enforce DSP1500 SAN Unit Operation Manual (for Firmware Version 3.x) SECOND Edition January 2010

Transcription

1 enforce DSP1500 SAN Unit Operation Manual (for Firmware Version 3.x) SECOND Edition January 2010 Automation Systems Quadrate Drive Phone: (586) Macomb, MI Fax: (586) Web: DSP1500E-HS-4

2 Revisions Revision Revision Date Revision History Firmware Version* 3 11/2007 Initial Release / /2010 Minor Revision Chapter 2 - Updated chart for new power requirements. Chapter 4 - Updated transformer sizing chart based on new power requirements. Added functionality for SAN4 Controller. Added functionality for DPM & DPS Series presses. Chapter 6 - Added Real Time Clock functionality for new SAN3-DP1/2S keypad display. Chapter 7 - Expanded on lubrication requirements * Firmware Version at Revision Date. Manual Numbering Convention DSP1500E-HS-4 DSP1500 = Servo Press AFC1500 = Nutrunner FUSION = DC Hand Tool E = English Version S = Spanish Version *Japanese Version furnished by DDK uses DDK numbering convention. Version Number Version Number (Major Revision Level) HS = SAN Unit Hardware Operation Manual HM = Multi / Main Unit Hardware Operation Manual HM-ENET = Ethernet Manual for Multi / Main Unit SW = Software Manual (Rev. 4) ii

3 Introduction Thank you for purchasing our Electric Servo Press - DSP1500 System. This instruction manual describes the procedures for installation, wiring, handling and actions to be taken in case of any failure. This instruction manual shall be delivered to the end user who operates the equipment. Read all instructions before use and always keep this instruction manual with the equipment. Items not described in this instruction manual shall be considered unavailable. The product specification and appearance described in this instruction manual is subject to change without notice. All rights reserved. Any disclosure, copying, distribution, or use of the information contained herein for other than its intended purpose, is strictly prohibited. For the safety of operator and equipment It is important for you to read all Safety Precautions before using the equipment, and understand and observe all instructions and recommendations included in this manual. Read all instructions and recommendations included in this manual, understand the functions and performance of this servo press, and correctly use this machine. Wiring and parameter setting shall only be conducted by a qualified professional. Never conduct a withstand voltage test or insulation resistance test on this equipment. Indicate the following on all instruction manuals that use this equipment. This equipment is capable of high voltages hazardous to human life. Points to check when unpacking Please confirm the following when unpacking this equipment: Ensure that you received the correct model as ordered. Ensure that there are no missing parts. Check for any damage caused during transportation. iii (Rev. 4)

4 Introduction Warranty Warranty Period The standard warranty period is one year from the date of purchase or one year from delivery to the designated End User (not to exceed 18 Months). Actual terms are order specific. Provision of warranty If at any time during the warranty period your product proves to be defective, it will be repaired free of charge as long as it was used properly in accordance with this instruction manual. However, the customer will be required to pay for repair charges in the following cases even if the defects occurred within the warranty period. 1. Any defect due to improper conditions, improper circumstances and improper handling. 2. Any defect due to modifications or repairs performed by the customer. 3. Any defect caused by other equipment. 4. Any defect caused by customer failing to meet the equipment s specification. 5. Any defect due to natural disasters and accidents. This warranty shall be limited to repairing or replacing this product. Any liability for indirect or consequential loss or damage of any kind incurred or suffered by the customer due to a defect of the product is excluded. (Rev. 4) iv

5 Safety Precautions Read all instructions before operating the equipment in order to use this equipment safely and correctly. Read this instruction manual carefully and fully understand the equipments functions, safety precautions and instructions prior to using the equipment. Safety precautions in this manual are marked with two symbols [Warning] and [Caution]. To prevent danger to the user and other persons as well as property damage, instructions that must be fully observed are marked with the symbols below. This instruction manual uses the following two symbols according to the degree of damage that may be caused when the instruction is not observed. Warning Caution This symbol indicates that failure to observe instruction marked with this symbol may result in severe personal injury or death. This symbol indicates that failure to observe instruction marked with this symbol may result in minor personal injury or material damage. Caution Even instructions that are marked with may result in severe damage if they are not observed according to conditions. Contents marked with the above symbols are very important instructions. For your safety, follow all instructions and especially those marked with these symbols. This instruction manual uses the following additional symbols for instructions that shall be observed. Warning: Pinch Point Warning: Electric shock Warning: Fire Caution: Fire Caution: Electric shock Caution: High Temperature Prohibited Do not disassemble Required Ground v (Rev. 4)

6 Safety Precautions Warning Never touch press ram during operation. Failure to do so may cause injury. Make sure that no part of your body gets near any moving part of the tool even while the equipment is at rest. The press ram may lower for some reason resulting in injury. When performing maintenance or inspection, be sure to secure the press ram with safety blocks to prohibit the ram from lowering. Do not remove the motor and gear case of tool. The press ram may lower resulting in injury. Do not repair, disassemble, or modify the equipment individual components of the system. Failure to observe this instruction may cause injury, electric shock, fire, and malfunction. Never operate the equipment where it is exposed to water, near a corrosive atmosphere or flammable gases. Failure to observe this instruction may cause fire. Keep fingers away from the connectors while the equipment is turned ON and for a while after the equipment is turned OFF. Failure to observe this instruction may cause electric shock. Wiring operation and maintenance work shall be conducted by a qualified professional. Failure to observe this instruction may cause electric shock and injury. Turn OFF the power when conducting wiring operation and maintenance. Failure to observe this instruction may cause electric shock and injury. Never damage the cables, apply excess stress to cables, or squeeze the cables. Never use damaged cables. Failure to observe this instruction may cause electric shock and fire. Conduct type-3 grounding of FG terminals. Failure to observe this instruction may cause electric shock. In case of an abnormal odor, noise, or operation error occurrence, stop operation immediately and turn OFF the power source. Failure to observe this instruction may cause injury and fire. Install a Power shutdown device in order to ensure the safety of equipment. Failure to observe this instruction may cause injury. Install an emergency stop circuit on the outside of equipment in order to stop operation promptly. Failure to observe this instruction may cause injury. Keep away from the equipment during recovery from a temporary blackout, and ensure safety measures are conducted after restarting the equipment. The equipment may suddenly restart. Failure to observe this instruction may cause injury. (Rev. 4) vi

7 Safety Precautions Transportation / Storage Caution Transport the equipment properly according to its weight. Failure to observe this instruction may cause injury and malfunction. The conditions when transporting the equipment by ship is as below. Ambient temperature: -5 C~+55 C (Avoid freezing) Ambient humidity: 50% RH or lower (Avoid moisture) Package: Tight seal Rust prevention measure: Apply grease or oil on tools. Failure to observe this instruction may cause earth leakage and malfunction. Do not hold cables or press ram when transporting the tools. Failure to observe this instruction may cause injury and malfunction. Do not hold the indictor on the front panel when transporting the SAN Unit. The indicator may come off and drop from the front panel. Failure to observe this instruction may cause injury and malfunction. The equipment shall be stored under the following conditions. Ambient temperature: -5 C~+55 C (Avoid freezing) Ambient humidity: 90% RH or lower (Avoid moisture) Atmosphere: Indoors (Avoid direct sunlight) No corrosive gases or flammable gases No oil mist, dust, water, salt, iron powder Avoid direct vibration or shocks Failure to observe this instruction may cause earth leakage and malfunction. vii (Rev. 4)

8 Safety Precautions Installation / Wiring Caution Install the tools in a place that can support the weight and maximum load during operation. Failure to observe this instruction may cause injury and malfunction. Install the SAN Unit firmly inside the control panel using the specified screws. Failure to observe this instruction may cause malfunction. Use the specified tool for the SAN Unit. Failure to observe this instruction may cause fire and malfunction. The SAN Unit shall maintain the specified distance from other devices. Failure to observe this instruction may cause fire and malfunction. Do not block the ventilation hole of the SAN Unit. Avoid any foreign body from entering inside the equipment. Failure to observe this instruction may cause fire and malfunction. The power source shall be provided with safety measures such as breakers and circuit protectors. Failure to observe this instruction may cause fire and malfunction. Do not use tools or SAN Units that are damaged or have missing parts. Failure to observe this instruction may cause fire, injury, and malfunction. Do not climb on top of the equipment or place heavy objects on the top of equipment. Failure to observe this instruction may cause injury, and malfunction. Do not subject the equipment to excess shock and impact. Failure to observe this instruction may cause malfunction. Conduct wiring properly and firmly. Failure to observe this instruction may cause injury, false operation, and malfunction. Operate the equipment within the specified power supply voltage. Failure to observe this instruction may cause injury, electric shock, fire, and malfunction. When operating the equipment in the following conditions, take sufficient measures to shield the equipment. Locations where electrical noise is generated. Locations where the equipment is subjected to a strong electric field or magnetic field. Locations near high power wiring. Failure to observe this instruction may cause injury, false operation, and malfunction. (Rev. 4) viii

