enForce SAN for Version 3.x Intro - FEC-USA€¦ · DSP1500 SAN Unit Operation Manual (for Firmware...

enFORCE

DSP1500 SAN Unit Operation Manual

(for Firmware Version 3.x)

SECOND Edition January 2010

Automation Systems

51327 Quadrate Drive Phone: (586) 781-2100 Macomb, MI. 48042 Fax: (586) 781-0044 Web: www.fec-usa.com E-mail: [email protected]

DSP1500E-HS-4

(Rev. 4) ii

Revisions

Revision Revision

Date Revision History FirmwareVersion*

3 11/2007 Initial Release 3.14

3.1 10/2008

Minor Revision Chapter 2 - Updated chart for new power requirements. Chapter 4 - Updated transformer sizing chart based on new power requirements.

3.156

4 01/2010

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.

3.201

* Firmware Version at Revision Date.

Manual Numbering Convention

DSP1500E-HS-4

DSP1500 = Servo Press AFC1500 = Nutrunner Version Number FUSION = DC Hand Tool

HS = SAN Unit Hardware Operation Manual HM = Multi / Main Unit Hardware Operation Manual HM-ENET = Ethernet Manual for Multi / Main Unit SW = Software Manual

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 (Major Revision Level)

iii (Rev. 4)

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

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.

Points to check when unpacking

◆ 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.”

Introduction

(Rev. 4) iv

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.

Warranty

Introduction

v (Rev. 4)

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.

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

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

Warning: Fire

Caution: Electric shock

Ground

Prohibited Do not disassemble

Required

Warning: Electric shock

Caution: Fire

Safety Precautions

Caution: High Temperature

Warning: Pinch Point

(Rev. 4) vi

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.

Warning

Safety Precautions

vii (Rev. 4)

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


Caution Transportation / Storage

Safety Precautions

(Rev. 4) viii

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.

Caution

Safety Precautions

Installation / Wiring

ix (Rev. 4)

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


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.

Caution

Safety Precautions

Operation / Adjustment

(Rev. 4) x

Table of Contents

Chapter 1: Outline 1.1 About this Operation Manual ..…..……………………………………………… 1-2 1.2 Features ………………………………………………………………………….. 1-3 1.3 Safety Precautions …. ………………………………………………………….. 1-4 1.4 Safety Labels................................................................................................ 1-5

Chapter 2: Specifications 2.1 System Specifications …..………………………………………………………. 2-2 2.2 SAN Unit Specifications …… ………………………………………………….. 2-3

2.2.1 Duty Cycle Calculation ..……………………..……………………………. 2-3 2.2.2 SAN Unit Dimensions ….. ………………..……………………………….. 2-4

2.3 Press Tool ………………………………………………………………………… 2-6 2.3.1 Part Number Breakdown …………………..……………………………… 2-6 2.3.2 Tool Specifications …………… …………………………………………… 2-7 2.3.3 Tool Dimensions ……………… …………………………………………… 2-8

2.4 Functions ….……………………………………………………………………… 2-9

Chapter 3: System Description 3.1 System Block Diagram ….. …………………………………………………….. 3-2 3.2 DSP1500 Front Panel (SAN Unit) ………….………………………………….. 3-3

3.2.1 DSP1500 Front Panel, Switches and Connectors ………………..…….. 3-3 3.2.2 DSP1500 Front Panel Condition Display LED …………….……………. 3-4 3.2.3 DSP1500 Detachable Keypad Buttons …………………………………… 3-5 3.2.4 DSP1500 Detachable Keypad Condition Display ………………………. 3-6

3.3 Press Tool ……..…………………………………………………………………. 3-7 3.4 Connection Diagrams.……………..…………………………………………… 3-8

Chapter 4: System Setup and Wiring 4.1 Design and Build Guidelines. ………………………………………………….. 4-2 4.2 SAN Unit Design and Mounting Dimensions …….…………………………… 4-3 4.3 Calculating Circuit Protection ………………………………………………….. 4-5 4.4 Input Power Supply Connection ………..……………………………………… 4-6

4.4.1 Input Motor & Control (SAN3)/Input Motor Power (SAN4) Connection.. 4-6 4.4.2 Input Control Power Connection (SAN4)……………………..………….. 4-7

4.5 Motor Power-Resolver Connections …….…..………………………………… 4-8 4.6 Pre-Amplifier Connection ……………………..………………………………… 4-9 4.7 External Control Connection ………….……………………………………….. 4-10

4.7.1 PLC Interface (I/O) Signal Chart [Main Unit Configuration]...………….. 4-10 4.7.2 PLC Interface (I/O) Signal Chart [Stand Alone Configuration]...……….. 4-11

4.7.2.1 Output Data Bank Signals………………………..……………………. 4-11 4.7.3 Input & Output Recommended Connection Circuit ..……………………. 4-13 4.7.4 Input & Output Signal Explanation ………………………………………… 4-14 4.7.5 Operation Timing Chart …………………………………………………….. 4-21

4.8 SW1 - SAN Unit DIP Switch Settings.…………………………………………. 4-22 4.8.1 SAN Unit Address Settings (DIP Switch 4~8)……………………………. 4-22 4.8.2 Special Configuration Settings (DIP Switch 1~3).……………………….. 4-23

xi (Rev. 4)

Table of Contents

4.9 MON. Signal (External Monitor Signal) ……………………………………….. 4-24 4.9.1 Calibration Method for External Monitoring Equipment..……………….. 4-25

4.10 RS-485 Interface Signal ………………………………………………………… 4-26 4.11 Firmware Flash Connector....…………………………………………..……….. 4-27 4.12 Cable Installation Guidelines...………………………………………………….. 4-28

4.12.1 Considerations for Cable Trolleys …………………………………………. 4-29 4.12.2 Considerations for Flexible Cable Track ………………………………….. 4-29 4.12.3 Considerations for Cable Trays & Ladders ……………………………….. 4-29

4.13 Tool Connections ………………………………………………………………… 4-30 4.14 Maintenance Lock Option..……………………………………………………… 4-31

Chapter 5: Powering Up and Initial Checks 5.1 Before Powering On …………………………………………………………….. 5-2 5.2 Initial Data Setting ………………………………………………………………. 5-3

Chapter 6: System Operation 6.1 Display and Programming Unit..……………………………………………….. 6-2

6.1.1 DP2S Serial Connection……………....................................................... 6-3 6.1.2 RS232 Output Data................................................................................ 6-4

6.2 Function of Display and Operating Panel.……………………………………. 6-6 6.3 RUN Status Mode Operating Instruction ……………………………………… 6-7

6.3.1 Display ……………………………………………………………………….. 6-7 6.3.2 Mode Change ……………………………………………………………….. 6-8 6.3.3 RUN Status Key Operation ………………………………………………… 6-9 6.3.4 Real Time Display Mode…..................................................................... 6-10 6.3.5 Press Result Display Mode……….......................................................... 6-11 6.3.6 Set Value Display Mode…...................................................................... 6-12 6.3.7 Operating Condition Display……............................................................ 6-13 6.3.8 Status Display Mode…........................................................................... 6-13

6.4 BYPASS（Spindle Off）Mode Operating Instruction …..…………………… 6-14 6.4.1 Download Mode and Setup Mode Selection …………………………….. 6-14 6.4.2 Data Edit Mode ……………………………………………………………… 6-15 6.4.3 Parameter Copying................................................................................. 6-16 6.4.4 Organization of Parameters………………………………………………… 6-17 6.4.5 Data Number Definitions........................................................................ 6-18

6.4.5.1 System Parameter (No. 00)............................................................. 6-18 6.4.5.2 Work Parameters (No. 01~32)......................................................... 6-23

Press Methods…….......................................................................... 6-25 Load Settings….......................................................................... 6-34 Distance Settings....................................................................... 6-36 Time Settings............................................................................. 6-37 Speed Settings.......................................................................... 6-38 Interference Check..................................................................... 6-39 Part Check…….......................................................................... 6-39 Part 3 Check….......................................................................... 6-40 Advance/Return Position Signal………………......................... 6-41 Band Check…........................................................................... 6-42

(Rev. 4) xii

Table of Contents

Judgment Operation......................................................................... 6-44 Loading Direction…......................................................................... 6-44 Return Operation………................................................................... 6-45 Step Press Using Time Controlled Press......................................... 6-46 Return Parameter Setup………………............................................. 6-47

Chapter 7: Maintenance & Inspection 7.1 Inspection Items…….. ………………………………………………………….. 7-2

7.1.1 Press Tool ……………………………………………………………………. 7-2 7.1.1.1 Lubrication.………………………………………………………………. 7-3 7.1.1.2 Ball Screw Inspection (DPT Series)..…………………………………. 7-4 7.1.1.3 Belt Tension Verification and Adjustment (DPS & DPM Series)……. 7-4

7.1.2 Press Fixture…………………………………………………………………. 7-5 7.1.3 Homerun Cables…………………………………………………………….. 7-5 7.1.4 SAN Unit……………………………………………………………………….7-5 7.1.5 Air Handling Unit…………………………………………………………….. 7-5

7.2 Basic Operational Tests..……………………………………………………….. 7-6 7.2.1 Load Cell……………………………………………………………………… 7-6 7.2.2 Resolver……………………………………………………………………… 7-6 7.2.3 Motor…………………………………………………………………………. 7-7

7.2.3.1 Motor Replacement Procedure……………………………………….. 7-8 7.2.3.2 Explanation of Home Position Search............................................. 7-9 7.2.3.3 Motor Tuning.................................................................................... 7-9

Chapter 8: Troubleshooting 8.1 Abnormal Display ……………………………………………………………….. 8-2 8.2 Load Cell Errors [A1_*].…………………..…………………………………….. 8-3 8.3 Offset Load Errors [A2_*].…………….………………………………………… 8-5 8.4 Tool EEPROM Errors [A3_*].…………………………………………………… 8-6 8.5 System Memory Errors [A4_*].…………………………………………………. 8-8 8.6 Servo Amplifier Response Errors [A5_*]……………………………………… 8-9 8.7 Servo Type Errors [A6_*].………………………………………………………. 8-10 8.8 Servo Amplifier Errors [A8_*].………………………………………………….. 8-11 8.9 Parameter Errors [A9_*]………………………………………………………… 8-14 8.10 Q & A....……………………………………………………………………………. 8-16

xiii (Rev. 4)

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

(Rev. 4) xiv

Blank Page

－1

Chapter 1: Outline

enFORCE DSP1500 SAN Unit Operation Manual

(Rev. 4) PAGE 1－2

Chapter 1: Outline

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 Preliminary power on and operational tests.

