enforce Digital Servo Press DSP1500 (SAN3) SYSTEM OPERATION MANUAL FIRST Edition June 2003 SECOND Edition July 2005

Transcription

1 enforce Digital Servo Press DSP1500 (SAN3) SYSTEM OPERATION MANUAL FIRST Edition June 2003 SECOND Edition July 2005 Automation Systems Quadrate Drive Phone: (586) Macomb, MI Fax: (586) Web:

2 **WARNING** All applicable national and local codes must be followed when installing and operating the equipment detailed in this manual. FAILURE TO ABIDE BY THESE CODES AND THE SPECIFICATIONS DESCRIBED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY TO PERSONNEL AND/OR DAMAGE TO THE EQUIPMENT. WARNING THIS EQUIPMENT IS CAPABLE OF HIGH PRESS FORCE & VOLTAGES HAZARDOUS TO HUMAN LIFE. DO NOT operate the press WITHOUT all safety guards and/or devices in place and operational. NEVER enter the press ram area with power applied to the press unit. Follow Lockout/Tagout and other safety precautions when performing maintenance or connecting / disconnecting cabling, wiring, and equipment. Do not open or remove any covers, even if the unit is disconnected from the power source. Only qualified personnel should attempt to modify or repair this product. There is a possibility of receiving an electrical shock from this equipment, if used improperly. WARNING Read this manual carefully before attempting to operate the equipment. If this System is being operated as a part of a larger system, the larger system should be clearly marked with the warning information, above. Also, a copy of this notice should be included in all pertinent operation and maintenance manuals. SAN Units must be placed in a NEMA 12 or similar enclosure. Some type of Air Handling Unit (air conditioner, heat exchanger, etc.) may also be required. Be sure to use the recommended circuit breakers with the power supply lines. Use the power supply voltages recommended in the specifications to prevent possible personnel injury and equipment damage. Operate equipment within the specified limits for force output and duty cycle. Exceeding these specifications could result in injury and/or shortened equipment life. Do not modify this equipment, or the warranty will be void. Please contact FEC INC. if any special modification is required. Inspect the equipment s safety devices and confirm they are operating properly. DO NOT OPERATE EQUIPMENT IF THESE DEVICES MALFUNCTION! Inspect the equipment for wear and damage at regular intervals. Use care when mounting or removing tools. Some tool models are very heavy. Avoid touching the moveable parts of the equipment. If this cannot be avoided, ensure that there is no power to the System before touching a moveable part. Specific precautions regarding equipment installation and location have been incorporated into this manual. Before operating the equipment, verify that countermeasures have been taken for any adverse conditions that may exist. Failure to address these conditions prior to operation could result in injury or damage to the equipment.

3 Revisions Revised date Revision History 06/2003 enforce DSP1500 (SAN3) First Edition 07/2005 enforce DSP1500 (SAN3) Second Edition

4 Table of Contents Chapter 1: Outline 1.1 About this Operation Manual Features Safety Precautions Safety Labels Chapter 2: Specifications 2.1 System Specifications SAN Unit Specifications Duty Cycle Calculation SAN Unit Dimensions Press Tool Part Number Breakdown Tool Specifications Tool Dimensions Functions. 2-9 Chapter 3: System Description 3.1 System Block Diagram DSP1500 Front Panel (SAN Unit) DSP1500 Front Panel, Switches and Connectors DSP1500 Front Panel Condition Display LED DSP1500 Detachable Keypad Buttons DSP1500 Detachable Keypad Condition Display Press Tool Connection Diagram Chapter 4: System Setup and Wiring 4.1 Design and Build Procedures SAN Unit Design and Mounting Dimensions Calculating Circuit Protection Input Power Supply Connection Motor Power-Resolver Connections Pre-Amplifier Connection External Control Connection PLC Interface (I/O) Signal Chart Input & Output Recommended Connection Circuit Input & Output Signal Explanation Synchronized Press Operation Operation Timing Chart SW1 - SAN Unit Number Setting MON. Signal (External Monitor Signal) RS-485 Interface Signal 4-21

5 Table of Contents 4.11 Firmware Flash Connector Cable Installation Guidelines Considerations for Cable Trolleys Considerations for Flexible Cable Track Considerations for Cable Trays & Ladders Tool Connections Brake Option 4-26 Chapter 5: Powering Up and Initial Checks 5.1 Before Powering On Initial Data Setting. 5-4 Chapter 6: System Operation 6.1 Display and Programming Unit DP2S and DP4S Serial Connection RS232 Output Data Function of Display and Operating Panel RUN Status Mode Operating Instruction Display Mode Change RUN Status Key Operation Real Time Display Mode Operation Result Display Mode Set Value Display Mode Operating Condition Display Status Display Mode BYPASS(Spindle Off)Mode Operating Instruction Download Mode and Setup Mode Selection Data Edit Mode Parameter Copying Data Number Conversion Table Data Number Definitions System Parameter (No. 00) Work Parameters (No. 01~32) Operation Methods Operation Steps Operation Finish Modes Step Press Considerations for Return Parameters External LVDT Sensor

6 Table of Contents Chapter 7: Maintenance & Inspection 7.1 Inspection Items Press Tool Press Fixture Homerun Cables SAN Unit Air Handling Unit Basic Operational Tests Load Cell Resolver Motor Motor Replacement Procedure Explanation of Home Position Search Motor Tuning Chapter 8: Troubleshooting 8.1 Abnormal Display Load Cell Errors Offset Load Errors Tool EEPROM Errors System Memory Errors Servo Amplifier Response Errors Servo Type Errors Internal Errors Servo Amplifier Errors Parameter Errors Q & A

7 Table of Contents Appendix A: Reference Drawings Power Wiring Reference - AC.... A-2 PLC I/O Wiring Reference Allen Bradley (SLC).. A-3 PLC I/O Wiring Reference Omron..... A-4 PLC I/O Wiring Reference Mitsubishi... A-5 PLC I/O Wiring Reference GE A-6 PLC I/O Wiring Reference Modicon 984 A-7 SAN Unit Connection Reference.. A-8 Standard Transformers.. A-9 Homerun Cable (SAN3-24S/40S) Motor/Resolver.. A-10 Homerun Cable (SAN3-120S with RM4 Motor) Motor/Resolver.. A-11 Homerun Cable (SAN3-120S with RM5 Motor) Motor..... A-12 Homerun Cable (SAN3-120S with RM5 Motor) Resolver..... A-13 Homerun Cable (SAN3-24S/40S/120S) Load Cell (Pre-Amplifier) A-14 Extension Cable (SAN3-24S/40S/120S with RM4 Motor) Motor/Resolver. A-15 Extension Cable (SAN3-120S with RM5 Motor) Resolver.... A-15 Extension Cable (SAN3-120S with RM5 Motor) Motor.. A-16 Extension Cable (SAN3-24S/40S/120S) Load Cell (Pre-Amplifier). A-17 SAN3-24S/40S Unit Power Cable... A-18 SAN3-120S Unit Power Cable... A-19 I/O Connection Cable. A-20 I/O Proximity Switch Breakout Adapter... A-21 Homerun Proximity Switch Cable.. A-22 Tool / Extension Proximity Switch Cable... A-23 Homerun Brake Cable A-24 Extension Brake Cable... A-25 External Brake Unit & Cable.. A-26 RS-485 Jumper Cable.. A-27 RS-485 to RS-232 PC Converter Cable A-28

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9 Page 1-1 Chapter 1: Outline

10 Chapter 1: Outline enforce Operation Manual 1.1 About this Operation Manual This manual details the configuration, specifications and the operation of the enforce Digital Servo Press System. The following table outlines the contents of each chapter. Chapter Title Contents 1 Outline Basic characteristics and requirements of the enforce System. 2 Specifications General specifications of the enforce System. 3 System Description Description of SAN Unit and Tools and their instructions. 4 System Setup and Wiring Equipment installation and wiring. 5 Power Up and Initial Checks 6 System Operations Preliminary power on and operational tests. Instructions for the input of preset data and monitoring explanations. 7 Maintenance About display tool of the axis unit. 8 Troubleshooting Description of abnormal conditions and corrective actions. Any questions regarding the contents of this document or any related matter should be directed to FEC Inc. at (586) or faxed to (586) The Information set forth in the following document is the property of FEC Inc. This document shall not be released to or copied for any person and/or organization without the expressed prior consent of FEC Inc. Unauthorized reproduction or distribution of this manual is strictly prohibited. Please contact FEC Inc. if additional copies are required. Related Documentation DSP User Console Manual Throughout this manual will be 2 types of note boxes used to magnify the importance of the subject being discussed: Text boxes showing this symbol contain Important information to aid in setup or to avoid complications. Text boxes showing this symbol contain Caution information and should be followed to avoid personal injury or damage to the equipment. Page 1-2

11 enforce Operation Manual Chapter 1: Outline 1.2 Features enforce is a Digital Servo Press System designed for use in both pressing and bonding applications in a low cost package. The system is a culmination of over twenty years of servo motor expertise based on our electric fastening system integrated with the latest digital servo technology. Compact Design As the result of miniaturization circuit technology, the compact units maintain a maximum width of mm (the largest model) in spite of the built-in power source and Servo Amplifier. System components are back panel mounted. Pressing/Bonding Pressing and bonding are possible by load and distance control. Load, distance and force rate can be monitored. 32 Different Parameters (Work Selects) Total digitalized system eliminates analog potentiometers. 32 different set values of parameters are possible from the front panel and can be stored into Flash ROM. Battery backup of memory is not required. Data Communication External communication is available through an RS485 port or the optional DP2 Keypad Display which has an RS232 port for outputting single press ASCII data. Connecting a group of presses (maximum of 31) to computers or setup equipment is also available through RS485. Parameter download and/or upload is possible through this port. Motor A permanent magnet DC motor provides for improved press control and compact design. The sealed design of the motor provides greater protection from contamination. The resolver is designed to withstand harsh environments and provide high resolution control / distance feedback. Preamplifier Quality control of the tool load transducer is accomplished electronically (digitally) through the EEPROM (Electrically Erasable Programmable Read Only Memory) in the preamplifier. During factory setup of the load transducer, the unit is dead weight and dynamically tested against Standards that are certified and traceable to the National Institute of Standards and Technology. The resultant data is then programmed into the preamplifier where it is stored on non-volatile EEPROM. TOOL-ID functions are also incorporated in the unit. Servo Amplifier (Servo Drive) Reduced equipment size with improved drive circuit strength is the result of incorporating Isolated Gate Bipolar Transistor (IGBT) technology into the drive system. Detachable Front Keypad Display An optional hot-swappable front Keypad Display is available for programming single units and/or monitoring the fastening results and status conditions of the system. Self-Check Function The system self-checks the calibration of the load cell at the start of the press cycle to check whether the function of the unit cable and preamplifier is normal, thereby preventing abnormal pressing / bonding and damage to the tool etc. Abnormal Condition Reporting When an abnormal condition occurs, a number code is displayed on the Keypad Display attached to the front panel of the associated SAN unit to aid in troubleshooting. Page 1-3

12 Chapter 1: Outline enforce Operation Manual 1.3 Safety Precautions To ensure the most effective and extended use of all equipment, adhere to the following precautions: Tool Installation The tool generates a great amount of force during operation and the reaction force is applied to the mounting area of the tool. Therefore, tools must be installed in the proper position and with adequate bolts. The tool assembly contains precision parts and electric components, and must not be subject to excessive shocks or stresses. Use the supplied bolts to prevent the tool from loosening due to vibration. Keep in mind that the load cell is a strain gage based instrument and, although it has been designed to withstand sudden shock, repeated shock (over time) could damage the load cell. Pressing Operation Avoid pressing beyond the rated full scale load. Even if the load is less than the maximum, be sure that the duty cycle is within the specified limits. Cable Wiring Use only the specified cables for all system connections. When multiple enforce units are used, ensure that each SAN unit is connected to its matching numbered tool and that all connectors are locked. Do not use a high voltage circuit as a frame ground (FG). Also, the frame ground should be separate from the power ground. The use of a grounding rod located as close as possible to the enclosure housing the enforce controller unit (SAN) is preferable. Circuit breakers or fuses are required on branch circuit power feeds to the SAN units. PLC I/O cables must be run separate from any high voltage sources or cabling, and must not exceed 50 feet. Installation Environment The enforce controller should be placed in a NEMA 12 enclosure. Using the equipment in the following locations may lead to malfunction or breakdown. Avoid using in these areas or use an air conditioner. Areas under direct sunlight or if the environmental temperature is out of the 32~122 (0~50 ) range. Areas where relative humidity is out of the 20-90% range, the temperature change is drastic or where the area is exposed to mist and water drops. Do not use at the following locations. (Contact FEC Inc. if necessary for clarification) Areas where conductive powder, oil, mist, salt or organic solvents exist. Areas that have corrosive or combustible gases. Areas that have strong electric or magnetic fields. Areas where strong vibration or shock could be transmitted directly to a SAN unit or tool. Static Electricity The enforce System incorporates many electronic Surface Mounted Devices (SMD). It is advisable to strictly adhere to practices for safe electrostatic discharge in order to prevent damage to the system components when handling them. Cleaning Do not use any organic solvents, such as thinner, to clean a SAN unit or tool. The solvent could melt the surface paint, or penetrate inside and cause damage. A cloth dampened with alcohol or warm water should be used to lightly wipe the components. Page 1-4