9 Safety Precautions Operation / Adjustment Caution Never operate the equipment with wet hands. Failure to observe this instruction may cause electric shock. Keep fingers away from the SAN Unit radiating fins and tool motor while the equipment is turned ON or for a while after the equipment is turned OFF. These parts may become very hot. Failure to observe this instruction may cause burns. Use the equipment under the following conditions. Ambient temperature: 0 C~+45 C (Avoid freezing) Ambient humidity: 90% RH or lower (Avoid moisture) Atmosphere: Indoors (Avoid direct sunlight) No corrosive gases or flammable gases No oil mist, dust, water, salt, iron powder Avoid direct vibration or shocks Failure to observe this instruction may cause earth leakage and malfunction. Confirm and adjust all parameters before operation in order to prevent unexpected movement of the equipment. Failure to observe this instruction may cause injury, false operation and malfunction. Never conduct extreme adjustments or setting changes that may cause instability of operation. Failure to observe this instruction may cause injury, false operation and malfunction. The equipment may restart suddenly when the equipment is reset with the start signal ON. Always ensure that the start signal is OFF before resetting the equipment. Failure to observe this instruction may cause injury. Do not turn ON and OFF the equipment repeatedly. Failure to observe this instruction may cause malfunction. Do not use the equipment at loads higher than the maximum load. Failure to observe this instruction may shorten equipment life or cause malfunction due to the high temperature caused by overload. The magnetic brake is for holding the press ram when performing maintenance procedures. Do not use for normal braking otherwise failure may result. The magnetic brake may fail to hold near the end of its life expectancy due to wear. Secondary braking structures should be installed on the machine side to safely secure otherwise injury may result. In case any abnormality occurs, remove the cause and ensure safety before resetting and restarting the equipment. Failure to observe this instruction may cause injury. ix (Rev. 4)

10 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 Diagrams Chapter 4: System Setup and Wiring 4.1 Design and Build Guidelines SAN Unit Design and Mounting Dimensions Calculating Circuit Protection Input Power Supply Connection Input Motor & Control (SAN3)/Input Motor Power (SAN4) Connection Input Control Power Connection (SAN4) Motor Power-Resolver Connections Pre-Amplifier Connection External Control Connection PLC Interface (I/O) Signal Chart [Main Unit Configuration] PLC Interface (I/O) Signal Chart [Stand Alone Configuration] Output Data Bank Signals Input & Output Recommended Connection Circuit Input & Output Signal Explanation Operation Timing Chart SW1 - SAN Unit DIP Switch Settings SAN Unit Address Settings (DIP Switch 4~8) Special Configuration Settings (DIP Switch 1~3) (Rev. 4) x

11 Table of Contents 4.9 MON. Signal (External Monitor Signal) Calibration Method for External Monitoring Equipment RS-485 Interface Signal Firmware Flash Connector Cable Installation Guidelines Considerations for Cable Trolleys Considerations for Flexible Cable Track Considerations for Cable Trays & Ladders Tool Connections Maintenance Lock Option Chapter 5: Powering Up and Initial Checks 5.1 Before Powering On Initial Data Setting. 5-3 Chapter 6: System Operation 6.1 Display and Programming Unit DP2S 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 Press 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 Organization of Parameters Data Number Definitions System Parameter (No. 00) Work Parameters (No. 01~32) Press Methods Load Settings Distance Settings Time Settings Speed Settings Interference Check Part Check Part 3 Check Advance/Return Position Signal Band Check xi (Rev. 4)

12 Table of Contents Judgment Operation Loading Direction Return Operation Step Press Using Time Controlled Press Return Parameter Setup Chapter 7: Maintenance & Inspection 7.1 Inspection Items Press Tool Lubrication Ball Screw Inspection (DPT Series) Belt Tension Verification and Adjustment (DPS & DPM Series) 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 [A1_*] Offset Load Errors [A2_*] Tool EEPROM Errors [A3_*] System Memory Errors [A4_*] Servo Amplifier Response Errors [A5_*] Servo Type Errors [A6_*] Servo Amplifier Errors [A8_*] Parameter Errors [A9_*] Q & A (Rev. 4) xii

13 Table of Contents Appendix A: Reference Drawings Power Wiring Reference (SAN3)... A-2 Power Wiring Reference (SAN4)... A-3 Standard Transformers.. A-4 Motor/Resolver Homerun Cable (DPT & DPS) - (RM1, RM2 & RM3 Motor). A-5 Motor/Resolver Homerun Cable (DPT & DPS) - (RM4 Motor)..... A-6 Motor Homerun Cable (DPT & DPS - (RM5 Motor) A-7 Resolver Homerun Cable (DPT & DPS) - (RM5 Motor)..... A-8 Load Cell Homerun Cable (DPT & DPS) - (RM1, RM2, RM3, RM4 & RM5). A-9 Motor/Resolver/Load Cell Homerun Cable (DPM Series). A-10 Motor/Resolver Ext.Cable (DPT & DPS) - (RM1, RM2, RM3 & RM4 Motor).. A-11 Resolver Extension Cable (DPT & DPS) - (RM5 Motor) A-11 Motor Extension Cable (DPT & DPS) - (RM5 Motor).... A-12 Load Cell Extension Cable (DPT & DPS) - (RM1, RM2, RM3, RM4 & RM5). A-13 Motor/Resolver/Load Cell Extension Cable (DPM Series). A-14 SAN3/4-24S/24HS/40S Unit Power Cable... A-15 SAN3/4-120S Unit Power Cable... A-16 SAN4 Control Power Cable... A-17 I/O Connection Cable.. A-18 I/O Proximity Switch Breakout Adapter (DPT & DPS)... A-19 Proximity Switch Homerun Cable (DPT Series).. A-20 Proximity Switch Tool / Extension Cable (DPT Series)... A-21 Brake Unit (Maintenance Lock) Homerun Cable (DPT Series). A-22 Brake Unit (Maintenance Lock) Extension Cable (DPT Series)... A-23 External Brake Unit (Maintenance Lock) Cable (DPT Series).. A-24 Proximity Switch & Brake Extension Cable (DPS Series)... A-25 Proximity Switch & Brake Y Cable (DPS Series)... A-26 Brake Cable (DPS Series)... A-27 RS-485 Jumper Cable.. A-28 RS-485 to RS-232 PC Converter Cable A-29 xiii (Rev. 4)

14 Blank Page (Rev. 4) xiv

15 PAGE 1-1 Chapter 1: Outline

16 Chapter 1: Outline enforce DSP1500 SAN Unit Operation Manual 1.1 About this Manual This manual details the configuration, specifications and operation of the enforce Digital Servo Press System. This manual is written for SAN Units with Firmware Version 3.x. If you have a SAN Unit with an earlier version, do not use this manual as reference. 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 standard and optional system components. 4 System Setup and Wiring Equipment installation guidelines, dimensions, wiring, Input and Output signal descriptions and requirements for PLC programming. 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 Guidelines for preventative maintenance. 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 Programming with the enforce DSP1500 User Console for Main Unit enforce DSP1500 Main Unit Hardware Manual (Rev. 4) PAGE 1-2

17 enforce DSP1500 SAN Unit 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 thirty 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) despite 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 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. 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 pressing 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 (Rev. 4)

18 Chapter 1: Outline enforce DSP1500 SAN Unit 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. (Rev. 4) PAGE 1-4

19 enforce DSP1500 SAN Unit 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 (Rev. 4)

20 Chapter 1: Outline enforce DSP1500 SAN Unit Operation Manual SAN3-24S SAN3-120S (Rev. 4) PAGE 1-6

21 Chapter 2: Specifications PAGE 2-1

22 Chapter 2: Specifications enforce DSP1500 SAN Unit Operation Manual 2.1 System Specifications Power Supply Voltage Operating Conditions Storage Conditions Shipping Conditions Temperature Humidity Temperature Humidity Temperature Humidity Operating Range Duty Cycle less than 60% Load stop accuracy 1 Load resolution Load control range Load judgment range Distance stop accuracy 1,2 Distance display minimum unit Distance internal control unit Load cell accuracy Load cell linearity Press method DPT & DPM Series DPS Series 180VAC ~ 242VAC, 3 phase, 50/60Hz From 1/2 to Full Scale Load From 1/4 to 1/2 of Full Scale Load From 1/4 to Full Scale Load Approx. 1/1000 of full scale load value 25% -100% of full scale load value 10% -100% of full scale load value ± 0.01mm (-0.0 ~ +0.02mm) 32 ~ 122 F (-0 ~ 50 C) 20 ~ 90% (no condensation) 32 ~ 122 F (-0 ~ 50 C) Below 90% (no condensation) 32 ~ 122 F (-0 ~ 50 C) 0.1mm (0.001mm condition limit) 0.001mm ± 1% (0 - full scale) ± 0.5% of Full Scale value (maximum) Load method / distance method Below 90% (no condensation) 1/6 or less of tool maximum load (up to 2kN) Ram tip pendant allowable load (With brake option) DPS-101R3-** tool is up to 0.6KN 1) When the press is operated according to FEC specifications. 2) When load is constant. 3σ less than 3% scatter of target load. 3σ less than 4% scatter of target load. 3σ less than 1.5% scatter of target load. (Rev. 4) PAGE 2-2

