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Numeric controlled indexing tables Series TO150A

1. Configure Network Symbol Table Ctrl alt4T PROFIBUS DP Report System Error SIMATIC 300 SIMATIC 400 Edit Catalog Profile Update Catalog SIMATIC PC Based Control 300 400 SIMATIC PC Station Install New GSE Import Station GSE Comment O address MPI address address PA AA ae A UR CPU 3152DP_ 6ES7315 2AF02 04B0_ 2 xp DP Aastra EA A DE E NN A A SS O gt A AA SA EE AAA AAA O A A AS AAA AA IA VAS AAA _ HHH 32 A AMA AAA O ae O A O Id Module Order number Installs new GSE Files in the system and updates the contents of the catalog Chg 2 HAE O SIMMAT DE HEH Cordier size TEST PR Remark Dk best PLC ew tons ndo He If a GSE file is already referenced you must at first close all stations in order to be able to import the GSE file After the import of the GSE file you open the stations again Install New GSE 13 4343 E xj An update is presently not possible In one or more STEP applications at least one GSE file or type file is being referenced Help TO150 MEN ELEKTRO 042006 DOC 04 06 35 3 Select GSE file from CD ROM a HW Config Configuring hardware Station PLC View Options Help rilgz a m 4 Customize Ctrl Alt E m les Li Edit Catalog Profile Update Catalog Profile Standard E S
2. Wire Tip Sleeves blue 1 5 4 mm brown 1 5 4 mm black 1 5 4 mm yellow green 1 5 4 mm white 0 75 1 mm white red 0 75 1 mm white blue 0 75 1 mm D i i i I 1 l 1 1 I 1 I i I 1 i 1 i 1 pog pog i 1 l l I l I l I 1 i i l l I l 1 I 1 I 1 I 1 i 1 pog pog i 1 l l white green 0 75 1 mm e Alle shields connected to the plug Cable lengths 5m 10m 15m 20m 25m available TO150 MEN ELEKTRO 042006 DOC 04 06 25 Structure of the encoder cable W2 Remark 1 1 Encoder cable 5 x 2 x0 25mm 2 x 0 5mm Circular connector 17 pin socket ASTA 035 FR 11 12 0005 000 EJ 3 DSUB housing 45 15 pin plug AAA Shrink wrap EA Circular connector Pn Descripion Function 12 JB JwWI X jChmelB 5V out 0 25A Encoder supply 5V Reference A e ecu EE EE COM 1 3 9 11 13 15 45V out 0 25A Sense COM Bi Sense 5V Ref yellow 0 25 mm gray 0 25 mm violet 0 25 mm Shield connected to plug housing 26 TO150 MEN ELEKTRO 042006 DOC 04 06 5 Description of the user interface The digital interface is described first The Profibus interface is built in a similar way but offers the option to transmit numerical values nominal position actual position fault number 5 1 Overview of Terminals Inputs l O extension CX408 2E GND 0V 24V supply of
3. 4 1 Motor The torque motor is development by WEISS A patented winding technique engineering holds the temperature low and lowers the manufacturing costs Head pipes are available optionally They advance heat dissipation around approx 30 As a result a higher continuous duty is get They are mounted below the base and enlarge the cooling area Heatpipes View from below be broken off d Caution The Heatpipes must be mounted straight It is not acceptably to Heatpipes exist intern from a capillary system filled with a special liquid If the Heatpipes broken off the liquid can t circulate The functionality is lost The motor is protected through a temperature sensor KTY83 130 TO150 MEN ELEKTRO 042006 DOC 04 06 13 4 2 Motor lines The cable shield for the motor line is connected with the ACOPOS housing via the grounding plate using the grounding clamp provided Please pay attention to the correct reservation of the lines U gt blue V brown W 3 black 4 3 Machine Zero Position After the setting up and connection of the indexing table you determine the machine zero position uniquely For this you move the axis via jog mode exact to this position where the angle should 0 0 be This will be normally the first processing stop Then give the command Set Zero via the display the Windows program or via the digital Input As a result you see that the actual position changes to 0 000 You must do this only
4. soon 193 ODA ul on aL un R2 X3 vx Trigger 12 Quickstop Trigger2 Ce COM 1 2 D t Shield rs End is 7 End i Ls Ref e Enable 24 Y ig Enable X41 e deeg e COM 8 9 TA COM 8 9 24V Sen i 9 0 t 24V a eS 24 COM 5 7 14 15 COM 5 7 14 15 COM 5 7 14 15 i 1022 1045 1090 O SS SS SS GA GA SS SS SS GARS GN mmm GRE UR GNU 12 EnDat 7 6 Resolver e 0 1 i i m nn A 11 t ir an a Le LI a Li i 18 TO150 MEN ELEKTRO 042006 DOC 04 06 4 9 Secure Restart Inhibit The ACOPOS drive have a built in secure restart inhibit to guarantee that the device is stopped securely and to prevent it from restarting unexpectedly It is designed to correspond to safety category 3 according EN 954 1 In addition to preventing the device from restarting unexpectedly according to EN 1037 this safety function also meets the requirements of EN 60204 1 regarding the stop function for categories O and 1 Both stop functions require the supply to the machine drives to be switched off immediately for category 0 and after stopping for category 1 The restart inhibit interrupts the supply to the motor by preventing the pulse to the IGBTs In this way a rotating field can no longer be created in synchronous and asynchronous motors For this function please use clamp X1 9 at the front side of the ACOPOS drive Clamp X1 10 is the GND
5. Clamp X1 9 X1 10 is galvanic isolated from 24 V supply Take note that multiple errors in the IGBT bridge can cause a short f advancing movement The maximum rotary angle q of the motor shaft that can occur during the jerking movement depends on the motor used For permanently synchronous motors is 360 2 p It is in the case of the TO150ABB approx 13 at the indexer plate We emphasize that the integrated secure restart inhibit does not interrupt the voltage supply to the motor It prevents only the build up of a rotating field and prevents thus the start up of the motor If electrical work is performed on the motor the mains power supply had to be interrupted with a mains contactor or a main switch Please note that at least 5 minutes discharging time for DC bus should be provided before any electrical work is performed When the LED s at the ACOPOS drive go off this is not an indication that the voltages are switched off and that the DC bus has been discharged to below 42 V be generated at the motor In case of work on the motor the mains have to be disconnected through a mains contactor or a main switch In case of a fault of the IGBT bridge a life threatening DC voltage may Selecting the suitable safety category must be done separately for each indexer for each servo drive based on a risk evaluation This risk evaluation is a part of the total risk evaluation for the machine On the delivered CD ROM you f
6. 30 lt 300000 in pos 0100 j Stations 2 ea Mode EE mathematic General General v start 200 200 RPM le e a Bod e SSC 45000 20000 RPM tabgfe No hz follow error 5000 Incr quick stop input Y a stop 1311 656 Rev s r Dy rride dcc BR H factor 102 102 Override 10000 IS Z Setting 2 indexer steps Setting Software limit switch blocked area 200 0 300 0 Additional hardware limit switches can be mounted im 1 0 Monitor E E loj x Inputs ACOPOS Inputs Enable Je MovetoPosCw D Step Cw T Zero Pos D 1 1 Trigger IT it A MovetoPosCCW TI Release break TI X1 2 Quickstop V Move to Pos abs T Cm E to last Pos I 1 5 Limit E Move to Pos rel T Zn Demo sequence I 176 Limit lo Move to Pos DW TI Jog CCW 7 Stop I 1 7 Reference v Move to Pos DW I Jog to Pos I Parameter 2 1 1 9 Enable Iv Move to Pos Bus T Store Pos I Search Home Sequence Alarm reset 7 Reserve D Force Inputs m Outputs Amplifier enabled 4 Trigger_41 T Cam1 In Pos Y Amplifier disabled Trigger A2 T Cam2 F Reserve I Reference ok V Trigger_43 T Cam 3 Reserve Ready to Start I Trigger A4 Cam 4 Reserve I Error Trigger_B1 T Cam5 F Reserve I Error flash Trigger B2 T Cam amp Reserve
7. timeout movement following error delay enable limit switch quick_stop_input 60 0l xi Ease eene ee cec General limit switch Un quick stop input Lancel Fixed setting of the movement timeout for all motor movements If a value of 0 0s is entered the timeout is calculated individually depending on the rotation angle speed etc In addition to the movement timeout the rotating movement can be monitored through the following error The enable of the axis with clamp X1 9 at the ACOPOS drive will be delayed in order to guarantee that the mains voltage is correctly on and the DC bus in the ACOPOS drive is ready Otherwise you can get an alarm message DC bus voltage too low slash unstably This delay time depends on the hardware wiring as soon as of the model of the drive If hardware limit are used they can be activated here Opening type switches have to be used Defines the function of the input X1 2 on the ACOPOS No function Quick stop LO active Quick stop Hl active If this input is active all movements are stopped As this is achieved through the ACOPOS operating system this input is on its own not sufficient to ensure a sufficient EMERGENCY Stop functionality TO150 MEN ELEKTRO 042006 DOC 04 06 The values in Part 5 are only display values Of special interest are the motor temperature and the temperature of the brake resistor TO150 MEN ELEKTRO 042006 DOC 04
8. 0 000 v stark 20 0 20 0 RPM e v max 30000 1000 0 RPM Setze a_stop 492 7 2464 Rev s Override SS x factor 1 02 102 Override 100 00 E Jog to Pos Cancel TO150 MEN ELEKTRO 042006 DOC 04 06 57 Pat Pat Pat3 Pats Pats Limits mas speed 1000 RPM j accel o Revs Fite 1 Tk 0 0012 decel 790 Rev g Fite 2 F0 00 L jerk 008 fs Fite 2B 00 Position loop Current loop 150 0 00 3953 is t ahead 0 0016 t total 0 0016 p mas 1000 mas o0 Cancel Group Speed loop Settings for the rotation speed controller These settings are only relevant for a WEISS technician Group Position loop Settings for the position controller These settings are only relevant for a WEISS technician Group Limits Max_speed accel and decel are defined by the indexer type and the mass inertia and cannot be changed t_jerk changes the movement profile A t_jerk of 0 0 s means very hard movements A t_jerk of 0 2 s means very gentle movements but longer movement times t_in_pos delays the completion message by the set time settling time 58 TO150 MEN ELEKTRO 042006 DOC 04 06 O x Part 1 Part 2 Reference Break resistor Method Dist Coded Mark intern extern nem zi Timeaut 100 s resistor 18 0 Ohm v1 100 RPM mas temp 1200 07 PC dE 18 RPM therm resistor 03 IT Aa att a home A Revs th
9. 06 Inputs ENABLE must be connected by the user At HIGH level the output stage of the ACOPOS drive is enabled at LOW it is blocked This enable signal software enable is AND linked with the contact X 19 on the ACOPOS drive The motor can therefore also be disabled from the customer PLC The contact X1 9 at the ACOPOS drive is intended for connection to the EMERGENCY Stop circuit The following has to be taken into account for door circuits The ACOPOS drives are only switched off if the output Disable is HIGH Only then the lock of the doors may be opened The input Enable on the PLC alone does not meet the requirements of the regulations for EMERGENCY Stop and door circuits as it requires a functioning link CAN Bus between PLC and the ACOPOS drive functioning software and functioning connection to the output To obtain the full EMERGENCY Stop functionality the contact X1 9 at the ACOPOS drive or the power supply of the ACOPOS drive has to be interrupted If you do not require software enable input you can simply ignore this function UO Config write Enable is then only via the hardware input clamp X1 9 possible That can be helpful if you use only Profibus interface and you want running the indexer the first time by using the jog mode without pro bus master Some customers want to block the indexer after a step During the customer time load unloading the indexer they want to block the indexer to avoid
10. CF AR Orange SERVICE DIAG BOOT mode Green RUN Green with orange blinking RUN BATTERY LOW Profibus TX Orange Profibus Send data O CAN TX Orange CAN Send de 10 TO150 MEN ELEKTRO 042006 DOC 04 06 3 5 Battery Replacement The battery of the controller has to be replaced every 5 years to prevent data loss The control computer monitors the battery voltage and gives a warning digital output if the voltage drops The replacement of the battery may take place when the control computer is switched of or when the 24 V supply voltage is on In some countries changing batteries is not permitted if the operating voltage is on The data in RAM stored positions movement sequences zero position are lost when the battery is removed when the supply voltage is off Save the data in advance Windows Program gt Store parameters Procedure for battery replacement 1 2 3 Drain electrostatic charge at the top hat rail or the ground connection do not reach into the power supply Remove the cover for the Lithium battery with a screwdriver Pull on the pullout strip to remove the battery do not grip the battery with a pair of pliers or bare pincers gt short The battery may only be touched by hand at the front and backside Correct Wrong 4 Insert new battery with correct polarity Lift the pullout strip and push the battery with the side towards the left into the battery compa
