H6681 User manual
Contents
1. lt H Oooo Pulse Output Beeee perate Switches Home Sensor AUX I O AC Input COM CW CCW 2 AC Output Cx O O Motor Driver lt 3r 2PhaseSTEP Motor AC Output EARTH AC Input Winding Spindle DC24V 12W Guiding Traverse MAX 400W Motor Brake CNC 210A Series H6681 User manual Page 15 of 20 9 ADJUSTMENT 9 1 Adjustments for 210 5 CL Output current limit 1 Connect a DC Amperes meter between terminal and DC motor as below 2 n ready mode make the DC motor starting rotate and then press to holding the winding spindle 3 Rotate CL to set limited current show on Amperes meter 2A for 180v DC motor 4A for 90v DC motor The CL have been set by factory before delivery Only adjust it when change DC motor and replace 210A DVR driver board IRL Torque compensation 1 Set the winding parameter H S L S in 20 then press to change the DISPLAY shows RPM Then to start winding 2 Rotate IR potentiometer to make it in same speed during the winding spindle shaft in full load and unload Then press key to stop winding MAXU Maximum winding speed 1 Set the winding parameter H S L S in2. CNC 210A Series H6681 User manual Page 2 of 20 1 INTRODUCTION CNC 210A is a series of COIL WINDING MACHINE CONTROLLER developed by TAILY AUTOMATION It not only retains all the features of previous designs it also has a low noise level and is less sensitive to external power fluctuation Furthermore it also includes a RS 485 network interface making coil winding operation easier to manage CNC 210A also features an integrated design putting stepper motor driver DC motor speed controller brake and power supplier control circuits into one control box simultaneously achieving size reduction high performance and low cost CNC 210A Series offers CNC 210AS Standard Model and CNC 210AE External Connection Model depending on whether a close loop driver is provided for various applications MODEL Winding Spindle Guiding Traverse CNC 210AS Drive 0 5hp DC motor in directly n two phases 2A STEP motor in irectly Drive two phases 2A stepper motor in External connect winding spindles directly CNC 210AE vem d 7 motor driver Or external connect guiding traverse STEP motor driver 2 MAIN FEATURES Single chip Microprocessor design has further higher performance and higher functions it also has less sensitive to external power fluctuation or to external electromagnetic interference Memory use FLASH ROM capacity capable storing up to 1000 steps winding data 9 winding parameters and 5 options can be independentl
3. O O O READY RUN SLOW MOVE O S LAN FINISH RPM QTY SHIFT WIDTH PITCH TURNS S SLOW E SLOW H S L S FUN Lit means in READY mode flash means PAUSE mode Not lit means winding or programming in progress Lit means winding in progress not lit means not in progress During winding lit means low speed winding not lit means high speed winding Lit means guiding traverse is fixing the starting position for winding or is returning to the home position lit means winding operation is over speeding guiding traverse and winding spindle shaft are out of synchronization Lit means currently are communicating with network Will lit when reaching the preset piece count Lit means the PIECE COUNT DISPLAY shows RPM Lit means the PIECE COUNT DISPLAY shows the piece count 5 Winding parameters definitions Start position of the guiding traverse Setting range 0 00 999 99 he traverse of the copper wire led by the traverse during winding Setting range 0 999 99 mm Diameter of the copper wire Setting range 0 9 999mm Total number of turns to be wound Setting range 0 0 9999 9 or 0 999969 turns Number of turns to be wound at low speed when start winding Setting range 0 999 9 turns Number of turns to be done at low speed prior to stopping Setting range O 999 9 turns High winding speed Setting range from 0 99 Low winding spee
4. 1 for CNC 210AS and CNC 210AE or occur a fault 7 10 Acceleration 9 Set the accelerate times for the winding spindle Setting range 00 99 00 means shortest acceleration times 99 means longest acceleration times 7 5 0 4 8 0 L S 0 XT NO 10 lt 0 CNC 210A Series H6681 User manual Page 11 of 20 7 11 Reset all configuration data e e J In READY mode it will reset all the configuration data and replace by initial data Be cautious in use this function 7 12 Data transmit The CNC 210AS has a RS 485 serial communication interface can be used to send the winding data to the others station Up to 32 stations can be operated on the same network In this function set station numbers to the controllers to recognize the controller to which the current data is being send Refer to the section 7 2 station numbers The communication bus wiring diagram as belowl CNC 210AS CNC 210AS CNC 210AS SET ED e See EET oa a CONNECTION BOX CONNECTION BOX afte LAST STATION i fe PREVIOUS STATION COOMUNICATION CABLE 6P4C COOMUNICATION CABLE 6P4C CN N 5j N TERMINATOR RESISTOR 47 1000hm In READY mode press following keys combination its will sent each setting data to target station em
