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modular trans-01 transfer line control user's manual

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1. ovn 1 oz i d f mE Roming whites i n ud 1 pph T Spindie comand brown Uses EL emer 25 i E tondttionet Jump 23 EK pingle command OY white QYenll 24 I i TO SPINDLE MOTOR CONTR GLER P Hi EE CABLE NO 84 0950 p MCN m m ed ud pa i Enenie Forvacd A A J Ee Manum Spjagie Enebl MOTE 1 TUR L senate 7 Npc tus ticoamandem iui Lint Rafr Input ju ET EN EL 5 aa itn aT i AR am Qvi i 8 3 TYPICAL CONTROL 3 i P E i 5 TYPICAL MOTOR INTERCONNECT ed 01 eis car 0 Wette pve ll 1213 24 vi 126 TT L TERMINAL LESEND t ap s 9 x 4 1 E i ATOR AE 1 TERMINAL STRIP ME 8 POSITION FEEDBACK 5 1 1 TERMINA NUMBER Es CABLE ND 83 8418 h ni ee eA 23 E REXROTH TRANS OIM fee HH INDRAMAT INTERCONNECTION 7 ni sis 209 0036 0604 04A Dna m EE HA REPRINTS PROHIBITED Thi dotomant For cuxiemar uta nat to coalad rmsasad Reference copyright lem Figure 7 4 TRANS 01 M Interconnect Diagram System With TDM AC Servo Controller IA 74718 7 7
2. 18 3X3 10 09 AITINGOW 57104 YOLOW OATS OVA JEAOUISE JO 3589 UOntsOd pue ASIO9S E Q 1070W usamjaq diysuone si s2uppureur SB pam Se Aejd pua peixe sosnboz Linear Scale Application With TRANS Figure 9 11 Rev A 10 87 9 33 IA 74718 APPENDIX A PARAMETER RECORD SHEETS The following pages are the parameter record sheets for the Modular TRANS Note that when certain options are not included in a control parameter numbers associated with those options will not be present in the software It is suggested that the parameters programmed in a TRANS be promptly documented and a copy of the form placed on or near the machine as a handy record See Chapter 4 for information on reading entering system parameters To determine the software version of a TRANS refer to the label located on the front of the TRANS cabinet Alternatively the REV key on the TAM panel may be pressed in Manual mode and the software version will appear on the display as follows NOOO TR 30 005 0US Block i e pace ca ee dra E e erit I A AE CIPRO NO NP i LANGUAGE Li ha d Neige make qeu SEO d oU RO US English U S D German I Italian French S Swedish IA 7471
3. 85 2 346 L 300 It amp a ux gt ia ro TO TERMINAL STRIP TO ON TRANS OI M WIRE COLOR FUNCTION PIN NUMBER white HOMING INPUT I7 I8 q brown AUTO MANUAL 3 n 19 groen ENABLE 5 yellow RE START 20 4 gray CONDITIONAL JUMP 2 RENT d pb 5 1 ink d dn Z 2 blue 2 93 7 3 ORANGE A rad TI n 2 n 24 7p 8 FERRULE 22 17 black FORWARD 9 T vioiat REVERSE 26 p 10 i z AR 27 gray pink START ENABLE FORWARD 88 I rad biue i2 whita green TOOL CHANGE 29 brown green MANUAL SPINDLE ENABLE n 30 d 7 14 T7 white yellow Nactual 2 N commanded IU are Te aic i MOTOR TAS2 32 yellow brown e white gray NOT USED NOT USED qroy brown USED NOT USED 2 WIRE SIZE 0 25mm 23 awe NOTE ALL DIMENSIONS ARE SHOWN IN mm inch FOR REFERENCE ONLY REXROTH REXROTH CONTROL CABLE FOR TRANSO X EE Sak T 209 0036 48 7 0l 05 225 5 7 remm RE REPRINTS PROHMEITED This document for customer vee not be copied or released Reference copyright law 64105 COMMENT SHEET MODULAR TRANS 01 TRANSFER LINE CONTROL USER S MANUAL Publication Number IA 74718 Your comments are valuable in helping us to produce manuals which best fit the needs of INDRAM
4. key Used in incremental motion commands to select motion in 2 10 POWER INDICATORS Description Power On Indicates that power to the servo drive is on Power Off Indicates that power to the servo drive is off Note that the system controls main power If everything is correct the TRANS will operate and some display mode will be selected e 2 11 OPERATION MODE KEYS The TRANS can be in Automatic Mode or in Manual Mode as determined by a signal from the Line Control or from the Operator Station in Manual Mode the operation mode keys described below are active Key Description Continuous Cycle Mode this mode the control will continuously cycle through the program after the Cycle Start key is pressed This mode is generally used only in set up and test operations Single Cycle Mode this mode the control will execute one cycle n after the Cycle Start key is pressed or the Start signal is supplied from the Line Control terminating operation when Jump To Block 000 And Stop is executed This is the normal operating mode of the control IA 74718 2 12 Rev A 10 87 Key Description e M Single Block Mode In this mode one program block is executed each time the Cycle Start key is pressed System Reset When this key is pressed a complete clear of the system occurs and all operations halt Note that this key is disabled during program execution R The position counters are reset and
5. DENOTES CUSTOMER SUPPLIED COMPONENTS EESE n 3 MOTOR POWER CABLE WIRE SIZE DEPENDENT UPON MOTOR TOM COMBINATION 18 SUPPLY 24VDC TO AXIS 2 Bb INPUT GN TRANS 1M n ey ant ERS ae 4 USE CABLE 23 0201 IF MOTOR HAS BLOWER TO SIGNAL READY CONDITION OF SPINDLE SYSTEM i on AXIS FROM TOR 5 5 i p axis 2 10 1 zs con uis PR pj dm E apu Serety 9 jones ux p ETC pee DE Hag Travel U6 Travel 5 9 cedo Poe Travel L S i ca cem z T E mi it 1 diei eres 8 CHEN IS ls 2 whtYer gr el x ks ze 7 lc 5 penea 8 1 Ea san TRANS L1 pU RN UNUSED MODULE w De 3 i vello 4 Es 04 9924 4 1 i e ao Intraa n Contra i F AF 2 UHUSEOC i sk a eliow 2 5 rs Broka Aeleome grey arene C Fault pink fault Paver Interrupt Ti Povar Interrupt o Ys I Durum PERL j Ei me Rm BER 1 De t 12 t a whi vesvellow a o e 25 FACH COMMAND ortan 1 1 p Voy tr n m CABLE 04 9256 BEER wate E i
6. Description With Lag Finishing Normally the control will begin executing the next block without waiting for the motor to come into position and take up the lag between the commanded and actual positions IF it is desired to have the motor in position and stopped before continuing with Lag finishing this key is pressed in response to the dialog display WITHOUT LAG If LF Line Feed is pressed instead the program will continue without waiting for zero lag Note all numerical controls have a following error between commanded and actual position based on the gain Indramat calls this following error lag Rapid Traverse When pressed in response to the dialog display FEEDRATE this key selects axis positioning at the rapid traverse rate specified in the system parameters This key is also used in Hand Mode to select jogging at the rapid jog rate Unconditional Immediate Jump When the Jump Programming function is selected in Dialog Mode this key can be pressed in response to the BLOCK JUMP display to specify an immediate jump to a specified block The block number is then keyed in The display code is JNXXX Jump To Subroutine When the Jump Programming function is selected in Dialog Mode this key can be pressed in response to the BLOCK JUMP display to specify a jump to a subroutine The block number is then keyed in Subroutine programming is described in detail in Section 5 3 15 2 The display code is Return Whe
7. Emergency Limit switch 7 5 1 Primary Overtravel Limit Switches These limit switches G and G in Figure 7 7 are used to inhibit travel against the Safety Emergency Limit switch because once the Emergency Limit switch is activated the slide must be manually moved correct position for the Primary Overtravel switches is then far enough in front of the Emergency Limit switch that the slide can decelerate before actuating the Emergency Limit switch In Manual Mode the axis may be moved off a Primary Overtravel Limit switch by pressing the appropriate Jog pushbutton a limit is encountered in Automatic Mode the program is stopped and the TRAVEL LIMIT diagnostic message is displayed IA 74718 7 13 Rev A 10 87 Gt LL Lu e d amp LIMIT DOG a s 5 L wes I E D ee 00000 emer Taser oc Figure 7 7 Limit Switch Positioning Programmable travel limits can be substituted for these limit switches but protection can be assured only after an auto home cycle has been performed If programmable travel limits are used some means of manually removing the slide from the Emergency Limit switch must be provided 7 5 2 Home Limit Switch As discussed in Section 7 4 the Home Limit switch in Figure 7 7 is used to provide a reference when searching for home position The exact reference is provided by the encoder The contacts of the Home Limit switch mus
8. For convenient interpretation of table position the TAM display modes present position as a value between 0 and this parameter value Each time the display reaches this parameter value it resets to zero and begins counting up again For negative movements passing Zero causes the display to roll over and begin counting down from this parameter value IA 74718 4 7 10 87 Parameter Number P08 9 10 11 12 IA 74718 Format Description Inch Metric GEARBOX REV IN Enter actual number of XXXX XXXX input turns corresponding to the number of output turns which is specified below Thus any non real gear ratio such as 142 6 can be entered GEARBOX REV OUT Enter actual number of XXXX XXXX output turns as described for Gearbox Rev In TRAVEL LIMIT Enter software travel limit XXX XXXX XXXX XXX on the plus side of home This parameter will prevent axis overtravel in the plus direction Physical travel limit switches may also be present and will be physically positioned beyond the programmed software travel limits in most cases The control includes provisions for sensing hardware overtravel and will halt and issue a diagnostic error message if a hardware overtravel occurs See the caution in P12 on the following page TRAVEL LIMIT Enter software travel limit on XXX XXXX the minus side of home See comment above CAUTION 1 Software travel limits must
9. Connector TRANS 11 Pin 11 Status Normally open Type Input 27 to TRANS This signal initiates the Automatic cycle operating the TRANS in Single Cycle Mode assuming that the following conditions are present 1 Selector switch at the Operator Station is on Automatic 2 Enable and Enable Forward signals have been present on the Cycle Interface for at least 50 msec 3 All acknowledgments agree with their associated auxiliary functions 4 The TRANS ensures that all start conditions are present and issues a Ready signal on the Cycle Interface Start is a high level sensitive signal but its receipt is latched stored in the TRANS control assuming the above conditions are present 6 4 3 Homing Connector TRANS 11 1 Status Normally open Type Input 17 to TRANS If in Automatic Mode receipt of this signal causes the unit to immediately execute the program beginning at the current reverse vector or block 120 if no reverse vector is specified If an automatic cycle is being executed it is interrupted Homing also performs the Emergency Home function The unit is homed per the user entered reverse program and can perform various functions such as tool retraction during program execution If a reverse vector ROOO has been executed in the current cycle no jump will be performed as the TRANS is considered to already be in a reverse program See Section 5 3 3 for information on the basic homing progra
10. The slide position at the end of the rapid traverse position X1 in Figure 9 5 should bring the encoder tip just short of the extreme back position of the part face X2 In other words the rapid traverse must be completed short of the closest point the part could be positioned to home The first portion of the feed at normal feedrate is selected by pressing the absolute positioning key shown at right It should Q end with the tip of the encoder at the extreme forward position 4 of the part face position X3 If the part is missing or too far forward the PART LOCATION ERROR diagnostic will be issued at the end of this first feed Now the value of parameter P35 Lin Encoder Pre Limit can be determined Referring to Figure 9 5 again it is X3 minus X2 the distance between the part face position extremes During the first feed of this operation if the part face is located closer to home than position X2 the TRANS will issue the LIN ENC PRE LIMIT diagnostic when the amount of encoder deflection exceeds the value in Parameter P365 Next select the value for the second feed in block 002 using the linear encoder selected by IA 74718 9 9 Rev A 10 87 This is equal to the desired depth of the hole plus or minus the distance between the tip of the encoder and the tip of the tool This will result in a final position somewhere between X4 and X5 depending on the part location Note that the software travel limit
11. With an optional Parallel Input Output Module PEA position correction values can be entered into the MODULAR TRANS s Correction Registers directly from outside devices Both Correction Register 01 and 02 may be addressed and values can either replace the current contents of the particular register absolute or be summed with the current contents of the particular register absolute or be summed with the current contents incremental Absolute or Incremental operation is parameter selectable Values between 0 9999 to 0 9999 inches 9 999 to 9 999 mm may be transmitted Two operations are possible transmission of a new value to a given Register or resetting to zero Clearing of a register Each operation occurs in a handshaking manner meaning a command is sent to the TRANS 01 M via an input signal after which the TRANS 01 M will initiate a sequence of commands waiting for an acknowledgment after each command before proceeding to the next following sections describe the TRANS O1M software and hardware requirements the signals associated with the PEA and a description of the transmission procedures 9 3 1 Software Requirements The Executive Software installed in the MODULAR TRANS must be revision TR3x 005 0 or later 9 3 2 Hardware Requirements All MODULAR TRANS Hardware versions may be used with the External Correction option however a PEA Parallel Input Output card must be installed in position on the V
12. i m jd d HB 2 00 M 5D CH m o Ra ES coer TO ED ITO RA 2 12 CO Oe ee Rev A 10 87 TABLE OF CONTENTS Paragraph Title Page Chapter 3 Operating the TRANS 01 M Control Cont d 3 5 Display Functions 3 6 3 5 1 Block Display Mode 3 6 3 5 2 Actual Position Display Mode 3 8 3 5 3 Destination Position Display Mode 3 8 3 5 4 Deviation Display Mode 3 8 3 5 5 Feedrate BCD Output and Tool Display Mode 3 9 3 5 6 Diagnostics Mode 3 9 3 5 7 Tool Correction Display Mode 3 9 3 6 Display Program Blocks 3 10 3 7 Display Parameter Values 3 10 3 8 Jogging Controls 3 11 3 9 Selecting Feedrate Override 3 12 3 10 Entering Tool Correction 3 12 3 11 Clearing Faults 3 14 Chapter 4 Reading Entering System Parameters 4 1 General 4 1 4 2 Displaying and Entering Parameters Using the TAM and LCA 4 1 4 2 1 Setting Parameter POO TRANS Number 4 1 4 2 2 Parameter Display Entry Edit Using a TAM 4 2 4 2 3 Parameter Display Entry Edit Using an LCA 4 3 4 3 Display Parameter Values 4 3 4 3 1 Parameter Display 4 3 4 3 2 Software Revision Level Display 4 4 4 4 Parameter Entry 4 4 4 5 TRANS O1 M Parameter List 4 6 4 6 Parameter Error Checking 4 20 4 7 Parameter Value Limits 4 22 4 8 Parameter Limit Formulas 4 23 4 9 Setting TRANS Number Versions TRANS 01 00 and 01 4 25 Chapter 5 Programming 5 1 General 5 1 5 1 1 Enabling Program Changes 5 1 5 1 2 Contents of this
13. 6 It then takes a conditional look at the current reverse vector block a If that block contains only auxiliary function changes no homing or other motion commands the TRANS does not wait for any pending acknowledgments of the restored auxiliary outputs but jumps to and executes the reverse vector block setting the auxiliary outputs as defined in that block It then waits for acknowledgments to these new auxiliary outputs before continuing with the reverse program 1 74718 6 16 Rev 10 87 This gives the user a chance to match outputs and acknowledgments on power fail recovery The easiest way to do this is to program the first block in the reverse program usually 120 to turn off all auxiliary outputs then program the next block with a homing function If the system follows the line control guidelines discussed in Section 6 10 3 that would automatically turn all acknowledgments off and the TRANS would proceed Of course you must be certain that axis movement is possible and safe with the auxiliary output setting you select b If the first block of the reverse program contains any function other than auxiliary output changes the TRANS waits for acknowledgments to the restored auxiliary outputs Once the correct acknowledgments are received the first block of the reverse program is executed 7 Normal program operation then continues re Lm ead Two signals Thrust Missing and Excessive Thrust are added to t
14. N command 2 This signal is not required for reverse programs to be executed This allows the spindle to run up to speed without any delay during the rapid traverse feed motion Also this allows the feed slide to be moved to the home position via the reverse program if the spindle is defective It is imperative that the spindle controller be able to output 24 volts to the TRANS both for proper operation of the program and to determine the status of the spindle motor 6 12 4 Spindle Enable Manual Mode Connector 11 Pin 14 Status Normally open Type Input 30 from TRANS When the TRANS is in Automatic Mode program execution can only occur if the connected spindle controller is operational and returning the Spindle Ready X8 2 signal The Spindle Enable Manual Mode signal is issued to enable spindle operation when the TRANS is in Manual Mode Thus it is possible to test programs in Manual Mode during their development spindle may be run in Manual Mode and will follow the program profile starts and stops when this signal is applied Also if the spindle is defective the Spindle Not Ready diagnostic error can be overridden by issuing this signal allowing the feed axis to be returned to the Home position IA 74718 6 15 Rev A 10 87 6 12 5 Spindle Temperature Switch TAS 2 Connector X11 Pin 16 Status Normally open Type Input 32 to TRANS When the spindle is enabled by parameter P40 t
15. 14 15 445 L 48 19 1 20 9 99095960966 SEE 8 SELECT CONTHOL NUMBER BEFORE INSTALLATION oceeoeococoooooooooOo0 DOOOOoO0OOOCcCOOoOOOO X11 amp NM NW ML EE ILE 25 4 9849 12 MS MELLE SEE NOTE 3 4 1 pf SELLIT OSTRE 54 NOTES XS amp 1 2 ALL DIMENSIONS ARE SHOWN IN MM INCHES FOR REFERENCE ONLY 2 MS IS STANDARD METRIC THREAU NUT TIGHTENING TORQUE FOR GROUND BOLT M5 2 5 Nm 22LB IN X7 X11 CONTROL CABLE INTERFACE PORTS X2 8 X3 AXIS COMMAND PORTS FOR TACH COMMAND 2 X12 8 KiS POSITION FEEDBACK PORT FEMALE CONNECTORS X14 amp X15zH5422 PORT FOR LCA MALE CONNECTORS TRANS OIM CONTROL NUMBER CAN BE SET FROM TO 30 AND CAN NOT OVERRIDDEN IN THE TRANS 1 PARAMETERS INTEAF aCe TRANS Oi MODULE 373 14 695 Qoo uU 390 15 384 355 13 8781 i RR 45 1 722 pu Loses 17 2 5698 7 198 276 t i 1 EUN 2 362 B OUTLINE TRANS 1 MODULE CHICAGD 109 0558 3001 014A 109 0568 3001 01A LB ZZ 5 7 dituns22 REPRINTS PRORABITED This document foi LueYomel nof to be copled or rsaead copynghi law F
16. 2 Block NOOO selected 3 Axis normalized homing performed since last power up by reset Normally a READY MISSING condition may be rectified by performing a homing operation READY MISSING can also occur as a Soft Fault in which case it will be accompanied by the illumination of the CE key Such a condition results when the CYCLE START key on the TAM is pressed but the axis has not been homed since the last power up or reset This will occur in Continuous Cycle Single Cycle or Single Block modes To recover press CE and home the slide RETURN ILLEGAL Soft Fault Indicates that during program execution the TRANS has encountered a block with a RETURN from a subroutine in it but is not presently executing a subroutine This can occur if the jump to subroutine is not programmed or if the main program is allowed to run into a programmed subroutine Press CE to clear the error then correct the program REVERSE FINISHED Normal Status Diagnostic Indicates that the Reverse input is activated but the TRANS has completed execution of the Reverse program IA 74718 8 15 Rev A 10 87 MESSAGE DESCRIPTION SUGGESTED RECOVERY REVERSE IMMEDIATE STOP Normal Status Diagnostic Indicates an interruption in the reverse cycle For example this diagnostic will be displayed after reset of a Soft Fault which occurred during execution of the reverse cycle or if CYCLE STOP is pressed during program execution REVERSE NO COMMAND Norma
17. 30 3 Press the Data In key 12 4 Key in the number zero and press ENTER ENTER 5 The TRANS is now responding as unit 00 and parameters can be set Unit 00 is a valid number for use only in TRANS set up It cannot be used as a working TRANS number The diagnostic message PROGRAM INVALID or PARAMETER INVALID should appear and the first two digits of the display will flash 00 If you are using new software in an older TRANS some other diagnostic message such as ENCODER LAMP FAULT may appear In that case you will need to change parameter P41 before you can select the TRANS NUMBER as described in step 9 below 6 Use the Parameter key to turn the Parameter keyswitch to the Parameter Entry Edit mode PARAMETER 7 Press RESET 8 Parameter POO and its present value will be displayed IA 74718 4 25 Rev A 10 87 9 Press the Edit key If NOT CHANGEABLE is displayed you will need to change parameter P41 as described below Otherwise skip to step 10 a Select parameter P41 by typing the following sequence woos b Press EDIT to display the present value of P41 C Retype the value for P41 changing bit 2 from a 0 to a 1 d Press ENTER This is a flag to let the new software know that it is running in an older version TRANS 10 Press the Edit key then key the TRANS NUMBER selected for this unit If you make a typing error press DEL to delete it and re key the number 11 Press ENTER to e
18. 33ue1 2 jeou asnesaq suoisuajxa uj2u3 3jesuaduio2 juod pue 323tdX10A 24 0 uueoaq A 3JOS eq HOLIMS LINII AHVGNOO S uad NOLLISOd AJJNJAAJJAN t Figure 7 6 Transfer Unit Design Criteria HOLIAS LWIT AWOH x B ET O el Eee ei a ro ES LED M a BO ie E 158 E 0 e 3S1949M Sui dnoo yenbs 1 5 OF 1 E uonesuaduro 5 erpel y BIXe SaptAoJd 1ea ESSET et P I 32310310 M uonisod 325u313j3y Ut Rev A 10 87 7 12 IA 74718 7 4 5 Positioning the Home Limit Switch As described earlier the Home Limit switch indicates to the TRANS that the reference position is located at the next zero pulse after actuation of the limit switch Therefore the reference position can be adjusted in increments of one motor revolution by moving the Home Limit switch Note however that problems may arise when the limit switch is located in a position near to where the zero pulse occurs In this situation switching tolerances such as contact bounce may cause irregular reference positions sometimes not capturing the first zero pulse To prevent this from occurring the TRANS monitors
19. 8 Press the Reset key to reset the control The TRANS again checks O the set of limit formulas If UNACCEPTABLE PARAMETERS is again displayed repeat this procedure Otherwise enter an applications program as described in Chapter 5 IA 74718 4 21 Rev A 10 87 4 7 PARAMETER VALUE LIMITS Table 4 1 below summarizes the maximum and minimum values which can be entered for each of the parameters TABLE 4 1 No Parameter TRANS NUMBER 01 TRANS GROUP NUMBER P02 SERIAL CYCLE INPUTS POS3 SERIAL ACKN INPUTS PO4 SERIAL CONDITIONS POS UNITS POG ENCODER CYCLES REV BALLSCREW LEAD 07 UNITS TABLE REV P08 GEARBOX REV IN 09 P10 TRAVEL LIMIT P11 TRAVEL LIMIT P12 REFERENCE POSITION P13 MOTOR RPM 10 VOLTS P14 KV FACTOR P15 HOMING SPEED P16 RAPID SPEED P17 JOGGING SPEED P18 JOGGING RAPID P19 RAMP 20 MAX FEEDRATE 21 22 DIRECTION POLARITY P23 HOMING DIRECTION P24 JOGGING DIRECTION P25 MAX FEEDRATE FOR G5 P26 TORQUE TO POS STOP P27 TORQUE AT POS STOP P28 AUX OUTP AT EM STOP P29 AUX OUTP AT IM STOP IA 74718 Minimum 1 1 00000 00000000 0 0 100 0 10000 1 0000 10 000 1 1 0 0000 0 000 0 0001 0 001 838 8600 8388 600 100 0 5 0 5 0 1 1 0 1 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0000 0 000 0 0 0 0 1 1 1 1 00000000 00000000 PARAMETER VALUE LIMITS Maximum 30 9 11111 11111
20. An assembly of interface modules called a TIM TRANS Interface Module is composed of the following components number of input modules 115 Vac to 24 Vdc called ACI s A number of output modules 24 Vdc to 115 Vac called AMMS s A 35 mm mounting rail Two end clamps number of jumpers to tie the 24 Vdc terminals on ACI modules together number of jumpers to tie the 0 Vdc terminals on AMMS modules together Normally a TIM is ordered by specifying the number of ACI and AMMS modules required The TIM is then delivered with the rail cut and drilied to the required length with the modules and end clamps mounted on it and the jumpers installed For cases where the quantity per TIM is unknown ACI and AMMS modules may be purchased mounted on 1 meter 39 4 in rails in which case cutting and drilling the rail must be done on site The dimensions and mounting information of a completed TIM are shown in drawing 2109 556 3001 A Notice that for both the and AMMS the terminals are designed so that 115 Vac always connects to screw type terminals and 24 Vdc always connects to spade type terminals IA 74718 9 29 Rev 10 87 9 8 2 AC input Modules The ACI AC Input Module converts a 115 Vac input signal to a 24 Vdc output signal The AC side of the circuit loads the driving device capacitively so normal commercially available solid state relays may be used without the necessity of an additional load Technical Dat
21. Note that it will probably be impossible to ever get the displayed value to consistently be zero and it is not required as the Jimit switch will not be repeatable enough PARAMETERS INVALID Hard Fault Indicates that the present TRANS parameters are not compatible with its executive software This diagnostic will occur if executive software has been changed in a TRANS to a version with different parameter requirements this case insert the Parameter key turn the keyswitch to the Entry Edit position and press Reset The old parameters will be erased and new ones must be programmed PARAMETER LOST Hard Fault Indicates that the parameter memory is unreadable usually as a result of removing the battery for an extended period of time a defective battery recover replace the battery insert the Parameter key turn it to the Parameter Entry Edit position then press Reset Now re enter the parameters manually or via the Line Controi Adaptor IA 74718 8 12 Rev A 10 87 MESSAGE DESCRIPTION SUGGESTED RECOVERY PARAMETER MODE Normal Status Diagnostic a Soft Fault or a Hard Fault When Diagnostic Display Mode is selected in Parameter Mode this diagnostic merely indicates that fact If however an attempt is made to select a different mode Hand Single Block etc while the Parameter keyswitch is in the Parameter Entry Edit position this diagnostic is displayed and the CE key is lighted to indicate a Soft Fault
22. The direction of motion selected in both blocks must be the same 2 The first block must not be programmed with lag finishing 3 Feed Ramp must be programmed into the second block 4 No conditional jumps are allowed in the first block The Feed Ramp can be useful in other situations such as 1 The system has a very high position loop gain for high accuracy but accelerations in the feed range would be excessive if limited only by that gain 2 It is desired to accelerate at normal rates to decelerate using a ramp such as in a speed reversal using a gearbox which has considerable play 9 6 2 Installing the Option Installation of TR32 executive software is done per the procedures described in Section 9 1 74718 9 25 Rev A 10 87 9 6 3 Parameter Parameter P36 is used only in TR32 software for Feed Ramp Para meter P36 9 6 4 1 7 Format Description Inch Metric FEED RAMP When selected in Dialog programming XXX X XXXX for a biock the value programmed in this parameter specifies the system acceleration limit for that block in all feed and rapid speed ranges Enter in inches sec sec or mm sec sec minimum value 0 1 inch sec sec 1 mm sec sec maximum value 999 9 inch sec sec 9999 mm sec sec Programming the Feed Ramp Switch the system to Manual Mode at the Operator Station Establish communication between your TAM and the TRANS as described in Section 3 4 Insert the correct k
23. connector X11 pin 2 low and actuating the REVERSE pushbutton connector X11 pin 10 Press the pushbutton to clear the fault Release it then press again and hold to execute the Reverse program 8 3 DIAGNOSTIC MESSAGES This section provides a list of diagnostic messages in alphabetical order which may be displayed with a description of the problem and suggested recovery procedures If the recovery procedure is simply to check for the problem and correct it follow the procedure as stated IA 74718 8 2 Rev A 10 87 MESSAGE No Message BUS ERROR COMMAND ERROR CONTROLLER OVERTEMP CORRECTION EXCEEDED DRIVE FAULT DRIVE NOT READY IA 74718 DESCRIPTION SUGGESTED RECOVERY When power is applied to the TRANS but no message appears on the TAM display or only one random digit is lit there could be a processor error or a time out error processor running out of the executive program caused by a severe noise spike First recheck your TAM connections then try turning power off then back on If the problem was a timeout error it wili be corrected If not replace the TRANS Hard Fault Indicates that an error has occurred on the TRANS BUS connectors X14 and X15 when using the Line Control Adaptor LCA Possible causes are defective cabling a power interruption at the LCA or a defective LCA Installing or removing TRANS BUS cables under power can also cause this fault message Soft Fault This err
24. otherwise NS P the Jump to Gap error LF gt yn JUMP TO OR RETURN IMMEDIATE JUMP FROM A SUBROUTINE CONDITIONAL JUMP JUMP amp STOP REVERSE VECTOR No NOTE AS be tarminaled with sut a RETURN Enter subroucine block number 2 ipe on ENTER 2 Cursut Input 5i Jump 16 block Cunditicnal Jump Ewer inp conditions I 0 0H To Bloch Store Page 5 27 IA 74718 9 36 Rev A 10 87 1 74718 BLOCK STORE From Page 5 36 Review block contents Change Contents Yes 5 37 DEL Rev A 10 87 it Edit Programmed Data gt Displays line of block Another line in this block Another block Data No incorrect ENTER DUENEAN IA 74718 5 38 Rev A 10 87 5 7 PROGRAMMING EXAMPLES To assist you in programming the TRANS this section includes two sample slide profiles the associated programs and a presentation of the actual keystrokes required to enter each program into the TRANS 5 7 1 Example Program i The first program is a simple slide profile consisting of a rapid advance a feed a dwell and rapid return profile of this program is drawn below Rapid Advance Feed Dwell l Sec i Rapid Return 10 2259 Each portion of the profile will be a block in the machining program
25. pulse occurs as expected The HOME SWITCH ERROR occurs if the Home Limit switch closes at a point other than the expected home position Homing Procedure 1 Homing command is issued If the slide is not on the Home limit switch it moves in reverse toward home until the switch closes as shown in the motion profile in Figure 7 5 It then decelerates reverses direction and moves forward off the switch If the slide is already on the switch when the command is issued it moves forward off the switch The axis moves at one of two feedrates a After a Reset after a power up and for the first homing only the axis moves at the homing speed specified in parameter P15 IA 74718 7 9 Rev A 10 87 b On all homing operations after the first homing the axis moves at the feedrate specified in the homing command If no feedrate is specified the command the slide moves at the homing speed specified in parameter 15 3 The axis decelerates reverses direction and creeps in the reverse direction until the Home Limit switch closes 4 It continues in the reverse direction at a super creep rate until the zero or marker pulse occurs 5 The axis then moves forward until it is exactly on the marker pulse about 100 of revolution m Homing Motion Profile jm After Power up or V2 Reset V2 HOME SWITCH ZERO PULSE Homing Motion Profile POSITION After Initial Homing Performed HOM
26. selected in Manual Mode at the Operator Station which produce slide movement following the programmed contour Note that the jogging rates are selected as program parameters The procedure for jogging is as follows 1 Switch the control to Manual Mode at the Operator Station O 2 Press the Hand key N 3 To jog at normal speed just press either Jog key The axis will move while the key is being held and wd will stop when the key is released 4 if you jog the slide to one of the hardware overtravel limits the appropriate diagnostic message TRAVEL LIMIT or TRAVEL LIMIT is displayed that jog key is disabled and a soft fault results At this point you can jog the slide in the other direction or Home it Press the CE Clear Error key to clear the diagnostic indication The control will not accept any other commands Note that software travel limits are selected via parameters P10 and P11 see Chapter 4 These limits are not active until a homing cycle has been performed Thus the slide could be jogged past the software limits CPE EYRE ENE ND MORS P IA 74718 3 11 Rev A 10 87 i P i I Hi i i 5 To jog at rapid jog speed the TRANS must be homed first first press the Rapid key If rapid jog is allowed the LED on this key will light and the jog keys will be operational If the slide has not been homed rapid jogging is not allowed HOMING MISSING appears in the displa
27. the fault will reoccur when the button is pressed the second time 6 3 4 Toolchange Connector TRANS X11 Pin 13 Status Normally open Type Input 29 to TRANS Releasing the pushbutton stops the movement Pressing and holding the button again continues the operation The TOOLCHANGE button s active only when the TRANS is at block zero and is not executing another program If necessary the RETURN pushbutton can be used to return the slide to Home before pressing TOOLCHANGE 6 4 CYCLE INTERFACE For operation of the transfer line through data bus control the TRANS is equipped with parallel Cycle Interface containing the signals described below The machine builder will wire these signals to the Line Control as required by the overall system design When Indramat s Line Control Adaptor is present the proper bits in parameter PO2 must be set to O s to enable the TRANS to accept the Forward Enable Restart Enable Start and Homing signals from the Cycle Interface Note that the TRANS is an intelligent subsystem and needs only a few signals to operate greatly simplifying line control functions as compared to conventional systems For example the TRANS will recognize and remember the fact that an automatic cycle was interrupted by loss of main power The signals on the Cycle Interface are nl ee MR aan These signals are described in Section 6 2 1 and 6 2 2 respectively IA 74718 6 4 Rev A 10 87 6 4 2 Start
28. 01 M controls on a high production line The LCA receives data such as slide position diagnostics I O status etc from each connected TRANS and buffers the information in its RAM memory RS 232C port on the front of the LCA connects to a user supplied device used to manipulate the data This device can range from a dumb terminal to a large computer Once connected to the LCA this device called the Line Control can request and obtain status information from any or all TRANS 01 M controls on the line It can upload complete part programs parameters diagnostics and tool corrections Additionally the Line Control can transmit programs parameters and tool corrections to any TRANS on the bus and transmit commands such as Start Enable and Homing See Indramat publication IA 74706 for complete information on the Line Control Adapter including instructions on how to transmit programs parameters and commands to the TRANS over the RS 422 serial channel 1 1 4 Diagnostic Monitoring The TRANS continuously monitors all important functions of the system for correct operation This includes all inputs outputs operating voltages axis components servomotor spindle motor when present tachometer incremental encoder limit switches parameters and the user program The monitoring is done at all times whether a TAM keyboard display unit connected or not When operating faults or disturbances are detected the control switches to the
29. 10 87 1 2 3 NET T 97 BECHS t 12 ig I 4 11s 08 NOTES A 1 CONTROL VOLTAGE 5115 or 228VAC MUST MATCH VOLTAGE 5 USE CABLE 03 0411 IF MOTOR HAS BLOWER INPUTS OF KOY X10 AND ANY BLOWERS 5 8 AWG MUST BE USED FOR KOV POWER WITH FOLLOWING MOTORS 2 3 PHASE AUTO TRANSFORMER 220V OUTPUT USE ISOLATION 1128 1 60 i12C 1 HD XFORMER IF 3 PHASE POWER IS NOT REFERENCED TO GROUND 112C 0 KD MAC 1120 CR1 AUXILIARY CONTROL RELAY FOR Mi CONTACTOR 24VDC COEL MAC 112C 1 KD 112C 1 ED CR2 BRAKE CONTROL RELAY oanly req d 1f motor hee brake C24VDC COIL MAC 112C 0 HD AND ALL MAC i120 8 T CR3 TAS RELAY 24VDC COIL 7 USE CABLE 95 0500 FOR TAM TO TRANS O1M DI Mi MAIN POWER CONTACTOR USE CABLE 05 0410 FOR TRANS 01M TO TRANS Q1M Cr ES TUE B Fi FUSE 3 EA 3 PHASE MAIN POWER 8 USE CABLE 85 0428 FOR LCA TO 5 1 t B F2 FUSE 2 EA C113 220V 1 PHASE 9 DENOTES CUSTOMER SUPPLIED COMPONENTS I 3 MOTOR POWER CABLE WIRE SIZE DEPENDENT UPON MOTOR KDS COMBINATION 18 SUPPLY 24 0 TO AXIS 2 8b INPUT ON TRANS 1M TAM INTERFACE sas 4 USE CABLE 03 0201 IF MOTOR HAS BLOWER TO
30. 402 15 827 MERC 4 0 157 20 827 EN 311 12 244 83 MIR 3 268 L ALL DIMENSIONS SHOWN IN mm inches FOR REFERENCE ONLY Figure 7 3 TAM 2 Portable TAM Outline Drawing 74718 7 5 10 87 7 2 4 Requirement For External Voltage Source The TRANS provides the highest possible noise immunity All inputs and outputs including the drive interface are both physically and electrically isolated from internal circuits Thus I O signals require the use of an external voltage source provided by the machine builder See the interconnect drawing Figure 7 4 and typical I O circuit diagram Figure 7 8 7 2 5 Rules For Installation For highest reliability the installation should be made according to the rules listed below This avoids not so obvious noise sources Feedback cables must be shielded and routed as directly as possible In no instance may these cables be routed along side of and parallel to power switching cables Inductive loads such as solenoids and motors that are switched at the unit must be suppressed with R C networks AC or diodes DC 1 0 cables which are routed through the machine e g the cycle interface inputs and outputs must be shielded Refer to the interconnect drawings supplied by Indramat for details on cabling for your particular system 7 3 MOUNTING THE SERVO MOTOR The mounting arrangement of the MAC servomotor must be designed so that if motors are exchange
31. 5 describes programming using the TAM Figure 2 3 TAM Control Panel IA 74718 2 3 Rev A 10 87 The TAM consists of a 32 character alphanumeric display several groups of pressure sensitive membrane type switches including a numeric keyboard cluster and on the lower left two keyswitches Several of the keys include an LED in the upper left hand corner These are illuminated to indicate the current status of the system informing the operator what mode the alphanumeric display is in what functions are contained in the current block etc These are described in more detail in following paragraphs The keyboard uses standard ISO symbols for various key functions Figure 2 4 is another illustration of the keyboard with each symbol labeled This is a copy of a paste in sticker that is mounted inside the door of every TAM 2 01 fixed keyboard display Callouts in Figure 2 3 indicate various elements of the panel including several functional keygroups The callouts are 1 32 Character Alphanumeric Display Displays program block data parameters current control status and diagnostic messages It is used in programming and parameter entry edit to provide a dialog prompting the operator with English language messages as he enters or changes program blocks or parameters 2 Display Mode Selection Keys Used to display system status including actual position commanded position deviation position lag feedrate BCD outputs and too
32. 838 8600 inch P11 0 0001 when X2 1 838 8600 inch lt 11 lt 0 0001 when X2 gt 1 X2 8388 600 mm Pil lt 0 001 when X2 1 8388 600 mm lt 11 lt 0 001 when X2 gt 1 X2 838 8600 inch P12 X2 838 8600 when X2 1 838 8600 inch lt P12 lt 838 8600 when X2 gt 1 X2 8388 600 mm P12 X2 8388 600 when X2 Conan mm lt 12 lt 8388 600 when X2 gt 1 P13 8388608 1000 X1 1 lt X3 65535 15 lt 4 1000 0 15 lt 65000 1000 0 and 15 lt P16 16 lt 4 1000 0 16 lt 196000 1000 0 17 lt X4 1000 0 and 17 lt 65000 1000 0 and 17 lt P16 18 lt X4 1000 0 and P18 lt 65000 1000 0 and 18 16 20 X4 1000 0 and 20 lt 32767 1000 0 and 20 16 25 lt 4 1000 0 P25 lt 32767 1000 0 and P25 P16 4 24 Rev 10 87 La TTT m aM i i M e ell Versions MOO and 01 do not have switches for setup of the TRANS NUMBER thus the following procedure must be used 1 First make sure that you have a TAM connected only to the control you are going to set If a number of controls are daisy chained you will need to interrupt the chain so the TAM is communicating only to the one you wish to set 2 The TAM should be displaying WAITING FOR CONTROL XX where XX scrolls from 01 to
33. At that point the TRANS will be in an immediate stop condition Examples of Temporary Faults are I O SUPPLY MISSING EMERGENCY STOP etc IA 74718 8 1 Rev 10 87 8 2 3 Soft Fault A Soft Fault is an error which can generally be cleared by pressing the CE key and correcting the cause of the fault such as re keying data which was entered incorrectly For example a key pressed in the incorrect sequence or an attempt to enter too many digits in a number results in the COMMAND ERROR or FORMAT ERROR diagnostic display and the lighting of the LED on the CE key Correct the fault by pressing CE and re keying the data 8 2 4 Hard Fauit Hard Fault is generally a hardware error of some kind such as a failure of the encoder a broken wire etc this case the position of the slide is no longer known When a Hard Fault is detected the following occur 1 The TRANS drops the Ready connector X10 pin 10 and Run connector X10 pin 9 signals on the Cycle Interface and drops the Fault signal connector X10 pin 6 2 The appropriate diagnostic message appears in the display and the LED on the Reset key is lighted You must remedy the fault then press the Reset key The TRANS comes O up in Single Cycle Operating Mode and Diagnostic Display Mode You must now home the axis before operations can continue Z 8 2 5 External Fault Reset Both Hard and Soft Faults can be reset by selecting Manual Mode on the Operator Interface
34. KbrioBi caTi amp nded uu TS nr hate aaa pnuren ES hotor 745 2 i EAS th XB 5 F 241 1S8fety 1 gt xi4 i on d NOTE 8 TYPICAL POWER CONTROL s is z TYPICAL MOTOR INTERCONNECT Fa 26 1 2 wu 8 T4 Vi WA j i DI L TERMINAL LEBEND 7 8 9 ig Tach ow 5 a ON t TERMINAL STRIP as i m TERMINAL HUMBER LS 5 amp 8 B zm Tater ee EME f 5 VoL pitt L ue ie 12 REXROTH KDS TRANS OIM rem M INDRAMAT INTERCONNECTION EH Rayo g CmICAQO ikl 209 0036 I608 O1A i REVISION FOR REVISED BY 61236 197 44 30 6 Figure 7 4A TRANS 01 M Interconnect Diagram System With KDS AC Servo Controller IA 74718 7 8 Rev A 10 87 CHAPTER 8 DIAGNOSTICS 8 1 GENERAL The TRANS control continuously monitors all important functions of the system for correct operation This includes all inputs outputs operating voltages axis components servomotor tachometer incremental encoder limit switches parameters and the user program When operating faults or disturbances are detected the control switches to the Diagnostic Mode even if the disturbance is momentary shuts the system down and issues a diagnostic message in English on the TAM This aids in quick determination