11. OP xu P 9 ox arenis ale 9 9 9 Baltery ISeplacelmiBrit sss den oio co otia a ie 11 3 6 Windows Operating Hrogram nennen nennen enne nnne nnne nennen 12 3 1 Hand held DISpla ER 12 A ACOPOS e e ET 13 A a a E NS 13 le A A 14 4o Macnine Zero E Te EE 14 4 4 Installation of the ACOPOS drive nennen nnns 15 A MAGIC AVON S PREMIT 16 4 6 Power Mains Connechon 16 ETE bo CE 17 4 9 Conneccion Diagram EE 18 4 9 Secure Restart InblDIE EE 19 4 T0 Schematics TOL E SIOD out latet dal de 20 sueco NP E ES 25 5 Description of Ihe user Ie aC ent eset aceite ioco ee ee 27 9 1 OVerview OF Terminals een 27 9 2 Terminal DESC e TR BE 28 ooa LINDA O9 gl 0 E 34 PINCHO NOMS NO MIDS ee een ee ame 35 6 Fland neld DISplay ssi suede a 41 6 T 9tructurecanmnd oDelallObl su o Renee ido 41 o RR c 42 f VAMICOWS POD Mais o 43 A Program lnstallallon zes ee als 43 7 2 Operation 0 the Pro a a E E 45 een BT e 68 9 Error Codes and Troubleshooting nennen nnne nnns 75 TAM Ge Ee e a near eines 75 IL EMO MESSI idad 15 9 9 Reset ng Error Messages nn usa 76 9 4 List of the most frequent error reports ccccoocncccccncccccnccncnnnnonononannnonanonnnnnnnonnnonannnenanenes 76 10 Transport and Mile Ee E Le ee 17 JO Mice COPA O e A E Tf 10 2 IAS VAM AU ON a2 Sos Er 78 10 9 Mantena NCE ss en ee eiserne 78 11 5pare parts ond diens atto vem etie reo eni ite ces ese
12. TEST FU dion Et Insert PLC View Gphons Window Help i Djali e e Bl giel Sf gi wi Profile standard FFFIGFIBUSITE DP matie system 1 9 LED for receive sending Properties PRUPIBUS interface AL LA Genes Parameter Adhere E a address iaren ale 1 5 Mb HIGH Byte BES 315 24 LOW Byte Read in only after power ON Profibus plug E APTLY LL sns e Cl Sw ching Denise p RB SIMATIC 300 Insertion possibles TO150 MEN ELEKTRO 042006 DOC 04 06 37 6 Now define the inputs and outputs In this example 2Byte inputs 16Bit and 2Byte outputs 16Bit are defined The S7 software allocate a free UO address You can change it each time Rem If you want to send the actual and nominal positions of the axis in addition to the 16 bit inputs and outputs choose a telegram length of 10Byte HW Config SIMATIC 300 1 Configuration TEST_PB al Station Edit Insert PLC View Options Window Help 8 x Dee S Sale dli am gel wl xl Profle Standard zl KZ PROFIBUS DP Se 2 3 Additional Field Devices 3 33 1 0 AMES Gateway a PLC H A SIMATIC Egg AC14x Universal module Mark the corresponding module and modul Die modul Dis drag it into the left table PROFIBUS 1 DP master system 1 modul 02e modul_02a modul 10e R modul_10a modul 32e mo
13. are allocated Example 1 Input Enable is allocated to input No 1 nput 11 1 Example 2 Input Enable is allocated to the first bit of the Profibus message nput Bit 1 is I O Configuration K d l0 x Inputs Enable oia Move to Pos Cw abs 118 Step Cw nm Zero Pos 11 15 BitA 11 2 Move to Pos CCW abs 11 10 Step CCW 11 12 Release break Bit B 11 3 Move to Pos abs z Toggle Move to last Pos Bit C 11 4 Move to Pos rel z Jog Cw 11 13 Demo sequence D Bit D 115 Move to Pos CW Bus Jog COW 1114 Stop Bit E iz Move to Pos CC W Bus z Jog to Pos es Parameter 2 iz Bit F l Move to Pos Bus Store Pos 118 Search Home I Bit G z Sequence Alarm reset 11 16 Reserve OK Cancel TO150 MEN ELEKTRO 042006 DOC 04 06 45 5 In the category display you can set a password protection for the display w Hardware Configuration 10 x i ter for m Display Password 0 0 gt without Password Hide Page 11 Set Zero Pos Cancel The input field Set Zero Pos on the display picture No 11 which is used for the definition of the mechanical zero point can fades out completely so that set zero is only possible via the Windwosprogramm w Hardware Configuration 3 0 x sesesssssssssssssssn Indexer type ro 150 ABB 120 Config Comment max 31 sign
14. as follows Receive Byte 9 Byte 0 Digital inputs Bit 0 Bit15 Chapter 5 2 Byte 1 Digital inputs Bit16 Bit31 Chapter 5 2 Byte 2 Reserve Byte 3 Reserve Byte 4 Nominal position LO Byte Byte 5 Nominal position Byte 6 Nominal position Byte 7 Nominal position HI Byte Byte 8 Nominal speed LO Byte Byte 9 Nominal speed HI Byte Remark Nominal position This is the nominal position to which the axis moves when the command Move to Pos Bus is executed The nominal position is standardised to 0 001 i e a numerical value of 90000 is interpreted as 90 000 The valid numerical range is 0 359999 0 359 999 The byte order was selected to allow direct mapping of the 32 bit numerical value to a Bit Memory Double Word MDW or a double word in a Data Block e g DB7 DBD100 Re sorting of the byte order of the 32 bit value in the Siemens S is not required Nominal speed The speed 0 10096 for the command Move to Pos Bus is set here The value is standardised to 0 01 i e a numerical value of 10000 is interpreted as 100 00 Send Byte 9 Byte 0 Digital outputs BitO Bit15 Chapter 5 2 Byte 1 Digital outputs Bit16 Bit31 Chapter 5 2 Byte 2 Reserve Byte 3 Reserve Byte 4 Actual position LO Byte Byte 5 Actual position Byte 6 Actual position Byte 7 Actual position HI Byte Byte 8 Fault No LO Byte Byte 9 Fault No HI Byte Remark Actual position The value
15. command Move to Pos CW abs but no teached position number is used The target position and the maximum speed are provided on the Profibus Move to Pos CCW Bus As above direction of rotation is left CCW Move to Pos Bus As above The direction of rotation is selected to ensure that the axis moves the shortest way Special function If you set the three inputs Move to Pos CW Bus Move to Pos CCW Bus Move to Pos Bus together to HIGH the position in the Profibus telegram is interpreted as a relative position Sequence With the rising edge the Sequence No xxx the number is binary coded on the Inputs Bit A Bit G starts Only after all commands have been completed the output Ready to Start goes HIGH again This function is otherwise identical with Move to Pos Sequences with the numbers 1 10 are available The commands for the sequences are described in detail in the following chapter 30 TO150 MEN ELEKTRO 042006 DOC 04 06 Step CW This command produces one step of the indexing table in direction CW The rotation angle depends on the selected graduation see dialog box axis The inputs Bit A Bit G have depending of the configuration indexer steps in the dialog box axis as special function a mathematic calculated steps The inputs Bit A Bit G selected a position in the table teached positions The position in the table is used as an offset Example 1 4 steps Bit A Bit G g
16. for the actual position is standardised to 0 001 i e a numerical value of 90000 is interpreted as 90 000 40 TO150 MEN ELEKTRO 042006 DOC 04 06 6 Hand held Display It is possible to operate the indexer from a hand held display for simple applications To achieve the full functionality the Windows Program has to be used 6 1 Structure and operation NC Indexer V 0 2 3 Page 023 4500 maximum speed Enter button The buttons F5 F6 are used to page between screens The buttons F3 F4 buttons are used to increase decrease a numeric value During this process the value field flashes The value is first written into an intermediate buffer and then accepted with the button F2 Enter button After acceptance the value field stops blinking The button F1 is used to acknowledge error messages You ll find a summary of the error codes below in chapter 9 Brightness Brightness can be switched darkly by pressing the buttons F2 and F3 together Brightness can be switched lightly by pressing the buttons F2 and F4 together TO150 MEN ELEKTRO 042006 DOC 04 06 41 6 2 Input fields Screen No Function Operating message only display Alarm message only display Actual position only display Cycle time only display Search home 11 Set zero position 12 Jogging operation Step manual operation Start demo sequence Indexer type 21 Indexer graduation 22 Mass iner
17. the inputs X1 2 24V DC OK 24V supply of the inputs Me E 1 1 Parameterise through Windows Program lee E 1 2 Parameterise through Windows Program NI E 1 3 Parameterise through Windows Program x1 6 E 1 4 Parameterise through Windows Program xc E120 Parameterise through Windows Program K1 6 E 1 6 Parameterise through Windows Program Parameterise through Windows Program Outputs Terminal on Function Remark O extension CX408 24V supply of he outputs 24V supply of the outputs Parameterise through Windows Program Parameterise through Windows Program Parameterise through Windows Program Parameterise through Windows Program Parameterise through Windows Program Parameterise through Windows Program Parameterise through Windows Program Parameterise through Windows Program Parameterise through Windows Program TO150 MEN ELEKTRO 042006 DOC 04 06 27 5 2 Terminal Description The terminal allocation can be freely configured through the Windows Program As there are more functions than input terminals a selection must be made To allocate terminals the dialog box below is called from the Windows Program with Options 2 HW Config gt O_Config To set the parameters for a digital input output an entry such as E1 1 or A1 1 is required To allocate functions on the Profibus an entry such as Bit 1 is required Profibus and digital l Os can be mixed as required w Hardware Configuration l AO
18. to Pos Cw Bus kz Jog COW mm Stop 1112 Bit E hz Move to Pos CCW Bus Jog to Pos Parameter 2 I Bit F iz Move to Pos Bus Store Pos Search Home kz Bit G Sequence EN Alarm reset 1116 Reserve OK Cancel I O Configuration Outputs lolx Amplifier enabled G 1 1 Trigger Al Cami InPos 014 Amplifier disabled Trigger A2 Camz f Reserve Reference ok T gge A3 Camz Reserve Ready to Stat 01 2 Trigger 44 Cam Reeve Ero 01 3 Trigger Bi DD Cams Reeve Error flash Trigger B2 Cam Reserve Battery empty Trigger B3 Camz Reserve Tet Tigger B Cam8 Reserve DK Cancel Input 11 1 Input 11 2 E1 3 Input 11 8 E1 9 Input 11 10 E1 11 Input 11 12 Input 11 16 Input 11 7 Output Q1 1 Output Q1 2 Output Q1 3 Output Q1 4 Software enable This input must be HIGH otherwise no movement is possible Pointer to table teached position Start indexing left right with rising edge Move indexer in jog mode if input is HIGH Stop Input to interrupt movements Reset alarm Set zero pos with rising edge Feed back axis enabelt Ready to Start gt most important handshake signal Shows you that the old command is finished an
19. used Normally these inputs are LOW They are used in case of an product alternation Teach stations The positions are taken from the table Stored Positions Example You have 4 stations with 4 nests offset 10 Now the axis move with each step command to the following positions 0 0 10 0 20 0 30 0 gt station 1 nest 1 4 90 0 100 0 110 0 120 0 gt station 2 nest 1 4 180 0 190 0 200 0 210 0 gt station 3 nest 1 4 270 0 280 0 290 0 300 0 gt station 4 nest 1 4 You must preset 16 stations 4 station x 4 nests each station You can set the counter for the next position number with the command Move to Pos xxx e g after Power ON or after hand mode With reference search or set zero the counter is set to the first position With the inputs Bit A Bit G the initial position is shifted here the number build from Bit A Bit G is added to the value 1 gg 10 xl Stored Baan E Dx Patt Pat2 Pat3 Pata Pats Actual Pos 90 001 P Reference TRUE Motion r Inertia y Parameter 1 2 mur 0 00038 kg m og ESI pam m ee Fe Dx I ewl w acc 9000 4421 Rewe S Em 45000 lI 100 008 decel 800 0 4421 Rev s 2 o ndexer 120 000 pos window 0 000 7 0 000 ipo 010 Stations 0 000 C mathematic 0 000 Jog Mode from table 0 000 Parameter 1 2 ibis Np 1
20. 06 61 Dialog box axis advanced part 1 im Aris Part 2 Encoder encoder type encoder dir encoders type encoder dir encoder incr encoderz incr diff enc1 encz basic distance diff distance correct encoder Group General motor torque indexer torque 62 O x General motor torque 50 0 Mm Indexer torque 50 0 Mm Gear numerator denominator Cancel Maximum peak torque of the motor A limit of the peak torque reduce not reduce the effects appreciably in the case of a crash It has the disadvantage that the indexer becomes slower you have low acceleration torque Reason 1 Crash in full movement The rotational plate with the gigantic MTM has the most energy The motor energy is small Also the stop ramp becomes longer so that the opposite occurs gt longer brake distance 2 The indexing table has a great ratio of reduction e g 1 190 If we reduce the allowed torque momentum e g from 100Nm on to 20Nm we have up 3800Nm 190 20 at the output shaft The indexing times slowed down strongly If you reduce more the torque the indexer gets stuck in friction To reduce the effects of a crash the following steps are helpful Reduce the limit for following error Consequently a crash becomes are early detected Reduce maximum speed As a result the energy in motion is reduced strongly The influence on indexing time is smaller than a reduction of th
21. 0mA e al SWO0 C 24V Supply er gt 24V Pin 7 n c GND SW1 C 12 GND Pin 8 Data IF 3 IF 2 Pin 9 CNTRL Profibus CAN Bus X1 Eo EE EE OO GO OO e OOOO Ok EE EE Jj H Sec OD gg SS SS SS SS 58388555 208989588 ELN aifig22 g Bie Se Se 7 8 3 e AL wee E o 2 EE E Es c O 3 s Se 22 2 5 ge i A ge E c o q O E ue Vers Name Date V1 0 Erbacher M osos Indexer TO150ABB WEISS GmbH PLC digital I O Sondermaschinentechnik Siemensstra e 17 display 74722 Buchen Odw page 4 4 WEISS worldwide Head office WEISS GmbH Sondermaschinentechnik Siemensstra e 17 D 74722 Buchen Odw Tel 49 0 6281 5208 0 Fax 49 0 6281 5208 99 e Mail info weiss gmbh de www weiss gmbh de Germany States Th ringen Sachsen Sachsen Anhalt K hn GbR Sondermaschinentechnik G ttendorf 16 D 07957 Langenwetzendorf Th ringen Tel 49 0 36625 20371 Fax 49 0 36625 31025 e Mail info kuehn somatech de www kuehn somatech de worldwide Austria ASP Automationstechnik Ing Walter Prenner Dammgasse 13 A 7111 Parndorf Tel 43 0 2166 2461 Fax 43 0 2166 2762 e Mail prenner asp1 at www asp1 de Buro Sud ASP Automationstechnik Ing Walter Schweighofer G m b H Oberfeistritz 79 A 8184 Anger bei Weiz Tel 43 0 3175 3339 0 Fax 43 0 3175 3339 39 e Mail office asp qmbh at www asp gmbh at Belgium A T B n v s a Bas