6 System Operations 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) 781-2100 or faxed to (586) 781-0044.

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.

Programming with the enFORCE DSP1500 User Console for Main Unit

enFORCE DSP1500 Main Unit Hardware Manual

Related Documentation


PAGE 1－3 (Rev. 4)

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 123.5 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.


(Rev. 4) PAGE 1－4

Chapter 1: Outline

1.3 Safety Precautions

To ensure the most effective and extended use of all equipment, adhere to the following precautions:

Tool Installation

• The tool generates a great amount of force during operation and the reaction force is applied to the mounting area of the tool. Therefore, tools must be installed in the proper position and with adequate bolts.

• The tool assembly contains precision parts and electric components, and must not be subject to excessive shocks or stresses. Use the supplied bolts to prevent the tool from loosening due to vibration.

• Keep in mind that the load cell is a strain gage based instrument and, although it has been designed to withstand sudden shock, repeated shock (over time) could damage the load cell.

Pressing Operation

• Avoid pressing beyond the rated full scale load. Even if the load is less than the maximum, be sure that the duty cycle is within the specified limits.

Cable Wiring

• Use only the specified cables for all system connections. • When multiple enFORCE units are used, ensure that each SAN unit is connected to its

matching numbered tool and that all connectors are locked. • Do not use a high voltage circuit as a frame ground (FG). Also, the frame ground should be

separate from the power ground. The use of a grounding rod located as close as possible to the enclosure housing the enFORCE controller unit (SAN) is preferable.

• Circuit breakers or fuses are required on branch circuit power feeds to the SAN units. • PLC I/O cables must be run separate from any high voltage sources or cabling, and must not

exceed 50 feet.

Installation Environment • The enFORCE controller should be placed in a NEMA 12 enclosure. • Using the equipment in the following locations may lead to malfunction or breakdown. Avoid

using in these areas or use an air conditioner. Areas under direct sunlight or if the environmental temperature is out of the 32~122℉

(0~50℃) range. Areas where relative humidity is out of the 20-90% range, the temperature change is

drastic or where the area is exposed to mist and water drops. • Do not use at the following locations. (Contact FEC Inc. if necessary for clarification)

Areas where conductive powder, oil, mist, salt or organic solvents exist. Areas that have corrosive or combustible gases. Areas that have strong electric or magnetic fields. Areas where strong vibration or shock could be transmitted directly to a SAN unit or

tool.

Static Electricity • The enFORCE System incorporates many electronic Surface Mounted Devices (SMD). It

is advisable to strictly adhere to practices for safe electrostatic discharge in order to prevent damage to the system components when handling them.

Cleaning

• Do not use any organic solvents, such as thinner, to clean a SAN unit or tool. The solvent could melt the surface paint, or penetrate inside and cause damage. A cloth dampened with alcohol or warm water should be used to lightly wipe the components.


PAGE 1－5 (Rev. 4)

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.

HIGH VOLTAGE: Do not touch exposed connector terminal. May cause electric shock. Disconnect power before servicing.

DANGER

CAUTION HOT SURFACE: Do not touch heatsink. May cause burn.

Use proper grounding techniques.May cause electric shock.

DANGER

Do not disassembleMay result in serious injury

Pinch Point Watch your handsKeep away

DANGER CAUTION

HOT SURFACE

Do not touch

HIGH VOLTAGE

HOT SURFACE

PROPERLY GROUND


(Rev. 4) PAGE 1－6

Chapter 1: Outline

SAN3-120S

SAN3-24S

－1

Chapter 2: Specifications


(Rev. 4) PAGE 2－2


2.1 System Specifications

Power Supply Voltage 180VAC ~ 242VAC, 3 phase, 50/60Hz

Operating Conditions Temperature 32 ~ 122°F (-0 ~ 50°C)

Humidity 20 ~ 90% (no condensation)

Storage Conditions Temperature 32 ~ 122°F (-0 ~ 50°C)

Humidity Below 90% (no condensation)

Shipping Conditions Temperature 32 ~ 122°F (-0 ~ 50°C)

Humidity Below 90% (no condensation)

Operating Range Duty Cycle less than 60%

Load stop accuracy1

DPT & DPM Series

From 1/2 to Full Scale Load

3σ less than 3% scatter of target load.

From 1/4 to 1/2 of Full Scale Load

3σ less than 4% scatter of target load.

DPS Series From 1/4 to Full Scale Load

3σ less than 1.5% scatter of target load.

Load resolution Approx. 1/1000 of full scale load value

Load control range 25% -100% of full scale load value

Load judgment range 10% -100% of full scale load value

Distance stop accuracy1,2 ± 0.01mm (-0.0 ~ +0.02mm)

Distance display minimum unit ０．１ｍｍ (0.001mm condition limit)

Distance internal control unit ０．００１ｍｍ Load cell accuracy ± 1% (0 - full scale)

Load cell linearity ± 0.5% of Full Scale value (maximum)

Press method Load method / distance method

Ram tip pendant allowable load 1/6 or less of tool maximum load (up to 2kN) (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.


PAGE 2－3 (Rev. 4)


2.2 SAN Unit Specifications

CPU: 32 bit RISC (Reduced Instruction Set CPU) Data Communication: RS485 (2 Ports) – 1 for DSP User Console Software Parameter / Firmware Storage: Flash ROM

SAN Unit Type SAN3 - 24HS SAN4 - 24HS

SAN3 - 24S SAN4 - 24S

SAN3 - 40SSAN4 - 40S

SAN3 - 120S SAN4 - 120S

Motor Type RH1 RM1 RM2 RM3 RM4 RM5

SAN3 Unit Input Power 180 ~ 242VAC, 3φ SAN4 Unit Motor Power

SAN Unit Frequency 50 / 60Hz

Max. Power Output 70W 60W 80W 200W 1500W 3000W

In-rush Current 19A 9.5A 18A 38.6A 7 9 . 2 A 116.4A

SAN Power Consumption

18W IDLE 25W*

IN CYCLE 23W*

IN CYCLE 55W*

IN CYCLE88W* IN CYCLE

1 0 7 W * IN CYCLE

1 3 4 W * IN CYCLE

* Total watts calculated running at 97% capacity, 99% stroke and 60% duty cycle.

SAN4 Control Power Supply Circuit Input Power Source Voltage (Power Source Frequency) Single phase 180V – 242V AC (50/60HZ)

Momentary Maximum Current (Including Inrush Current) 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.

2.2.1 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.


(Rev. 4) PAGE 2－4


2.2.2 SAN Unit Dimensions

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

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.

SAN3/4-24S, SAN3/4-24HS, SAN3/4-40S


PAGE 2－5 (Rev. 4)


Mounting: Top 2 places #8-32 screw Bottom 2 places #8-32 screw Weight: SAN3/4-120S - 3.6kg.

SAN3/4-120S


(Rev. 4) PAGE 2－6


2.3 Press Tool

2.3.1 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) S = SPLINE SHAFT G = GUIDE SHAFT

(H) MAINTENANCE LOCK B = WITH LOCK BLANK = NO LOCK (I) MOUNTING 00 = STANDARD (BACK MOUNTING) 01 = 90 DEGREES 02 = TAPPED 03 = FRONT MOUNTING 10 = SPECIAL (CUSTOM DESIGN)

(J) VERSION/REVISION A = CURRENT B = FUTURE UPGRADES C = FUTURE UPGRADES


PAGE 2－7 (Rev. 4)


2.3.2 Tool Specifications Motor: Permanent magnet DC Force Monitor: Inline Load Cell Distance Monitor: 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 1.000 130.0 0.4 30 DPT-021R1-**F 1.96 416.6 0.4 31 DPT-051R2-**F 4.90 333.3 0.3 32 DPT-101R3-**F 9.81 277.7 0.3 85 DPS-101R3-**F 10.0 222.2 0.3 33 DPT-151R3-**F 14.7 277.7 0.3 13 DPT-151R4H-**F 14.7 296.3 0.6 43 DPT-201R3-**F 19.6 166.6 0.2 09 DPT-201R4H-**F 19.6 200.0 0.5 42 DPT-301R4H-**F 29.4 320.0 0.7 84 DPS-301R4H-**F 30.0 200.0 0.7 40 DPT-501R4H-**F 49.0 200.0 0.5 89 DPS-501R4H-**F 50.0 160.0 0.4 14 DPT-501R5-**F 49.0 194.4 0.6 41 DPT-701R4H-**F 68.6 133.3 0.3 37 DPT-102R5-**F 98.1 116.6 0.4 38 DPT-152R5-**F 147.1 77.77 0.22 81 DPT-202R5A-**F 196.1 66.67 0.17

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 0.500 130.0 0.4 50 DPT-021R3-**P 1.96 208.3 0.2 65 DPT-051R3-**P 4.90 95.24 0.01 52 DPT-101R4H-**P 9.81 133.3 0.3 62 DPT-151R4H-**P 14.71 114.2 0.3 54 DPT-201R4H-**P 19.61 80.00 0.16 55 DPT-301R4H-**P 29.42 64.00 0.14 64 DPT-501R5-**P 49.03 58.33 0.17 68 DPT-701R5-**P 68.65 47.61 0.12 63 DPT-102R5-**P 98.1 29.16 0.09 58 DPT-152R5-**P 147.1 22.22 0.06 59 DPT-202R5-**P 196.1 16.37 0.05

*Standard part numbers shown. Contact FEC for non-standard part specifications. 1KN = 224.81 Lbs.