5. 99 and press key to change the DISPLAY shows RPM Then to start winding 2 Rotate MAX potentiometer to make the winding speed RPM as you want Then press key to stop winding DC MOTOR 10A AMPERE METER 0 100 120V TF808C1 AC 220 240V TF808C2 R33 CN4 CN3 O uro 210A DVRID XXXXXX O CNC 210A Series H6681 User manual Page 16 of 20 9 2 Adjustments for CNC 210AE Speed Mode selection To select the speed signal output mode for winding driver Selected by JP1 1 V out model Represents the speed signal with DC 0 10v output 2 model Represents the speed signal with HI LOW lever output Hi speed with HI lever low speed with LOW lever V out adjust 1 Set the winding parameter H S L S in 99 and press key to change the DISPLAY shows RPM Then to start winding 2 Rotate V out potentiometer to make the winding speed RPM as you want Then press key to stop winding 3 This function only worked in Vout mode i L 5 FUSE2 FUSE1 T1 AG POWER 100 120V TF808C1 AC 220 240V TF808C2 3 zI ES CN2 tdf 62 eile 4 lt gt OO d d CN4 TAILY AUTO 210A EXD ID
6. Counting sensor connection cable HOME SR Home sensor Counting disc Push button switch Push button switch Foot switch RUN STOP Foot switch Power cord AC Power cord x not use in this model Page 13 of 20 CNC 210A Series H6681 User manual 8 2 Wiring diagram for CN2 CN6 ala O O 21552 359 all gt O lt gt Z5 2 79 70 AUX I O Heee Home Sensor Turn Counter Pulse Output CN7 CN4 CN5 CN6 Ul CN4 CN5 AUX I O FOOT SW STOP START Operate Switches Home Sensor Turn Counter RS 485 Connection Box I o oo ala 2 2 a lt Hooo He Heeee i Home Sensor Turn Counter Pulse Output RS 485 CN7
7. counter will decrease by one Reset piece counter In any time holding down key for two seconds it will set the piece counter to zero _ 210 Series H6681Usermanual age 9 of 20 7 CONFIGURATION SETTING CNC 210A is a multi purpose design to meet various requirements additional settings are configured to provide flexibility for additional applications In the READY mode press the following keys combination as section 7 1 7 10 the DATA DISPLAY will show corresponding setting value If no change is necessary press the s key get back to READY mode Or press to get into change mode then the parameter can be changed by pressing the numerical key followed by 7 1 Winding mode 0 In this function the STEP display and the DATA display will shows eight digits representing eight winding mode selections respectively Press numerical keys as below to set each digit Ooo ooodo t t 1 t t t t 1 ej BAe 1 Moving speed The guiding traverse moving speed 0 represents high speed 1 represents low speed 2 Moving increment The travel increment of the guiding traverse 1 represents 0 01mm 4 mm per revolution 2 represent 0 02mm 8 mm per revolution 4 represent 0 04mm 16 mm per revolution Counting model Select the counting mode of the winding spindle shaft 0 represents with zero point and using absolute counting mode 1 represents without zero point and u
8. fo o 9 Sends configuration setting data to the specify station een Ed 2 09 99 Sends password to specify station lt will sends from START STEP to END STEP during sent the winding parameters 00 99 Represents target station number If the target station number specify as OO all the Stations on the same network will receive the data is being sent 00 88 en Sends winding parameters to the specify station _ 8 210 Series H6681Usermanual Page 12 0 20 8 INSTALLATION AND WIRING The controllers should be operated in an environment that is protected from moisture corrosive gases or liquid and free from airborne dust metallic particles and magnetic noise Do not block the intake exhaust ports of the controller Otherwise a fault may occur Make sure that the power source supplies the correct voltage and is capable of supplying the required current to the controllers Do not connect or disconnect wires and connectors while power is applied to the controller Make sure the machine and controllers are properly grounded Make sure that the leads and connectors are connected correctly Normally operate under 10 C 40 C environment over 40 C should perform under good ventilation avoid heating 8 1 Accessories and options 210A CN2 5 485 Connectionbox 210A CN3 Operate switches connection cable _ O 210A CN4 Home sensor connection cabe 210A CN5