13 enforce Operation Manual Chapter 1: Outline Electrical Noise Prevention SAN units must be located a minimum of 600mm from high transient voltage sources such as transformers, motor starters, AC inverters and AC contactors. If it cannot be avoided, the unit must be shielded. If high powered devices are used inside the enclosure, they must use a surge suppression device. Make sure that the power supply lines and cables for connecting the unit and tool are not run together inside the same duct. Handling and Shipping It is critical that enforce System components are properly handled and shipped in order to maintain the system s integrity. Adhere to the following requirements for shipping and handling: Loose enforce System components must be individually packaged and shipped in anti-static containers or wrap to prevent damage from electrostatic discharge. If the SAN unit is to be shipped in an enclosure, tighten all mounting screws to prevent the unit from being dislodged. Do not package the tool with the weight of the unit resting on the press ram as damage to the load cell may occur. The tool is heavy. Use lifting rings provided when necessary to move the tool. Enclosure must be protected with shrink wrap. Enclosure and system components should be shipped on an air ride trailer whenever possible. All non-painted metal parts (except the electric motor and connectors) must be greased or oiled to prevent rust. Do not ship or store the system components in environments where the temperature is out of the 23~131 (-5~55 ) range or where the humidity is above 90%. 1.4 Safety Labels Various labels are used on the SAN Unit and Press Tool to warn of possible harm or injury. These labels should be taken very seriously. Refer to the following page for label location. DANGER HIGH VOLTAGE: Do not touch exposed connector terminal. May cause electric shock. Disconnect power before servicing. CAUTION HOT SURFACE: Do not touch heatsink. May cause burn. Use proper grounding techniques. May cause electric shock. DANGER CAUTION HIGH VOLTAGE Pinch Point Watch your hands Keep away HOT SURFACE DANGER Do not disassemble May result in serious injury HOT SURFACE Do not touch PROPERLY GROUND Page 1-5

14 Chapter 1: Outline enforce Operation Manual SAN3-24S SAN3-120S Page 1-6

15 Chapter 2: Specifications PAGE 2-1

16 Chapter 2: Specifications enforce Operation Manual 2.1 System Specifications Power Supply Voltage 180VAC ~ 242VAC, 3 phase, 50/60Hz Operating Conditions Temperature: 0 ~ 50 (32 ~ 122 ) Humidity: 20-90%, no condensation Operating Range Duty Cycle less than 60% Storage Conditions Temperature: -5 ~ 55 (23 ~ 131 ) Humidity: Below 90%, no condensation Shipping Conditions Temperature: -5 ~ 55 (23 ~ 131 ) Humidity: Below 90%, no condensation Press Accuracy Minimum Distance Display Distance Control Resolution Force Transducer Accuracy Linearity of Force Transducer Operation Method Load/Distance Rate Setting From 1/2 to full scale - 3σ less than 3% scatter of target load. From 1/4 to 1/2 of full scale load - 3σ less than 4% scatter of target load. 0.01mm (up to 99.99mm), 0.1mm (over 99.99mm) 0.001mm ±1% (0 Full Scale) ±0.5% of Full Scale value (maximum) Load Control / Distance Control 2 points Force Needed Motor Used Required SAN Unit Tool Type Up to 0.2 ton 60W SAN3-24S DPT-021R1-**FS Up to 0.5 ton 80W SAN3-24S DPT-051R2A-**FS Up to 0.5 ton 1500W SAN3-120S DPT-051R4H-**PS Up to 1.0 ton 200W SAN3-40S DPT-101R3-**FS Up to 1.0 ton 1500W SAN3-120S DPT-101R4H-**PS Up to 1.5 ton 200W SAN3-40S DPT-151R3-**FS Up to 1.5 ton 1500W SAN3-120S DPT-151R4H-**PS Up to 2.0 ton 200W SAN3-40S DPT-201R3-**FS Up to 2.0 ton 1500W SAN3-120S DPT-201R4H-**PS Up to 3.0 ton 1500W SAN3-120S DPT-301R4H-** S Up to 5.0 ton 1500W SAN3-120S DPT-501R4H-**FS Up to 5.0 ton 3000W SAN3-120S DPT-501R5B-**PS Up to 7.0 ton 1500W SAN3-120S DPT-701R4H-**FS Up to 10.0 ton 3000W SAN3-120S DPT-102R5B-** S Up to 15.0 ton 3000W SAN3-120S DPT-152R5B-** S Up to 20.0 ton 3000W SAN3-120S DPT-202R5B-** S PAGE 2-2

17 enforce Operation Manual Chapter 2: Specifications 2.2 SAN Unit Specifications CPU: Data Communication: Parameter / Firmware Storage: 32 bit RISC (Reduced Instruction Set CPU) RS485 (2 Ports) 1 for DSP User Console Software Flash ROM SAN Unit Type SAN3-24S SAN3-40S SAN3 120S Motor Type RM1 RM2 RM3 RM4H RM5(B) SAN Unit Input Power SAN Unit Frequency MAX. POWER OUTPUT IN-RUSH CURRENT SAN POWER CONSUMPTION 180~242VAC, 3φ 50/60HZ 60W 80W 200W 1500W 3000W 18A 38.6A 116.4A 18W IDLE 31W IN CYCLE 18W IDLE 39W IN CYCLE 18W IDLE 109W IN CYCLE After powering down wait at least 5 seconds (1 minute recommended) before powering up again. If the equipment is powered ON and OFF repeatedly without this delay, the in-rush current circuit will stop the unit from functioning. If this happens it may take up to five minutes before the unit will power up again Duty Cycle Calculation Duty Cycle is rated as a percentage of the time the motor is running to the overall cycle time of the machine. This is an important factor in determining overload protection for servo amplifiers and motors as it directly relates to the amount of power or heat dissipation of the motor / servo package. The rated duty cycle for the enforce system is calculated as follows: Duty Cycle Percentage (%) = Tool Pressing Time x 100 Total Cycle Time (Tool Pressing + Tool Waiting) Duty cycle ratings vary between tools. As a general rule, however, it should not exceed 60%. If duty cycles remain above 60% for extended periods, a Servo Amplifier Error / Overload will result (see Abnormal Code 8-10). Protection for high duty cycle is a standard feature of the servo amplifier to prevent servo or motor damage. PAGE 2-3

18 Chapter 2: Specifications enforce Operation Manual SAN Unit Dimensions SAN3-24S, SAN3-40S Mounting: Top 1 place #8-32 screw Bottom 2 places #8-32 screw Weight: SAN3-24S kg SAN3-40S kg Note: The diagram shown above reflects dimensions for the SAN3-40S. The SAN3-24S does not have a heat sink plate so the width is 60mm as opposed to 74mm. PAGE 2-4

19 enforce Operation Manual Chapter 2: Specifications SAN3-120S Mounting: Top 2 places #8-32 screw Bottom 2 places #8-32 screw Weight: SAN3-120S - 3.6kg. PAGE 2-5

20 Chapter 2: Specifications enforce Operation Manual 2.3 Press Tool Part Number Breakdown DPT-[151]R[3]-[25][F][S][B]-[00][A] A B C D E F G H (A) PRESS FORCE 050=50kg ( LB) 151=1.5ton 202=20ton (B) MOTOR 1 = RM1A 2A = RM2A 3 = RM3A 4H = RM4HB (B=INTERNAL BRAKE) 5 = RM5B, RM5 (B=INTERNAL BRAKE) (C) STROKE 15 = 150mm 25 = 250mm (D) PRESS TYPE F = PRESSING (Holding time <1sec.) P = BONDING (Holding time >1sec.) (E) SHAFT TYPE S = SPLINE SHAFT G = GUIDE SHAFT (F) EXTERNAL BRAKE B = WITH BRAKE BLANK = NO BRAKE (RM4 ALWAYS WITH BRAKE) (G) MOUNTING 00 = STANDARD (BACK MOUNTING) 01 = 90 DEGREES 02 = TAPPED 03 = FRONT MOUNTING 10 = SPECIAL (CUSTOM DESIGN) (H) VERSION/REVISION A = CURRENT B = FUTURE UPGRADES C = FUTURE UPGRADES PAGE 2-6

21 enforce Operation Manual Chapter 2: Specifications Tool Specifications Motor: Force Monitor: Distance Monitor: Permanent magnet DC Inline Load Cell High Resolution Resolver Tool Type (Fitting) Full Scale Load [KN] Maximum Speed [mm/sec] Minimum Speed [mm/sec] DPT-021R1-**F DPT-021R2A-**F DPT-051R2A-**F DPT-101R3-**F DPT-151R3-**F DPT-201R3-**F DPT-301R4H-**F DPT-501R4H-**F DPT-701R4H-**F Tool Type(Bonding) Full Scale Load [KN] Maximum Speed [mm/sec] Minimum Speed [mm/sec] DPT-051R4H-**P DPT-101R4H-**P DPT-151R4H-**P DPT-201R4H-**P DPT-301R4H-**P DPT-501R5B-**P DPT-102R5B-**P DPT-152R5B-**P DPT-202R5B-**P *Standard part numbers shown. Contact FEC for non-standard part specifications. 1KN = Lbs. PAGE 2-7

22 Chapter 2: Specifications enforce Operation Manual Tool Dimensions Drawing Shown For Reference Only TOOL NUMBER STROKE A B C D E F G H J K L DPT-021R1-**F N/A 9(4) N/A 126 DPT-051R2A-**F N/A 14(4) N/A DPT-101R3-**F N/A 18(4) N/A DPT-101R4H-**P N/A 18(4) N/A DPT-151R3-**F N/A 18(4) N/A DPT-201R3-**F N/A 18(4) N/A 245 DPT-301R4H-**F N/A 22(4) N/A 255 DPT-501R4H-**F (6) N/A 313 DPT-501R5B-**P (6) N/A 371 DPT-701R4H-**F (6) N/A 334 *Standard part numbers and strokes shown. Contact FEC for non-standard part number dimensions. PAGE 2-8