22. 100000024 digital inputs W2 Encoder line w1 M Motor line 563 200000010 mains connection TO150 MEN ELEKTRO 042006 DOC 04 06 3 2 Naming TO 150 J A JB B type motor coil TO diameter encoder xxxx mm design 3 3 ACOPOS drive WEISS provides a suitable drive for the control of the motor It has its own intelligence for the control of rotation speed and position loop Two plug in cards are inserted into the ACOPOS drive controller AC140 and encoder interface AC 120 The ACOPOS drive communicates through the CAN Bus with separate digital I O The requirements for the CAN Bus cabling have to be adhered to terminating resistors at both ends of the CAN Bus Newest technique for emergency stops quick stop ramp and also a secure restart inhibit category 3 are integrated Surplus brake energy can be transferred to an internal brake resistor 3 4 Controller The controller AC140 is a convenient interface between the customer interface and the ACOPOS drive It provides the required movement commands at the correct time and converts the preselected position values of degree into motor increments The operation for standard tasks indexing table with fixed graduation is performed with a hand held display A Windows Program is available to use the full scope of the software It is connected to the controller through a serial interface RS 232 The RS 232 interface is also used for debugging and remote maint
23. 20 964KB win 19 02 03 16 57 Edu Profibus zl Disk1 id IKB Date 12 11 97 09 05 E E Setup bmp 206 KB Irfan 06 03 02 10 30 PO Setup exe ANKER Ap IE IE 13 04 5C Utes El Setup in 1KB Kont 2510001019 ei 5 win prag Ge en au Weser 1B4KB Einst 17 02 03 16 15 B g Projekte auf Ws srv3 07 la setup pkg 24KB Date 19 02 03 16 57 a a2 Allgemein sit Ws T Me Setup b bmp 1 04 KB Iran 06 03 02 10 39 13 Toms 22 2 MB Freier Speicher O Bote Arbeitsplatz E TO150 MEN ELEKTRO 042006 DOC 04 06 43 Installation of the Windows Program On the CD ROM in the directory Win Prog start the file setup exe EJ Explorer E Xwin prog Datei Bearbeiten Ansicht Wedhseln zu Favoriten Extras 7 Zuruck Mmes Aufw rts Ausschneiden Kopieren Einfugen Huckgangig Loschen Eigenschaften GG Desktop program files Dateiordner 08 04 03 12 03 E B Arbeitsplatz Systems D ateierdner 08 04 03 12 03 H 2 el 3 5 Diskethe L El aes Ini DER Konfigurationzer 07 04 02 12 31 Deal A A KR Konfigurationsei 01 04 02 12 32 FEB Konfigurationzer 01 04 02 12 32 FEB Konfigurationzer 01 04 02 12 33 FEB Konfigurationzer 01 04 02 12 33 DER Konfigurationzer 01 04 02 12 34 2 1031 mst SIEB Date MST 08 04 03 11 48 e 1033 mst AER Date MST 08 04 03 11 48 e 1034 mst 23 KB Datei MST 04 04 03 11 48 e 1036 mst 30 KB Datei MST 04 04 03 11 48 Eg Benutzer auf Weiss server P la 1040 met 30 KB Datei MST 04 04 03 11 48 Eg Proj
24. 4V supply GND display Profibus outputs 24V 24V supply GND w i a KI LJ gt LJ P wi P X3 encoder inputs 24V RS232 Vers Name Date V1 0 Erbacher M 100308 Indexer TO150ABB WEISS GmbH overview Sondermaschinentechnik Siemensstra e 17 74722 Buchen Odw block diagram page 1 4 ACOPOS 1022 Slot Slot2 Saz Slot4 LI CLIE a ii PLC Encoder AC140 AC120 Vers Name Date V 1 0 Erbacher M 10 03 06 Indexer TO150ABB WEISS ambu Sondermaschinentechnik Siemensstra e 17 74722 Buchen Odw motor connection page 2 4 10A TN 5 time delay min 4 x 2 5mm L 1 3 x 400 480 VAC L2 50 60 Hz L3 gt lt DC1 N DC2 Ls D Trigger 1 mm Quickstop e COM 1 2 Shield zO Ze Limit switch ACO POS 530 G Limit switch Reference switch 1 022 enable Enable 24V Enable mO COM 8 9 g COM 8 9 6A KR time delay SE id 24V zO 24V DAY 50 24V supply Fi COM 5 7 13 15 mO COM 5 7 13 15 GND o zS m COM 5 7 13 15 xi sm M TEXTE Indexer TO1 50ABB WEISS Gm
25. 7 Cam 8 Lam 1 ESI position invert output 20 000 TI AMD lt 30 000 In the example above the output goes HIGH if the axis is in the range between 20 0 30 0 The cams are always calculated even when the axis is moved in jogging operation or if the axis is disabled and the indexer is turned by hand 7 2 8 Alarm History Up to 20 error messages can be displayed in the alarm history If the PLC clock has been set a time stamp is provided as well w Alarm History E Ol xl 10 05 05 2003 15 38 06 40 Value of parameter higher than maximum value 32 05 05 2003 15 37 21 Timeout Mov 05 7 wm co Mm cm Fe GO A 10 The values in brackets provide an accurate description of the error message The WEISS Service evaluates this information Fault No 10 concern error messages of the ACOPOS drive The error number of the ACOPOS drive as well as plain text information are provided in the alarm text 54 TO150 MEN ELEKTRO 042006 DOC 04 06 7 2 9 Axis Important axis settings can be set under the menu entry Options gt Axis Due to the large number of setting the dialog box is split into five parts For the customer only part 1 is important In the menu options gt axis advanced you ll find more settings Some of this only enabelt for WEISS service technicians Motion Parameter 1 2 0 050 kg n max speed 100 0 60 0 RPM EE 0 000 Kg me accel ER 35 Revs load 1 0
26. 70 AB Barneveld Tel 31 0 342 403230 Fax 31 0 342 403290 e Mail j morren radine nl www radine nl Norway Stang Maskin AS Olav Brunborgsv 27 N 1361 Billingstad Tel 47 0 66 848069 Fax 47 0 66 848122 e Mail post stang maskin no www stang maskin no Poland IGIS Automatyzacja Sp z 0 0 ul T KoSciuszki 16 PL 42 300 Myszk w Tel 48 0 12 278 12 96 Fax 48 0 12 278 12 97 e Mail igis automatyzacja info neostrada pl www igis com pl Singapore Thailand Ultra Industrial Automation PTE LTD Jacky Tan General Manager Blk 30 Loyang Way 05 20 Loyang Industrial Estate Singapore 508769 Phone 65 6549 7918 Fax 65 6549 7919 e Mail jacky tan uia com sg www uia com sg Slovenija VIAL Automation doo Gregorciceva 2 SI 3310 Zalec Tel 386 0 3 713 27 90 Fax 386 0 3 713 27 94 e Mail info vial automation si www vial automation si Spain Weiss Espa a Tecnolog a en m quinas especiales S L C D maso Alonso 22 28806 Alcal de Henares Madrid Phone 34 91 882 26 23 Fax 34 91 882 82 01 e Mail info weiss gmbh es www weiss gmbh es Sweden Bellows Automatik Produkter AB Hantverkarvagen 2 S 14502 Norsborg Tel 46 0 853 470 280 Fax 46 0 853 470 299 e Mail sven dahlqvist bellows se Switzerland LIMATEC Automation AG Burgunderstrasse 13 CH 4562 Biberist Tel 41 0 32 654 29 00 Fax 41 0 32 654 29 01 e Mail office
27. Battery empty I Trigger B3 Camz Reserve I Test Trigger B4 7 Camp Reserve D Force Outputs Cancel With rising edge at input toggle you ll make alternate steps between 0 0 and 180 0 If a command will be interrupted E Stop or alarm the movement will be continued with a new toggle command This means the direction will be changed only if the final position 0 0 or 180 09 is reached 74 TO150 MEN ELEKTRO 042006 DOC 04 06 9 Error Codes and Troubleshooting 9 1 Error Codes When an error occurs the output Error is set In the Windows Program the error number and a clear text message are displayed In addition two more parameters that may be useful for error finding are shown in brackets Parameter 1 Program position Step No in the PLC program Parameter 2 Additional information e g error message of the drive 9 2 Error messages Initaxs Fault during initialisation Possible reasons during initialisation Possible reasons CAN connection to ACOPOS drive faulty 24V control voltage to ACOPOS drive not present 2 Timeout network init A fault occurred during the initialisation phase 1 network init DIP switch must be 0 A at AC140 CAN connection to ACOPOS drive faulty 24V control voltage to ACOPOS drive not present 8 CAN I O missing CAN Module CX408 missing no connection O Zeroposiionlost 2 Checksum Battery RAM after PowerON w
28. C 55 C 40 F 130 F Be Operation 15 C 35 C 60 F 95 F Stall Peak torque 20 0 50 Nm Temperature monitoring KTY Sensor 2 1 3 Encoder AMO Type WMI 200 Power Supply 5V 5 260mA Output signal 1 Vpp Absolute accuracy 35 0 01 with correction table Encoder Mechanic Distance coded marks Permitted temperature ranges Storage 20 C 85 C 4 F 185 F Operation 0 C 50 C 32 F 104 F 6 TO150 MEN ELEKTRO 042006 DOC 04 06 2 2 Electrical connection 24 Volt control voltage 20 28V DC residual ripple 10 96 Power input 24 Volt ACOPOS drive PLC Display 0 3A typical 2 0A max please use fuse 6A time delay Digital inputs Level LOW OV 4 V HIGH 15V 30 V Input current approx 4 mA at 24 V Input filter Digital outputs max 0 5 A per output Profibus Profibus DP Slave lt 12 Mbit floating TO150 MEN ELEKTRO 042006 DOC 04 06 3 Structure 3 1 Overview The system consists of the following modules Mechanics ACOPOS drive Cable set W1 W2 W3 W10 W11 W20 Option Digital I O Option Display Inputs of the drive Enable Emergency stop Option Quick Stop BER 24V supply m ACCPOS 1090 W11 563 200000017 563 200000015 or 563 200000016 E Profibus digital outputs W10 CAN Bus Option Digital I O 563 200000060 563 200000064 563 100000020 563
29. EF PROFIBUS DP 2 Additional Field Devices oC Closed Loop Controller Eg Configured Stations H CP 342 5 as DP Master Bg DP AS4 oC DP PA Link mg ENCODER mg ET 2008 mg ET 200 mg ET 200L o ET 200M Bg ET 2005 mg ET 200U mg ET 200 CC Function Modules BH IDENT EH IPC Be NC BMC SIMADYN BM SIMATIC Eg SIMODRIVE Bg SIMOREG EM SIMOVERT mg SIPOS BMC Switching Devices mH SIMATIC 300 cH SIMATIC 400 H E SIMATIC PC Based Control 300 400 o BR SIMATIC PC Station Install New GSE Import Station GSE Te Field devices defined via device database files as DP slaves Ey Installs new GSE files in the system and updates the contenfk of the catalog El Installing new GSE ki E3 Eigene Dateien Rem Y Arbeitsplatz s SYSTEM IC 2 CD Laufwerk D c Profibus Tat Se Wechseldatentraler E e projekte auf ws sPv3 Q allgemein auf ws srv3 T Ze allgemein auf weiss server W t4 Netzwerkumgebung Abb st rechen in the folder Installing new GSE Suchen in Bay O6e6 gsd Dateiname B amp Det gsd Dateityp GSE files gs y Abbrechen You ll find the GSE file at the CD ROM Profibus Ac14x 36 TO150 MEN ELEKTRO 042006 DOC 04 06 4 Now find in the hardware catalog under PROFIBUS DP Additional Field Devices PLC the imported file for the Profibus interface AC140 Mark it a
30. Indexer type To 150 ABB DI 120 Config Comment max 31 signs Comment I Example Use of digital I Os i I O Configuration O x Inputs Enable ial Move to Pos Cw abs 113 Bit A na Move to Pos CCW abs 11 10 Move to Pos abs Move to Pos rel ES Bit D 11 5 Move to Pos Cw Bus mz Bit E Zz Move to Pos CCW Bus Bit F oo Move to Pos Bus Zz Bit G Sequence Bit B 11 3 Bit C 11 4 Step Cw mm Step CEW 1112 Toggle Jog CW 1113 Jog CCW 11 14 Jog to Pos Po Store Pos 118 Alarm reset 11 16 Zero Pos 11 15 Release break Move to last Pos Demo sequence en Stop Parameter 2 Search Home Reserve i I O Configuration Dutputs Amplifier enabled 011 Trigger A1 Amplifier disabled Trigger 2 Reference ok Zz Trigger_A3 Ready to Start 01 2 Trigger A4 mz Error 013 Trigger_B1 Zz Error flash Zz Trigger_B2 Battery empty Trigge_B3 Test Trigger_B4 Cam Cam2 Camz Cam Cams Cam amp Camz Cam8 InPos 014 Reserve Reserve Reserve Reserve Reserve Reserve Reserve 28 OK Cancel TO150 MEN ELEKTRO 042006 DOC 04
31. MEN ELEKTRO 042006 DOC 04 06 7 2 5 Demo Sequence The demo sequence works similar to the normal sequence Difference At the end of the sequence the system jumps automatically to command 1 The demo sequence is used for presentations and for startup to run in the system m Demo Sequence E Ol x PL PLE shore Stark load Stop Sequence Cycle time 28 Reference TRUE Step Ha leed Un E duck Stap du Quit Override Override 100 00 The fields in detail 1 2 3 Cycle time Movement time Step No Displays the currently active step Override Refers to the overall speed override i e all speeds are multiplied with this factor 0 01 100 00 PC gt PLC Stores the demo sequence in the PLC Start Starts a demo sequence Stop The system stops after the last command Quick Stop The system stops immediately Quit Acknowledge fault Store The demo sequence is stored on the hard disk of the PC 10 Load A demo sequence is loaded from the hard disk of the PC It must then be stored with the button PC gt PLC O co 4o00 gt TO150 MEN ELEKTRO 042006 DOC 04 06 53 Other dialog boxes under the menu entry Options 7 2 7 Cams Up to 8 software cams can be defined The output is provided at the outputs Cam 1 Cam 8 see HW Config l O Config i amp l xi Cam 1 Cam 2 Cam 3 Cam 4 Cam 5 Cam 6 Cam
32. Note By defining the indexer type as well as the mass inertia the upper limit is automatically set Configuration External brake resistor present yes no Switching is only possible when the drive has been disabled axis disabled e g by Emergency Off etc The language of the hand held display can be set here TO150 MEN ELEKTRO 042006 DOC 04 06 7 Windows Program 7 1 Program Installation The programs were developed in Microsoft Visual Studio and require an up to date computer for installation Windows 95 or newer Internet Explorer 5 5 or newer due to the installed drivers Please make sure to read the Readme file on the CD ROM Procedure The installation of the Windows Program is performed in two steps Installation of the PVI monitor for communication between the ACOPOS drive and the Windows computer Installation of the program NC Indexer BR EXE Installation of the PVI monitor On the supplied CD ROM in the directory PVI Eng start the file Setup exe Kopieren Ausschneiden Fa Einf gen Huckgangig X Loschen Zuruck Wintel ts Adresse EAPV Ger Ordner Z Desktop wm Inst22iex 313KB Date 05 11 96 16 17 E B Arbeitsplatz 7 IsDel ese ORB Anw 07 03 35 13 22 Es 2 5 Diskette D sl _Setup dil 10KB Prog 13 12 01 10 37 H C jm _ setup lib 909KB Date 19 02 03 16 57 ES E CO BrSetup z 39KB win 1802 03 16 55 a Docu O Data z