9. 681 User manual Page 18 of 20 10 3 Error message When a fault occurs during operation the DATA DISPLAY shows error massage stop winding and then RESET go back to the READY mode 0 The parameters or data in memory are fault 1 Thel SHIFT value sets exceed the Travel Limit 2 During winding the guiding traverse to exceed the Travel Limit Err 3 During winding the guiding traverses reach to the Home sensor Err 5 RS 485 communication error Err p Password error key in 4 numbers password before edit 10 4 To abort seeks the original position At boot and reset procedures if because of unknown reason however engender the winding shaft and guiding traverse can t find out the original position and make the controller can t get into ready mode can press key to abort seeks the original position make controller get into ready mode 10 5 Troubleshooting This section provides information to guide the user in understanding different fault condition and their general troubleshooting procedures and with their possible solutions Do not connect or disconnect wires and connectors while power is applied to the controller Make sure that the leads and connectors are connected correctly before doing the troubleshooting procedures Do not remove welded parts on the PC board without appropriate tools Fault Description Correctives Action Power ON but the display Check AC powe
10. CN2 CN4 CN5 CN6 AUX I O STEP Motor CN8 AC Input Winding Driver Brake 59 CW CCW Vout 6 F F BK BK ELMO 0 O AC Output 2 EARTH i Winding Spindle DC24V 12W 2Phase 6V 2A Brake Guiding Traverse Motor STEP Motor CNC 210A Series H6681 User manual Page 14 of 20 8 4 Wiring diagram for CNC 210AE Drive STEP Motor in directly 15215 v 216155 oa Olo I S m Heeee Heeee Home Sensor Turn Counter AUX CN4 CN5 CN6 A lt EH ooo Pulse Output e 8 Winding Driver STEP Motor 5 2 5 CW CCW Vout 4 GND e O O z Motor Driver gt AC Output EARTH AC Input Winding Spindle DC24V 12W 2 2A MAX 400W Motor Brake Guiding Traverse STEP Motor External connect STEP Motor driver SSS 5 lt ol a E 5 5 5 5 Z gt a Ola s lt lt 59 m
11. ESCRIPTION Prior to winding the general winding principles are explained below so the operators can have a better understanding of the performance of the controller and make better use of it 5 1 Counting mode Absolute counting mode Winding spindle shaft is capable of fixed point stopping Upon each restart the turn count will reset only the integer portion of the turn s to zero with the decimal unchanged For example for a previous number of 100 3 turns when restarting the next step winding the counting will start with 0 3 to avoid accumulation of spindle shaft free play error from consecutive windings This counting method may cause insufficient winding by one turn Therefore when starting from 0 9 the spindle will turn to the 0 0 before it starts counting Relative counting mode This counting method zeros the counter upon each restart therefore it is easy to understand and will not cause insufficient winding 5 2 Wire guiding mode Interlace wire guiding If theL WIDTHL of the step is zero the wire guiding becomes interlace mode When it begins winding the wire guiding will follow the wire direction to proceed two wire diameters and regress one wire diameters cyclically until the step of winding ends This mode especially suits the inductor winding Non wire guiding sometimes the winding device may be used to winding adhesive tapes or copper foil When the wire guiding is not needed PITCH may be adjusted to zer
12. XXXXXX CNC 210A Series H6681 User manual Page 17 of 20 10 MAINTAIN AND TROUBLESHOOTING 10 1 Internal wiring diagram i CN6 210A CNB CN8 a CN5 a CN4 CN9 2 CN7 CN2 e i 210A DVR CN5 MHB 2S 210A CPU CN4 210A CPU CN2 CN3 210A CPU CN3 CN3 210A DVR 210A EXD 210 KBD 210A CPU 210A DVR CN2 210A DVR CN1 POWER SW 1 TLP 503D 210 DC 12V FAN 10 2 Periodically maintain Please periodically clean up the controller inner accumulate dust and dopants Please periodically check the wire connection between controller and machine if have loose or bad contact The following parts must be maintained or changed periodically as list below If any part is found faulty it must be changed immediately even when it has not yet reached the end of its life which depends on the operating method and environmental condition For parts replacement please contact your sales representative Winding spindles Turns counter CNTB 03B 03C Guiding traverses HOME SENSOR on the 210A DVR driver board it used to 100 000 times switching the winding direction Carbon BRUSH of the DC motor o Ours 3 12 60 _ CNC 210A Series H6