23 enforce DSP1500 SAN Unit 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 SAN3-24HS SAN4-24HS SAN3-24S SAN4-24S SAN3-40S SAN4-40S SAN3-120S SAN4-120S Motor Type RH1 RM1 RM2 RM3 RM4 RM5 SAN3 Unit Input Power SAN4 Unit Motor Power SAN Unit Frequency Max. Power Output In-rush Current SAN Power Consumption 180 ~ 242VAC, 3φ 50 / 60Hz 70W 60W 80W 200W 1500W 3000W 19A 9.5A 18A 38.6A A 116.4A 25W* IN CYCLE 23W* IN CYCLE 18W IDLE 55W* IN CYCLE 88W* IN CYCLE * Total watts calculated running at 97% capacity, 99% stroke and 60% duty cycle. 107W* IN CYCLE 134W* IN CYCLE SAN4 Control Power Supply Circuit Input Power Source Voltage (Power Source Frequency) Momentary Maximum Current (Including Inrush Current) Single phase 180V 242V AC (50/60HZ) 0.25A rms (36Amax) 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 (Rev. 4)

24 Chapter 2: Specifications enforce DSP1500 SAN Unit Operation Manual SAN Unit Dimensions SAN3/4-24S, SAN3/4-24HS, SAN3/4-40S Mounting: Top 1 place #8-32 screw Bottom 2 places #8-32 screw Weight: SAN3/4-24S, 24HS kg SAN3/4-40S kg Note: The diagram shown above reflects dimensions for the SAN3/4-40S. The SAN3/4-24S and SAN3/4-24HS do not have a heat sink plate so the width is 60mm as opposed to 74mm. (Rev. 4) PAGE 2-4

25 enforce DSP1500 SAN Unit Operation Manual Chapter 2: Specifications SAN3/4-120S Mounting: Top 2 places #8-32 screw Bottom 2 places #8-32 screw Weight: SAN3/4-120S - 3.6kg. PAGE 2-5 (Rev. 4)

26 Chapter 2: Specifications enforce DSP1500 SAN Unit 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 I J (A) PRESS SERIES ( )DPT = STANDARD (*)DPM = MINI SERIES (500 & 1000N) (**)DPS = SLIM-LINE SERIES (1, 3 & 5ton) (B) PRESS FORCE 050=0.05ton * 201=2.0ton 202=20.0ton (In Metric Tons) 011=0.1ton * 301=3.0ton ** 021=0.2ton 501=5.0ton ** 051=0.5ton 701=7.0ton 101=1.0ton ** 102=10.0ton 151=1.5ton 152=15.0ton (C) MOTOR 1 = RM1A H1 = RM1H 2A = RM2A 3 = RM3A 4 = RM4 4H = RM4H 5 = RM5 (D) REVISION BLANK = STANDARD MOTOR A, 3, ETC. = ALPHA NUMERIC REVISION CODE (E) STROKE 10 = 100mm 15 = 150mm etc.. 25 = 250mm 20 = 200mm (F) PRESS TYPE F = PRESSING (Holding time <1sec.) - DPT & DPS P = BONDING (Holding time >1sec.) - DPT & DPM (G) SHAFT TYPE (DPT) (H) MAINTENANCE LOCK (I) MOUNTING (J) VERSION/REVISION S = SPLINE SHAFT G = GUIDE SHAFT B = WITH LOCK BLANK = NO LOCK 00 = STANDARD (BACK MOUNTING) 01 = 90 DEGREES 02 = TAPPED 03 = FRONT MOUNTING 10 = SPECIAL (CUSTOM DESIGN) A = CURRENT B = FUTURE UPGRADES C = FUTURE UPGRADES (Rev. 4) PAGE 2-6

27 enforce DSP1500 SAN Unit Operation Manual Chapter 2: Specifications Tool Specifications Motor: Force Monitor: Distance Monitor: Permanent magnet DC Inline Load Cell High Resolution Resolver List of standard tools for press-fitting (F type) - Use when operating with instantaneous load. Tool No. Tool type Maximum load [KN] Maximum speed [mm/sec] Minimum speed [mm/sec] 114 DPM-011H1-**F DPT-021R1-**F DPT-051R2-**F DPT-101R3-**F DPS-101R3-**F DPT-151R3-**F DPT-151R4H-**F DPT-201R3-**F DPT-201R4H-**F DPT-301R4H-**F DPS-301R4H-**F DPT-501R4H-**F DPS-501R4H-**F DPT-501R5-**F DPT-701R4H-**F DPT-102R5-**F DPT-152R5-**F DPT-202R5A-**F List of standard tools for press-bonding (P type) - Use when operating while holding load. Tool No. Tool type Maximum load [KN] Maximum speed [mm/sec] Minimum speed [mm/sec] 113 DPM-050H1-**P DPT-021R3-**P DPT-051R3-**P DPT-101R4H-**P DPT-151R4H-**P DPT-201R4H-**P DPT-301R4H-**P DPT-501R5-**P DPT-701R5-**P DPT-102R5-**P DPT-152R5-**P DPT-202R5-**P *Standard part numbers shown. Contact FEC for non-standard part specifications. 1KN = Lbs. PAGE 2-7 (Rev. 4)

28 Chapter 2: Specifications enforce DSP1500 SAN Unit Operation Manual Tool Dimensions Drawing Shown For Reference Only TOOL NUMBER STROKE A B C D E F G H J K L DPM-050H1-**P N/A M5-10(4) N/A 153 DPM-011H1-**F N/A M5-10(4) N/A 153 DPT-021R1-**F N/A 9(4) N/A 126 DPT-051R2-**F N/A 14(4) N/A 188 DPT-051R3-**P N/A 14(4) N/A 227 DPT-101R3-**F N/A 18(4) N/A 240 DPS-101R3-**F N/A 11(4) N/A 209 DPT-101R4H-**P N/A 18(4) N/A 240 DPT-151R3-**F N/A 18(4) N/A 240 DPT-151R4H-**P N/A 18(4) N/A 240 DPT-201R3-**F N/A 18(4) N/A 247 DPT-201R4H-**P N/A 18(4) N/A 247 DPT-301R4H-**F N/A 22(4) N/A 255 DPS-301R4H-**F N/A 14(4) N/A 262 DPT-301R4H-**P N/A 22(4) N/A 304 DPT-501R4H-**F (6) N/A 313 DPS-501R4H-**F N/A 18(4) N/A 322 DPT-501R5-**P (6) N/A 371 DPS-501R5-**F N/A 18(4) N/A 322 DPT-701R4H-**F (6) N/A 334 DPT-701R5-**P (6) N/A 415 DPT-102R5-**F *330 *300 N/A N/A 18(10) DPT-102R5-**P *330 *300 N/A N/A 18(10) DPT-152R5-**F *380 *340 N/A N/A 22(8) DPT-152R5-**P *380 *340 N/A N/A 22(8) DPT-202R5-**F *450 *410 N/A N/A 26(8) DPT-202R5-**P *450 *410 N/A N/A 26(8) Standard part numbers and strokes shown. Contact FEC for non-standard part number dimensions. Dimensions shown are subject to change without warning due to design improvements. (Rev. 4) PAGE 2-8

29 enforce DSP1500 SAN Unit 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 4. Load Rise Detection 5. Specified Range Peak Load Judgment 6. Time Controlled Press 7. Load Drop Detection 8. Load Drop Detection (Point Stop) 9. Distance Control with Load Limit Load and Distance can be monitored in any configuration. Early Interference Detection If the parameters are set up for Interference Check Distance and Interference Check Load, interferences early in the press cycle can be detected. Interference Checking is performed during the high speed portion of the press stroke and is useful for detecting: tooling left in the press path, misfed parts caught in receivers, etc. Part Checking Work level part checks If the parameters are set up for Part Check 1 Load, Part Check 1 Distance Low and Part Check 1 Distance High, part checking will be performed. Low Part Checking is useful in detecting: attempting to press completed parts, parts larger than spec., holes smaller than spec., misaligned parts, etc. High Part Checking is useful in detecting: missing parts, parts smaller than spec., holes larger than spec., etc. 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. 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 (Rev. 4)