23 enforce Operation Manual Chapter 2: Specifications 2.4 Functions Pressing Function The following press control methods can be selected for the enforce System. 1. Load Control 2. Distance Control 3. Specified Point Load Judgment / Load Inflection Detect 4. Time Controlled Press 5. Load Drop Detection 6. Specified Distance Peak Load Detection 7. Load Drop Detection (Point Stop) 8. Distance Control with Load Limit Load, Distance, Press Rate and Time can be monitored in any configuration. The system has the capability to perform 1 or 2 step press operations. In a 2 step operation, SAN units can perform synchronized pressing using the SYNC signal, which controls the simultaneous synchronization upon start. Thus, the controllers start and stop the presses when they have reached a previously defined load value or distance. They will start again simultaneously to reach the final load or final distance. Premature Load Detection If the parameters are set up for 1 ST Step Distance and 1 ST Step Load, the press will stop if it detects a load equal to or higher than 1 ST Step Load before it reaches 1 ST Step Distance. If FIRST STEP HI/LOW CHECK is selected, the above check will be performed (HI Check). In addition, after the press reaches 1 ST Step Distance it will verify that the load detected is at least that as specified in Threshold Load (LOW Check). If not, the press operation will stop. Self-Check Function If the SELF-CHECK OFF signal is HIGH (inactive or unconnected), the home-position (zero) voltage level and CAL (full scale) voltage level of the load cell are automatically checked before the cycle starts. If the automatic system self-check of the load cell is not required, this function can be disabled by forcing the SELF-CHECK OFF signal LOW before the cycle starts. When operating with the signal HIGH, the equipment will correct the zero load level so the equipment can adjust to external load changes, such as vacuum or gravity. The equipment will use the previous zero load level if the equipment was started with the signal LOW (Active). Press Bypass Function (BYPASS) When the Bypass input signal is activated through a PLC or when the RUN/BYPASS switch on the front panel is switched to the Bypass position, the Bypass output signal is activated. In this condition, the controller will not START. The SYNC signal will be in high impedance condition to avoid affecting synchronized operations. If the unit is put into bypass mode when in cycle, it will stop functioning. Reject (NG) / Abnormal Condition Display If a press reject or a system abnormal occurs, the tool will stop and output the appropriate signal. It will also display the resultant reject data or abnormal number on the front panel. When a press reject occurs, the tool will return if programmed. Tool Type Check Function The contents of the ID is read in the following conditions When a tool is already connected at the time of powering on. When the tool is connected and preset data is downloaded from a users console to the SAN unit. The tools have an EEPROM in the preamplifier that contains tool data specific for each tool. The tool type check function reads the information of the tool EEPROM and compares it to the information contained in the SAN unit; any mismatch is reported as a Tool Type Error Abnormal. PAGE 2-9

24 Chapter 2: Specifications enforce Operation Manual PAGE 2-10

25 Chapter 3: System Description PAGE 3-1

26 Chapter 3: System Description enforce Operation Manual 3.1 System Block Diagram The enforce system can consist of a stand alone unit or combined in a multiple press configuration. Discrete 24VDC (Sinking) I/O on the SAN unit provides direct communication with the PLC for individual or multiple press control. In a multiple press configuration, SAN units can perform synchronous pressing using the SYNC signal. Press programming / monitoring can be accomplished using the hot-swap detachable keypad for individual controllers, or by a PC running the DSP User Console software package for simultaneous upload / download and monitoring of up to 31 SAN controllers via an RS485 series connection on the front of each SAN unit.. PAGE 3-2

27 enforce Operation Manual Chapter 3: System Description 3.2 DSP1500 Front Panel (enforce Controller) DSP1500 Front Panel Switches and Connectors D S P C O N 1 CON1: SW1: RUN/BYPASS: RUN: BYPASS: RS485: For Display Unit (SAN-DP*S) connection. Sets press number and special configuration features.(see Section 4.8) Controller Enable/Disable switch. Enable Bypass Mode(Disable) Bi-directional Communication ports. R U N S W1 B Y P A S S P O WE R B U S Y S V. A B N. A C. R E J. RESOLVER: MON.: T/D: Resolver connection for tool Motor/Resolver cable. (Monitor Output) Pressure analog voltage and distance pulse output connection. Connection for tool Load Cell cable. R S PLC: Connection for I/O & Limit Sensor Cable. Connects to press limit sensors and PLC or Input-Output devices. R E SO L V E R MOTOR: Motor Connection for tool Motor/Resolver cable. M O N. AC V: Connection for Input Power. 3 phase, VAC, 50/60Hz T / D M OT O R A C V P L C FEC SAN3-24S PAGE 3-3

28 Chapter 3: System Description enforce Operation Manual DSP1500 Front Panel Condition Display LED s D S P C O N 1 POWER LED (Yellow) Lights when 180~242VAC input power is applied to the controller. R U N R S S W1 B Y P A S S P O WE R B U S Y S V. A B N. A CC. R EJ. BUSY LED (Orange) Lights up when in cycle Blinks when returning Blinks when running in MANUAL Lights up when powering on and initializing SV. [SERVO] LED (Red) Lights up when a servo amplifier fault condition exists. ABN. [ABNORMAL] LED (Red) Lights up when an abnormal condition occurs M O N. T / D P L C FEC R E S O L V E R M O T O R A C V SAN3-24S ACC. [ACCEPT] LED (Green) Lights up when normal or within limits REJ. [REJECT] LED (Red) Lights up or blinks when exceeding judgment limit Solid light: exceeding load control limits Fast blink: exceeding distance control limits Slow blink: exceeding load rate/time limits BYPASS/RUN LED (Red) Solid light when switch is in RUN position and not receiving a BYPASS signal from an external source. Blinking light when switch is in BYPASS position or when a BYPASS signal from an external source is received. *Switch in BYPASS position overrides signal from an external source. PAGE 3-4

29 enforce Operation Manual Chapter 3: System Description DSP1500 Detachable Keypad Buttons S T A R T M A N U A L C A L R E S E T ( S E A R C H ) D A T A D S P Operating Button START Button MANUAL Mode Button CAL Manual Button RESET Button B Y P A S S R U N P A R M M O D E S E T ( H O M E ) A B N. A C. R E J. D - N O D A T A Data Display / (Operating) Button MODE Button SET Button(Home Return) DATA UP Cursor Button(Manual Return) DATA DOWN Cursor Button (Manual Advance) R S R E S O L V E R M O N. T / D M O T O R A C V P L C F E C S A N 3-24S PAGE 3-5

30 Chapter 3: System Description enforce Operation Manual DSP1500 Detachable Keypad Condition Display S T A R T M A N U A L C A L R E S E T ( S E A R C H ) D A T A DATA Display (4 figure) Data Display (Load, Distance, etc.) D S P PARM Display (2 figure) Parameter Number Display Or Abnormal Number Display B Y P A S S R U N P A R M M O D E S E T ( H O M E ) A B N. A C. R E J. D - N O D A T A D-NO Display (2 figure) Data Number Display Press Unit Number Display Or Abnormal Sub-Code Number Display R S R E S O L V E R M O N. T / D M O T O R A C V P L C F E C S A N 3-24S PAGE 3-6

31 enforce Operation Manual Chapter 3: System Description 3.3 Press Tool Drawing Shown For Reference Only A) MOTOR: Totally enclosed DC permanent magnet motor Refer to Chapter 2 for available motor sizes B) RESOLVER: Provides feedback for speed regulation to servo amplifier Provides distance monitoring capability to press operation C) PRE-AMPLIFIER: Amplifies load transducer signal. Houses I.D. chip used to verify tool functionality D) LOAD CELL: Precision strain gage load transducer Provides press force feedback to servo amplifier E) HOME POSITION PROXIMITY: Counter-clockwise (return) limit sensor F) ADVANCED PROXIMITY: Clockwise (advance) limit sensor G) GEAR HOUSING: Durable gear transmission H) SPLINE: Ball screw driven press ram I) MOUNTING FLANGE: See Chapter 2 for size and hole pattern J) GREASE FITTING: Spline lubrication point. K) LUBE ACCESS POINT: Gear lubrication point (availability and location dependant on press size) PAGE 3-7

32 Chapter 3: System Description enforce Operation Manual 3.4 Connection Diagram Controller TO PLC OR I/O DEVICE Tool CON1 BRAKE CABLE BRAKE MOTOR LOAD CELL CCW CONNECT TO COMPUTER, PC OR NEXT SAN UNIT CONNECT TO PLC OR I/O DEVICES RS485 RS485 MON T/D PLC RESOLVER MOTOR AC V RESOLVER CABLE MOTOR CABLE INPUT POWER CABLE RES. 3 PHASE VAC 50/60Hz *ORG CW PRE- AMPLIFIER I/O & LIMIT SENSOR CABLE LOAD CELL CABLE *ORG Connection is for special applications. PAGE 3-8

33 Chapter 4: System Setup & Wiring PAGE 4-1

34 Chapter 4: System Setup and Wiring enforce Operation Manual 4.1 Design and Build Guidelines Review Chapters 1 and 2 prior to designing a System. If requirements and specifications in these two chapters are not addressed, there is a possibility for degraded system performance. ITEM COMMENTS 1 Select the correct tool size 2 Design tool mounting plate and press fixtures. Keep force range between 50% and 75% of tool capability for press performance. Design of mounting plate MUST BE stronger than the maximum capability of the press selected. Section Reference 2.1, Select correct SAN Unit for the tool selected. Different size tools require different size SAN Units. Ensure the correct one is selected. 2.1, Select adequate circuit protection Circuit protection for the SAN Unit should be separate from other devices Select an air handling unit as required. (Air Conditioner, Heat Exchanger, etc.) Select a unit applicable to the environmental conditions Select adequate PLC hardware if required. PLC must facilitate direct connection to the enforce system I/O (24VDC true low). 4.7, Design PLC logic PLC program can be written using signal descriptions and timing charts provided. 4.7, Select NEMA 12 enclosure and backpanel. Backpanel must be large enough to allow adequate space between SAN units Set SAN Unit DIP switches Verify the SAN Unit address and special functions setting Mount SAN Units onto backpanel. Mount with adequate spacing between each unit and between unit and other devices Wire input power connections. VERIFY VOLTAGE PRIOR TO APPLYING POWER Wire I/O Connections. VERIFY VOLTAGE SOURCES PRIOR TO CONNECTION & AGAIN BEFORE POWER UP Route homerun & extension cables. ADHERE TO CABLE INSTALLATION GUIDELINES Connect homerun & extension cables to SAN Unit and tool. 15 Power up the equipment. 16 Input preset data. 17 Perform initial checks. VERIFY POWER IS OFF. Connect cables for tool motor power, resolver, transducer, limit sensors and brake if required. VERIFY WIRING & VOLTAGES OF ALL POWER SUPPLIES PRIOR TO POWER UP. Set the preset data for force, distance, speed, time, etc. according to customer specifications. Set Stop signal high & Work Select signals low. Verify there are no obstructions in the press ram travel path. 3.4, 4.5, 4.6, 4.13 Chapter 4 Chapter Verify normal operation. Confirm automatic operation. 5-2 PAGE 4-2

35 enforce Operation Manual Chapter 4: System Setup and Wiring 4.2 SAN Unit Design and Mounting Dimensions SAN units must be mounted with a minimum clearance of 12mm on each side to allow proper heat dissipation. Cable connections on the front of the units require 100mm of clearance. Allow a minimum of 100mm clearance on the bottom of each controller for cable hook up when updating firmware. SAN units must be located a minimum of 600mm from any high transient voltage power source. SAN3-24S, SAN3-40S Mounting: Top (1) place #8-32 screw Bottom (2) places #8-32 screw Weight: SAN3-24S 1.4 kg SAN3-40S 1.8 kg The diagram shown above shows the dimensions of the SAN3-40S. The protrusion of the heat sink plate (14mm) is on the SAN3-40S only, therefore the width of the SAN3-24S is 60mm as opposed to 74mm. PAGE 4-3

36 Chapter 4: System Setup and Wiring enforce Operation Manual SAN3-120S Mounting: Top (2) places #8-32 screw Bottom (2) places #8-32 screw Weight: SAN3-120S kg PAGE 4-4

37 enforce Operation Manual Chapter 4: System Setup and Wiring 4.3 Calculating Circuit Protection RATED VALUES FOR CALCULATING CIRCUIT PROTECTION MOTOR # OF SAN3 UNITS KVA PER MOTOR TYPE WATTAGE SAN3 UNIT PER 1 KVA SAN3 UNIT R1 60 SAN3-24S R2 80 SAN3-24S R3 200 SAN3-40S R SAN3-120S R SAN3-120S The chart above shows nominal motor ratings for standard press motors, along with the power requirements for each SAN unit. Use the formula below to calculate transformer secondary fuse or circuit breaker sizes. Transformer (VA) 1.5 x Secondary Voltage 3 = Secondary Fuse Size Example: 1000 (VA) 1.5 x 200 VAC 3 = 4.33 Amps (Use 5 Amp Fuses)* * Use a fuse or circuit breaker with the next available highest rating. Due to the high inrush current at power up, it is recommended to use Slow Blow type fuses or fuses rated for motor loads such as Bussman type FRS or FRN. PAGE 4-5