13. d Setting range from 0 25 Winding complete output signal set CNC 210A Series H6681 User manual Page of 20 4 PROGRAMMING WINGING PARAMETER 4 1 MEMORY RANGE SELECTION CNC 210A contains 1000 memory step by defining the region users can effectively manage the memory Various winding parameter can be stored in different regions and can be retrieved instantaneously After specifying the regions programming and winding can be done in those regions all un selected regions will retain their original contents and unmodified When setting the STEP number the Ending step number must be larger than the Starting step number or the winding operation will not start Specifying starting step In ready mode press i 0 999 to selected Setting range 0 999 Specifying ending step In ready mode press st 0 999 en to selected Setting range 0 999 4 2 Programming winding parameter In READY mode the programming mode the STEP DISPLAY shows START STEP the parameter indicator SHIFT Jit the DATA DISPLAY shows SHIFT setting value the SHIFT can be changed by pressing the numerical keys followed by the key After that the STEP number will automatically increase by one to continue set the SHIFT for next step When the STEP number is larger then the END STEP the STEP number will restore to the START STEP and the indicator light will change from SHIFTU toU WIDTH to specify
14. ey work with 5 5 How to set winding turns accurately Preset method Set the 1 E SLOWL to zero first and then set the TURNS to the desired number Set proper parameters according to copper wire bobbin tension etc then start winding When finished obtain the actual number of turns and calculate the number of overshot turns Go into programming mode and subtract the number of the overshot turns from the 1 TURNS to obtain the required setting This method has a higher throughput however the resulting stopping location may not be precise High Low speed method This method uses a combination of U H S L S and E SLOWI to achieve the desired number of turns L S should not be too high The number E SLOWI Jturns must be adequate to allow the spindle shaft to slow down to low speed before reaching the total number of turns This can result in precise stopping location Double brake method As the winding turns of the winding shaft reach the numbers of the E SLOWL brake for a short period first After the winding shaft stops continue winding at low speed Therefore the numbers of the slow speed may be reduced and the efficiency of winding may be increased Refer to the section 7 1 braking mode CNC 210A Series H6681 User manual Page 8 of 20 6 WINDING EXECUTION 6 1 To start winding After set up all data items press Jkeyr the winding process begin
15. he power or press You must to remember the password or you cannot change any data Setting range 0000 9999 Set 0000 means no password 7 4 Travel limit 3 3 set the maximum travel distance of guiding traverse During winding when the guiding traverse reaches this position the motor stop winding immediately and the DATA DISPLAY shows error massage then RESET and go back to the READY mode Setting range 000 00 999 99 999 99 Means no limit 7 5 Fixed locatione 2 To set how often must be correct the guiding traverse location Each time when finish this number of product pieces the guiding traverse will moves to the home position to correct the location before moving to starting position Setting range 00 99 Set 00 means not to do this function 7 6 Limited winding speed s This value is to limited winding speed and make sure the winding spindle shaft and guiding traverse are in synchronization The controller uses this value to calculate with wire PITCH of current step and then to limited maximum winding speed of current step Setting range 0 99999 Set 0 means no limit speed 7 7 Brake holding time s To set the hold times for brake Setting range 0 1 9 9 sec 7 8 Guiding traverse moving speed selection The speed at which the guiding traverse moving to the starting position and returning to the home position Setting range 0 9 7 9 Winding spindle output mode selection set to