(Rev. 4) PAGE 2－8


2.3.3 Tool Dimensions

Drawing Shown For Reference Only TOOL NUMBER STROKE A B C D E F G H J K LDPM-050H1-**P 100 260 50 110 275 110 42 42 N/A M5-10(4) N/A 153DPM-011H1-**F 100 260 50 110 275 110 42 42 N/A M5-10(4) N/A 153DPT-021R1-**F 150 432 60 126 449 85 45 70 N/A 9(4) N/A 126DPT-051R2-**F 250 665 85 160 695 140 50 115 N/A 14(4) N/A 188DPT-051R3-**P 250 663 85 160 695 140 50 115 N/A 14(4) N/A 227DPT-101R3-**F 250 690 110 205 735 180 75 145 N/A 18(4) N/A 240DPS-101R3-**F 200 556 68 197 573 118 46 95 N/A 11(4) N/A 209

DPT-101R4H-**P 250 690 110 221.6 785 180 75 145 N/A 18(4) N/A 240DPT-151R3-**F 250 690 110 205 735 180 75 145 N/A 18(4) N/A 240

DPT-151R4H-**P 250 690 110 205 735 180 75 145 N/A 18(4) N/A 240DPT-201R3-**F 250 690 110 210 735 180 75 145 N/A 18(4) N/A 247

DPT-201R4H-**P 250 690 110 210 735 180 75 145 N/A 18(4) N/A 247DPT-301R4H-**F 250 744 128 229 789 180 90 140 N/A 22(4) N/A 255DPS-301R4H-**F 200 640 93 237 658 160 60 130 N/A 14(4) N/A 262DPT-301R4H-**P 250 773 128 229 789 180 90 140 N/A 22(4) N/A 304DPT-501R4H-**F 250 885 155 264 940 250 100 200 50 22(6) N/A 313DPS-501R4H-**F 200 732 115 293 757 185 80 150 N/A 18(4) N/A 322DPT-501R5-**P 250 885 155 322 940 250 100 200 50 22(6) N/A 371DPS-501R5-**F 200 732 115 293 757 185 80 150 N/A 18(4) N/A 322

DPT-701R4H-**F 250 885 155 285 940 250 100 200 50 22(6) N/A 334DPT-701R5-**P 250 895 190 285 940 250 100 200 50 22(6) N/A 415DPT-102R5-**F 250 927 210 370 972 *330 *300 N/A N/A 18(10) 36 432DPT-102R5-**P 250 926 210 370 972 *330 *300 N/A N/A 18(10) 36 505DPT-152R5-**F 250 1007 230 425 1050 *380 *340 N/A N/A 22(8) 45 500DPT-152R5-**P 250 962 230 425 1050 *380 *340 N/A N/A 22(8) 45 500DPT-202R5-**F 250 1116 300 535 1050 *450 *410 N/A N/A 26(8) 45 626DPT-202R5-**P 250 1055 300 535 1050 *450 *410 N/A N/A 26(8) 45 520

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.


PAGE 2－9 (Rev. 4)


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.


(Rev. 4) PAGE 2－10


Blank Page

－1

Chapter 3: System Description


(Rev. 4) PAGE 3－2


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.


PAGE 3－3 (Rev. 4)


3.2 DSP1500 SAN Unit Front Panel

3.2.1 SAN Unit Front Panel Switches and Connectors

CON1: For Display Unit (SAN3-DP*S) connection. SW1: Sets press number and special configuration features.（See Section 4.8） RUN/BYPASS: Controller Enable/Disable switch. RUN: Enable BYPASS: Bypass Mode（Disable） RS485: Bi-directional Communication ports. RESOLVER: Resolver connection for tool Motor/Resolver cable. MON.: (Monitor Output) Pressure analog voltage and distance pulse output connection. T/D: Connection for tool Load Cell cable. PLC: Connection for I/O & Limit Sensor Cable. Connects to press limit sensors and PLC or Input-Output devices. MOTOR: Motor Connection for tool Motor/Resolver cable. AC 200-220V: Connection for Input Power. (SAN3) 3 phase, 180-242VAC, 50/60Hz Connection for Input Motor Power. (SAN4) 3 phase, 180-242VAC, 50/60Hz CONTROL IN: Connection for Input Control Power. (SAN4) 1 phase, 180-242VAC, 50/60Hz

M O T O R A C 2 0 0 - 2 2 0 V

P L C

T / D

R S 4 8 5

R U N

B Y P A S S

S W 1

C O N 1

P O W E R B U S Y S V . A B N . A C C . R E J .

FEC SAN3-24SM

ＤＳＰ１５００

M O N .

R E S O L V E R

CONTROL IN


(Rev. 4) PAGE 3－4


3.2.2 SAN Unit Front Panel Condition Display LED’s

POWER LED (Yellow) Lights when 180~242VAC input power is applied to the controller. 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 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 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.

M O T O R A C 2 0 0 - 2 2 0 V

P L C

T / D

R S 4 8 5

R U N

B Y P A S S

S W 1

C O N 1

P O W E R B U SY S V . A B N . A C C . R E J .

FEC SAN3-24SM


M O N .

R E S O L V E R


PAGE 3－5 (Rev. 4)


3.2.3 SAN Unit Detachable Keypad Buttons

Operating Button START Button MANUAL Mode (Jog) Button CAL Button RESET Button Data Display / (Operating) Button MODE Button SET Button（Home Return） DATA UP Cursor Button（Manual Jog Return） DATA DOWN Cursor Button (Manual Jog Advance)

S E T

M O D E D A T A

S T A R T M A N C A L R E S E T

D A T A

P A R M D - N O

D S P 1 5 0 0

M O TO R A C 2 0 0 - 2 2 0 V

P L C

T / D

R S 4 8 5

R U N

B Y P A S S A B N . A C C . R E J .

F E C S A N 3 -24SM

M O N .

R E S O L V E R

( S E A R

U A L

C H )

( H O M E )


(Rev. 4) PAGE 3－6


3.2.4 SAN Unit Detachable Keypad Condition Display DATA Display (4 figure) Data Display (Load, Distance, etc.） 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

S E T

M O D E D A T A

S T A R T M A N C A L R E S E T

D A T A

P A R M D - N O

D S P 1 5 0 0

M O T O R A C 2 0 0- 2 2 0 V

P L C

T / D

R S 4 8 5

R U N

B Y P A S S A B N . A C C . R E J .

F E C S A N 3 -24SM

M O N .

R E S O L V E R

( S E A R

U A L

C H )

( H O M E )


PAGE 3－7 (Rev. 4)


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)


(Rev. 4) PAGE 3－8


3.4 Connection Diagrams

DPT Series 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.

Motor

CW

CCW

Brake

※ORG

SSAANN UUnniitt TTooooll

180～242VAC

I/O Cable

PL

C

Monitor Signal

PC, PLC or Main Unit

Motor Cable

Resolver Cable Br

ake

Cab

le

Resolver

Pre

ampl

ifier

Customer Supplied Noise Filter

Circuit Protector

Limit Sensor Cable

Preamplifier Cable

Power Cable

LMT

Control Power Cable

※On SAN4 Only

SAN4 Contactor


PAGE 3－9 (Rev. 4)


DPS Series

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.

CCW Motor

Brake

SSAANN UUnniitt

TTooooll

I/O Cable

PL

C

Monitor Signal


Brake Cable

Resolver

Limit Sensor / Brake Cable

Preamplifier Cable

LMT

BRK

Resolver cable

Motor cable

180～242VAC

Customer Supplied

Noise Filter

Circuit Protector

Control Power Cable ※On SAN4 Only

SAN4 ContactorPower

Cable

Pre

ampl

ifier


(Rev. 4) PAGE 3－10


DPM Series

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.

SAN3-24HS

ＰＬＣ

Motor

SSAANN UUnniitt

TTooooll

Monitor Signal


Resolver

Tool Cable

Pre-amplifier

180～242VAC

Customer Supplied

Noise Filter

Circuit Protector

Control Power Cable ※On SAN4 Only

SAN4 ContactorPower

Cable

－1

Chapter 4: System Setup & Wiring


(Rev. 4) PAGE 4－2

Chapter 4: System Setup and Wiring

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

Section Reference

1 Select the correct tool size Keep force range between 50% and 75% of tool capability for press performance. 2.1, 2.3

2 Design tool mounting plate and press fixtures.

Design of mounting plate MUST BE stronger than the maximum capability of the press selected. 2.3

3 Select correct SAN Unit for the tool selected.

Different size tools require different size SAN Units. Ensure the correct one is selected. 2.1, 2.2

4 Select adequate circuit protection

Circuit protection for the SAN Unit should be separate from other devices. 4.3

5 Select an air handling unit as required. (Air Conditioner, Heat Exchanger, etc.)

Select a unit applicable to the environmental conditions. 2.1

6 Select adequate PLC hardware if required.

PLC must facilitate direct connection to the enFORCE system I/O (24VDC true low). 4.7, 4.14

7 Design PLC logic PLC program can be written using signal descriptions and timing charts provided. 4.7, 4.14

8 Select NEMA 12 enclosure and backpanel.

Backpanel must be large enough to allow adequate space between SAN units. 4.2

9 Set SAN Unit DIP switches Verify the SAN Unit address and special functions setting. 4.8

10 Mount SAN Units onto backpanel.

Mount with adequate spacing between each unit and between unit and other devices. 4.2

11 Wire input power connections. VERIFY VOLTAGE PRIOR TO APPLYING POWER. 4.4

12 Wire I/O Connections. VERIFY VOLTAGE SOURCES PRIOR TO CONNECTION & AGAIN BEFORE POWER UP. 4.7

13 Route homerun & extension cables. ADHERE TO CABLE INSTALLATION GUIDELINES 4.12

14 Connect homerun & extension cables to SAN Unit and tool.

VERIFY POWER IS OFF. Connect cables for tool motor power, resolver, transducer, limit sensors and brake if required.

3.4, 4.5, 4.6, 4.13

15 Power up the equipment. VERIFY WIRING & VOLTAGES OF ALL POWER SUPPLIES PRIOR TO POWER UP. Chapter 4

16 Input preset data. Set the preset data for force, distance, speed, time, etc. according to customer specifications. Chapter 6

17 Perform initial checks. Set Stop signal high & Work Select signals low. Verify there are no obstructions in the press ram travel path. 5-2

18 Verify normal operation. Confirm automatic operation. 5-2


PAGE 4－3 (Rev. 4)


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.

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.

SAN3/4-24S, SAN3/4-24HS, SAN3/4-40S


(Rev. 4) PAGE 4－4


Mounting: Top (2) places #8-32 screw Bottom (2) places #8-32 screw

Weight: SAN3/4-120S - 3.6 kg

SAN3/4-120S


PAGE 4－5 (Rev. 4)


4.3 Calculating Circuit Protection

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.

RATED VALUES FOR CALCULATING CIRCUIT PROTECTIONMOTOR # OF SAN3/4 UNITS KVA PER

MOTOR TYPE WATTAGE SAN3/4 UNIT PER 1 KVA SAN3/4 UNITR1 60 SAN3/4-24S 10 .100

R1H 70 SAN3/4-24HS 8 .125R2 80 SAN3/4-24S 8 .125R3 200 SAN3/4-40S 6 .166R4 1500 SAN3/4-120S 3 .333R5 3000 SAN3/4-120S 1.5 .666


(Rev. 4) PAGE 4－6


M O T O R A C 2 00 - 2 2 0 V

P L C

T / D

SAN3-24SM

1 : F G

2 : W 3 : V

4 : U

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.

4.4.1 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.