38 Chapter 4: System Setup and Wiring enforce Operation Manual 4.4 Input Power Supply Connection Adequate circuit protection must be provided for the SAN unit input power. Recommended conductor size should be a minimum of #16AWG. Suggested color code (FEC standard): U Red, V White, W Black, FG Green. T / D P L C M OT O R A C V 4 : U 3 : V 2 : W 1 : F G Wiring Chart SAN3-24S, 40S 4:U 3-Phase 3:V 180 ~ 242VAC 2:W 50/60Hz. 1:FG SAN3-120S (Shown Below) A5:U B5:U 3-Phase A4:V B4:V 180 ~ 242VAC A3:W B3:W 50/60Hz. A2:NC B2:NC A1:FG B1:FG *Connect wires to both the A side and B side. SAN3-24S Mating Connectors SAN3-24S, 40S Manufacture: AMP Housing Part No.: Contact Part No.: (Qty.-4) SAN3-120 SAN3-120S Manufacture: AMP Housing Part No.: Contact Part No.: (Qty.-8) B A PAGE 4-6

39 enforce Operation Manual Chapter 4: System Setup and Wiring 4.5 Motor Power-Resolver Connections The motor connector provides control power to the motor. The resolver connector handles the signals that define the rotation of the motor. The controller provides a signal to the winding of the rotor. As the rotor spins, two sets of stators, electrically shifted 90 degrees, generate a sine wave and a cosine wave signal. Both signals are processed by the controller to define position and speed of the motor. The signals for the motor and resolver are contained in one cable. See Section 4.13 and Appendix A for connecting cable part numbers and specifications. RESOLVER Wiring Chart 1: (R1) Rotor 6: (R2) Rotor 2: (S2) Stator 7: (S4) Stator 3: (S1) Stator 8: (S3) Stator 4: Not Used 9: Shield 5: Not Used 10: Not Used Mating Connector Manufacture: Molex Housing Part No.: Contact Part No.: (Qty.-7) MOTOR SAN3-24S, 40S 1: Frame Ground 2: Not Used 3: W Phase 4: V Phase 5: U Phase Wiring Chart SAN3-120 B A SAN3-120S (Shown Below) 1: Frame Ground 6: Frame Ground 2: Not Used 7: Not Used 3: W Phase 8: W Phase 4: V Phase 9: V Phase 5: U Phase 10: U Phase Mating Connectors SAN3-24S, 40S Manufacture: AMP Housing Part No.: Contact Part No.: (Qty.-4) SAN3-120S Manufacture: AMP Housing Part No.: Contact Part No.: (Qty.-8) PAGE 4-7

40 Chapter 4: System Setup and Wiring enforce Operation Manual 4.6 Pre-Amplifier Connection The pre-amplifier connector links the SAN controller to the tool load cell in order to perform the following functions: 1. Reads the load voltage values from the pre-amplifier. 2. Tests the pre-amplifier condition by generating a voltage signal for full scale load by the Calibration function. 3. Tests the Pre-amplifier Zero level by the Zero Level Check function. See Section 4.13 and Appendix A for connecting cable part numbers and specifications. Wiring Chart 1: (SCL) Signal Clock 5: Frame Ground 2: (SDA) Signal Data 6: Ground 3: (CAL) Calibration 7: -12VDC 4: Load Input 8: +12VDC Mating Connector Manufacture: Molex Housing Part No.: Contact Part No.: (Qty.-8) PAGE 4-8

41 enforce Operation Manual Chapter 4: System Setup and Wiring 4.7 External-Control Signal Connection Mating Plug Manufacturer:Honda Tsushin Kougyo (HONDA) Vertical Housing Part No.: MR-34L Male Insert Part No.: MR-34M (See Appendix A for connecting cable part numbers) PLC I/F(AXIS I/O)Signal Pin No. Signal Name IN/OUT Description 1 STOP IN (N.C.) Stops System operation upon loss of signal. 2 RESET IN (N.O.) Resets to the initial condition. (>100 ms pulse) 3 MANUAL IN (N.O.) Manual mode. 4 START IN (N.O.) Starts Press Cycle. 5 BYPASS IN (N.O.) Disables Press operation. 6 SYNC COM Synchronizing signal common. 7 SYNC COM Use only for synchronizing signal common. 8 SYNC IN/OUT Synchronizing signal (5V TTL) 9 NEAR-ORG/BANK1 IN (N.O.) Near Origin sensor input/bank 1 Select.(Use for special applications) 10 OPTION IN IN (N.O.) Use when inputting option and special specification 11 BANK0 IN (N.O.) Bank 0 Select input 12 SYNC IN/OUT Synchronizing signal (5V TTL) 13 IN COMMON Input signal common. (+12 ~ +24VDC) 14 SELF CHECK OFF IN (N.O.) Disable the self-check function. 15 CW LIMIT IN (N.C.) CW limit sensor input.(advance limit) 16 CCW LIMIT IN (N.C.) CCW limit sensor input.(return limit) 17 WORK SELECT 0 IN (N.O.) 18 WORK SELECT 1 IN (N.O.) 19 WORK SELECT 2 IN (N.O.) 20 WORK SELECT 3 IN (N.O.) These 5 inputs form a binary code which is capable of selecting up to 32 different parameters. (In Manual Mode these inputs become selecting signals for advance, return, home-position search and home-position return operations.) 21 WORK SELECT 4 IN (N.O.) 22 OUT DATA11 OUT (N.O.) Echo of Bank 0 Select Signal 23 OUT COMMON Output signal common. (0VDV) 24 OUT DATA0 OUT (N.O.) 25 OUT DATA1 OUT (N.O.) 26 OUT DATA2 OUT (N.O.) 27 OUT DATA3 OUT (N.O.) 28 OUT DATA4 OUT (N.O.) 29 OUT DATA5 OUT (N.O.) 30 OUT DATA6 OUT (N.O.) 31 OUT DATA7 OUT (N.O.) 32 OUT DATA8 OUT (N.O.) Outputs system condition signals based on which Bank is selected. 33 OUT DATA9 OUT (N.O.) 34 OUT DATA10 OUT (N.O.) Echo of Bank 1 Select Signal IN: Input Signal OUT: Output Signal NC: Normally Closed NO: Normally Open Only when the MANUAL signal is ON for inputting in to( ). PAGE 4-9

42 Chapter 4: System Setup and Wiring PAGE 4-10 enforce Operation Manual System Parameter 00, D-No. 08 NEAR ORG/BANK1 signal is normally BANK 1. To enable Output Banks 2 & 3, set Parameter to 2. (See Page 6-22) If using the CYCLE OK signal, BANK 1 output is not available in Bank 1. The BUSY signal is normally used to operate the brake. When changing Banks, the meaning of the BUSY signal will change when a bank other than Bank 1 is selected. (See Section 4.14 for Brake Operation) BANK1 BANK0 OUT DATA Signal Name Description OFF OFF ON ON OFF ON OFF ON OUT DATA0 BYPASS Output when press is in BYPASS OUT DATA1 ORG OK Output after home position has been defined. OUT DATA2 POS STOP Output when the cylinder is stopped in home position. OUT DATA3 BUSY Output while operating. OUT DATA4 READY Output when the system is READY to operate. OUT DATA5 ABNORMAL Output when an Abnormal condition occurs. OUT DATA6 ACCEPT Output when the system has halted without failure. OUT DATA7 REJECT Output when the system has halted with failure. OUT DATA8 ADVANCED Output when the press has reached target load or distance. OUT DATA9 TIMING Output timing signal. Used when Par. 00, D-No. 0A is set. OUT DATA10 CYCLE OK/BANK1 Output when the press reaches the distance set in Param. 00, D-No. 0A (1~9) / Output echo of Bank Select 1 Input. OUT DATA11 BANK0 Output echo of BANK Select 0 Input. OUT DATA0 OUT DATA1 OUT DATA2 OUT DATA3 WORK SELECT 4 OUT DATA4 WORK SELECT 3 OUT DATA5 WORK SELECT 2 Output echo of selected Input. OUT DATA6 WORK SELECT 1 OUT DATA7 WORK SELECT 0 OUT DATA8 OUT DATA9 OUT DATA10 BANK1 Output echo of BANK Select 1 Input. OUT DATA11 BANK0 Output echo of BANK Select 0 Input. OUT DATA0 LOAD_LOW Output on a Low Load Reject. OUT DATA1 LOAD_HIGH Output on a High Load Reject. OUT DATA2 Rt2_LOW Output on a Low Rate 2 Reject. OUT DATA3 Rt2_HIGH Output on a High Rate 2 Reject. OUT DATA4 Rt1_LOW Output on a Low Rate 1 Reject or 1 ST zone High Abnormal OUT DATA5 Rt1_HIGH Output on a High Rate 1 Reject or 1 ST zone Low Abnormal. OUT DATA6 DIS_LOW Output on a Low Distance Reject OUT DATA7 DIS_HIGH Output on a High Distance Reject. OUT DATA8 OUT DATA9 OUT DATA10 BANK1 Output echo of Bank Select 1 Input. OUT DATA11 BANK0 Output echo of Bank Select 0 Input. OUT DATA0 OUT DATA1 OUT DATA2 OUT DATA3 OUT DATA4 OUT DATA5 OUT DATA6 OUT DATA7 OUT DATA8 OUT DATA9 OUT DATA10 BANK1 Output echo of Bank Select 1 Input OUT DATA11 BANK0 Output echo of Bank Select 0 Input.

43 enforce Operation Manual Chapter 4: System Setup and Wiring Input and Output H/W Recommended Connecting Circuit I/OConnector *See Synchronization for SYNC signal connections. All enforce inputs and outputs are active true low. All interface devices must accommodate active true low connection (NPN) for correct operation. When an input card with high input resistance is used, it may not normally receive OUT DATA signals depending on the external environment and other conditions. Note that when Mitsubishi I/O composite cards #A1SH42 and #A1SZ42 are used, the above mentioned trouble may occur. PAGE 4-11

44 Chapter 4: System Setup and Wiring enforce Operation Manual Input and Output Signal Explanation Input Signals Inputs are sourced (normally high) and activated when pulled low (0VDC). START:Cycle Start signal (Normally Open) The unit reads the WORK SELECT signal and SELF-CHECK signal at the start ( OFF -> ON ) of this signal and starts pressing. This signal must be maintained until the cycle is complete. The press unit will be in BUSY (in cycle) status after start of press. When the SYNC signal input is turned OFF, the SYNC output signal turns ON. In the following conditions the READY output signal is turned OFF, and the START signal input cannot be received: While stopping While resetting Bypass condition Abnormal condition If the start signal is turned ON while in MANUAL mode, the press will perform the function defined in the MANUAL operation of the selected WORK SELECT. (See MANUAL and WORK SELECT chart on the following page) If the START input signal is turned off while in cycle the unit will stop and return as programmed in the RETURN MODE parameter. STOP: Emergency Stop signal (Normally Closed) This signal must be active (on) for controller operation. When it is inactive (off), controller operation will stop, press motion stops and input/outputs will be disabled. If the signal is turned off during a press cycle, press motion stops but the cycle data collected is retained. A judgment will be made based upon the limits set in the active parameter. The SYNC signal stays ON compulsorily when STOP is activated. MANUAL: Manual Mode signal (Normally Open) While the signal is ON, the mode is set to MANUAL. If parameter 1 (no Work Selects are selected) is active, Manual+Start initiates home position search. If parameter 2 thru 8 is active, Manual+Start initiates the function shown in the chart on the following page. A signal will not be accepted during a reset or when in cycle. RESET: Reset signal (Normally Open) When active (on), this signal will clear all data and discrete outputs. A Zero Check of the force transducer will be performed. During the Zero Check, the ACCEPT or REJECT lamp will light to indicate the result of the Zero Check. If the system has been disabled by an ABNORMAL output, the system will not return to normal operation until the abnormal condition has been corrected. This signal has to be input for 200~500ms. Do not input this signal between cycles due to the potential for data loss. If the reset signal is turned ON while in cycle, press motion stops. SELF CHECK OFF: Load transducer automatic check OFF signal When this signal is OFF (or unconnected) at the time of inputting a START signal, the home-position voltage level and CAL voltage level of the load transducer is automatically checked before the press cycle begins. If the automatic check of the transducer is not required, turning ON this signal at the time of inputting a START signal will cause this test not to be performed. BYPASS: Press off signal (Normally Open) When active (on), all functions of the press controller are disabled and a BYPASS signal is output, making it impossible to start the press. If the signal becomes active during a press cycle, the press cycle is stopped. In order to avoid an adverse effect on synchronous pressing being performed by another press, the SYNC signal is turned OFF (open) at the time of bypass. PAGE 4-12