16. ing the width for each STEP Repeat the same procedure using numerical keys and the s key all winding parameters for each STEP can thus programmed after that press key again to go back to ready mode The following functions are also available 90 To select guiding direction forward or reverse cal To select winding direction clockwise or counter clockwise 5 To specify whether to suspend winding when the guiding traverse moves to the two edges of the width MAO To select whether guiding traverse returns to the starting position automatically or upon a manual pressing of the key 0 Select whether to have auto starting function for each step s Clear the current value to zero Copy the content of the previous step to the current step H Go back to the previous programming step CN To scroll through different parameters Each time when change the PARAMETER or OPTIONS key must pressed to effect the change CNC 210A Series H6681 User manual Page 6 of 20 4 3 Guiding traverse shaft introduce setting During set thel SHIFT WIDTH guiding traverse travel limit can use numeric keypad to set location data or can also use ev s keys to leading the guiding traverse shaft location 4 4 Clear all winding parameter In the READY mode presse s J e will clear all the winding parameter in the memory Be cautious in using this function or all the data will be lost 5 WINDING METHOD D
17. o and the wire guiding won t be move 5 3 Operation mode Single click mode When press the start switch the motor start winding and when you release the start switch the motor stop winding immediately Double click mode When press the start switch the motor start winding and if you want to pause the motor you have to release the start switch then press it again CNC 210A Series H6681 User manual Page 7 of 20 5 4 Running mode Continual mode Before it begins winding if SHIFT of the step set as 999 99 then the starting position the width the wire guiding direction and the winding direction won t be re read The values are not changed that is the wire guiding will continue guiding wires on the same position The width and left right margins are the same as the ones of the previous section Both the wire guiding and winding directions are not changed either This mode especially suits to winding which have the multiple drawing tops in the same sets of coils Edges slow mode The winding speed will slow down before the guiding traverse reach to the two edges of the width work E SLOWI turns After the guiding traverse veered then restore to hi speed winding Refer to the section 7 1 edge slow mode Automatically circularly mode If key set to on it means Automatically circularly mode in this mode when finish a step of winding it will automatically get into next step and start winding without pressf k
18. r input shows nothing Check the LED lamp on TLP 503D power supply if not lit replace TLP 503D Replace 210A CPU 2 Power ON but the display shows confusion massage Replace 210A CPU Power ON but winding Pregs s to make the controller get into READY mode spindle didn t rotate or cannot stop rotation And Check the winding parameter L S setting value of START controller cannot get into STEPO ready mode Replace turns counter CNTB 03B Replace 210A CPU Power ON but guiding Pregs s to make the controller get into READY mode traverse didnt move or cannot stop moving And Replace HOME SENSOR controller cannot get into Replace 210A DVR ready mode Replace 210A CPU CNC 210A Series H6681 User manual Page 19 of 20 NO Fault Description Correctives Action Cannot edit parameters Check the READY LED lamp if not lit do procedures number 3 and 4 Key in four numbers password before edit if the password has z been set before Replace 210 KBD Replace 210A CPU Display shows Err 0 Replace 210A CPU then reset and get into H READY mode Display shows Check winding parameters SHIFT and WIDTH setting value hen b Check configurations TRAVEL LIMIT setting value and get into READY mode Display shows Err 3 Check winding parameters SHIFT and WIDTHL setting then reset and get into value H READY mode Heplace HOME SENSOR Display show
19. s Err 5 Check wire connection of RS 485 connection box e uem Brake failure Check wire connections of brake 10 Replace brake Replace 210A DVR Winding spindle configurations Winding spindle control mode 11 not switching winding selection setting value direction Replace 210A CPU Replace 210A CPU Guiding traverse moves Check Configurations Moving increment setting value 13 half pitch or double pitch 20 20 5 i 1 iE 1 E es k 1 i BUY min FAVA a AOA tes ttt ui A ee eae ea d 1 T i e i ae Ue ee A ri a AE MS iE Eten qum Li d ku es er 5 AE