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：ＵＢ５：Ｕ 3-Phase Ａ４：ＶＢ４：Ｖ 180 ~ 242VAC Ａ３：ＷＢ３：Ｗ 50/60Hz. Ａ２：ＮＣＢ２：ＮＣＡ１：ＦＧＢ１：ＦＧ *Connect wires to both the A side and B side. Mating Connectors SAN3/4-24S, 24HS, 40S Manufacture: AMP Housing Part No.: 1-178128-4 Contact Part No.: 1-175218-3 (Qty.-4) SAN3/4-120S Manufacture: AMP Housing Part No.: 1-917659-5 Contact Part No.: 1-917511-3 (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.

SAN3/4-120S

5

4

3

2

1

B A


PAGE 4－7 (Rev. 4)


4.4.2 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.

Wiring Chart ３：Ｕ 1-Phase ２：Ｖ 180 ~ 242VAC １：ＦＧ 50/60Hz. Mating Connectors Manufacture: AMP Housing Part No.: 1-178128-3 Contact Part No.: 1-175218-3 (Qty.-3)

SAN4-120S SAN4-24S, 24HS, 40S


(Rev. 4) PAGE 4－8


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.: 39-01-2105 Contact Part No.: 39-00-0047 (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

Mating Connectors SAN3/4-24S, 24HS, 40S Manufacture: AMP Housing Part No.: 1-178288-5 Contact Part No.: 1-175218-3 (Qty.-4)

SAN3/4-120S Manufacture: AMP Housing Part No.: 1-178289-5 Contact Part No.: 1-175218-3 (Qty.-8)

1 2 3 4 5

B A

SAN3/4-120S


PAGE 4－9 (Rev. 4)


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.: 39-01-2085 Contact Part No.: 39-00-0047 (Qty.-8)


(Rev. 4) PAGE 4－10


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)

4.7.1 PLC Interface (I/O ) Signals [Main Unit Configuration]

IN: Input Signal OUT: Output Signal NC: Normally Closed NO: Normally Open

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 Allowed11 NOT USED No Connection Allowed12 NOT USED No Connection Allowed13 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

No Connection Allowed

18 NOT USED 19 NOT USED 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)

No Connection Allowed

25 NOT USED 26 NOT USED 27 NOT USED 28 NOT USED 29 NOT USED 30 NOT USED 31 NOT USED 32 NOT USED 33 NOT USED 34 NOT USED


PAGE 4－11 (Rev. 4)


4.7.2 PLC Interface (I/O) Signals [Stand Alone Configuration]

IN: Input Signal OUT: Output Signal NC: Normally Closed NO: Normally Open

4.7.2.1 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)

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

32 different parameters. (In Manual Mode these inputs become selecting signals for advance, return, home-position search and home-position return operations.)

18 WORK SELECT 1 IN (N.O.) 19 WORK SELECT 2 IN (N.O.) 20 WORK SELECT 3 IN (N.O.) 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.)

Outputs system condition signals based on which Bank is selected. Echo of Bank 1 Select Signal

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.) 33 OUT DATA9 OUT (N.O.) 34 OUT DATA10 OUT (N.O.)


(Rev. 4) PAGE 4－12


*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

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.

OFF ON

OUT DATA0 HOME RET’D Output when the press is between Home Position and the position shown in System Parameter 00-35.

OUT DATA1 BYPASS Output when the press is in Bypass (switch or input) OUT DATA2 OUT DATA3 WORK SELECT 4

Output echo of selected Input. OUT DATA4 WORK SELECT 3 OUT DATA5 WORK SELECT 2 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.

ON OFF

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

Hi h Ab lBoth ON: Interference Reject OUT DATA5 CK1_HIGH Output on a Check 1 High 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.

ON ON

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.


PAGE 4－13 (Rev. 4)


4.7.3 Input and Output Ｈ／Ｗ Recommended Connecting Circuit

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.

DSP1500 SAN UNIT

OUTPUT

OUTPUT

PLC

INPUT

INPUT

24 VDC

PLC

CON

NEC

TOR

40mA Max.

40mA Max.


(Rev. 4) PAGE 4－14


4.7.4 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 4-16. 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.


PAGE 4－15 (Rev. 4)


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 00-36.

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:


(Rev. 4) PAGE 4－16


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 SELECT 4

WORK SELECT 3

WORK SELECT 2

WORK SELECT 1

WORK SELECT 0

Param No. MANUAL mode

OFF (OPEN) OFF (OPEN) OFF (OPEN) OFF (OPEN) OFF (OPEN) 1 H o m e - p o s i t i o n s e a r c hOFF (OPEN) OFF (OPEN) OFF (OPEN) OFF (OPEN) ON 2 H o m e - p o s i t i o n r e t u r nOFF (OPEN) OFF (OPEN) OFF (OPEN) ON OFF (OPEN) 3 A d v a n c e h i g h s p e e d j o gOFF (OPEN) OFF (OPEN) OFF (OPEN) ON ON 4 R e t u r n h i g h s p e e d j o gOFF (OPEN) OFF (OPEN) ON OFF (OPEN) OFF (OPEN) 5 Ad va nc e m i dd le sp ee d j ogOFF (OPEN) OFF (OPEN) ON OFF (OPEN) ON 6 R e t u r n m i d d l e s p e e d j o gOFF (OPEN) OFF (OPEN) ON ON OFF (OPEN) 7 A d v a n c e l o w s p e e d j o gOFF (OPEN) OFF (OPEN) ON ON ON 8 R e t u r n l o w s p e e d j o gOFF (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 00-31 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 7.2.3.2)


PAGE 4－17 (Rev. 4)


♦ Output Signals Outputs are rated at +12~24VDC, 200ma. When activated, open collector sink outputs (normally high) pull the input device low (0VDC).

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.

OUTPUT BANK 1: Bank0 – Off / Bank1 - Off


(Rev. 4) PAGE 4－18


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.

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).

50

53

ON

OFF

51OFF

ON 52

0mm

150mm

Example #1

[50: 50.0mm] [51: 120.0mm] [52: 150.0mm] [53: 100.0mm]

50

53

ON

OFF

150mm

Example #2

[50: 50.0mm] [51: Max Distance] [52: Max Distance] [53: 100.0mm]

0mm


PAGE 4－19 (Rev. 4)


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 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).


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.

OUTPUT BANK 2: Bank0 – On / Bank1 - Off

OUTPUT BANK 3: Bank0 – Off / Bank1 - On


(Rev. 4) PAGE 4－20


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.



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.





ABN_CODE0: [OUT DATA4] Abnormal Code Bit 0 Signal Bits 0 thru 3 are binary bits used together to represent the Abnormal Code.










OUTPUT BANK 4: Bank0 – On / Bank1 - On


PAGE 4－21 (Rev. 4)


4.7.5 Operation Timing Chart

OFF

STOP ON ON READY OFF ON RESET OFF ON START OFF Condition Operating Operating ON BUSY OFF ON ACCEPT OFF ON REJECT OFF ON ABNORMAL OFF WORK SELECT Parameter select fixed Parameter select fixed 0～4

ON MANUAL OFF ON START 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 ON BUSY OFF ON READY 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.

MANUAL Mode

Automatic Mode

Timing to set the START signal OFF, it is voluntary if the BUSY is OFF.

Above 10ｍｓ

When the START or RESET signal is turned ON the ACCEPT and REJECT signals turn OFF.

Above 10ｍｓ


(Rev. 4) PAGE 4－22


4.8 SW1 - SAN Unit DIP Switch Settings

4.8.1 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).

DIP Switch Number Unit Number 4 5 6 7 8

1 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

RUN

BYPASS

SW1

CON1

POWER

BUSY

SV.

ABN.

ACC.

REJ.

ＡＦＣ１５００

12345678

OFF側ON側



PAGE 4－23 (Rev. 4)


4.8.2 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).

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.

Advance

Return

470ms 30ms

470ms 470ms

Advance

Return

488ms 14ms

488ms 456ms

DIP Switch 3 OFF

DIP Switch 3 OFF

DPT-021R1

DPT-201R3


(Rev. 4) PAGE 4－24


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.: 39-01-2065 Contact Part No.: 30-00-0047 (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.

63

5

4

2

1


PAGE 4－25 (Rev. 4)


4.9.1 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

Position Pulse, CW/CCW

＋

－

１ｋΩ

OUTPUT ±10mA Max

UPC812 (NEC or equivalent)

５V

74LS06

Open Collector Output OUTPUT －40mA Max

１ｋΩ

４．７ｋΩ


(Rev. 4) PAGE 4－26


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

Mating Connector: RJ45 SAN Unit Jumper Cable: 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-485 １２ extended ３ to other DSP1500 ４５６７８ GND RS-485 １２３ to other DSP1500 ４５６７８

ＳＮ75176

1

8


PAGE 4－27 (Rev. 4)


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


(Rev. 4) PAGE 4－28


4.12 Cable Installation Guidelines

Improper installation of cables can reduce cable life expectancy drastically. The following guidelines should be used when installing cables.

• The cables must be prepared for installation without twists, bends or kinks. Upon unpacking the cables, any tie wraps used in shipping should be removed.

• Before inserting the cables in the cable tray, cable track or other overhead suspension, it is important that the cables be laid out or hung prior to installation long enough to relax any stresses and remove any “memory” resulting from packaging, transit or storage. If the cables cannot be relaxed, they should be shook out by grasping the cable length at its mid point and shaking the cables as you move to each end. Then, wrap the end of each cable with masking tape and make alignment marks on the top of each end. Maintain this alignment throughout the installation to assure cable is not being twisted.

• The minimum recommended bending radius of the cable should not be exceeded. The minimum bend radius is calculated by multiplying the cable’s outer diameter by ten (Rmin = O.D. x 10). When multiple cables are run together, the largest diameter cable in the bundle should be used for calculating bend radius. Minimum bend radius must be increased when repeated flexing occurs at a given point on the cables.

• Use the most direct path when routing cables. • Do not weave cables between or wrap around one another. • Route cables and connectors away from liquid of any type. • Protect cable connectors from any impact or abrasion that may cause damage (IE: pulling

cables through cable tray and dropping cables to the floor). • Check cable route for possible chafing or abrasion points. Re-route or protect cable at these

points with a nylon cable wrap or similar means to avoid future cable damage. • The use of plastic cable ties (ty-wraps) should be avoided if possible. The use of Velcro

straps is preferable. If the use of plastic cable ties cannot be avoided, the following practices should be followed:

o Cables should not be tied so tight as to cause indentations in the cable jacket. Flexible cables are designed to move inside their cable jacket. If this movement is restricted, wires in the cable may become stressed and break.

o Plastic cable ties around grouped cables should be used minimally so that cables have the ability to move individually rather than all as one.

o An acceptable method is to include the use of a flexible tubing or sleeve between the plastic cable tie and the cable(s).