33. Numeric controlled indexing tables Series TO150A Operating Instructions We reserve the right to change the content of this documentation without prior notification The WEISS GmbH is not responsible for technical and printing faults in this documentation and accepts no liability for damages that result directly or indirectly from its delivery provision or usage Windows and Windows NT are registered trademarks of Microsoft Corporation entered in the USA and or other countries Simatic STEP7 and S7 are registered trademarks of Siemens AG The pictures of chapter 5 4 Including the Profibus are make with friendly permission of Siemens AG Department Automation amp Drives N rnberg This documentation is protected by copyright Copying in whole or in part is not permitted without prior written permission of WEISS GmbH Status April 2006 Copyright WEISS GmbH Sondermaschinentechnik Siemensstra e 17 D 74722 Buchen Odw Germany Tel 49 0 6281 5208 0 Internet www weiss gmbh de TO150 MEN ELEKTRO 042006 DOC 04 06 Table of contents Sato y Regulations s odio iuret orbes oa boss ID Selen 4 1 1 Safety and application notes bau 4 22 FechnicalDala 222 222 P C 6 2 IRI rss Hr 6 Er er Er aie 8 MEO i ees ae 8 3 2 cado RI L H 9 OPAC
34. OFF Trigger B32ON OFF Trigger BAZON OFF End TO150 MEN ELEKTRO 042006 DOC 04 06 51 The commands in detail Move to Pos CW abs The indexer moves to the teached position number xx with absolute coordinates The rotation direction is right CW The position number is the value in the column Option i Sequence B nBl x Sequence PC PLE Sequence No 1 C Eommand o E Move to Pos CCW abs As above The rotation direction is left CCW Move to Pos optim abs As above The rotation direction is selected to ensure that the axis moves the shortest way Move to Pos rel As above only the position is interpreted as relative position Step CW The indexer performs one step i e it moves to the next graduation position Rotation direction is right CW Step CW As above Direction of rotation is left CCW Wait time A waiting period is inserted The numerical value in the column Option specifies the waiting time in milliseconds Trigger A B ON OFF The respective trigger output is set deleted Trigger outputs of the Group A are automatically set to LOW after completion or termination through fault Emergency Stop Triggers of Group B are retained End End of sequence Finally do not forget to save the sequence on the PLC with the button PC PLC m Sequence 3 E B x Sequence Sequence Ma 1 TI Gd a Command 3 wait time ms 250 52 TO150
35. activate the system and prevent unexpected re operation This corresponds to Safety Category 3 according to EN 954 1 In addition to preventing unexpected re operation according to EN 1037 this safety installation also provides the stop functions of the Categories O and 1 required by EN 60204 1 This is described in a separate chapter in these operating instructions Chapter 4 9 The instructions in the chapter must be adhered to A wiring diagram is also provided in this document TO150 MEN ELEKTRO 042006 DOC 04 06 5 2 Technical Data 2 1 General data 2 1 1 ACOPOS drive ACOPOS 8V1022 00 2 Permitted temperature ranges Storage 25 C 55 C 13 F 131 F Operation 0 C 40 C 32 F 104 F vertical Airhumdity Air humidity 0 5 to 9596 not condensing 3 x 400 VAC to 480VAC 10 48Hz to 62Hz mains filter according to EN 61800 3 A11 second environment Installed load can max 3kKVA e power without brake resistor According to EG Guideline 89 336 EWG Applied harmonised standards EN 61800 3 Noise resistance EN 550011 Class B Noise emission Low voltage guideline According to EG Guideline 73 23 EWG Applied harmonised standards EN60204 1 VDE113 EN50178 VDE160 Protection according to IP 20 IEC 60529 C UL US listed Dimensions Width 70 5mm Height 375mm Depth 236mm Weight 4 0 kg 2 1 2 Motor Protection according to IP 20 Permitted temperature ranges Storage 5
36. ation concerning the connected hardware as well as the operating system of the PLC and the ACOPOS drive is provided TO150 MEN ELEKTRO 042006 DOC 04 06 67 8 Program example Detailed program example This chapter provides a detailed program example The example uses a controller with digital l Os The Profibus version works similar Procedure 1 Hardware configuration Supply device with 24V Establish PC gt PLC connection lt 32 NC Indexer 0 2 4 File Program Options Test Help Zu o 2 99 Sim 9 The PLC was recognised at the interface COM 1 the connection is established 2NC Indexer Y0 2 4 File Program Options Test Help SN od Rit ae Ad The connection PC lt gt PLC was established The system can be addressed through the Windows Program Wat for Command 68 TO150 MEN ELEKTRO 042006 DOC 04 06 First the type of the connected indexer has to be entered BCE A Comment Indexer type TO 150 ABB v 1 0 Config Comment max 31 signs m Apply Cancel Then the inputs and outputs are allocated w 1 0 Configuration 10 x Inputs Enable 111 Move to Pos Cw abs Step Cw 118 Zero Pos D Bit A 11 2 Move to Pos CCW abs Step CCw ns Release break zz Bit B 11 3 Move to Pos abs I Toggle ges Move to last Pos z Bit C Bm Move to Pos rel Jog Cw 11 10 Demo sequence EN Bit D Move
37. bH main power X1 plug Sondermaschinentechnik Siemensstra e 17 74722 Buchen Odw page 3 4 CAN Adresse SWO0 D 1 i SW1 D Display i ACOI OS X1 1022 F1 F2 F3 Fa F5 F brown DON e 24V display supply i GND X1 16 eia Ri cs p 3 E E m g S 0 arabe a 5 2 8 2 E i 2259525 i i 5 E i S ZE oO e DEN osos rs EAZ R i PLC SAA es a EE uu AC140 D Oi OO Y 9 010 O OO 9 10 0 1909 9 Q O Os Os Os Os O o O O94 9A 2 3 4 945 A 7 Be Eso Ebo bom X2 X3 Profibus high CAN address address N A OAhex digital I O ll ES EA Term S CX408 CAN H C Ow red mark CAN_GND O Pin 1 Shield v CAN L Ox Pin 2 nc eb HEN Shield O i Pin 3 DATA O O cav n o gt gen e sol fee By CAN GND o ge Pin 4 CNTRL O O O O CAN L oTe lt y Pin 5 Profibus GND O o9 CAN Adresse Shield oa lt Pin 6 5V B
38. bled before opening the contacts and the motor current is interrupted switching the contacts without power A quick start required when using a light curtain is possible The TO indexer has no break So he spins out TO150 MEN ELEKTRO 042006 DOC 04 06 21 Example 3a Interrupt clamp X1 9 at ACOPOS drive x HO Trigger 1 70 Quickstop miO Le COM 1 2 HO Shield ACOPOS i Limit switch E Stop i AS m Limt switch 24V 439 Reference switch 439 Enable XY a Enable 9 COM 8 9 19 COM 8 9 9 fe n c ES n c 24V HO c 24V ndo H 24V HO fe COM 5 7 13 15 if COM 5 7 13 15 GND 4 9 COM 5 7 13 15 bete scd aec Slot 1 Slot2 Slot3 Slot4 1 Safety considerations Please see chapter 4 9 secure restart inhibit For frequent switching no switch on interval Wear resistant A quick start required when using a light curtain is possible Meets the requirements 3 of EN 954 1 secure restart inhibit safety category 0 1 2 Motor clamps U V W can also lead tension after shutdown of clamp X1 9 Electric works on the indexer are not allowed You have to interrupt the main power You ll find further information in the ACOPOS user s manual see File ACOPOS men pdf on added CDROM chapter 5 1 2 page 126 The TO indexer has no break So he spins
39. d a new command will be accept Alarm message Additional position windows InPos TO150 MEN ELEKTRO 042006 DOC 04 06 69 This configuration is then stored in the PLC GER mM Indexer type ro 150 ABB 170 Config Comment max 31 signs Comment The button Apply stores all the information in the PLC The following question appears Restart PLE EE xj The values become effective First after a new PLC restart Abbrechen After a restart the changed configuration is active 2 Settings in dialog box Options gt Axis ES Motion r Inertia Parameter 1 2 OL 0 050 kg m max speed 100 0 60 0 RPM indexer e accel 7 0 35 me Indexer in pos 0100 P Stations Parameter 1 2 v start 05 05 RPM E An 100 559 RPM tabele No a stop 70 50 Revs r Override factor 103 103 Override 10000 4 With the specification of the load mass inertia the maximum acceleration will be calculated new Specify the number of steps E g 4 steps per round gt you ll got the angle 0 0 90 0 180 0 270 0 Specify pos window 0 000 gt defines the end of the move command gt Output Read to Start Specify in pos 0 1 A second position window will be calculated who com
40. d with the output Ready to Start As soon as this output is HIGH the signal Move to Pos is accepted As soon as this command is accepted the output Ready to Start goes LOW Now the Move to Pos input must become LOW As soon as the axis has reached the position window the output Ready to Start goes HIGH again and a new start command can be accepted see timing diagram at the end of the chapter The position number O has a special function The user has therefore positions 1 127 freely available For each of these 127 positions an individual speed override can be set through the Windows Program These preset values are then multiplied with the general speed override 0 100 If an invalid position number is provided or the position has not yet been teached an error message occurs Special function A reference run is started by providing the Position Number 0 and the command Move to Pos only for indexer without an absolute encoder Move to Pos CCW abs As above direction of rotation is left CCW Move to Pos abs As above The direction of rotation is selected to ensure that the axis moves the shortest way Move to Pos rel This command is similar to the command above However the position values teached are here interpreted as relative values The position number 0 is here invalid Example Current position 45 0 Teached position 10 0 gt The axis moves to 55 0 Move to Pos CW Bus Like the
41. delivered model of the indexing table is attached as appendix to the delivery documents The list is also attached to the operating instructions To prevent misunderstandings in connection with the order of spare parts please include always the following data in your spare parts order O Item number according to WEISS name plate on the indexing table O Order number of the spare part according to the list of spare parts O Number of parts Please send your spare parts order to WEISS GmbH Sondermaschinentechnik Siemensstra e 17 D 74722 Buchen Odw Germany Tel 49 0 6281 5208 0 Fax 49 0 6281 9150 E mail service weiss gmbh de Internet http www weiss gmbh de All addresses of agents are available on the internet TO150 MEN ELEKTRO 042006 DOC 04 06 79 12 Disposal and Recycling 12 1 Disposal and Recycling A indexing table that cannot be used anymore may not be disposed of as a complete unit N WARNING The oil in the indexing table has to be drained before the table is disassembled and has to be delivered to an authorised oil collection place for environmentally compatible disposal Thereafter the indexing table has to be disassembled The individual parts have to be recycled according to their type Materials that cannot be recycled have to be disposed of according to their type Information concerning disposal and collection point is available from your local authorities The relevant national and regiona
42. dul 32a modul 54e modul 54a ER Compatible PROFIBUS DP Slaves 3 Closed Loop Controller 3 Configured Stations 3 CP 342 5 as DP Master 3 DP AS i E DP PA Link 4 ENCODER 3 ET 2008 3 ET 200 I ET 200L I ET 200M 33 ET 2005 3 ET 200U CH ET 200 3 Function Modules 1 acis Slot 9 Module Order number Addre e IN E TN Wan FR SE CES l ana FA ee FA ceo e en e co ro eo zech i onl N per n p cz x I t eee a BR ep ed a BE RR e ee n RR zi D Insertion possible Chg HW Config SIMATIC 300 1 Configuration TEST_PB al Station Edit Insert PLC View Options Window Help 18 x pelse al He dh Clg ei vi x Profile Standard DI BIS nk PROFIBUS DP PROFIBUS 1 DP master system 1 Additional Field Devices 2 09 1 0 1 AC14 SC Gateway naci 4 To get data consistency please use xz H E SIMATIC Universal module Egg ACT4x Id Universal module modul Die modul Dia modul 2e e modul 02a D F F F F Id modul 10e F F F E modul_10a modul_32e modul_32a The S7 software allocate a free 1 acus Slot 4 Module Order number F l Address D Address Womment modul 02e EI modul 2a 0 UO addre
43. e First initiation 2 Possibilities Alarm 1 O CX408 not found a at CX408 module for line termination resistor are not CAN adapter with double side DSUB defect internal wrong wired First initiation Open dialog box I O Monitor Watch inputs Software Enable and Enable at ACOPOS clamp X1 9 Sometimes the customer forget wiring clamp X1 10 and X1 3 at ACOPOS These clamps must connected to GND The inputs X1 2 Quickstop and X1 9 Enable are galvanic isolated So you need a separate GND wiring m MEN You defined digital input outputs e g 11 1 Q1 4 in dialog box EES l O config and no CX408 is wired f you use Profibus change the l O config to e g Bit 1 Bit 4 If you disconnect the display from CAN bus the CAN bus between drive and I O module did not work correct motor will interrupt and you got the alarm Jumper for line termination at CX408 module are not wired CAN I O CX408 missing Sporadic alarm Motor Encoder Wrong indexing type defined Display did not work Axis are disabelt Enable not possible Pin in motor plug are moved back If the round motor plugs are not mounted correct the pins inside the plug are moved back Switch of main power and check motor plugs encoder plug Sporadic Encoder Alarm If the motor and encoder line is much too long and you make a coil you ll got problems T m The right DIP switch at the AC140 slot PLC must be 0 A NE Perhaps