30 Chapter 2: Specifications enforce DSP1500 SAN Unit Operation Manual Blank Page (Rev. 4) PAGE 2-10

31 Chapter 3: System Description PAGE 3-1

32 Chapter 3: System Description enforce DSP1500 SAN Unit Operation Manual 3.1 System Block Diagram (Main Unit Configuration) (Stand Alone Configuration) The enforce system can consist of a single unit or combined in multiple press configuration controlled by one main controller (Main Unit) using one set of I/O to control the group of presses. Discrete 24VDC (Sinking) I/O on the SAN unit provides direct communication with the PLC for individual press control (Stand Alone). 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. (Rev. 4) PAGE 3-2

33 enforce DSP1500 SAN Unit Operation Manual Chapter 3: System Description 3.2 DSP1500 SAN Unit Front Panel SAN Unit Front Panel Switches and Connectors D S P C O N 1 CON1: SW1: RUN/BYPASS: RUN: BYPASS: RS485: For Display Unit (SAN3-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 W 1 B Y P A S S P O W E R B U S Y S V. A B N. A C 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 S O L V E R MOTOR: Motor Connection for tool Motor/Resolver cable. M O N. T / D M O T O R AC V: CONTROL IN: Connection for Input Power. (SAN3) 3 phase, VAC, 50/60Hz Connection for Input Motor Power. (SAN4) 3 phase, VAC, 50/60Hz Connection for Input Control Power. (SAN4) 1 phase, VAC, 50/60Hz A C V P L C FEC SAN3-24SM CONTROL IN PAGE 3-3 (Rev. 4)

34 Chapter 3: System Description enforce DSP1500 SAN Unit Operation Manual SAN Unit 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 W 1 B Y P A S S P O W E R B U SY S V. A B N. A C C. R E J. 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 R E S O L V E R M O T O R A C V 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 interference limits on a Home Search time-out P L C FEC SAN3-24SM 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. (Rev. 4) PAGE 3-4

35 enforce DSP1500 SAN Unit Operation Manual Chapter 3: System Description SAN Unit 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 (Jog) Button CAL Button RESET Button P A R M D - N O M O D E D A T A S E T ( H O M E ) Data Display / (Operating) Button MODE Button SET Button(Home Return) DATA UP Cursor Button(Manual Jog Return) DATA DOWN Cursor Button (Manual Jog Advance) B Y P A S S A B N. R U N A C C. R E J. R S R E S O L V E R M O N. T / D M O TO R A C V P L C F E C S A N 3-24SM PAGE 3-5 (Rev. 4)

36 Chapter 3: System Description enforce DSP1500 SAN Unit Operation Manual SAN Unit 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 P A R M D - N O M O D E D A T A S E T ( H O M E ) B Y P A S S A B N. PARM Display (2 figure) Parameter Number Display Or Abnormal Number Display D-NO Display (2 figure) Data Number Display Press Unit Number Display Or Abnormal Sub-Code Number Display R U N A C C. R E J. 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 3-24SM (Rev. 4) PAGE 3-6

37 enforce DSP1500 SAN Unit 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 (Not present on DPM Series) F) ADVANCED PROXIMITY: Clockwise (advance) limit sensor (Not present on DPS or DPM Series) G) GEAR HOUSING: Durable gear transmission. (Belt Drive on DPS & DPM) 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 and series) PAGE 3-7 (Rev. 4)

38 Chapter 3: System Description enforce DSP1500 SAN Unit Operation Manual 3.4 Connection Diagrams DPT Series SAN Unit Brake Cable Tool Brake Motor CCW ORG Preamplifier Resolver PC, PLC or Main Unit Resolver Cable Monitor Signal CW Motor Cable Customer Supplied PLC I/O Cable Power Cable SAN4 Contactor Noise Filter Circuit Protector 180~242VAC LMT On SAN4 Only Control Power Cable Limit Sensor Cable Preamplifier Cable NOTE: 1. Origin Sensor (ORG) is used on 10, 15 and 20 ton presses. 2. Motor and Resolver cable is separate on presses using an RM5 motor only. 3. Motor and Control input power is separated on SAN4 Units only. (Rev. 4) PAGE 3-8

39 enforce DSP1500 SAN Unit Operation Manual Chapter 3: System Description DPS Series Brake Tool SAN Unit Preamplifier CCW Motor Resolver PC, PLC or Main Unit Resolver cable Monitor Signal Motor cable Customer Supplied PLC I/O Cable Power Cable SAN4 Contactor Noise Filter Circuit Protector 180~242VAC LMT On SAN4 Only Control Power Cable Limit Sensor / Brake Cable Brake Cable Preamplifier Cable BRK NOTE: 1. Clockwise Sensor (CW) is not used in this series. 2. Motor and Resolver cable is separate on presses using an RM5 motor only. 3. Motor and Control input power is separated on SAN4 Units only. PAGE 3-9 (Rev. 4)

40 Chapter 3: System Description enforce DSP1500 SAN Unit Operation Manual DPM Series SAN Unit Tool Motor Tool Cable Resolver Preamplifier PC, PLC or Main Unit Monitor Signal PLCPower Cable SAN4 Contactor Customer Supplied Noise Filter Circuit Protector 180~242VAC SAN3-24HS On SAN4 Only Control Power Cable NOTE: 1. Clockwise and Counter-clockwise Sensors/cables (CCW & CW) are not used in this series. 2. Motor, Resolver and Transducer (Load Cell) cables are combined into 1 cable. 3. Motor and Control input power is separated on SAN4 Units only. 4. This press series uses the SAN3/4-24HS controller. It cannot use the SAN3/4-24S. 5. Brake Units are not available in this series. (Rev. 4) PAGE 3-10

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

42 Chapter 4: System Setup and Wiring enforce DSP1500 SAN Unit 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 (Rev. 4) PAGE 4-2

43 enforce DSP1500 SAN Unit 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 SAN4 control power connection and for flash connector hook up when updating firmware. SAN units must be located a minimum of 600mm from any high transient voltage power source. Layout SAN Unit(s) to allow proper heat dissipation. Install fan or cooling device so that the ambient temperature of the SAN Unit does not exceed 122 F (50 C). Locate fan to blow directly onto heat sink plate and/or draw heat from top of unit. SAN3/4-24S, SAN3/4-24HS, SAN3/4-40S Mounting: Top (1) place #8-32 screw Bottom (2) places #8-32 screw Weight: SAN3/4-24S, 24HS 1.4 kg SAN3/4-40S 1.8 kg The diagram shown above shows the dimensions of the SAN3/4-40S. The protrusion of the heat sink plate (14mm) is on the SAN3/4-40S only, therefore the width of the SAN3/4-24S & SAN3/4-24HS is 60mm as opposed to 74mm. PAGE 4-3 (Rev. 4)

44 Chapter 4: System Setup and Wiring enforce DSP1500 SAN Unit Operation Manual SAN3/4-120S Mounting: Top (2) places #8-32 screw Bottom (2) places #8-32 screw Weight: SAN3/4-120S kg (Rev. 4) PAGE 4-4

45 enforce DSP1500 SAN Unit Operation Manual Chapter 4: System Setup and Wiring 4.3 Calculating Circuit Protection RATED VALUES FOR CALCULATING CIRCUIT PROTECTION MOTOR # OF SAN3/4 UNITS KVA PER MOTOR TYPE WATTAGE SAN3/4 UNIT PER 1 KVA SAN3/4 UNIT R1 60 SAN3/4-24S R1H 70 SAN3/4-24HS R2 80 SAN3/4-24S R3 200 SAN3/4-40S R SAN3/4-120S R SAN3/4-120S 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 (Rev. 4)

46 Chapter 4: System Setup and Wiring enforce DSP1500 SAN Unit Operation Manual 4.4 Input Power Supply Connection(s) On SAN3 Units, Motor and Control input power is supplied on one connector. On SAN4 Units the Motor and Control input power can be separated. This allows the removal of motor power without the press losing its Home Position. Adequate circuit protection must be provided for the SAN unit input power Input Motor & Control (SAN3) / Input Motor Power (SAN4) Connection 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 O T O R A C V SAN3/4-120S B 4 : U 3 : V 2 : W 1 : F G SAN3-24SM A Wiring Chart SAN3/4-24S, 24HS, 40S 4:U 3-Phase 3:V 180 ~ 242VAC 2:W 50/60Hz. 1:FG SAN3/4-120S (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. Mating Connectors SAN3/4-24S, 24HS, 40S Manufacture: AMP Housing Part No.: Contact Part No.: (Qty.-4) SAN3/4-120S Manufacture: AMP Housing Part No.: Contact Part No.: (Qty.-8) Install adiquate circuit protection on the input power feed. (Refer to Appendix A for wiring) When using a transformer that is not isolated or if incoming power is known to be noisy, install a filter in the input power circuit. Recommended Filters: SAN3/4-24S, 24HS TDK #ZRWT2205-ME SAN3/4-40S TDK #ZRWT2210-ME SAN3/4-120S TDK #ZRWT2220-ME If using a SAN4 Unit with separately wired motor and control input circuits be aware that when motor power is dropped during operation the press does not come to an immediate stop due to momentum. If normal operation requires the motor power to be dropped for safety (IE: interruption of safety gates, etc.) turn the STOP signal off at the same time the motor power is dropped so that the dynamic braking circuit stops press motion. (Rev. 4) PAGE 4-6