35. Mode to be selected Pressing the Hand key on the TAM enables the jogging keys on the panel IA 74718 3 1 Rev A 10 87 and allows jogging of the axis Forward and Return profile operations are not possible from the TAM panel nor is jogging possible from the Operator Station controls 2 Forward Generally wired to a pushbutton The Automatic Manual switch must be in the MANUAL position to enable this button While this button is held depressed the transfer unit will perform the programmed operation beginning at block 000 following the programmed forward profile Releasing the pushbutton stops the movement Pressing the button again continues the operation When first pressed the FORWARD button will be effective only when the correct program and zero references are present These beginning conditions can be achieved by pressing the RETURN pushbutton described below moving the slide to the Home position The Forward program must end with a Jump To Block 000 And Stop This can be done in one of two ways either by an immediate jump to the reverse program normally block 120 or by an absolute move to the home position followed by a Jump To Block 000 And Stop If a block of the Forward program specifies a Reverse Vector Jump of 000 the FORWARD button will execute the program up to and including the block with 000 Program execution will then halt and only the RETURN button will be recognized 000 serves as a flag to in
36. PARAMETER ERROR CHECKING The TRANS checks for parameter errors at three different points during parameter entry These three different types of error checking are l Format Check As parameters are being keyed in they are checked for correct format such as correct number of digits keyed FORMAT ERROR is displayed if an incorrect format is used for a parameter Press CE to clear this diagnostic then re enter the parameter value 2 Range Check When you press the ENTER key to enter a parameter into memory that parameter value is checked to determine that it is within the acceptable range as defined in Section 4 7 below If the value is out of range RANGE ERROR is displayed Press CE to clear this diagnostic then re enter the parameter value 3 Unacceptable Parameter Check When all parameters have been entered and the Parameter Entry Edit Mode keyswitch is returned to its normal position the TRANS executes a set of limit formulas to determine if it can physically operate within the specified parameter set Section 4 8 lists the limit formulas used If an unacceptable parameter is found execution stops and UNACCEPTABLE PARAMETERS appears in the diagnostic display This calculation is necessary because two parameters may each individually be within range but the effect of their interaction may be out of range of the system s physical capabilities If this diagnostic appears correct the problem as follows 1 Insert the correct
37. Position command either absolute or incremental positioning G4 Dwell time G5 Feed to a positive stop or optional function F Feedrate T Tool correction register number to be used S Analog spindle RPM output Analog spindle output must be enabled in Parameter P41 Auxiliary functions BCD output Block repeats Program jumps Q mm z N Unconditional jump U Jump to subroutine R Reverse vector programming S Jump and stop C Conditional jump based on 4 input lines RETURN Return from subroutine Feed ramp feed adaption and idle detection can also be programmed provided the appropriate software option is present in the system See Chapter 9 for details on these options including instructions for programming 5 3 APPLICATION PROGRAMMING REQUIREMENTS Remote operation of the TRANS 01 M via the Cycle and Operator Interfaces requires that certain rules for machining reverse movements and tool change programs must be established and scrupulously observed by the programmer This is necessary to insure that program execution will always be started in the proper manner independent of unexpected events and actions and that the system will always remain controllable in all operating situations via the Operator and Cycle Interfaces If these programming rules are not obeyed the TRANS will depending on the type of violation refuse to issue a Ready signal for the start of automatic operation or it will not be possible
38. SIGNAL READY CONDITION OF SPINDLE SYSTEM e e 1 salte 1 breve 2 18 ftr ation Tas river d d i me Hd o o dm T E x x EL rien dd ssi IB m ape easel n CABLE HD ns T 9 a mum 1 EX i GOTE 6 if B reu blua HN 14 avn or een 2 eer TRANS 1 E e MEE MODULE BE Hp Lii pum 2 1 5 Anat C F bd Hf o UhJSEG troke Helonge m EDT e Powar interrupt 3 o ECT Lem 2 me roy 2 9 oreen ue Ll Pr yalbowstroyn m 2 e H E 1 49 Tae Cn tae 0 T7 6 n m T grey bred 1 z e m ain 24 7 m Meg T m Ti Auto em Enavle e Stort i i Spinola f Congiticant Jusp 2 d ue ES Um rare ays erates d E z i ay a 99 oO tee gomma ae men L1 12 3 7 2 FO SRIMULE MOTON COuTR LIER 8 Pee gt mE Hl Ld CABLE D 2 i BILL pd TT E ns EN ila Pt ase os Sptnsle Enable biue AT 1 fasnh Stor ri i 22 E pase 115 2227 rad tlus hable Forwerd 1 0 T TW UEM H mer POR pourrai ids ckiov
39. Station provides control of a servo drive with incremental position feedback and inputs for home and overtravel limit switches provides control of a spindle drive with control signals for proper operation and monitoring used for direct control and acknowledgment of program dependent switching functions used for high speed communication with Indramat s Line Control Adaptor LCA Functions include program or parameter downloading or uploading status and diagnostics reporting and line operation used for communication between the TAM keyboard display and up to 10 TRANS control modules 1 12 Rev A 10 87 CHAPTER 2 TAM CONTROL PANEL DESCRIPTION 2 1 PHYSICAL DESCRIPTION 2 1 1 General Two models of the TAM keyboard display are available One portable and one designed for permanent mounting at the machine The TAM modules are identical in function but they differ physically Throughout the functional descriptions in this document TAM refers to either unit Where a specific unit is discussed it will be referred to as TAM 2 portable or TAM 2 01 fixed 2 1 8 2 Portable Keyboard Display Unit Figure 2 1 is an outline drawing of the portable TAM 2 keyboard Display It is designed to be hand carried to the machine then hooked to a TRANS using a serial cable from the connector in the lower left corner of the panel to either connector X4 or X5 on the TRANS 4a Leta no 3 R
40. Target block Specified input line configuration Line 1 Line 2 Line 3 Line 4 In the above example the program starting at block 015 is executed when line 4 of the selector switch is high and all others are low The program at block 026 is executed when line 3 of the selector switch is high and all others are low and the program at block 034 is executed when lines 3 and 4 are high and all others are low Block 003 is programmed with Jump To Block 000 And Stop the case where the selector switch has an invalid input combination this will cause the program to return to the beginning and stop rather than proceeding in an uncontrolled manner Note that conditional jumps may point only to blocks which contain valid program instructions Otherwise the TRANS will respond to the jump command with the diagnostic message JUMP TO GAP IA 74718 5 10 10 87 5 3 15 4 Jump And Stop NC Code J5 The Jump And Stop instruction causes an unconditional jump to the target block and subsequent stop of the program without execution of that target block Continuation of the program occurs only after a renewed Start signal is issued This instruction is used mainly at the end of a machining program where a Jump To Block 000 And Stop instruction is required Jump And Stop can also be used at other positions in a program if it is desirable to continue the program only after a renewed state 5 3 15 5 Reverse Vector NC Code JR W
41. action when the fault occurs However the axis must be homed before a program can be executed Note that this interrupt occurs only if power drops during a cycle not at rest or while jogging If power drops during jogging the system comes up in a reset mode and will allow normal jog only The axis must then be homed before a program can be executed Refer to Section 6 13 for more information on power interrupt operation and recovery PROGRAM INVALID Hard Fault Indicates that the present TRANS program is not compatible with its executive software This diagnostic occurs if executive software is changed in a TRANS to a version with different program requirements In this case insert the Program key turn the keyswitch to the Entry Edit position and press Reset The old program will be erased and a new one must be entered PROGRAM LOST Hard Fault Indicates that the program memory is unreadable usually as a result of removing the battery for an extended period of time or a defective battery recover replace the battery insert the Program key turn it to the Program Entry Edit position then press Reset Now re enter the program manually or via the Line Control Adaptor PROGRAMMING MODE Normal Status Diagnostic a Soft Fault or a Hard Fault When Diagnostic Display Mode is selected in Programming Mode this diagnostic merely indicates that fact If however an attempt is made to select a different mode Hand Single Block
42. and the programming process Key IA 74718 Mode Selected and Description Parameter Entry Review Mode This key is effective only when the control is not in Automatic Mode If the Parameter keyswitch has been used to select Parameter Entry Edit Mode the control will accept machine parameter data such as maximum feedrate rapid traverse rate inch or metric mode accel decel ramp etc If the keyswitch has not been set to the Parameter Entry Edit position pressing this key allows only review of the parameters Tool Correction Programming Mode In this mode tool corrections can be entered into up to 20 tool correction registers or can be reviewed This key is effective only when the control is not in Automatic Mode Tool Correction Programming Mode is not affected by the Program and Parameter keyswitches Program Entry Review Mode When the control is not in Automatic Mode this key can be pressed to select Program Read Mode where program blocks can be read into the aiphanumeric display for review This key is used in conjunction with the N key Block Number Select described below to read a block When the Program keyswitch has been used to select Program Entry Edit Mode this key is used with the DIALOG and EDIT keys to create and edit part programs Block Number Select Selects a specific block number for inspection programming or editing Dialog When this key is pressed in Program Entry Edit Mode an Englis
43. be programmed in relation to the actual reference position Home They are not affected by the zero reference setting or by zero offset 2 Software travel limits are not active until a homing cycle has been performed Thus the axis could be manually jogged via the panel controls past the software limits REFERENCE POSITION In many cases some XXX XXX XXXX XXX position other than the home position such as the center line of the slide is used as the reference position All programmed distances are then specified in reference to this point Enter either O or the distance from home to the reference position into this parameter Refer to Figure 7 7 page 7 14 When the TRANS is homed this value is loaded into the counters and all moves are made in reference to this position Thus if the reference position was 3 inches and the slide was at home an absolute move to 1 inch would result in 2 inch move in the negative direction 4 8 Rev A 10 87 Parameter Number P13 P14 P15 P16 P17 P18 P19 IA 74718 Description MOTOR RPM 10 VOLTS This is a specification of the drive and is entered in RPM For TDM DSC and KDS controllers refer to the MOD X personality module value specified for E1 E2 KV FACTOR This is the position gain of the system Enter in inches min mil ipm 001 or meters min mm This is the following error expressed in units of velocity Standard KV factor 1 0 En
44. be turned off press DEL to maintain current output status a dash appears in the display to indicate this 5 The display then advances to M 1 Continue programming the functions as described above If the displayed status of an auxiliary function is acceptable press LF Line Feed to increment the pointer to the next function After auxiliary function 7 is programmed the pointer will wrap around to M 0 Any mistakes made in the programming can be corrected by again following the above procedure At any time you can press ENTER to exit auxiliary function input mode and the TRANS will accept the function as displayed 74718 5 21 Rev A 10 87 BCD Outputs 6 Once auxiliary functions are selected or skipped BCD OUTPUT appears in the display If you want to select a BCD output code key in a two digit code 00 99 and press ENTER If a BCD output is not desired press LF Line Feed to skip to the Block Jump selection step 7 The specified value will be represented in binary coded decimal format on the BCD output lines when this block is executed Block Jump 7 When BLOCK JUMP appears in the display you can select one of five types of jumps as described below or press LF line Feed to skip Block Jump entry and advance to Block Store step 10 IA 74718 NOTE A jump must be made only to a block with programmed functions Immediate Unconditional Jump l Press J 2 J N appears in the display Key in t
45. block IA 74718 9 22 Rev 10 87 If feed adaption is chosen MIN THR CURRENT minimum thrust current will appear on the display The value entered here from 1 to 99 will represent the minimum thrust current that should be present during the feed process Note that the value entered is a percentage of the current rating entered in parameter P30 NOM CURRENT If the complete block is executed without the thrust current exceeding this value the Thrust Missing output will be turned on immediately and the THRUST MISSING diagnostic will occur at the end of the cycle after a Jump to Block 000 And Stop This is only a warning possibly indicating a broken tool or missing part so no fault occurs Minimum thrust current will be displayed as IMI xx where xx is the percentage entered above when reviewing or editing the block FEED REDUCTION now appears in the TAM display The value entered here may be from 1 to 99 and represents the maximum feedrate reduction that may occur in percent before the Excessive Thrust output is turned on The output will turn on immediately if this percentage factor is exceeded and the EXCESSIVE THRUST diagnostic will be displayed at the end of the cycle Jump to Block 000 And Stop Feed reduction will be displayed as FR xx during block review or editing For example if a Feed Reduction of 25 is entered the Excessive Thrust output is turned on if the machining feedrate is reduced to 75 of the programmed
46. but a Jump and Stop has been executed the program This diagnostic will not be displayed after a reverse vector of ROOO indicating end of the Forward program is encountered Instead in that case REVERSE NO COMMAND will be displayed because the Forward input is ignored after a reverse vector of ROOO is encountered Normal Status Diagnostic Indicates an interruption of the forward cycle This diagnostic will be displayed after reset of a soft fault which occurred during execution of the forward cycle or if Cycle Stop is pressed during program execution 8 6 Rev A 10 87 MESSAGE FORWARD NO COMMAND FORWARD OPERATING HOME SWITCH ERROR HOMING HOMING FINISHED HOMING MISSING IMMEDIATE STOP IA 74718 DESCRIPTION SUGGESTED RECOVERY Normal Status Diagnostic Indicates that the FORWARD pushbutton at the Operator Station was pressed in Manual Mode but released before the forward cycle was completed Normal Status Diagnostic Indicates that the TRANS is executing the Forward program via activation of the Forward input FORWARD pushbutton in Manual Mode Soft Fault Indicates that the TRANS has detected an error in the actuation of the Home Limit switch Once the first homing function is performed after a power up or hard reset the TRANS will remember where home position is A subsequent move to home position i e the execution of homing command or a positioning command resulting in a move to home cause
47. currently selected tool correction register Selected spindle speed in rpm 4 digits Status of 8 auxiliary output functions Se on is a zero filled with lines off Two digit BCD output value Will appear in the display only when the Feed Adaption option is installed IA 74718 5 14 10 87 9 5 3 Line 7 J Jump as follows JN Unconditional jump to block xxx JS XXX Jump to block xxx amp Stop JC xxx 1234 Conditional jump to block xxx based on the state of condition lines 1234 JU XXX Jump to subroutine at block xxx JR XXX Reverse vector jump to block xxx J RETURN Return from subroutine Line 8 E Specifies number of times execution of this block will be repeated before the next sequential block is executed Line 9 A Feed adaption only when Feed Adaption option is installed See Section 9 5 Line 10 0 Idle detection only when Feed Adaption option is installed See Section 9 5 Programming Block Functions Because the program must be protected from accidental or intentional alteration by unauthorized personnel programming access is only possible by using the Program key to enable Program Entry Edit Mode The TRANS monitors the parameters and the applications program to assure that all program functions are performed within the constraints established by the system parameters If a function is programmed or attempted which would exceed the bounds es
48. etc while the Program keyswitch is in the Program Entry Edit position this diagnostic is displayed and the CE key is lighted to indicate a Soft Fault IA 74718 8 14 Rev A 10 87 MESSAGE DESCRIPTION SUGGESTED RECOVERY PROGRAMMING MODE Cont d If the Program keyswitch is turned to the Program Entry Edit position while a program is being executed this diagnostic is displayed and the Reset key is lighted to indicate a Hard Fauit In addition to previous operation this condition will also be diagnosed as a hard fault if the spindle was enabled spindle regulator release RF on at the time the parameter key was switched regardless of whether a cycle was being executed or not This is done to insure that an unpredictable restart of the spindle will not occur when the parameter key is removed RANGE ERROR Soft Fault Indicates that the number e g parameter value entered is outside the range limitations of the TRANS For example this would occur if the ballscrew lead entered is greater that 3 0000 inches 30 000 mm READY MISSING Normal Status Diagnostic or Soft Fault Occurs in Automatic Mode indicating that not all of the conditions have been met to accept a Start signal When this diagnostic occurs the Ready output on the Cycle Interface used to indicate that the TRANS is ready for operation goes low to indicate Not Ready The conditions required for the TRANS to be in a Ready state include 1 Automatic Mode selected
49. executed TOOL CORRECTION now appears in the display From this point you will program the TRANS following the standard programming procedure starting as described in Section 5 5 3 2 step 11 You can select Tool Correction and various Miscellaneous Functions Note that FEEDRATE was not displayed because the TRANS will use the last feedrate programmed IF the last programmed feedrate exceeds the value set in parameter P25 a soft fault will occur and the RANGE ERROR diagnostic will be displayed 9 2 4 Linear Encoder Deflection The TRANS will move the slide as required to cause the linear encoder to be deflected the amount programmed for Lin Destination Because the TRANS closes a position loop using the linear encoder meaning that the encoder must reflect the movement when the motor is turned the linear encoder must be in contact with the part when the adaptive depth block is reached The instant the linear encoder encounters the part surface the TRANS will begin counting the distance the encoder is deflected Thus the normal movement of the slide plus the movement commanded in the adaptive depth block will make the total deflection equal to the value entered as Lin Destination Example Tool Part i 0 5 1 1 Linear Encoder Figure 9 4 Example of Linear Encoder Deflection IA 74718 9 7 Rev A 10 87 To cut a 1 1 inch hole in a part given a slide with the tip of the linear encoder 0 5 inches behind the ti
50. feedrate After feed reduction is entered the dialog process will continue with normal miscellaneous functions see Section 5 5 3 5 9 5 3 Associated Signals Two additional signals are available on the TRANS with the feed adaption option All signals are 24 VDC operated from the customer supplied 1 0 power supply used for normal TRANS interface signals described in Chapter 6 9 5 3 1 Thrust Missing Connector TRANS X10 Pin 4 Status Normally open Type Output from TRANS Thrust Missing will be turned on at the end of a block containing the feed adaption function if the actual thrust current never exceeded the minimum thrust current value programmed in the block Thrust Missing may indicate broken tooling or a missing part The output is reset at the beginning of each cycle 74718 9 23 Rev A 10 87 9 5 3 2 Excessive Thrust Connector TRANS X10 Pin 3 Status Normally open Type Output from TRANS The TRANS will turn this output on whenever the feed reduction required to maintain desired thrust current exceeds the programmed feed reduction value It will be turned off upon receipt of the next Cycle Start command in Automatic Mode or the next Forward command in Manual Mode If this output is accompanied by the Fault output feedrate was reduced by 99 without reducing thrust current to the desired value either case the output may indicate excessively hard part material or dull or broken tooling 9 5
51. for 100 msec soft fault will also result at the TRANS O1M and the message CORRECTION EXCEEDED will be displayed on the TAM if connected 9 3 6 Clearing a Correction Register The sequence to clear a Register set it s value to zero is a Bring the Clear input high b Bring the desired Register Select TO1 or T02 high After the clear function is performed the TRANS will respond by bringing Complete high at which time the Register select line may be brought low 9 3 7 Programming Hints It is recommended that a time out be incorporated into the program in the transmitting unit to avoid a lock up condition if a signal fails to occur for example if a wire breaks This timer would start when one of the Register Select lines or Data Valid is brought high and be reset by a rising edge on any of the eight PEA outputs Sign Digit 1 etc 9 4 ROTARY MOTION CONTROL The optional TR33 software configures the TRANS to control the motion of a rotary rather than a linear application This option is used for applications such as rotary tables or lift and transfer drives Rotary positions can be programmed in any type of units convenient to the application Rotary speeds are also entered in these same units Provisions have been made to allow operation with an external brake disabling the motor under program control This feature is intended for those applications where the sizing of the AC Servomotor is based on the load requ
52. has the option to 1 re enter parameter mode and change to the previous setting by turning the parameter key on pressing the Reset key and changing to the original parameter setting or 2 reset the current program and enter a new part program NOTE After initial parameters are entered and the TRANS is successfully started up a change of these parameter digits without changing the TRANS wiring could result in damage to the TRANS control the servo controller or both P4i OPERATION MODE 2 Analog Spindle Output See description Option software TR30 004 0 and above This parameter allows the selection of 8 special functions without the necessity of rewriting the part program However great care should be taken to ensure that the parameters are programmed to correspond to the physical manner in which the TRANS in interconnected to the machine Failure to program the parameters correctly will result in the malfunction of the control and or servo controller and in incorrect fauit diagnostic messages IA 74718 4 16 Rev A 10 87 Parameter Number 41 Cont d IA 74718 Description Function selection is illustrated on the below 01234567 Immediate Stop for Spindle 0 Continuous Spindle Rotation 1 With Commanded Stop Home Switch Monitoring 0 Active 1 Inactive Control Type 0 TRANS 01 M02 or higher 1 TRANS 01 MOO or MOL External Correction Value Input 0 Not Selected 1 Selected Ty
53. is acceptable lag finishing not required you press the Line Feed key instead of the Lag Finishing key this case the position lag from one block will not be completed before the next block or the miscellaneous functions in the current block are executed It is important to note that in a program block the TRANS does the positioning first then performs any miscellaneous functions such as jumps or turning auxiliary functions on or off when it finishes the movement If you select without lag finishing the movement is considered to be finished once the axis is moving into position but prior to the time the position is actually reached Thus any auxiliary functions in this block or the next block may be turned on while the axis is still in motion Therefore lag finishing may not be necessary to your positioning operation but you may need to select it to insure that auxillary functions are not turned on too soon 5 3 8 Feedrate NC Code In order to enable position commands a feedrate must be programmed A programmed feedrate remains valid until a new one is set Thus it is not necessary to program a feedrate for a position command if a valid feedrate has previously been programmed However it is good practice to always enter a feedrate in a block unless program operation dictates a block without a feedrate NOTE When checking the feedrate always check the feedrate override also The programmed feedrate is effective only to th
54. key into the Parameter Keyswitch and turn it to the Parameter Entry Edit Mode 2 Press the CE Clear Error key The unacceptable parameter will be displayed 3 Refer to the limit formulas in Section 4 8 and determine a corrected value for the parameter CAUTION Check your entire parameter set before mak ng any corrections The TRANS checks the parameters in order starting with 00 The parameter you are correcting is the first unacceptable parameter not necessarily the only one and not necessarily even the erroneous parameter For example assume you have a 2000 RPM motor Parameter P13 but enter 200 in error This is a low value but within range so is accepted by the control In parameter P16 you select a rapid speed of 300 inches min well within range for that parameter However when you exit Parameter Entry Edit Mode the TRANS indicates P16 unacceptable parameter It is unacceptable but because P13 is incorrect 74718 4 20 10 87 4 Press Edit then key in the revised parameter value If you make a Q typing error press DEL to delete it then re key the information 5 When satisfied with the new value press ENTER to enter the parameter value into memory 6 Successively press LF Line Feed to advance the display if you wish to change another parameter Repeat from step 4 above 7 When all corrections have been made turn the keyswitch back to its normal position and remove the key
55. made This is generally used to correct keying errors Note that Delete can be used to delete a sequence of keystrokes For example if you ve selected Edit mode X line and typed in 10 pressing DEL once deletes the 0 pressing DEL a second time deletes the 1 pressing it the third time deletes the selection of Edit mode Line Feed This key is pressed to advance to the next line within a block during display programming and parameter entry edit It is also used during programming to skip over a line function within a block that is not desired such as skipping auxiliary function entry when it is not required in a block Enter This key is used to enter line data within a block during programming It is pressed when a certain line function is desired or after numerical data has been entered TA 74718 2 11 10 87 2 9 NUMERIC KEYPAD The numeric keypad includes a pad of keys used to enter parameter program and tool correction values These include Key Description Data keys i 788 Data keys Used to enter information as program commands 000 parameters and tool corrections are keyed in Whenever one of 1 these keys is pressed the corresponding number will be displayed in UR the position in the command block currently being entered the positive or negative direction Used in absolute positioning commands to select a motion to the plus or minus side of zero If minus is not specified plus is assumed
56. mode it is essentially transparent for both the forward and reverse profiles will be executed normally However receipt of the homing input after reverse vector ROOO has been encountered will not cause a jump to be made because the TRANS is already executing a return program It is good practice to program a homing command in the part program after reverse vector RO00 however it is not required TRANS operates correctly without the homing command in all cases except where power has dropped after execution of reverse vector ROOO and before execution of the Jump to Block 000 and Stop In that case when power is re applied the TRANS has stored the fact that a reverse program was in progress and it continues where it left off when the Home command is received Automatic Mode or the RETURN pushbutton is pressed manual Mode When the reverse program is complete the TRANS checks if a homing command was performed If not it displays HOMING MISSING Manual or READY MISSING Automatic Issuing the Home command again or pressing RETURN a second time transfers control to block 120 and the slide is then properly homed Note that some users omit the homing command in the reverse program because they don t want to take the time for the system to execute the complete homing process in each cycle Instead they program an absolute move to zero Unlike many other controls this is not a problem in the TRANS because it executes the complete homi
57. must be present to enable this button While this button is held depressed the TRANS will perform the programmed operation beginning at block 000 following the programmed forward profile Releasing the pushbutton stops the movement Pressing the button again continues the operation When the control completes execution of a block containing a reverse vector of JROOO which indicates the end of the forward profile fuil depth program execution halts and this input will be ignored At this point the Return input should be activated to perform the return reverse profile When first pressed the FORWARD button will be effective only when the slide is in the Home position and the correct program and zero references are present These beginning conditions can be achieved by pressing the RETURN button Section 6 3 3 moving the slide to the Home position If during forward cycle operations the RETURN button is pressed the unit must be Homed before the FORWARD button again becomes effective 6 3 3 Return Reverse Connector TRANS X11 Pin 10 Status Normally open Type Input 26 to TRANS Generally wired to a pushbutton which is usually labeled RETURN REVERSE or RETURN TO HOME The unit must be in the Manual Mode to enable this button While this button is held depressed the transfer unit will jump to block 120 or the current reverse vector and perform its reverse operation as programmed in that block returning to the Home po
58. normal configuration for remote operations Various other display and operating modes can be selected from the TAM control panel The functions of the Display Mode keys are described below O Q 28 es s s ea Figure 3 2 Display Mode Keys 3 5 1 Block Display Mode Key 9 When this key is pressed the alphanumeric display indicates the functions used in the current block The display will be as shown on the following page JA 74718 3 6 Rev A 10 87 N G X N indicates block XXX indicates current block number Summary of contents of block Presence of a letter indicates the type of information programmed in this block A appears at a letter position if that function is not programmed in this block X Position Feedrate or Dwell Time Tool Correction Register Number Analog Spindle Output Auxiliary Function Outputs BCD Output Value Jump Block Repeat Feed Adaption Programmed Idle Detection Programmed NC G code as GO Homing Gi Position G4 Dwell G5 Move To Positive Stop Opt Function G6 Feed Ramp opt TR32 software il It Line displays This area is used to display the data programmed in each of the individual lines in the display The LF Line Feed key is pressed to sequentially step through and inspect each line from X thru O The line displays will be decimal points appear as appropriate L
59. offset value of 0 must be entered However if the measurements in the program are to be programmed with respect to some other reference such as the face of the workpiece the distance from the machine reference point to the workpiece reference point is entered as the zero offset providing a new reference point which is offset some specified distance from the machine reference point The value entered as zero offset is added to the reference position after homing has occurred Thus the zero offset can be used by the programmer in order to program the measurements in a machining program with respect to one of the surfaces of the work piece In order to assure correct measuring references programs which use zero offset referenced measurements must be started with a homing instruction which sets the corresponding zero offset Note that the control is at home when the slide is at the position where the first marker pulse zero pulse occurs after closure of the Home Limit switch The zero offset provides the flexibility to change the reference point whenever a different part is handled on the transfer line or to correct differences between actual and designed home position 5 3 6 Positioning NC Code G1 Two types of positioning can be selected in the system absolute and incremental In absolute positioning all movements of the slide are made to some absolute distance from the machine reference position which will either be home or som
60. or released Reference copyright iaw 77441 RECON f 77141 MAC TRANS 03 0410 DETAIL OF i91 CONNECTOR 12 PIN FEMALE KEY ON 7 11 4 L LENGTH AVAILABLE CONTINUOUS CABLE BEND RADIUS Samm 3 54 ONE TIME BEND RADIUS 40mm 1 57 TO MOTOR ST B CONNECTOR SHIELD CONNECTOR OUTLINE FEMALE TO MODULAR TRANS 1 0mm 17 AWG 9 10 12 NOT USED VIOLET dis LC BLUE 2 1 IIB PINK 1 8 B lax GRAY Mu B GREEN 5 2 BROWN Noon 1 4 10 BLACK 3 110 RED w gt 7 KEY 770 TWISTED PAIR 25mm2 23 AWG CABLE 4x2x0 25mm 2xi mm 3 MAXIMUM POSITION CABLE LENGTH IS 30 METERS 98 43 FEET REXROTH CHICAGO ILL POSITION FEEDBACK CABLE 209 0036 4830 004A DRAWN BY D 26 7 EB REVISION FOR SHEET 2 7 ar N or 2 lt lt 2 724 TS REVISED BY 1 REPRINTS PROHIBITED Thia document for customer uae not to be copied or released Reference copyright law X12 REDRAVN 77141 MAC TRANS 01M 3 0411 DETAIL OF IN 101 CONNECTOR 12 PIN FEMALE KEY ON 7 d m o CONNECTOR L LENGTH AVAILABLE UE CONTINUOUS CABLE BEND RADIUS 930mm 3 54 ONE TIME BEND RADIUS 4 mm 1 57 6 6 TO MOTOR ST B TO MODULAR TRANS CONNECTOR X12 SHIELD l 0mm 17 AWS NOT USED VIOLET 11 T 11 LC B
61. parameter P10 or P11 should be greater that the sum of the distance between home and the point X5 plus the maximum amount of tool correction that may be used 9 2 6 Illustration Figure 9 7 is a flowchart of the programming procedure using adaptive depth control TA 74718 9 10 Rev A 10 87 aivd ON 30 4 TUT TTT P padda T 002027 px 2 TTT ITE lc udi x NOI1YNILS3G HO 32NY1SIG 138430 E xX x E E z un X 4 E 5 39NYH2 ON 31 39MNYH2 Seo n NOH 23880 170901 30NYH2 0 do x1YHd0334 Ol vM DNIHSINI 3 1 M E Typical Adaptive Depth Cycle Programming Worksheet Figure 9 6 Rev A 10 87 9 11 IA 74718 IA 74718 Figure 9 7 SELECT BLOCK Lin Destination Key In Data lt gt Adaptive Depth Control Programming Flowchart No Change Register Number 0 Enter Tool Correction To misc functions Page 5 35 ENTER Tool Corre Tool Correction ction Rev A 10 87 THE FOLLOWING INFORMATION SECTION 9 3 IS PRELIMINARY CONTACT INDRAMAT ENGINEERING IF YOU HAVE ANY QUESTIONS 9 3 OPTIONS EXTERNAL CORRECTION TRANS 01 M
62. position Key on the TAM keyboard to be pressed Circle in upper left corner of box indicates key with LED If circle is filled in LED is lighted TAM display Enter data from TAM numeric keypad Procedure functional only when automatic mode is not selected on the Operator Interface Follow procedure outlined by text in the symbol This indicates that a procedure described in another flowchart must be followed Branch If the statement written within the symbol is true the yes branch is taken Otherwise the no branch is taken 5 27 Rev A 10 87 question is shown in the TAM display to allow the user to select a branch in the programming procedure Indicates manual procedures performed on mechanical or electrical assemblies IA 74718 5 28 Rev A 10 87 Sel Tool Correction Input Correction Data T Tool 1 X0 0 Offset correction data LF Data incorrect IA 74718 5 29 Rev A 10 87 Set Feedrate Override Override NOT in programming mode Enter feed rate value IA 74718 5 30 Rev 10 87 IA 74718 Select Parameter Display P t arameter AN meter Next parameter Back to first parameter 5 31 10 87 Set Parameter Parameter Input New data entered Correct wrong data Previous No ze IA 74718 5 32 Rev A 10
63. the block counter is reset to block 000 in effect providing the Jump to Block 000 and Stop command that is required to properly terminate a program This key must be pressed or the Return signal issued to clear a Hard Fauit generally a hardware error and allow restart of the TRANS once the error has been remedied The LED on this key will light to indicate that a hard error has occurred Note that a Homing operation must be executed after the system is reset to once again enable system operations Hand Jogging Mode When this key is pressed and the TRANS is in Manual Mode the Jog Forward Jog Reverse Rapid Traverse and Auto Home keys are enabled and the axis can be jogged from Manual Mode Manual Mode must be selected at the Operator Station by the Line Control in order for Hand Mode to be enabled Only jogging or homing using the TAM panel keys can be done in Hand Mode Cycle Start Pressing this key starts the control when Continuous Cycle Single Cycle or Single Block Mode This will generally be done when testing the system Cycle Stop Pressing this key causes an immediate stop of program execution Input Data Pressing this key signals the TAM to accept a TRANS NUMBER from the keyboard then press ENTER to establish communication with the Modular TRANS which is assigned that number on the TRANS BUS e Output Data Unused the Modular TRANS 01 IA 74718 2 13 Rev A 10 87 CHAPTER 3 OPER
64. to travel to reach the stop Key that value in press ENTER and go to step 5 If the slide travels the specified distance without encountering a stop movement halts POS STOP MISSING is displayed and a soft error occurs 5 FEEDRATE now appears in the display Key in the desired feedrate value then press ENTER Parameter P25 specifies Feedrate For G5 If a feedrate value greater than this is keyed in a soft fault will result and RANGE ERROR will be displayed 6 TOOL CORRECTION now appears in the display Press LF Line Feed if there is no requirement for operator accessible dimensions offsets or if the tool correction register number and its associated value chosen in a previous block is still to be used To select a correction register key in a number from 1 to 20 then press ENTER The operator can then enter a value in that correction register which will be added to the dimension in this and all subsequent moves until a different tool correction register number is selected or the control is reset if you had selected a tool correction register in a previous block but do not wish to use it in this or subsequent blocks enter a tool correction number of 0 then press ENTER IA 74718 5 20 Rev A 10 87 7 SPINDLE RPM now appears the display if analog spindle output is enabled in parameter P40 Key in tbe speed in rpm at which the spindle is to operate in this and subsequent blocks then press ENTER If you
65. to the label on the front of your TRANS cabinet to determine the software version installed REV or select manual mode on the Operator interface and press the Reverse Vector Jump key to see the software version number in the TAM display as NOOO TR30 005 0 US Block number Revision Language US English U S D German Italian French Swedish 1 F S H If you expand your system to add options you will need to install new executive software The executive program of the TRANS is fixed and is supplied by INDRAMAT This program is contained on an EPROM Erasable Programmable Read Only Memory mounted on the CPP 2 card of the TRANS as illustrated in Figure 9 1 on page 9 2 Install a new executive software EPROM as follows I Turn power OFF If you insert or remove an EPROM while the TRANS is powered you will destroy the program and probably ruin the EPROM 2 If necessary remove the TRANS from its mounting cabinet then loosen the screws on the right side panel and remove the panel You will see the PRP 2 printed circuit board containing one 27256 EPROM mounted in the upper left hand corner of the CPP 2 printed circuit board as illustrated in Figure 9 1 IA 74718 9 1 10 87 3 Remove the EPROM which contains your original software 4 Install the new 27256 EPROM Make sure the notch on the EPROM matches the notch on the socket 5 Replace the right side panel and re inst
66. together as illustrated in the sketch below External Voltage Source IA 74718 7 17 10 87 5 An input driven by an open collector output is illustrated below Input high min 15V Input low max 3V External Open Voltage Related to OVE Collector Source Output Input high min 15V Open Input low max 3V Collector Related to OV xt Output External Voltage R lt 1K 22 Source 6 An input driven by an active voltage is illustrated below 4 V Signal E 18 30V DC Source IA 74718 7 18 Rev A 10 87 7 7 CHECKOUT MOTOR DIRECTION POLARITY ON START UP 000 M M er The motor direction polarity depends on the machine design Parameter P22 is provided to reverse the direction of polarity if necessary avoiding the necessity for rewiring CAUTION Do not run the servo drive in any mode other than jogging before correct polarity has been determined Check out correct direction polarity as follows 1 After start up jog the slide into the center position 2 Press Reset 3 Select Manual Mode at the Operator control panel 4 Press one of the Jog pushbuttons and observe the direction of slide motion 5 Compare the actual direction of motion to the polarity of the motion selected 6 If the observed polarity is opposite to that desired change Parameter 22 from O to 1 or vice versa to reverse polarity IA 74718 7 19 Rev A 10 87 EL