44. e ACOPOS drives are switched on The ACOPOS drive are allowed to be operated directly on grounded three phase industrial mains TN TT systems Control and power connections may be live even if the motor is standing still Never remove or plug the electrical connections of the system when they are live All pluggable connections should only be connected or disconnected when power is off Wait at least 5 minutes after the system has been switched off before touching live parts or disconnecting connections All supply voltages connected to the system have to be safely separated from the power mains Appropriate usage This system is intended for industrial and professional plants and complies with current standards and regulations All information concerning technical data and the permitted conditions at the site of installation has to be adhered to at all times This system is a component to be installed in machines The initial operation start of the appropriate use in prohibited until it has been established that the machine complies with the EMC Guideline 89 336 EWG and that the final product complies with the Machine Guideline 98 37 EG Transport and storage The systems have to be protected from inappropriate exposure mechanical load temperature humidity aggressive atmosphere during transport and storage EMERGENCY STOP The contact Enable at the ACOPOS drive contact X1 9 is implemented as a secure restart inhibit to de
45. e of the Windows Program can be set The following languages are available English German French Italian Spanish in preparation Dutch in preparation 64 TO150 MEN ELEKTRO 042006 DOC 04 06 7 2 11 Manual Mode only output fields w Manual Mode Actual Position 60 000 Enable speed override Enable Disable fe Enabeld Override 10000 Disabeld i DES Ee pum Axis moves with jog speed until these keys are pressed Step Togge 4 Jog Q CO Q Axis makes a step in accordance with the preset Stations Position Diae C left C right optim By pressing the START bottom the axis move to the present position Possibilities left right optimized way Position abs Angle 0 000 D rel means a relative position In the dialog box manual mode some important control elements are summarized for manual operation TO150 MEN ELEKTRO 042006 DOC 04 06 65 Other dialog boxes under the menu entry File 7 2 12 Store Parameters This menu item is used to read all data from the ACOPOS drive and to store them on the hard disk in a file similar to a ini file This has the following purpose The customer can save document the delivery status of the machine Support for problems If problems occur during startup it
46. e start stop ramp Max permitted torque of the gearbox motor side TO150 MEN ELEKTRO 042006 DOC 04 06 Group Encoder Setting of encoder type and direction These settings are configured automatically by definition of an indexer type in dialog box hw config The customer can change only the direction Normally it is set that you got increased position values if the indexer turns in right direction Diff Enc1 Enc2 Maximum difference between encoder 1 motor encoder and encoder 2 encoder at gear The difference between these two encoders are monitored If the limit is exceed belt or coupling broken e g the system will generate an alarm So this value must be lager then the elasticity of the mechanic Group Gear The gear ratio will be automatic set when you select an indexer type dialog box hw config Dialog box axis advanced part 2 m Axis Part 2 O x Find Motor Phase simulation Method G eluctance ACOPOS type Current 302 switch frequency Commutate 0 0 phase monitoring E motorkemp sensor Cancel Simulation The drive can be switched into a simulation mode so that it can be operated without motor Phase monitoring The drive monitors all three main lines L1 L2 L3 You can disable this monitoring Default is on TO150 MEN ELEKTRO 042006 DOC 04 06 63 7 2 10 Options E ini xl Language English Level E User M Cancel The languag
47. ed 16 TO150 MEN ELEKTRO 042006 DOC 04 06 4 7 External I O If the bus interface Profibus is not used an external I O module can be connected It has 16 inputs and 16 outputs with 24 V 250 mA It is suited for DIN rail mounting as well as for direct attachment with screws It can be connected to the ACOPOS drive through a CAN Bus Dimensions Depth 60mm 80mm DIN rail Operating elements 24V supply outputs Output 1 16 Status LED Green Normal operation Green flash Start up ges T Red RESET pe Red flash node number wrong geg Orange Faulty output oc OUTPUT gavoo 120 44 4x24 max oA Orange flash Supply outputs Bice ben oed UC i ag a 1 Hr E se i y is H B8 70 T TZ 13 174 15 16 I O Monitor The button Select switched between display of the inputs green and outputs red 3 Bridge Terminating resistor for CAN Bus j P CANH i GAN G i CAN Rotary switch CAN Bus Pr CAMH Se of the CAN address al CANG lt q Cable w10 SWO C e mvc oc INPUT esvoo amaj 0K 123456765901 12 0 34 15 36 E Der PI iu WW he zp li gt GND DC OK 24V Input 1 16 24V supply inputs TO150 MEN ELEKTRO 042006 DOC 04 06 17 4 8 Connection Diagram Q1 L1 3 400 480VAC L2 50 60 Hz L3 ee das nad cir EE ea A T met laedi reos ac abere 229220 O pg ZELLE y
48. ed 79 e ee 79 UE RI le Eiere Recycling seta 80 12 1 Disp sal and Recycling use ea 80 Ei Ao 81 TO150 MEN ELEKTRO 042006 DOC 04 06 1 Safety Regulations 1 1 Safety and application notes The operating instructions should be read carefully before initial operation The initial operation of the indexing table may only take place once the total system and control especially the safety system comply with the Machine Guideline 98 37 EG Before adjustment or maintenance work the power supply to the motor has to be switched off and the motor has to be protected against re start To protect the operators from crushing by the mechanical system during normal operation appropriate protective devices such as protective grids covers light barriers or step sensors have to be installed Any work such as transport storage installation initial operation and service of the control system and the mechanical system may only be performed by trained expert staff Trained expert staff consists of persons that have the appropriate qualifications and are familiar with performing the aforementioned work and the operation of the product The national accident prevention regulations have to be adhered to The safety guidelines connection descriptions in the technical data and the documentation are to be read carefully before installation and commissioning must be observed Unauthorized removal of the required covers inapprop
49. ekte auf wie spei IO e 1043 mst 3 U KB Datei MST 08 04 03 11 48 El Allgemein auf ws srv3 T a instmsla exe 1 669 KB Anwendung 11 03 02 03 45 3 Allgemein auf Weiss server b i Fl instmziw exe 1 780 KB Anwendung 11 03 02 10 06 El Xal auf ws dbs bi i isscript mel HI Z ED Windows Install 28 05 02 13 13 Drucker i HL Indexer BR msi 7 267 KB Windows Install 06 04 03 11 48 fu Systemsteuerung ei setup exe ZU0 KB Anwendun 8 04 03 11 48 a DFII Metzwerk E Setup ir 2EB Konfigurationzer 06 03 02 10 28 E Scheduled Tasks 2 o OR P 48 MB Freier Speicher 0 Byte E Arbeitsplatz _ program files Ce 5g System32 7 1 1 PVI Monitor General The PVI monitor is used as a driver between the Windows Program and the ACOPOS drive It is provided by the manufacturer of the drive B amp R The PVI monitor runs license free for 2 hours An error message will appear when the two hours are exceeded When NC Indexer BR EXE is restarted the program is ready to run for another two hours Alternatively a security key or a safety code is available The driver has a wide range of functions It connects all kinds of serial interfaces of the PC with the ACOPOS drive PCMCIA adapters or USB adapters USB to RS 232 can also be used This is becoming increasingly important for the operation with laptop computers It is further possible to connect a modem into the RS 232 line The connection cable is arranged as follows Pin 2 g
50. el A total of 127 positions with the descriptions No 1 No 127 are available for teaching The Position O has a special meaning If Position O is called a reference run is triggered This function is ignored by systems with an absolute encoder indexer types NCxxxTBx Setting of the values The blue cursor is set to the position number that is to be teached Thereafter the axis is moved to the target position with the keys CW and CCW jogging operation The actual positions are accepted into the input field through a double click when the blue cursor is at the column Angle im Stored Positions E ioj xj Actual Pos 90 000 7 Reference TRUE Set Zen Double clicking on one of these fields accepts the values of the actual position 48 TO150 MEN ELEKTRO 042006 DOC 04 06 Alternatively the position can be entered directly as numerical value if known It should be noted that the numerical input is only accepted after pressing RETURN If the input field is left with TAB or a mouse click the new input value is discarded For each individual position a v max 0 100 can be specified Set Zero Jag to Pos Cancel Once all values have been specified they are transferred to and stored in the PLC by clicking the button PO PLC Alternatively the individual positions can be teached through the customer interface Set ero gus EN The button Jog to Pos is used to mo
51. enance through a modem or for visualisation An OPC server for connecting professional visualisation programs WIN CC Wonderware Intellution is also available The following interfaces are supported in addition DDE server HTML server und Intouch Fast DDE Digital l Os and a Profibus interface Profibus DP Slave lt 12Mbit are available as customer interfaces Other interfaces CAN RS232 RS485 Ethernet etc are available on request The controller allows the following modes of operation Jogging operation Teach zero position Move to fixed stations graduation from 2 1500 Teach positions Move to position 1 127 absolute or relative 10 sequences with 40 commands each 8 freely programmable cams 8 trigger outputs TO150 MEN ELEKTRO 042006 DOC 04 06 9 Slot PLC Type AC140 The Slot PLC are mounted in the left slot of the ACOPOS drive requires two slots The module offers interchangeable application memory in the form of a Compact Flash card as well as a separate backup battery PLC FF Application Interface IF1 Indications Application Interface IF2 o RX TX LED s Application Interface IF3 Max Baud Rate Bus Lengths up to 100m 12 Mbit s Bus Lengths up to 200m 1 5 Mbit s Bus Lengths up to 400m 500 kBit s Indications Status RUN Red ERROR RESET Red with orange blinking Load unload and start BOOT AR Red green blinking 1Hz Startup of BOOT or
52. erm capacity 24 7 ws tr s block on NM tr s rel f 0 000 NM H switch positiv trigg dir positiv r start dir pozitiv ref impulse fo n T Help Cancel Group Reference A reference run has to be performed for indexers without an absolute encoder This is not relevant for the indexer types NCxxxTBx as they use an absolute encoder Group Brake Resistor internal external Switches between internal and external brake resistor If the internal brake resistor is selected the subsequent settings are irrelevant Switching is only possible if the motor is disabled resistor Resistance value of the external brake resistor max temp The external resistor is monitored through a temperature model The value for the max temperature is the threshold at which the resistor is switched off therm resistor Thermal resistance value of the external resistor manufacturer information therm capacity Thermal capacity of the external resistor manufacturer information The ACOPOS drive for the indexer types NCxxx ACOPOS1022 1045 1090 have an sufficiently sized internal brake resistor so that this function is not significance TO150 MEN ELEKTRO 042006 DOC 04 06 59 E E err Part 1 Fart 2 Pat3 Software Limit W enable blocked position gt 200 000 TI 330 000 7 General timeout movement DU s K000 Incr 3 000 s following error delay enable Group General
53. es earlier Output InPos Q1 4 The output Ready to Start means not automatically that the position is reached The movement also can be interrupt by E Stop or interrupt by an alarm 70 TO150 MEN ELEKTRO 042006 DOC 04 06 3 Define zero position ia Manual Mode B Bl x Actual Position 60 000 7 Enable Enable Disable P Enabeld Override 100 00 Disabeld Open Break Release Break Break released Coe 3 s Step Toggle Position Direction C left C Vight optim Position abs Angle 0 000 Start C rel Use the jog buttons CW and CCW to move the indexer to zero position Then apply the zero position by pressing the button Set Zero The display of the actual position changes to 0 000 Now the indexing table is ready to work By using the input 11 8 Step CW the indexer makes step by step 0 0 90 0 180 0 270 0 2NC Indexer 0 3 11 EN Lini x File Program Options Test Friction Help Ki Parameter El Es a S Ab d Load Parameter Connection Exit Wait for Command COM 1 ONLINE A These settings are now saved in the parameter file Store the parameter file and keep well Add a copy of the parameter file during delivery TO150 MEN ELEKTRO 042006 DOC 04 06 71 4 Product change Extension of the task You have an indexer with 4 positions and y