47 enforce DSP1500 SAN Unit Operation Manual Chapter 4: System Setup and Wiring Input Control Power Connection (SAN4 Only) Recommended conductor size should be a minimum of #16AWG. Suggested color code (FEC standard): U Red, V White, FG Green. SAN4-24S, 24HS, 40S SAN4-120S Wiring Chart 3:U 1-Phase 2:V 180 ~ 242VAC 1:FG 50/60Hz. Mating Connectors Manufacture: AMP Housing Part No.: Contact Part No.: (Qty.-3) PAGE 4-7 (Rev. 4)

48 Chapter 4: System Setup and Wiring enforce DSP1500 SAN Unit Operation Manual 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 (except for presses using an RM5 motor). 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 Wiring Chart SAN3/4-24S, 24HS, 40S 1: Frame Ground 2: Not Used 3: W Phase 4: V Phase 5: U Phase SAN3/4-120S (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 SAN3/4-120S Mating Connectors B A SAN3/4-24S, 24HS, 40S Manufacture: AMP Housing Part No.: Contact Part No.: (Qty.-4) SAN3/4-120S Manufacture: AMP Housing Part No.: Contact Part No.: (Qty.-8) (Rev. 4) PAGE 4-8

49 enforce DSP1500 SAN Unit Operation Manual Chapter 4: System Setup and Wiring 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 4-9 (Rev. 4)

50 Chapter 4: System Setup and Wiring enforce DSP1500 SAN Unit Operation Manual 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 Interface (I/O ) Signals [Main Unit Configuration] Pin No. Signal Name IN/OUT Description 1 NOT USED No Connection Allowed 2 NOT USED No Connection Allowed 3 NOT USED No Connection Allowed 4 NOT USED No Connection Allowed 5 NOT USED No Connection Allowed 6 NOT USED No Connection Allowed 7 NOT USED No Connection Allowed 8 NOT USED No Connection Allowed 9 NEAR ORIGIN IN (N.O.) Home sensor input (Used for special applications) 10 NOT USED No Connection Allowed 11 NOT USED No Connection Allowed 12 NOT USED No Connection Allowed 13 IN COMMON Input signal common. (+12 ~ +24VDC) 14 NOT USED No Connection Allowed 15 CW LIMIT IN (N.C.) Clockwise limit sensor input.(advance limit) 16 CCW LIMIT IN (N.C.) Counter-clockwise limit sensor input.(return limit) 17 NOT USED 18 NOT USED 19 NOT USED No Connection Allowed 20 NOT USED 21 NOT USED 22 NOT USED 23 OUT COMMON Output signal common. (0VDV) 24 SERVO ON OUT (N.O.) May be used to turn on the optional brake unit (disengage) 25 NOT USED 26 NOT USED 27 NOT USED 28 NOT USED 29 NOT USED No Connection Allowed 30 NOT USED 31 NOT USED 32 NOT USED 33 NOT USED 34 NOT USED IN: Input Signal OUT: Output Signal NC: Normally Closed NO: Normally Open (Rev. 4) PAGE 4-10

51 enforce DSP1500 SAN Unit Operation Manual Chapter 4: System Setup and Wiring PLC Interface (I/O) Signals [Stand Alone Configuration] 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 NOT USED No Connection Allowed 7 NOT USED No Connection Allowed 8 NOT USED No Connection Allowed 9 HOME / OPTION IN IN (N.O.) Home sensor input/option In input (Use for special applications) 10 BANK 1 IN (N.O.) Bank 1 Select input 11 BANK 0 IN (N.O.) Bank 0 Select input 12 NOT USED No Connection Allowed 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.) These 5 inputs form a binary code which is capable of selecting up to 18 WORK SELECT 1 IN (N.O.) 32 different parameters. 19 WORK SELECT 2 IN (N.O.) (In Manual Mode these inputs become selecting signals for advance, 20 WORK SELECT 3 IN (N.O.) 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 Output Data Bank Signals (Stand Alone Configuration Only) Bank Select Inputs are used to multiplex the output signals allowing up to 32 signals from only 8 physical outputs. By changing the input conditions of these two inputs, up to four Banks may be selected changing the definition of each output point. The SERVO ON signal is sometimes monitored to operate the brake. When changing Banks, the meaning of the SERVO ON signal will change when a bank other than Bank 1 is selected. (See Section 4.14 for Brake Operation) PAGE 4-11 (Rev. 4)

52 Chapter 4: System Setup and Wiring enforce DSP1500 SAN Unit Operation Manual *Allow at least 20ms from the time the desired bank is selected before reading the OUT DATA signal. BANK1 BANK0 OUT DATA Signal Name Description OFF OFF ON ON OFF ON OFF ON OUT DATA0 SERVO ON Output when press motor is on (running) OUT DATA1 HOME SET Output after home position has been defined. OUT DATA2 PRESS RET D Output when the press 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 ADV / RET POS. Advance / Return Position Output signal. OUT DATA10 BANK1 Output echo of BANK Select 1 Input. OUT DATA11 BANK0 Output echo of BANK Select 0 Input. OUT DATA0 HOME RET D Output when the press is between Home Position and the position shown in System Parameter OUT DATA1 BYPASS Output when the press is in Bypass (switch or input) 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 DIS_ LOW Output on a Low Distance Reject OUT DATA3 DIS_ HIGH Output on a High Distance Reject OUT DATA4 CK1_LOW Output on a Check 1 Low Reject Both ON: OUT DATA5 CK1_HIGH Output on a Check 1 High Reject Interference Reject OUT DATA6 CK2_LOW Output on a Check 2 Low Reject OUT DATA7 CK2_HIGH Output on a Check 2 High Reject. OUT DATA8 CK3_LOW Output on a Check 3 Low Reject OUT DATA9 CK3_HIGH Output on a Check 3 High Reject. OUT DATA10 BANK1 Output echo of Bank Select 1 Input. OUT DATA11 BANK0 Output echo of Bank Select 0 Input. OUT DATA0 ABNSUB-CODE0 Abnormal Sub Code Bit 0 Output OUT DATA1 ABNSUB-CODE1 Abnormal Sub Code Bit 1 Output OUT DATA2 ABNSUB-CODE2 Abnormal Sub Code Bit 2 Output OUT DATA3 ABNSUB-CODE3 Abnormal Sub Code Bit 3 Output OUT DATA4 ABN-CODE0 Abnormal Code Bit 0 Output OUT DATA5 ABN-CODE1 Abnormal Code Bit 1 Output OUT DATA6 ABN-CODE2 Abnormal Code Bit 2 Output OUT DATA7 ABN-CODE3 Abnormal Code Bit 3 Output OUT DATA8 OUT DATA9 OUT DATA10 BANK1 Output echo of Bank Select 1 Input OUT DATA11 BANK0 Output echo of Bank Select 0 Input. (Rev. 4) PAGE 4-12

53 enforce DSP1500 SAN Unit Operation Manual Chapter 4: System Setup and Wiring Input and Output H/W Recommended Connecting Circuit DSP1500 SAN UNIT PLC OUTPUT 40mA Max. OUTPUT 40mA Max. PLC CONNECTOR INPUT INPUT 24 VDC All SAN Unit 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 #A1SX42 are used, the above mentioned trouble may occur. PAGE 4-13 (Rev. 4)

54 Chapter 4: System Setup and Wiring enforce DSP1500 SAN Unit Operation Manual Input and Output Signal Explanation Input Signals Inputs are sourced (normally high) and activated when pulled low (0VDC). 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. If a display unit is attached to the SAN Unit, the following will be displayed: When the STOP signal is turned off during operation, the internal dynamic braking circuit engages causing the press to immediately stop. If using a SAN4 Unit with separately wired motor and control input circuits be aware that when motor power is dropped during operation the press does not come to an immediate stop due to momentum. If normal operation requires the motor power to be dropped for safety (IE: interruption of safety gates, etc.) turn the STOP signal off at the same time the motor power is dropped so that the dynamic braking circuit stops press motion. 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, the press cycle will be aborted. 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 parameters 2 thru 8 are active, Manual+Start initiates the function shown in the chart on page A signal will not be accepted during a reset or when in cycle. 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 (Busy signal goes low). The press unit will be in BUSY (in cycle) status after start of press. 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 page 4-16) If the START input signal is turned off while in cycle the unit will stop and return as programmed in the RETURN OPERATION parameter. (Rev. 4) PAGE 4-14

