraco Automation Preface Chapter 1 Chapter 2 Chapter 3 Chapter 4 Chapter 5 Chapter 6 Chapter 7 CONTENTS Vertical Motion Control for 2 Spray Gun Reciprocators Quick introduction Summary 3 4 The Start up Display Page how to select a program number The Start up display page To choose a program NUMDEL cccccceecceceeececeeececeeeeeceeeeeseeeeeeees 5 To decide the turning or reciprocating points of the vertical stroke Change over to MANUAL JOG MOde ccccccecccceceeeeeeceeeeeeeeseeeeeesaeeeeesseeeeeesseeeeeesaeseeeesaeeees ees 5 Starting with T1 and T2 in their home positions position indicators SHOW Zero cccseeeeeees 6 Jogging T1 and T2 up and reading their positions cece ceeccceeeeceeeeceeeeaeeesaeeeeaeeesaeeeseeeeaeeenaes 6 Teach in programming of the turning reciprocating points cccceecccceececeeececeeeeeeeeeeeseeeeeeees 6 Press PROGRAM button to program the desired SPGEdS ccccceecceceecceceeceeceeeesaeeesaeeeseaeess 6 Programming Check Modify the values for the turning points ccccccccsseseeeceeeececsesseeeceeeesecssaaeeesseaeeeeeses 7 Enter a speed value aro oases anee ee
10. Reciprocator will hold its motion for 2 seconds If you program the value 5 it will hold for 0 5 second The value is entered here and is directly stored in the selected program number Note In order to use the Pause Timer setting push the ACTIVATE button UPPER gpm HOLD 5 x CPR E PROG NBR 6 PROGRAMMING AID The System is provided with functions that can be used to speed up the programming job if you want to develop several similar programs By means of COPY and PASTE you can quickly produce several identical programs and then make adjustments as required START PAGE SYNCH INDIVIDUAL ON OFF gt MODE Ti STOP PROG NR ACTIVATED ha START 1 1002 PROGRAR A 2 ACTI ois 1 E STOP i Procran I corr Paste a EA SETUP 3 Here s how 1 Copy Choose a program that contains the settings you want to copy for example program 1 Press the button COPY 2 Change program number Press PROG NR and choose for example program 2 and press ENTER 3 Paste Press the button PASTE 4 Paste the copied program into more program positions Choose another program number for example program 3 Press once more on PASTE Now you have made programs 1 2 and 3 identical If required you can now choose any of these programs and make desired adjustments This method is practical if you have several programs which have similar settings Normal proceedings when you have a number of complete pro
11. alues for the High and the Low Turning Points When we are in Manual Jog Mode we can enter the values for the turning points by using the Teach in method which is even easier than programming the values via the virtual key board How to perform the manual jogging is explained step by step in detail inside this manual HOW TO CHANGE PROGRAMS AND HOW TO ACTIVATE A PROGRAM The settings we enter in a program are stored directly in the program To activate the selected pro gram so that the controller can use the program to run the machines we have to press a button label led ACTIVATE The ACTIVATE button can be found on almost everyone of the controller s display pages OPTIONAL SPRAY GUN TRIGGER FUNCTION In the version without the Trigger Function 6 Relay Outputs are free not used and can be used for triggering up to 6 Spray Guns In addition 5 Transistor Outputs are free Some of those can also be used as Trigger Outputs in case a relay is added In order to incorporate the Trigger Function the Program Software must be upgraded by replacing the Plug in EEPROM Memory Cassette A Pulse Generator must be fitted to the Convyor Drive Station and a Measuring Station must be arranged The latter can consist of a simple Photocell or preferably a Light Beam Array in front of the Spray Booth 1 HANDLING IS EASY HERE IS THE START UP DISPLAY PAGE The image below shows the start up display of the control system Here we show how to
12. cators automatically running them down to their bottom Home positions Position displays will indicate O for both T1 and T2 Press here to select MANUAL JOG MODE Note the WARNING above Now the button changes both text contents and color shade which is shown in the lower picture Push for 4 Manual T2 Press and hold the button T1 UP until the Spray guns are in the desired position for the LOW TURNING POINT Press the Teach In Button labeled T1 LOW TURN in the lower pic MANUAL JOG EEE ture This saves the T1 AND Joggi n Low Turning Point into TEACH IN up pa D the program you selected POSITION T1 POSITION T2 before program nbr 1 O Now run the spray guns up to the desired HIGH TURNING POINT O i DOUN Press T1 HIGH TURN in the picture to save this position in the program Repeat the above procedure for T2 When you are done with Manual Jogging press the MANUAL button again so that its appearance again shows Now press the PROGRAM button to go to the Program display page to check the settings for the turning points There you will set the desired speed as well 6 3 CHECK ADJUST TURNING POINTS amp PROGRAM THE SPEEDS On this display page you can check and if needed adjust the turning points and you also have to program the speed for T1 here UPPER TURN HOLD x 0 is POINT Ti PROC NBR ri ON are LOVER TIIRN POINT Ti IMPORTANT Set the desired