54. ich is defined in the dialog box axis It includes values for speed start ramp stop ramp and jogging operation Search Home With this command a reference run can be initialized After Power ON you have to give this signal once to search the reference You need a valid reference before you can give a movement command Move to Pos or Start Sequence etc For the Jog Mode you don t need a reference point A reference run can alternately initialized at the Move to Pos 0 command or by the Windows program or by the Hand held Display page 10 Reference search home must give after every switching of 24V supply since otherwise no valid reference point is available and or the actual position is wrong any values in the actual position No positioning can be started zero pos on the other hand is only given uniquely during the mechanical assembly of the rotary indexer This command is used to determine the mechanical built in offset of the indexer It looks as follows in practice mount and pin table mechanically start reference search drive table onto the first processing station with the aid of the jog function give command zero pos uniquely gt actual position changes to 0 000 now give only search home after switching the 24V supply output Reference o k shows whether valid reference point is available 32 TO150 MEN ELEKTRO 042006 DOC 04 06 Outputs Amplifier enabled As soon as
55. ind the manual of the drive manufacturer as soon as the T V Certificate File ACOPOS_men_V131_04 2004 pdf SecureRestartInhibit UVCertificate_8V1180 00 2 pdf In the manual you find further information in the chapter 1 3 secure restart closure TO150 MEN ELEKTRO 042006 DOC 04 06 19 4 10 Schematics for E Stop The customer must put the indexing table into a safety category which corresponds to the danger potential of the entire machine For the interruption of energy supply in case of E Stop there are three examples given below Example 1a Interrupt of the main power L4 e L2 o L3 e PE re Au K2 4 DIESER ne zbucdokm P p 1 1 j i 2000 ptos opas Lon 3388 3338 i X2 X3 Weste 448 co Trigger 1 459 e Quickstop SE 139 Cm COM 1 2 O Shield ACOPOS O Limit switch E Stop O Limit switch 439 Reference switch ENS Enable e ai e Enable K1 K2 19 COM 8 9 9 COM 8 9 KC al n C TO n c 24V Slot1 Slot2 Slot3 Slot4 A 24V DELL DELG SALL DALE ii j PLC Resolverf i p ey AC140 ACI22 i he 9 COM 5 7 13 15 Jan COM 5 7 13 15 GND 4 0 COM 5 7 13 15 Ee JE X4a orc ON Dann Lg Safety considerations size main contactor sufficiently Open clamp X1 9 at the ACOPOS dri
56. irectly on grounded three phase industrial mains TN TT systems The power mains connection is made using terminals X3 L1 L2 L3 and PE The permissible supply voltage range for ACOPOS servo drive is 3 x 400VAC to 3 x 480 VAC 10 Always use at least 2 5mm or AWG12 cabling The grounding conductor has to have the same cross section Servo drives are systems with an increased discharge current larger than 3 5mA AC or 10mA DC Therefore a fixed not mobile protective grounding conductor is required on the servo drives Mains connection Contact X3 4 Fixed grounding connector Mains fuse The power mains are to be equipped with over current protection in the form of a circuit breaker or a fuse Circuit breakers time delay with type C tripping characteristics according to IEC 60898 or fuses time delay with type gM tripping characteristics according to IEC 60269 1 are to be used Fault current Servo drives have an internal power rectifier If a short circuit to the frame occurs a flat DC fault current can be created which prevents an AC current or pulse current sensitive RCD Type A or AC from being activated therefore canceling the protective function for all connected devices Fault current protection with a rated fault current of 100mA can be used For example the AC DC sensitive 4 pole fault current protective device F 804 from ABB fault current 300mA nominal current 63A can be us
57. is useful the send the generated parameter file through E mail to a service technician of WEISS He will check your file and recommend any modifications changes The file can have up to approx 2000 values Data for the case that the drive is defect and must be exchanged file during delivery d Store the parameter file and keep well Add a copy of the parameter 7 2 13 Load Parameters m Load Parameter E 1 z rmi sl Iv Hw Config v Axis v Teached Positions Iv Cam Iw Sequence e Demo Sequence Zeta Paint Cancel When stored values are loaded it is possible to select which groups will be loaded 66 TO150 MEN ELEKTRO 042006 DOC 04 06 7 2 14 Connection im Serial Interface PC lt gt PLE E BD x General Serial Interface PE PLE Interface com Baud rate Simulation Cancel It is important to define the serial interface used on the PC COM1 COM8 The baud rate is set permanently to 57600 It has to correspond with the baud rate of the PLC 7 2 15 Info dialog box lolx NC Indexer Version number of the Windows Program Version 445 0 lt gt Copyright c 2002 by WEISS GmbH Software V 4 05 2 PLC AD140 2 v2 82 Indexer T0150 ABB Motor FISCHER_TO150 COPOS 1022 NL Manager 1 185 WEISS GmbH Siemensstralle 1 7 D 74722 Buchen O dw Tel 43 016281 5208 0 Internet wt welss qmbh de Detailed inform
58. kg m decel m 35 Rev calculate pos window 0 000 Y In pos 0 100 f Indexer Stations 4 mathematic fram table Jag Made Parameter 1 A v start n5 05 RFM tabele Mo v max 100 0 60 0 APM a stop FO DU Rev z Override factor 1 03 1 03 Override 100 00 Cancel Group Motion The parameters for normal movement are specified here e g the speed and start stop ramps max speed The maximum rotation speed of the motor axis is defined accel Start ramp relating to the motor shaft decel Stop ramp Usually equal to the start ramp pos window The position window influences the time of the completion message not the accuracy If the position window is gt 0 000 the completion message is generated as soon as the axis is within the position window However the axis still completes its movement This function has the purpose of compensating for delays ACOPOS drive gt PLC gt customer PLC in pos Size length of the software cam InPos gt See description of Output InPos The settings for max speed accel and decel are predefined when the indexer type and the inertia are set The limits for these inputs are provided by the Group Limits in part 2 of the dialog box The input fields for the parameter sets 1 and 2 are shown Switching between those sets is achieved through a digital input TO150 MEN ELEKTRO 042006 DOC 04 06 55 Group Jog Mode v Sta
59. l laws and guidelines have to be adhered to during the disposal process 80 TO150 MEN ELEKTRO 042006 DOC 04 06 13 Appendix EC Manufacturer Declaration according to the EC Machine Guideline 98 37 EC Appendix II B WEISS GmbH Sondermaschinentechnik Siemensstra e 17 D 74722 Buchen The manufacturer Germany declares hereby that the machine described Indexing tables TO150ABB with associated B amp R below control system is not a useable machine according to the EC Machine Guideline and does therefore not comply in full with the requirements of this guideline The initial operation of this system is prohibited until the conformity with the EC Machine Guideline of the total machine in which this system is installed has been established EG Guidelines used O 98 37 EC Machine Guideline 1 73 23 EEC Low voltage Guideline Harmonised standards used DIN EN 60034 Rotating electrical machines DIN EN 60204 Safety of machines electrical equipment DIN VDE 0470 1 Protection types through casings DIN EN 414 Safety of machines possible hazards DIN EN 1050 Safety of machines reasons for hazards Major design changes that affect the technical data provided in this product description and the appropriate usage of the product make this conformity declaration invalid Buchen 10 of March 2006 Uwe Weiss CEO TO150 MEN ELEKTRO 042006 DOC 04 06 81 main power 3x400 480V 3kVA 124V enable 2
60. last movement command It is comparable to a cam for which the position is set to the target position for every movement command The size of the cam is set in the dialog box axis Part 1 Input Field InPos TO150 MEN ELEKTRO 042006 DOC 04 06 33 5 3 Timing diagram Enable Bit A Bit G pointer to dialogbox stored position in binary coded form Input Move to Pos Output Ready to Start 34 TO150 MEN ELEKTRO 042006 DOC 04 06 5 4 Including the Profibus This chapter explained you how to parameterise the Profibus interface Chapter 5 4 1 explains the works on the Profibus master side that is on a Siemens S7 by using a S7 300 Chapter 5 4 2 explains the parameterisation at the B amp R ACOPOS drive Additional you can use the parameter channel You ll find this docu in an own file at the CD ROM Profibus Parameter Channel en pdf 5 4 1 Parameterising the Profibus Master 1 Generate a new project Here e g with a S7 300 PLC Remark If you have only a few stations a baud rate from 1 5Mbits s satisfies As a result you have the same reaction time as in the case of 12Mbits s In this way you can even achieve advantages in the case of a bad line quality 2 Install new GSE file DG HW Config SIMATIC 300 1 Configuration TEST PB ol Station Edit Insert PLC View Options Window Help l x x Profile Standard hd I I 2S Ed amp Bal Customize Ctr Alt E Specify Module
61. limatec ch www limatec ch Turkey GERDEM Otogaz Otomasyon Tekstil Kimya San Tic Ltd Sti Perpa Ticaret Merkezi B Blok Kat 13 No 2305 Okmeyani 80270 Istanbul Tel 90 0 212 210 10 44 Fax 90 0 212 210 09 76 e Mail info gerdem com tr WWW gerdem com tr United Kingdom Eire WEISS UK Ltd 27 Manchester Drive Leegomery Telford Shropshire TF1 6XY Tel 44 0 1952 240953 Fax 44 0 1952 244442 e Mail info weiss uk com www weiss uk com USA Precision Detroit Company Inc 4658 East 355th St Willoughby OH 44094 Tel 1 440 946 3304 Fax 1 440 942 9083 e Mail sales pdc inc com www pdc inc com WEISS GmbH Sondermaschinentechnik Siemensstr 17 D 74722 Buchen Tel 49 6281 5208 0 Fax 49 6281 9150 Internet www weiss gmbh de eMail info weiss gmbh de 980 260093010 V07 2005
62. nd drag it to the Profibus master system by pressing the left mouse key i HW Config SIMATIC 300 1 Configuration TEST PB al Station Edit Insert PLC View Options Window Help Dcs s w el ai mej al SE 2 wi Profile Standard zu 0 UR zm PROFIBUS DP EROFIBUS 1y DP master system 1 CH Additional Field Devices 2 3 10 DP Masfer S C Compatible PROFIBUS DP Slaves 3 Closed Loop Controller 3 Configured Stations sl 3 CP 342 5 as DP Master gt zd DP AS4 E DP PA Link 3 ENCODER 3 ET 2008 zy ET 2000 zy ET 200L zy ET 200M zy ET 2005 zy ET 200U 3 ET 200 3 Function Modules A IDENT 3 IPC NC 1 SIMADYN 3 SIMATIC C SIMODRIVE 5 SIMOREG 3 SIMOVERT 3 SIPOS E Switching Devices Ei SIMATIC 300 Comment HH HH HH ED RT ED E HH RE E ED RET ET ET E E E L t Insertion possible 5 Now a dialog box is opened where you can set the slave address These address must be agree with the switches at the front of the slot PLC AC140 in the ACOPOS drive Rem You can change the address later at any time Profibus address at the slot PLC AC140 ACOPOS drive INT Config SIMATIC SOM 1 Configuration
63. ong 00 a clear text message are part of the fault message 12 ncaction command neaction Sy command failed It was attempted to move to a position that does not exist PosNo lt 1 or gt 127 The 2 parameter in the Windows Program indicates the faulty position number The 2 parameter in the Windows Program indicates the faulty position number The movement was not competed in the calculated timeout period Possible reasons Shaft does not move easily Shaft blocked TO150 MEN ELEKTRO 042006 DOC 04 06 15 Fault messages of the ACOPOS drive When the fault number is 10 the alarm list provides more accurate information concerning the cause of the fault of the ACOPOS drive You ll find a file with the description of the ACOPOS error codes at the CD ROM in path Docu BrAutomation ErrorCodes 9 3 Resetting Error Messages There are two ways of resetting a error message Set Input Quit Error to high for a short time gt 20 ms Reset the error through the Windows Program 9 4 List of the most frequent error reports Reason Help First initiation Motor line U V W connected wrong Motor did not move makes a small flip U blue hot after some attempts V brown Alarm W black IGBT Temperature Alarm Following Error First initiation If you did not know the correct indexer model chapter 3 2 call WEISS We need then the serial number A wrong indexer model hw config did not damage the hardwar
64. ou need to handle two products The mounts between product 1 and product 2 are displaced around 10 0 im Stored Positions loj xj ActualPos 90 001 Reference TRUE 10 000 100 00 Ras 3 a 10 000 10 09 Pos 4 gege 40 00 ESE 0 000 100 00 Pos 6 0 000 100 00 0 000 100 00 0 000 100 00 El 0 000 100 00 Pos 10 0 000 100 00 PC PLC Cancel Insert in the dialog box Stored Positions the offset between the two products e g 10 0 Also the speed 100 for the second product ACOPOS Ingakr ALOPOS Inputs Step Oa KR fee Pre IT XUT Tagger MT Move to Por Cw F Step Cw IV Zen Por M X A Tigga F i cow E e T SUP Oechkaegn F Move t Pos COW 7 Step COw 7 Relea tenak T7 XI Queksop FF Tezga Move ho lit Per o BLS Leg P Move to Pos abs 7 Toge Move to lait Por 7 xX Let n Aeg Cur Deme sequence 7 KU Limi n Move to Pos rel dog Ow Demo sequence X1 6 Let r de a JI She I HUT Beieneen Fr Novelo Pas Cw 7 dog COW Sten FP SOL Relesenee FF Jegte Par 7 Pasar o MIS orla F Mowe to Pes COW 7 Jegto Pee 7 Passate 7 SOL Enable H Stone Por 7 SemchHome Move to Pos Bust 7 Store Pos 7 Search Homer 7 Alamat T Bene 7 Seel Segue M Alam reset I Reine 7 Force ken Can T In Pos F Tigas A1 7 Can t 7 InPox F tone P Reserves Trigger A3 7 Can 2 7 Reserve 7 mi TF Fire 7 Tope A3 7 Can 3 7 Ree I7 Cd 7 Rare MT Trigger A4 r Cana 7 Res 7 Cam