55 enforce DSP1500 SAN Unit Operation Manual Chapter 4: System Setup and Wiring 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. NEAR ORIGIN: Near Home sensor signal (Normally Open) Used in special applications on 10 ton and larger presses. It is only used when performing a Home Position Search. When the near origin sensor is used it must be enabled in System Parameter SELF CHECK OFF: Load Cell 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 cell is automatically checked before the press cycle begins. If the automatic check of the load cell is not required, turning ON this signal at the time of inputting a START signal will cause this test not to be performed. *Allow at least 10ms from the time this signal is turned on before turning on the START signal. Do not turn this signal off at least until BUSY goes HIGH. CLOCKWISE: Advanced Limit proximity signal (Normally Closed) When the CW LIMIT signal is "OFF" or is not connected, it is not possible to move the press in the advance direction. Only Home Position Search or Manual Jog operation in the return direction is possible. If a display unit is attached to the SAN Unit, the following will be displayed: COUNTER-CLOCKWISE: Returned Limit proximity signal (Normally Closed) When the CCW LIMIT signal is "OFF" or is not connected, it is not possible to move the press in the return direction. Only Home Position Search or Manual Jog operation in the advance direction is possible. If a display unit is attached to the SAN Unit, the following will be displayed: PAGE 4-15 (Rev. 4)

56 Chapter 4: System Setup and Wiring enforce DSP1500 SAN Unit Operation Manual WORK SELECT 0 thru 4: Parameter Select signal (Normally Open) These 5 inputs [WORK SELECT 0-4] form a binary code which is capable of selecting up to 32 different sets of press parameters. *Allow at least 10ms from the time this signal is turned on before turning on the START signal. Do not turn this signal off at least until BUSY goes HIGH. 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 Advance high speed jog OFF (OPEN) OFF (OPEN) OFF (OPEN) ON ON 4 Return high speed jog OFF (OPEN) OFF (OPEN) ON OFF (OPEN) OFF (OPEN) 5 Advance middle speed jog OFF (OPEN) OFF (OPEN) ON OFF (OPEN) ON 6 Return middle speed jog OFF (OPEN) OFF (OPEN) ON ON OFF (OPEN) 7 Advance low speed jog OFF (OPEN) OFF (OPEN) ON ON ON 8 Return low speed jog OFF (OPEN) ON OFF (OPEN) OFF (OPEN) OFF (OPEN) 9 OFF (OPEN) ON OFF (OPEN) OFF (OPEN) ON 10 OFF (OPEN) ON OFF (OPEN) ON OFF (OPEN) 11 OFF (OPEN) ON OFF (OPEN) ON ON 12 OFF (OPEN) ON ON OFF (OPEN) OFF (OPEN) 13 OFF (OPEN) ON ON OFF (OPEN) ON 14 OFF (OPEN) ON ON ON OFF (OPEN) 15 OFF (OPEN) ON ON ON ON 16 ON OFF (OPEN) OFF (OPEN) OFF (OPEN) OFF (OPEN) 17 ON OFF (OPEN) OFF (OPEN) OFF (OPEN) ON 18 ON OFF (OPEN) OFF (OPEN) ON OFF (OPEN) 19 ON OFF (OPEN) OFF (OPEN) ON ON 20 ON OFF (OPEN) ON OFF (OPEN) OFF (OPEN) 21 ON OFF (OPEN) ON OFF (OPEN) ON 22 ON OFF (OPEN) ON ON OFF (OPEN) 23 ON OFF (OPEN) ON ON ON 24 ON ON OFF (OPEN) OFF (OPEN) OFF (OPEN) 25 ON ON OFF (OPEN) OFF (OPEN) ON 26 ON ON OFF (OPEN) ON OFF (OPEN) 27 ON ON OFF (OPEN) ON ON 28 ON ON ON OFF (OPEN) OFF (OPEN) 29 ON ON ON OFF (OPEN) ON 30 ON ON ON ON OFF (OPEN) 31 ON ON ON ON ON 32 If the start signal is turned ON while in MANUAL (JOG) mode, the press will perform the function defined in the MANUAL operation of the selected Parameter Number; Home-position search, Home-position return, Advance jog and Return jog. The speed of the operation of MANUAL mode is set in the Data Number 00-32: MANUAL OPERATION SPEED System Parameter. (See Page 6-21)The speed of the Home-position return and High speed jog is set to this set value. 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. The speed of Home Position Search is set in the Data Number System Parameter. If a value greater than 10mm/sec. is entered for Home Position Search speed, the system will limit Home Position Search speed to 10mm/sec. On a Home Position Search, the return operation operates first and when the CCW limit sensor turns OFF, the operation changes to 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 ) (Rev. 4) PAGE 4-16

57 enforce DSP1500 SAN Unit Operation Manual Chapter 4: System Setup and Wiring 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 SERVO ON: [OUT DATA0 - PIN #24] Servo Running Signal Output when the servo is running. This signal will turn OFF when a reset is input. May be used to monitor when to engage/disengage the maintenance brake (See Section 4.14). When the Servo On signal is high (ON) the brake should disengage. THE FOLLOWING OUTPUTS ARE ONLY AVAILABLE WHEN THE SAN UNIT IS CONFIGURED FOR STAND ALONE OPERATION: HOME SET: [OUT DATA1 - PIN #25] 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. PRESS RETURNED: [OUT DATA2 - PIN #26] Return position stop signal Output when the press is stopping between home-position (0mm position) and the selected parameter [41: Job Start Position] when it is not in cycle. If the selected parameter [41: Job Start Position] is set to 10mm, the signal is output when it is stopping between 0 to 10.9mm. *When using Load Return Operation Finish Mode, PRESS RETURNED is output only when at home-position. (version 1.94 and higher) 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 [41: Job Start Position], the PRESS RETURNED signal may go low (OFF). BUSY: [OUT DATA3 - PIN #27] Operating signal When the press unit is in cycle, the signal is ON. READY: [OUT DATA4 - PIN #28] 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 5 seconds) o When in MANUAL mode o When an abnormal signal is output o When in Bypass status (when setting 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 o On SAN4 Units - on loss of Drive Power ABNORMAL: [OUT DATA5 - PIN #29] 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. ACCEPT: [OUT DATA6 - PIN #30] Press ACCEPT (OK) Signal Output when the press result is within the press limits. This signal turns on just before BUSY goes LOW. Output remains active until the start or reset signal is input. REJECT: [OUT DATA7 - PIN #31] Press REJECT (NG) Signal Output when the press result exceeds the press limits. This signal turns on just before BUSY goes LOW. Output remains active until the start or reset signal is input. PAGE 4-17 (Rev. 4)

58 Chapter 4: System Setup and Wiring enforce DSP1500 SAN Unit Operation Manual PRESS ADVANCED: [OUT DATA8 - PIN #32] Outputs when the press reaches the target load or target distance for a time that is set in [61: Load Hold Time]. If Load Hold Time is set to zero the PRESS ADVANCED signal will not turn on. TIMING SIGNAL: [OUT DATA9 - PIN #33] (Advance / Return Position Signal Output) Data Numbers 50, 51, 52 and 53 of Parameters 1~32 are used to set ON and OFF limits for the Timing Signal. [50: Advance Position ON Distance] [51: Advance Position OFF Distance] [52: Return Position ON Distance] [53: Return Position 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 [50: 50.0mm] [51: 120.0mm] [52: 150.0mm] [53: 100.0mm] 150mm 52 ON 0mm ON OFF Example #2 [50: 50.0mm] [51: Max Distance] [52: Max Distance] [53: 100.0mm] 150mm BANK 1: [OUT DATA10 - PIN #34] Bank 1 Input Echo Signal Output when the BANK SELECT 1 input is high (On). BANK 0: [OUT DATA11 - PIN #22] Bank 0 Input Echo Signal Output when the BANK SELECT 0 input is high (On). (Rev. 4) PAGE 4-18

59 enforce DSP1500 SAN Unit Operation Manual Chapter 4: System Setup and Wiring 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. DIS_LOW: [OUT DATA2] 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 DATA3] 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. CK1_LOW: [OUT DATA4] Part Check 1 Low / Interference Zone REJECT Signal Output when the distance where Part Check 1 Load is sensed is below the acceptable Part Check 1 Distance Low Limit. Output along with CK1_HIGH signal when an Interference Zone Reject occurs. Output remains active until the start or reset signal is input. CK1_HIGH: [OUT DATA5] Part Check 1 High / Interference Zone REJECT Signal Output when the distance where Part Check 1 Load is sensed is above the acceptable Part Check 1 Distance High Limit. Output along with CK1_LOW signal when an Interference Zone Reject occurs. Output remains active until the start or reset signal is input. CK2_LOW: [OUT DATA6] Part Check 2 Low REJECT Signal Output when the load sensed by the press between Part Check 2 Start Distance and Part Check 2 End Distance is below the acceptable Part Check 2 Load Low Limit. Output remains active until the start or reset signal is input. PAGE 4-19 (Rev. 4)