• Do not tie or hang anything, whatsoever, from tool cables.

• Avoid running cables directly next to high voltage or high frequency lines.

• Cables must be supported near connectors in panel and at tool to avoid strain on connection points.

• Certain tool operations may have foreseeable cable damaging aspects which are unavoidable. In these situations a shorter “extension” cable can be provided with the expectation of replacing this intermediate, less expensive cable as required. The use and proper placement of an “extension” cable will also make cable replacement less time consuming.


PAGE 4－29 (Rev. 4)


4.12.1 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.

4.12.2 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.

4.12.3 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.


(Rev. 4) PAGE 4－30


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): FEC P/N: FEB-1251 RM4 (FIELD): FEC P/N: FEB-1605 RM1, RM2, RM3, RM4 (EXTENSION): FEC P/N: FEB-1283

Nominal OD = .505” Min. Bend Radius = 6.0“

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


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


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


PAGE 4－31 (Rev. 4)


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

* 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 00-36 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 00-36 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

Brake

０Ｖ２４Ｖ

24 SERVO ON

I/O Connector

X000 SERVO ON

Y001 RELEASE BRAKE

RY

SSAANN UUnniitt PPLLCC

*PLC I/O shown for reference only.

PPrreessss Reference Circuit

red/grn

blu/grn

A B

BRKVarister


(Rev. 4) PAGE 4－32


Blank Page

－1

Chapter 5: Power Up & Initial Checks


(Rev. 4) PAGE 5－2

Chapter 5: Powering Up and Initial Checks

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.


PAGE 5－3 (Rev. 4)


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 00-03. (See section 6.3.6 and 6.4.2 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 7.2.3.3 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.).


(Rev. 4) PAGE 5－4


Blank Page

－1

Chapter 6: System Operation


(Rev 4) PAGE 6－2


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 00-37 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)


PAGE 6－3 (Rev 4)


6.1.1 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

D-SUB 9 PIN D-SUB 25 PIN ＴＸＤ 3 3 ＲＸＤＲＸＤ 2 ＣＴＳ 8 20 ＤＴＲＧＮＤ 5 7 ＧＮＤ

2) Connection for output in any condition

D-SUB 9 PIN D-SUB 25 PIN ＴＸＤ 3 3 ＲＸＤＲＸＤ 2 ＲＴＳ 7 ＣＴＳ 8 20 ＤＴＲＧＮＤ 5 7 ＧＮＤ

Communication Protocol Data Bits 8Error Control No Parity No Start Bits 1 Stop Bits 2 Speed* 9600bps(default), 19200, 38400 *Communication Speed is set in System Parameter 00-36.

DSP1500

DSP1500 Output Device


(Rev 4) PAGE 6－4


6.1.2 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)

COUNT Number: ‘0001’ is displayed after powering ON. 1 is added after each cycle.

Normal data format (Judgment is an ACCEPT) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Cycle Count Press

Number

Parameter Number

30H 30H 30H 30H 30H 30H 30H 31H 20H 30H 31H 20H 20H 31H 20H 20H

０００００００１０１１

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Judgment Load Judgment

Judgment Distance Judgment

31H 32H 2EH 33H 34H 20H 20H 31H 32H 33H 2EH 34H 35H 36H 20H 20H

１２．３４１２３．４５６

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

Final Load Judgment

Final Distance Judgment


１２．３４１２３．４５６

49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64

Part Check 1 Distance Judgment

Part Check 2 Maximum Load Judgment

31H 32H 33H 2EH 34H 35H 36H 20H 20H 31H 32H 2EH 33H 34H 20H 20H

１２３．４５６１２．３４

65 66 67 68 69 70 71 72 73 74 75 76 77 78


Judgment

Rea son

ＣＲＬＦ

31H 32H 2EH 33H 34H 20H 20H 20H 4FH 20H 20H 20H 0DH 0AH

１２．３４Ｏ

Overall Judgment

"Ｏ"(4FH)：ＡＣＣＥＰＴ

"00000001 01 1 12.34 123.456 12.34 123.456 123.456 12.34 12.34 O "+CR+LF

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


PAGE 6－5 (Rev 4)


Data format when the judgment is a REJECT 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Cycle Count Press

Number

Parameter Number

30H 30H 30H 30H 30H 30H 30H 31H 20H 30H 31H 20H 20H 31H 20H 20H

０００００００１０１１

17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32

Judgment Load Judgment

Judgment Distance Judgment

31H 32H 2EH 33H 34H 48H 20H 31H 32H 33H 2EH 34H 35H 36H 4CH 20H

１２．３４Ｈ１２３．４５６Ｌ

33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

Final Load Judgment

Final Distance Judgment


１２．３４１２３．４５６

49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64

Part Check 1 Distance Judgment


31H 32H 33H 2EH 34H 35H 36H 5AH 20H 31H 32H 2EH 33H 34H 48H 20H

１２３．４５６Ｚ１２．３４Ｈ

65 66 67 68 69 70 71 72 73 74 75 76 77 78


Judgment

Rea son

ＣＲＬＦ

31H 32H 2EH 33H 34H 4CH 20H 20H 58H 20H 20H 20H 0DH 0AH

１２．３４ＬＸ Overall Judgment Reason for Stop

"Ｘ"(58H)：ＲＥＪＥＣＴ

"00000001 01 1 12.34H 123.456L 12.34 123.456 123.456Z 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.


(Rev 4) PAGE 6－6


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」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.

[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.

Manual Operation Buttons

Data Display - 7 Segment LED

Data Display Operation Buttons


PAGE 6－7 (Rev 4)


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.

6.3.1 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.


(Rev 4) PAGE 6－8


6.3.2 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.

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

Displayed set values can be scrolled through with the [↑] and [↓] buttons.

PAGE 6-12

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] will be displayed when abnormalities occur or when the STOP or Limit signals are OFF.

PAGE 6-13

Press Result Display Mode

ParameterDisplay Mode

Real TimeDisplay Mode

Status Display

Power ON

START

START

MODE

MODE

MODE

MODE


PAGE 6－9 (Rev 4)


6.3.3 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.

[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.

Real TimeDisplay Mode



Operating Condition Display

Power ON Press Start Press Finish

[MODE]

[MODE] [MODE]

D-NO 1 Digit Display


D-NO Digit on the Left

D-NOin: initial Fr: Approach SL: Slow Down Ld: Load Speed

Real Time Display Mode


StatusDisplay


D-NO Digit on the Left

Abnormal or STOP / Limit signal OFF

DATA Abn/STOP



[MODE] [MODE]

[MODE] [MODE]

D-NOIn: Slow Start Fr: Approach SL: Part Search L1: Press Speed 1 L2: Press Speed 2 r1: Decompression ru: Return


(Rev 4) PAGE 6－10


6.3.4 Real Time Display Mode

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

0 Load value display Displays present load applied on the load cell in real time.

1 Load voltage value display Displays present load signal voltage applied on the load cell in real time.

2 Maximum load value display (Maximum value hold) Displays peak load from the time when the [RESET] switch was last pressed in this mode.

3 Moving distance display

Displays distance of absolute position from the home position. Press and hold [SET] to see the 3 decimal place resolution value.

4 Electronic thermal value (Overload at 100) Present electronic thermal value is displayed.

5 Current value (Max 1023) Displays present current value.

6 Resolver position data display (0 to 4093) Displays present resolver position.

7 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.)

8～ For in-house use only

Input and output signal monitor

* This can be used for firmware version 1.96 or later of the SAN unit.

D-NO: 1 Digit Display

0

1

2 [↑], [↓] switch

～

“D-NO” “DATA”

Load value display Load voltage value display

Maximum load value display

n

ON: Lights up OFF: Lights off


PAGE 6－11 (Rev 4)


6.3.5 Press Result Display Mode

The following is displayed on the screen in the Press Result Display Mode. The [D-NO] changes by pressing the [↑] and [↓] buttons.

D-NO DATA UNIT ＿０ Peak Load Value（Judgment Load Value） KN ＿１ Final Distance Value mm ＿２ Distance Measurement Start Load distance mm ＿３ Distance at Interference Check Load mm ＿４ 1st Zone Operating Time Sec ＿５ Final Zone Operating Time Sec ＿６ Cycle Time Sec ＿７ Press Mode Number ＿８ Electronic Thermal Value at Operation End (Load Factor) [*100:”Load Over”] ＿９ Last 4 digits of Final Distance mm －０ Last 4 digits of Distance Measurement Start Load distance mm －１ Absolute Final Distance mm －２ Last 4 digits of Absolute Final Distance mm －３ Self Check ON: performed OFF: not performed －４ Speed when Part Check 1 Load was Detected mm/sec

－５

Cause of press stop 0: Reset／No Data／After manual operation 1: Abnormal 2: BYPASS signal 3: STOP signal 4: REJECT 5: ACCEPT signal 6: START signal OFF 7: CW signal 8: CCW signal

－６ Load Judgment ＬｄＨ／Ｌ－７ Distance Judgment ｄＳＨ／Ｌ

－８ Work Check

0: Interference Check 1: Part Check 1 with High or Low Judgment 2: Part Check 2 with High or Low Judgment

3: Part Check 3 with High or Low Judgment

－９ Distance at Part Check 1 Load mm ＝０ Part Check 2 Minimum Load KN ＝１ Part Check 2 Maximum Load KN ＝２ Part Check 2 Distance at Minimum Load mm ＝３ Part Check 2 Distance at Maximum Load mm ＝４ Part Check 3 Minimum Load KN ＝５ Part Check 3 Maximum Load KN ＝６ Part Check 3 Distance at Minimum Load mm ＝７ Part Check 3 Distance at Maximum Load mm ＝８ Final Load KN ＝９ Distance at Judgment Load mm

「D-NO」「DATA」 Peak load value Final Distance value Distance at Judgment Load

D-NO：Digit on the Left

０

１

9

[↑] / [↓] buttons


(Rev 4) PAGE 6－12


6.3.6 Parameter Display Mode

The following data is displayed on the screen in the Parameter Display Mode. By pressing the [↑] and [↓] buttons, the [D-NO] changes and the value of the data number is displayed in the [DATA] area. If [↓] is pressed at the first data number of each parameter number, [PARM] parameter number will increment by 1. If [↑] is pressed at the last data number of each parameter number, [PARM] parameter number will decrement by 1.