67. user program is displayed along with its value IA 74718 3 9 Rev A 10 87 i E fi i 3 3 TH IRR 3 6 DISPLAY PROGRAM BLOCKS Use the following procedure to step through and display the blocks of a program 1 Generally you will want to select Manual Mode selected from the Operator Station Block display can occur while the unit is operating but you can only examine the various lines within a block while that block is being executed When execution of the first block is complete the next block comes up in the display 2 Press lt gt then press 3 Type the number of the first block you wish to examine leading zeros need not be entered then press ENTER 4 If you make an error while entering the biock number press and re key the number then press ENTER 5 The first line of the block is now displayed Data will appear in the format described in Section 3 5 1 A program block can contain up to 10 lines of information Each time you press LF you will step to the next line in the current block 6 When you wish to examine the next block press N then LF to advance to the next sequential block number then successively 5 LF press LF to step through and examine each line 7 Exit from Block Display Mode by selecting any other mode or by pressing Reset key to reset the control 3 7 DISPLAY PARAMETER VALUES
68. when the necessary enables are present The following signals are provided 6 3 1 Automatic Manual Connector TRANS X11 Pin 2 Type Input 18 to TRANS Generally wired to a selector switch With Automatic selected the TRANS will be in Automatic Mode and can be operated only by control signals provided by the Line Control This is the normal mode of operation for the TRANS where it performs a single program cycle each time the Line Control issues a Start signal Manual control at the unit Operator Station is possible only with the selector switch in MANUAL line open and when the TRANS diagnostic checking has not detected any interruptions Should the TRANS refuse to operate it will diagnose and display the reason See Chapter 8 for a complete list of system diagnostics 74718 6 2 Rev A 10 87 If the TRANS is in Automatic Mode and is executing a part program bringing this input low will cause an immediate stop condition and will force the TRANS into Manual Mode The TRANS may be switched back into Automatic Mode and restarted by a Restart signal provided that no manual operations have been performed If manual operations i e forward and reverse are performed a restart in Automatic Mode is not possible 6 3 2 Forward Connector TRANS Xii Pin 9 Status Normally open Type Input 25 to TRANS Generally wired to a pushbutton The Automatic Manual switch must be in MANUAL position and the Enable Forward signal
69. where they match their acknowledgments The next block then will usually be a homing command This should only be performed if it is indeed safe to force auxiliary outputs off and move Reverse vector programming is described in Section 5 3 15 5 example of reverse vector programming is presented in Programming Examples Section 5 7 5 3 4 Tool Change Program Pressing the toolchange key at the Operator Station initiates the toolchange program starting at block 110 In order to start the machining cycle directly from the toolchange position the program must be terminated with a Jump To Block 000 And Stop The simplest such program for travel to the toolchange position starting with block 110 is therefore N110 G1 X 5 0000 RAPID J S 000 Block 110 first block for tool change program G1 position command Tool change position destination Specifies rapid traverse speed J specifies Jump S specifies Stop Target block 000 IA 74718 9 4 Rev A 10 87 5 3 5 Homing and Zero Offset NC Code 60 o M aa m A ee When Homing is selected during dialog programming the TAM will display ZERO OFFSET Note that a reference value is entered as system parameter P12 This reference value is used to establish the machine reference point as some point other than home such as the center point of the slide If all references to the part are to be programmed with respect to this machine reference point a zero
70. 1 Type Inputs to TRANS O1M Correction values are transmitted to the TRANS 01M by placing each digit as requested by the TRANS 01M in BCD fashion on these four lines For example 5 is represented by bringing Data Lines 1 and 4 high keeping 1 and 8 low When the Sign plus or minus bit is transmitted to the TRANS Data Line 1 is used sign is indicated by Data Line 1 being low a by setting it high 9 3 4 4 Clear Register Connector TRANS 01M X17 Pin 18 Type Input to TRANS 01M To clear a Register reset it s value to zero this input is brought high then the appropriate Register Select line is brought high This signal MUST be high and stabie before selecting Register TO1 or 02 otherwise the 5 01 will interpret the command as a value transmission 9 3 4 5 Data Valid Connector TRANS O1M X17 Pin 19 Type Input to TRANS 01M Data Valid is used during the transmission procedure as a handshake acknowledgment after each portion of the sequence is completed Data being sent should be placed on the Data Lines allowed to stabilize then the Data Valid line brought high The Data Valid signal should remain high for at least 60 milliseconds to be recognized by the 5 01 9 3 4 6 Digit Request Lines Connector TRANS 01M X17 Pins 22 Sign Plus or Minus 10 Digit 1 Most significant digit 23 Digit 2 11 Digit 3 24 Digit 4 Least significant digit Type Output fr
71. 111 1 1 9999 83 80000 838 0000 1000 000 9999 9999 838 8600 8388 600 838 8600 8388 600 838 8600 8388 600 9999 9 0 5 0 6500 00 65000 19600 0 196000 6500 0 65000 6500 0 65000 999 9 9999 3276 7 32767 2 0000 20 000 1 1 1 3276 7 32767 100 100 11111111 11111111 Units cycles lines rev inches mm revolutions revolutions inches num inches mm inches mm RPM ipm mil m min per mm inches min mm min inches min mm min inches min mm min inches min mm min inches sec sec mm sec sec inches min mm min inches mm inches min mm min percent percent Rev A 10 87 P30 P31 P32 P33 P34 P35 P36 P37 P38 P39 P40 41 4 8 TABLE 4 1 Parameter NOM CURRENT A MAC NO THR CURRENT LIN ENC RESOLUTION LIN ENCODER DIRECTION MAX LIN ENC DEFL LIN ENCODER PRE LIMIT FEED RAMP SPINDLE DIRECTION SPINDLE RPM 10 VOLTS MAXIMUM CORRECTION OPERATION MODE 1 OPERATION MODE 2 PARAMETER LIMIT FORMULAS Minimum 25 1 0 00001 0 0001 0 0 0000 0 000 838 8600 8388 600 0 1 1 9 100 0 0 0 00000000 00000000 PARAMETER VALUE LIMITS Cont d Maximum 200 99 0 01000 0 1000 1 838 8600 8388 600 838 8600 8388 600 999 9 9999 1 9999 3 2767 32 767 11111111 11111111 Units amps percent inches line mm line inches mm inches mm inches sec sec mm sec sec RPM inches mm As previously described the TRANS parameters are c
72. 2 R44 Ld 2 3 600 M ALL DEMEMSIONE SHOWN iN mm FOR MRFERERCE QUY Figure 2 1 Outline Drawing TAM 2 Portable Keyboard Display IA 74718 2 1 Rev A 10 87 2 1 8 TAM 2 01 Permanently Mounted Keyboard Display Figure 2 2 is an outline drawing of the TAM 2 01 Keyboard Display This unit is designed for permanent mounting on the machine It features a lockable front cover which provides sealed protection for the keyboard window in the cover provides visibility for the 32 character alphanumeric display at all times A connector on the rear of the TAM 2 01 is used to interconnect the TAM to the X4 or X5 connector on the TRANS Up to 10 TRANS modules can be daisy chained via the X4 X5 connectors to one TAM See Chapter 7 for a discussion of mounting and installation i am cH EE i i 22 METRE THREAD Figure 2 2 Outline Drawing TAM 2 01 Permanently Mounted Keyboard Display Unit IA 74718 2 2 Rev A 10 87 2 1 4 TAM Keyboard Display Panel Description Figure 2 3 illustrates the TAM keyboard display panel Note that the keys switches and diagnostic displays are identical for both model TAMs as well as for the TRANS O01 This chapter describes the individual functions of all the keys switches and indicators Chapter 3 describes the use of the TAM in operating the TRANS Chapter 4 describes the use of the TAM in entering parameters and Chapter
73. 3 Pin 2 Status Normally open Type Output from TRANS Spindle Enable Connector X3 Pin 3 Status Normally open 1 Output from TRANS When a program block containing a spindle rpm value is executed an analog voltage proportional to that rpm and direction is output to the spindle controller starting from the beginning of execution of the block The Spindle Enable is simultaneously turned on If a spindle rpm value of O is programmed upon execution of that block the TRANS first switches off the analog voltage 0 volt output then waits for receipt of the N actual N command input One hundred msec after receipt of that signal the TRANS turns the Spindle Enable signal off IA 74718 6 14 Rev A 10 87 6 12 3 N actual N commanded Connector X11 Pin 15 Status Normally open Type Input 31 to TRANS This signal is sent by the spindle controller to signify to the TRANS that the spindle has reached the commanded speed Command rpm not reached Command rpm reached H 24 V Once a spindle speed is commanded the TRANS executes no feed axis movement as long as this signal is not present During this time the diagnostic N CMD appears in the TAM display Feed movement will be continued as soon as the signal is sent Exceptions 1 Rapid traverse motions which are blocks in which the underlying rapid traverse is programmed as the speed are executed regardless of the status of N actual
74. 4 Diagnostics With the diagnostic display mode selected a special message is displayed during a feed adaption process to provide information concerning feed and load performance The format is Nxxx IO aa bb ff gg Where aa actual idle thrust current factor bb maximum idle thrust current programmed in the parameter It cc actual present load factor dd commanded desired load factor ee minimum thrust current factor programmed in the block ff actual feed reduction in gg feed reduction trigger level excessive thrust trip point in Additional diagnostic messages are DIAGNOSTIC MESSAGE MEANING EXCESSIVE IDLE CURRENT Soft Fault Occurs when the idle current exceeds that value entered in the MAX NO THR CUR parameter THRUST MISSING Normal Status Diagnostic Occurs when the thrust current during a cycle never exceeded the MIN THR CURRENT value programmed in the block This is not diagnosed as a fault rather as a warning indicating possible broken tooling or a missing part EXCESSIVE THRUST Either a Normal Status Diagnostic or a Soft Fault If the thrust current required in a cycle is ever great enough that feed reduction beyond the programmed FEED REDUCTION value is necessary this diagnostic will occur at the end of a cycle possibly indicating dull tooling or excessively hard part material If the diagnostic is accompanied by illumination of the CE key a Soft Fault has occurred in
75. 4718 iv Rev A 10 87 Paragraph 1 1 1 1 1 1 1 2 1 1 3 1 1 3 1 1 1 3 2 1 1 4 1 1 5 1 1 6 1 2 1 3 1 4 1 5 1 6 1 7 1 8 2 1 2 1 1 2 1 2 2 1 3 2 1 4 2 2 2 3 2 4 2 5 2 6 2 7 2 8 2 9 2 10 2 11 3 1 3 2 3 4 3 4 1 3 4 2 TA 74718 MODULAR TRANS 01 TRANSFER LINE CONTROL USER S MANUAL TABLE OF CONTENTS Title Chapter 1 General Description Introduction The TRANS 01 Family of Controls Description of Modular TRANS Programming Programming with TAM Keyboard Display Line Control Adaptor Diagnostic Monitoring Adaptability of the Control Options Operating Modes Display Modes English Language Programming TAM Keyboard Display Panel User Access Levels System Elements Technical Data Chapter 2 TAM Control Panel Description Physical Description General TAM 2 Portable Keyboard Display Unit TAM 2 01 Permanently Mounted Keyboard Display TAM Keyboard Display Panel Description 32 Character Alphanumeric Display Display Mode Selection Keys Programming and Parameter Mode Keys Programmable Function Keys Jog Keys Keyswitches Miscellaneous Function Keys Numeric Keypad Power Indicators Operation Mode Keys Chapter 3 Operating the TRANS 01 M Control General Operator Functions Toolsetter Functions Using the TAM TRANS Numbers and the TAM Communicating Using the TAM Dd PO BS 1 4 Ld SCADA A pod c e eerte acd ee ien oc e
76. 6 5 BRAKE OUTPUT Connector TRANS X10 Pin 5 Status Normally open Type Output 11 from TRANS This output is a signal from the TRANS to release the servomotor brake if included it is wired directly to a relay that controls the electrically lifted motor brake When the TRANS has control of the system it issues the brake output and the brake must be lifted to allow motor operation If the TRANS detects a fault or is placed in programming mode it drops this output relinquishing control of the motor The brake must then be applied The machine builder must wire this output to a 24V relay The normally open contact from that relay is wired into the brake circuit the location depending on the type of Indramat servo controller e g TDM DSC being used in the system Refer to your system interconnect diagram for wiring details This signal is not handled internally in the Indramat control circuitry because of the wide variation in servomotors brake current requirements available This method allows proper relay sizing for the individual application 6 6 CONDITIONAL JUMP INPUTS Conditional TRANS X11 Pins Bit3 5 Bit2 6 Bit1 7 Bit 0 8 Status Normally open Type Inputs 21 22 23 24 to TRANS Four inputs for conditional jumps are provided on the TRANS interface Up to 16 different program jumps can be performed using the 4 bits of the conditional jump control signal These could be used to cal
77. 8 1 10 87 This page intentionally left blauk IA 74718 A 2 Rev A 10 87 PARAMETER RECORD SHEET TRANS 01 M Machine Number Form Completed By Key No 01 PO2 POS3 4 3 PO5 POG 3 2 POS 10 52 P12 P13 P16 17 18 19 See page TA 74718 Parameter TRANS NUMBER A NES TRANS GROUP NUMBER pod SERIAL CYCLE INPUTS o4 SERIAL ACKN INPUTS SERIAL CONDITIONS UNITS ioi ENCODER CYCLES REV BALLSCREW LEAD UNITS TABLE REV GEARBOX REV IN 3 GEARBOX REV OUT L1 TRAVEL LIMIT TRAVEL LIMIT REFERENCE POSITION MOTOR RPM 10 VOLTS E MEME KV FACTOR HOMING SPEED RAPID SPEED JOGGING SPEED JOGGING RAPID RAMP A 5 for an explanation of the key Axis Unit Value Date 1 INCHES in in in ipm ipm ipm 041 mm min t l l mm min mm min t Lo mmm min E d mm s Rev A 10 87 Key No P20 P21 P22 P23 P24 P25 5 P26 5 P27 P28 P29 4 P30 4 P31 6 P32 6 P33 6 P34 6 P35 i P36 7 P37 7 P38 7 P39 7 P40 7 P41 PARAMETER Parameter MAX FEEDRATE RETRACT DIRECTION POLARITY HOMING DIRECTION JOGGING DIRECTION MAX FEEDRATE FOR G5 TORQUE TO POS STOP TORQUE AT POS STOP AUX OUTP AT EM STOP AUX OUTP AT IM STOP NOM CURRENT A MAX NO THR CURRENT LIN ENC RESOLUTION RECORD SHEET TRANS O1 M Cont d LIN ENCO
78. 8 8 Rev A 10 87 MESSAGE MEMORY LOST Cont d MEMORY OVERFLOW MOTOR OVERTEMP N NCMD NEW PARAMETER NEW PROGRAM 74718 i1 t DESCRIPTION SUGGESTED RECOVERY Note that any tool correction values current I O status slide position and reverse vector are all lost when this fault occurs If the axis was mid cycle at the time this occurred and a complex cycle with reverse vectors was being used it may be necessary to recover return to home by hand due to possible interference problems Soft Fault Indicates that the TRANS has continued past block 127 without encountering a block jump Press CE then correct the program Soft fault AN overtemperature condition has been detected in a servo axis servo motor sensed by loss of 24 volts at connector X8 pin 3 This can be caused by an excessively high duty cycle stalled motor faulty controller cooling system etc may also indicate a defective servo motor or controller or incorrect wiring Remedy the situation then press CE Note that when the TRANS senses that the overtemperature switch in the axis servo motor has opened it will first finish the cycle if one is in progress end of a cycle is detected by executing a Jump and Stop at block NOOO After the cycle is complete the TRANS will display the fault and open the Regulator Release RF for the servo controller and spindle if present Cycle information current position Home et
79. 87 Select Block Recall Block Blank Block Clear Block NOTE OR block information is completely erased when programming Therefore it is not necessary to first erase ald block Select block Enter block number Error in block entry Contents of selected block is displayed Finish Another block IA 74718 5 33 Rev A 10 87 PROGRAM BLOCK FUNCTION See Flowchart on page 5 33 FEED TO 2 MISC POSITIONING POS STOP HOMING DWELL FUNCTIONS Enter absolule position of home if thin is ENTER before block ii eaecuted No D Ta Misc F unctians Coni d 1 A IA 74718 5 34 Rev A 10 87 POSITIONING Cont d Fram Page 5 34 T this option is selected the Inst feedrate selected in the program will be used TOOL CORRECTION No Change Tool 7 7 Change Enter Toot Correction Register Number 1 201 D 74718 MISC FUNCTIONS Cont d From Page 5 14 AUXILIARY FUNCTIONS No Status change Change status No change out change showing Change status of this function S Function Function M m Aux function Change To fock Jump 415 581 10 87 From Page 5 35 m Went BLOCK JUMP NOTE Z M Jumps may he programmed la only to blocks which have been programmed
80. ANS in a system must have a unique number from 01 30 Versions TRANS 01 MOO and 01 require an operator set up procedure for parameter P00 See Section 4 9 for details Once a TRANS is assigned a unique TRANS NUMBER it can be addressed by the TAM or LCA and parameters can be entered Because the entry of incorrect data can result in damage to the machine access at this level is possible oniy by using the Parameter Keyswitch on the TAM to enable Parameter Entry Edit Mode Parameter entry is described in Chapter 4 2 Programmer Interface At this level the control program is entered and possibly edited in Dialog Mode This program must be protected from accidental or intentional alteration by unauthorized personnel Thus access to the user program can be made only by utilizing the Programming Keyswitch on the TAM to enable Programming Entry Edit Mode Programming entry is described in Chapter 5 3 Toolsetter Interface Operations at the toolsetter level are possible when the panel cover of the fixed TAM is unlocked or when the portable TAM is plugged into the system and the proper TRANS NUMBER is selected The toolsetter can then examine the program and parameters operate the manual controls and enter tool correction values as described in Chapter 3 He cannot change the program or parameters without using a keyswitch to separately enable each of those modes 4 Operator Interface Because it is necessary for an Operator to have ac
81. AT product users Please note your suggestions or report errors please specify page number below then mail this form to INDRAMAT Division of the Rexroth Corporation Publications Department 255 Mittel Drive Wood Dale Illinois 60191 NAME DATE TITLE COMPANY ADDRESS CITY STATE ZIP Please check here if you wish a written reply
82. ATING THE 5 01 M CONTROL 3 1 GENERAL As discussed in previous chapters the TRANS 01 M is designed for operation under control of a remote Line Control such as a programmable controller which interfaces to the TRANS via the Cycle Interface However various manual operations are necessary And are provided by an Operator Station and the TAM keyboard display panel Access to the TRANS controls parameters and program is provided at several different levels to provide for maximum security of machine operations This chapter discusses procedures available at the Operator and Toolsetter levels 1 The Operator interface to the system is provided by a separate Operator Station which allows certain manual operations At this level access to the TAM is not necessary 2 At the Toolsetter interface level the toolsetter will have access to the portable TAM or he will have a key to the TAM 2 01 fixed TAM cabinet and can display the current status can examine the program and parameters can enter tool corrections can select feedrate override and perform manual program independent operations jogging He can also bypass the Line Control signals to execute the program in Single Block Single Cycle or Continuous Cycle Modes to verify proper operation However he cannot change the program or parameter values without additional keys to enable Program Entry Edit and Parameter Entry Edit Modes Each of the functions listed above is
83. Arrangement and Installation of Electrical Equipment 7 1 7 2 1 Distributed Control 7 1 7 2 2 Mounting Considerations 7 28 7 2 3 Heat Dissipation 7 2 7 2 4 Requirement for External Voltage Source 7 6 7 2 5 Rules for Installation 7 6 7 3 Mounting the Servo Motor 7 6 7 4 Establishing a Reference Position 7 9 7 4 1 General 7 9 7 4 2 Reference Homing Procedure 7 9 7 4 3 Slide Mechanics Requirements 7 11 7 4 4 Placement of the Reference Position 4 11 7 4 5 Positioning the Home Limit Switch 7 13 7 4 6 Actuating the Home Limit Switch 7 13 IA 74718 viii Rev A 10 87 TABLE OF CONTENTS Paragraph Title Page Chapter 7 Mounting and Installation Cont d 7 5 Limit Switch Positioning on a Numerically Controlled Axis 7 13 7 5 1 Primary Overtravel Limit Switches 7 13 7 5 2 Home Limit Switch 7 14 7 5 3 Safety Emergency Limit Switch 7 14 7 6 TRANS Input Output Circuits 7 15 7 7 Checkout Motor Direction Polarity on Start Up 1 19 Chapter 8 Diagnostics 8 1 General 8 1 8 2 Types of Diagnostic Messages 8 1 8 2 1 Normal Status Diagnostics 8 1 8 2 2 Temporary Faults 8 1 8 2 3 Soft Fault 8 2 8 2 4 Hard Fault 8 2 8 2 5 External Fault Reset 8 2 8 3 Diagnostic Messages 8 2 8 4 Interaction of Drive Fault Tach Fault and Encoder Fault 8 19 Chapter 9 TRANS 01 M Options 9 1 Installing Software Options 9 1 9 2 Adaptive Depth Control 9 3 9 2 1 Associated Parameters 9 3 9 2 2 Installing the Adaptive Depth Control Option 9 4 9 2 3 Programming the Ada
84. Because block 000 the starting block of the program could never be used as a reverse vector reverse vector ROOO is used for a special purpose Whenever the TRANS executes block containing a reverse vector of R000 it considers all following blocks to be the return portion of the part program even if they specify forward motions Reverse vector ROOO is useful primarily manual mode but also has an important effect in automatic mode In Manual Mode You should program a block containing a Reverse Vector Jump to 000 to indicate the end of the Forward program profile Manual Mode pressing and holding the FORWARD button at the Operator Station causes the TRANS to execute the Forward program When the TRANS completes execution of a block containing a reverse vector of ROOO the Forward input will be ignored and only the Return Reverse input can be used While the Forward profile is being executed FORWARD OPERATING will appear in the display When reverse vector ROOO is reached the display will become REVERSE NO COMMAND indicating that only the Return input will be accepted IA 74718 9 11 Rev A 10 87 Note that if reverse vector ROOO is not programmed at the end of the Forward program continuing to hold the FORWARD button depressed while in Manual Mode will cause the TRANS to execute the entire program both the Forward and Reverse profiles In Automatic Mode When a Reverse Vector Jump to 000 is encountered jn automatic
85. CLES REV Enter number of XXXX XXXX encoder lines per revolution for Indramat Style 1 feedback assemblies This number be found on the motor name plate e g MAC 132 AOED 85 0 1625 S01 Value entered in PO6 For other styles of feedback assemblies e g Style 4 WIxxx packages Refer to the support documentation for that package to determine the encoder cycles rev The Indramat Product Type Code Manual Publication IA 74711 contains a list of Style 4 encoder specifications BALLSCREW LEAD All except Rotary software XX XXXXX XXX XXXX option Enter as distance per revolution a rack and pinion drive train is used multiply the pitch diameter of the pinion by pi 3 1415926 and enter the result UNITS TABLE REV Rotary software option TR33 XXXX XXX XXXX XXX This parameter determined how many display programming units one revolution of the drive train output e g table will be divided into Any value between 10 and 1000 may be set into this parameter with three decimal place precision e g 10 000 to 1000 000 Speeds in both parameters and programs are expressed in units table rev min For example if programming in degrees is desired this parameter would be 360 Programming as well as position display would then be in degrees with a resolution down to 0 001 degrees Speeds would be in degrees minute This parameter is limited by the bit weight of the system see parameter limits
86. CONTROLLER Bb CONTROLLER 2 MOTOR TAS 1 STOP SAFETY LIMIT HOME L S NEG TRAVEL L S POS TRAVEL 1 8 ACKNOWLEDGEMENT 7 UNUSED NOT USED WIRE SIZE 0 25 mm 23 AWG WN BY PROVED SCALE Ze pa Ms MTS PROHIBITED This document for customer use not to be copied or released Reference copyright law 6 REVISION FOR REVISED BY a 90 3 543 1 FUNCTION INPUT 16 UNUSED NOT USED TO X8 ON 6 E 20 0787 TRANS 01 PIN NUMBER I 2 3 umm 4 Lb 5 6 D 7 b 8 un 9 10 12 13 14 15 16 m 17 ALL DIMENSIONS ARE SHOWN IN mm inch FOR REFERENCE ONLY SHEET DRAWING NUMBER 209 0036 48 I7 1 02 l ue 2 X9 CONTROL CABLE 04 0914 10 0 394 SOLS L 55 2 165 5 Id 20 0787 TERMINAL STRIP TO X9 ON TRANS 01 WIRE COLOR FUNCTION PIN NUMBER white z BCD Ot OUTPUT I F I brown 02 u 2 M o green z 04 n 3 3 43 yeliow 08 4 pe 4 ORANGE e LA Jae Ra 5 FERRULE i T pink 20 6 6 blue 40 1 s 80 8 re 4 black Int refresh ralay input E STOP 2 M 9 Tq violat main contactor control E STOP be 10 WIRE SIZE 025mm 23 AWG ALL DIMENSIONS ARE SHOWN IN mm inch FOR REFERENCE ONLY A E REXROTH mee e INDRAMAT X9 CONT
87. CORRECTION now appears in the display Press LF Line Feed if there is no requirement for operator accessible dimension offsets or if the tool correction register number and its associated value chosen in a previous block is still to be used To select a correction register key in a number from 1 to 20 to specify the desired correction register then press ENTER You can then enter a value in that correction register which will be added to the dimension in this and all subsequent moves until a different tool correction register is selected or the control is reset If you had selected a too correction register in a previous block but do not wish to use it in this or subsequent blocks enter a tool correction register number of 0 then press ENTER 20 AUX FUNCTION now appears in the display You can now step through and select any desired miscellaneous functions such as auxiliary functions BCD outputs block jump or block repeat Selection of these functions or skipping them occurs in every block which is programmed See Section 5 5 3 5 for a description of programming procedures Note that normal positioning and positioning using Feed Ramp are differentiated by the NC G codes in the block display where G1 Normal positioning with instantaneous speed changes 66 Positioning with continuous speed changes controlled by Feed Ramp IA 74718 9 28 10 87 9 7 MODIFIED AUXILIARY OUTPUT FUNCTIONS TRANS executive
88. Chapter 5 1 5 2 Functions Which Can Be Programmed 5 2 5 3 Application Programming Requirements 5 2 5 3 1 Start of the Program 5 3 5 3 2 End of the Program 5 3 5 3 3 Basic Homing Program 5 3 5 3 4 Tool Change Program 5 4 5 3 5 Homing and Zero Offset NC Code GO 5 5 5 3 6 Positioning NC Code G1 5 5 5 3 7 Lag Finishing During Positioning 5 6 IA 74718 vi Rev A 10 87 Paragraph 5 3 8 5 3 9 5 3 10 5 3 11 5 3 12 5 3 13 5 3 14 5 3 15 5 3 15 1 5 3 15 2 5 3 15 3 5 3 15 4 5 3 15 5 5 3 16 5 4 5 5 5 5 1 5 5 2 5 5 3 5 5 3 1 5 5 3 2 5 5 3 3 5 5 3 4 5 5 3 5 5 5 4 5 6 5 7 5 7 1 5 7 2 6 1 6 2 6 2 1 6 2 2 6 3 1 6 3 2 6 3 3 6 3 4 6 4 6 4 1 6 4 2 6 4 3 6 4 4 IA 74718 TABLE OF CONTENTS Title Chapter 5 Programming Cont d Feedrate NC Code F Dwell NC Code G4 Feed To Positive Stop NC Code G5 Tool Corrections NC Code T Analog Spindle Output NC Code S Auxiliary Functions NC Code M BCD Output NC Code B Program Jumps Unconditional Jump NC Code JN Jump to a Subroutine NC Code JU Conditional Jump NC Code JC Jump and Stop NC Code J5 Reverse Vector NC Code JR Block Repeat NC Code E Program Data Programming Display Program Blocks Block Display Mode Programming Block Punctions Homing Positioning Dwell Feed to Positive Stop Miscellaneous Functions Program Editing Procedures Programming Flowcharts Programming Examples Example Program 1 Example Program 2 Chapter 6 Funct
89. D 112 112C 1 HD 112 0 112 1 AND ALL MAC 112 D s AC POWER 01 8200 4 TAM 2 TAM 2 BUS CABLE 05 0500 CONTROL CABLE MODULAR MOTOR POWER 04 0918 TRANS 01 04 0350 KDV KDS SEE NOTE 1 MAC 04 0912 AC POWER dde 01 8481 ALL S ARE NEEDED MOTOR FEEDBACK 93 0209 2 POSITION FEEDBACK 03 0418 3 LCA TO ADDITIONAL MODULAR TRANS 81 s LCA BUS 05 0430 ADDITIONAL MODULAR TRANS Di s BUS 05 0410 SERIAL INTERFACE CABLE 85422 05 0428 TO HOST CONTROL SERIAL INTERFACE CABLE 85232 NOTES 1 MOTOR POWER CABLES ARE SELECTED BASED ON SPECIFIC MOTOR DRIVE COMBINATION REFER TO MOTOR POWER CABLE SELECTION LIST FOR PART NUMBERS 2 USE CABLE 03 0201 IF MOTOR HAS BLOWER USE CABLE 03 9230 FOR RIGHT ANGLE CONNECTOR 3 USE CABLE 03 0411 IF MOTOR HAS BLOWER USE CABLE 93 0430 FOR RIGHT ANGLE CONNECTOR 4 8 AWG WIRE MUST BE USED FOR KDV POWER WITH THE FOLLOWING MOTORS 112B 1 GD 112C 2 KD MAC l112C 1 KD MAC 112C 0 HD MAC 112C 1 HD MAC 112 0 112 1 AND ALL MAC 112 D s Changad sheet no 2 87 REXROTH SYSTEM CABLE REQUIREMENTS DRAWING NUMBER 5 1 f 2 CHICAGO ILL DRAWN BY 2 23 87 APPROVED BY SCALE REVISION FOR SHEET D 77 N T S REVISED BY 10 or 14 1 REPRINTS PROHIBITED This document for customer use not to be copied
90. D outputs jumps and repeat NOTE you program a block you can generally press LF Line Feed to skip lines you don t wish to program BCD outputs for example However the COMMAND ERROR diagnostic message is displayed if you attempt to line feed past a required input If this occurs press CE to clear the error then program the required function 5 5 3 1 Homing 1 To select homing press the Homing key r 3 If no zero offset is desired enter O If an offset is required key in the amount of the offset See Section 5 3 5 for a discussion of homing and zero offset If you make an error press DEL Delete and re key the data 2 ZERO OFFSET appears in the display If you attempt to press LF instead of entering 0 or some value COMMAND ERROR appears in the display as described in the note above IA 74718 5 16 10 87 4 When your data is correct press ENTER 5 FEEDRATE now appears in the display If you want the machine to operate at the homing rate specified in parameter P15 press LF Line Feed Note that the system will operate at the parameter specified homing speed during its first homing operation regardless of any feedrate you may select To select a feedrate for this homing operation key in a feedrate value then press ENTER 8 AUX FUNCTION now appears in the display You will now step through and select any desired miscellaneous functions such as auxiliary outputs BCD outputs block jum
91. DER DIRECTION MAX LIN ENC DEFL LIN ENCODER PRE LIMIT FEED RAMP SPINDLE DIRECTION SPINDLE RPM 10 VOLTS MAXIMUM CORRECTION OPERATION MODE 1 OPERATION MODE 2 See the following page for an explanation of the key IA 74718 Value t i 4 i ipm i of 4 l F imm min 1 11 iin Pot dor d mMM i 0 1 I 1 0 1 1 0 1 i 3 41 i fd ipm 01 i 1 i mm min 3 E t 1 4 t I 1 1 1 t 1 t 1 i r t 3 F 4 F 1 LI r 4 1 H 1 1 f 1 1 H 1 1 1 4 1 3 L 4 H 1 1 1 1 3 L Pob b I oL din poh ae 1 0251 E d i f ijn ioi d i i E 4 mm Lg riot 4 tin sec 11 Imm sec 4 0 1 i 1 t 3 F d soi t i Ei fin ot tb omm 1 1 r r 1 1 H r 1 i 1 Li 1 t r r 3 t t t 1 1 1 i 1 f 1 4 Rev A 10 87 EXPLANATION OF KEY 1 This parameter will be present only with version TR32 software 2 This parameter will be present only with version TR33 software 3 These parameters will NOT be present with version TR33 software 4 This parameter will be present only with version TR34 software 5 These parameters will NOT be present with version TR35 software 6 These parameters will be present only with version TR35 software IA 74718 5 10 87 APPENDIX B HARDWARE AND SOFTWARE TYPE CODE KEYS B 1 TRANS HARDWARE TYPE CODE KEY TT an e rm d TRANS 01 M XX io me ie Contro
92. Dens ui 5 RSS e pr s gg 8 Eo VERE A ision No IA 74718 October 198 7 Rev MODULAR TRANS O01 TRANSFER LINE CONTROL USER S MANUAL COPYRIGHT C 1987 BY INDRAMAT DIVISION THE REXROTH CORPORATION PUBLICATION NUMBER IA 74718 REVISION A OCTOBER 1987 All rights reserved No part of this publication be reproduced stored in a retrieval system e g in memory disk or core or be transmitted by any means electronic mechanical photocopy recording or otherwise without prior written permission from the publisher IA 74718 ii Rev A 10 87 IMPORTANT PLEASE COMPLETE THIS REVISION REGISTRATION FORM TO AUTOMATICALLY RECEIVE REVISIONS TO THIS MANUAL AS SOON AS THEY ARE PRINTED RETURN THIS FORM TO Indramat Division of the Rexroth Corporation 255 Mittel Drive Wood Dale IL 60191 312 860 1010 PUBLICATION Modular TRANS 01 Transfer Line Control User s Manual Publication Number IA 74718 Revision A October 1987 NAME COMPANY ADDRESS CITY STATE ZIP TELEPHONE COMMENTS 1 74718 Rev A 10 87 RECORD OF REVISIONS ERU RC RERO NP RE I MESRINE I ah a Revision Level Date Description of Change ttn tA ar eS Torment ML ELE cc A 10 87 Initial Release TA 74718 iii Rev 10 87 This Page Intentionally Left Blank IA 7
93. Diagnostic Mode and shuts the system down When a TAM keyboard display module is connected and the control number of this TRANS has been selected a simple English Language diagnostic message appears on the display This aids in the quick determination and correction of faults A special advantage is that the TRANS records causes of problems and also diagnoses and identifies faults which trigger sequential events such as loss of main power This aids quick correction of faults by plant personnel rather than specialized electronic technicians IA 74718 1 5 Rev A 10 87 The diagnostic status of the control can be interrogated at any time even when no error is present by selecting Diagnostic Display Mode Thus normal status indications such as NO START can be observed and causes of interruptions which do not appear as errors such as the control waiting for an auxiliary function acknowledgment can be determined When using a TAM the TRANS NUMBER of a control is selected on the TAM then Diagnostic Display Mode is selected to examine the diagnostic status of that control In on line operation the diagnostic status can be examined by the customer s Line Control via the data bus and Line Control Adaptor if present 1 1 5 Adaptability of the Control The TRANS is integrated to the machine and the axis and spindle drives by entering various parameters when the system is initialized e g maximum feedrate accel decel rate incr
94. E SWITCH CLOSURE POINT Figure 7 5 Homing Motion Profile The zero pulse appears once in each motor revolution The function of the Home Limit switch is to indicate the specific motor revolution in which the zero pulse is used In the homing procedure regardless of the beginning position the slide must stop on the Home Limit switch closing it The next zero pulse after the closing of the Home Limit switch indicates the reference position In many cases some position other than home such as the center line of the transfer bar is used as the reference position for machining All programmed distances are then specified in reference to this point This is established by entering the distance from home to the new reference location as the Reference Position parameter P12 See Section 4 4 for details on parameter entry When the control is homed this value will be loaded into the position counter and all moves will be made in reference to this position This is illustrated in Figure 7 6 Transfer Unit Design Criteria IA 74718 7 10 Rev A 10 87 7 4 3 Slide Mechanics Requirements NOTE Because all program dimensions are measured in relation to the reference position they depend on the location of both the home limit switch and the zero marker pulse Thus the machine builder must insure that the ballscrew zero pulse orientation is maintained if the motor is replaced To guarantee that this can be performed in a failsafe manner an
95. Editing Procedures 1 At the Operator Station switch the system to MANUAL 2 Establish communication between your TAM and the selected TRANS as described in Section 3 4 3 Insert the correct key into the Program keyswitch and turn it to the Program Entry Edit Mode 4 Press Q then press lt gt 5 Type the number of the block you wish to edit leading zeros need not be entered then press ENTER 6 Successively press LF Line Feed to advance the display to the line where a change is necessary 7 To change the displayed line press the Edit key key in the revised value then press ENTER Note that leading and trailing zeros need not be typed If the Program keyswitch is not in Program Entry Edit gt Mode when Edit is pressed WRITE PROTECTED will appear in the display If you make a typing error or want to back up in the sequence for some reason press DEL to delete the last entry Note that DEL can be used to delete a sequence of keystrokes For example if you ve selected Edit mode line X and typed in 10 pressing DEL once deletes the 0 pressing DEL a second time deletes the 1 pressing it a third time deletes your selection of Edit mode 8 When satisfied with the revised block press the Store key to enter it into memory If another block must be edited repeat this procedure from step 4 9 When all incorrect blocks have been corrected turn the keyswitch back to its locked position and remove the key 10
96. Fault overtemperature condition has been detected in the spindle motor sensed by loss of 24 volts at connector X11 pin 16 This can be caused by an excessively high duty cycle stalled motor faulty controller cooling system etc It may also indicate a defective spindle motor or controller or incorrect wiring Remedy the situation then press Note that when the TRANS senses that the overtemperature switch in the spindle motor has opened it will first finish the cycle if one is in progress The end of a cycle is detected by executing a Jump and Stop at block NOOO After the cycle is complete the TRANS will display the fault and open the Regulator Release RF for the spindle and servo controllers Cycle in ormation current position Home etc will not be lost SPINDLE RUNAWAY A hard fault indicating spindle has moved without command Possible causes Parameter 42 bit 0 incorrect Spindle encoder cable or encoder disconnected or defective spindle controller defective spindle motor defective SPINDLE STALLED A hard fault indicating the Spindle is not moving at the commanded rate Most likely causes blocked spindle bad tooling jammed spindle gear box excessively high or low spindle KV P37 or incorrect parameter P38 SPINDLE 10 VOLTS Can also be a defective motor or controller TACHO FAULT Hard Fault Indicates a problem in the tachometer feedback The TRANS constantly monitors the tachometer and encoder feed
97. HARDFAULT and no fault exists No Tach Loss Encoder Fault Etc SOFTFAULT FAULT No I O Error Programming Error Ete Figure 6 1 Typical Emergency Stop Circuit IA 74718 6 10 10 87 6 9 1 Emergency Stop Connector TRANS X8 Pin 4 Status Normally ciosed Type Input 13 to TRANS This signal is normally supplied by the machine builder depending on the emergency stop design for the system If this line opens the relay for main power to the servo controller opens dropping power to the motor and controller If this input is not provided the machine builder must wire pin 4 to 24 volts 6 9 2 Safety Limit Switch Connector TRANS X8 Pin 4 and 5 Status Normaliy closed Type Input 12 to TRANS This signal is normally supplied as a part of the emergency stop circuit The normally closed contact will be opened if the slide reaches its secondary emergency overtravel limit This signal is normally supplied by the machine builder depending on the emergency stop design for the system If this line opens the main power relay to the servo controller opens dropping power to the motor and controller this situation the axis cannot be jogged but must be manually cranked off the limit switch If this input is not provided the machine builder must wire pins 4 and 5 to X9 9 See Section 7 5 3 for a discussion of installation considerations for this switch 6 9 3 Main Contact
98. INE TRANS 01 SERVO AXIS CONTROL CONTROLLER CONTROL CONTROL MODULE 7 ADAPTER r j L PARALLEL CYCLE o INTERFACE MAY BE USED AUXILIARY OUTPUTS BCD OUTPUTS OPERA TOR 28 OPERATOR ACKNOWLEDGEMENTS INTERFACE ON THE MACHINE MISC CONTROL SIGNALS TAM KEYBOARD DISPLAY NOTES 1 The Parallel Cycle Interface and Line Control Adaptor may be used in the same system 2 If the optional Line Control Adaptor is not used the customers Line Control device communicates directly with the TRANS using the Parallel Cycle Interface Figure 1 1 TRANS 01 M System Block Diagram IA 74718 1 4 Rev A 10 87 1 1 3 1 Programming with TAM Keyboard Display As previously mentioned either the portable or fixed keyboard display be connected to the TRANS control The two units function identically TAM keyboard is used for programming start up and service TAM also includes alphanumeric display for display of current program data axis position data system status diagnostics and program information Using simple English commands the TRANS 01 M user program is entered via the keyboard and display directly into the CMOS memory of the control Program changes and editing of program data are accomplished in the same manner using the TAM keyboard display 1 1 3 2 Line Control Adaptor Indramat s Line Control Adaptor LCA is designed to communicate simultaneously over an RS 422 serial link with up to 30 TRANS
99. If the Parameter keyswitch is turned to the Parameter Entry Edit position while a program is being executed this diagnostic is displayed and the Reset key is lighted to indicate a Hard Fault In addition to previous operation this condition will also be diagnosed as a hard fault if the spindle was enabled spindle regulator release RF on at the time the parameter key was switched regardless of whether a cycle was being executed or not This is done to insure that an unpredictable restart of the spindle will not occur when the parameter key is removed PART LOCATION ERROR Soft Fault Can occur when using the optional Adaptive Depth Control package It indicates that the linear encoder was not deflected by the time the TRANS encountered a block using Adaptive Depth Control The linear encoder must make contact with the part before the block programmed for Adaptive Depth is executed To recover press CE This fault sometimes occurs in systems that have been operating properly but have had feedrates increased The reason is that the TRANS begins executing a block before the motor has reached the position commanded in the previous block unless With Lag Finishing is selected speed is increased the lag distance increases If the lag distance becomes too large the linear encoder may not yet be deflected when the TRANS begins executing the Adaptive Depth block The solution is to increase the distance traveled in the block previous to t
100. It will display WAITING FOR CONTROL XX O 2 Press the Data In key 9 o 3 Key in the TRANS NUMBER of the TRANS 01 M module you wish to access then press ENTER Example ENTER 4 When the selected TRANS responds you will see a message in the alpha numeric display of the TAM appropriate to the condition of that TRANS This could be a display of the block presently being executed a status message a diagnostic message etc Regardless of the message in the display the number of the TRANS being accessed will appear in the last two digits of the display If a long message is being displayed the last three digits of that message blink on and off alternating with the TRANS number 5 When communication is established the red TAM ACTIVE LED on the selected TRANS will be lighted You can now display enter or edit parameters as described in the following paragraphs IA 74718 4 2 Rev 10 87 You must use the TAM to set up TRANS parameter POO to specify the TRANS NUMBER You may then use the LCA to communicate with the TRANS Refer to Indramat document IA 74708 for complete details on installation and use of the LCA 4 3 DISPLAY PARAMETER VALUES 4 3 1 Parameter Display You can display parameter values from the TAM at anytime in Manual Mode but these values can only be changed by using the Parameter keyswitch to select Parameter Entry Edit Mode The display procedure is 1 Switch the control to Manual Mode at the Operat