65. out 22 TO150 MEN ELEKTRO 042006 DOC 04 06 Example 3b Additional use of Quicksto Emergency Stop stop 1 Hj KB KN i5 e Trigger 1 Asc Quickstop Trigger 2 0v c COM 1 2 82 oV sc Shield j amp c End na End e Ref amp Enable Lei Enable X1 o v eCOM 8 9 SE COM 8 9 So ne ot n c Sc 24V a DE 24V K K3 LI Me COM 5 7 13 15 Tea COM 5 7 13 15 Lov Lov 0 V z Sc COM 5 7 13 15 Slot 1 Input clamp X1 2 at ACOPOS 1 The contactors K2 K3 must correspond to the respective safety category 3 An interrupt of the 24V will stop the brake and the axis spin out and or the mechanical brake in the motor fails An error temperature following error or an interrupt at the main power clamp X3 also interrupts the active electrical braking Pressing the E Stop switch S1 causes relay K2 to be released In this way the ACOPOS input Quickstop triggers active braking If the drive etc is faulty then auxiliary relay K3 is released after a defined delay and causes the energy feed to the motor to be cut off The customer has set the delay time to the calculated time of the stop ramp With this you got the shortest braking time TO150 MEN ELEKTRO 042006 DOC 04 06 23 Part 1 Part 2 Part 3 Part 4 Part 5 Software Limit v enable blocked position gt 200000 P 30 330000 r General Gene
66. produce the position the axis had before opening the door circuits Demo sequence An rising edge starts the demo sequence It is used for example for the startup operation of the axis or for demonstrate the functions The demo sequence must first defined in the Windows Program at the menu Demo sequence The commands available are the same as for the normal sequence The difference to the sequence is that the demo sequence works in an endless loop i e after the last command it jumps automatically to the first command The sequence is stopped through the input Stop or through the Windows Program Stop This command stops all started movements Move to Pos Sequence Demo Sequence This command does not affect the jogging function Some customers requests if movement is ended and he begins processing e g loading unloading the indexer that the indexer does not start unintentionally and causes a crash with high material damage For this this stop input would be able to be used It is also possible to remove the input Enable alternatively However this would result that the position loop is disconnected and the position is not checked and correct no more An small drifting from the position away is to be found then 0 1 The stop command is not intended for an Emergency Stop For this purpose the input Enable clamp X1 9 at the ACOPOS drive must used Parameter 2 This is used to switch to the Parameter Set 2 wh
67. ral timeout movement 0 0 s limit switch Off E following error 5000 Iner quick stop input LOW delay enable 3 000 s Cancel The customer has configure the input Quickstop via the Windows Program NR indexer BR exe Pati i Pat Pat3 Pat4 Pats Speed loop Limits kp 1 8 max speed 3400 0 RPM tn 0 05 s accel 984 2 Filter 1 TI 0 0008 s Filter 2 FO 0 0 Hz Fe 28 00 Hg tin pos 00 s Position loop kp amp 00 tn ooo s t_ahead 0 0004 s L total 0 0004 s p max 4000 0 max 0 0 Cancel The limit values deceleration ramp describes the stop ramp The customer must carry out and check these settings independently after every change in settings He can use the oscilloscope function in the software This is to be considered especially if a light curtain is used For Quickstop use clamp X1 2 at the front side of the ACOPOS drive Clamp X1 3 is GND 24 TO150 MEN ELEKTRO 042006 DOC 04 06 4 11 Cable Motor cable construction W1 white blue white gree while red white brown blue black yellow green 1 Motor ines j4x 5mm 2x2x0 75 mm BSTA 108 FR 19 08 0006 000 Shrink wrap Shrinkwrap Wire tip sleeve So Circular connector Pin Description Function Motor Plug B Temperature sensor 1 amp
68. riate use and improper installation or operation can cause bodily injuring and or severe damage to the systems The installation and cooling of the systems has to be performed according to these specifications The control system PLC and ACOPOS drive has to be protected from improper usage ACOPOS drive and PLC contain electrostatically sensitive components that can easily be damaged by improper handling Electrical components may not be mechanically damaged or destroyed possible health risk WEISS systems comply with the currently valid VDE regulations The VDE regulations also have to be taken into account when the systems are modified or un installed Notes concerning correct installation with regard to electromagnetic compatibility EMC e g shielding grounding and installation of cables are included in this documentation Adherence to the thresholds required by the EMC legislation is the responsibility of the manufacturer of the system Unauthorized changes and the use of spare parts and add on devices that are not recommended by the manufacturer may lead to injuries of persons and damage to the mechanics and control system Some components motor ACOPOS drive may have hot surfaces during operation The operating temperatures may be gt 60 C gt 140 F Skin contact leads to burns 4 TO150 MEN ELEKTRO 042006 DOC 04 06 It has to be ensured that the casing is properly connected with the ground potential PE busbar before th
69. rt Starting rotation speed for jogging operation v max Max rotation speed for jogging operation a stop Stop ramp for ending of jogging operation factor Factor determining the speed of change from rotation speed v start to v max A v_end E v end v start v start ES d gt t small factor 1 01 large factor 2 0 Group Inertia The mass inertia of the indexer as well as the inertia of the customer load are set The inertia of the indexer is set automatically when the definition of the indexer type is provided An input causes recalculating of the start and stop ramps in the motion and jog parameters as soon as at the limit values Group Override The general override speed override factor for all movements can be entered here The input field is identical to the input field override of the dialog box Demo Sequence 56 TO150 MEN ELEKTRO 042006 DOC 04 06 Group Indexer If a indexer with fixed graduation is used the graduation is set here The graduation applies for the commands Step CW and Step CCW Values between 2 1500 can be entered There are two possibilities to specify a graduation Calculate graduation mathematically The positions are spread symmetrically i e the axis moves about s 360 0 stations e g 0 0 90 0 180 0 270 08 The inputs Bit A Bit G defines an position offset taken from the table stored position Also the speed override defined in the table is
70. rtment To make it possible to pull the battery out again the pullout strip must be on the right side of the battery Pullout strip Lithium battery TO150 MEN ELEKTRO 042006 DOC 04 06 11 5 Push the end of the pullout strip that stands out under the battery so that it does not extend from the battery compartment 6 Replace the cover The recess for the screwdriver should point upwards nonu ooo oO 8 Lithium batteries are hazardous waste Spent batteries have to be disposed of appropriately The battery has the type CR2447N with a voltage of 3 V 3 6 Windows Operating Program The controller can be linked to a PC through a serial RS 232 interface The Windows Program can be used for easy configuration of the system No permanent connection is required The PC is only needed for the initial operation This is described in detail in Chapter 7 3 7 Hand held Display An additional option for operating the system in addition to using the Windows Program is the connection of a hand held display It provides the easiest form of operation and can be used to make adjustments and to operate the indexer The hand held display is especially suited for beginners who want to use only a part of the extensive functions 12 TO150 MEN ELEKTRO 042006 DOC 04 06 4 ACOPOS drive Motor and drive are optimally tuned The drive is part of the Series ACOPOS Special attention was given to operational safety and extensive monitoring functions
71. s Comment M Apply Cancel 6 The button Apply transfers the settings to the controller and stores them there The controller has to be restarted to make the new setting effective TO150 MEN ELEKTRO 042006 DOC 04 06 7 2 2 Debug The functions Restart PLC Set Date Logbook and I O Monitor are available under the menu item Options gt Debug 210 x Restart PLE 01711011 71111011011 TOTO T0TOU TC error Fj 10 1 AOL 170 Monitor Set Date 2 The button Set Date is used to set the PLC time and date to the current PC date The PLC date is used to attach a time stamp to each error message The button I O Monitor opens the I O Monitor that displays the current states HIGH LOW of the individual input and output bits The inputs and outputs can also be forced for startup purposes The frame around the inputs Bit A Bit G and the input field is intended to make the representation of these signals easier The inputs Bit A Bit G represent the numbers of the commands Move to Pos and Sequence in binary form The input field can be used to specify these values in the familiar decimal system m 1 0 Monitor EE Dl x Inputs ACOPOS Inputs Enable MovetoPos Cw D Step Cw Zero Pos 1 1 Trigger m Move to Pos CCw Step CCW T Release break 1 2 Quickstop 7 Move to Pos abs T Toggle Move to la
72. s Meer 7 Trigger Di 7 Can 5 7 Reserve 7 Cane M Beieeeg T Inogs 82 Cab M Remera F7 Car Fein T Ta 83 7 Ce 7 Bergen 7 Ca Reaerve 7 Fass Dupuis Trigger B amp 7 Can amp 7 Reserve 7 Force Output Commands product 1 Bit_A 0 Commands product 2 Bit A 1 0 0 90 0 180 0 270 0 10 0 100 0 190 0 280 0 72 TO150 MEN ELEKTRO 042006 DOC 04 06 5 fast slow speed Now switch between fast and slow speed m Stored Positions Actual Pas 90 001 Leet 10000 100 00 D 10 000 0 000 0 000 0 000 0 000 0 000 0 000 0 000 PC gt PLC Commands J og to Pos 10 0 10 00 100 00 100 00 100 00 100 00 100 00 100 00 100 00 10 x Reference TRUE EE Jag COW cw Cancel fast step product A 0 0 fast step product B 0 1 slow step product A II 0 slow step product B TO150 MEN ELEKTRO 042006 DOC 04 06 73 Example 2 Indexer with two stations no endless rotation allowed BEE SE E Lia xl TTT Pati Pat2 Pat3 Pata Pats Pat Pat2 Para Pat4 pats Ansssssssssnsnnssnenunnen Motion Inertia Parameter 1 2 EIE 0 00012 kg m max speed 4500 0 2000 0 RPM TEC kom accel 131 1 65 6 Rev s Cat 100 0 kg m decel 131 1 65 6 Rev s calculate pos window 0 000 1 v enable blocked position gt 200000
73. s HIGH the indexer moves with jogging speed in direction CCW Inputs Bit A Bit G as above Jog to Pos The indexer moves with jogging speed to the provided position number Bit A Bit G i e the axis moves first slowly and then increasingly faster If the signal goes LOW the indexer stops immediately even if the target position has not been reached No completion message is provided when the position has been reached The signal is only used for the startup operation and is not intended for permanent operation The position number O reference run is not valid Store Pos With rising edge on this input the actual position is stored at the position number that is provided at the inputs Bit A to Bit G Position number 0 is not valid Alarm Reset An rising edge gt 20 ms acknowledges all pending fault messages Alternatively the faults can be acknowledged through the Windows Program or the hand held display TO150 MEN ELEKTRO 042006 DOC 04 06 31 Zero Pos With an rising edge the actual position is set to 0 000 axis is zeroed This zero position is now used as starting point for all movements It is assumption that the axis is Enabelt Release brake Can be used to open the brake manually Requirement is the operating mode Axis disabled Move to last Pos With this command the indexer moves to the previous position e g after opening the door circuits the axis is slightly pulled off its position The command can be used to re
74. ss d modul 64a Here in this example EN ae 10 0 SE 11 8 and 00 0 SES Q1 8 3 Closed Loop Controller 3 Configured Stations 3 CP 342 5 as DP Master A DP AS i 3 DP P Link 3 ENCODER 3 ET 2008 3 ET 200 I ET 200L I ET 200M 3 ET 2005 73 ET 200U 3 ET 200 Function Modules co mina co ro nh co FE E 8 RR a E FB Lat Insertion possible Chg 38 TO150 MEN ELEKTRO 042006 DOC 04 06 5 4 2 Parameterisation of the B amp R ACOPOS drive If the Profibus is used the Profibus message can be configured It can be determined if only the digital inputs and outputs Chapter 5 2 should be send or if the nominal and actual positions should be send as well The additional information increases the length of the Profibus message from 2 Bytes to 10 Bytes E imi x Select whether the nominal position EC and the nominal speed should be send as well Profibus Input nam position speed Display of the new message length Input length The shown text modul_02e or modul_10e corresponds to the configuration selection in the Profibus S7 Master System Output act position alarm no Output length modul D s The same applies to the send message Parameter channel Apply Cancel TO150 MEN ELEKTRO 042006 DOC 04 06 39 The Profibus message is structured
75. st Pos I 125 Limit ln Move to Pos rel I Jog Cw Demo sequence D 1 5 Limit E Move to Pos Cw TI Jog CCW Stop T X1 7 Reference D Move to Pos CCw D Jog to Pos I Parameter 2 1 9 Enable Iv Move to Pos Bus T Store Pos I Search Home I Sequence Alarm reset Reserve I Force Inputs m Outputs Amplifier enabled IV Trigger amp 1 I Cam1 F In Pos I Amplifier disabled Trigger amp 2 7 Cam2 7 Reserve I Reference ok 4 Trigger_43 Cam3 F Reserve J Ready to Start 4 Trigger_44 Cam4 Reserve I Error Trigger B1 Camp Reserve I Error flash Trigger B2 Cam 6 Reserve I Battery empty I Trigger B3 Ir Cam 7 Reserve I Test 7 Trigger B4 Camp Reserve I Force Dutputs It is recommended to use the I O Monitor during startup to control the wiring If a bus system is used e g Profibus its function can be checked as well On the right side the inputs of the ACOPOS drive are shown They cannot be forced TO150 MEN ELEKTRO 042006 DOC 04 06 47 7 2 3 Teach Positions After the hardware has been configured and the I O interface has been tested with the I O Monitor the individual positions are teached im Stored Positions E Ioj x Actual Foz 90 001 7 Reference TRUE Jog Angle Y_ MER Ange wm ewl cw 45 000 100 00 30 000 120 000 0 000 0 000 0 000 0 000 0 000 0 000 0 000 Set Zero Jog to Pos Canc