45 enforce Operation Manual Chapter 4: System Setup and Wiring WORK SELECT 0 thru 4: Parameter Select signal (Normally Open) These 5 inputs [WORK SELECT 1-4] form a binary code which is capable of selecting up to 32 different sets of press parameters. WORK WORK WORK WORK WORK Param SELECT 4 SELECT 3 SELECT 2 SELECT 1 SELECT 0 No. MANUAL mode OFF (OPEN) OFF (OPEN) OFF (OPEN) OFF (OPEN) OFF (OPEN) 1 Home-position search OFF (OPEN) OFF (OPEN) OFF (OPEN) OFF (OPEN) ON 2 Home-position return OFF (OPEN) OFF (OPEN) OFF (OPEN) ON OFF (OPEN) 3 Descent high speed jog OFF (OPEN) OFF (OPEN) OFF (OPEN) ON ON 4 Ascent high speed jog OFF (OPEN) OFF (OPEN) ON OFF (OPEN) OFF (OPEN) 5 Descent middle speed jog OFF (OPEN) OFF (OPEN) ON OFF (OPEN) ON 6 Ascent middle speed jog OFF (OPEN) OFF (OPEN) ON ON OFF (OPEN) 7 Descent low speed jog OFF (OPEN) OFF (OPEN) ON ON ON 8 Ascent low speed jog OFF (OPEN) ON OFF (OPEN) OFF (OPEN) OFF (OPEN) 9 (Home-position search) OFF (OPEN) ON OFF (OPEN) OFF (OPEN) ON 10 (Home-position return) OFF (OPEN) ON OFF (OPEN) ON OFF (OPEN) 11 (Descent high speed jog) OFF (OPEN) ON OFF (OPEN) ON ON 12 (Ascent high speed jog) OFF (OPEN) ON ON OFF (OPEN) OFF (OPEN) 13 (Descent middle speed jog) OFF (OPEN) ON ON OFF (OPEN) ON 14 (Ascent middle speed jog) OFF (OPEN) ON ON ON OFF (OPEN) 15 (Descent low speed jog) OFF (OPEN) ON ON ON ON 16 (Ascent low speed jog) ON OFF (OPEN) OFF (OPEN) OFF (OPEN) OFF (OPEN) 17 (Home-position search) ON OFF (OPEN) OFF (OPEN) OFF (OPEN) ON 18 (Home-position return) ON OFF (OPEN) OFF (OPEN) ON OFF (OPEN) 19 (Descent high speed jog) ON OFF (OPEN) OFF (OPEN) ON ON 20 (Ascent high speed jog) ON OFF (OPEN) ON OFF (OPEN) OFF (OPEN) 21 (Descent high speed jog) ON OFF (OPEN) ON OFF (OPEN) ON 22 (Ascent middle speed jog) ON OFF (OPEN) ON ON OFF (OPEN) 23 (Descent low speed jog) ON OFF (OPEN) ON ON ON 24 (Ascent low speed jog) ON ON OFF (OPEN) OFF (OPEN) OFF (OPEN) 25 (Home-position search) ON ON OFF (OPEN) OFF (OPEN) ON 26 (Home-position return) ON ON OFF (OPEN) ON OFF (OPEN) 27 (Descent high speed jog) ON ON OFF (OPEN) ON ON 28 (Ascent high speed jog) ON ON ON OFF (OPEN) OFF (OPEN) 29 (Descent middle speed jog) ON ON ON OFF (OPEN) ON 30 (Ascent middle speed jog) ON ON ON ON OFF (OPEN) 31 (Descent low speed jog) ON ON ON ON ON 32 (Ascent low speed jog) If the start signal is turned ON while in MANUAL mode, the press will perform the function defined in the MANUAL operation of the selected Parameter Number; Home-position search, Home-position return, Descent jog (Advance) and Ascent jog (Return). The speed of the operation of MANUAL mode is set in the Data Number OE: MANUAL SPEED system parameter. (See Page 6-23)The speed of the Home-position search, Home-position return, High speed jog is set to this set value. If a value greater than 10mm/sec. is entered, the system will limit Home Position Search speed to 10mm/sec. The speed of the middle speed jog is set to 1/10 of this set value or the tool s minimum speed. The speed of the low speed jog is set to 1/100 of this set value or the tool s minimum speed. On a Home Position Search, the ascent (return) operation operates first and when the CCW limit sensor turns OFF, the operation changes to descent (advance) operation. After the CCW limit sensor turns ON again, the motor will advance until the resolver location (in pulses) is at 0. This point is set to the zero point and becomes the home position. (See Section ) PAGE 4-13

46 Chapter 4: System Setup and Wiring enforce Operation Manual Output Signals Outputs are rated at +12~24VDC, 200ma. When activated, open collector sink outputs (normally high) pull the input device low (0VDC). OUTPUT BANK 1: Bank0 Off / Bank1 - Off REJECT: [OUT DATA7] Press REJECT (NG) Signal Output when the press result exceeds the press limits. Output remains active until the start or reset signal is input. ACCEPT: [OUT DATA6] Press ACCEPT (OK) Signal Output when the press result is within the press limits. Output remains active until the start or reset signal is input. ABNORMAL: [OUT DATA5] System Abnormal/Abnormal Result Output when abnormalities are detected during a system check performed by the unit or during a press cycle. Output remains active until the reset signal is input. READY: [OUT DATA4] Input Enable Signal Output when the SAN Unit is capable of an input signal from external equipment, such as a PLC. READY output turns OFF in the following conditions: o During initial processing at powering up (for 15 seconds) o When in MANUAL mode o When an abnormal signal is output o When in Bypass status (when set and during download communication). o While STOP signal is inactive o While in cycle, resetting and checking CAL o When operation of the press unit by an external input is impossible BUSY: [OUT DATA3] Operating signal When the press unit is in cycle, the signal is ON. POS STOP: [OUT DATA2] Return position stop signal Output when the press is stopping between home-position (0mm position) and the selected parameter [62: Return Position] when it is not in cycle. If the selected parameter [62: Return Position] is set to 10mm, the signal is output when it is stopping between 0 to 10mm. Note that the press is not always resting at the home position (0mm). Caution should be taken when selecting different Parameter numbers. If the new parameter number selected does not have the same [62: Return Position], the POS STOP signal may go low (OFF). ORG OK: [OUT DATA1] Home-position confirm signal Output after a home-position search has been performed and a home position has been defined. *Home Position must be defined before Automatic operation will be allowed. BYPASS: [OUT DATA0] Press off status Outputs ON when the press is in the off status. PRESS ADVANCED: [OUT DATA8] Outputs when the press reaches the standard load or standard distance for a time that is set in [61: Recovery Time]. The front display panel will show d when in recovery. Do not remove start signal until this signal goes low (OFF). If this happens, when the start signal goes high (ON) again, the tool will go back to standard distance or load point then recover for the set time before continuing. PAGE 4-14

47 enforce Operation Manual Chapter 4: System Setup and Wiring TIMING SIGNAL: [OUT DATA9] (Special Function) This signal is active if Parameter 00, D-No. 0A (Option Output Signal) is set to a number other than 0. When activated, D-No. 30, 31, 32 and 33 of Parameters 1~32 (normally Rate 1 and Rate 2 limits) will be used to set ON and OFF limits for the Timing Signal. [30: Advance Direction ON Distance] [31: Advance Direction OFF Distance] [32: Return Direction ON Distance] [33: Return Direction OFF Distance] This may be useful when interfacing with other fixture processes or tooling (IE: vacuum, clamps, etc.) or when other processes need to know when the press ram is clear. 0mm ON OFF OFF Example #1 [30: 50.0mm] [31: 120.0mm] [32: 150.0mm] [33: 100.0mm] 150mm 32 ON 0mm ON OFF Example #2 [30: 50.0mm] [31: Max Distance] [32: Max Distance] [33: 100.0mm] 150mm CYCLE OK: [OUT DATA10] (Special Function Distance Control Methods) This signal is active if Parameter 00, D-No. 0A (Option Output Signal) is set to a number other than 0. When inactive this signal is the BANK 1 Input Echo signal. This setting represents a distance (in millimeters) that the CYCLE OK signal will turn on before reaching Standard Distance. The signal will turn off when Standard Distance is reached. A setting of 1 to 9mm is possible. Example: If Parameter 00, D-No. 0A is set to 6xxx. The CYCLE OK signal will turn on 6mm before reaching Standard Distance. ON 6 mm Standard Distance PAGE 4-15

48 Chapter 4: System Setup and Wiring enforce Operation Manual OUTPUT BANK 2: Bank0 On / Bank1 - Off WORK SELECT 4: [OUT DATA3] Work Select 4 Input Echo Signal Output when the WORK SELECT 4 input is high (On). WORK SELECT 3: [OUT DATA4] Work Select 3 Input Echo Signal Output when the WORK SELECT 3 input is high (On). WORK SELECT 2: [OUT DATA5] Work Select 2 Input Echo Signal Output when the WORK SELECT 2 input is high (On). WORK SELECT 1: [OUT DATA6] Work Select 1 Input Echo Signal Output when the WORK SELECT 1 input is high (On). WORK SELECT 0: [OUTDATA7] Work Select 0 Input Echo Signal Output when the WORK SELECT 0 input is high (On). BANK 1: [OUT DATA10] Bank 1 Input Echo Signal Output when the BANK SELECT 1 input is high (On). BANK 0: [OUT DATA11] Bank 0 Input Echo Signal Output when the BANK SELECT 0 input is high (On). OUTPUT BANK 3: Bank0 Off / Bank1 - On LOAD_LOW: [OUT DATA0] Low Load REJECT Signal Output when the press result is below the acceptable Low Load Limit. Output remains active until the start or reset signal is input. LOAD_HIGH: [OUT DATA1] High Load REJECT Signal Output when the press result has exceeded the acceptable High Load Limit. Output remains active until the start or reset signal is input. Rt2_LOW: [OUT DATA2] Rate 2 Low REJECT Signal Output when the press result is below the acceptable Rate 2 Low Limit. Output remains active until the start or reset signal is input. Rt2_HIGH: [OUT DATA3] Rate 2 High REJECT Signal Output when the press result has exceeded the acceptable Rate 2 High Limit. Output remains active until the start or reset signal is input. Rt1_LOW: [OUT DATA4] Rate 1 Low REJECT Signal Output when the press result is below the acceptable Rate 1 Low Limit. Output when a 1 ST Judgment Zone Reject occurs. Output on a High Reject when using 1 ST Step H/L Check. Output remains active until the start or reset signal is input. Rt1_HIGH: [OUT DATA5] Rate 1 High REJECT Signal Output when the press result exceeds the acceptable Rate 1 High Limit. Output on a Low Reject when using 1 ST Step H/L Check. Output remains active until the start or reset signal is input. DIS_LOW: [OUT DATA6] Low Distance REJECT Signal Output when the press result is below the acceptable Distance Low Limit. Output remains active until the start or reset signal is input. DIS_HIGH: [OUT DATA7] High Distance REJECT Signal Output when the press result exceeds the acceptable Distance High Limit. Output remains active until the start or reset signal is input. BANK 1: [OUT DATA10] Bank 1 Input Echo Signal Output when the BANK SELECT 1 input is high (On). BANK 0: [OUT DATA11] Bank 0 Input Echo Signal Output when the BANK SELECT 0 input is high (On). PAGE 4-16

49 enforce Operation Manual Chapter 4: System Setup and Wiring Synchronized Press Operation SYNC: Synchronized Press Signal For using multiple numbers of press units, connect parallel with SYNC common. SAN Unit1 6,7 SYNC COM 8,12 SYNC SAN Unit2 6,7 SYNC COM 8,12 SYNC SAN Unit3 6,7 SYNC COM 8,12 SYNC SAN Unit n 6,7 SYNC COM 8,12 SYNC Multiple Press Synchronized Sequence At the start of the cycle until reaching the synchronization point (1 ST Load), the SYNC signal is ON (LOW condition) to stop other Units from continuing to the second step. When the 1 st load is reached, the signal works as an input signal (Wired OR). If it reads LOW - meaning that the other units have not reached 1 ST Load yet - the unit stays in the standby state waiting for all connected presses to reach 1 ST Load. When the SYNC signal is HIGH (all units have completed the first step), all units simultaneously start the second step. If a unit is in bypass mode, its SYNC signal stays off (High Condition) to prevent the other units from being in a waiting condition. The SYNC signal stays ON (LOW) in the following conditions: Powering on After Reset Emergency Stop Right after Start PAGE 4-17