101. LUE 2 2 N 1 EE 1 B GRAY GREEN 9 y 5 A BROWN 5 5 Li BLACK i 5 0 3 4 V 7 KEY TWISTED PAIR 25mm 23 AWG MAXIMUM POSITION e 2222 METERS 98 43 FEET REXROTH FEEDBACK CABLE INDRAMAT H SLEEVE REDRAWN px DA ORAWING NUMBER CHICAGO ILL DRAWN BY O 22 97 APPROVED Y SCALE REVISION FOR SHEET raw LAE NTS REVISED BY REPRINTS PROHIBITED This document for customer use not to be copied or released Reference copyright law 77141 MAC TRANS 01 03 0431 DETAIL OF IN 101 CONNECTOR 12 PIN FEMALE KEY ON 7 CONNECTOR OUTLINE LENGTH AVAILABLE FEMALE 2 174 11 4 CONTINUOUS CABLE BEND RADIUS 98mm 3 54 ONE TIME BEND RAOIUS 4 1 57 6 6 TO MOTOR ST B TO MODULAR TRANS CONNECTOR X12 SHIELD 1 17 AWG 9 9 10 12 12 12 NOT USED VIOLET 11 ra 11 LC BLUE 2 2 IIB PINK j 1 i nad GREEN je Ned gt 0 BLACK 4 4 3 4 8 50 GN 3 Z 7 KEY 72 rursteD PAIR 25mm 23 AWG CABLE 4x2x8 25mm 2 1 mm 3 MAXIMUM POSITION FEEDBACK CABLE LENGTH IS 30 METERS 98 43 FEET REXROTH POSITION FEEDBACK CABLE INDRAMAT WITH RIGHT ANGLE CHICAGO ILL Eus yi BY u REVISION FOR SHEET LA 5 REVISED BY REPRINTS PROHIBITED This document for customer use not to be copied or released Reference copyright law lel TACH COMMA
102. NATION appears in the display Key in the required destination as inches or mm Note that the TRANS assumes a positive move if no sign is entered minus sign can be keyed before or after the number is keyed Also note the the negative sign is a toggle press to enter minus press again to delete minus Now skip to step 8 IA 74718 5 17 Rev A 10 87 5 If absolute positioning is not desired incremental positioning must be selected by pressing 6 ju 6 WITHOUT LAG now appears in the display If positioning with lag finishing is required slide stopped in position before the next iq function is executed press the lag finishing key If positioning without lag finishing is OK press LF Line Feed In this case the position lag from one block will not be LF completed before the next block is executed See Section 5 3 7 for more information on positioning with without lag finishing 7 Because incremental positioning was selected DISTANCE now appears in the display Key in the required positioning distance XXX XXXX inches or XXXX XXX When this command is executed the slide will travel the specified distance from its current position in the specified direction 8 When entering either distance or destination if you make an error press DEL Delete and re key the data 9 When your data is correct press ENTER ENTER 10 FEEDRATE now appears in the display Ke
103. NCY STOP CIRCUIT The TRANS normally includes an emergency stop circuit for protection of both the equipment and operating personnel Figure 6 1 illustrates a typical circuit Following paragraphs describe the signals input to the TRANS from the machine Refer to Figure 6 1 Relay CR1 opens whenever the EMERGENCY STOP button is pressed the Safety Limit switch is opened or the TRANS detects a fault CRI is a 24V relay with a normally open contact which controls the power relay which switches three phase power to the servo controller It is important to connect pin 6 of X8 directly to a 24V relay with no interruption in the circuit This is necessary to ensure that the TRANS will always detect when three phase power has been dropped Note that there are no semiconductor devices in this circuit The only reason the emergency stop circuit is wired into the TRANS is so that the TRANS can 1 detect that power to the drive has been dropped and the drive will not respond to any command and 2 to determine and display the appropriate diagnostic IA 74718 6 9 Rev A 10 87 INDRAMAT MACHINE TRANS 01M BUILDER S CIRCUITRY Wire EMERGENCY STOP EMERGENCY STOP gt 24 Vext SAFETY SAFETY LIMIT gt SWITCH MAIN CONTACTOR CONTROL REFRESH WATCHDOG TIMER mma microprocessor is Relay running amp Closed when program TRANS 01 processor is active
104. ND CABLE 04 0350 TERMINAL BLOCK CABLE 2x0 5mm 2xt2x0 22mm C SEE NOTE I M 13 4 4 MODUL AR 3 TRANS X3 KDS TDM Us011 CMM M a 1 2 WHITE avaoll M rP Lrb E 5 UTach 3 3 EL E J Tach sense c 4 YELLOW LI a z TD 9 m z 2 5 PINK amp Imees a 5 RAY Ired lt L E iD 2 l YELLOW FERRULE 7 RF BL RF ORANGE FERRULE 3 ALONG OUTSIDE OF CABLE FASTEN A MULTI STRANDED BLUE WIRE 8 5mm 20 AWG FOR THE RF SIGNAL REXROTH X3 TACH COMMAND CABLE INDRA RB NACH COMMAND GABLE 01M X3 TO KDS TDM mv mm Pamano 509 0036 4829 004A UN REPRINTS PROHIBITED Thie document for customer use not to be copled or released Reference copyright law 4105 ORANGE FERRULE TO TERMINAL STRIP au 4 d ij d jJ amp ABER ca CI C a REXROTH _INDRAMAT CHICAGO ILL WIRE COLOR white brown green yellow gray pink blue red black vioiet gray pink red bius white grean brown green white yellow brown white gray groy brown CONTROL CABLE 04 0912 10 0 594 300 11 811 L Bb
105. NK1 card bottom of the MODULAR TRANS and the associated cable connected between the PEA card and the bottom of the MODULAR TRANS 9 3 3 Parameters To select External Correction set bit 3 in OPERATION MODE 2 parameter P41 to 1 The PEA card must be installed when this is done otherwise UNACCEPTABLE PARAMETER will be displayed when the parameter key is removed OPERATION MODE 2 parameter P41 bit 4 is also used in conjunction with External Correction Input selecting whether input values should be treated as absolute or incremental Absolute means that when a new value is transmitted it will replace the current contents in the register whereas incremental values will be summed with the current contents IA 74718 9 13 Rev A 10 87 9 3 4 External Correction Interface Signals The following signals are provided to interface the TRANS 01 M with the device transmitting correction values to the TRANS 01M All signals are located on connector X17 a 25 sub D connector on the bottom side of the MODULAR TRANS 01 The basic specifications for all signals are as follows INPUTS Input Resistance 8 Kilo Ohm Input Current at 4 VDC Input Voltage 3 Milliamps Input Voltage 24 VDC 30 On high voltage range 16 8 VDC 31 2 VDC OFF low voltage range 15 VDC 8 VDC All voltages with respect to OVI O on connector X17 OUTPUTS Output Voltage On High 26VDC gt 20 20 32 VDC Output Current On High 50 Mi
106. Press the Reset key to reset the control then perform homing operation Assuming all elements of the system are indicating correct status you can now use the FORWARD and RETURN pushbuttons at the Operator Station to check the forward and reverse portions of your revised program 11 If additional program errors are discovered repeat the edit procedure 12 When the program is properly checked out home the axis then select Automatic Mode at the Operator Station Assuming all elements of the system are reporting correct status NO START will appear in the TAM display The applications program is now ready to be run under control of the Line Control device _ TA 74718 5 25 10 87 13 Note that once all changes are made the Delete key can be used to back out of Edit mode as described in 5 above without the need to press Reset This has the advantage that the axis does not have to be re homed 5 6 PROGRAMMING FLOWCHARTS The following pages present TRANS 01 M programming information in handy flowchart form Following the flowcharts you will find two examples each complete with sample programming worksheets a drawing of the program profile and a list of keystrokes required to enter the program into the TRANS IA 74718 5 26 10 87 The following symbols are used in the TRANS flowcbarts IA 74718 Programming Keyswitch in the programming position Parameter Keyswitch in the parameter entry
107. ROL CABLE FOR TRANSOIM eben DRAWING NUMBER 209 O3 6 48 7 Ol 03 A DRAWN BY PERO VED BY SCALE REVISION FOR SHEET 252 8 28 8 V Li 9 4 BS N T S REVISED BY or 2 REPRINTS PROHIBITED This document for customer use not to be copled or released Reference copyright 64105 Ges 4105 XIO CONTROL CABLE 04 0916 20 0 787 REXROTH INDRAMAT ORANGE FERRULE t mE TO TERMINAL STRIP WIRE COLOR white brown green yellow gray pink blue rad biack violet groy pink red blue white green brown green white yellow yellow brown white gray groy brown DRAWING NUMBER RF2 UNUSED RF UNUSED UNUSED UNUSED BRAKE RELEASE FAULT POWER INTERRUPT HOME RUN READY AUXILIARY FUNC WIRE SIZE 0 FUNCTION RF2 RFI OUTPUT 9 NOTE E ALL DIMENSIONS ARE SHOWN IN mm io 6 359 4 5 3 740 L 300 41 841 TO XIO ON TRANS OL M PIN NUMBER IO tl i2 13 17 18 inch FOR REFERENCE ONLY 209 0036 4817 01 04 CHICAGO ILL E SCALE REVISION FOR SHEET Chang A 7 N T S REVISED BY or 2 REPRINTS PROMMHTED This document for customer ues not to be copied or released Reference copyright jaw CONTROL CABLE 04 0918 L O O i n 6 5 T Bg HX Hd d d gd Ii d DB fj 4 4 5 20 0 78 er 5524 10 0 394
108. Return is activated the tool must pass through the part surface at a reduced feedrate until it is clear of the part reverse vectors must be used The toolsetter will need control of the final depth so tool correction value number 1 will be provided for his use The part cross section and the resultant profile appear as follows Previously drilled hole 0 Operation to be performed Tool at home position Distance 0 29 5 5 6 travelled Profile The next two pages are programming worksheets illustrating the program for example 2 as it would be entered into the TRANS 74718 5 43 Rev 10 87 E B LU ub AT T T LI HL P eoa XL X px eo face LLL Aas adoa p AI X god Eb CLE E ER HIA TS XXX we yer OEE o MOILVNLLS 2d 329WNYiSIQ 195430 2 30NYH2 NOIJ234H02 173040 21Vu0231 DONIHSIMIA DV DNIHSINIZ VAN JM3HONI Rev A 10 87 5 44 IA 74718 2 83 MMENTS co DORT YET DM ESSE es SESSEL BSE EE EEE EEE eve bee ea ate Soe Se T ONIHSINI3 DNIHSINEX DYI O M YAN 3P3UDNI Chang
109. T CIRCUITS pamm SS m a TT e Various input output requirements are discussed and illustrated in this paragraph 1 For high noise immunity all of the TRANS input output signals are optically isolated from the internal bus system and must be operated by using an external 24V control voltage source as illustrated in Figure 7 8 This is valid for all I O including the operator interface cycle interface and auxiliary functions Where current requirements are low the controller s internal 24V supply can be used Contact Indramat for application guidelines before using this supply In addition wire routing considerations are important IA 74718 7 15 Rev A 10 87 Ur 24 DC 18 30V External Control Voltage Source Type A 150mA B 50 EET TK From TRANS 01 Internal Bus Type A Auxiliary outputs Type B All other outputs To TRANS 01 Internal m Bus x Input high min 15V 12V g x input low max 3V Related to OVgxt Figure 7 8 Typical TRANS Input Output Circuits IA 74718 7 16 Rev A 10 87 2 TRANS inputs may be driven directly by TRANS outputs 3 The sketch below illustrates an input driven by contact External Voltage Source 4 Auxiliary function outputs require an acknowledgment signal when used If no acknowledgment is required for a given function then tie the auxiliary function output the acknowledgment input and the load
110. You can display parameter values form the keyboard at any time in Manual Mode but these values can be changed only by using the Parameter keyswitch to select Parameter Entry Edit Mode The display procedure is ds Switch the control to Manual Mode at the Operator Station 2 Parameter POO and its value are displayed meter 3 Each time you press LF Line Feed you will advance scroll forward the display to the next parameter IA 74718 3 10 Rev A 10 87 a PA E TENTENE E ERER Press ENTER to return the display to the previous parameter scroll backward ENTER You can display any specific parameter by pressing the N key keying the parameter number then pressing Enter Example If a non existent parameter number is entered the highest numbered valid parameter is displayed See Chapter 4 for a complete list of parameters and their values Note that some parameters are not used with various software options so the parameter number wili be omitted when scrolling through the display 4 If you wish to return to the first parameter press 5 Exit from Parameter Display Mode by selecting any other mode or by pressing Reset key to reset the control 3 8 JOGGING CONTROLS In Hand Mode the Toolsetter can jog the slide forward and reverse at either the normal or rapid jog rates This results in movement of the slide which does not follow the program contour as opposed to Forward and Return
111. a Dimensions Height Width Depth Terminal Identification Terminal 1 AC common Terminal 2 AC signal input Terminal 3 24 V supply Terminal 4 DC output Input Specifications On voltage requirement Off voltage requirement Input impedance 48 62 Hz Input current at 1i5 Vac Output Specifications Output voltage Maximum output current Current limit level 55 mm 2 17 inches 11 5 mm 0 45 inches 49 mm 1 93 inches screw terminal screw terminal spade terminal 2 x 2 8 x 0 8 mm spade terminal same as above 115 Vac 15 48 62 Hz 0 35 Vac 48 62 Hz 6200 4200 Hz capacitive 28 ma at 60 Hz 20 ma at 50 Hz 24 Vdc 20 100 ma about 110 ma Output is short circuit proof and polarity protected Switching Times Turn on Turn off IA 74718 15 msec 30 msec 9 30 Rev A 10 87 9 8 3 AC Output Modules The AMMS module converts a 24 Vdc input signal to a 115 Vac output signal Technical Data Dimensions Height 55 mm 2 17 inches Width 11 5 mm 0 45 inches Depth 49 mm 1 93 inches Terminal Identification Terminal 1 DC signal input spade terminal 2 x 2 8 x 0 8 mm Terminal 2 DC common spade terminal 2 x 2 8 x 0 8 mm Terminal 3 AC output screw terminal Terminal 4 AC line input screw terminal Input Specifications On voltage requirement 4 30 Vdc Off voltage requirement Greater than 2 Vdc Maximum input current 10 ma Output Specifications Output voltage 24 280 Vac Maxim
112. a O manaa Q H The TRANS 01 M is simple and easy to program The TAM contains all controls and indicators necessary to program and operate the control The program keys are identified with ISO symbols which indicate their function The keyboard display panel is used 1 To enter parameters such as maximum feedrate rapid traverse rate etc which used to adapt the control to the characteristics of a particular machine 2 To enter a control program to perform the required machine functions 3 To enter tool correction values 4 For operation of the control in Single Cycle Single Block and Hand Modes 5 For display of diagnostic codes which indicate the nature of any problems detected in the machine control motor and feedback loop 1 6 USER ACCESS LEVELS Access to the TRANS 01 M functions is for practical needs divided into 5 levels They are interlocked to provide the widest possible margin of safety to prevent misuse of the control 1 Engineering Interface At this level the TRANS is adapted to the drive and machine via input of parameters either by entering them via the TAM keyboard display or by downloading them via the Line Control Adaptor IA 74718 1 8 Rev A 10 87 The first parameter POO is the TRANS NUMBER which determines the address each TRANS control will have on the TRANS BUS This must be manually set with two selector switches on the TRANS module Each TR
113. a sturdy lockable cover containing a window through which the display can be viewed Thus it does not require mounting in a separate cabinet can be daisy chained to up to then TRANS controls maximum length of the serial channel cable is 80 feet starting from the farthest connected TRANS 01 M to the TAM The TRANS 01 M must be mounted to allow a minimum of 3 inches top and bottom for cable clearance For suitable mounting procedures refer to the outline and mounting diagrams on the following pages They are 7 2 3 Figure 7 1 TRANS 01 M Outline Drawing Figure 7 2 TAM 2 01 Fixed TAM Outline Drawing Figure 7 3 TAM 2 Portable TAM Outline Drawing Heat Dissipation Under worst case conditions the servo controller dissipates up to 300 watts thus the installation must insure that sufficient cooling can take place The power transformer should be arranged so that it will not cause heating of the AC servo controller or the TRANS 01 M in the control cabinet IA 74718 7 2 Rev A 10 87 NEGO 316 12 441 7 278 408 16 063 FLAT SEAL 65 20 0 787 NOTES 1 ALL DIMENSIONS SHOWN IN mm INCHES FOR REFERENCE ONLY 2 M5 I STANDARD METRIC THREAD 366 1 DOOR 14 409 MEE 1 m J E REAR VIEW Figure 7 2 TAM 2 01 Fixed TAM Outline Drawing IA 74718 7 4 Rev A 10 87 7 poem m 190 7 480 IEEE 1 575
114. able is at fault If with both connector X12 and X13 on the TRANS open the diagnostic is still displayed after Reset is pressed the TRANS is defective and should be replaced EXCESSIVE IDLE CURRENT Soft Fault Occurs in conjunction with optional Feed Adaption software TR34 This message indicates that the amount of thrust measured at the beginning of the feed adaption block exceeds the value entered in the MAX NO THRUST CURRENT parameter Since this is a measure of current required before machining it indicates an excessive amount of resistance in the drive train for the spindle if spindle power is being monitored or the slide if axis power is being monitored Correct the mechanical problem press CE and retry the cycle IA 74718 8 5 Rev A 10 87 MESSAGE EXCESSIVE LAG EXCESSIVE POS COMMAND EXCESSIVE THRUST FINISHING LAG FORMAT ERROR FORWARD FINISHED FORWARD IMMEDIATE STOP IA 74718 DESCRIPTION SUGGESTED RECOVERY Hard fault indicating axis drive velocity did not keep up with commanded velocity resulting in the following error or lag exceeding it s limits Possible causes include incorrect parameters KV parameter too high for system inertia and or friction excessive friction torque in system Remedy the fault and press RESET Soft Fault The slide has been commanded to move to a position outside of the software travel limits during program execution This could be caused by incorrect programming o
115. agnostic LEDs on the servo controller refer to the appropriate user s manual After the fault has been located and corrected press Reset to clear the error Then home the axis SPINDLE NOT IN POSITION Normal status diagnostic that may occur during a spindle positioning command the TRANS has completed commanding the spindle to position but the position has not yet been reached Persistence of this diagnostic can indicate an excessive amount of resistance in the spindle drive train ie high friction or blocked drive train too low a spindle KV value parameter P37 or an incorrect spindle sensitivity parameter P38 IA 74718 8 16 Rev A 10 87 MESSAGE DESCRIPTION SUGGESTED RECOVERY SPINDLE NOT READY Temporary Fault Occurs in conjunction with TRANS Executive Software incorporating analog spindle output capability Indicates that the TRANS has not received the Ready contact closure from the spindle drive sensed by the absence of 24 VDC on connector X8 pin 2 Possible causes may be no control voltage or main power at the spindle controller blown fuses etc Refer to the trouble shooting section of the appropriate spindle controller user s manual to determine the exact cause The occurrence of this condition is treated by the TRANS as a temporary fault meaning that while no other signals will be accepted by the TRANS 01 as long as the condition persists no reset of the TRANS is required after restoration SPINDLE OVERTEMP Soft
116. al homing procedure every time homing GO function is commanded Thus after the TRANS has been powered up and homing is commanded the slide will move at the speed specified in the homing speed parameter P15 dE For Rotary Table Option software version TR33 the home switch monitoring function is inactive and programming of this digit is not necessary Bit 2 Control Type This parameter matches the TRANS hardware version being used with the executive software Versions TRANS 01M 02 and above contain hardware improvements and require a 0 programmed in this bit For versions TRANS 01M 00 and 01 this bit must be set to a 1 Bit 3 External Correction Value Input A 1 in this bit allows the acceptance of external correction values by the TRANS a 0 disables this function The necessary hardware expansion module is needed to accept the values sent from the correction device Also TRANS auxiliary functions 6 and 7 are reserved for the high byte and low byte acknowledgments being sent to the TRANS IA 74718 4 18 Rev 10 87 Parameter Number P41 Cont d IA 74718 Description Bit 4 Incremental Correction Input With a PEA installed in a TRANS 01 M correction values that are either absolute replace current correction register contents or incremental summed with current correction register contents can be sent This bit selects that feature External Correction values are absolute External C
117. al Mode or after the I O supply has been lost and then reapplied If Immediate Stop occurs in Automatic Mode recovery may be performed either by applying the Restart signal to continue program execution or by applying the Homing signal 8 7 Rev A 10 87 MESSAGE I O SUPPLY MISSING JOGGING NO COMMAND JOGGING OPERATION JUMP TO GAP LAG LIN ENCODER FAULT LIN ENC PRE LIMIT MEMORY LOST IA 74718 DESCRIPTION SUGGESTED RECOVERY Temporary Fault Indicates that the 24 volt supply used for external signals is not present on connector X7 pins 1 and 3 This condition is treated as a temporary error meaning that while no other signals will be accepted by the TRANS as long as the condition persists no reset of the TRANS is required after restoration of the I O supply The TRANS will be in an immediate stop condition Normal Status Diagnostic Indicates that Hand jogging Mode has been selected on the TAM keyboard but no actions are being commanded Normal Status Diagnostic indicates that Hand jogging Mode has been selected on the TAM keyboard and one of the Jog keys is being pressed Soft Fault Occurs during program execution indicating that the current block commands a jump to a non programmed block Clear by pressing CE then either correct the block jump or program the destination block Diagnostic message occurring in TRANS Executive Software previous to e TR3x 005 0 If Reset key is also illuminate
118. all the TRANS in its enclosure 6 Make sure you correct the Software Version label on the TRANS Usually not supplied 7 You can now power up the TRANS and load parameters and a program Figure 9 1 Executive EPROM Location In TRANS IA 74718 9 2 Rev A 10 87 9 2 ADAPTIVE DEPTH CONTROL As provided by optional software TR35 the TRANS has the capability of positioning the slide directly from a linear encoder instead of using the feedback from the motor s encoder With this function it is possible to compensate for both drive train variations and workpiece position variations By using incremental positioning it is possible to program distances relative to the face of the workpiece 9 2 1 Associated Parameters A variety of linear encoders can be used in TRANS systems with adaptive depth control The parameters described below are used to adapt the system to work with a particular encoder Para Format meter Description Inch Metric P25 MAX FEEDRATE FOR G5 Sets the maximum feedrate that can XXXX X XXXXX be programmed for the TRANS while operating with the linear encoder If a higher feedrate is encountered in a block programmed using a linear encoder a soft fault will occur and the RANGE ERROR diagnostic will be displayed P32 LIN ENC RESOLUTION Specifies the linear distance X XXXXX traveled per linear encoder line Note that the encoder provides four pulses per line Thus an encoder with 2 5 micro me
119. ameter TRANS GROUP NUMBER Specifies a group the X X TRANS will be a part of for LCA giobal commands in binary format Enter a number from 1 to 9 SERIAL CYCLE INPUTS This parameter See description determines from where the TRANS will accept its cycle interface commands either the TRANS BUS or connector X11 Using the key below enter a 1 to accept the command from the serial TRANS BUS O to select the normal input at connector X11 00000 Enable Forward Re Start Enable Start Homing f SERIAL ACKN INPUTS Specifies from where See description the TRANS will expect auxiliary function acknowledgments and is programmed as P02 above Enter a 1 to accept acknowledgments from the TRANS BUS 0 to accept them from connector X8 00000000 Acknowledgment 7 itildi Acknowledgment 0 SERIAL CONDITIONS Specifies from where the X X TRANS will accept conditional jump inputs which are used in making block jump decisions during program execution There are four conditional jump inputs on the TRANS Either a 0 or a 1 may be entered for this parameter 0 causes the conditional jump inputs to be accepted from the parallel input lines located on connector 11 A 1 causes them to be accepted from the TRANS BUS ignoring the inputs on 11 UNITS Enter O to select metric 1 to select inch X X 4 6 10 87 Parameter Format Number Description Inch Metric PO6 ENCODER CY
120. and correction of faults The diagnostic status of the control can be interrogated at any time even when no error is present by selecting Diagnostic Display Mode Thus normal status indications such as READY MISSING can be observed and causes of operation interruptions which do not appear as errors such as the control waiting for an auxiliary function acknowledgment can be determined In on line operation the fault can be detected by the Line Control via the data bus The Line Control then switches to Diagnostic Mode and the diagnostic message appears in the display 8 2 TYPES OF DIAGNOSTIC MESSAGES MEM MITTIT iii There are four categories of diagnostic messages which may appear Normal Status Diagnostics Soft Faults Hard Faults and Temporary Faults The description of each diagnostic message in Section 8 3 specifies its category 8 2 1 Normal Status Diagnostics These are normal status displays indicating current machine conditions They include DRIVE OPERATING DWELL TIME IMMEDIATE STOP NO START etc They indicate the operation currently being performed or some operation ready or interrupted which will be performed as soon as the appropriate signal is received 8 2 2 Temporary Fault This type of fault is treated by the TRANS as a Temporary Error No other signals will be accepted by the TRANS as long as this condition persists but no Reset of the control is needed once the problem is rectified
121. ary device status state of acknowledgments Destination Position Display Mode Selects a display of the commanded destination position of the slide the current programmed feedrate and the programmed auxiliary function status Deviation Display Mode Selects a display of the position deviation position error or lag of the slide the feedrate override in percent and the auxiliary function deviation The position deviation is the difference between the actual position and the commanded position The auxiliary function deviation indicates any functions commanded but not yet acknowledged Feedrate BCD and Tool Display Mode Selects a display of the current programmed feedrate feedrate override selected BCD output current tool correction register number and current reverse vector Diagnostics Mode This is the normal display mode where the contro displays a diagnostic error message if an error has been detected or indicates the status of the system i e operating dwell waiting for auxiliary ackn wledgment etc Tool Correction Display Mode Displays amount of programmed compensation in the tool correction register currently in use within the user program The LED on one of these keys will be illuminated to indicate the current display mode IA 74718 2 6 Rev A 10 87 2 4 PROGRAMMING AND PARAMETER MODE KEYS perator L This group of keys selects and controls parameter entry
122. aximum spindle rpm range is 9999 rpm However your input range is limited in both and directions by the maximum rpm 10 volts specified in parameter P38 Ten volts is the maximum value of the analog command signal to the spindle controller If the value of P38 is reduced after your program is entered the instructions will be executed but the spindle speed will be limited by the new value in P38 regardless of a higher speed entered in a program block 13 AUX FUNCTION now appears in the display You can now step through and select any desired miscellaneous functions such as auxiliary functions BCD outputs block jump or block repeat Selection of these functions or skipping them occurs in every block which is programmed See Section 5 5 3 5 for a description of programming procedures 5 5 3 3 Dwell 1 To select a dwell time press the Dwell key 2 DWELL TIME appears in the display Key in the dwell time in seconds from 0 01 to 99 99 You must enter the decimal point in the proper position or the TRANS assumes whole seconds If you make an entry error press DEL Delete and re key the data If you attempt to enter too many digits the diagnostic message FORMAT ERROR appears in the display and the LED on the CE key lights Correct by pressing CE to clear the error then enter the correct data 3 When your data is correct press ENTER 4 AUX FUNCTION now appears in the display You can now step through and sele
123. back signals comparing them to each other and to the commanded velocity and position If the encoder is indicating correct operation but the tachometer is not this message will be displayed Causes may be a defective tachometer motor feedback cable or NC cable Correct the problem and press Reset IA 74718 8 17 Rev A 10 87 MESSAGE TACHO FAULT Cont d THRUST MISSING TOOL CHANGE FINISHED TOOL CHANGE IMMEDIATE STOP TOOL CHANGE NO COMMAND TOOL CHANGE OPERATING TOOL CORRECTION TRAVEL LIMIT IA 74718 DESCRIPTION SUGGESTED RECOVERY Under rare conditions this diagnostic message may occur if the acceleration rates demanded by the system determined by the Ramp and Max Feedrate parameters cannot be met caused either by unrealistic parameter values or excessive drive train inertia or friction In this case correct the drive train problems or reduce these two parameter values Normal Status Diagnostic Can occur when using the optional Feed Adaption Software TR34 This diagnostic will be displayed at the end of a cycle after a jump to biock 000 and stop that contained an adaptive feed block and indicates that the thrust never exceeded the minimum thrust value programmed in the MIN THR CURRENT line of the adaptive feed block This is simply a warning possibly indicating a broken tool or missing workpiece Normal Status Diagnostic Indicates that the Tool Change input is activated but the TRANS has com
124. brought low as an acknowledgment to the TRANS d Once Data Valid is low the TRANS will bring the Digit 1 output high indicating it is ready to read the most significant digit of the value Place that digit s value in BCD form on the 4 Data Lines When the Data Lines are stable bring Data Valid high e After Data Valid is high the TRANS will read Digit 1 s value from the data lines then bring the Digit 1 output low Acknowledge by bringing Data Valid low f The procedure ins steps d and e is repeated for Digit 2 Digit 3 and Digit 4 g Once Data Valid is brought iow after the TRANS has read Digit 4 the TRANS will indicate a successful transmission by bringing the Complete output high Complete will remain on until the Register Line Register 01 or Register 02 is brought low In any case Complete will remain high at least 100 milliseconds 74718 9 16 Rev A 10 87 After the transmission sequence is complete the display on the TAM if one is connected will show the Correction Register and it s new value regardless of the current display mode This will remain on the display until the Register Select line is brought low and in any case for at least 100 msec if at anytime an error is detected during transmission such as the Register select line going low before the sequence is completed or an attempt was made to exceed the maximum allowable correction Parameter P39 the appropriate Error output will go high
125. c will not be lost Normal Status Diagnostic Occurs in conjunction with TRANS executive software incorporating analog spindle output voltage capability This diagnostic indicates that the spindle is not outputting the signal which indicates it is running at the commanded speed or stopped if so commanded When speed changes are commanded by the TRANS it halts program execution until the spindle responds with an indication that it has reached the new commanded speed or stopped IF the diagnostic persists it may indicate a spindle overload condition blown fuses defective spindle controller or motor defective cabling etc Hard Fault Issued as as warning that new parameters have been downloaded into the RAM memory from the Line Control Adaptor To clear insert the key into the Parameter keyswitch and turn it to the Parameter Entry Edit position then press the Reset key This prevents unauthorized personnel from altering TRANS memory contents Hard Fault Issued as a warning that a new program has been downloaded into RAM memory from the Line Control Adaptor To clear insert the key into the Program keyswitch and turn it to the Program Entry Edit position then press the Reset key This prevents unauthorized personnel from altering memory contents 9 0 Rev 10 87 MESSAGE DESCRIPTION SUGGESTED RECOVERY NO ACKNOWLEDGMENT ON X Either a Normal Status Diagnostic or a Soft Fault X is a specified auxiliary function The Nor
126. can be executed from any point in the main program and a return to that point is assured after completion of the subroutine J Jump To Subroutine must jump to a valid block or the error diagnostic JUMP TO GAP will occur JA 74718 5 9 Rev A 10 87 Subroutines are programmed just like main programs Note however that a subroutine must always contain a J RETURN instruction as its last entry However a Return may not appear in a program which has not been declared as a subroutine because this would confuse the program sequence In such a case the TRANS responds with the diagnostic message RETURN ILLEGAL 5 3 15 3 Conditional Jump NC Code JC A conditional jump transfers program control to the specified block number only if the programmed condition exists on the four conditional jump control inputs These are user interface inputs allowing the user to determine via external signals such as selector switch inputs whether a programmed jump should be executed Example Assume the TRANS bas three different programs which start at the following block numbers Program 1 Block 015 Program 2 Block 026 Program 3 Block 034 One of these three programs can be executed based on the position of a selector switch by programming the following routine starting at block 000 with conditional jumps NOOO J C 015 0001 001 J C 026 0010 N002 J C 034 0011 NOO3 J S 000 Block Number J specifies jump S specifies jump and stop
127. cceleration for that block in all speed ranges Enter in in sec sec or mm sec sec SPINDLE DIRECTION Analog Spindle Output X X Option software TR30 004 0 and above This parameter determines the direction of spindle rotation for a given program command or It may be 1 or 0 When used with Indramat AC Spindle Drives entering a 0 causes the motor to rotate CCW as viewed from the output shaft for a programmed positive spindle speed For direct drive spindle applications this would yield the normal tool rotation required for positive speed values Entering a 1 produces CW rotation for a programmed spindle speed This would be the normal value for a spindle with gearing such that tool rotation is opposite motor rotation Technical note For a programmed spindle speed 0 produces negative analog command a 1 produces a positive analog command 4 14 Rev A 10 87 Parameter Number P38 P39 P40 IA 74718 Description SPINDLE RPM 10 VOLTS Analog Spindle Output Option software TR30 004 0 and above This parameter is a specification of the spindle controller and is entered in RPM Refer to the appropriate spindle controller user s manual for information on determining this value For example if an Indramat KDA CDM AC Spindle Drive is being used this value would be the same as that entered for the MAXIMUM RPM parameter in the CDM This parameter is the maximum programmable spindle RPM in the part pr
128. ce Modules 9 29 9 8 1 General Description 9 29 9 8 2 AC Input Modules 9 30 9 8 3 AC Output Modules 9 31 9 9 Using a TRANS with a Linear Scale 9 31 9 9 1 Introduction 9 31 9 9 2 Parameter Adaption 9 32 9 9 3 Pulse Weight 9 32 Appendix A Parameter Record Sheets Appendix B Hardware and Software Type Code Keys B 1 TRANS Hardware Type Code Key B 1 B 2 TRANS Executive Software Type Code Key 1 B 3 TRANS Executive Software Detail B 2 B 4 TAM 2 Typecode B 2 Appendix C TRANS System Cable Drawings C 1 Introduction C 1 IA 74718 X Rev A 10 87 CHAPTER 1 GENERAL DESCRIPTION 1 1 INTRODUCTION 1 1 1 The TRANS 01 Family Of Controls Indramat TRANS 01 Transfer Line Control family is a series of microprocessor based programmable controls designed for control of transfer lines and other high production machining systems The TRANS is a single axis control designed to provide numerical control of an Indramat MAC AC servo drive used as a feed drive operating slide or rotary table The TRANS is available with software options for feed ramp adaptive depth control adaptive feed control and rotary motion control Hardware software options include external tool correction interface modules for 115 VAC signals and mounting in the sealed KSC enclosure with servo and spindle drives TTT lt This document describes the TRANS 01 M Modular Transfer Line Control System is an open frame constr
129. cess to Manual Mode controls in the course of normal operation the TRANS includes a parallel interface for a unit Operator Station This station and its control buttons and switches is provided by the machine builder Normal programmed movements including forward reverse homing and move to toolchange position can be commanded from this station assuming the necessary enables are provided by the TRANS Operator functions are described in Chapter 3 5 Cycle Interface For operation of the TRANS 01 M by the customer s Line Control it is equipped with a parallel cycle interface over which operating commands can be transmitted In Automatic Mode all control of the TRANS occurs either via this interface or the optional Line Control Adaptor The Cycle Interface is described in Chapter 6 IA 74718 1 9 Rev A 10 87 1 7 SYSTEM ELEMENTS The TRANS 01 M Control System includes The control computer with diagnostic system and monitor logic An EPROM memory for the executive program and a CMOS memory for user programs and data protected for up to 10 years against power failure by battery backup Numerical control interface for the axis with input circuitry for the incremental position encoder travel limit switches and homing switch Interface for the spindle control including various status lines Input output bus interface for the customer s Line Control Signal interface for an Operator Station panel Control and monitor
130. ck Store e Jump and Stop 1 2 To select Jump and Stop press J S appears in the display Key in the target block number then press ENTER Skip to step 10 Block Store f Reverse Vector 1 Block Repeat To select Reverse Vector programming press REV J R appears in the display Key in the new target block to which the TRANS will jump is a Return command is issued then press ENTER If this is the end of the Forward profile full depth enter 000 for the reverse vector Skip to step 10 Block Store 8 If an Immediate unconditional Jump or a Jump To Subroutine has been programmed BLOCK REPEAT appears in the display IA 74718 5 23 Rev 10 87 9 If repetition of the current block is not required press LF Line Feed If the block is to be repeated key in the number of repetitions from 1 to 99 then press ENTER Block Store 10 11 12 13 14 15 16 At this point all lines of the block have been programmed but it has not yet been stored in memory The LED on the Store key see drawing in step 11 will be lighted indicating that the block can bow be stored in memory If you choose you can successively press LF Line Feed to step through and review each line of the block If you wish to edit a line press the Edit key then key in the correct data and press ENTER Q To store the completed block in memory press the Store key The display is then
131. ct any desired miscellaneous functions such as auxiliary functions BCD outputs block jump or block repeat Selection of these functions or skipping them occurs in every block which is programmed See Section 5 5 3 5 for a description of programming procedures 74718 9 19 Rev 10 87 5 5 3 4 Feed To Positive Stop 1 select Feed To Positive Stop press the O key 2 ABSOLUTE appears in the display As in normal positioning Section 5 5 3 2 press LF to select absolute positioning or to select incremental positioning if incremental positioning is chosen skip to step 4 3 When absolute positioning is selected DESTINATION appears in the display Because the function is used to move against a stop the final position is unknown This value is used to limit the maximum travel of the slide in its search for the stop Enter a destination value just greater than the position where the positive stop is expected Press ENTER then skip to step 5 If the slide reaches this destination without encountering a stop movement halts POS STOP MISSING is displayed and a soft fault occurs 4 When incremental positioning is selected DISTANCE appears in the display Because this function is used to position against a stop the final position is unknown This value is used to limit the maximum travel of the slide in its search for the stop Calculate the maximum distance from the current position which the slide will need
132. ctions and their respective expected acknowledgments 5 Display of current programmed feedrate feedrate override BCD output spindle speed currently selected tool correction register number and current reverse vector block number 6 Status and fault diagnostics 7 Tool correction display mode IA 74718 1 7 10 87 1 4 ENGLISH LANGUAGE PROGRAMMING The basic program for standard motions is preprogrammed user simply prepares program of up to 128 motion control blocks each consisting of up to 8 operating commands such as type and length of axis movement feedrate homing BCD outputs spindle speed dwells and auxiliary operations Jump programming including a jump based on externai inputs and repetition of one or a number of commands is easily selected for programming cyclic operations Tool position corrections can be programmed to allow operator compensation for tool wear When using numeric controls programming a control requires the memorizing of many NC codes and symbols that are recognizable by the control but not particularly meaningful to the operator This problem is eliminated in the Modular TRANS by using simple English language dialog programming The TRANS talks with the programmer requesting him to select a function then prompting him through the entry of the information required to perform that function using simple English prompts on the TAM display 1 5 TAM KEYBOARD DISPLAY PANEL neam
133. d a hard fault has occurred Refer to EXCESSIVE diagnostic the absence of an illuminated Reset key see FINISHING LAG for description Hard Fauit Can occur when using the optional Adaptive Depth Control package During an adaptive depth control function the TRANS constantly monitors the linear encoder rotary encoder and tachometer signals If the rate and or direction of movement indicated by the tachometer and rotary encoder do not agree with the linear encoder this fault will be displayed The cause may be an incorrect parameter value for linear encoder resolution loose drive train or defective linear encoder or linear encoder cable Press Reset and home the axis to recover Hard Fault Can occur when using the optional Adaptive Depth Control package It indicates that the linear encoder was deflected more than the limit specified in parameter P35 before adaptive depth control program block was encountered This is usually an indication of a mislocated part or an obstruction in the path of the linear encoder Correct the problem press Reset then home the axis Hard Fault Indicates that TRANS working memory is unreadable usually as a result of removing the battery for an extended period of time or a defective battery Replace the battery and press Reset If HOMING MISSING is displayed recover by homing the axis If PROGRAM LOST or PARAMETER LOST is displayed you will need to re enter the missing data