13. ckup of the PLC Control Program on a plug in type EEPROM Memory Capsule 3 HMI Terminal Program on a standard USB Memory for easy backup and upgrades 4 Easily upgraded with Trigger function with necessary hardware already fitted 5 Compact dimensions 500x300x200mm or optionally 600x400x200 The controller PRC TWD provides the user with easy handling and excellent control functions We recommend that the contents of this manual is studied before taking the equipment in use IMPORTANT The basic model of the PRC TWD Novo Control System provides programmable control of the Upper and Lower Turning Points as well as the Motion Speed of the Vertikal Stroke Pattern of two Reciprocators referred to in the following text as T1 and T2 Before you start PROGRAMMABLE UPPER STROKE LIMITS If this is the first time you use the system if you have upgraded the PLC software ican for any reason have replaced the basic PLC unit then You need to check the Programmable Upper Stroke Limits for T1 and T2 The procedure to do this is described on pages 9 and 6 in this Manual PROGRAMMING IS AS EASY AS THIS In order to run the machines in Auto Mode all you have to program is 1 Lower turning point of each of the two Reciprocators hereafter called T1 and T2 2 Upper turning point of each of T1 and T2 3 The desired Speed of T1 and T2 4 Optional Program a pause time in the High Position as desired TO RUN THE MACHINES IN AUTO MODE
14. d and Individual Motion Modes with one button push toggle function In Synch mode T2 automatically assumes the same settings as T1 for speed and turning points Also note in Synch mode the Pause function is made ineffective PROGRAMMING OCH EDITING The display screen area of the HMI terminal contains touch sensitive areas or spots serving as virtual push buttons In order to input or modify a numerical value simply press lightly on the spot where the value is found Then the whole display area is transformed into a numerical key board START AND STOP THE FUNCTIONS ON THE START UP DISPLAY PAGE Only the start up display page has functions for individual start and stop of the machines IMMEDIATE STOP THE LARGE ROUND BLACK BUTTON ON THE LOWER LEFT OF THE CABINET FRONT When this button is pushed all motions of T1 and T2 come to an immediate stop In order to re start the machines this button needs to be turned a few millimeters counter clockwise COPY AND PASTE The start up display page also contains a COPY and PASTE function offering a method to simplify and speed up the programming procedure The function will be described later in this manual MANUAL JOG MODE Both reciprocators can be jogged up and down manually First they have to be stopped in auto mode The display page with control buttons for manual jogging can be reached from the start up display page Manual jogging is practical to use when we want to determine v
15. entered cede ig ueraneieac Sibu eiescb sedi eeacebese bentdeedetieac eeneeeansues i Blinking warning text on the Start Up display page ccceccceccseseeeeceeeeeeesseeeeeeeseeeeeesaeeeeessaaeeees T Two Auto Modes Individual or Synchronized Motions Individual Mode T1 and T2 have individual speeds and turning PoOints cccceecceeeeeeeeeee aoe 8 Synchronized Mode T2 runs with the same speed and turning points aS 11 cceeceeeeeeeees 8 Motion Pause at the Upper Turning Point How to program a pause time at the upper turning points cece ee ccc eeee ce eeeeeeeeeeeeeaeeeseeeesaees 8 Functions that facilitate the programming Copy a program and paste it into one or several other program numbers cccsecceeeeeeeeeeeees 9 Functions that facilitate the programming Copy a program and paste it into one or several other program numbers cccsecceeseeeeeeeeees 9 Appendix Technical Section Cabinet inside and outside and the PLC System Composition 1 page Electric connexion of the PLC Modules ae sesssseseeeeeeseeenenes 1 page Electric hookup diagram Electric connection diagram for external equipment ccceceeececeeeeeceeeeeseeeeesseeeeeeeeeeees 1 page PREFACE SUMMARY OF THE IMPORTANT FUNCTIONS The brand new model PRC TWD Novo preliminary name offers the following design features 1 HMI Terminal with a 5 7 TFT Color Touch Screen 2 Full ba
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