20. s in accordance with the set up content Press key to pause winding During winding press key the winding speed can be switch between high speed and low speed The following key functions are available during PAUSE mode Give up the numbers of the winding turns and regress one step Finish current step and proceed to next step Continue winding Give up winding and go back to the READY mode 6 2 Change the display mode During winding or during PAUSE mode the DATA DISPLAY can be change the display mode between turns or guiding traverse position 6 3 Winding speed RPM display Pressing key will cause the PIECE COUNT DISPLAY to display the spindle shaft RPM without interrupting the counting Pressing again will change the PIECE COUNT DISPLAY back to displaying the piece count 6 4 Piece counter management Upon turning on the POWER SWITCH PIECE COUNT DISPLAY will shows the number of piece produced During wining each time the CONTROLLER goes from the START STEP to the END STEP the piece counter will automatically increase by one Preset piece counter In READY mode once and key in desired valueso sssesfollowed by When the PIECE COUNTER reaches the preset value the FINISH led will lit Setting range 0 99999 Decrease piece counter During READY or PAUSE mode press the and hold down for two seconds the piece
21. sing relative counting mode Edge slow Slow down the winding speed before the guiding traverse reach to the two edges of the width 0 represents not slow down 1 represents to slow down 5 Braking Select the braking mode of the winding spindle 0 represents single brake mode 1 represents double brake mode 6 Counting unit Select 0 1 or 1 turns as your count unit 0 represents 0 1 0 0 to 9999 9 turns 1 represents 1 0 to 99999 turns Guiding traverse unit Select the basic unit of guiding traverse 0 represents mm 1 represents inch must using lead screw in imperial Operation mode Select operation mode for the START switch 0 represents Single click mode 1 represents Double click mode The on the front panel always as the Double click mode CNC 210A Series H6681 User manual Page 10 of 20 7 2 Station number zz oet the station number of the winding machine controller This number is used to identify the station when using RS 485 communication function Up to 32 stations can be operated on the same network Setting range 01 99 7 3 Passworde 2 This password is used to protect the setting data in memory After you set this password you cannot change any winding parameter and configuration data in normal sequence You have to key in four numbers of password before press the e 50 2 If the password has been passed once you can change any data in normal sequence until you turn off t
22. winding direction for each step sel0 To specify whether to suspend winding during the guiding traverse moving to the edge of the width 0 Select whether to have auto positioning function for each step sw Select whether to have auto starting function for each step Reduce step number by one or reduce PIECE COUNTER by one i During programming clear current data to zero Copy the data of previous step into current step Write data into memory Switch display to shows PIECE COUNT or RPM Es Hold down this key for two seconds to reset PIECE COUNTER to zero To switch between AUTO and NON AUTO mode 0 Switch whether brake will be applied to the win spindle during stopping Skip current step and go to the next step B amp O Discard current step and go to the previous step Fe At any time discontinues current operation and return to ready mode Pause during winding Restart during pause or pause during winding CNC 210A Series H6681 User manual Page 4 of 20 3 3 Digital display STEP DISPLAY Show the current step number being wound or being programmed DATA DISPLAY During programming in combination with LED shows H H the parameter being programmed During winding ready mode show the current number of turns or show the guiding traverse shafts position A A A COUNTER DISPLAY Shows PIECE COUNT or RPM 3 4 Status indicators L 2
23. y assigned for each step Off power memory retention without battery Winding speed can be specified using the front panel keypad resulting in easy programming of multi step multi speed settings Guiding traverse shaft stepper motor with a constant current driver offering fast wire guiding speeds Guiding traverse shaft offering 10 steps moving speed selection Offering RS 485 interface for PC linking and data transfer Software be update through the personal computer Power input AC100V 120V 220V 240V 600VA max CNC 210A Series H6681 User manual Page 3 of 20 3 FRONT PANEL DESCRIPTION ES3MOVE SHIFT TURNS HS ES RUN E30 5 EXWIDTH E3SSLOW 5 E2SLOW ESLAN E3PICH ESE SLOW ESFUN ES STAR 68888 Sm 000E a A id 3 ES 88 e STEP E3RPM FINISH hwiND AUTO 1 DIR HOME rpm lz BBBBB mm i m reno sTOP START U See 3 1 Power switch Power supplier equipped controls the AC power to the controller 3 2 Key pads 9 0 10 key for entering numerical values Enter into EDIT mode Specify target production quantity Specify starting step in memory 590 Specify ending step in memory T Select parameter to be programmed or to switch display mode ke Select guiding direction for each step E Select
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