134. d the previous relationship between the slide position and the motor shaft position is guaranteed If this is not taken into consideration changing motors could cause an offset in all programmed positions For further details refer to Section 7 4 below In order to prevent damage to the motor bearings from excessive forces the motor coupling to the machine must provide radial and axial compensation addition to the component tolerances at least 0 040 inches 1 mm axial compensation should be provided This is needed to prevent damage to motor bearings from motor heat expansion machine heat expansion or axial motion of machine parts If MAC motor is direct coupled to the ballscrew our experience has shown that use of bellow type servo coupling such as Jakob couplings is best If gearing is used the required compensation can be obtained by directly mounting the input gear to the motor shaft without extra bearings supporting this gear Keep in mind that this driver gear and its mating driven gear should be marked so that the motor shaft ballscrew relationship is maintained as mentioned earlier Note that spiral gears are undesirable because they cause axial loads and position displacement IA 74718 7 6 Rev 10 87 i 7 4 ESTABLISHING A REFERENCE POSITION MALLA M LLLA AA AAT Hem 7 4 1 General The TRANS utilizes a digital incremental feedback device to obtain position in
135. d to prevent unnecessary downtime after changing motors the zero pulse position on INDRAMAT s MAC motor has been standardized to a certain keyway motor frame orientation There is a 10 degree difference between the keyway and the center line of the motor That is the zero point The machine design must insure that the motor is always coupled to the ballscrew with the same orientation The most reliable way is through a mechanical design that allows only one orientation this is not done the machine should be clearly labeled as such and marked e g gearteeth to guarantee correct coupling of the motor For the same reason if the machine is ever disassembled the actual reference position must be measured after start up and the reference position parameter edited accordingly 7 4 4 Placement of the Reference Position Because the transfer unit must be able to move to the reference home position at any time this position must be located at a point where the tool is out of and at a safe distance from the workpiece However the reference position should not be placed too far back from the workpiece in order to enable reference checking during operation without waste of machining time It is advantageous when the reference position can also be used as the starting point of the machining cycle to check that the slide indeed is returned in case of drive train breakage 74718 7 11 Rev A 10 87 dois Jo u01 ut suado
136. dent functions such as solenoids switches clamps full depth indicators lights that must be turned on dependent on a position etc Auxiliary functions can be turned or off by entering a 0 or 1 in the proper command positions When an auxiliary function is selected it is turned on or off at the completion of the G code movement or dwell An acknowledgment is required for each auxiliary function When the command is executed the TRANS awaits the acknowledgments for any functions which were turned on or off before it executes the next block During this wait the TAM displays the diagnostic message NO ACKNOWLEDGMENT ON X where X is the first missing auxiliary function number 0 7 Once an acknowledgment is issued the signal line must be held in that state until the function output changes not program execution halts and a soft fault occurs There is one important exception to the above The TRANS allows a jump to the reverse program to be performed even if the acknowledgments do not match their associated auxiliary outputs This can occur on an emergency return or upon recovery from a power failure In this case in the first block of the homing program it is necessary to insure that all auxiliary outputs are forced into a state where they match their acknowledgments The easiest way to do this is to program the first block of the reverse program usually 120 to turn off all auxiliary functions and program the next block with a
137. der to enable operation of the TRANS They are provided on the parallel Cycle Interface or by the Line Control Adaptor over the RS 422 serial channel when the proper bits in parameter 02 set to I s The Enable signal must be present to allow any operation to occur The Enable Forward signal is required to enable execution of the Forward cycle JA 74718 6 1 Rev A 10 87 6 2 1 Enable Connector TRANS X11 Pin 3 Status Normally open Type Input 19 to TRANS This signal is required to enable operation of the TRANS Loss of Enable interrupts both automatic and manual operation Enable is a master release whose purpose is to ensure that motion of the unit can occur only when the machine is in the correct state such as a workpiece in correct position guards closed etc 6 2 2 Enable Forward Connector TRANS X11 Pin 12 Status Normally open Type Input 28 to TRANS This signal is required to enable operation of the Forward cycle in both Manual and Automatic Modes Loss of this signal stops execution of the Forward program This signal is ignored in both the Tool Change and Return homing programs 6 3 OPERATOR INTERFACE d Operator manual controls are available through a parallel operator interface The machine builder will wire these signals to selector switches and pushbuttons at the transfer station The normal programmed movements may be executed manually from this station and they may be made only
138. described in Sections 3 3 through 3 10 3 2 OPERATOR FUNCTIONS Manual operator controls are available through a parallel operator interface provided by Indramat The machine builder may wire these signals to selector switches and pushbuttons at the transfer station Only the normal programmed movements are possible from this station and they may be made only when the necessary enables are provided on the cycle interface or serial interface by the Line Control The following functions are provided 1 Automatic Manual Modes Generally wired to a selector switch With AUTOMATIC selected the TRANS will be Automatic Mode and can be operated only by control signals provided by the Line Control This is the normal mode of operation where the TRANS performs a single program cycle each time the Line Control issues a Start signal Manual control at the unit s Operator Station is possible only with the selector switch in the MANUAL position and when the TRANS 01 M diagnostic checking has not detected any interruptions Should the TRANS refuse to operate it will diagnose the reason and provide an English language display on the TAM display panel See Chapter 8 for a complete list of system diagnostics Note that Manual Mode is distinct from Hand Mode Manual Mode enables the Forward and Return Reverse operations as described below In addition Manual Mode must have been selected at the Operator Station or by the Line Control in order for Hand
139. dicate end of the Forward program in Manual Mode only and will normally be programmed at the end of the forward profile full depth See Section 5 3 15 5 for more information on reverse vector programming If the RETURN button is pressed during forward cycle operations the slide must be homed before the FORWARD button again becomes effective Note that at the toolsetter level the slide can jogged forward and reverse using the jog keys on the TAM keyboard In contrast to the action of the FORWARD switch jogging motion does not follow the programmed profile 3 Return Generally wired to a pushbutton The Automatic Manual switch must be in the MANUAL position to enable this button While this button is held depressed the TRANS will jump to the current reverse vector and perform its reverse operation as programmed in that block returning to the Home position If previous to the actuation of the RETURN button program execution was halted by a reverse vector of ROOO as described above the TRANS will execute the program beginning with the next sequential block after the block containing the 000 See Section 5 3 3 for programming requirements for this operation Releasing the pushbutton stops the movement Pressing the button again continues the operation Once the RETURN button has been pressed the other operator controls are disabled until the slide has returned to the Home position IA 74718 3 2 Rev A 10 87 Note that th
140. dicating that 99 feed reduction occurred without reduction of thrust current JA 74718 9 24 Rev A 10 87 9 6 FEED RAMP OPTION 9 6 1 General Description TRANS executive software version TR32 provides a feed ramp capability plus modified auxiliary outputs discussed in Section 9 7 The standard TRANS software controls system acceleration as follows 1 Below the maximum feedrate specified in parameter P20 acceleration is limited oniy by the system gain parameter P14 This is true because maximum acceleration deceleration is usually desired for speed changes in the cutting speed range Controlled ramping of acceleration in the cutting speed range is not available in the standard TRANS software but is provided by the Feed Ramp option 2 Above the maximum feedrate acceleration in standard software is limited to the value specified in the Ramp parameter P19 This limit is necessary to avoid excessive mechanical stresses on the drive train caused by accels decels to and from rapid traverse speeds The optional Feed Ramp capability allows ramping acceleration in any speed range but is usually used for a smooth transfer from one speed to another within the cutting speed range to avoid instantaneous jumps in speed as the feedrate changes from one block to another In order to obtain a smooth acceleration deceleration from speed V1 to speed V2 from one block to the next the following conditions must be met 1
141. display to the next valid parameter or press ENTER to return the display to the previous LF parameter Continue this parameter entry procedure from step 4 until the PARAMETER desired number of parameters have been set or edited Then turn the keyswitch back to its locked position and remove the key KD At this point the entire parameter set is checked for interrelationships such as selected rapid speed excessive for a given available motor RPM If the selected parameters cannot be used together UNACCEPTABLE PARAMETERS is displayed and a soft error results See Section 4 6 for more details on error checking and a description of recommended recover procedures 8 Press RESET to reset the control You are now ready to enter Q an application program as described in Chapter 5 Note that the Parameter keyswitch can be used to select Parameter Entry Edit Mode while the system is operating although this is not recommended In this case the drive immediately shuts off the PARAMETER MODE diagnostic is displayed and a hard fault occurs See Section 3 11 for a discussion of the procedure for clearing faults IA 74718 4 5 Rev A 10 87 4 5 01 M Parameter Number 00 01 2 4 5 IA 74718 PARAMETER LIST Format Description Inch Metric TRANS NUMBER Specifies the address of the XX XX TRANS control on the TRANS BUS See Section 4 2 1 for information on the setting of this par
142. e IA 74718 5 45 10 87 The program assumes home to be zero on the absolute grid that the spindle should be turned off after each cycle and that the full depth indicator should be cleared when returned To enter the program select Manual Mode on the Operator Interface press the Reset key and insert the Programming key into the Program keyswitch and turn it to the Program Entry Edit Mode The display will now contain N along with whatever command is currently in block 000 Now enter each block by pressing the appropriate keys The correct key sequence for each block in program 2 is shown below Block 000 EXER T ov Block 001 SITIO RST 2 Block 002 S00080c 00 S000 Dooce Block 003 ma Jt Jun J 6 Jim CCID ese Block 004 JOS Jem pr 2 2 Block 005 in COA foresee 1 CASCO CE C3 IA 74718 5 46 Rev 10 87 59 X83 Cr C D esf 08 Block 117 OUO eJ e Jp JL Jen 8 J 0 COLO DRODOSOCZOUODOU ef Jo Jor JC Jn C0 Jem C e Co 54 0 Jem Jer 0 0 Jene Gr J Co Jen 1A 74718 5 47 10 87 CHAPTER 6 FUNCTIONAL DESCRIPTION 6 1 GENERAL This chapter provides a functional description of the TRANS 01 M interfaces to the machine builder s equipment and describes the power interrupt handling features of the TRANS These interfaces are 1 Interface to the Operator Station which contains the pushbuttons for manual controls 2 Cycle Int
143. e is at or behind the home position The following conditions must also be satisfied 4 Reference position is known homing done since last reset 2 Slide is stopped and position 3 No program is being executed 6 4 8 Power Interrupt Connector TRANS X10 Pin 7 Status Normally open Type Output 13 from TRANS When power is re applied after a failure this signal is issued by the TRANS to indicate that an operation Manual or Automatic had been interrupted by a power failure This signal is provided for the machine builder s use in determining the problem The response will depend on the design of the overall transfer line system See Section 6 13 for a discussion of power interrupt handling in the TRANS Power Interrupt is issued only when Automatic mode has been selected on the Cycle Interface This signal is dropped whenever homing is completed or the Reset key is pressed IA 74718 6 7 Rev A 10 87 6 4 9 Fault Connector TRANS X10 Pin 6 Status Normally closed Output 12 from TRANS Type In both Automatic and Manual Modes loss of the Fault output is indicated when the TRANS has diagnosed malfunction This signal indicates that the respective unit is not operational When a fault occurs an operator must determine and resolve the problem utilizing the diagnostic display capabilities of the TRANS then reset the TRANS homing the axis if necessary in order to bring it to Ready status once more
144. e offset position from home Thus if the slide is at 2 inches from home a command to travel to 3 inches results in a one inch feed in the positive direction In incremental positioning all movements of the slide are made in the commanded direction to the distance specified starting from the current position of the slide Thus if the slide is at 2 inches from home a command to travel 3 inches incrementally results in the slide positioned at 5 inches from home IA 74718 5 5 10 87 5 3 7 Lag Finishing During Positioning When a position command is issued the servomotor moves the axis in response to that command There will always be some finite lag time between the time the command is issued and the time the servomotor brings the axis into position When programming your positioning commands you will be required to respond to the Without Lag display which is an abbreviation for Without Lag Finishing Lag finishing specifies that the axis must be stopped in position before any miscellaneous functions remaining in the block are executed or before the next block is executed This would be required at full depth for example It is important to note that this is also required where you have programmed miscellaneous functions such as auxiliary outputs Section 5 3 13 which are to turn on only when the axis is in position Lag finishing is selected by pressing the Lag Finishing key K If a lag during positioning
145. e selected percentage of feedrate override ie programmed feedrate is effective only if the feedrate override is set to 100 5 3 9 Dwell NC Code 64 A dwell is programmed to allow time for some action to occur such as a dwell programmed after a forward cutting motion to allow a drill to clean the borehole and prevent burrs Dwell times can be programmed from 0 01 to 99 99 seconds IA 74718 5 6 10 87 5 3 10 Feed To Positive Stop NC Code 65 This function may be used when it is necessary to position the slide against a positive mechanical stop The slide will move at the feedrate programmed in this block The available torque of the motor will be reduced to the percentage value specified in parameter P26 Torque To Pos Stop When the TRANS senses that the motor has stalled the motor s available torque will be changed to the percentage value programmed in parameter P27 54 Torque At Pos Stop This torque value will be used for any Dwell or other waiting period e g auxiliary function acknowledgments The torque value will be switched back to 100 torque at the time the next movement is begun An incremental distance programmed in a block following a feed to positive stop will be based on that point where the stall occurred distance incremental or destination absolute programmed with this function is the maximum distance the slide will be allowed to travel and should be a point just past the expected positive
146. ed 6 11 BCD CODED OUTPUTS Connector TRANS X9 Pins Units biti 1 Units bit2 2 Units bit4 3 Units bit 8 4 Tens bit 1 5 Tens bit 2 6 Tens bit 4 7 Tens bit 8 8 Status Normally open Type Outputs 1 8 from TRANS These BCD coded outputs can be used to energize multi speed motors energize reversing contactors communicate to a line controller etc The outputs are 24 Vdc 50 mA per output optically isolated from internal circuitry Example If BCD output 01 is programmed pin 1 of X9 is high all other lines are low 6 12 SPINDLE CONTROL SIGNALS A This paragraph describes the TRANS control interface for a spindle Note that spindle operation is enabled using parameter P40 IA 74718 6 13 Rev A 10 87 6 12 1 Operating Conditions Spindle Ready Status Bb Connector X8 Pin 2 Status Normally open Type Input 15 to TRANS If spindle analog output is selected in parameter 40 the Ready status signal Bb of the feed drive and also the Ready status of the spindle drive Bb must be transmitted to the TRANS The diagnostic message SPINDLE NOT READY is displayed if the Spindle Ready signal is not received by the TRANS Note that when the TRANS is first started up the Spindle Enable RF signal is not sent 6 12 2 Spindle Command and Enable Signals Spindie Command Connector X3 Pin 1 Status Normally open Type Output from TRANS Spindle Command Ov Connector X
147. ed in that parameter such as 625 instead of 1250 If the parameter is correct either the incremental encoder or its cable is faulty Replace the defective component press Reset then home the axis EE A A TT M M amm mem eem me When the system issues a command voltage for drive motion it expects to see a tachometer voltage feedback within a voltage window of the opposite polarity If there is no tachometer voltage or it is the wrong polarity and encoder pulses are present TACHO FAULT is diagnosed If the tach is correct but there are no encoder pulses or they are the wrong polarity ENCODER FAULT or LIN ENCODER FAULT is diagnosed as appropriate If neither tachometer nor encoder feedback is present after the command voltage is issued DRIVE FAULT is diagnosed Note that DRIVE FAULT is also diagnosed if no command has been issued but tachometer and encoder feedback are present IA 74718 8 19 Rev A 10 87 CHAPTER 9 TRANS 01 M OPTIONS 9 1 INSTALLING SOFTWARE OPTIONS This chapter contains descriptions of various TRANS options including Adaptive Depth Control Externa Tool Correction Input Rotary Motion Control Feed Adaption Option Feed Ramp Option Modified Auxiliary Output Functions x X X X When one of these options is provided modified executive software for the TRANS is also provided Appendix B lists the versions of executive software presently available and the options supported by each Refer
148. ed to select some percentage of feedrate to clear errors to delete data while entering a block and to properly terminate the entry of a program block Key Description Feedrate Override When this key is pressed the operator can enter a value from 1 to 100 that represents a percentage of the programmed feedrate and rapid traverse rate The system will operate under this percentage of maximum feedrate until a new feedrate override percentage is selected This is often used during setup and toolchange to operate the slide at a slower than normal speed to verify correct operation This key is not affected by the Program Parameter keyswitches and is only active in Manual Mode Store During programming the LED indicator on this key lights after all necessary data for the block being programmed has been entered Pressing this key then transfers the data into memory Clear Error When an error has been detected during programming parameter entry tool correction entry or during operation an error message such FORMAT ERROR is displayed the alphanumeric display and the LED on this key is lighted The error will be a Soft Fault such as a key pressed in an incorrect sequence and can be cleared by pressing this key This key must be pressed before the operation or programming continue Generally the data must be re entered Delete When this key is pressed the last key entry is deleted and another entry can be
149. emental encoder cycles per revolution etc This feature allows drive conditions and positioning resolution characteristics for a number of different machines to be adapted to a single type of control with the control then producing correct position gain Thus standard programming procedures maintained regardless of machine structure With this system ballscrew pitch and gear ratios can be chosen based solely on thrust needs and desired rapid traverse rates Thus drives and position encoders can be standardized This concept permits standard components to easily be adapted to differing machine requirements reduces requirements for spares and allows quick and easy replacement of controls by plant electricians if service is necessary 1 1 6 Options number of hardware options are available with the TRANS including external tool correction and interface modules for 115 VAC signals By installing the appropriate optional software adaptive depth control feed adaption rotary motion control and or feed ramp capabilities are provided Options including interfacing and programming are discussed in Chapter 9 1 2 OPERATING MODES The Modular TRANS is a complete NC control and can be operated off line or can be tied to a Line Control system over a data bus This permits TRANS to be employed for completely self contained tasks When complete processing lines are put into initial operation this off line capability al ws initia
150. enter the selected feedrate override value into memory 3 10 ENTERING TOOL CORRECTIONS The TRANS allows the toolsetter to enter one or more correction compensation values to compensate for tool wear or when changing tools to compensate for differences between tools The operating program is written to refer to one of these values by its tool correction register number from 1 to 20 The correction value in the referenced register is then added to the programmed dimensions to compensate for tool wear or the difference between tools IA 74718 3 12 10 87 An example of entering a tool correction value is l Examine the program to determine the tool correction register 1 20 being used see Section 3 5 2 Set the tool correction value in that register to zero see description below 3 Change the tool and run a test part 4 Measure the part and note the variance 5 Enter this variance as the tool correction If the slide did not feed enough e g hole too shallow program a tool correction value If the slide fed too much e g hole too deep program a correction value assuming parameter P22 is set so that a is into the work piece Note that tool correction values can be positive or negative up to 3 2767 inches 32 767 mm Enter tool correction values as follows 1 Switch the TRANS to Manual Mode at the Operator Station 2 Press gt Tool Correction Programming Mode 3 The displa
151. er Entry keys are not required This design allows the entry of corrections by the Toolsetter without the danger of inadvertently changing the program 5 3 12 Analog Spindle Output NC Code S This function is programmed for a TRANS which is controlling a spindle axis You enter the actual speed in rpm at which you want the spindle to operate TRANS then sends an analog command voltage to the spindle controller to generate that speed The commanded spindle speed is effective until changed in another program block Thus if you do not program a spindle speed of zero in your homing block the spindle will continue to run at the last commanded speed IA 74718 5 7 10 87 Unlike the 5 01 the Modular TRANS allows both analog spindle output and feed to positive stop to be active simultaneously Note that several parameters affect spindle operation 1 Bit 0 of Parameter 40 enables or disables analog spindle output 2 Bit O of Parameter P41 determines whether or not the spindle will halt when an Immediate Stop occurs A number of operating signals are returned by the spindle controller as described in Chapter 6 If a spindle fault is diagnosed the TRANS halts and the appropriate diagnostic message is displayed on the TAM See Chapter 8 for a list of diagnostic messages 5 3 13 Auxiliary Functions NC Code M Eight auxiliary function outputs are available in the system They are used to operate position depen
152. er closure of the Drive Ready contact 8 3 Rev 10 87 DRIVE NOT READY Cont d DRIVE RUNAWAY DRIVE STALLED DRIVE OPERATING DWELL TIME EMERGENCY LIMIT EMERGENCY STOP IA 74718 On TRAN s incorporating rotary software this diagnostic has an additional meaning If a part program is written such that a movement is commanded during the time the Controller Enable signal is off accomplished by turning on auxiliary function 7 this diagnostic will be displayed and a hard fault will result Hard fault diagnostic indicating axis drive has moved when not commanded to Possible causes Vertical slide with insufficient torque to hold unit defective disconnected encoder or cable defective axis controller motor or TRANS Hard fault indicating axis drive has not moved when commanded Most likely causes Jammed drive train dull or broken tooling blown servo controller main power fuses or incorrect TRANS servo controller MAC Motor wiring May also indicate a defective MAC motor or controller Normal Status Diagnostic Automatic Mode this indicates that the motor is moving during a cycle operation Normal Status Diagnostic Indicates that the TRANS is presently executing a block containing a dwell time function During this period block display mode can be selected and if the F line is displayed the actual countdown of the dwell time may be observed Hard Fault Indicates that the Safety Limit secondary ov
153. erface to the customer s Line Control which is usually a programmable control which controls automatic operation of the system 3 RS 422 Serial Interface for Indramat s Line Control Adaptor LCA The LCA communicates simultaneously with up to 30 TRANS controls transmitting programs parameters and tool corrections receiving data such as slide position diagnostics etc The LCA connects to a user supplied device such as a programmable controller terminal or computer When the LCA is present parameter P02 is used to specify whether the Enable Forward Restart Enable Start and Homing signals are accepted from the serial bus or from the Cycle Interface See Section 4 5 for details 4 Other inputs and outputs are provided including Four conditional jump input lines Overtravel and limit switch inputs Emergency stop circuit inputs outputs Auxiliary Function outputs Acknowledgment inputs Spindle control inputs and outputs ox x TRANS user interconnections are illustrated in the TRANS Interconnection Diagram included with your system documentation package The various signals on the TRANS interfaces are described below Note that the wire numbers listed for each signal are applicable to standard INDRAMAT manufactured cables only Two signals are added to the interface with the Feed Adaption option They are described in Section 9 5 3 6 2 ENABLES There are two enable signals which must be provided by the machine buil
154. ertravel switch has been opened dropping power to the servo controller Check and correct the reason for the overtravel then manually move the axis off the limit switch Next press Reset then home the axis The Safety Limit switch is wired between pin 7 and pin 5 on TRANS connector X8 If no Safety Limit switch is used these three wires must be tied together Temporary Error The Emergency Stop circuit has opened sensed by loss of voltage on pin 4 of connector X8 This signal is supplied by the machine builder and is often part of the Emergency Stop chain for the entire machine The occurrence of this condition is treated by the TRANS as a temporary error meaning that while no other signals will be accepted by the TRANS as long as the condition persists no reset of the TRANS is required after the condition is remedied If the Emergency Stop input is not used pin 4 on connector X8 must be tied to 24 volts to prevent this error from occurring 8 4 Rev A 10 87 MESSAGE DESCRIPTION SUGGESTED RECOVERY ENCODER FAULT Hard Fault Indicates a problem in the encoder feedback The TRANS constantly monitors the tachometer and encoder feedback signals comparing them to each other and tot he velocity and presently commanded position If the tachometer is indicating correct operation but the encoder signals aren t this message will be displayed Causes may be a defective incremental encoder or position feedback cable Correct the pr
155. ess ENTER ENTER 6 Using the example above if WAITING FOR CONTROL 02 remains displayed for several seconds after you ve pressed ENTER modular TRANS 02 is not responding Refer to the WAITING FOR CONTROL XX diagnostic in Chapter 8 and or check that the TRANS NUMBER is correctly set see Section 4 2 7 When the selected TRANS responds you will see a message in alphanumeric display of the TAM appropriate to the condition of that TRANS This could be a display of the block presently being executed a status message a diagnostic message etc Regardless of the message in the display the number of the TRANS being accessed will appear in the last two digits of the display a long message is being displayed the last three digits of that message blink on and off alternating with the TRANS number 8 When communication is established the red TAM ACTIVE LED on the selected TRANS will be lighted The functions described in the remainder of this chapter are available at the Toolsetter Program and Parameter levels IA 74718 3 5 10 87 3 5 DISPLAY FUNCTIONS Refer to Figure 3 2 This illustrates the top row of keys While power is on the control will always be in one of these display modes When a TRANS 01 M is first powered up it will be in Single Cycle Operating Mode and Diagnostic Display Mode TAM connected to that TRANS will have the LED s on the Single Cycle and DIAG keys lighted This is the
156. estion IDLE DETECTION appears on the TAM display Pressing ENTER will cause the TRANS to measure the idle current present at the beginning of the block s execution and store this value This value will be subtracted from all future thrust current measurements to determine the actual machining thrust current measurements to determine the actual machining thrust current required With idie detection enabled maximum no thrust current will also be checked as described in Section 9 5 1 Idle thrust current detection may be programmed in the same block as the adaptive feed or possibly in an earlier block e g after the spindle is energized Pressing LF in response to the question IDLE DETECTION will disable the function Feed adaption may still be performed however to determine actual cutting thrust the TRANS will subtract the last known idie value from the measured thrust current or will subtract zero if no idle detection has been performed since the last power up or reset D in the block summary see Section 5 5 2 indicates that idle current detection has been programmed in the displayed block 9 5 2 2 Feed Adaption After IDLE DETECTION the question FEED ADAPTION will appear in the display Pressing LF will skip over feed adaption function and a number of dialog questions will occur Note that the letter A will appear at this time in the summary of block contents Section 5 5 2 indicating feed adaption is present in this
157. ether the axis must be in position before continuing with the next positioning command The Positioning NC code is G1 Dwell Function Allows programming a dwell function of from 0 01 to 99 99 seconds in the present block The NC code is 64 Block Jump Block Repeat Auxiliary Functions This key enables the programming of several different functions in the current block including block jumps unconditional conditional subroutine jumps and returns block repeats up to 99 times spindle speed tool correction register number and auxiliary outputs turn up to 8 lines on or off Feed To Positive Stop Select Optional Function Allows programming a feed into a positive stop at a parameter determined torque setting The NC code is G5 This key can also be used to select optional adaptive depth control see Section 9 2 for details The next two rows of Programmable Function keys are used to complete the programming of the function selected by one of the five keys in the first row TA 74718 Key Q Description Incremental Positioning When programming a block where axis positioning takes place the dialog display will be ABSOLUTE Pressing LF Line Feed selects absolute positioning where all moves are made in reference to the zero position pressing this key selects incremental positioning where all moves are made the specified distance from the current position 2 8 Rev 10 87 IA 74718 E a E 8 SUB
158. ey into the Program keyswitch and turn it to select Program Entry Edit Mode Press Block No Select Type the number of the first block you wish to program leading zeros need not be entered then press ENTER NOTE At any time if you make an error while entering data press DEL Delete to delete the last data entered then re key the data and press ENTER You can use the N and LF Line Feed keys to successively increment the displayed block number Press DIALOG Q and FUNCTION will appear in the display Dialog SOR To guard against accidental program changes DIALOG must be pressed to program each block After pressing DIALOG you can exit Programming Mode without changing the block by pressing the Reset key Select positioning by pressing the Positioning key Q IA 74718 9 26 10 87 8 ABSOLUTE appears in the display In absolute positioning all movements of the slide are made to some absolute distance from the machine reference position Thus if the slide is at 5 inches a command to travel to 46 results in a 1 inch feed in the positive direction Press LF Line Feed to select absolute positioning If absolute positioning is not desired skip to step 11 Note that absolute positioning must be selected in the first positioning command of the program since program operation could begin at the home or toolchange position 9 WITHOUT LAG now appears in the display If positioning with lag finishing i
159. flection including the deflection that occurred in the previous block This block is automatically programmed using absolute positioning and lag finishing to ensure that the programmed distance is reached before the next command is executed If the workpiece has not been contacted by the time this block is reached the TRANS will shut down and issue the diagnostic message PART LOCATION ERROR Block 003 Specifies a dwell t me plus a reverse vector of 000 which indicates the end of the forward profile Block 004 A return of the slide is programmed followed by a Jump to Block 000 and Stop The actual movement of the slide is illustrated in the profile shown in Figure 9 5 Figure 9 6 is a programming worksheet for the program just described IA 74718 9 8 Rev A 10 87 Extremes of part face position Rapid Traverse Slide Position 9 Home Position Avg part face position Figure 9 5 Profile of Operation Using Adaptive Depth Control In determining program values it is best to make a chart similar to the above Determine the values as follows 1 Calculate the average distance between the face of the part and the tip of the linear encoder with the slide at the home position Determine the maximum amount of deviation in the part position illustrated as the distance between X2 and X3 in Figure 9 5 again referenced to the tip of the linear encoder at the home position
160. formation The preferable method of determining slide position is to utilize the servomotor s integral incremental encoder An alternative method is to measure position via an incremental linear scale When supply voltage is lost the TRANS stores the last known motor position however because of motor coasting the exact position of the axis must be re established after each power loss using the Homing instruction which moves the slide to the reference position Using the operator and cycle interfaces any of the following methods may be used to move the slide to the reference position home At the programming level by programming a homing instruction anywhere in the program At the toolsetter level via the TAM keyboard or at the operator level discussed below At the operator level by switching the control to manual and using the RETURN pushbutton to execute the Reverse program Via the cycle interface by issuing the Homing input signal 7 4 2 Reference Homing Procedure The TRANS responds to a homing command in one of two ways 1 After a power up or Reset clear Hard errors the TRANS goes through the complete procedure described below Once the first homing function is performed the TRANS remembers where home is A subsequent homing command causes the slide to return to the original home position without repeating the complete physical homing procedure It merely checks that the zero or marker
161. h language dialog is created between the control and the user as a complete program block is entered into a buffer TRANS will utilize the alphanumeric display to request the user to select some function to be performed then it will prompt the user through the programming of a block to execute that function This is the normal mode of program entry and is described in detail in Chapter 3 Edit Mode This mode is used to revise some portion of a program or parameter block When selected allows numerical data within a block to be changed Note that only numerical data can be changed If a different function is desired Dialog Mode must be used to change the program This key is effective only when program Entry Edit Mode or Parameter Entry Edit Mode has been enabled using the proper keyswitch 2 7 Rev A 10 87 2 5 PROGRAMMABLE FUNCTION KEYS These keys are used in response to program entry dialog prompts to select various functions to be programmed into the individual program blocks Key Description The five keys in the first row of Programmable Function keys can be pressed in response to the Function question during Dialog programming BO ne Auto Home This function returns the axis to its home position The Auto Home NC code is GO appears in alphanumeric display Positioning This function is used to position the axis The dialog will request distances feedrate absolute or incremental positioning and wh
162. hat point the TRANS will be an Immediate Stop condition 2 Soft Fault A soft fault such as a key pressed in the incorrect sequence or an attempt to enter too many digits in a number results in the FORMAT ERROR COMMAND ERROR etc diagnostic display and the lighting of the LED on the CE key Correct the fault by pressing CE Clear Error and re keying the data 3 Hard Fault A hard fault is generally a hardware error of some kind such as failure of the encoder a broken wire etc this case the position of the slide is no longer known When this occurs the appropriate diagnostic message appears in the display and the LED on the Reset key 15 lighted You must remedy the fault then press the Reset key The TRANS comes up in Single Cycle Operating Mode and Diagnostic Display Mode You must now home the axis before operations can continue Faults can be cleared from the Operator Station when in Manual mode Pressing the RETURN button clears the fault Releasing the button then pressing it again causes the TRANS to begin its reverse program If the cause of the fault has not been remedied it will reoccur when RETURN is pressed the second time IA 74718 3 14 Rev A 10 87 CHAPTER 4 READING ENTERING SYSTEM PARAMETERS 4 1 GENERAL The TRANS 01 M is adapted to the machine and drive characteristics by entering values for various parameters This permits a standard control system to be adapted to various types
163. hat the drive system is operating a rotary table and 360 has been entered for units table rev Block NOOO moves the table to the 90 degree position and turns on auxiliary function 7 This causes the Controller Enable to the AC servo to be dropped and is also used to energize the clamp The TRANS halts program execution and waits for auxiliary function 7 to be acknowledged When it is time to move the table once again the controlling device e g programmable controller will give acknowledgment 7 to the TRANS allowing it to continue program execution Block 001 turns off auxiliary function 7 which turns off the clamp and restores the Controller Enable to the AC servo Program execution is then halted at block N002 by the jump and stop in NOO1 The subsequent blocks perform similar moves resulting in 4 positions per table revolution IA 74718 9 20 Rev 10 87 30 AH BELL ELI SC LL Um Liu 000 PS E DNAR Fe AD ee IS a 2 NE HO X MENU p BERE XU 7 Sx 2 4 ANI xxx gt 2 H LEGAS SNOILIONO 1z208vl HO aLvuowaa 3943AVYHl DNIHSINIA DYI Q DNIMHSINI S Ov O M m Rev A 10 87 10 Programming Worksheet Example Using Rotary Motion Control Soft
164. he Adaptive Depth block POSITION ERROR Hard Fault Indicates an error in the encoder circuit the encoder or its wiring When the TRANS traverses out from the home marker zero pulse it maintains a count of the distance traveled in terms of encoder pulses It expects to encounter exactly that same number of pulses on its return to the zero point This error occurs anytime there is more than a 3 pulse discrepancy in position For example this error will occur if the TRANS is homed from a position 10 000 pulses from the marker pulse but travels 10 004 pulses on its return ETETEN YNNN PANSAN nO IA 74718 8 13 Rev A 10 87 MESSAGE DESCRIPTION SUGGESTED RECOVERY POSITIVE STOP MISSING Soft Fault Indicates that the current block which contains a move to positive stop function has been executed but the axis traveled the full programmed distance without encountering a stop Press CE home the slide and correct either the program or the mechanical fault POWER INTERRUPT Normal Status Diagnostic When power is dropped during a cycle the TRANS records that fact and issues the POWER INTERRUPT diagnostic when power returns It also places high signal on the Power Interrupt line on the Cycle Interface connector X10 pin 7 The last known position of the slide is stored when power drops The position will be accurate within 0 080 inch 2 mm because of motor drift It is up to the system designer to determine the recovery