50 Chapter 4: System Setup and Wiring enforce Operation Manual Operation Timing Chart Automatic Mode Timing to set the START signal OFF, it is voluntary if the BUSY is OFF. STOP READY RESET START OFF ON ON OFF ON OFF ON OFF Condition Operating Operating BUSY ACCEPT REJECT ON OFF ON OFF ON OFF ON Above 10ms ABNORMAL OFF WORK SELECT Parameter select fixed Parameter select fixed 0~4 MANUAL Mode MANUAL START ON OFF ON OFF ON WORK SEL. 0 OFF ON WORK SEL.1 OFF ON WORK SEL.2 OFF Condition Home position search Home position return H.S. Descent H.S. Ascent BUSY READY ON OFF ON OFF To start the Home-Position Search and Home-Position Return, set the START signal ON for more than 20ms. READY is not output while the MANUAL signal and START signal are ON. PAGE 4-18

51 enforce Operation Manual Chapter 4: System Setup and Wiring 4.8 SW1 - Axis Unit Number Setting In a multiple SAN Unit system, it is necessary to address each unit for communication purposes. The number is set with the front DIP switch (4 thru 8) of the SAN Unit. If the display unit is installed, it must be removed to access the DIP switches. No two units can share the same number. However, units may be skipped or started from a number besides one. Typically, units should be numbered sequentially (Ex: 1-31). DSP1500 ` e b P T O O ON SW1 BYPASS RUN CON1 OFF POWER BUSY SV. ABN. ACC. REJ. DIP Switch Number Unit Number OFF OFF OFF OFF ON 2 OFF OFF OFF ON OFF 3 OFF OFF OFF ON ON 4 OFF OFF ON OFF OFF 5 OFF OFF ON OFF ON 6 OFF OFF ON ON OFF 7 OFF OFF ON ON ON 8 OFF ON OFF OFF OFF 9 OFF ON OFF OFF ON 10 OFF ON OFF ON OFF 11 OFF ON OFF ON ON 12 OFF ON ON OFF OFF 13 OFF ON ON OFF ON 14 OFF ON ON ON OFF 15 OFF ON ON ON ON 16 ON OFF OFF OFF OFF 17 ON OFF OFF OFF ON 18 ON OFF OFF ON OFF 19 ON OFF OFF ON ON 20 ON OFF ON OFF OFF 21 ON OFF ON OFF ON 22 ON OFF ON ON OFF 23 ON OFF ON ON ON 24 ON ON OFF OFF OFF 25 ON ON OFF OFF ON 26 ON ON OFF ON OFF 27 ON ON OFF ON ON 28 ON ON ON OFF OFF 29 ON ON ON OFF ON 30 ON ON ON ON OFF 31 ON ON ON ON ON Special Settings (positions 1-3) 1 ON: CAL/Zero acceptance window = +/-10% of full scale load. OFF: CAL/Zero acceptance window = +/-4% of full scale load. (Default) 2 ON: Parameter changes made by communicating are not saved on EEPROM. OFF: Parameter changes made by communicating are saved on EEPROM. (Default) 3 ON: Ramp Down Disabled The slow down is done rapidly. It is used to gain cycle time, etc., however, the burden on the gear will be greater. OFF: Ramp Down Enabled (Default) The slow down is done slowly. If not used, set DIP switches number 1 thru 3 in the OFF position. SAN Unit must be powered off and on again for switch changes to take effect. PAGE 4-19

52 Chapter 4: System Setup and Wiring enforce Operation Manual 4.9 MON. Signal (External Monitor Signal) This auxiliary connector is used to output Load, Position, Current and Speed signals to external equipment for monitoring purposes. This connection is not required for the system to operate. enforce outputs 1 digital pulse per 0.1mm moved distance and press proportionate to load by the MON>OUT connectors. (There are some time differences in the distance pulse) Mating Connector Manufacture: Molex Housing Part No.: Contact Part No.: (Qty.-6) NO Signal Name IN/OUT Description 1 LOAD OUT OUT Load voltage Monitor Output full-scale load 2.5V 2 POSITION PULSE OUT Distance pulse Monitor Output TTL 3 POSITION CW/CCW OUT Advance/Return Monitor Output TTL 4 Current Monitor OUT -10V~+10V (10V=SAN40S=40A/ SAN80S=80A/ SAN120S=120A) 5 Speed Monitor OUT -10V~+10V (10V = Maximum Speed) 6 GND GND for Monitor Signal Output LOAD OUT - Load Voltage (Analog Voltage) Monitor voltage represents zero load to full-scale load by an electric potential difference of 2.5V. Home-position voltage is voltage measured when the press is stopped. The Home position voltage is not 0V. (It may differ but the voltage is within -2V to +2V) Home position voltage of the same tool type differs as well. Example: If the Home position voltage is 0.5V, the full-scale load voltage is +2.0V and the voltage change (potential difference) is 2.5V. *This signal will not output without a load transducer. POSITION PULSE - Distance Pulse: (TTLsignal 0V or 5V) Distance pulse is output at 1 pulse per 0.1mm. It slightly differs from the actual distance moved. POSITION CW/CCW - Advance/Return Signal: (TTLsignal 0V or 5V) HIGH signal is output on advance (clockwise revolution) and LOW signal is output on return (counter-clockwise revolution). 0.1mm Distance Pulse Advance/Return Signal Advance Stop Operating Condition Return *This is based on the rotation direction of the motor so it may show Advance while returning for tools with inverted motors. PAGE 4-20

53 enforce Operation Manual Chapter 4: System Setup and Wiring 4.10 RS485 Interface Connection The enforce system communication is performed via the RS485 port. These ports are provided to link each SAN Unit together by jumpering from one controller to the next or for connecting to a PC equipped with DSP User Console software. Both connectors are identical and are internally connected. There is no order (upper or lower connection) in how the cables must be connected from SAN Unit to SAN Unit. NO Signal Name Channel 1 TX+ / RX+ CH1 2 TX- / RX- CH1 3 RX+ CH2 4 TX- CH2 5 TX+ CH2 6 RX- CH2 7 GND 8 GND 1 8 Mating Connector: SAN Unit Jumper Cable: RS232 to RS485 PC Cable: RJ45 FEC Part No.: FEB-1268 or standard CAT-5 cable FEC Part No.: FEB-1266 DO NOT connect these ports to an Ethernet Network or circuit damage may occur. Internal circuit RS extended 3 to other DSP GND RS to other DSP SN75176 PAGE 4-21

54 Chapter 4: System Setup and Wiring enforce Operation Manual 4.11 Firmware Flash Connector (CN8) Upgrades or revisions to Firmware are handled easily with the on board Flash connector located on the bottom of each SAN Unit. There is no need to remove or disassemble the unit. A Flash adapter (SAN-ROM) containing the new firmware can be connected to connector CN8 with the power off to the unit. The power is then cycled on and off with the adapter in place and the firmware is automatically updated. Note: This connector is for FEC use only and it is not recommended for use other than FEC. CN 8 Bottom View of SAN Unit PAGE 4-22

55 enforce Operation Manual Chapter 4: System Setup and Wiring 4.12 Cable Installation Guidelines Improper installation of cables can reduce cable life expectancy drastically. The following guidelines should be used when installing cables. The cables must be prepared for installation without twists, bends or kinks. Upon unpacking the cables, any tie wraps used in shipping should be removed. Before inserting the cables in the cable tray, cable track or other overhead suspension, it is important that the cables be laid out or hung prior to installation long enough to relax any stresses and remove any memory resulting from packaging, transit or storage. If the cables cannot be relaxed, they should be shook out by grasping the cable length at its mid point and shaking the cables as you move to each end. Then, wrap the end of each cable with masking tape and make alignment marks on the top of each end. Maintain this alignment throughout the installation to assure cable is not being twisted. The minimum recommended bending radius of the cable should not be exceeded. The minimum bend radius is calculated by multiplying the cable s outer diameter by ten (Rmin = O.D. x 10). When multiple cables are run together, the largest diameter cable in the bundle should be used for calculating bend radius. Minimum bend radius must be increased when repeated flexing occurs at a given point on the cables. Use the most direct path when routing cables. Do not weave cables between or wrap around one another. Route cables and connectors away from liquid of any type. Protect cable connectors from any impact or abrasion that may cause damage (IE: pulling cables through cable tray and dropping cables to the floor). Check cable route for possible chafing or abrasion points. Re-route or protect cable at these points with a nylon cable wrap or similar means to avoid future cable damage. The use of plastic cable ties (ty-wraps) should be avoided if possible. The use of Velcro straps is preferable. If the use of plastic cable ties cannot be avoided, the following practices should be followed: o Cables should not be tied so tight as to cause indentations in the cable jacket. Flexible cables are designed to move inside their cable jacket. If this movement is restricted, wires in the cable may become stressed and break. o Plastic cable ties around grouped cables should be used minimally so that cables have the ability to move individually rather than all as one. o An acceptable method is to include the use of a flexible tubing or sleeve between the plastic cable tie and the cable(s). Do not tie or hang anything, whatsoever, from tool cables. Avoid running cables directly next to high voltage or high frequency lines. Cables must be supported near connectors in panel and at tool to avoid strain on connection points. Certain tool operations may have foreseeable cable damaging aspects which are unavoidable. In these situations a shorter extension cable can be provided with the expectation of replacing this intermediate, less expensive cable as required. The use and proper placement of an extension cable will also make cable replacement less time consuming. PAGE 4-23

56 Chapter 4: System Setup and Wiring enforce Operation Manual Considerations for Cable Trolleys Cables hung by festooning type systems must be secured to the individual cable trolley and positioned to avoid sharp bends and eliminate or minimize any torsion twisting. Restraint cords should be used in between cable trolleys to limit movement and reduce the stress on cables as they are extended. Restraint cord lengths must always be shorter than the length of cable hung between trolleys. Cable loops should be consistent in length, typically not exceeding 5 feet in depth between trolleys. Sufficient number of trolleys should be used in a system to support the entire length of moving cable and to allow relaxed stacking/festooning of cable loops when tool is in the retracted position. One trolley should be fixed to the runway rail to eliminate tugging on or stretching of cables Considerations for Flexible Cable Tracks Cables must under no circumstances have the opportunity to tangle. Therefore the clearance height of a track compartment with several similar cables next to one another must not amount to more that one and a half times the cable diameter. There should be an all around minimum clearance between cables of 10% of the cable s diameter. Cables and hoses with very different diameters should be laid separately. Separation is achieved by using Flexible Track separators. The following rules should be followed for cable separation: o If (Cable 1 Diameter) + (Cable 2 Diameter) > 1.2 x Track Inner Height, then no separation is necessary. o If (Cable 1 Diameter) + (Cable 2 Diameter) 1.2 x Track Inner Height, then a horizontal or vertical separator must be used to reduce the inner height, thereby preventing the entanglement of the cables. The cable weight should be symmetrically distributed along the width of the track. Cables must be able to move freely along the radius. The cables must be secured with strain relief at both ends. In exceptional cases, the cables may be fixed with strain relief at the moving end only. Unless using a Flexible Cable Track with integrated strain relief, a gap of 10~30 x cable diameter between the end of the bending segment and the fixed point is recommended for most cables. Under no circumstances should excess cable be put into a Flexible Cable Track Considerations for Cable Trays & Ladders Cable drop out panels should be used where cables enter and exit a tray or ladder system. Sharp bends need to be avoided whenever possible. Cables should be secured at both entry and exit points of a tray or ladder. Avoid running high voltage or high frequency cables in the same tray or ladder as signal or control cables unless cables are designed for such environments. If excess cable is to be stored in a tray or ladder, do not tightly coil cable. Cable should be laid in as large of a loop as possible. PAGE 4-24