「D-NO」「PARM」「DATA」

0 Load digit Number 0 SP Version 0 Amplifier Version 32 Decompression Speed 32 Return Speed

D-NO: 2 Digit Display

00

[↑] / [↓] buttons

01

02

75

76


PAGE 6－13 (Rev 4)


6.3.7 Operating Condition Display The following speed conditions are shown on the display when in automatic operation:

■ Slow Start Speed ■ Approach Speed ■ Part Search Speed ■ Press Speed 1

■ Press Speed 2 ■ Decompression ■ Return

The following speed conditions are shown on the display when in Jog (Manual) operation. ■ Home Search ■ Home Return ■ Advance Jog (1) ■ Return Jog (2)

(1) Advance Jog is depicted in 3 speeds; J3 = High Speed Advance, J5 = Middle Speed Advance, J7 = Slow Speed Advance.

(2) Return Jog is depicted in 3 speeds; J4 = High Speed Return, J6 = Middle Speed Return, J8 = Slow Speed Return.

6.3.8 Status Display

When an abnormal occurs or when the STOP or Limit signals are OFF, the status is displayed as follows:

■ ABNORMAL ■ STOP signal OFF ■ CW signal OFF ■ CCW signal OFF (Advance Limit) (Return Limit)


(Rev 4) PAGE 6－14


6.4 BYPASS Mode Operating Instruction When the RUN/BYPASS switch is moved to the BYPASS position or when a Bypass signal is received from a PLC the BYPASS led will blink and the unit will be in the BYPASS state. In this state, the Press Unit number (U.01 to 32) is displayed on the screen.

6.4.1 Download Mode and Setup Mode Selection “Download Mode”

Immediately after the Bypass condition has been entered, the unit is in the Download Mode, which allows the system to be set up using the DSP User Console software via the RS-485 port. The DSP software allows SAN Unit setup via a computer versus programming with the Display Panel. It is highly recommended that, with multiple numbers of enFORCE Units, the DSP software be used because all presses can be programmed and downloaded to at the same time. L.485 is displayed on the screen when downloading or uploading data.

To program the SAN Unit with the Display Panel, press the [MODE] button to change from “Download Mode” to “Setup Mode”.

When the SAN Unit is performing a data transfer with an external computer, changes cannot be made until the operation has been completed.

“Setup Mode”

Immediately after entering into the Setup Mode, a cursor (blinking for data entry) appears on the “PARM” display. Each time the [MODE] button is pressed, the cursor (blinking character) will shift to the right. By pressing the [↑] and [↓] buttons, the value of the blinking character will increase or decrease. The data corresponding to the selected parameter number “PARM” and data number “D-NO” is shown in the “DATA” display. You may edit the currently indicated data using the Data Edit Mode. Press the [SET] button to enter into the Data Edit Mode for the indicated “D-NO” you want to change.

MODE

MODE MODE

Data Edit Mode

SET SET SET


PAGE 6－15 (Rev 4)


6.4.2 Data Edit Mode

Immediately after entering the “Data Edit Mode”, the cursor (blinking number) is displayed in the left most digit on the “DATA” display (DATA ①). Each time the [MODE] button is pressed, the cursor (blinking character) will shift to the right. When the cursor (blinking character) is in the right most position (DATA ④), pressing the [MODE] button will change the mode back to the “Setup Mode” (without saving any changes). By pressing the [↑] and [↓] buttons, the value of the blinking character will increase or decrease.

After changes have been made, pressing the [SET] button will save the changes and exit to the “Setup Mode” If the entered values are out of range / limits, “Err.” will appear and the entered data will be ignored. In this case, return to the parameter number selection (using the [MODE] button) and enter data that is acceptable.

When a System Parameter (PARM 0, D-NO 00~0F) or the Tool Type Parameter (PARM 0, D-NO 20) is changed, the [DATA] display will show “ＣＨｎＧ.” and “ｎＯ” will appear on the “D-NO” display. YES or NO can be selected by pressing the [↑] and [↓] buttons. If ｙＥＳ is selected, confirm the entered data by pressing the [SET] button. The [SET] and [MODE] buttons will have no effect when ”ｎＯ” appears. *If neither YES or NO is selected within 5 seconds, the new data will be ignored and the system will exit the “Data Edit Mode”.

• If the tool number (PARM ： 0 D-NO ： 20) is changed, the Load Data (D-NO：00～26) will be cleared and the default value will be set for Speed Data (D-NO：70～76).

• The changed set value will be saved into the internal memory at the moment the RUN/BYPASS switch is fixed to the RUN side from the BYPASS side. If the power is turned off when changing the set value in BYPASS mode, the changed set value will be canceled and will be set back to the original value.

MODE MODE MODE

① ② ③ ④

Setup Mode

SET SET SETSET MODE

↑

↓

Setup ModeSET SET


(Rev 4) PAGE 6－16


6.4.3 Parameter Copying To speed data entry, it may be beneficial to copy from one parameter set to another parameter set. This is especially convenient in the case where minor changes must be made to parameters sharing common data. Refer to the example procedure below to copy between parameters using the Display Panel:

（1）Selecting the Parameter and Data Number. When in Setup Mode, select Parameter 00 and D-No. 01. The number shown in the [DATA] display reflects the “SP Version” and is read only. It cannot be changed. However, the [DATA] fields are available for changing allowing a copying of data from the parameter shown in the first two [DATA] fields to the parameter shown in the last two [DATA] fields. In the following example we want to copy data from Parameter 04 to Parameter 05. Press the MODE button to begin changing data.

（2）Enter the Parameter you want to copy from. The cursor will be flashing in the first position allowing changes to the “tens” digit of the “From” parameter. Press the [↑] or [↓] button until “0” is shown. Press the MODE button to move to the next cursor position. The cursor will move to the second position allowing changes to the “ones” digit. Press the [↑] or [↓] button until “4” is shown. Press the MODE button to move to the next cursor position.

（3）Enter the Parameter you want to copy to. The cursor will be flashing in the third position allowing changes to the “tens” digit of the “To” parameter. Press the [↑] or [↓] button until “0” is shown. Press the MODE button to move to the next cursor position. The cursor will move to the fourth position allowing changes to the “ones” digit. Press the [↑] or [↓] button until “5” is shown. Press the SET button to proceed with the copy.

（4）Confirm the Copy. The [DATA] display will show “ＣＨｎＧ.” and “ｎＯ” will appear on the “D-NO” display. Press the [↑] or [↓] button until ｙＥＳ is shown. Confirm the parameter copy by pressing the [SET] button. (If no action is taken within 5 seconds, the display will return to the Setup Mode and no changes will take place.)

MODE MODE MODE

(2)

↑

↓

Setup Mode

SET

MODE

(1) From To From

To From To

SET

(2) (3)

(3) (3) (4) (4)


PAGE 6－17 (Rev 4)


6.4.4 Organization of Parameters This system is capable of storing up to 32 different parameters for pressing.

System Parameter (Parameter 0) The common settings used for Parameters 1 to 32 Load Unit [KN/KLBS/TON] Dynamic Hold SP Version Manual Speed Preamp Version Tool Type No Load Current Special Settings, etc.

Parameter 32

Parameter 5

Parameter 4

Parameter 3

Parameter 2

Parameter 1

Full-Scale Load Minimum Load Maximum Load Target Load . . . Distance Settings Time Settings Speed Settings


(Rev 4) PAGE 6－18


6.4.5 Data Number Definitions 6.4.5.1 System Parameter: Parameter Number 00

Data Number 00 Load Unit Load Unit 0: KN 1: KLBS 2: METRIC TON

Data Number 01 SP Version This is the Unit Software Version. No changes can be made. However, the [DATA] fields are made available for Parameter Copying. The first two digits of the [DATA] section are for the Parameter number to copy from and the second two digits are for the Parameter number to copy to. See Page 6-16 for operation method.

Data number 02 Preamplifier Version This is the preamplifier version. No changes can be made.

Data number 03 Functioning Version Used for special function settings. The following values are set at the factory depending on which configuration is required. This value should not be changed without first consulting FEC.

SAN Unit (Main Configuration): 0180 SAN Unit (Stand Alone Configuration): 0103

Item PARAMETERPARM

DATA NO. D-NO DATA

System

００００ Load Unit 0: KN 1: KLBS 2: METRIC TON ０００１ SP Version / Parameter Copy (cannot change version) ０００２ Amplifier Version (no change allowed) ０００３ Function Version (0103=Stand Alone / 0180=with Main)０００４ Offset Load [KN] ０００５ Distance Compensation [mm]０００６ No Load Current Limit 0～1023 ０００７ Current Load Conversion Ratio ％０００８ Home Position Offset [mm] ０００９ Resolver Position 0～4095

Tool Data

(No

Change)

００１０ Tool Number００１１ Tool Calibration Load [KN] ００１２ Tool Calibration Voltage [Ｖ] ００１３ Tool Zero Load Voltage [Ｖ] ００１４～１Ａ In House Control Data

Tool Type ００２０ Tool Number

System

００３０ Home Position Search Timeout 0.1[sec] increments ００３１ Home Position Search Speed [mm/s] ００３２ Manual Operation Speed [mm/s]００３３ Stroke Distance Limit [mm] ００３４ Approach Distance Limit [mm] ００３５ Home Returned Signal Output Range [mm] ００３６ Option Setting 1００３７ Option Setting 2００３８ Option Setting 3００３９ Option Setting 4

Real Time Clock

００４０ RTC Date: Year “2008” = 2008 ００４１ RTC Date: Month / Day “705” = July 5th ００４２ RTC Time: Hours / Minutes “1510” = 3:10PM ００４３ RTC Time: Seconds “50” = :50


PAGE 6－19 (Rev 4)


Data number 04 Off Set Load [-(Calibration Load x 0.1) ~ Calibration Load] This setting is used when there is heavy tooling attached to the tool that would require added load for the press operation. If it requires 5KN to move the tooling, set at 5. The press will see the 5KN as 0 and control the operation accordingly *Do not use if the tooling is free hanging and pulling on the press ram. Negative values are not allowed, use “9” to depict negative The setting is normally 0.

Setting Example: DPT-501R4H-25FS -4.9KN ~ 49.0KN, so range setting is 904.9 ~ 49.0KN

Data number 05 Distance Compensation [0 ~ 9.999mm] This setting is used to compensate for the target distance value shifting due to part movement or bending when a load is applied. The value to be entered reflects the maximum movement/bend measured when the rated load of the press is applied to the part/fixture. When set, the target distance will be adjusted proportionate to the load being applied. This is effective when you want to accurately control the distance in applications where the fixture may deflect or part may bend when a load is applied.