165. he correct key into the Program keyswitch and turn it to select Program Entry Edit Mode Press Block No Select Type the number of the first block you wish to program leading zeros need not be entered then press ENTER NOTE At any time if you make an error while entering data press DEL Delete to delete the last data entered then re key the data and press ENTER You can use the N and LF Line Feed keys to successively increment the displayed block number Press and FUNCTION will appear in the display Dialog 9 6 Rev A 10 87 NOTE To guard against accidental program changes DIALOG must be pressed to program each block After pressing DIALOG you can exit Programming Mode without changing the block by pressing the Reset key 7 Select adaptive depth programming by pressing the E key LIN DESTINATION will appear on the display 8 Key in the total linear deflection desired then press ENTER The linear encoder must already be deflected before this function is used so when this block is executed the slide will move the distance programmed minus the pre deflection described below See Section 9 2 4 for details on linear encoder deflection requirements 9 The TRANS automatically selects absolute positioning and lag finishing for blocks using the linear encoder for adaptive depth control Thus after each positioning command is executed the motor will come into position and stop before the next block is
166. he interface when the Feed Adaption option is installed They are described in Section 9 5 3 IA 74718 6 17 Rev A 10 87 i CHAPTER 7 MOUNTING AND INSTALLATION 7 1 GENERAL The use of completely interchangeable functional modules is an unconditional requirement for highest operating uptime of any machine The INDRAMAT TRANS 01 M control and drive package consists of only a few modules Highly developed technology has enabled standardization of these modules regardless of the different details of various applications the case of a malfunction the diagnostic system will indicate the defective unit which then can be replaced without complicated adjustments This technique was developed because analysis showed that this is the only way complex systems can be operated with minimum down time This analysis proved that the majority of down time is spent finding problems and correcting details Often the actual time consuming problems are caused by detailed trouble shooting where measures are taken whose indirect effects are not recognized such as adjustments required but not made INDRAMAT s Modular TRANS control package offers perfect solution to this trouble shooting problem However this concept will work only when the machine design and installation also provides quick and failsafe mechanical interchangeability of the modules without the danger of damage or changes in the machining results Cables wi
167. he target block number then press ENTER Skip to step 8 Block Repeat Jump to Subroutine 1 Press SUB SUB 2 J U appears in the display Key in the block number of the first block of the subroutine Then press ENTER Skip to step 8 Block Repeat Note that all subroutines must be terminated with a J RETURN Return 1 Press RET 2 Skip to step 10 Block Store Conditional Jump 1 Press COND 2 appears in the display Key in the target block number Then press ENTER 5 22 Rev A 10 87 3 6 The display is now JC XXX 0 000 Condition bit 4 Condition bit 3 Condition bit 2 Indicates cursor position Condition bit 1 target block number J specifies conditional jump Press 1 to specify bit on zero filled with lines appears in the display to indicate the on condition selected cursor moves to bit 2 Press O to specify bit 1 off 0 appears in the display to indicate the off condition selected cursor moves to bit 2 Press Line Feed to move the cursor to the next bit position without changing the displayed value After condition bit 4 has been programmed the cursor will wrap around to point to bit 1 again Proceed as indicated in step 4 until the selected condition has been keyed in then press ENTER Any mistakes can be corrected by repeating the procedure after bit 4 is programmed and the cursor has returned to bit 1 Skip to step 10 Blo
168. hecked for interaction according to the set of formulas listed below To work with these formulas first calculate values for the operating variables listed below 10000 when 5 1 inch mode 1000 when 5 0 metric mode Xi 09 0 08 X2 X1 4 PO6 Resolution X3 1 597806 10 10 X P14 X1 P13 X4 7 P13 Pod XO PO8 1000 The resolution is in units of 1074 inches pulse or 1076 meters pulse and is the positioning accuracy of the system 1 74718 4 23 Rev A 10 87 06 10 11 12 1 14 15 16 P17 P18 20 P25 TABLE 4 2 PARAMETER LIMIT FORMULAS Parameter Encoder Cycles Rev Ballscrew Lead Travel Limit Travel Limit Reference Position Motor RPM 10 Volts KV Factor Homing Speed Rapid Speed Jogging Speed Jogging Rapid Max Feedrate Max Feedrate for G5 IA 74718 Limit Formulas 0 0625 lt X2 lt 1024 Note The bit weight resolution which is the positioning accuracy of the system can be derived using the formula for X2 eliminating the value for XO when calculating the value of X1 which is part of the formula for X2 4 lt X1 33554432 1 0 0000 inch lt P10 lt X2 838 8600 when X2 1 0 0000 inch lt 10 838 8600 when X2 gt 1 0 000 mm lt 10 X2 8388 600 when X2 1 0 000 mm lt 10 lt 8388 600 when X2 gt 1 X2
169. hen an executing user program is interrupted with a Return signal and the axis is to be returned to the home position it is often necessary to execute different program sequences depending on the status of the user program at the time the Return signal was received For example if the tool is in the part your Return Reverse program may be different than if the tool were at the face of the workpiece This situation may occur in slide units both during manual operation when the Return input is triggered and during automatic operation when the Homing input is triggered A special type of jump command the Reverse Vector Jump specifies with which block the Return program is to start when a Return or Homing signal is issued The reverse vector is set to block 120 when the TRANS is reset and is reset to block 120 each time the TRANS executes a Jump To Block 000 And Stop jump to beginning of program As previously described block 120 is the beginning location for the basic homing program At any point in the forward program you can use the Reverse Vector Jump command to set some block other than 120 as the start of your Return Reverse program A starting point programmed in this manner will remain effective until it is replaced by a new reverse vector of the same type executed in your program This allows coordination of very complicated Return programs within the user program with a minimum of programming overhead Reverse Vector 000
170. here must be a voltage available at this input indicating proper spindle temperature conditions for operations to occur If this input is not present the SPINDLE OVERTEMP diagnostic message is displayed on the TAM If this signal drops during a program cycle the cycle is not interrupted and the diagnostic message does not appear until the cycle is ended If the spindle does not have a temperature switch then this input must be wired to 24 volts for proper TRANS operation 6 13 POWER INTERRUPT HANDLING The TRANS features an advanced power interrupt handling feature that ensures rapid accurate recovery from power outtages and emergency return conditions The sequence which is followed is 1 TRANS senses loss of power 2 If the motor is running the TRANS immediately commands it to stop step command so the stopped position can be read and stored before power is completely lost and the encoder can no longer be read 3 All variable conditions are stored including currently selected reverse vector status of auxiliary outputs and status of BCD outputs 4 When power is re applied the TRANS restores the variable conditions to their previous state except all outputs are off Power Interrupt output is issued and the TRANS awaits a Homing Automatic or Return Manual signal It will accept no other commands 5 When a Homing or Return command is received the TRANS first sets the auxiliary outputs to their last known state
171. homing function Assuming all acknowledgments will also be off then homing will always be possible When programming this of course it must be certain that axis movement is possible and safe with all outputs off Section 6 10 provides a functional description of auxiliary outputs acknowledgments and presents line control interface guidelines for the system designer IA 74718 5 8 10 87 5 3 14 BCD Output NC Code B Eight BCD outputs are available on the TRANS They can be turned on and off in BCD Binary Coded Decimal format within a machining program These outputs can be used to signal certain positions to another control or display panel to control auxiliary equipment etc A two digit code 00 99 is entered into the block line and the corresponding outputs will be turned on or off after the completion of the main block function Refer to Section 6 11 for additional information on BCD outputs 5 3 15 Program Jumps Several types of program jumps are available as discussed in the following paragraphs If program jumps have been selected in a block together with other functions their execution will occur at the end of the block after all other functions have been executed 5 3 15 1 Unconditional Jump NC Code JN unconditional jump transfers control to another block number anywhere in the program This allows the programmer to change the sequence of program execution It is helpful when patching programs The
172. icate using one RS 232 serial channel throughout the system The Cycle Interface provides control lines for one TRANS 01 M while the Line Control Adaptor LCA can communicate with up to 30 TRANS controls receiving status and position data transmitting commands and downloading programs and parameters The customer s Line Control can control the TRANS via the LCA or the LCA can be used to monitor position and status information for display with the actual control handled over the Cycle Interface This is determined by setting up TRANS parameters The TRANS can be operated both on line controlled by the customer s line control and off iine controlled either from an Operator Station mounted on the machine and or by the TAM keyboard display panel Two models of the TAM keyboard display are available The TAM 2 is a portable unit which is plugged into a single TRANS control when needed The TAM 2 01 is a machine mounted unit which communicates with up to 10 TRANS controls via daisy chain cabling typical system consists of several 01 M controls with one more TAM keyboard display modules per 10 TRANS controls Each TRANS can provide control for 1 One feed axis controlled by an Indramat Servo Controller amplifier such as a TDM with a model MAC AC Servomotor with integral incremental encoder for position feedback 2 One spindle drive controlled by an Indramat spindle controller such as the or KDW
173. igure 7 1 TRANS 01 M Outline Drawing IA 74718 7 3 Rev A 10 87 Lp 0 rp x2 7 3 4 ls 8 4 I 39 E o a 185 7 74 ee Too 319 20 NOTES 1 CONTROL VOLTAGE 115 or 228VAC MUST MATCH VOLTAGE 5 USE CABLE 03 8411 IF MOTOR HAS BLOWER 24 vbLT Be 1 8 INPUTS TVM X10 AND ANY BLOWERS 6 8 AWG MUST BE USED FOR TYM POWER WITH THE FOLLOWING MOTORS SUPPLE 2 Ti 3 PHASE AUTO TRANSFORMER 220 DUTPUT USE ISOLATION 1128 1 60 112 1 XFORMER IF 3 PHASE POWER IS NOT REFERENCED TO GROUND MAC i12C 0 KD MAC 142C ED ov savot CR1 AUXILIARY CONTROL RELAY FOR 1 CONTACTOR 24VDC COIL 112 1 112 1 CR2 BRAKE CONTROL RELAY oniy req d if motor hes brake C24VDC COIL 112C HD AND ALL MAC 112076 ru ext 1 CR3 TAS RELAY 24VDC 7 3 USE CABLE 05 0580 FOR TAM TO TAANS iK B E 1 POWER CONTACTOR USE CABLE 05 0410 FOR TRANS 81M TO TRANS 801M T RE RUNE Li 5 9 CH E ove Fi FUSE 3 EA 3 PHASE MAIN POWER USE CABLE 05 0420 FOR LCA TO TRANS Q1M i Rp we 1 0 F2 FUSE 2 EA 115 220V 1 PHASE 9
174. inch or metric 0 0001 inches 0 001 mm 838 8600 in 8388 600 mm programmable programmable 0 1 to 3200 0 in min 1 0 to 32000 mm min 3200 0 in min 32000 mm min Forward reverse up to 128 up to 99 up to 20 correction registers programmable from 0 01 to 99 99 sec up to 8 individually programmable on off include encoder pulses motor rev maximum feed rate jog speed inch metric units auto home direction reversal zero reference position rapid traverse rate jogging speed motor direction reversal spindle rpm 10 volts detection of over 50 possible malfunctions including drive fault encoder fault parameter invalid motor overtemperature limit switch activated servo voltage error normal stop enable signal missing auxiliary function acknowledgment missing memory overflow 24 Vdc I 0 01 A isolated from internal control circuitry 24 Vdc I max 50 mA Cycle Interface and BCD outputs 150 mA auxiliary outputs per output short circuit protected isolated from internal control circuitry 1 11 Rev A 10 87 Interfaces Described in detail in Chapter 6 Parallel cycle interface Paraliel operator interface Servo interface Spindle interface Auxiliary functions acknowledgments RS422 serial interface bus TAM serial bus IA 74718 used to exchange control interlock and status information with the customer s Line Control used for control signals to from a Local Operator
175. incremented to the next sequential block number Store key cannot be pressed until you have gone through the entire programming procedure even if you need none of the miscellaneous functions Now you can return to the beginning of the program procedure Section 5 5 3 and program the next block You must press DIALOG to again begin the program procedure If you wish to program some block other than the one displayed press key in the block number press ENTER then press DIALOG Continue the programming procedure described in the above paragraphs until the desired number of blocks have been programmed Then turn the Program keyswitch back to its locked position and remove the key Press the Reset key to reset the control then perform a homing routine Assuming all elements of the system are indicating correct O status you can now use the FORWARD and RETURN pushbuttons at the Operator Station to check the forward and reverse portions of your program If program errors are discovered edit your program as described in Section 5 5 4 Program Editing Procedures When the program is properly checked out home the axis then select Automatic Mode at the Operator Station Assuming all elements of the system are reporting correct status NO START will appear in the TAM display The applications program is now ready to be run under control of the Line Control device IA 74718 5 24 10 87 5 5 4 Program
176. ine 1 X Distance in inches or mm 7 digits Line 2 F Feedrate inches or mm per min 5 digits or Dwell Time in seconds 4 digits Two digit number of currently selected tool correction register Line 4 Spindle speed in rpm 4 digits Line 5 Status of 8 auxiliary output functions on is zero filled with lines 0 off Line 6 S Two digit BCD output value Line Jump as follows JN Unconditional Jump to block xxx JS XXX Jump to block xxx and stop H ci 1 Line 3 i 0 i i i Hi A Will appear in the display only when the Feed Adaption option is present IA 74718 3 7 Rev A Line 10 87 Line 7 cont d JC xxx 1234 Conditional jump to block xxx based on state of condition lines 1234 JU xxx Jump to subroutine at block xxx JR XXX Reverse vector jump to block J RETURN Return from subroutine Line 8 E Specifies number of times execution of this block will be repeated before the next sequential block is executed Indicates that feed adaption is programmed in the current block See Feed Adaption Section 9 6 4 Line 10 D Indicates that idle detection is programmed in the current block See Feed Adaption Section 9 6 4 H gt Line 9 3 5 2 Actual Position Display Mode Key When this key is pressed the actual position of the slide feed Axis as determined by the encoder measured position of the motor the curre
177. ing for up to 8 auxiliary functions Interface for external tool correction input 1 8 TECHNICAL DATA Dimensions and Physical Specifications TRANS 01 M height 15 36 in 390 mm At least 3 in 76 mm must be allowed top and bottom for plug in connector access width 4 14 in 105 mm depth 12 45 in 316 mm weight 16 7 25 kg TAM keyboard display module specifications TAM 2 Portable TAM 2 01 Fixed height 17 41 in 442 mm 16 08 in 408 mm width 12 25 in 811 mm 12 45 in 316 mm depth 3 27 in 83 mm 2 56 in 65 mm including plus 79 in 20 mm connector for connector 14 42 in 366 mm req d for panel door swing clearance Power requirements Power consumption TRANS only 20 watts Control power 24 VL 0 7A w o TAM 1 0 A with TAM 15V 0 05A 15V 0 05 Ambient temperature 0 45 c 32 1130 F operating range Control interconnections via plug in connectors IA 74718 1 10 Rev A 10 87 Control Specifications Number of feed axes controlled Number of spindle axes controlled Dimensioning system Programming resolution Maximum traverse Feedrate Rapid traverse rate Maximum system speed Maximum rapid traverse rate Jogging Number of program blocks Repetition cycles blocks Programmed tool position corr Dwell time Auxiliary functions Adjustable machine parameters Self diagnostic conditions Interface Requirements Input signals Output signals IA 74718 one one
178. ion output off TRANS waits until an acknowledgment is received then continues its processing iiu Note that the constraint is that the state of an auxiliary output is changed then the change must be acknowledged A change in an acknowledgment level must always be preceded by a change in the auxiliary output Figure 6 2 illustrates how an acknowledgment without a request is diagnosed as a fault EXAMPLE The system moves at rapid feedrate into position to cut a part and clamps the workpiece during the rapid movement to save time Prior to cutting an auxiliary output is issued to verify that the clamp is down acknowledgment will allow cutting to proceed Note that if the acknowledgment is issued as soon as the clamp is down it may be diagnosed as a fault It must not be given until the TRANS requests it via auxiliary output and the clamp is down In your programmable controller we suggest use of a contact which is closed when an auxiliary output is issued By placing this contact in the ladder rung where the associated acknowledgment is generated you enable the acknowledgment by closing a contact in series with it Thus the acknowledgment never comes on before it is requested and goes off immediately when the auxiliary output is dropped Of course this may not apply in all cases necessary you can bridge the auxiliary output contact to prevent the acknowledgment from turning off until the proper conditions have occurr
179. ional Description General Enabies Enable Enable Forward Operator Interface Automatic Manual Forward Return Reverse Toolchange Cycle Interface Enable and Enable Forward Start Homing Restart vii 0010 0 o pcd A rm O 0 awa DD f e T i 1 IO t oO i gt Ed og oan amp Ge ee Be A e 10 87 TABLE OF CONTENTS Paragraph Title Page Chapter 6 Functional Description Cont d 6 4 5 Ready 6 6 6 4 6 Run 6 7 6 4 7 Home 6 7 8 4 8 Power Interrupt 6 7 6 4 9 Fault 6 8 6 5 Brake Output 6 8 6 6 Conditional Jump Units 6 8 6 7 Primary Overtravel Limit Switches 6 9 6 8 Home Limit Switch 6 9 6 9 Emergency Stop Circuit 6 9 6 9 1 Emergency Stop 6 11 6 9 2 Safety Limit Switch 6 11 6 9 3 Main Contactor Control 6 11 6 10 Auxiliary Functions 6 11 6 10 1 Auxiliary Function Outputs 6 11 6 10 2 Auxiliary Acknowledgments 6 12 6 10 3 Line Control Interface Guidelines 6 12 6 11 BCD Coded Outputs 6 13 6 12 Spindle Control Signals 6 13 6 12 1 Operating Conditions Spindle Ready Status Bb 6 14 6 12 2 Spindle Command and Enable Signals 6 14 6 12 3 N actual N commanded 6 15 6 12 4 Spindie Enable Manual Mode 6 15 6 12 5 Spindle Temperature Switch TAS 2 6 16 6 13 Power Interrupt Handling 6 16 6 14 Signals Added to TRANS with Hardware Options 6 17 Chapter 7 Mounting and Installation 7 1 General 7 1 7 2
180. ique TRANS NUMBER its address on the bus in parameter POO before communication can occur This is a number from 01 to 30 which must be unique for each TRANS control Once a TRANS NUMBER is set for a unit the LCA or TAM can communicate with that TRANS addressing it by its number This procedure is done when the TRANS is installed then repeated only if the number is changed or memory is lost such as when a battery is replaced Model TRANS 01 M02 A set of switches is used to set the TRANS NUMBER in controls of Version TRANS 01 M02 and above 1 Access these switches by removing the cover plate on the front of the modular TRANS as illustrated in Figure 4 1 2 The left most switch specifies the tens digit Set it to 1 2 or 3 3 The right switch specifies the ones digit Set it to 1 through 9 4 The TRANS NUMBER is now set in parameter POO and cannot be changed from the LCA or the TAM although it can be examined IA 74718 4 1 Rev A 10 87 LIRE EIL SELECT CONTROL NUMBER SELECT CONTROL NUNBER BEFORE INSTALLATION FAS MIY BEFORE INSTALLATION CONTROL NUMBER _ ge 4 V 9 TONO TRANS 01 MODULE Figure 4 1 TRANS NUMBER Switches 5 Replace the cover 6 We suggest that you label this unit with its TRANS NUMBER for easy reference in the future 4 2 2 Parameter Display Entry Edit Using 1 Make sure a TAM is connected to the selected TRANS as described in Section 3 4
181. irements when positioning and where the loads seen by the motor during machining may be greater The TRANS may be purchased complete with version TR33 software or the software may be installed in an existing TRANS 9 4 1 Associated Parameters Since the system of units for rotary motions is arbitrary the UNITS parameter has been eliminated No travel limits exist so both TRAVEL LIMIT amp TRAVEL LIMIT are also eliminated as well as BALLSCREW LEAD When reviewing parameters these 4 are simply skipped over by the TRANS One additional parameter UNITS TABLE REV is included with rotary software This parameter number PO7 is described in Section 4 5 IA 74718 9 17 Rev A 10 87 Para Format meter Description Inch Metric UNITS TABLE REV Tbis parameter functions the same as with standard software see 4 5 however the value is expressed in Units Table Rev limited to the value set for the UNITS TABLE REV parameter P19 RAMP The ramp is expressed in units table rev sec sec XXX X XXXX For example if 360 is chosen for units table rev the ramp is programmed in degrees sec sec E SPEEDS Homing Speed Rapid Speed Jogging Speed See parameter Jogging Rapid Max Feedrate and Max Feedrate description in For G5 are all expressed in units table rev min Chapter 4 9 4 2 Installing the TRANS Rotary System Installation of the TRANS and AC Servo drive is carried out as normal see Cha
182. is creating the problem turn the Parameter keyswitch back to the Entry Edit Mode and press the Clear Error CE key The first parameter causing a problem will now be displayed See Section 4 6 for a more detailed description of parameter error checking and recovery procedures plus complete tables of parameter limits and parameter calculation formulas WAITING FOR CONTROL XX Normal status diagnostic This will occur if the TAM programming panel has not been assigned to communicate a specific TRANS 01 M WRITE PROTECTED Soft Fault Indicates that an attempt has been made to enter or change system parameters or the program without using the Program Parameter keyswitch to enable Program Parameter Entry Edit Mode The diagnostic display occurs when the Dialog or Edit keys are pressed WRONG LIN ENC DIRECTION Hard Fault Indicates that the linear encoder was deflected opposite from the expected direction This could be caused by an obstruction near the linear encoder a loose workpiece or the linear encoder direction parameter P33 set to a O instead of a 1 Remedy the problem press Reset then home the slide ZERO PULSE MISSING Hard Fault Indicates that during a homing function the encoder turned full revolution without the TRANS detecting a zero marker pulse Because the TRANS uses the ENCODER CYCLES REV parameter to determine what one motor revolution is many times this message means that the wrong value was enter
183. is key in Manual Mode results in the display of the current software version number as described in Section 4 3 2 2 6 JOG KEYS These keys are used for forward and reverse jogging while in Hand Mode See Section 2 11 for a discussion of operation mode selection Description Jog Forward Jogs the slide forward at the current feedrate or at the rapid jog rate if selected and enabled If the overtravel limit switch is reached a diagnostic message is displayed and this key is deactivated Jog Reverse Jogs the slide in reverse at the current feedrate or at the rapid jog rate if selected and enabled If the overtravel limit switch is reached a diagnostic message is displayed and this key is deactivated OROL 2 7 KEYSWITCHES Two keyswitches provide a write protect feature for the control They are Description Key Program Entry Edit Mode Keyswitch The proper key must be inserted into this keyswitch and turned to the Enter position to enable the entry and editing of programs When this is done the control will be switched out of Automatic Mode ENTER POSITION Parameter Entry Edit Mode Keyswitch The PARAMETER proper key must be inserted into this keyswitch and turned to the Enter position to enable the entry and editing of system parameters When this is done the control will be switched out of Automatic Mode 74718 2 10 Rev A 10 87 2 8 MISCELLANEOUS FUNCTION KEYS These keys are us
184. is signal line is labeled Return in the TRANS Depending on the user s design the pushbutton on the operator panel may be labeled RETURN REVERSE etc 4 Toolchange Generally wired to a pushbutton The Automatic Manual switch must be in the MANUAL position to enable this button While this button is held depressed the slide travels to its programmed toolchange position This will be a position of the slide which provides the proper clearance for tool changing There are specific requirements for this portion of the program as described in Section 5 3 4 Releasing the pushbutton stops the movement Pressing and holding the button again continues the operation When first pressed the TOOLCHANGE button will only become active if the correct program and zero references are present control at block zero and homing performed since the last power up or reset These beginning conditions can be achieved by pressing the RETURN pushbutton as described above moving the slide to the Home position 3 3 TOOLSETTER FUNCTIONS The toolsetter can change tools enter tool correction values into the correction registers and verify system operation With Manual Mode selected he can access the various displays to obtain extensive information about the program such as program status position auxiliary functions etc to aid him in performing his duties He execute program independent functions in Jogging Mode and bypass the Line Control to execu
185. l Eds OUR AS o S Revision Index 00 01 02 Ik Original Release Switch selected TRANS number B 2 TRANS EXECUTIVE SOFTWARE TYPE CODE KEY ee NN TT eS Wren initia TRANS Executive Software Version 30 see Revision 24 Ea Ros ma 39 Standard Software software detail next page Major revisions Patch revision Language US DE IT SW FR ES IA 74718 BO cow o 9 C 5 gt 3 b gt English German Italian Swedish French Spanish Bo b b a ee 9 gt 9 3G TR 30 XXX X US 9 0 ob 4 9 bo 9 4 o a 9 amp o P 9 d Y 9 OB 0 48 9 9 gt c 4 9 bo bo 5 d oa 9 b amp 9 Rev A 10 87 A TA raa Aa Type amp Index Description Languages TR30 Standard Software US TR32 Feed Ramp US TR33 Rotary Axis Software US TR34 Adaptive Feed Control US TR35 Adaptive Depth Control Only US TYPE CODE FOR TAM 2 EI M TAM with handle for carrying w o locking door 01 TAM with fro
186. l correction data and diagnostics 3 Programming and Parameter Mode Keys Used to select and control the parameter entry and programming process 4 Programmable Function Keys Used to select various functions during the programming process 5 Jog Keys Used for forward and reverse jogging in Manual Mode 6 Keyswitches Provide memory protect functions Program key must be used to enable Program Entry Edit mode Parameter key must be used to enable Parameter Entry Edit mode Without these keys the program and parameters can be displayed but cannot be changed 7 Miscellaneous Keys These keys are used in Program and Parameter Entry Edit and Toolsetter Modes to clear errors delete data and properly terminate the entry of data lines 8 Numeric Keypad Used to enter numeric information into the control 9 Power Indicators Indicate the on off status of servo drive power 10 Operation Mode Keys Used to select various operating modes IA 74718 2 4 10 87 2 2 32 CHARACTER ALPHANUMERIC DISPLAY The alphanumeric display is used to display 1 weg English prompts to guide the user as the program commands and parameters entered The actual command and parameter information as it is keyed in System status Program blocks parameters words diagnostics and tool correction values selected for review from the keyboard The current program block as it is executed Err
187. l Status Diagnostic Indicates 1 that the REVERSE pushbutton at the Operator Station has been pressed in Manual Mode but released before the Reverse program was completed or 2 that reverse vector of R000 was encountered during manual execution of the Forward program signaling the end of that program This diagnostic message will also be displayed if the TRANS is switched from Automatic to Manual Mode during Reverse program execution REVERSE OPERATING Normal Status Diagnostic Indicates that the Reverse input is actuated in Manual Mode and the program is being executed Note if the block being executed contains a homing instruction HOMING will be displayed instead of REVERSE OPERATING SCANNING INTERRUPTED Soft Fault Indicates that scanning between the Line Control Adaptor LCA and the TRANS was interrupted for more than 500 msec during a cycle initiated by the LCA over the serial bus This is a safety measure to insure that if a TRANS is being controlled via the LCA that communications between the LCA and the TRANS will be present at all times SERVO VOLTAGE ERROR Hard Fault Indicates that one of the servo controller voltages 24 or 15 is either missing or not within limits This could be the result of a defective NC cable an excessively long NC cable an NC cable that is routed in a very noisy environment a defective servo controller or a defective motor feedback package area can be isolated by referring to the di
188. l operation and testing of each TRANS unit even before the Line Control installation has been completed IA 74718 1 6 Rev A 10 87 The following modes of operation are provided by the TRANS for execution of its control functions Automatic Operation Remote operations via the Cycle Interface signals supplied from the customer s Line Control device Functions Include Programmed motions Single cycle Emergency home Operator Interface Operation using pushbuttons mounted on an operator control panel external to the TRANS Functions Include Programmed forward motion via pushbutton Programmed reverse motion via pushbutton Move to toolchange position Set up Operation Operation using the TAM keyboard display Functions Include Homing Continuous operation Single block operation Jogging forward and reverse 1 3 DISPLAY MODES The TAM keyboard display provides the following display modes for programming program testing checking system status and operator and service support 1 Block display for Programming Program review Display of the current block during program execution 2 Display of actual position actual feedrate and actual auxiliary function status 3 Display of commanded position destination programmed feedrate and programmed auxiliary function status 4 Display of following error deviation feedrate override and existing discrepancies between commanded auxiliary fun
189. l up various part programs or reverse programs stored in the TRANS These lines could be wired to a selector switch or tied to the Line Control IA 74718 6 8 Rev A 10 87 NOTE If the system uses the Line Control Adaptor LCA parameter P04 specifies from where these conditional jump inputs will be accepted P04 0 specifies to accept the inputs from the TRANS interface connector 11 P04 1 specifies to accept the inputs only from the serial TRANS BUS LCA a TT nit Connector TRANS X8 Pins Positive direction 8 Negative direction 7 Status Normally closed Type Inputs 9 10 to TRANS Two hardware overtravel limit switch inputs are provided If desired the machine builder will wire these to physical travel limit switches on the machine This may be desirable because the software travel limits are not active until a homing cycle is performed Prior to that time the axis could be manually jogged via TAM panel controls only past the software limits These inputs must be tied to 24 volts if unused 6 8 HOME LIMIT SWITCH ee RTE Connector TRANS X8 Pin 6 Status Normally open Type Input 11 to TRANS This switch is closed when the slide is physically at the home position See Section 7 4 for a detailed discussion of Home Limit switch installation Because the TRANS performs time critical monitoring of this switch it must be wired Directly To The Input not through other logic 6 9 EMERGE
190. lected TRANS as illustrated in Figure 3 1 below b This can be done while the TRANS is powered c The TAM will display WAITING FOR CONTROL XX Bim BTRANS 01 i 5 01 ms MODULE po MODULE ES Figure 3 1 Connecting the Portable TAM IA 74718 3 4 Rev A 10 87 2 TAM 2 01 Fixed TAM a The fixed TAM will already be permanently mounted on the machine and may be daisy chained to up to ten TRANS 01 M modules b Unlock the cabinet door to access the keyboard c The TAM may display WAITING FOR CONTROL XX or may display some other message if a TRANS NUMBER had previously been selected For TRANS 01 M 01 and below follow procedures 4 8 For TRANS 01 M 02 and above follow procedures 3 8 3 For the TRANS 01 M 02 a set of switches is used to set the TRANS NUMBER in the parameters so that you can communicate with that selected TRANS a Access these switches by removing the cover plate on the front of the MODULAR TRANS b The leftmost switch specifies the tens digit Set it to 1 2 or 3 c The rightmost switch specifies the ones digit See it to 1 through 9 d The TRANS NUMBER is now set in Parameter POO and cannot be changed from the LCA or the TAM although it can be examined 4 Press the Data In key to specify selection of a O TRANS for communication 45 5 Key the TRANS NUMBER of the selected module you wish to access then pr
191. lliamps maximum Output Voltage Off Low 4 5VDC no load Output Resistance Off Low 22 Kilo Ohms All outputs are short circuit proof CONNECTOR SPECIFICATIONS Type 25 Pin Sub D On TRANS 01M ITT Cannon Type DB 5 255 Mating Cable Connector ITT Cannon Type DB 25 P Standard Indramat Cable 209 0036 4859 00 9 3 4 1 OVI O Connector TRANS 01M X17 Pins 1 2 3 4 5 6 7 8 9 These pins are tied to the common of the internal 24 V supply of the TRANS 01M sourced from the connected modular power supply KDV or TDM and may be used as a reference for all input and output signals on connector X17 9 3 4 2 Register Select Connector TRANS 01M X17 21 Register T01 20 Register TO2 Type Inputs to TRANS 01M These inputs select which Correction Register is to be written to or cleared Orly one input should be brought high at a time however if both are high the one that was detected as high first will be the Register selected by the TRANS 01M If both are brought high at the exact same time Register TO1 has precedence IA 74718 9 14 Rev A 10 87 When the TRANS sees one of the Register Select lines go high it will examine the Clear Register input If that input is high it will perform a Register Clear operation otherwise it will assume a value is to be transmitted to the TRANS 9 3 4 3 Data Lines Connector TRANS O1M X17 Pins 17 Data Line 8 16 Data Line 4 15 Data Line 2 14 Data Line
192. m Conditions for acceptance of the Homing signal are 1 Selector switch at the Operator Station is on Automatic 2 Enable signal has been present on the Cycle Interface for at least 50 msec IA 74718 6 5 Rev A 10 87 6 4 4 Restart Connector TRANS X11 Pin 4 Status Normally open Type Input 20 to TRANS This signal can be used to complete an automatic cycle after an Immediate Stop has occurred For example an immediate stop may occur if auxiliary function acknowledgment is lost or if an emergency stop is executed IMMEDIATE STOP is displayed Once the condition is rectified the automatic cycle can be completed by applying 24 volts to this input Note that a normal Start signal Section 6 4 2 will not be recognized after an immediate stop Likewise Restart will not be recognized if the automatic cycle is completed or has not begun This can be useful when machining criteria dictates that a surface cannot be machined twice if an emergency stop occurs When a Restart is issued only those units that did not complete their cycles will operate all others will remain in the non operating state If desired in a system Restart and Start may be tied together to perform both functions with one input signal Restart is recognized only when the Enable and Forward Enable signals have been present on the interface for at least 50 msec If a homing cycle is being restarted Forward Enable is not required 6 4 5 Ready Co
193. mal Status Diagnostic occurs during the time between the turning on or off of an auxiliary function and the receipt of its matching acknowledgment For example assume auxiliary function 2 is used to turn on the coolant pump with the acknowledgment wired to a coolant pressure switch NO ACKNOWLEDGMENT ON 2 would be displayed between the time the coolant pump is turned on and the time the pressure switch closes A Soft Fault occurs if an acknowledgment was received matching a function output either on or off and then is lost without a corresponding change in the function To recover remedy the problem then press CE cycle then may be continued use Restart if in Automatic Mode Acknowledgments are expected on connector X8 pins Pin 16 Acknowledgment 0 Pin 15 Acknowledgment 1 Pin 14 Acknowledgment 2 Pin 13 Acknowledgment 3 Pin 12 Acknowledgment 4 Pin 11 Acknowledgment 5 Pin 10 Acknowledgment 6 Pin 9 Acknowledgment 7 NO ENABLE Normal Status Diagnostic Indicates that the Enable signal on the Cycle Interface connector X11 pin 3 is missing This signal must be provided by the customer s Line Controi for automatic operations to occur Enable is sometimes conditioned on the proper closure of protective gates at the machine If Enable is expected but not present check for the cause of the fault and correct NO ENABLE FORWARD Normal Status Diagnostic Indicates that 24 volts is not present at connect
194. n the Jump Programming function is selected in Dialog Mode this key can be pressed in response to the BLOCK JUMP display to specify a return to the main program from a subroutine The display code is J RETURN Conditional Jump When the Jump Programming function is selected in Dialog Mode this key can be pressed in response to the BLOCK JUMP display to specify a conditional jump When conditional jump is executed a jump is taken depending on the state of the 4 coded conditional jump control lines Thus up to 16 different program jumps can be performed based on an external signal These could be used to select various part programs stored in memory The display code is JCXXX BBBB Jump To Block and Stop When the Jump Programming function is selected in Dialog Mode this key can be pressed in response to the BLOCK JUMP dialog display to specify a jump to the specified program block but the control will stop prior to executing that block A jump to Biock 000 and Stop is required to properly end all control programs The display code is JSXXX 2 9 Rev 10 87 Key Description Reverse Vector Jump When the Jump Programming function 15 REV selected in Dialog Mode this key can be pressed in response to the BLOCK JUMP dialog display to specify a new reverse vector to be stored and used when a return or homing procedure is called for The display code is JRXXX See the Reverse Vector description Section 5 3 15 5 Pressing th
195. nch Swedish H gn jj orm od 4 4 PARAMETER ENTRY Enter or review TRANS Parameters as follows 1 Switch the control to Manual Mode at the Operator Station 2 Establish communication between your TAM and the selected TRANS as described in Section 3 4 Insert the correct key into the Parameter keyswitch and turn it to Parameter Entry Edit Mode 595 4 Parameter POO and its present value will be displayed This is the TRANS NUMBER You cannot change the displayed value so press LF Line Feed to advance the display to the next parameter 5 change displayed parameter press the Edit key then key in the revised value you make a typing error press DEL to delete it O and re key the information Note that leading and trailing zeros need not be typed IA 74718 4 4 Rev 10 87 If you attempt to enter too many digits or a decimal point where one isn t allowed FORMAT ERROR is displayed and a soft fault results Press CE to clear the error then re enter the value If the keyswitch is not in Parameter Entry Edit Mode when Edit is pressed WRITE PROTECTED will appear in the display 5 When satisfied with the new value press ENTER to enter the parameter value into memory this value is greater than the ENTER limiting value for that parameter see table in Section 4 7 the value will be rejected RANGE ERROR will be displayed and a soft error will result 6 Press LF Line Feed to advance the
196. ned on during program execution the AC Servo s Controller Enable will be removed allowing free movement of the servomotor no servo lock At the same time auxiliary function output will turn on and can be used to energize the clamp or brake The Controller Enable will be restored when 07 is turned off During the time that MO7 is on no movements should be commanded otherwise DRIVE NOT READY will appear on the display resulting in a hard fault Only dwell times block jumps or waits for acknowledgments should be performed while 07 is on While MO7 is on the destination will be made equal to the actual position so that no jump will occur if the motor is rotated then M07 is turned off This means that the next positioning command made after a clamping operation should be absolute move Incremental moves would be made referenced to last commanded position If incremental moves are required after a move to positive stop they should be preceded by an absolute move to the last position to correct for any shift in position during clamping IA 74718 9 19 Rev A 10 87 The last move made before a clamping operation should be programmed with lag finishing so that the motor is stopped in position before the Controller Enable is removed If the block is programmed without lag finishing the commanded position may not be reached before power to the motor is dropped An example of programming clamping is shown in Figure 9 11 Assume t