57 enforce Operation Manual Chapter 4: System Setup and Wiring 4.13 Tool Connections Tools are connected to the SAN controller using three or four cables. The first cable connects to the Load Cell Force Transducer preamp. Second is a combination Motor / Resolver Cable. The third cable connects the position proximity switches for home and advanced position indication. A fourth cable is for an external brake if ordered. Each cable is separated from the Motor / Resolver cable to reduce the possibility of high voltage noise interference. In multiple press systems, each cable is labeled with a corresponding press number and should be connected to the corresponding SAN Controller and Tool. Cables should be secured to the motor similar to the method as shown below. If cable ties are used, they should be loose enough to allow the cable to move, but yet hold it in place. Cable ties too tight cause a stress point leading to premature cable failure. *Recommended Cable Lengths: 75 or less. *Maximum Cable Lengths: 100 (must be free from Electrical Noise) MOTOR / RESOLVER CABLE SAN-24S/40S (FIELD): FEC P/N: FEB-1251 SAN-120S WITH RM4 MOTOR (FIELD): FEC P/N: FEB-1605 SAN-24S/40S/120S W/RM4 (EXTENSION): FEC P/N: FEB-1283 Nominal OD =.505 Min. Bend Radius = 6.0 SAN-120S (MOTOR FIELD): FEC P/N: FEB-1604 SAN-120S (MOTOR EXTENSION): FEC P/N: FEB-1606 Nominal OD =.415 (x2) Min. Bend Radius for group = 10.0 SAN-120S (RESOLVER FIELD): FEC P/N: FEB-1603 SAN-120S (RESOLVER EXTENSION): FEC P/N: FEB-1283 Nominal OD =.535 Min. Bend Radius = 6.0 LOAD TRANSDUCER (PRE-AMP) CABLE SAN-24S/40S/120S (FIELD): FEC P/N: FEB-1173 SAN-24S/40S/120S (EXTENSION): FEC P/N: FEB-1284 Nominal OD =.405 Min. Bend Radius = 4.0 POSITION SENSOR CABLE: Brad Harrison female 4 pin Micro style cable or equivalent (See Appendix A) PAGE 4-25

58 Chapter 4: System Setup and Wiring enforce Operation Manual 4.14 Brake Option Reference Circuit Diagram Brake Unit: Permanent Magnet type - Brake normally engaged Power Requirements: RM1 ~ RM4 Motor 24VDC, 0.5 Amps RM5 Motor (Internal Brake) 24VDC, 0.7 Amps RM5 Motor (External Brake) 24VDC, 1.2 Amps In the example circuit above, the brake is disengaged (ON) while the motor is rotating because the BUSY signal is output. Once Origin has been defined (Org. OK), the brake will stay latched on (disengaged) unless the STOP input signal goes low, the ABNORMAL output signal goes high or the BYPASS output signal goes high. The MAINTENANCE Relay provides a means to manually release the brake when required. System Parameter #0F should be configured for No Brake. The brake should be used for maintenance purposes only, not for control. Setting the No Brake configuration forces the motor to control the holding of position in normal operation. Manual operation is possible from the front display panel of the SAN unit. Using the BUSY signal allows the brake to be controlled when operating the press from this panel. This circuit is shown for reference only and does not guarantee the safe operation of this press. Safety measures must be examined for each application. When bank change operation is used, the meaning of the BUSY signal will change when a bank other than Bank 1 is selected. Be sure Bank 1 is selected and confirmed before initiating a Home Position Search. BRAKE CABLE: (FIELD): FEC P/N: FEB-1314 (EXTENSION): FEC P/N: FEB-1609 PAGE 4-26

59 Chapter 5: Power Up & Initial Checks PAGE 5-1

60 Chapter 5: Powering Up and Initial Checks enforce Operation Manual WARNING DO NOT operate the press WITHOUT all safety guards and/or devices in place and operational. NEVER enter the press ram area with power applied to the press unit. Follow Lockout/Tagout and other safety precautions when performing maintenance or connecting / disconnecting cabling, wiring, and equipment. There is a possibility of receiving an electrical shock from this equipment, if used improperly. 5.1 Before Powering On Verify SAN Unit DIP switch settings (4.8) Verify that the eight (8) DIP switches visible on the front of each unit are set to indicate the appropriate press number and options. Check connection between tool and controller (3.4, 4.5, 4.6) Verify that the homerun and extension cables (resolver/motor, load cell, brake and proximity switches) connecting the tool to the SAN unit are secure. Ensure that each numbered set of cables are connected to the identically numbered tool and SAN unit. If the press application requires the press to move, visually inspect all components to ensure that there is proper clearance and that cables have sufficient length. If movement would create any excessive stress on a cable or create any potential for damage to the system, then make appropriate adjustments. WARNING: DO NOT make motor connections with the power on. Turn off all controller power before attempting to connect or disconnect any motor cables or system damage may occur. Check SAN Unit I/O cable wiring (4.7) Connections with external control equipment are done between SAN unit I/O connectors. Verify that the I/O interface wiring is connected to the corresponding PLC terminals. Remember, all inputs and outputs are wired active true low. All interface devices must accommodate active true low connection for correct operation. EXTERNAL PLC PAGE 5-2

61 enforce Operation Manual Chapter 5: Powering Up and Initial Checks Check the Input Voltages (2.1, 4.4) Verify that the Input Power Connector is properly wired and that the voltage to be applied is within the specified range. Verify that the 24VDC and 0VDC common wires are properly connected. Damage may occur if wired improperly. Be sure to check the previously mentioned items before turning the power on. Power Voltage Re-Checks Re-check the input power voltage after turning the power on to make sure the voltage does not drop due to loading. Check again for loading when the Servo Press has started and the load is at its maximum level for the press cycle (maximum power consumption time). After powering the SAN unit down, the power must not be applied again for at least 5 seconds (1 minute recommended). Repeated power up and power down may temporarily disable the SAN unit. If a SAN unit does become disabled, keep the power off for at least five (5) minutes, then power on again to reset the fault. PAGE 5-3

62 Chapter 5: Powering Up and Initial Checks enforce Operation Manual 5.2 Initial Data Setting (Display Module Required) After the previous items have been completed, turn on the power supply and then verify that the necessary parameter data required for pressing has been entered and is correct (IE: distance, load, speed, etc). To perform these checks, the following signals from external control equipment (PLC, selector switch, etc) to the SAN unit must be set. STOP signal must be set high. All WORK SELECT signals must be set low. 1) Zero Value Check Press the RESET button on the Display Unit and check that the value displayed on the unit is at or near zero and that the NG LED (red) is not on. 2) CAL. Point Check Press the CAL button on the Display Unit and check that the NG LED (red) is not on. 3) MANUAL Movement Check If more than one (1) press is used in the system, disable all other units except the one to be tested by moving the RUN/BYPASS switch to BYPASS. While pressing the MANUAL button of the Display Unit, press the down arrow button to move the press ram forward and check that the correct tool is operating. Also check that nothing interferes with the press ram through to the operating limit (High Distance Limit). Next, while pressing the MANUAL button of the Display Unit, press the up arrow button to move the press ram backward. Check that nothing interferes with the press ram through to the return limit. The Display will show CC when the return limit is reached. Repeat this test for all connected presses, one at a time, until all have been verified. The speed of Manual movement is set in Data Parameter 0e. Manual Speed can be increased or decreased by changing this value. Before performing the following test, make sure the travel path of the press ram is clear. When performing a HOME POSITION SEARCH, the press ram will continue moving until home position has been defined. 4) HOME POSITION SEARCH Check While pressing the MANUAL button of the Display Unit, press the START button. The home-position search will be initiated and, when it is completed, the OK (green) light will be on and the unit will be ready for automatic operation. After completing the home-position search, the position of the resolver when the CCW limit sensor is ON will be shown on the display D-No. area for one second. If the value is not within 1500 to 2500, there is a possibility that the home-position will change every time. If this happens, please refer to Section or contact FEC. 5) Manual START Check Press and hold the START button of the Display Unit and verify the automatic operation of the press. Because no WORK SELECT is active (ON), the press will perform the operation defined for Parameter 1. 6) External Instruction Operation Check Verify that the equipment will operate with an instruction from the exterior control equipment (PLC, selector switch, etc.). PAGE 5-4

63 Chapter 6: System Operation PAGE 6-1

64 Chapter 6: System Operation enforce Operation Manual 6.1 Display and Programming Unit (DP*S) An optional detachable display / programming unit is available for the SAN Unit. The display unit allows the viewing of press results as well as viewing / programming of press parameters if the optional DSP software is not being used. The DP1S & DP2S are for the SAN3-24S/40S and the DP3S & DP4S are for the SAN3-120S. DP1S & DP3S DP2S & DP4S (RS-232) The DP2S and DP4S have the same functionality as the DP1S and DP3S with the added function of a serial RS-232 port for output of press data from the associated SAN Unit. The RS232 port may also be used to input external measurement data in applications requiring an external measurement probe. PAGE 6-2

65 enforce Operation Manual Chapter 6: System Operation DP2S & DP4S Serial Connection Connector: DB-9P (Male) Mating Connector: DB-9S (Female) PIN No. Signal Signal Description 1 Not Used 2 RXD Not Used 3 TXD Output data for printer 4 DTR ON output (always) 5 GND Signal ground 6 Not Used 7 RTS ON output (always) 8 CTS Connects to DTR signals such as printers 9 Not Used The CTS signal needs to be activated in order for the press data to be output. If it is not activated, the data will be stored in the output buffer (up to 16KB). Once the buffer is full, the data will be overwritten in a First In-First Out (FIFO) process. The CTS signal may be connected to the RTS signal if data is to be dumped at every process. 1) Connection for confirming the DTR device DSP1500 D-SUB 9 PIN D-SUB 25 PIN TXD 3 3 RXD RXD 2 CTS 8 20 DTR GND 5 7 GND 2) Connection for output in any condition DSP1500 D-SUB 9 PIN D-SUB 25 PIN TXD 3 3 RXD RXD 2 RTS 7 CTS 8 20 DTR GND 5 7 GND Output Device Communication Protocol Data Bits 8 Error Control No Parity No Start Bits 1 Stop Bits 2 Speed 9600bps PAGE 6-3

66 Chapter 6: System Operation enforce Operation Manual RS-232C Output Data Result data is output every time the operation is finished. The result output is possible for each unit that has a SAN DP2S/SP4S installed. Use SAN IF unit if you want to output multiple results. Result Output Data Data Length: 78 bytes fixed (78 letters) Normal data format COUNT Number Press PARM Number Number 30H 30H 30H 31H 20H 20H 20H 20H 30H 31H 20H 20H 20H 31H 20H 20H PEAK LOAD Judg FINAL DISTANCE Judg ment ment 31H 32H 2EH 33H 34H 20H 20H 20H 31H 32H 2EH 33H 34H 20H 20H 20H FINAL LOAD 1ST RATE Judg ment 31H 32H 2EH 33H 34H 20H 20H 20H 30H 2EH 31H 32H 33H 20H 20H 20H ND RATE Judg 1ST TIME Judg ment ment 30H 2EH 31H 32H 33H 20H 20H 20H 20H 31H 30H 2EH 30H 20H 20H 20H ND TIME Judg ment Judg ment CR LF 20H 20H 32H 2EH 30H 20H 20H 20H 4FH 20H 20H 20H 0DH 0AH 2. 0 O Overall Judgment "O":4FH ACCEPT "X":58H REJECT " O" +CR+LF Judgment letters displayed beside PEAK LOAD value H: Exceeded High Value L: Below Low Value A: Abnormal S: STOP B: BYPASS (Press Unit Off) Judgment letter displayed beside DISTANCE, RATE and TIME value H: Exceeded high value L: Below low value COUNT Number: 0001 is displayed after powering ON. 1 is added after each cycle. PAGE 6-4

67 enforce Operation Manual Chapter 6: System Operation Data format when the judgment is a REJECT COUNT Number Axis PARM Number Number 30H 30H 30H 31H 20H 20H 20H 20H 30H 31H 20H 20H 20H 31H 20H 20H PEAK LOAD Judg FINAL DISTANCE Judg ment ment 31H 32H 2EH 33H 34H 20H 20H 20H 31H 32H 2EH 33H 34H 20H 20H 20H FINAL LOAD 1ST RATE Judg ment 20H 31H 2EH 32H 33H 20H 20H 20H 30H 2EH 31H 32H 33H 20H 20H 20H ND RATE Judg 1ST TIME Judg ment ment 30H 2EH 31H 32H 33H 20H 20H 20H 20H 31H 30H 2EH 30H 20H 20H 20H ND TIME Judg ment Judg ment CR LF 20H 20H 32H 2EH 30H 20H 20H 20H 58H 20H 20H 20H 0DH 0AH 2. 0 X Overall Judgment "O":4FH ACCEPT "X":58H REJECT " X" +CR+LF PAGE 6-5