60 Chapter 4: System Setup and Wiring enforce DSP1500 SAN Unit Operation Manual CK2_HIGH: [OUT DATA7] Part Check 2 High REJECT Signal Output when the load sensed by the press between Part Check 2 Start Distance and Part Check 2 End Distance is above the acceptable Part Check 2 Load High Limit. Output remains active until the start or reset signal is input. CK3_LOW: [OUT DATA8] Part Check 3 Low REJECT Signal Output when the load sensed by the press between Part Check 3 Start Distance and Part Check 3 End Distance is below the acceptable Part Check 3 Load Low Limit. Output remains active until the start or reset signal is input. CK3_HIGH: [OUT DATA9] Part Check 3 High REJECT Signal Output when the load sensed by the press between Part Check 3 Start Distance and Part Check 3 End Distance is above the acceptable Part Check 3 Load 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). OUTPUT BANK 4: Bank0 On / Bank1 - On ABNSUB_CODE0: [OUT DATA0] Abnormal Sub Code Bit 0 Signal Bits 0 thru 3 are binary bits used together to represent the Abnormal Sub Code. Output remains active until the reset signal is input. ABNSUB_CODE1: [OUT DATA1] Abnormal Sub Code Bit 1 Signal Bits 0 thru 3 are binary bits used together to represent the Abnormal Sub Code. Output remains active until the reset signal is input. ABNSUB_CODE2: [OUT DATA2] Abnormal Sub Code Bit 2 Signal Bits 0 thru 3 are binary bits used together to represent the Abnormal Sub Code. Output remains active until the reset signal is input. ABNSUB_CODE3: [OUT DATA3] Abnormal Sub Code Bit 3 Signal Bits 0 thru 3 are binary bits used together to represent the Abnormal Sub Code. Output remains active until the reset signal is input. ABN_CODE0: [OUT DATA4] Abnormal Code Bit 0 Signal Bits 0 thru 3 are binary bits used together to represent the Abnormal Code. Output remains active until the reset signal is input. ABN_CODE1: [OUT DATA5] Abnormal Code Bit 1 Signal Bits 0 thru 3 are binary bits used together to represent the Abnormal Code. Output remains active until the reset signal is input. ABN_CODE2: [OUT DATA6] Abnormal Code Bit 2 Signal Bits 0 thru 3 are binary bits used together to represent the Abnormal Code. Output remains active until the reset signal is input. ABN_CODE3: [OUT DATA7] Abnormal Code Bit 3 Signal Bits 0 thru 3 are binary bits used together to represent the Abnormal Code. Output remains active until the 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). (Rev. 4) PAGE 4-20

61 enforce DSP1500 SAN Unit Operation Manual Chapter 4: System Setup and Wiring Operation Timing Chart Automatic Mode Timing to set the START signal OFF, it is voluntary if the BUSY is OFF. When the START or RESET signal is turned ON the ACCEPT and REJECT signals turn OFF. STOP READY RESET START OFF ON ON OFF ON OFF ON OFF Condition Operating Operating BUSY ON OFF ACCEPT ON OFF REJECT ON OFF Above 10ms Above 10ms ON 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 Advance Jog Return Jog BUSY READY ON OFF ON OFF When the START signal turns on, BUSY turns ON and ACCEPT, REJECT and READY signals turn 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 4-21 (Rev. 4)

62 Chapter 4: System Setup and Wiring enforce DSP1500 SAN Unit Operation Manual 4.8 SW1 - SAN Unit DIP Switch Settings SAN Unit Address Settings (DIP Switch 4~8) 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). AFC1500 ON 側 SW1 BYPASS RUN DSP CON1 OFF 側 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 (Rev. 4) PAGE 4-22

63 enforce DSP1500 SAN Unit Operation Manual Chapter 4: System Setup and Wiring Special Configuration Settings (DIP Switch 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 Up / Down Software Configured (default) Ramp Up and Ramp Down are set in the User Console Software. OFF: Ramp Up / Down Hardware Configured (see below) Ramp Up and Ramp Down are hardware set. The diagrams below show the effects of the DIP switch 3 setting in the OFF position as seen on an oscilloscope for a DPT-021R1 press (top diagram) and a DPT-201R3 press (bottom diagram). Both presses were set up to run Distance Control at maximum speed with the brake disabled (always disengaged). DPT-021R1 Advance 470ms 30ms DIP Switch 3 OFF Return 470ms 470ms DPT-201R3 Advance 488ms 14ms DIP Switch 3 OFF Return 488ms 456ms If not used, set DIP switches number 1 and 2 in the OFF position and DIP switch number 3 in the ON position. SAN Unit must be powered off and on again for switch changes to take effect. PAGE 4-23 (Rev. 4)

64 Chapter 4: System Setup and Wiring enforce DSP1500 SAN Unit 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 Δ 2.5V 2 POSITION PULSE OUT Distance pulse Monitor Output 5V TTL Signal 3 POSITION CW/CCW OUT Advance/Return Monitor Output 5V TTL Signal 4 Current Monitor OUT -10V~+10V (+10V=SAN24S:24A/ SAN40S:40A/ 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 and vise-versa for tools with inverted motors or different gearing. (Rev. 4) PAGE 4-24

65 enforce DSP1500 SAN Unit Operation Manual Chapter 4: System Setup and Wiring Calibration Method for External Monitoring Equipment When the CAL switch on the SAN unit display is pressed, load voltage is outputted on the LOAD OUT at a potential difference of approximately 2.5V. The load value which the SAN unit recognizes at this time is displayed on the DATA display. Make adjustments so that the load value that is displayed at this load voltage is the same as the external monitoring equipment. * The load voltage at zero load is not 0V. The load voltage depends on the tool therefore, correction for zero point is required by external monitoring equipment. Output Circuit Load Voltage Output 1kΩ - + 1kΩ UPC812 (NEC or equivalent) OUTPUT ±10mA Max Position Pulse, CW/CCW 5V 4.7kΩ Open Collector Output 74LS06 OUTPUT -40mA Max PAGE 4-25 (Rev. 4)

66 Chapter 4: System Setup and Wiring enforce DSP1500 SAN Unit Operation Manual 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 the Main Unit. 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: RJ45 FEC Part No.: FEB-1268 or standard CAT-5 cable 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 (Rev. 4) PAGE 4-26

67 enforce DSP1500 SAN Unit Operation Manual Chapter 4: System Setup and Wiring 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 4-27 (Rev. 4)

68 Chapter 4: System Setup and Wiring enforce DSP1500 SAN Unit Operation Manual 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. (Rev. 4) PAGE 4-28

69 enforce DSP1500 SAN Unit Operation Manual Chapter 4: System Setup and Wiring 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 4-29 (Rev. 4)

70 Chapter 4: System Setup and Wiring enforce DSP1500 SAN Unit Operation Manual 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 (maintenance lock) 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 (DPT & DPS Series) RM1, RM2, RM3 (FIELD): RM4 (FIELD): RM1, RM2, RM3, RM4 (EXTENSION): Nominal OD =.505 Min. Bend Radius = 6.0 FEC P/N: FEB-1251 FEC P/N: FEB-1605 FEC P/N: FEB-1283 RM5 (MOTOR FIELD): FEC P/N: FEB-1604 RM5 (MOTOR EXTENSION): FEC P/N: FEB-1606 Nominal OD =.415 (x2) Min. Bend Radius for group = 10.0 RM5 (RESOLVER FIELD): FEC P/N: FEB-1603 RM5 (RESOLVER EXTENSION): FEC P/N: FEB-1283 Nominal OD =.535 Min. Bend Radius = 6.0 LOAD TRANSDUCER (PRE-AMP) CABLE (DPT & DPS Series) RM1, RM2, RM3, RM4, RM5 (FIELD): FEC P/N: FEB-1173 RM1, RM2, RM3, RM4, RM5 (EXTENSION): FEC P/N: FEB-1284 Nominal OD =.405 Min. Bend Radius = 4.0 POSITION SENSOR CABLE (DPT Series): Brad Harrison female 4 pin Micro style cable or equivalent (See Appendix A). POSITION SENSOR/BRAKE CABLE (DPS Series): FEC P/N: FEB-1626 MOTOR/RESOLVER/TRANSDUCER CABLE (DPM Series):. FEC P/N: FEB-1524 (Rev. 4) PAGE 4-30