Data number 06 No Load Current Limit [0 ~ 1023] This sets the current limit of the Servo when operating without load. This softens the shocks caused from a crash at high speed by not raising the current level more than is needed. If set correctly, any excessive load will cause the press motor to stall. *The normal setting is 250 ~ 500. If the press seems to stall because of weight on the tip of the output shaft, set the value higher.

Data Number 07 Current Load Conversion Ratio [0 ~ 999%) This data field sets the conversion ratio (as a percentage) of current control without the load transducer. *Normally it is set to 100(%).

Data number 08 Home Position Offset [0 ~ 99.99mm] This setting is for adjusting the Home Position after the “Home Position Search” has been performed. (Example: If 10 is set; after the Home Position Search has been performed and the zero point set, the Home Position will be reset to 10mm from that zero point.) Due to the fact that the Home Position is calculated from a proximity switch position, the distance between Home and distance related data can also very between presses. So if different presses are running the same operation or if a press needs to be changed out, this setting is used to adjust for the difference between press units. In this case, parameter settings can stay consistent for the part/operation.

Data Number 09 Resolver Position [0 ~ 4095] Offset adjustment for the resolver position value. (Example: If the resolver position is 2816 and a value of 200 is input, then the controller will see the resolver at position 2616) *This only changes how the controller interprets the resolver position but does not change the actual position of the resolver.

Data number 10 Tool Number This displays the tool number. No changes can be made.

Data number 11 Tool Calibration Load This displays the tool calibration load. No changes can be made.

Data number 12 Tool Calibration Voltage This displays the tool calibration voltage. No changes can be made.

Data number 13 Tool Zero Load Voltage This displays the tool zero load voltage. No changes can be made.

Data number 14~1A In House Control Data This displays in house control data. No changes can be made.


(Rev 4) PAGE 6－20


Data Number 20 Tool Number The connected tool number is set from the following tool table.

Tool Number

Tool Name （F-Type）

Maximum Load [KN]

Maximum Speed

[mm/sec]

Minimum Speed

[mm/sec]

Load Decimal

Point

SpeedDecimal

Point30 DPT-021R1-**F 1.96 416.6 0.4 XX.XX XXX.X 31 DPT-051R2A-**F 4.90 333.3 0.3 XX.XX XXX.X 32 DPT-101R3-**F 9.81 277.7 0.3 XX.XX XXX.X 33 DPT-151R3-**F 14.7 277.7 0.3 XXX.X XXX.X 43 DPT-201R3-**F 19.6 166.6 0.2 XXX.X XXX.X 42 DPT-301R4H-**F 29.4 320.0 0.7 XXX.X XXX.X 40 DPT-501R4H-**F 49.0 200.0 0.5 XXX.X XXX.X 41 DPT-701R4H-**F 68.6 133.3 0.3 XXX.X XXX.X 37 DPT-102R5-**F 98.1 116.6 0.4 XXX.X XXX.X 38 DPT-152R5-**F 147.1 77.77 0.22 XXX.X XX.XX 39 DPT-202R5-**F 196.1 58.33 0.16 XXX.X XX.XX 80 DPT-501R5C-**F 49.0 222.2 0.6 XXX.X XXX.X 81 DPT-202R5A-**F 196.1 66.67 0.17 XXX.X XX.XX

Tool Number

Tool Part No. (P-Type)

Maximum Load [KN]

Maximum Speed

[mm/sec]

Minimum Speed [mm/sec]

Load Decimal

Point

Speed Decimal

Point 50 DPT-021R3-**P 1.96 208.3 0.2 XX.XX XXX.X 51 DPT-051R3-**P 4.90 95.24 0.01 XX.XX XX.XX 52 DPT-101R4H-**P 9.81 133.3 0.3 XX.XX XXX.X 62 DPT-151R4H-**P 14.71 114.2 0.3 XX.XX XXX.X 54 DPT-201R4H-**P 19.61 80.00 0.16 XX.XX XX.XX 55 DPT-301R4H-**P 29.42 64.00 0.14 XX.XX XX.XX 56 DPT-501R5-**P 49.03 66.66 0.17 XX.XX XX.XX 57 DPT-102R5-**P 98.10 33.33 0.09 XXX.X XX.XX 58 DPT-152R5B-**P 147.1 22.22 0.06 XXX.X XX.XX 59 DPT-202R5B-**P 196.1 16.37 0.05 XXX.X XX.XX 64 DPT-501R5B-**P 49.03 58.33 0.17 XX.XX XX.XX 63 DPT-102R5B-**P 98.1 29.16 0.09 XXX.X XX.XX 65 DPT-051R3-**P 4.90 95.24 0.01 XX.XX XX.XX

Tool Number

Tool Part No. “Mini”

Maximum Load [KN]

Maximum Speed

[mm/sec]


Load Decimal

Point

Speed Decimal

Point 113 DPM-050H1-**P 0.500 133.3 0.4 X.XXX XXX.X 114 DPM-100H1-**F 1.000 180.0 0.4 X.XXX XXX.X

Tool Number

Tool Part No. “Slimline”

Maximum Load [KN]

Maximum Speed

[mm/sec]


Load Decimal

Point

Speed Decimal

Point 85 DPS-101R3-**F 10.0 222.2 0.3 XXX.X XXX.X 84 DPS-301R4H-**F 30.0 200.0 0.5 XXX.X XXX.X 89 DPS-501R4H-**F 50.0 160.0 0.4 XXX.X XXX.X 88 DPS-501R5-**F 50.0 200.0 0.5 XXX.X XXX.X

*The most common models are shown. Contact FEC for models not shown above.


PAGE 6－21 (Rev 4)


Data Number 30 Home Position Search Time Out [0 ~ 999.9 sec.] It sets the time limit of the home position search operation. The default setting is 120.0. *If the operation has not finished within the time limit an abnormal will occur and the Reject light will flash.

Data number 31 Home Position Search Speed [Tool minimum speed ~ 10mm/sec.] This data field sets the speed of the Home Position Search operation. * The maximum speed of the Home Position Search operation is 10mm/sec. If the value set is higher than 10mm/sec., the speed will be limited to 10mm/sec.

Data Number 32 Manual Operation Speed [Tool minimum speed ~ maximum speed] This data field sets the speed of MANUAL operations. The manual Jog operating speed and the speed of the Home Return operation will be set to this value.

Data Number 33 Stroke Distance Limit [0 ~ 999] This data field sets the maximum stroke the press will be allowed. If set to zero, the distance is unlimited. The default setting is zero. * If setting Distance High Limit Stop [00-37] to “1” a Stroke Distance Limit must be set. If set to zero Distance High Limit Stop will be disabled.

Data Number 34 Approach Distance Limit [0 ~ 999] This data field sets the distance limit that the press can run at Approach Speed. If set to zero, the distance is unlimited. The default setting is zero.

Data Number 35 Home Returned Signal Output Range [0 ~ 999] The Home Returned signal will be output when the press stops within +1mm of the value set. (Ex: If 10 is set, the Home Returned signal will be output if the press stops between 0 and 11mm) The default setting is zero.

Data number 36 Load Cell / Dynamic Hold / Home Sensor / RS232&485 Comm. Speed □ □ □ □ 0: Load Cell [Yes] (Default) 1: Load Cell [No] 0: Dynamic Hold [On] (Default) 1: Dynamic Hold [Off]

Dynamic Hold should be set to 0 [ON] unless instructed by FEC. This allows the servo motor to hold the press ram when the operation has stopped. If Dynamic Hold option is set to 1 [OFF], system will automatically be set to SERVO OFF mode after the operation has finished.

0: Home Position Sensor [No] (Default) 1: Home Position Sensor [Yes] (Option on larger presses) *0: RS-485 9600bps RS-232C 9600bps *1: 19200bps 9600bps 2: 38400bps 9600bps *3: 9600bps 19200bps *4: 19200bps 19200bps 5: 38400bps 19200bps *6: 9600bps 38400bps *7: 19200bps 38400bps 8: 38400bps 38400bps Power must be cycled for these changes to take effect. *Available only when configured for Stand Alone


(Rev 4) PAGE 6－22


Data number 37 Distance High Limit Stop / Distance Sampling / Deadman Function □ □ □ □ 0: Distance High Limit Stop [Yes] (Default) 1: Distance High Limit Stop [No]

* When set to “1”, Stroke Distance Limit [00-33] is used for judgment. 0: 0.1mm distance sampling (Default) 1: 0.01mm distance sampling 2: 0.005mm distance sampling

* For correct waveform sampling, the speed should be at or less than 20mm/sec. for 0.1mm, 2mm/sec. for 0.01mm and 1mm/sec. for 0.005mm.

Deadman Function: 0: Normal (Default) 1: Home Position Search Only 2: Return Only 3: Home Position Search and Return

RS232 Output Select:

0: No Data Output (Default) 1: Press Result Data Output 2: Waveform Display

Data number 38 Band Check * □ □ □ □ 0: Disable [No] (Default) 1: Enable [Yes]

*(Requires Main Unit firmware version 1.06 and/or SAN Unit firmware version 3.11

minimum)

Data number 39 (Reserved for special functions. Do Not Use.)