68 Chapter 6: System Operation enforce Operation Manual 6.2 Function of Display and Operating Panel [START]: Cycle START Button Pressing this button initiates the press cycle. The press will perform the operation as defined in the active parameter while pressing. This button must be held until the press cycle ends. If the button is released in the middle of the operation, the press will stop and, if programmed to do so, will return. [MANUAL]: MANUAL Mode Button While pressing this button and the [ ] button at the same time, the press will return. While pressing this button and the [ ] button at the same time, the press will advance. Pressing this button and the [START] button at the same time will enable Home-Position Search operation. Pressing this button and the [SET] / (HOME) button at the same time will enable Home-Position Return operation. The speed of MANUAL movement is set in Data Parameter 0e. Manual speed can be increased or decreased by changing this value. [CAL]: CAL Voltage Check Button Press this button to obtain the CAL voltage level from the press load cell pre-amplifier. This value is compared to the data stored in memory. If the difference is within the allowed range, the ACCEPT LED will light. If the difference is not within the allowed ranged, the REJECT LED will light and an abnormal will be generated. The system will be disabled until the abnormal is reset. [RESET]: RESET Button Press this button to reset the SAN Unit. If this button is pressed during a press cycle, the unit will stop and all press data and output signals will be reset. Also, the Zero Level of the load cell will be checked. If it is within the acceptable range, the ACCEPT LED will light. If is not within the acceptable range, the REJECT LED will light and an abnormal will be generated. The system will be disabled until the abnormal is reset. Data Display - 7 Segment LED DATA Data Display (4 digits) The operation result and each setting data are displayed. PARM Parameter Number / Abnormal Code Display (2 digits) The parameter number used for operation is displayed after the operation finishes. When an abnormal occurs, the abnormal error code will be displayed. D-NO Data Number / Abnormal Sub-Code Number Display (2 digits) Displays the Data Numbers for the selected parameter when programming. Displays the Data Code Number when in Real Time Display Mode or Operating Result Display Mode. Press Unit number (U.01 to U. 32) is displayed right after powering on or after reset. Data Display Operation Buttons Manual Operation Buttons [MODE]: Mode Button Used to change modes and while in the RUN state. Used to move the cursor while in the BYPASS (program) state. [SET] / (HOME): Set Button Used to enter the data in edit mode, and to confirm data setting changes. [ ],[ ]: Cursor Buttons Used to scroll the displayed data and change data setting. PAGE 6-6

69 enforce Operation Manual Chapter 6: System Operation 6.3 RUN Status Mode Operating Instruction The enforce System has two operational states which are selected with the RUN/BYPASS switch on the front of the SAN Unit or by the PLC Bypass input. When the RUN/BYPASS switch is in the RUN position or when the PLC Bypass input is low (OFF), the unit is in RUN status. In the RUN status, press results, abnormalities and preset values are displayed Run Status Display DATA Displays the press result and data setting. Displays the load value of the load transducer when in Real Time Display Mode. PARM Displays the operating parameter number. Displays the abnormal number when abnormalities occur. D-NO Displays the data number displayed on DATA. 1 figure display : Real-time Display Mode left side figure : Press Result Display Mode 2 figure display : Parameter Display Mode Displays the abnormal sub-code when abnormalities occur. Parameter Number: 1, Data Number: 10 Abnormal Number: 1, Sub Code: 0 When [CAL] button is pressed with full-scale load not set or when the connected tool number is wrong. When resetting immediately after powering-up, a press unit number is displayed. PAGE 6-7

70 Chapter 6: System Operation enforce Operation Manual Mode Change Three display modes can be selected while in the RUN state by pressing the [MODE] button. In addition, the values of each mode can be scrolled through by pressing the [ ] and [ ] buttons. When the unit powers on, the display defaults to the Real Time Display Mode. When the press cycle starts, the display switches to the Press Condition Display until the end of cycle. At that time the display switches to the Press Result Display Mode. Mode displays cannot be changed with the buttons during a press cycle. Press Result Display Mode MODE The result details can be scrolled through with the [ ] and [ ] buttons. It is only displayed at the end of the press operation. PAGE 6-11 START Power ON Parameter Display Mode MODE Displayed set values can be scrolled through with the [ ] and [ ] buttons. PAGE 6-12 START Real Time Display Mode MODE When the power is turned on, the default display mode is the Real Time Display Mode. Display contents can be scrolled through with the [ ] and [ ] buttons. See table for data number. PAGE 6-10 Status Display MODE [Status Display] will be displayed when abnormalities occur or when the STOP or Limit signals are OFF. PAGE 6-15 PAGE 6-8

71 enforce Operation Manual Chapter 6: System Operation RUN Status Key Operation Selecting [Real Time Display Mode], [Press Result Display Mode] and [Parameter Display Mode] is possible by pressing the [MODE] button. When the press is operating, the [Press Condition Display] is displayed. Operating Condition Display Power ON Press Start D-NO In: in: Initial initial Fr: Free Run SL: Slow Down Ld: Load ru: S Return d d : Recovery Press Finish Real Time Display Mode D-NO 1figure [MODE] Press Result Display Mode D-NO Left side fig [MODE] D-NO 2 figure Parameter Display Mode [MODE] [Status Display] will be displayed when abnormalities occur or when the STOP or Limit signals are OFF. The following diagram shows how to change the display with the [MODE] button. Abnormal or STOP / Limit signal OFF Status Display DATA Abn/STOP [MODE] [MODE] Real Time Display Mode Press Result Display Mode D-NO 1figure D-NO Left side fig [MODE] [MODE] D-NO 2 figure Parameter Display Mode PAGE 6-9

72 Chapter 6: System Operation enforce Operation Manual Real Time Display Mode D-NO: 1 figure The following data is displayed on the screen in the Real Time Display Mode. The [D-NO] changes by pressing the [ ] and [ ] buttons. D-NO DATA D-NO DATA 0 Load Value Display 4 Electric Thermal Value(Overheat when 100) 1 Load Voltage Value Display 5 Current Value( Max 1023 ) 2 Maximum Load Value Display (Maximum Value Hold) 3 Distance Moved Display 7~ FEC use only 6 Resolver Position Data Display(0~4093) 0: Load Value Display Displays present load applied to the load transducer in real time. 1: Load Voltage Value Display Displays the present load signal voltage applied to the load transducer in real time. 2: Maximum Load Value Display Displays the peak load measured from the last time the display was switched to this mode. This is reset when leaving Real Time Display Mode. This value can be held for 1 minute by pressing the [SET] button. 3: Distance Moved Display Displays the absolute distance from the home position. 4: Electric Thermal Value Displays the present electric thermal value. 5: Current Value Displays the present current value. The maximum amplifier current value is : Resolver Position Data Display Displays the position (in pulses) of the resolver at the present time. 7~: In-house Adjusting Display Displays the in house adjustment value. D-NO DATA 0 Load value Display [ ],[ ] Button 1 2 Load Voltage Value Display Maximum Load Value Display n PAGE 6-10

73 enforce Operation Manual Chapter 6: System Operation Press Result Display Mode D-NO:left side figure The following is displayed on the screen in the Press Result Display Mode. The [D-NO] changes by pressing the [ ] and [ ] buttons. D-NO DATA UNIT _0 Peak Load Value(Judgment Load Value) KN _1 Final Distance Value mm _2 1ST Load Rate Value KN/mm _3 2ND Load Rate Value KN/mm _4 1ST Field Operating Time Sec _5 Final Field Operating Time Sec _6 Cycle Time Sec _7 Operating Mode Number -0 Operating Method Number -1 Step -2 (Monitor)not used -3 Self Check ON: performed OFF: not performed -4 Inversion Plug ON: inverted OFF: not inverted Cause of press stop 0: Reset/No Data/After hand operated, -5 1: Abnormal 2: BYPASS signal 3: STOP signal 4: REJECT 5: ACCEPT(normal) -6 Load Judgment Ld H/L -7 Distance Judgment ds H/L -8 Load Rate Judgment rt H / L(1 ST, 1 ST ZONE) H / L(2 ND ) -9 Time Judgment Γi H/L(1 ST ) H/L(FNL) =0 1 ST Load Rate Area Increment Load KN =1 2 ND Load Rate Area Increment Load KN =2 1 ST Final Load KN =3 1 ST Peak Load KN =4 Final Load Value KN =5 Distance at Peak Load (judge load) mm D-NO DATA 0 Peak load value 1 Final Distance value [ ] / [ ] buttons 2 1ST Load Rate 5 Distance at Peak Load PAGE 6-11

74 Chapter 6: System Operation enforce Operation Manual Parameter Display Mode D-NO: 2 figure display The following data is displayed on the screen in the Parameter Display Mode. By pressing the [ ] and [ ] buttons, the [D-NO] changes and the value of the data number is displayed in the [DATA] area. If [ ] is pressed at the first data number of each parameter number, [PARM] parameter number will decrement by 1. If [ ] is pressed at the last data number of each parameter number, [PARM] parameter number will increment by 1. D-NO PARM DATA 00 0 Load digit Number 01 0 SP Version 02 0 Amplifier Version [ ] / [ ] buttons Δ f Distance Offset PAGE 6-12

75 enforce Operation Manual Chapter 6: System Operation Item System Tool Data Parameter Number PARM Data Number D- No PAGE 6-13 DATA Load unit number 0:KN <No change> SP version/copy between parameter <No change> Amplifier Version <No change> Function Version <No change> Off Set Load [KN] Full Scale Extended Length [mm] Free Run Current Limit 0~ Home Position Off Set [mm] Near Origin Sensor Availability/Bank Change Enable Home position search time out 0.1[sec] unit 00 0A Distance Decimal 0: NONE,1:0.1,2: B Free Run Distance Limit/Load Transducer Availability 00 0C Current Load Conversion Ratio [%] 00 0D Stroke Distance Limit/Recovery Time Decimal Point 00 0E MANUAL Speed [mm/sec] 00 0F Option/Speed Decimal Point Tool Number Tool CAL Load [KN] Tool CAL Voltage [V] Tool Zero Load Voltage [V] <No change> 00 14~1A In Home Control Data Tool Type Tool Number 01~32 00 Operation Mode (Operation Method+Operation Step+Operation Finish Mode) 01~32 10 Full-Scale Load [KN] 01~32 11 Minimum Load Value [KN] 01~32 12 Maximum Load Value [KN] 01~32 13 Standard Load [KN] Load 01~32 14 Speed Change Load [KN] 01~ ST Load [KN] 01~32 16 SNUG Load [KN] 01~32 17 THRESHOLD Load [KN] 01~32 18 CROS Load [KN] 01~32 20 Minimum Distance Value [mm] 01~32 21 Maximum Distance Value [mm] Distance 01~32 22 Standard Distance [mm] 01~ ST Distance [mm] 01~32 24 CROS Distance [mm] 01~32 30 Minimum Rate 1 [KN/mm] Rate 01~32 31 Maximum Rate 1 [KN/mm] 01~32 32 Minimum Rate 2 [KN/mm] 01~32 33 Maximum Rate 2 [KN/mm] 01~32 40 Initial Time [sec] Time 01~32 41 Maximum 1 ST Time [sec] 01~32 42 Maximum 2 ND Time [sec] 01~32 50 Initial Speed [mm/sec] 01~32 51 Free Run Speed [mm/sec] Speed 01~32 52 Slow Down Speed [mm/sec] 01~32 53 Load Speed [mm/sec] 01~32 54 Return Speed [mm/sec] 01~32 60 Free Run Distance [mm] 01~32 61 Recovery Time [sec] Special Setting 01~32 62 Operation Finish Return Position [mm] 01~32 63 f [KN] 01~32 64 Distance Off Set [mm]

76 Chapter 6: System Operation enforce Operation Manual Operating Condition Display Speed conditions are shown on the display when in operation. While running at Initial Speed While running at Freerun Speed While running at Slowdown Speed While running at Load Speed While in Recovery While Returning PAGE 6-14