76. t Pin 3 Pin 3 gt Pin 2 Pin 5 gt Pin 5 This cable is delivered with the CD ROM During the installation of the PVI monitor an OPC driver can be installed as well It makes it possible to connect the ACOPOS drive to professional visualisation programs WinCC Intellution Wonderware to achiever the same functionality that the program NC Indexer BR EXE provides 44 TO150 MEN ELEKTRO 042006 DOC 04 06 7 2 Operation of the program The Windows Program has the following functions Configuring Axis Profibus Debug l O Monitor Parameter download Teach positions Create sequences 7 2 1 Configure Under the menu item Options gt HW Config the indexer type as well as the I O configuration and Profibus are configured first gt See example in Chapter 8 w Hardware Configuration Indexer type ro 15 ABB LU Contig Comment max 31 signs _ 1 The indexer type NC220TBA is entered first This makes it possible to load the default parameters for this system type 2 The name of the system e g welding robot can be entered in the comment field 3 If a Profibus is used one can configure whether the actual position nominal position or alarm number should transmitted The Profibus address is set with DIP switches on the PLC see circuit diagram 4 Under the I O Config button the individual functions of the input terminals or the bits at the Profibus
77. t The indexer moves to the positions 0 90 180 270 Example 2 4 steps Bit A Bit G gt Position in the table no 3 5 0 gt The indexer moves to the positions 5 95 185 275 Also the speed entry override 0 100 from the table is used b steps teached in the table In the dialog box axis the initial value and the number of steps is defaulted With the number build by Bit A Bit G the initial value is moved Example 1 Bit A Du G 0 4 steps initial value gt The positions no 1 2 3 4 from the table stored positions are started Example 2 Bit A Bit G 8 4 steps initial value gt The positions no 9 10 11 12 from the table stored positions are started The offset from Bit A Bit G is used to set an offset in case of an product alternation or to set different speeds position entry in the table 0 0 Normal these inputs Bit A Bit G are LOW Step CCW As above only rotation direction CCW Toggle This input is valid only if you define two steps dialog boxes axis With each rising edge the indexer toggle between position no 1 and position no 2 direction changes left right Jog CW As long as this input is HIGH the indexer moves with jogging speed in direction CW The inputs Bit A Bit G defines an override for the speed The override is taken from the table stored position But normally these inputs are LOW Jog CCW As long as this input i
78. teleusstraat 2 Langeveldpark Unit 11 B 1600 Sint Pieters Leeuw Tel 32 0 2 3349999 Fax 32 0 2 3349960 e Mail atb spI skynet be www atb automation be Czech Republic STASTO Automation s r o K N kl 512 CZ 25741 Tynec nad S zavou Tel 420 0 317 701 700 Fax 420 0 317 701 701 e Mail stasto stasto cz www stasto cz Denmark Poul Johansen Trading Ovangsvej 1 DK 4540 Faarevejle Tel 45 0 59 655836 Fax 45 0 59 646598 e Mail pjt pit dk www pjt dk Finland STIG WAHLSTR M OY Hannuksentie 1 FIN 02270 ESPOO Tel 358 0 9 502 4400 Fax 358 0 9 452 2735 e Mail info swoy fi http www swoy fi France Weber Assemblages Automatiques Chapelle du Puits B P 125 F 74410 Saint Jorioz Tel 33 0 450 685990 Fax 33 0 450 68691 1 e Mail weber weberaa com Israel DIES Company Ltd Engineering amp Automation Paz Hateomim Center 1st Floor Mishmar Hashiva IL 61211 Tel Aviv Tel 972 0 72 3 9605008 Fax 972 0 72 3 9605004 e Mail dies dies co il Italy Schluderbacher Via Marconi 45 7 I 40010 Maddalena Bo Tel 39 0 51 6640 750 Fax 39 0 51 6640 513 e Mail mail schlu com www schlu com Korea JUNGWOO International Inc 21 8 Dodang Dong Wonmi Gu Bucheon City Gyeonggi Do 420 801 Korea Tel 82 0 32 676 1822 Fax 82 0 32 676 1991 e Mail jungwoo jwint co kr www jwint co kr Netherlands Radine B V Postbus 50 NL 37
79. the ACOPOS drive has been switched on with the Input Enable this signal goes HIGH This signal is not protected against cable breakage i e if the signal goes LOW it cannot be concluded that the indexer cannot move anymore Amplifier disabled As soon as the Input Enable goes LOW and all movements have stopped this signal goes HIGH to indicate that the doors can now be unlocked Reference OK This output indicates that a valid reference point is provided Only then the moving commands Move to Pos Start Sequence and Store Pos can be executed Only relevant for indexer without an absolute encoder Ready to Start This output indicates that the ACOPOS drive is ready to accept a new start command Error This output indicates that an error has occurred Error flash This output can be used to connect a light that flashes in case of an error Battery Warning If this output goes HIGH it indicates that the battery should be exchanged Trigger A1 Trigger B4 These outputs can be set from a sequence Trigger A These outputs are automatically reset after a sequence has been completed or terminated e g error message or door circuit opened The outputs of the group Trigger B are retained until they are reset by a command Cams 1 8 A maximum of 8 cams can be defined through the Windows Program These are the corresponding outputs InPos This output indicates that the axis has reached the target position of the
80. this DIP switch was mixed with the left DIP switch for Profibus address 76 TO150 MEN ELEKTRO 042006 DOC 04 06 10 Transport and Installation 10 1 Transport bg WARNING Please transport the indexer only with lifting equipment that is suited for the respective weight see following weight table To fasten the indexer to the lifting tools use eye bolts that can safely withstand the load according to the following weight table Weights of the indexers o Te Weight Ek TO 150 ABB 13 kg TO150 MEN ELEKTRO 042006 DOC 04 06 77 10 2 Installation Flatness of the support surface The flatness of the machine frame has direct implications on the concentricity and axial run out tolerances of the indexing ring The heat dissipation between indexer and base frame must be guaranteed no thermal insulation through enamels or similar things Installation position Installation of the NC types indexer in any position possible Protection class The indexer mechanics motor has the protection class IP20 Cable connectors The cable connectors for motor and encoder can be turned down Also a version with straight departures to the left and right side are available 10 3 Maintenance The system is absolute maintenance and wear resistant That in accordance with no maintenance operations are to be carried out 78 TO150 MEN ELEKTRO 042006 DOC 04 06 11 Spare parts 11 1 Spare parts A list of replacement parts of the
81. tia of the load Max speed 24 Start ramp 25 Stop ramp 26 External brake resistor Description in detail Page 1 Page 2 Page 3 Page 4 Page 10 Page 11 Page 12 Page 13 Page 15 Page 20 Page 21 Page 22 Page 23 Page 24 Page 25 Page 26 Page 30 42 Operating message The current state of the control system is shown e g Ready for Operation Motor turns Waiting for Command Display of the current fault message Display of the current position rotating angle of the indexer in degrees Display of the movement time of the last movement command The button F2 starts an reference run The button F2 sets the current position to 0 000 zero calibration Button F3 and F4 can be used to move the indexer in jogging mode The and the button can be used to move the indexer in jogging mode The button starts a step in clockwise direction The button starts a step in counter clockwise direction The button F2 starts stops the demo sequence Setting of the indexer type Setting of the indexer graduation Setting of the mass inertia of the load This may result in different start stop ramps The maximum motor speed can be set here Note By defining the indexer type the upper limit is automatically set Setting of the start ramp Note By defining the indexer type as well as the mass inertia the upper limit is automatically set Setting of the stop ramp
82. unintentional movements For this the STOP input is better because the position controller is switched off if you disable the axis When the position loop is open the indexer lost his position Bit A Bit G Coding of commands At these inputs the position or sequence numbers for the following commands are provided Jog to Pos No xxx Move to Pos No CW CCW abs rel xxx Start Sequence No xxx Store Pos No xxx Numerical values between 0 and 127 can be provided This number is read when there is an rising edge in one of the above signals The numbers are provided in binary form e g Position Number 2 0000010 e g Position Number 3 0000011 e g Position Number 12 0001100 e g Position Number 45 0701107 e g Position Number 83 1010011 These Inputs are also used for the commands JOG and STEP In the hardware configuration Menu HW Config of the Windows Program these functions Bit A Bit G are assigned to the corresponding input terminals If the 127 possible positions are not required only the required functions Bit A Bit G have to be assigned Unassigned functions are automatically set to O TO150 MEN ELEKTRO 042006 DOC 04 06 29 Move to Pos CW abs At an rising edge at this input the indexer moves to the absolute position number that is provided at the inputs Bit A Bit G The direction of rotation is right CW This signal normally starts a positioning process The signal is closely associate
83. uniquely this after mounting the indexer This offset is then stored in the battery RAM of the controller IMPORTANT The machine zero position is invalid after you unmount the indexer or the plate if you disconnect the second encoder if you change the ACOPOS drive or if the battery is empty Note Mark this place permanently e g through red arrows or by a fit boring in the plate So you can find and re teach the machine zero position fast after a repair 14 TO150 MEN ELEKTRO 042006 DOC 04 06 4 4 Installation of the ACOPOS drive The ACOPOS drive may only be used in environments that comply with Pollution Level Il non conductive pollution The maximum operating temperature of 40 C 104 F that is specified in the technical data as well as the protective system IP20 have to be taken into account when the system is installed A free space of at least 80 mm should be provided above and below the ACOPOS drive to ensure sufficient air circulation Al ir Incoming air TO150 MEN ELEKTRO 042006 DOC 04 06 15 4 5 Indications LED Description READY green Lit when the ACOPOS drive is ready for operation main power and clamp X1 9 HIGH Lit when the axis is enable hardware enable AND software enable is HIGH ERROR red Lit during POWER ON boot procedure mm Lit if hardware enable clamp X1 9 if OFF E STOP Lit if an error at the ACOPOS drive exist 4 6 Power Mains Connection The ACOPOS drive are allowed to be operated d
84. ve in jogging mode to the position No currently marked by the blue cursor TO150 MEN ELEKTRO 042006 DOC 04 06 49 7 2 4 Adjust Sequences At the menu entry Program Sequence sequences can be stored Sequences are started like movements to individual positions but instead of the command Move to Pos the command Start Sequence is given Up to 10 sequences can be stored Each sequence can have a maximum of 40 commands w Sequence S E Bl x Sequence PC PLE Sequence No 1 Move to Pos CW abs Trigger AT ON Walt time m Move ta Pos CW abs Trigger AT DFF Walt time ma 1 Enter sequence No number between 1 10 2 Specify commands 1 40 The commands are described below 3 Store sequence on the PLC PC PLC 50 TO150 MEN ELEKTRO 042006 DOC 04 06 A right mouse click on the column Commands xxx opens a menu where lines can be inserted or deleted Sequence No 1 SE Ems Jl Command 1 Move to Pos Cw abs u Trigger AT ON Insert Line Com ko S Pos Cw abs Trigger_4A1 OFF MM wait time ms 250 End Command 5 The following commands are available Move to Pos CW abs Move to Pos CCW abs Move to Pos optim abs Move to Pos rel Step CW Step CCW Wait time ms Trigger A12ON OFF Trigger A22ON OFF Trigger A32ON OFF Trigger _A4 ON OFF Trigger B12ON OFF Trigger B22ON
85. ve simultaneous with the main contactor Because of time overlap a error main power low can occur Switch on interval gt 10sec Please note Wait at least 5 minutes after the system has been switched off before touching live parts or disconnecting connections A quick start required when using a light curtain is not possible please consider switch on interval The TO indexer has no break So he spins out 20 TO150 MEN ELEKTRO 042006 DOC 04 06 Example 2a Interrupt of the motor lines i Lp e Aen en bro 9 Trigger 1 9 Quickstop SC O C COM 1 2 i ji UD Toe ses ACOPOS O e Limit switch ni E Stop Limit switch 4349 a Reference switch ELS a Enable 10 Enable in jl K1 K2 79 COM 8 9 0 COM 8 9 m ME Lj N C Ida 4 Im 24V OUT SS 0 24V ae an ES Resolver o HOA AC140 aci22 im COM 5 7 13 15 e O COM 5 7 13 15 p mo 49 COM 5 7 13 15 Safety considerations size main contactor sufficiently Open clamp X1 9 at the ACOPOS drive simultaneous with the main contactor Because of time overlap a error motor phase can occur If the clamp X1 9 is not opened a defect in the ACOPOS drive can occur An opening of the clamp X1 9 takes care besides of the contacts of the contactor since the ACOPOS drive is disa

Numeric controlled indexing tables Series TO150A

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