71 enforce DSP1500 SAN Unit Operation Manual Chapter 4: System Setup and Wiring 4.14 Maintenance Lock Option Power Requirements Voltage 24VDC to disengage brake Current Consumption RM1 Motor 0.5A RM2 Motor 0.5A RM3 Motor 0.5A RM4H Motor 0.8A RM5 Motor 1.2A Reference Circuit Press Varister BRK red/grn blu/grn Brake A B RY 24V 0V SAN Unit I/O Connector 24 SERVO ON PLC Y001 RELEASE BRAKE X000 SERVO ON *PLC I/O shown for reference only. * When a fixture, heavy enough to pull the press ram down when the servo is not running, is attached to the press ram use Servo On to monitor when to engage/disengage the brake (maintenance lock). When Servo On signal goes high (On) release (disengage) the brake. * Under normal circumstances, the brake (maintenance lock) can be engaged/disengaged by wiring it directly to the Control Power circuit; only engaging (locking) on loss of Control Power. Unless instructed by FEC, System Parameter should always be configured for Dynamic Hold. Setting the Dynamic Hold configuration allows the servo motor to dynamically hold the press ram when stopped. Setting System Parameter to Off forces the Maintenance Lock (when equipped) to hold the press ram when the servo stops. The maintenance lock should be used for maintenance purposes only, not for control. Using the maintenance lock to control stopping of the press ram will decrease the life of the lock unit dramatically. 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. BRAKE CABLE (DPT): (FIELD): FEC P/N: FEB-1314 (EXTENSION): FEC P/N: FEB-1609 BRAKE CABLE (DPS): (FIELD): FEC P/N: FEB-1625 PAGE 4-31 (Rev. 4)

72 Chapter 4: System Setup and Wiring enforce DSP1500 SAN Unit Operation Manual Blank Page (Rev. 4) PAGE 4-32

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

74 Chapter 5: Powering Up and Initial Checks enforce DSP1500 SAN Unit 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 mounting fixture 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 Main Unit I/O connectors and/or SAN unit I/O connectors. SAN Unit I/O connectors are still required when the system is configured with a Main Unit. 24VDC and limit signals for the press proximity switches are supplied through this connector. 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. Check the Input Voltages (2.1, 4.4) Verify that the Input Power Connector(s) 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. (Rev. 4) PAGE 5-2

75 enforce DSP1500 SAN Unit Operation Manual Chapter 5: Powering Up and Initial Checks 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 SAN Units are set with the correct function version. This number is set in System Parameter (See section and to see how to check and edit this setting) The settings should be as follows: SAN Unit (Main Configuration): 0180 SAN Unit (Stand Alone Configuration): 0103 Next, verify that the necessary parameter data required for pressing has been entered and is correct (IE: distance, load, speed, etc). To perform the checks below, 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. (Stand Alone Configuration) 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 (Jog) 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 1000 to 3000, there is a possibility that the home-position will deviate. 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 5-3 (Rev. 4)

76 Chapter 5: Powering Up and Initial Checks enforce DSP1500 SAN Unit Operation Manual Blank Page (Rev. 4) PAGE 5-4

77 Chapter 6: System Operation PAGE 6-1

78 Chapter 6: System Operation enforce DSP1500 SAN Unit Operation Manual 6.1 Display and Programming Unit 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 DSP software is not being used. SAN3-DP1S SAN3-DP2S (RS-232) The DP2S has the same functionality as the DP1S 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. System Parameter must be set to enable the desired data output. Default setting is 0. If set to 0 no data will be output. (See page 6-22) (Rev 4) PAGE 6-2

79 enforce DSP1500 SAN Unit Operation Manual Chapter 6: System Operation DP2S 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(default), 19200, *Communication Speed is set in System Parameter PAGE 6-3 (Rev 4)

80 Chapter 6: System Operation enforce DSP1500 SAN Unit 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 SAN3 DP2S installed. Result Output Data Data Length: 78 bytes fixed (78 letters) Letters Displayed After Judgment Load: Letters Displayed After Judgment Distance: " "(20H):ACCEPT "H"(48H):HIGH REJECT "L"(4CH):LOW REJECT Letters Displayed After Check 1,2 or 3 Data: " "(20H):ACCEPT "H"(48H):HIGH REJECT "L"(4CH):LOW REJECT "Z"(5AH):INTERFERENCE CHECK REJECT (After CHECK 1 Data) Overall Judgment Letters: "O"(4FH):ACCEPT "X"(58H):REJECT Reason Letter (Stop Reason): " "(20H):Normal "A"(41H):Abnormal "S"(53H):STOP(Loss of Stop Signal) "B"(42H):BYPASS "R"(52H):STOP CCW "F"(46H):STOP CW "E"(45H):STARTOFF COUNT Number: 0001 is displayed after powering ON. 1 is added after each cycle. Normal data format (Judgment is an ACCEPT) Cycle Count Press Number Parameter Number 30H 30H 30H 30H 30H 30H 30H 31H 20H 30H 31H 20H 20H 31H 20H 20H Judg Judg Judgment Load Judgment Distance ment ment 31H 32H 2EH 33H 34H 20H 20H 31H 32H 33H 2EH 34H 35H 36H 20H 20H Judg Judg Final Load Final Distance ment ment 31H 32H 2EH 33H 34H 20H 20H 31H 32H 33H 2EH 34H 35H 36H 20H 20H Part Check 1 Distance Judg Judg Part Check 2 Maximum Load ment ment 31H 32H 33H 2EH 34H 35H 36H 20H 20H 31H 32H 2EH 33H 34H 20H 20H Judg Judg Rea Part Check 3 Maximum Load CR LF ment ment son 31H 32H 2EH 33H 34H 20H 20H 20H 4FH 20H 20H 20H 0DH 0AH O Overall Judgment "O"(4FH):ACCEPT " O "+CR+LF (Rev 4) PAGE 6-4

81 enforce DSP1500 SAN Unit Operation Manual Chapter 6: System Operation Data format when the judgment is a REJECT Cycle Count Press Number Parameter Number 30H 30H 30H 30H 30H 30H 30H 31H 20H 30H 31H 20H 20H 31H 20H 20H Judg Judg Judgment Load Judgment Distance ment ment 31H 32H 2EH 33H 34H 48H 20H 31H 32H 33H 2EH 34H 35H 36H 4CH 20H H L Judg Judg Final Load Final Distance ment ment 31H 32H 2EH 33H 34H 20H 20H 31H 32H 33H 2EH 34H 35H 36H 20H 20H Part Check 1 Distance Judg Judg Part Check 2 Maximum Load ment ment 31H 32H 33H 2EH 34H 35H 36H 5AH 20H 31H 32H 2EH 33H 34H 48H 20H Z H Judg Judg Rea Part Check 3 Maximum Load CR LF ment ment son 31H 32H 2EH 33H 34H 4CH 20H 20H 58H 20H 20H 20H 0DH 0AH L X Overall Judgment Reason for Stop "X"(58H):REJECT " H L Z 12.34H 12.34L X "+CR+LF When the reject is for Final Load or Final Distance the Judgment Load and Judgment Distance are also judged. PAGE 6-5 (Rev 4)

82 Chapter 6: System Operation enforce DSP1500 SAN Unit 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 (Jog) Button While pressing this button and the [ ] button at the same time, the press will jog in the return direction. While pressing this button and the [ ] button at the same time, the press will jog in the advance direction. 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. (Rev 4) PAGE 6-6

83 enforce DSP1500 SAN Unit 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 or when in bypass, a press unit number is displayed. PAGE 6-7 (Rev 4)

84 Chapter 6: System Operation enforce DSP1500 SAN Unit 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 Operating 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 6-13 (Rev 4) PAGE 6-8

85 enforce DSP1500 SAN Unit 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 [Operating Condition Display] is displayed. Operating Condition Display Power ON Press Start D-NO In: in: Slow initial Start Fr: Fr: Approach SL: SL: Part Slow Search Down L1: Ld: Press Load Speed 1 L2: Press Speed 2 r1: Decompression ru: Return Press Finish Real Time Display Mode D-NO 1 Digit Display [MODE] Press Result Display Mode D-NO Digit on the Left [MODE] D-NO 2 Digit Display 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 D-NO 1 Digit Display Press Result Display Mode D-NO Digit on the Left [MODE] D-NO 2 Digit Display Parameter Display Mode [MODE] PAGE 6-9 (Rev 4)

86 Chapter 6: System Operation enforce DSP1500 SAN Unit Operation Manual Real Time Display Mode D-NO: 1 Digit Display 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 Load value display Displays present load applied on the load cell in real time. Load voltage value display Displays present load signal voltage applied on the load cell in real time. Maximum load value display (Maximum value hold) Displays peak load from the time when the [RESET] switch was last pressed in this mode. Moving distance display Displays distance of absolute position from the home position. Press and hold [SET] to see the 3 decimal place resolution value. Electronic thermal value (Overload at 100) Present electronic thermal value is displayed. Current value (Max 1023) Displays present current value. Resolver position data display (0 to 4093) Displays present resolver position. Input and Output signal monitor (Software version 1.96 or later) Displays ON/OFF state of PLC I/F input and output signal. (See below for details.) For in-house use only [ ], [ ] switch D-NO n DATA Load value display Load voltage value display Maximum load value display ~ Input and output signal monitor * This can be used for firmware version 1.96 or later of the SAN unit. ON: Lights up OFF: Lights off (Rev 4) PAGE 6-10