197. ng of the rotary table can be performed as either absolute positioning a point referenced to home position or incremental positioning referenced to present position If absolute positioning is selected the table will move to the programmed DESTINATION using the shortest possible path less than one half table revolution The destination may be any value between 0 and the number set in the parameters as UNITS TABLE REV No negative values are allowed Incremental positioning will cause the table to move the specified DISTANCE from the present position Direction may be specified by programming the distance as a positive or negative value The value of the distance is limited to plus or minus the value for UNITS TABLE REV If more than one table revolution must be made block repeats E line can be used in which case up to 100 table revolutions may be performed in one block 9 4 8 3 Clamping If the drive train is configured so that the system will be clamped when in position for example to prevent overloading of the AC Servo resulting in undesired movement during machining the servo controller must be disabled during that time If it is not the system may attempt to hold a position or even move the drive train causing servo overload Auxiliary function MO7 has been dedicated in the rotary software to accommodate this need This auxiliary function should be used for no other purpose than clamping or braking the drive train If is tur
198. ng process only when first powered up Subsequent homing commands are essentially an absolute move to zero with the TRANS remembering where home is and checking that it is reached when commanded 5 3 16 Block Repeat NC Code E If an unconditional jump JN or a jump to subroutine JU has been programmed in a block a block repeat value XX can also be entered This causes the complete block including the G code and jump to be repeated up to 99 times 5 4 PROGRAM DATA Because the control adapts to any incremental encoder resolutions position programming is always uniform Travel units are 0 0001 inches or 0 001 mm Maximum travel range 838 8600 inches or 8388 600 mm IA 74718 5 12 Rev 10 87 5 5 PROGRAMMING This section first describes the procedure for displaying a program block without changing it This can be done from the keyboard without using the Program keyswitch The following paragraphs then describe procedures for entering a program This requires that the Program keyswitch be used to enable Program Entry Edit Mode Note that values must be entered for all parameters before an application program can be entered 5 5 1 Display Program Blocks Use the following procedure to step through and display the blocks of a program 1 Generally you will want to select Manual Mode selected from the Operator Station Block display can occur while the unit is operating but you can only examine the various line
199. nnector TRANS X10 Pin 10 Status Normally open Type Output 16 from TRANS The TRANS issues the Ready signal to indicate that all conditions are correct for the automatic cycle Ready will continue to be present on the Cycle Interface as long as all conditions for an automatic cycle remain acceptable These conditions are 1 Automatic Mode selected connector X11 pin 2 high 2 Axis normalized homing performed since power up or clear 3 Block 000 selected When the Ready line is high a Start signal from the Line Control will be accepted by the TRANS as long as the Enables are also present IA 74718 6 6 Rev 10 87 6 4 6 Run Connector TRANS X10 Pin 9 Status Normally open Type Output 15 from TRANS The Run signal is issued by the TRANS during the time that an Automatic signal is being executed Because Run is provided to indicate completion of a cycle it will remain high even during an immediate stop condition Run is issued during the Automatic cycle and when homing is performed as commanded on the Cycle Interface Run is not issued during any manual functions such as Forward and Return 6 4 7 Home Connector TRANS X10 Pin 8 Status Normally open Type Qutput 14 from TRANS The Home output indicates that the slide is in a position where the tool is clear of the workpiece therefore a part transfer is possible It is related to the Home Limit switch and indicates that the slid
200. nt 6 10 Acknowledgment 7 9 Status Normally open Type Inputs 1 8 to TRANS Each of the acknowledgment inputs is associated with a corresponding auxiliary function When that function line is turned on or off under program control an acknowledgment of that action must be returned to the TRANS for programmed operations to continue Once an acknowledgment is issued it must remain unchanged in that state until the corresponding auxiliary function output is changed Otherwise a soft fault will occur NOTE If the system uses the Line Control Adaptor LCA parameter PO3 specifies from where the acknowledgments will be accepted P03 0 specifies the TRANS interface connector X8 1 specifies accept the acknowledgment inputs only from the serial TRANS BUS LCA 6 10 3 Line Control Interface Guidelines m M M e TIT In most cases the customer s host control for the TRANS is a programmable controller This paragraph provides helpful hints on using the programmable controller with auxiliary function outputs and acknowledgments Figure 6 2 is an example of timing for auxiliary functions Auxiliary Function Output 1 i Acknowledgement Input i t 1 Wait F Wait Fault Figure 6 2 Example of Auxiliary Function Timing IA 74718 6 12 Rev 10 87 Required Sequence Turn on an auxiliary function output TRANS waits until an acknowledgment is received Turn auxiliary funct
201. nt actual feedrate feedrate x feedrate override and the current status of the auxiliary functions acknowledgments actually received are displayed As the feed axis moves you will see the actual position changing 3 5 3 Destination Position Display Mode Key Q When this key is pressed the commanded destination position the current programmed feedrate and the programmed auxiliary function status are displayed the slide moves you will see the commanded position changing 3 5 4 Deviation Display Mode Key This key selects a display of the position deviation or lag between the commanded position and the actual position displayed in inches or mm the slide moves you will see the data change The feedrate override in percent is also displayed This indicates the percentage of programmed feedrate or rapid traverse rate at which the control is operating See Section 3 9 for a discussion of feedrate override selection IA 74718 3 8 Rev A 10 87 The existing deviations between the commanded auxiliary functions and their acknowledgments are also displayed acknowledgment is required whenever an auxiliary function is turned on or off If the TRANS stops and displays NO ACKNOWLEDGMENT ON X where X is the first auxiliary function which is missing a required acknowledgment you would press this key to determine the area of the problem dash indicates that an acknowledgment has been received for an a
202. nt locking door and cabinet mounting capability with rear mounting of TAM bus w o carrying handle Early Software TAM 02 01 TAM 2 software superseding through TAM 03 02 TAM 2 software superseding through TAM 04 IA 74718 2 10 87 APPENDIX C TRANS SYSTEM CABLE DRAWINGS C 1 INTRODUCTION This appendix consists of a series of cable drawings including System Cable Requirements Position Feedback Cables Cables Control Cable IA 74718 C 1 Rev A 10 87 27141 AC POWER 01 0200 TAM 2 TAM 2 BUS CABLE 05 0508 CONTROL CABLE MODULAR TACH COMMAND HOTOR POWER 04 0910 5 01 TVM TDM SEE NOTE 1 MAC 04 8912 AC POWER ALL S ARE NEEDED MOTOR FEEDBACK POSITION FEEDBACK 03 0410 3 LCA TO ADDITIONAL MODULAR TRANS 01 s TO HOST CONTROL SERIAL INTERFACE CABLE 15232 05 0208 REXROTH INDRAMAT CHICAGO ILL LCA BUS 05 0430 TO ADDITIONAL MODULAR TRANS O1 s TAM BUS 85 8419 SERIAL INTERFACE CABLE RS422 05 0420 NOTES 1 MOTOR POWER CABLES ARE SELECTED BASED ON SPECIFIC MOTOR DRIVE COMBINATION REFER TO MOTOR POWER CABLE SELECTION LIST FOR PART NUMBERS 2 USE CABLE 03 2201 IF MOTOR HAS BLOWER USE CABLE 03 0230 FOR RIGHT ANGLE CONNECTOR 3 USE CABLE 03 0411 IF MOTOR HAS BLOWER USE CABLE 03 0430 FOR RIGHT ANGLE CONNECTOR 4 8 AWG WIRE MUST BE USED FOH TVM POWER WITH THE FOLLOWING MOTORS 1128 1 60 112C 0 KD 112C 1 K
203. nter the TRANS NUMBER into memory 12 We suggest that you label this unit with its TRANS NUMBER for ease of reference in the future 13 Now you can enter the other parameters for this TRANS following the procedure in Section 4 4 IA 74718 4 26 Rev A 10 87 CHAPTER 5 PROGRAMMING 5 1 GENERAL 5 1 1 Enabling Program Changes Because it is important to protect the part program from accidental or unauthorized alterations program changes must be enabled as follows 1 Fixed TAM TAM 2 01 Unlock the panel cover 2 Portable TAM TAM 2 Connect the serial cable from the TAM to the selected TRANS 3 Establish communication between the TAM and the selected TRANS as described in Section 3 4 4 Insert the Program key in the Program Entry Edit keyswitch and turn to enable Program Entry Edit Mode 5 1 2 Contents of this Chapter This chapter contains 1 A discussion of required programming formats for each type of function which can be selected 2 description of the procedures required for entry of each possible type of program line 3 A set of flow charts which present the programming information in a handy graphic form 4 Examples of typical part programs IA 74718 5 1 10 87 5 2 FUNCTIONS WHICH CAN BE PROGRAMMED P pop apa _ The TRANS has 128 blocks which be programmed Any of the following functions can be programmed in each block NC CODE FUNCTION GO Homing 61
204. oblem and press Reset Under rare conditions this diagnostic message may occur if the acceleration rates demanded by the system determined by the Ramp and Max Feedrate parameters cannot be met caused either by unrealistic parameter values or excessive drive train inertia or friction In this case correct the drive train problems or reduce these two parameter values ENCODER FAULT LAMP Hard Fault Indicates failure of the incandescent lamp used as a light source in the encoder Replace the lamp press Reset and home the axis ENCODER SUPPLY MISSING Hard Fault Indicates that the incremental encoder supply internal to the TRANS is low This supply is used by the axis incremental encoder connected to X12 on the TRANS and also any optional device that may be connected to X13 The cause could be faulty cabling on X12 or X13 a faulty incremental encoder or a faulty optional device To isolate the problem area initiate an emergency stop by removing voltage from pin 4 of connector X8 Remove the position feedback cable from the incremental encoder and press the Reset key If the fault disappears the problem is in the encoder the fault does not disappear remove the position feedback cable from X12 on the bottom of the TRANS and press Reset again If this diagnostic disappears the position feedback cable is defective not and an optional device is connected to X13 repeat the above procedure to determine if that device or its c
205. of drives and incremental encoders which can be chosen to best suit the system requirements It also insures that all application programs are written with a uniform data format Because entry of incorrect data can result in damage to the machine parameters are entered into the system at the engineering interface level Access at this level is possible only by using the Parameter key to enable Parameter Entry Edit Mode the system has a TAM 2 01 fixed TAM its cover must be unlocked to access the keyboard Note that values for all parameters must be entered into the machine before an applications program can be written The TRANS monitors the parameters and the applications program to assure that all program functions are performed within the constraints established by the system parameters If a function is programmed or attempted which would exceed the bounds established by these parameters the control halts and a diagnostic error message is displayed This chapter contains a complete list of all parameters and their required formats in both inch and metric dimensioning and a description of procedure for entry of system parameters into the TRANS 2 DISPLAYING AND ENTERING PARAMETERS USING THE AND LCA ee Ty panini AS 4 2 1 Setting Parameter POO TRANS Number A system may have more than one TRANS therefore each unit must be programmed with its un
206. ogram If the programmed value is larger than this parameter value the output speed command voltage is limited to 10 volts MAXIMUM CORRECTION Analog Spindle Output Option software TR30 004 0 and above This parameter limits the maximum programmable values for tool correction This parameter is valid for both manual correction values and the external correction value Entering correction values larger than this maximum results in an immediate stop condition in the part program at the point where the correction value was to be used The CORRECTION EXCEEDED diagnostic message is displayed This parameter is not included in the Rotary Table Option software TR33 OPERATION MODE 1 Analog Spindle Output Option software TR30 004 0 and above This parameter allows the selection of 8 basic program functions as illustrated below 01234567 0 Disable Analog Spindle Output 1 Enable Analog Spindle Output Not used at this time It is advisable to enter the parameters first then enter the part program because a change in this parameter results in the current TRANS program becoming invalid Format Inch Metric XXXX XXXX X XXXX XX XXX See description Rev A 10 87 Parameter Number Description 40 Cont d For example If parameter digit is changed and an exit is made from parameter mode by turning the keyswitch the Program Invalid diagnostic message is displayed The programmer now
207. om 5 01 74718 9 15 10 87 These outputs are used to indicate which digit is currently being requested by the TRANS 01M Their actual weight depends on the System of Units used as indicated by the below Digit Inch Mode Metric Mode 1 0 X000 X 000 2 0 0X00 0 X00 3 0 00X0 0 0X0 4 0 00X 0 00X 9 3 4 7 Complete Connector TRANS O1M X17 Pins 25 T01 Error 13 T02 Error If an error occurs during transmission of a value the Error output associated with the Register being worked with will go high for 100 milliseconds The error diagnostic CORRECTION EXCEEDED will also appear on the TAM display if connected and a soft fault will resuit 9 3 5 Transmission Procedure A typical transmission sequence is as follows a Select Register to be written to by bringing Register 01 or Register TO2 high This input must remain high throughout the entire sequence otherwise an error will result with the current Register contents remaining unchanged b The TRANS 01M will respond by bringing the Sign output high sign or of the value is indicated by setting Data Line 1 high for a minus value low for a plus Set the data bit accordingly keeping Data Lines 2 4 and 8 low When the 4 Data Lines are stable bring Data Valid high B After the TRANS 01M sees Data Valid go high it will read the Sign data then bring the Sign output low At this point the Data Valid line must also be
208. opped in position before the next function is executed press the Lag Finishing key If positioning without lag finishing is OK press LF Line Feed In this case the position lag from one block will not be completed before the next block is executed See Section 5 3 7 for more information on positioning with without lag finishing IA 74718 9 27 Rev A 10 87 14 FEED RAMP now appears in the display Press the ENTER key if the feed ramp is to be used to control the ENTER acceleration deceleration of speed changes involving this block Press Line Feed if feed ramp is not applicable to this block 15 Because incremental positioning was selected DISTANCE now appears in the display Key in the required positioning distance as XXX XXXX inches or XXXX XXX mm When this command is executed the slide will travel the specified distance from its current position in the specified direction 16 When entering either distance or destination if you make an error press DEL Delete and re key the data 17 Whey your date is correct press ENTER 18 FEEDRATE now appears in the display Key in a feedrate value then press ENTER If you attempt to select a feedrate greater than the parameter specified maximum rapid traverse speed P16 the RANGE ERROR diagnostic occurs If you wish the feed to occur at rapid traverse rate press the Rapid key fixed rapid rate specified by program parameter Wo P16 is then selected 19 TOOL
209. or Control Connector TRANS X9 Pin 10 Status Normally open Type Output from TRANS 6 10 AUXILIARY FUNCTIONS 6 10 1 Auxiliary Function Outputs Connector TRANS X10 Pins Auxiliary function O 18 Auxiliary function 1 i7 Auxiliary function 2 16 Auxiliary function 3 15 Auxiliary function 4 14 Auxiliary function 5 13 Auxiliary function 6 12 Auxiliary function 7 11 Status Normally open Type Outputs 17 24 for TRANS IA 74718 6 11 Rev 10 87 These programmable output signals are provided by the TRANS and can be tailored to the user s needs for any additional status signals such as Full Depth In Toolchange Position etc They are also used for clamping spindle control tool expansion etc Outputs are 24 Vdc 150 mA per output short circuit protected optically isolated from internal circuitry Note that each auxiliary function has an associated acknowledgment input When an auxiliary function is turned on or off an acknowledgment is required because the control issues the output then waits for the acknowledgment before continuing with its cycle See Section 6 10 3 for guidelines and timing for use of auxiliary outputs and acknowledgments 6 10 2 Auxiliary Acknowledgments Connector TRANS X8 Pins Acknowledgment 0 16 Acknowledgment 1 15 Acknowledgment 2 14 Acknowledgment 3 13 Acknowledgment 4 12 Acknowledgment 5 11 Acknowledgme
210. or Station 2 Press ObPara Parameter Entry Review Mode meter Parameter POO and its value are displayed 3 Press LF Line Feed to advance the display to the next higher valid parameter Press ENTER if you wish to return the display to the previous valid parameter ENTER Any specific parameter can be displayed by pressing the N key followed by the parameter number then the ENTER key Example If non existent parameter number is entered the highest numbered vaiid parameter is displayed 4 If you wish to return to the first parameter press Delete DEL Exit Parameter Display Mode by selecting any other mode or by pressing Reset to reset the control e IA 74718 4 3 Rev A 10 87 4 3 2 Software Revision Level Display Some of the parameters discussed in this chapter are not available on all versions of TRANS executive software depending on what features are available To determine what parameters are available on a specific TRANS the type of executive software installed in it must be known This may be found in one of two ways either by checking the Software Version label on the front panel of the TRANS or by pressing the REV key on the TAM while in Manual Mode which wili cause the version number to be displayed as illustrated beiow The software version number will be displayed as 000 TR30 005 0 US Block Number Version Revision Language US English D German Italian Fre
211. or X11 pin 12 and the Forward program cannot be executed This signal can be tied to Part Clamped and Spindle On Logic to prevent feeding into the part Tool Change Return homing programs may performed without this signal present NO FEED ADAPTION WITH RAMP Soft Fault occur in conjunction with Feed Adaption option Feed adaption may only be performed at feedrates less than the value programmed for Max Feedrate Parameter P20 If attempted at higher rates or programmed after a block containing a higher rate th s message will result Press CE correct the program and home the axis IA 74718 8 10 Rev A 10 87 MESSAGE DESCRIPTION SUGGESTED RECOVERY NO FEEDRATE Soft Fault Indicates that this block contains a positioning command but no feedrate other than possibly rapid was programmed in this or any previous block executed Note that it is possible to program a positioning function without specifying a feedrate however a feedrate other than rapid must have been programmed in a previous block In that case the feedrate used will be the last feedrate programmed This feature is required in some program schemes however it is good practice to program feedrates in each block whenever possible Note that no memory is wasted by programming a feedrate To recover from this fault press CE and correct the program NO START Normal Status Diagnostic Indicates that the TRANS is ready to perform some operation and i
212. or diagnostic messages as they occur T Um Sc ey WI Ti m 5 7 bene a Miet EN e 1 4 Thur m e Hama p mH 4 ges rp O NAR rid He RE m neo 9 m e D 45 TIONAL BLOCK aa j PROGRAM NENYAT RUIT MODE 071765 M 77 TRANS O1 d Figure 2 4 TAM Keyboard with Labels for ISO Key Symbols IA 74718 2 5 Rev A 10 87 2 3 DISPLAY MODE SELECTION KEYS 2 r top row of keys selects the type of information to be displayed in the alphanumeric display The control will always be in one of these modes while power is on ED E EI HN Mode Selected and Description Block Display Mode When this key is pressed the alphanumeric display indicates the functions used in the current block as X indicates a feed length programmed XF indicates a feed length and feed speed programmed Additional information is provided as you step through a display sequence as described in Section 3 5 1 This key selects block display only It cannot select data entry Position Display Mode Selects a display of the actual position of the slide the actual feedrate feedrate x feedrate override and the current auxili
213. or generally indicates the pressing of an incorrect key Correct by pressing the CE key then pressing the correct sequence of keys Soft Fault An overtemperature condition has been detected in the motor controller This can be caused by an excessively high duty cycle stalled motor faulty controller cooling system etc Locate the cause and correct it then press the CE key A soft fault indicating that an attempt was made to enter a correction value into one of the correction registers that is greater than the limit set in parameter P39 MAXIMUM CORRECTION This may occur while sending values automatically via a PEA on a TRANS 01 M Press CE to clear the fault Hard fault occurring on TRANS 01s incorporating software previous to TR3x 005 0 Indicates that axis drive either moved when not commanded or didn t move when commanded See DRIVE RUNAWAY and DRIVE STALLED for possible causes Temporary Error Indicates that the Ready contact closure from the servo controlier has not been received This can be caused by no main power to controller no control voltage to controller or a defective controller Refer to the diagnostic LED s on the servo controller and the appropriate user s manual to determine the exact cause The occurrence of this condition is treated by the TRANS as a temporary error meaning that while no other signals will be accepted by the TRANS as long as the condition persists no reset of the TRANS is required aft
214. orrection values are incremental 0 1 The status of this bit is ignored if bit 3 of this parameter is 0 External Correction Input disabled If however no is installed UNACCEPTABLE PARAMETERS will result as with bit 3 Bit 5 Tach Sensitivity This bit specifies the motor s tach sensitivity The standard tach sensitivity for Indramat MAC servomotors is 3V 1000 RPM however rare earth magnet servomotors such as the MAC 63 71 93 115 etc have a tach sensitivity of 1 5V 1000 RPM Typical Indramat MAC motor tach sensitivity selected by this bit is 0 3V 1000 RPM MAC motors with closed loop operational speeds of 3000 RPM or less I 1 5V 1000 RPM MAC motors with closed loop operational speeds above 3000 RPM Note The above is an Indramat standard for MAC servomotors and does not reflect special applications This digit must be correctly programmed for the type of servomotor used in your system If it is not sporadic DRIVE FAULT TACH FAULT and or ENCODER FAULT diagnostics may occur Bit 6 Auto Manual Function Switching 0 programmed in this bit selects normal monitoring of the Auto Manual switch A 1 in this bit specifies that the switch to Manual Mode will be ignored until a program stop has occurred This is typically at the end of the part program cycle or when the cycle has been interrupted by an Immediate Stop or Emergency Stop signal 4 19 10 87 4 6
215. otion as programmed into the TRANS will cause increased deflection of the linear encoder A 1 indicates that minus motion increased deflection of the linear encoder 4 13 Rev A 10 87 Parameter Number P34 P35 P36 P37 IA 74718 Format Description Inch Metric MAX LIN ENC DEFL Adaptive Depth Control XXX XXXX Option software TF35 This parameter specifies the maximum possible deflection of the linear encoder This value is determined by the full stroke limit of the linear encoder used less any pre deflection present in the mechanical linkage Enter in inches or mm If an attempt is made to program an adaptive depth block with a LIN DESTINATION value higher than the value specified by this parameter a Range Error will occur LIN ENCODER PRE LIMIT Adaptive Depth Control Option software TR35 Sets the maximum amount of deflection the linear encoder may have while the motors encoder is active normal positioning The value of P33 will determine if this parameter is positive P33 0 or negative P34 1 This parameter can be used to indicate part mislocation Enter in inches or mm FEED RAMP software TR32 Provides for a XXX X XXXX acceleration ramp see P19 RAMP which can be utilized in the feed speed range When FEED RAMP is selected in Dialog programming see Section 9 6 the value programmed in this parameter specifies the system a
216. ove to 5 inches plus a Jump To Block 000 And Stop T Block 120 must contain homing program It will be programmed with a homing function with the zero offset set to 0 a feedrate of 30 0 inches min and a Jump To Block 000 And Stop 8 No auxiliary functions tool correction values spindle outputs or BCD codes will be used To enter this program select Manual Mode on the Operator Interface press the Reset key then insert the Program key into the Program keyswitch and turn it to the Program Entry Edit Mode The display will now contain N along with whatever command is currently in block 000 Now enter each block by pressing the appropriate keys The correct key sequence for each block is shown below Block 000 O 00000 Block 001 O 10 SAO c0080 0 00c O00 Block 002 ff De Block 003 IA 74718 5 40 10 87 Block 110 oes Block 120 20802 If COMMAND ERROR is displayed at any time during program entry press to clear the soft error then continue with the entry Now turn the Program keyswitch to its normal position and press the Reset key Perform a homing function using the Return input on the Operator Interface then step through the Forward program and monitor the program for errors After the dwell time is completed the dispiay au should be REVERSE NO COMMAND because of the execution of the 000 reverse vecto
217. p or block repeat Selection of these functions or skipping them occurs in every block which is programmed See Section 5 5 3 5 for a description of programming procedures 5 5 3 2 Positioning 1 To select positioning press the Positioning key 2 ABSOLUTE appears the display absolute positioning all movements of the slide are made to some absolute distance from the machine reference position Thus if the slide is at 5 inches a command to travel to 6 results in 1 inch feed in the positive direction Press LF Line Feed to select absolute positioning If absolute positioning is not desired skip to step 5 Note that absolute positioning must be selected in the first positioning command of the program since program operation could begin at the home or toolchange position 3 WITHOUT LAG appears in the display If positioning with lag finishing is required press the lag finishing key This specifies that the slide must be stopped in position before any K miscellaneous functions e g auxiliary functions and block jumps remaining in this block are executed or before the next block is executed If positioning without lag finishing is OK press LF Line Feed In this case the position lag from one block will not be completed before the next block is executed LF See Section 5 3 7 for more information on positioning with without lag finishing 4 Because absolute positioning was selected DESTI
218. p of the tool a 0 6 inch deflection is required and is entered as the Lin Destination value The complete program contains a rapid advance a normal feed greater than 0 5 inches to get the linear encoder deflected and an adaptive depth block of 0 6 inches If the first part run causes the encoder to be deflected 0 15 inches during the normal feed the TRANS will move the slide 0 45 inches under adaptive depth control to equal 0 6 inches total linear deflection 9 2 5 Typical Program Structure The simplest part program using adaptive depth control consists of five program blocks They are Block 000 Specifies a rapid movement that will bring the slide to a point close to the workpiece without any deflection on the linear encoder Block 001 Programmed with a normal feed using the motor s encoder for position feedback to a point where the linear encoder is deflected but not greater than the value specified by parameter P35 Lin Encoder Pre Limit The linear encoder must be deflected because the next block will close the position loop around the linear encoder In the example program of Figure 9 6 note that block 001 is programmed selecting Without Lag Finishing which results in a smooth transition between the normal feed biock and the linear encoder block no stopping the motor Block 002 This block contains a movement using the linear encoder The distance programmed in this block will be the total amount of linear encoder de
219. pe of Corrective Move Absolute 0 Incremental 1 Tach Sensitivity 0 3V 1000 RPM 1 1 5 1000 RPM Auto Manual Function Switching 0 Always Possible 1 Oniy Possible After Cycle Stop Unused By default all digits of this parameter are initially set to O Bit 0 Immediate Stop For Spindle Setting this bit to O selects a continuous spindle output from the TRANS during an immediate stop condition whereby the spindle motor would continue to run under power Setting this bit to a 1 selects a commanded immediate stop output whereby the spindle motor is commanded to stop immediately during an immediate stop stop condition addition after a restart the TRANS will wait until the spindle 1s at speed before continuing execution of the part program An immediate stop occurs after any interruption emergency stop soft fault hard fault etc 4 17 10 87 Parameter Number Description P41 Cont d it 1 Home Switch Monitoring In certain applications the Home Limit switch is mounted on the motor shaft rather than in a linear plane hence it is actuated more than once in the same direction In this situation the home switch monitoring function will continuously detect the HOME SWITCH ERROR fault Setting this bit to a O activates the monitoring function Setting this bit to a 1 deactivates the monitoring function Note When the monitoring function is inactive the TRANS will execute an initi
220. pleted the tool change program Normal Status Diagnostic Indicates an interruption in the tool change cycle For example this diagnostic will be displayed after reset of a Soft Fault which occurred during execution of the tool change cycle or if CYCLE STOP is pressed during program execution Normal Status Diagnostic Indicates that execution of the tool change program was initiated by activating the Tool Change input in Manual Mode but the input signal was dropped before completion of the program Normal Status Diagnostic Indicates that the Tool Change input is activated in Manual Mode and the TRANS is executing the tool change program Normal Status Diagnostic indicates the Tool Correction Entry Edit Mode is selected Soft Fault indicates that one of the overtravel limits has been reached This can be either a software overtravel or one of the physical overtravel limit switches You must press CE then move or jog the axis off the switch or software limit Positive overtravel limit switch connector X8 pin 9 Negative overtravel limit switch connector X8 pin 10 8 18 10 87 MESSAGE DESCRIPTION SUGGESTED RECOVERY UNACCEPTABLE PARAMETERS Soft Fault Each time the Parameter keyswitch is returned to its normal position the TRANS calculates necessary data based on the existing parameters If the calculated values fall outside the operating system limits this diagnostic wili appear To determine which parameter
221. poradic home position errors of one motor revolution depending on whether the switch closes just before just after the marker pulse occurs IA 74718 8 11 Rev A 10 87 MESSAGE DESCRIPTION SUGGESTED RECOVERY OPT O POS DIST To prevent such a situation from occurring the TRANS X XXX X Cont d monitors the distance in motor revolutions between the closure of the Home switch and the occurrence of the marker pulse this distance is ever less that 90 degrees 1 4 motor revolution the TRANS will shut the motor down light the Reset key indicating a hard fault and display this diagnostic The value displayed is the distance the actuation point of the Home Limit switch should be moved to have it close at the optimum point which is 180 degrees away from the marker pulse The units of measurement are the same as those chosen in the parameters inch or mm If the distance between the limit switch closure and the marker pulse is greater than 90 degrees this message will still be displayed as it is possible that the Home switch is on the edge and sporadic faults could occur To determine the value at which this number will result in a a fault determine what 1 4 motor revolution will be as Ballscrew Lead x Gear Box Rev Out Gear Box Rev In x 4 All of the above values can be found in the parameters It is recommended that the value displayed in this diagnostic never be more than 1 2 of the value calculated above
222. press LF to skip this entry the last spindle speed selected will be used in this block 8 AUX FUNCTION now appears in the display You can now step through and select any desired miscellaneous functions such as auxiliary functions BCD outputs block jump or block repeat Selection of these functions or skipping them occurs in every block which is programmed See Section 5 5 3 5 below for a description of programming procedures 5 5 3 5 Miscellaneous Functions 1 To select miscellaneous functions directly press P This portion of dialog programming also occurs as a part of all the other programming functions 2 AUX FUNCTION now appears in the display If you want to select auxiliary functions press ENTER If not press LF Line Feed to skip to the BCD output selection step 6 3 When auxiliary functions have been selected the display will be Function 0 1234567 M 07 SS M indicates auxiliary functions being _ programmed 0 specifies auxillary function 0 can now be programmed Indicates function O Decimal point indicates pointer Indicate functions 1 through 7 4 One of three different conditions may be selected for each auxiliary function on off or maintain current status Press 1 to turn the function on zero filled in with lines appears in the display to indicate the function to be turned on Press 0 to turn the function off 0 appears in the display to indicate the function to
223. pter 7 The reducer ratio between the AC servomotor and the output of the drive train may be any whole value number because it is parameter adaptable Home Limit switch components must be designed so that the limit switch will remain closed from the time the switch is first actuated until the unit decelerates and reverses direction 9 4 3 Programming Rotary Motions Rotary software uses conventional TRANS programming techniques as described in Chapter 5 Only certain motions and or working units change ARAM Ales When Homing is selected during dialog programming the TRANS will display ZERO OFFSET The value entered as the zero offset will determine the value of the home position on the absolute grid of the table For example if degrees are used as the units 360 units table rev and 10 is programmed as the zero offset home position will be called 10 degrees If an absolute move to zero degrees is commanded after that the table would move 10 degrees Note that no additional motion will occur with the inclusion of a zero offset it is simply a value to be used for home position once it is reached If a value other than zero is programmed in the parameter for reference position this value will only show positive values 25 10 or 15 degrees Since the display will only show positive values this would appear as 360 15 or 345 degrees IA 74718 9 18 Rev A 10 87 9 4 3 2 Positioning NC code G1 Positioni
224. ptive Depth Control Function 9 6 9 2 4 Linear Encoder Deflection 9 7 9 2 5 Typical Program Structure 9 8 9 2 6 Illustration 9 10 9 3 Options External Correction TRANS 01 M 9 13 9 3 1 Software Requirements 9 13 9 3 2 Hardware Requirements 9 13 9 3 3 Parameters 9 13 9 3 4 External Correction Interface Signals 9 14 9 3 4 1 OVI O 9 14 9 3 4 2 Register Select 9 14 9 3 4 3 Data Lines 9 15 9 3 4 4 Clear Register 9 15 9 3 4 5 Data Valid 9 15 9 3 4 6 Digit Request Lines 9 15 9 3 4 7 Complete 9 16 9 3 5 Transmission Procedure 9 16 9 3 6 Clearing a Correction Register 9 17 9 3 7 Programming Hints 9 17 IA 74718 10 87 TABLE OF CONTENTS Paragraph Title Page Chapter 9 TRANS 01 M Options Cont d 9 4 Rotary Motion Control 9 17 9 4 1 Associated Parameters 9 17 9 4 2 Installing the TRANS Rotary System 9 18 9 4 3 Programming Rotary Motions 9 18 9 4 3 1 Homing and Zero Offset NC code GO 9 18 9 4 3 2 Positioning NC code G1 9 19 9 4 3 3 Clamping 9 19 9 5 Feed Adaption Option 9 22 9 5 1 Associated Parameters 9 22 9 5 2 Programming Adaptive Feeds 9 22 9 5 2 1 Idle Detection 9 22 9 5 2 2 Feed Adaption 9 22 9 5 3 Associated Signals 9 23 9 5 3 1 Thrust Missing 9 23 9 5 3 2 Excessive Thrust 9 24 9 5 4 Diagnostics 9 24 9 6 Feed Ramp Option 9 25 9 6 1 General Description 9 25 9 6 2 Installing the Option 9 25 9 6 3 Parameter 9 26 9 6 4 Programming the Feed Ramp 9 26 9 7 Modified Auxiliary Output Functions 9 29 9 8 TRANS Interfa
225. r Press the RETURN button at the Operator Station to execute block 003 Now try executing the program several times but select a different display mode each time to see the various display modes in use The following page is a programming worksheet illustrating the program as it would be entered into the TRANS IA 74718 5 41 10 87 Rev A 10 87 xl RR 110 15501 EE EHE eet seta CECE eee EI 5 42 EE HH tt CERE 70 Aul bx Xovard p XL wy EEE 8 2181 4 3 jS 20 pal pase et X 100 LLL LPS ooo X bee iic NOILYNUS 3G BO AINVISIC 126440 anil 13390 24 35u3AYH4 DNIHSINI3 DYI ONIHSINIA Ow O M IA 74718 5 7 2 Example Program 2 Our first program was a simple slide profile illustrating how programming works Example 2 illustrates a more complex program In this case an operation is to be performed that requires a rapid traverse up to the workpiece slowing of the axis to pass the tool through a previously drilled hole at a reduced feedrate returning to rapid traverse velocity to move to the workface machining the part a dwell to allow cleaning of the borehole and a return Auxiliary function O will control the spindle and auxiliary function 1 will be the full depth indication If Emergency
226. r excessive tool correction values The sum of the position command and the tool correction value cannot exceed the travel limit parameters Either a Normal Status Diagnostic or a Soft Fault This message occurs in conjunction with optional Feed Adaption software If the thrust required in a cycle is ever great enough that feed reduction beyond the programmed Feed Reduction value occurs this diagnostic will be displayed at the end of the cycle possibly indicating dull tooling or excessively hard work piece material If the diagnostic is accompanied by illumination of the CE key a Soft Fault has occurred because the TRANS reduced the feedrate by 99 and was still unable to reduce the thrust to the target value programmed in the Feed Adaption block Normal status diagnostic indicating the TRANS has commanded the axis to stop and is waiting during the decelerate phase bringing position error or lag to zero This will occur when a block is programmed with lag finishing indicated by illuminated Lag Finishing key Persistence of this diagnostic may indicate an obstruction very close to the final position or excessively low KV parameter Soft Fault An error has occurred while keying numeric information such as entering too many significant digits or attempting to enter a decimal point when the value can have none Press CE and re enter the data Normal Status Diagnostic Indicates that the Forward input is activated in Manual Mode
227. r mode or by resetting the control 5 5 2 Block Display Mode The Alphanumeric display indicates the functions used in the current block The display is shown as follows IA 74718 5 13 10 87 N indicates block XXX indicates current block no Summary of contents of block NXXX XFTSMBJE GX Line Presence of a letter indicates the type of information programmed in this block a letter position if that functi programmed in this block appears at on is not X Position F Feedrate or Dwell Time T Tool Correction Register Number S Analog Spindle Output RPM M Auxiliary Function Outputs B BCD Output Value J Jump E Block Repeat A Feed Adaption Programmed 0 Idle Detection Programmed NC G code as GO Homing G1 Position G4 Dwell G5 Feed to Positive Stop Optional Function G6 Feed Ramp optional TR32 software only Line Displays This area is used to display the data programmed in each of the individual lines in the display The LF Line Feed key is pressed to sequentially step inspect each line from X O through and The line displays will be decimal points appear as appropriate Line 1 X Line 2 F Line 3 T Line 4 S Line 5 M Line 6 B Position in inches or mm 7 digits Feedrate inches or mm per min 5 digits or Dwell Time in seconds 4 digits Two digit number of
228. required new program section can be written into some available block locations and tied to the original program by an unconditional jump instruction jump instruction at the end of the new program section transfers controi back to the original program In addition a jump instruction can be used to fulfill the requirement that all machining programs must start with block 000 even if the first block 000 will contain a jump instruction which transfers program control to the corresponding program starting block Note that jumps may point only to blocks which contain valid program instructions otherwise the TRANS will respond with the diagnostic error message JUMP TO GAP M ed Programs which contain identical program sequences in two or more places can be simplified by designating these identical sections as subroutines or subprograms These subroutines can be executed called from the main program by executing a Jump To Subroutine instruction When the Jump To Subroutine occurs the TRANS transfers program execution to the block number specified in the Jump instruction while storing the number of the block which initiated the jump to subroutine When the TRANS encounters a Return instruction in the subroutine sequence it returns program control to the main program block from which it executed the Jump To Subroutine instruction Program execution then continues with the next block A Jump To Subroutine
229. rmat Inch XXXX X X XXXX X XXXX X XXXX X Metric XXXX X X XXXXX XXXXX XXXXX XXXXX 10 87 Parameter Format Number Description Inch Metric P20 MAX FEEDRATE Maximum feedrate which will XXXX X XXXXX be encountered in the part program Above this speed the acceleration ramp parameter P19 will be activated Below this speed the KV factor parameter 14 is the only acceleration limit 21 RETRACT When Cycle Stop is pressed in Manual XXX XXXX Mode or when an auxiliary function acknowledgment is lost while executing the user program the axis will reverse from its present position by the amount specified in this parameter prior to the immediate stop This function could be useful in the case when it is desired to move the tool away from the part when not feeding tool relief P22 DIRECTION POLARITY Reverses the direction of X X rotation for a given plus and minus command Allows wiring all slides up the same way compensating for the presence or absence of a gearbox by providing direction reversal in software 0 negative 1 positive Set this parameter as follows 1 Select Hand Mode and jog the axis in a given direction 2 If the position display does not show the desired polarity e g display indicates minus when advancing the axis and plus is desired change this parameter to the opposite of its presen
230. rs see Section 6 9 This can be useful in situations where some functions must be interrupted if an emergency stop occurs Eight positions are available in this parameter corresponding to auxiliary function outputs 1 to 7 PPPPPPPrPP t aux output 7 aux output 0 Programming a O forces the corresponding output off during an emergency stop regard less of previous status a 1 forces it on Skipping over a position using either the LF or DEL keys causes that output to remain at the level it was before the emergency stop occurred indicated by a dash in the display Once an E stop occurs the outputs will assume the levels programmed here 4 11 Rev A 10 87 Parameter Number P28 Cont d P29 Format Description Inch Metric When the emergency stop condition is removed program execution may be resumed provided the following sequence is performed 1 Before a restart is issued the acknowledg ents for each output must match the conditions those outputs assumed when the emergency stop occurred 2 Restart may then be issued and the outputs will revert to the levels they were at before the emergency stop occurred 3 The acknowledgments must again be set to match the output status after which program execution will continue Note that when an emergency stop occurs the TRANS treats it as both an emergency stop and an immediate stop If any outputs force condition specified in this parame
231. s a Home Limit switch check to be made The TRANS first checks if the Home Limit switch has ever closed while the unit was farther than one motor revolution away from home If so the TRANS will stop immediately and display this diagnostic If no false Home Limit switch actuations have been detected the TRANS moves to home checking that the Home Limit switch closes in the last motor revolution before the home position is reached If it closes too early or does not close at all this diagnostic is displayed Possible causes are loose switch or dog interference causing switch actuation away from home excessively noisy switch or excessive backlash in the drive train Normal Status Diagnostic Indicates that the TRANS is executing a block which was programmed with homing function Normal Status Diagnostic May occur in Automatic Mode indicating homing is completed jump and stop to block 000 executed however the Homing input is still on Soft Fault Occurs when an attempt is made to select jogging rapid in Hand Mode before a homing operation is performed Press CE then home the axis before selecting jogging rapid Normal Status Diagnostic Indicates that the cycle was interrupted but is now ready for restart both in Manual and Automatic Modes This can occur after an emergency stop condition occurs then is remedied after an acknowledgment is lost then corrected and CE is pressed when the Immediate Stop key is pressed in Manu
232. s only waiting for a Start signal In Automatic Mode this means that the TRANS is ready to execute the program beginning at block zero as soon as a Start signal is received on the Cycle Interface In Single Biock Mode this message will appear each time the TRANS completes a block and simply indicates that it is ready for another Start command via the CYCLE START key on the TAM keyboard In Continuous Cycle Mode it also indicates that the TRANS is waiting for the CYCLE START key to be pressed OPERATOR HOMING MISSING Normal Status Diagnostic Indicates that Manual Mode is selected at the Operator Station but the axis has not been homed since the last power upon reset The only command which will be accepted is Return to home the axis OPERATOR NO COMMAND Normal Status Diagnostic Indicates that Manual Mode was selected at the Operator Station and the TRANS is waiting for a command This diagnostic will be displayed when a Forward Reverse or Toolchange cycle is compieted OPT 0 POS DIST X XXX X Either a Normal Status Diagnostic or a Hard Fault Indicates the optimum zero position distance Home position is determined by the first encoder marker pulse after the Home switch is closed Limit switches have a finite time delay between actuation and closure along with certain inaccuracy thus the Home Limit switch must be positioned so that it does not close too near the occurrence of a marker pulse Doing so can result in s
233. s opposed to the Modular TRANS 01 M is supplied in a rigid compact sealed enclosure designed for wet machining environments One TRANS 01 is generally mounted directly at each station of a transfer line for true distributed control Each TRANS 01 has a built in operator panel which has the same functions as the TAM keyboard display panel IA 74718 1 1 Rev A 10 87 Distinctions Between TRANS 01 and Modular TRANS 01 M 0 AAN Dima iere ei mm ms Most programming and operator functions plus actual operation of the TRANS 01 and TRANS 01 M are identical However interfacing mounting and installation of the two controls are quite different addition the Modular TRANS 01 M offers certain signal lines and options not available on the TRANS 01 Thus it is important that you refer oniy to this document for data on the Modular TRANS 0O1 M Refer to Indramat document IA 30058 for information on the TRANS 01 1 1 2 Description of Modular TRANS The TRANS 01 M is intended for remote operation where it is controlled by the customer s Line Control device usually a computer or a programmable controller which controls the entire flexible machining system The function of the customer s Line Control device is to convey commands to and receive information from each TRANS in the system It can do this using discrete wires to each TRANS the parallel Cycle Interface or it can use Indramat s optional Line Control Adaptor LCA and commun
234. s required press the Lag Finishing key This specifies that the slide must be stopped in K position before any miscellaneous functions and block jumps remaining in this block are executed or before the next block is executed If positioning without lag finishing is OK press LF Line Feed In this case the position lag from one block will LF not be completed before the next block is executed See Section 5 3 7 for more information on positioning with without lag finishing 10 FEED RAMP now appears in the display Press the ENTER key if the feed ramp is to be used to control the ENTER acceleration deceleration of speed changes involving this block Press Line Feed if feed ramp is not applicable to this block 11 Because absolute positioning was selected DESTINATION appears in the display Key the required destination as inches or XXXX XXX mm Note that the TRANS assumes a positive move if no sign is entered The minus sign can be keyed before or after the number is keyed Also note that the negative sign is a toggle press to enter minus press again to delete the number that is keyed Aiso note that the negative sign is a toggle press to enter minus press again to delete minus Now skip to step 16 12 If absolute positioning is not desired incremental positioning must be selected by pressing O 13 WITHOUT LAG now appears in the display If positioning with lag finishing is required slide st
235. s within a block while that block is being executed When execution is complete the next block comes up in the display 2 Establish communication between the TAM and the selected TRANS as described in Section 3 4 3 Press PROGRAM then press ENTRY NO REVIEW SELECT MODE 4 N will appear in the first positions of the display Select the block number to examine by one of the following a Advance the block number successively pressing N and LF Line Feed to increment the block number to the one you wish to examine or b Type the number of the first block you wish to examine leading zeros need not be entered then press ENTER you make an error while entering the block number press DEL Delete once for each digit to be deleted and re key the digits then press ENTER 5 summary of the contents of the block plus the first line of the block are displayed as described below in Section 5 5 2 When ready press LF Line Feed to examine the second line of the block Data will appear in the format described for line displays below 6 Each program block can contain 8 lines of information 10 lines for feed adaption option Each time you press LF you will step to the next line of the current block 7 When you wish to examine the next block press N and LF to advance to the next sequential block number then use LF to step through and examine each line 8 Block Display Mode is exited by selecting any othe
236. sition See Section 5 3 3 for programming requirements for this operation Releasing the pushbutton stops the movement Pressing the button again continues the operation If this pushbutton is pressed after the control has halted on a reverse vector JROOO end of forward profile se above the transfer unit will jump to block 120 or the current reverse vector and perform its reverse operation as programmed in that block returning to the Home position See Section 5 5 3 for programming requirements for this operation IA 74718 6 3 Rev A 10 87 Releasing the pushbutton stops the movement Pressing the button again continues the operation If this pushbutton is pressed after the control has halted on a reverse vector JROOO end of forward profile see above the control will continue executing the program beginning with the next sequential block If the pushbutton is pressed before a reverse vector JROOO is reached program execution will begin with the block whose number is currently stored in the reverse vector After reset or if no reverse vector is programmed execution begins with block 120 Once the RETURN button has been pressed the other operator controls are disabled until the slide has returned to the Home position If a fault exists pressing the RETURN pushbutton clears the fault Releasing the button then pressing it again causes the TRANS to begin its reverse program If the cause of the fault has not been remedied
237. so four blocks will be needed Block 000 rapid advance Block 001 feed Block 002 dwell Block 003 rapid return As we write the program consider the following 15 Absolute dimensioning will be used and home will be called zero on the absolute grid 2 Block 000 is programmed with rapid advance to point 10 from home Without Lag Finishing will be selected so that the feedrate changes smoothly from rapid advance to feed without stopping the axis Note however that all other positioning blocks will be programmed with lag finishing to ensure that the slide is completely stopped and in position before executing the next block 3 Block 001 will be programmed as a feed to 12 5 from home A feedrate of 10 inches per minute is specified 4 Block 002 selects a 1 second dwell to ensure proper completion of the operation A reverse vector of 000 will also be entered in block 002 to disable the manual FORWARD pushbutton after the dwell time has elapsed This indicates the end of the Forward profile IA 74718 5 39 10 87 5 Block 003 selects a rapid return to home Jump To Block 000 And Stop will also be programmed in this block to positign the program back at block 000 after the rapid return is executed 6 Block 110 is used by the TRANS as the starting block for the tool change program We specify the point 5 inches behind home as the tool change position so block 110 is programmed with an absolute m
238. software version TR32 handles auxiliary output functions differently from standard TRANS software in standard software the TRANS turns an auxiliary function on at the end of a block then begins to decelerate the servomotor until an acknowledgment is received Then the next block is executed Even if the output is tied directly to the acknowledgment some time is required to turn the output on debounce the input then read the input Thus time lags of around 30 msec may occur during which the drive is braked and not accelerated These are normally partially compensated for in NC systems by the high mass moment of inertia This is totally compensated for in software version TR32 When a block is programmed without lag finishing the TRANS turns the auxiliary output on at the end of a block then immediately begins execution of the next block Program execution is continued for 50 msec without any interruptions After 50 msec the TRANS checks for correct acknowledgment of the output If the acknowledgment has not been received the TRANS diagnoses a fault and shuts the system down Note that movement is not interrupted at the end position of the block in which the switching function was programmed but later in the path covered within the 50 msec 9 8 TRANS INTERFACE MODULES 9 8 1 General Description For situations where the TRANS I O must be interfaced directly with devices requiring 115 Vac rail mounted interface modules are available
239. stop If the slide reaches this position without the motor stalling movement will stop the diagnostic POS STOP MISSING will be displayed and a soft fault will result To recover you must press the CE Clear Error key and perform a homing function 5 3 11 Tool Corrections NC Code T The TRANS includes a feature which allows programmed corrections to be entered to compensate for changes in the tool or part dimensions Tool corrections are effective only when programmed together with a position command Program entry is in a two digit tool correction register which has an associated correction or compensation value Twenty tool correction registers are available Correction values are entered as described in Section 3 10 Entering Tool Corrections When the TRANS is operating the correction value in the specified tool correction register is added to the programmed position value i e the target position of the TRANS is the sum of the programmed position and the correction value Once a correction register is specified in a block it remains valid for all subsequent moves until a different tool correction register is specified in a position command or until the control is reset Zero setting of the tool correction value is accomplished by specifying tool correction register OO in a position command Tool correction values are entered at the Toolsetter level and only access to the TAM keyboard is needed program Entry and Paramet
240. t indicate what direction or the slide is from home at all times Therefore the dog must be designed such that reopening of the switch contacts is not possible on the minus side of home 7 5 3 Safety Emergency Limit Switch The Emergency Limit switch S in Figure 7 7 is required to prevent moves against the mechanical stops caused by wiring errors during startup component failures human errors etc This is done by dropping three phase power to the servo controller and actively braking the motor The dogs for this switch must be placed far enough from the mechanical stop to provide sufficient time for application of the brake The switch dogs must be of such a design that it is not possible to reclose the contact by continuing to move after actuating the switch It is recommended that the dogs be fastened securely so that inadvertent repositioning is avoided During startup proper operation of this limit switch should be assured before applying power to the slide As an extra precaution during startup center the slide unit and position the switch dogs close to the emergency switch Apply power and run the slide with rapid speed against the limit switch Note the distance required to stop once the switch is activated Use this value as a guide when placing the dogs in their final positions Figure 7 6 illustrates transfer unit design criteria including limit switch requirements IA 74718 7 14 Rev A 10 87 7 6 TRANS INPUT OUTPU
241. t value P23 HOMING DIRECTION Reverses the direction in X X which the control searches for the Home Limit switch 0 search in plus direction when the switch is open usually into the part 1 search in minus direction usually away from the part Minus is normally chosen as the homing direction P24 JOGGING DIRECTION Reverses the direction in X X which the axis will move when the jog keys on the TAM are used IA 74718 4 10 Rev A 10 87 Parameter Number 25 26 P27 P28 IA 74718 Format Description Inch Metric MAX FEEDRATE FOR 65 This is the maximum XXXX X XXXXX feedrate which can be programmed when using the Feed To Positive Stop function G5 or other option such as Adaptive Depth Control see Chapter 9 A soft fault results if an attempt is made to program a higher feedrate than this parameter specified maximum in a block using one of these function TORQUE TO POS STOP This is the XXX XXX percentage 01 100 of maximum motor torque that will be available while feeding to a positive stop using the Feed To Positive Stop function G5 X TORQUE AT POS STOP This is the XXX XXX percentage 01 100 of maximum motor torque that will be available while stalled at a positive stop when using the Feed To Positive Stop function 05 AUX OUTP AT EM STOP This parameter can be See description used to force the level of the auxiliary function outputs whenever an emergency stop occu
242. tablished by these parameters the control will halt and a diagnostic error message will be displayed Enter a TRANS Program as follows 1 2 At the Operator Station Switch the system to Manual Establish communication between your TAM and the selected TRANS as described in Section 3 4 Insert the correct key into the Program keyswitch and turn it to select Program Entry Edit Mode Press Block No Select Type the number of the first block you wish to program leading zeros need not be entered then press ENTER IA 74718 5 15 10 87 NOTE At any time if you make an error while entering data press DEL Delete to delete the last data entered then re key the data and press ENTER You can use the N and LF Line Feed keys to successively increment the displayed block number 6 Press DIALOG Q Dialog NOTE SYSTEM RESET To guard against accidental program changes DIALOG must be pressed to program each block After pressing DIALOG you can exit Programming Mode without changing the block by pressing the Reset key 7 FUNCTION appears in the display Now you must select one of the various functions as described in the following sections 5 5 3 1 Homing 5 5 3 2 Positioning includes absolute and incremental positioning tool correction and analog spindle output 5 5 3 3 Dwell 5 5 3 4 Feed To Positive Stop 5 5 3 5 Miscellaneous Functions Includes auxiliary outputs BC
243. te step and automatic cycles necessary interlocks with the Line Control continue to function via the Cycle Interface 3 4 USING THE TAM The functions described in the remainder of this chapter are all performed using the TAM keyboard and display The descriptions assume that a TAM is communicating with a selected TRANS Establishing that communication is described below 3 4 1 TRANS Numbers and the TAM Because the TAM can communicate with any one of several TRANS controls the operator must specify the TRANS with which to communicate Each TRANS in a system is assigned a unique TRANS NUMBER from 01 to 30 The TAM or LCA can then communicate with that TRANS addressing it by its unique number The TRANS NUMBER is a system parameter selected when the TRANS is installed or replaced the modular TRANS version TRANS 01 02 and above the TRANS NUMBER is selected via switches on the front of the unit as described in Section 4 2 1 On version TRANS 01 M 01 the number is selected via an operator procedure described in Section 4 9 Once the TRANS NUMBER is set it will seldom need to be changed except if TRANS memory is lost such as when a battery is replaced IA 74718 3 3 Rev 10 87 3 4 2 Communicating Using the TAM The procedure to use the TAM with any TRANS 01 M control is 1 TAM 2 Portable a Connect the serial channel cable from the connector on the front of the TAM to connector X4 or X5 on the se
244. ter conflicts with those given in P29 the level in P29 will take precedence while the Emergency Stop signal is low When Emergency Stop is brought high the values in P29 will be assumed until an action Restart Homing etc is commanded AUX OUTP AT IM STOP Used to force the See description levels of auxiliary function outputs when an immediate stop condition occurs Immediate stop is the condition assumed by the TRANS when a soft fault occurs or in Manual mode when a Forward Return or Tool change cycle has been initiated but interrupted before completion by bringing the corresponding input low This parameter is programmed similarly to P28 above NOTE The parameters described below on the following pages will be present in the TRANS software only when the option they pertain to is present in the system P30 IA 74718 NOM CURRENT A Feed Adaption Option XXX XXX software TR34 This parameter specifies the continuous current rating for the motor whose current is measured for feed adaption This could be either the spindle or axis motor After this value is entered any references to motor current encountered in programming or in diagnostic displays will be expressed in a percentage of this parameter value 4 12 Rev A 10 87 Parameter Number P30 Cont d P31 P32 P33 IA 74718 Format Description Inch Metric To find the value to be entered here first determine if the TRANS is meas
245. tering a larger number will yield a tighter system but entering too large a number can result in oscillation and sporadic faults HOMING SPEED Specifies the speed at which the axis will be homed when reference position Home is not known i e after power up or reset or when no feedrate value is entered in a homing function block This can be the same as the rapid traverse rate but can also be any other value In some cases homing may occur under different conditions than rapid traverse and a different feedrate may be required Note that homing must be programmed as described in Section 5 3 3 RAPID SPEED Specifies the rate at which the axis will be moved when rapid traverse is specified and feedrate override is set at 100 This parameter is the limit for all feedrates in the user program JOGGING SPEED Speed at which normal jogging commanded using the TAM jog keys will occur JOGGING RAPID Speed at which rapid jogging commanded using the TAM keys will occur when it is selected and enabled The axis must have been homed for rapid jogging to be enabled RAMP The system acceleration is limited only by the system gain KV Factor P14 up to the maximum feedrate parameter P20 below Above maximum feedrate it operates under a controlled acceleration ramp specified in this parameter This limits system acceleration at high speeds to avoid excessive mechanical strains Enter in in sec sec or mm sec sec Fo
246. ters per pulse is entered in this parameter as 10 micrometers per line P33 LIN ENCODER DIRECTION Coordinates the linear encoder X X deflection with slide direction 0 indicates that positive motion as programmed into the TRANS will cause increased deflection of the linear encoder A 1 indicates that negative motion cause increased deflection of the linear encoder P34 MAX LIN ENC DEFL This parameter specifies the maximum XXX XXXX possible deflection of the linear encoder This value is determined by the full stroke limit of the linear encoder used less any pre deflection present in the mechanical linkage Enter in inches or mm A RANGE ERROR diagnostic will occur if an attempt is made to program an adaptive depth program block with a LIN DESTINATION value higher than the value specified in this parameter IA 74718 9 3 Rev A 10 87 Para Format meter Description inch Metric P35 LIN ENCODER PRE LIMIT Sets the maximum amount of XXX XXXX XXXX XXX deflection the linear encoder may have while the motor s encoder is active normal positioning The value of P33 will determine if P35 is positive P33 0 or negative P33 1 This parameter can be used to indicate part mislocation 9 2 2 Installing The Adaptive Depth Control Option Install the Adaptive Depth Control Option as follows 1 Install the TRANS system using the guidelines described in Chapter 7 2 Mount the linear encoder in the selected posi
247. th a Jump to Block 000 and Stop N120 GO X0 000 J S 000 Block 120 first block for _ basic homing program Homing command Zero offset 0 J specifies Jump S specifies Stop Target block 000 IA 74718 5 3 Rev A 10 87 The homing program must be designed so that safe retraction is possible under any condition including power shutdown To insure this the TRANS has been provided with reverse vectors which will determine the block number to which the program will jump if a reverse command is issued both in Operator manual and Automatic modes The reverse vector is initially set to block 120 but can be changed to any block number in the machining program Each time the TRANS executes a Jump To Block 000 And Stop the reverse vector is reset to 120 The reverse vector number is retained even if a power failure occurs As described in Section 5 3 13 auxiliary outputs can be issued at various points in the program and the TRANS waits for an acknowledgment for each output turned on or off before it executes the next block The one exception to this is that a jump to a reverse program is performed even if the acknowledgments do not match their associated outputs provided that the first block of that program performs only auxiliary output functions This is useful for an emergency return or upon recovery from a power failure This first block in the reverse program usually 120 should force the auxiliary outputs into a state
248. th connectors should also be installed in such a manner that complete replacement is possible Note that Indramat can supply complete interconnect cable sets It is the responsibility of the machine builder to minimize downtime through quick and failsafe module interchangeability RRR RNR ER 7 2 1 Distributed Control INDRAMAT s Modular TRANS 01 system is designed employing the principie of distributed control The AC servo controller and TRANS 01 M control a feed axis and spindle on a single unit and are designed to be mounted in a sealed cabinet on or near the machine Advantages of this distributed control principle are Cables are kept short Because of the high performance available in the system it is possible to standardize the transfer units Critical signal cables such as the position feedback cable do not have to be routed through the entire machine thereby eliminating the noise problems normally encountered with such cables The transfer unit can be operated independently and therefore can be tested separately from the rest of the transfer line system IA 74718 1 1 10 87 1 2 2 Mounting Considerations The following points must be taken into consideration during installation The Modular TRANS servo controller and spindle controller are mounted in a sealed cabinet and are generally powered from a single power supply The fixed TAM TAM 2 01 is protected by
249. the distance between limit switch contact closure and the zero pulse If the switching point is closer than one quarter of a revolution to the marker pulse the home cycle is aborted and the 0 POS Dists X XXX diagnostic message is displayed If this occurs the Reset key is also lighted to indicate a hard error 7 4 6 Actuating the Home Limit Switch Actuation of the Home Limit switch must be arranged so that the switch contact is closed as the unit travels back away from the workpiece See Figure 7 6 The dog used to activate this switch must be long enough to maintain contact closure from the reference position all the way back to the travel limit if parameter P23 is a i or the travel limit if P23 is 0 This is done to indicate to the control in which direction the slide must be moved to reach the reference position It is also required because the Home Limit switch signal is usod to indicate that the tool is clear of the workpiece Because the machine design dictates the relationship between motor rotation direction and slide direction Homing Direction has been assigned as a user entered parameter in the TRANS See Chapter 4 for details 7 5 LIMIT SWITCH POSITIONING ON A NUMERICALLY CONTROLLED AXIS Saena mmn e AT MOAPA a Three types of limit switches may be included in the machine design as illustrated in Figure 7 7 They are Primary Overtravel Limit switches Home Limit switch and Safety
250. tion and mount the pulse forming module as close as possible to the encoder Figure 9 2 page 9 5 illustrates the TRANS Adaptive Depth Control interconnection Figure 9 3 is a dimensional drawing of the EXE 601 Pulse Shaper 3 Route the orange cable from the EXE 601 Pulse Shaper to the TRANS connector X13 4 Install the new optional executive software PROM as described in Section 9 1 IA 74718 9 4 Rev A 10 87 BOTTOM VIEW OF 5 01 Fixed machine Reference position datum point HE Workpiecc 3 3 XX pi EOFT naa m HIE E H A a eae ae T TIE EXE 601 MT30W Pulse Shaper Linear Encoder Note Use this drawing in addition to drawing 209 030 2701 4A Figure 9 2 Adaptive Depth Control Interconnection IA 74718 9 5 Rev A 10 87 80 3 15 40 1 575 9 2 3 1 2 6 74718 68 2 677 2 mounting screws M4 x 20 DIN 812 57 2 24 175 6 89 16 0 63 40 3 575 22 886 163 0 2 8 417 gt 008 min rad for frequent flexing R gt 100 mm 4 07 Linear Encoder input min rad for rigid configuration R gt 40 mm 1 5 Outpul lo Trans Of 515 Figure 9 3 EXE 601 Pulse Shaper Dimensional Drawing Programming The Adaptive Depth Control Function Switch the system to Manual Mode at the Operator Station Establish communication between your TAM and the TRANS as described in Section 3 4 Insert t
251. to execute a homing command or manual operation selected from the Operator Station The various programming situations and the requirements for each are summarized in following sections 1 74718 5 2 10 87 5 3 1 Start of the Program All machining programs must start with block 000 If several different machining programs are to be written branching must be accomplished such that an unconditional or conditional jump from block 000 will be executed to jump to the start of the program First Positioning In order to assure that machining programs will be executed with a correct absolute reference under all circumstances the first positioning in a machining program must be programmed in Absolute Positioning Mode i e under no circumstances in Incremental Mode 5 3 2 End of the Program All programs must be terminated with a Jump To Block 000 And Stop command This applies equally to machining programs reverse programs and tool change programs 5 3 3 Basic Homing Program A homing program for travel to the reference position is required at block 120 It must conform to the following requirements 1 No instruction for travel to a particular position is permitted if there is no prior instruction for homing 2 The program must always contain a Homing instruction 3 The program must always be terminated with a Jump To Block 000 And Stop instruction The simplest such program following block 120 is therefore Homing wi
252. uction electronic module designed for panel mounting in sealed enclosure such as a NEMA 12 cabinet or KSC together with a power supply and one or more AC controllers generally one for the feed axis servo drive and one for the spindle drive The TRANS 01 M is generally used in a flexible machining system or dial type rotary machine where one TRANS is used per station In turn multiple TRANS controls are under the system control of the customer s Line Control device such as a programmable controller or computer This device can communicate with any TRANS control uploading downloading parameters programs status and diagnostic information This can be accomplished using Indramat s Line Control Adaptor which provides a communication link with up to 30 TRANS controls The TRANS 01 M controls are often built into a machine cabinet and are not readily accessible to an operator The operator communicates to the modular TRANS via a TAM keyboard display plug in TAM 2 01 keyboard display module is mounted in a convenient location for the operator and cabled to up to 10 TRANS 01 M controls system with more than ten TRANS modules requires multiple TAM s Alternately a portable plug in TAM 2 keyboard display is carried to the machine and plugged into an individual TRANS 01 M as needed for parameter entry programming tool correction entry and data and diagnostic display TRANS 01 Distributed Control The TRANS 01 control a
253. um output current 1 2 A M M M a AMETE rere MA ET 9 9 1 Introduction The TRANS may be used with a linear scale providing incremental encoder type outputs without any modifications to the TRANS The AC servomotor used in such an application does not require position feedback only tach and commutation feedback IA 74718 9 31 10 87 9 9 2 Parameter Adaption When using a linear scale parameter PO6 Encoder Cycles Rev must be calculated using the following formula Baliscrew Lead EXE multiplication factor Encoder Cycles Rev Linear scale constant Gear reduction Example Ballscrew Lead 10 mm EXE Mult Factor 5 Gear Reduction 2 1 Linear Scale Constant z 10 um 1250 Cycles Rev it 10 000 mm 5 20 um 5 All other TRANS parameters are entered as normal 9 9 3 Pulse Weight If the pulse weight of the completed system is required it may be calculated as follows Linear Scale Constant EXE Mult Factor TRANS Multiplication factor In the above example this would be 20 um 1 um 4 Note the TRANS always multiplies by four IA 74718 9 32 Rev A 10 87 9991d YOM sour siq Ajajes 7 0197 IULI SS PIN SS NISS S80q ynag younas LOM LLL 22021324 uonisod di smd 0127 ae HH HAH H IL TIPF LT TT e KOJN
254. uring current from an Indramat spindle drive or a standard induction motor If an Indramat spindle drive is used the value may be found on the nameplate of the induction motor or on the controller personality module in the case of a MAC spindle drive If another manufacturer s induction motor is used refer to that manufacturer s specifications The minimum value for this parameter is 25 the maximum value is 200 See Section 9 5 for a description of the Feed Adaption option and discussion of the use of this parameter MAX NO THR CURRENT Feed Adaption Option XX XX software TR34 This parameter defines the maximum no thrust idle current that the system may have No thrust current is the motor current required during a non cutting condition This parameter is entered as 00 99 of the current rating entered in parameter P30 See Section 9 5 for a description of the Feed Adaption option and the use of the parameter LIN ENC RESOLUTION Adaptive Depth Control X XXXXX XX XXXX Option software TR35 This parameter pertains to a linear encoder and specifies the linear distance per linear encoder line Note that the encoder provides 4 pulses per line Thus an encoder with 2 5 micros per pulse has 10 microns per line Enter in inches or mm per line LIN ENCODER DIRECTION Adaptive Depth Control X X Option software TR35 Coordinates the linear deflection with slide direction 0 indicates that positive m
255. uxiliary output a indicates that the required acknowledgment has not yet been received 3 5 5 Feedrate BCD Output and Tool Display Mode Key O 652 This key selects a display of the current programmed feedrate the feedrate override percent of programmed feedrate the BCD output value the current tool correction register number and the current reverse vector 3 5 6 Diagnostics Mode Key This is the normal display mode entered when the TRANS is powered up or reset The TRANS will be in this display mode when in Automatic Mode under the control of the Line Control In this mode the current status of the unit will be displayed This can be a normal status diagnostic such as NO START which indicates that the TRANS is awaiting a command from the Line Control a soft fault diagnostic such as COMMAND ERROR which means an incorrect key was pressed or a hard fault diagnostic such as ENCODER FAULT which indicates a disabling hardware problem which must be corrected When a soft fault is detected the LED on the CE Clear Error key is lighted You must press CE then continue SYSTEM the operation When a hard fault is detected the LED on ERROR Z RESET the Reset key is lighted You must correct the fauit then press Reset and home the axis to continue operations 3 5 7 Tool Correction Display Mode Key When this key is pressed the tool correction register number currently being used in the
256. ware 9 21 Figure 9 IA 74718 9 5 FEED ADAPTION OPTION With optional TR34 software the TRANS can be configured to automatically alter the feedrate of an axis drive to maintain constant loading It will also indicate via outputs available on control connector X10 whether the maximum allowable thrust current for the application has been exceeded indicating worn or broken tools for example or whether the cycle required too little thrust current e g missing part or broken tool On a TRANS containing feed adaption software all normal functions are available except the feed to positive stop function 9 5 1 Associated Parameters Two additional parameters are included in software incorporating the adaptive feed function They are P30 NOM CURRENT and P31 MAX NO THR CURRENT These parameters are described in Section 4 5 9 5 2 Programming Adaptive Feeds The programming of adaptive feeds is performed within a block containing the positioning function G1 the same block containing the move where thrust will be developed Since the TRANS dynamically controls the feedrate in a feed adaption process the feedrate programmed in such a block will be used as the upper limit in the adaption process Note that block repeats may not be programmed in a block containing an adaptive feed For details on programming positioning moves refer to Section 5 5 3 2 9 5 2 1 Idle Detection After tool correction is entered or bypassed the qu
257. with a MAC AC spindle motor Complete interconnect cable sets are also available from Indramat Components are chosen to best fit the required application and are matched through plug in personality modules to provide optimum performance without the necessity for further field adjustments Figure 1 1 is a block diagram illustrating typical system configurations IA 74718 1 2 Rev A 10 87 Both positioning accuracy and system speed are optimized by utilizing closed loop digital positioning The axis can be positioned either incrementally or absolutely The TRANS 01 M control includes a memory which can store up to 128 program blocks Each block contains up to 8 instructions which are Homing or Position Command Feedrate or Dwell Time Auxiliary Functions BCD Output Tool Correction Spindie RPM Output Block Repeats and Program Jumps Additional instructions for special applications are available with certain modular TRANS software packages 1 1 3 Programming The TRANS control can be programmed using either of two methods 1 The TAM keyboard display panel 2 Indramat s optional Line Control Adapter LCA a microprocessor based serial bus driver RS 422 74718 1 3 Rev A 10 87 SUPPLIED BY INDRAMAT 255 25 21 SPINDLE DE SPINDLE CONTROLLER MOTOR CONTROL FEEDBACK LOOP RS 232 RS 422 SERIAL SERIAL CHANNEL CHANNEL CUSTOMER SNOPAMAT INDRAMAT LINE L
258. y and a soft fault results Press the CE Clear Error key to clear RAPID the diagnostic indication Once you have pressed the CE key TRAVERSE and homed the slide rapid jogging can be selected Press the Rapid key a second time to switch from rapid to normal jogging speed 8 Exit from Jogging Mode by selecting any other mode or by pressing Reset Key to reset the control 3 9 SELECTING FEEDRATE OVERRIDE A feedrate override establishes some percentage of the normal feedrate and rapid traverse rates as the maximum rates for the system In normal operation feedrate override wouid be set at 100 While changing tools or testing the operator may wish to select some lower percentage while verifying that the program is correct and the system is functioning normally Set the feedrate override as follows 1 The control must be in Manual Mode and may not be in Program Entry Mode 2 Press Feedrate Override M 3 Key in the selected percentage feedrate value between 1 and 100 If you make an error press DELETE and re enter the data If a FORMAT ERROR diagnostic appears if you attempt to enter 4 digits for example press to clear the error then re key the data If you attempt to enter a value larger than 100 your selection is ignored and the previous override value is retained The diagnostic RANGE ERROR is issued and a soft fault results Press the CE key to clear the error then enter a valid value 4 Press ENTER to
259. y in feedrate value then press ENTER If you attempt to select a feedrate greater than the parameter specified maximum rapid traverse speed P16 the RANGE ERROR diagnostic occurs If you wish the feed to occur at rapid traverse rate press the Rapid key A fixed rapid rate specified by program parameter f P16 is then selected 11 TOOL CORRECTION now appears in the display Press LF Line Feed if there is no requirement for operator accessible dimension offsets or if the tool correction register number and its associated value chosen in a previous block is still to be used To select a correction register key in a number from 1 to 20 to specify the desired correction register then press ENTER The operator can then enter a value in that correction register which will be added to the dimension in this and all subsequent moves until a different tool correction register is selected or the control is reset If you had selected a tool correction register in a previous block but do not wish to use it in this or subsequent blocks enter a tool correction register number of 0 then press ENTER IA 74718 5 18 Rev A 10 87 12 SPINDLE RPM now appears in the display if analog spindle output is enabled in parameter P40 Key in the speed in rpm at which the spindle is to operate in this and subsequent blocks then press ENTER If you press LF to skip this entry the last spindle speed selected will be used in th s block The m
260. y will show tool correction register number 1 and its present value as TO1 XXXXX 4 If you do not wish to change this value press LF Line Feed to display the next tool correction register number and its value If you wish to display a specific tool correction register number and its value number 12 for example press ENTER 5 To change the value first press the Edit key 6 Now key in the desired correction value If you make an error press Delete to eliminate it and re key the data DEL 7 When the value is correct press ENTER This value is then entered in memory IA 74718 3 13 Rev A 10 87 8 To go back to tool correction register number 1 press then press or press ENTER 9 Exit Tool Correction Entry Mode by selecting any other mode or by pressing Reset to reset the control After the correction values have been entered the Toolsetter will usually check out system operation using Continuous or Single Cycle Modes 3 11 CLEARING FAULTS There are three types of faults possible in the system 1 Temporary Fault Certain errors such 1 0 SUPPLY MISSING and EMERGENCY STOP are treated by the TRANS as Temporary Errors When such a condition is detected the TRANS halts and displays the appropriate diagnostic message other signals will be accepted by the TRANS as long as this condition persists but no reset of the control is needed once the problem is rectified At t

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