* Data number 40, 41, 42 and 43 require the use of a SAN3-DP(1 or 2)S module (new version) and SAN Unit firmware version 3.18 minimum. Data number 40 Real Time Clock - Date: Year Data

□ □ □ □

Data number 41 Real Time Clock - Date: Month / Day Data □ □ □ □

Data number 42 Real Time Clock - Time: Hours / Minutes Data (24 Hour Clock) □ □ □ □

Data number 43 Real Time Clock - Time: Seconds Data

□ □ □ □

8 0 0 2 = “2008”

9 0 7 = “07 / 09” (July 9th)

0 1 5 1 = “15:10” (3:10PM)

0 5 = “:50”


PAGE 6－23 (Rev 4)


6.4.5.2 Work Parameters: Parameter Number 01 to 32

Item Parameter No. PARM

Data No. D-NO DATA

Load

０１～３２００ Press Mode (Press Method ＋ Judgment Operation ＋ LoadingDirection＋Return Operation)

０１～３２１０ Calibration Load ［KN/KLBS/METRIC TON］

０１～３２１１ Final Load High Limit ［KN/KLBS/METRIC TON］

０１～３２１２ Load Low Limit ［KN/KLBS/METRIC TON］

０１～３２１３ Load High Limit ［KN/KLBS/METRIC TON］

０１～３２１４ Target Load ［KN/KLBS/METRIC TON］

０１～３２１５ Interference Check Load ［KN/KLBS/METRIC TON］

０１～３２１６ Press Speed 1 Start Load ［KN/KLBS/METRIC TON］０１～３２１７ Press Speed 2 Start Load ［KN/KLBS/METRIC TON］

０１～３２１８ Distance Measurement Start Load ［KN/KLBS/METRIC TON］

０１～３２１９ Load Change / Load Rate Change ［KN/KLBS/METRIC TON］

０１～３２２０ Time Start Load ［KN/KLBS/METRIC TON］

０１～３２２１ Return Load ［KN/KLBS/METRIC TON］

０１～３２２２ Part Check 1 Load ［KN/KLBS/METRIC TON］

０１～３２２３ Part Check 2 Load Low Limit ［KN/KLBS/METRIC TON］

０１～３２２４ Part Check 2 Load High Limit ［KN/KLBS/METRIC TON］

０１～３２２５ Part Check 3 Load Low Limit ［KN/KLBS/METRIC TON］

０１～３２２６ Part Check 3 Load High Limit ［KN/KLBS/METRIC TON］

Distance

０１～３２３０ Final Distance High Limit ［mm］０１～３２３１ Distance Low Limit ［mm］０１～３２３２ Distance High Limit ［mm］０１～３２３３ Target Distance ［mm］０１～３２３４ Judgment Load Detection Point ［mm］０１～３２３５ Approach Distance ［mm］０１～３２３６ Interference Check Distance ［mm］０１～３２３７ Press Speed 1 Start Distance ［mm］０１～３２３８ Press Speed 2 Start Distance ［mm］０１～３２３９ Detection Start Distance ［mm］０１～３２４０ Detection End Distance ［mm］０１～３２４１ Job Start Distance ［mm］０１～３２４２ Part Check 1 Distance Low Limit ［mm］０１～３２４３ Part Check 1 Distance High Limit ［mm］０１～３２４４ Part Check 2 Start Distance ［mm］０１～３２４５ Part Check 2 End Distance ［mm］０１～３２４６ Part Check 3 Start Distance ［mm］０１～３２４７ Part Check 3 End Distance ［mm］

Advance / Return

Position Signal

０１～３２５０ Advance Position ON Distance ［mm］０１～３２５１ Advance Position OFF Distance ［mm］０１～３２５２ Return Position ON Distance ［mm］０１～３２５３ Return Position OFF Distance ［mm］

Time

０１～３２６０ Slow Start Time [sec] ０１～３２６１ Load Hold Time [sec] ０１～３２６２ Press Time [sec] ０１～３２６３ Press Time Low Limit [sec] ０１～３２６４ Press Time High Limit [sec] ０１～３２６５ Acceleration Time [sec] ０１～３２６６ Deceleration Time [sec]


(Rev 4) PAGE 6－24


Item Parameter No. PARM

Data No. D-NO DATA

Speed

０１～３２７０ Slow Start Speed [mm/sec] ０１～３２７１ Approach Speed [mm/sec] ０１～３２７２ Part Search Speed [mm/sec] ０１～３２７３ Press Speed 1 [mm/sec] ０１～３２７４ Press Speed 2 [mm/sec] ０１～３２７５ Decompression Speed [mm/sec] ０１～３２７６ Return Speed [mm/sec]

Data Number 00 Press Mode（Press Method＋Judgment Operation＋Loading Direction＋Return Operation）

This data field will set the Press Method, Judgment Operation, Loading Direction and Return Operation.

□ □ □ □ Press Method 0: Load Control 1: Distance Control 2: Specified Point Load Judgment 3: Load Rise Detection 4: Specified Range Peak Load Judgment 5: Time Controlled Press 6: Load Drop Detection 7: Load Drop Detection (Point Stop) 8: Distance Control with Load Limit Judgment Operation 0: Final Load Low Limit Judgment Disable 1: Final Load Low Limit Judgment Enable 2: Final Load Low Limit Judgment Disable + Part 3 Check 3: Final Load Low Limit Judgment Enable + Part 3 Check * 4: Final Load Low Limit Judgment Disable + Band Check * 5: Final Load Low Limit Judgment Enable + Band Check (*Must be enabled in System Setting [00-38] to use) Loading Direction 0: Positive Load (Default) 1: Negative Load Return Operation 0: Return 1: [ACCEPT] Return, [REJECT] No Return 2: [ACCEPT] No Return, [REJECT] Return 3: [ACCEPT] and [REJECT] No Return 4: Jog Return 5: Keep Load 6: Load Ignore Return 7: Load Return (Software version 1.94 or later) *For further detailed Press Mode instruction, see the following items.


PAGE 6－25 (Rev 4)


♦ Load Control (Method 0)

Upon start of cycle, the press will operate until it achieves [14: Target Load]. During the press cycle, checks are performed for “Interference Check” / “Part Check”, Load and Distance. If any of these values are compromised, the press will stop and return as programmed. (See corresponding sections for Interference Check and Part Check explanations.)

Press Methods

Load

Distance

[13] Load High Limit

[14] Target Load

[12] Load Low Limit

[31] Distance

Low Limit

[32] Distance High Limit

Final Judgment Zone


(Rev 4) PAGE 6－26


♦ Distance Control (Method 1) Upon start of cycle, the press will operate until it achieves [33: Target Distance]. During the press cycle, checks are performed for “Interference Check” / “Part Check”, Load and Distance. If any of these values are compromised, the press will stop and return as programmed. (See corresponding sections for Interference Check and Part Check explanations.)

Load

Distance


[12] Load Low Limit

[31] Distance

Low Limit


Final Judgment Zone

[33] Target Distance


PAGE 6－27 (Rev 4)


♦ Specified Point Load Judgment (Method 2) This Load Control press method allows judgment of a load (PS) at a given distance [34: Judgment Load Detection Point]. Upon start of cycle, the press will operate until it achieves [14: Target Load]. During the press cycle, checks are performed for “Interference Check” / “Part Check”, Load and Distance. If any of these values are compromised, the press will stop and return as programmed. The Final Judgment will be based upon the load value (PS) at [34: Judgment Load Detection Point]. (See corresponding sections for Interference Check and Part Check explanations.)

Load

Distance

[11] Final Load High Limit

[12] Load Low Limit

[14] Target Load

[31]Distance

Low Limit


Final Judgment Zone

[34]Judgment Load Detection Point

Judgment Load (PS) [13] Load High Limit


(Rev 4) PAGE 6－28


♦ Load Rise Detection (Method 3) This Load Control press method allows judgment of a distance (DS) at a given press rate [19: Load Rate Change]. Upon start of cycle, the press will operate until it achieves [14: Target Load]. During the press cycle, as soon as [39: Detection Start Distance] is reached, a rate calculation will begin based upon the load seen at a distance of .1mm before the [39: Detection Start Distance] point and will continue to be calculated every .1mm until [19: Load Rate Change] is exceeded. During the press cycle, checks are performed for “Interference Check” / “Part Check”, Load and Distance. If any of these values are compromised, the press will stop and return as programmed. Final Judgment is based on the distance where the rate exceeds [19: Load Rate Change] after [39: Detection Start Distance] has been reached. (See corresponding sections for Interference Check and Part Check explanations.)

[19: Load Rate Change] is a “control” function and is not used for judgment. Load Rate Change = (Load @ (DS+.1mm) - Load @ (DS)) x 10

* To determine Load Rate Change, view CSV data file for a good part.

Load

Distance


[12] Load Low Limit

[14] Target Load

[39]Detection

Start Distance

[30] Final Distance Limit

Final Judgment Zone

(DS)Judgment Distance


[39] Detection

Start Distance (DS) - .1mm

(DS) + .1mm

[19] Load Rate Change


(DS)


PAGE 6－29 (Rev 4)


♦ Specified Range Peak Load Judgment (Method 4) This Load Control press method allows judgment of a peak load (PS) and judgment of the final distance (DS). Upon start of cycle, the press will operate until it achieves [14: Target Load]. During the press cycle, as soon as [39: Detection Start Distance] is reached, the press will begin looking for a peak in press force (PS). The press will attempt to detect (PS) until [40: Detection End Distance] has been reached. During the press cycle, checks are performed for “Interference Check” / “Part Check”, Load and Distance. If any of these values are compromised, the press will stop and return as programmed. Judgment is based on the press force peak (PS) while within the “Detection Range”. Final Judgment is based on the distance (DS) where the press force reaches [13: Target Load]. (See corresponding sections for Interference Check and Part Check explanations.)

Load

Distance


[12] Load Low Limit

[14] Target Load

[31] Distance

Low Limit


Final Judgment Zone

[40]Detection

End Distance


(DS) Judgment Distance

DetectionRange

Judgment Zone

[39]Detection

Start Distance


(Rev 4) PAGE 6－30


♦ Time Controlled Press (Method 5) This Load Control press method allows a pressing operation to be performed based off of a given time [62: Press Time]. Upon start of cycle, the press will operate until it achieves [14: Target Load]. During the press cycle, after achieving [20: Time Start Load], the press speed will be adjusted to achieve [14: Target Load] in proportion to the time specified in [62: Press Time] (Example: if [62: Press Time] is set to 10 seconds, it will take 10 seconds to go from [20: Time Start Load] to [14: Target Load]). During the press cycle, checks are performed for “Interference Check” / “Part Check”, Load and Distance. If any of these values are compromised, the press will stop and return as programmed. (See corresponding sections for Interference Check and Part Check explanations.)

This press can be done with an ‘F’ type tool but make sure not to overload.

In this special setup, [62: Press Time] is a “control” function and is not used for judgment.

To use this method in a Step Press Operation, refer to page 6-46.

Load

Distance


[14] Target Load

[31] Distance

Low Limit


[62] Press Time

(Control)

Final Judgment Zone

[20] Time Start Load

[12] Load Low Limit


PAGE 6－31 (Rev 4)


♦ Load Drop Detection (Method 6) This Load Control press method allows judgment of a load “drop off” or yielding point [19: Load Change]. Upon start of cycle, the press will operate until it achieves [14: Target Load]. During the press cycle, as soon as [39: Detection Start Distance] is reached, the press will begin looking for a yield in press force [19: Load Change]. The press will attempt to detect [19: Load Change] until [14: Target Load] has been reached. During the press cycle, checks are performed for “Interference Check” / “Part Check”, Load and Distance. If any of these values are compromised, the press will stop and return as programmed. Final Judgment is based on the distance of the peak point (DS/PS) prior to where the decreasing change in press force equals or exceeds [19: Load Change]. (See corresponding sections for Interference Check and Part Check explanations.)

[19: Load Change] is a “control” function and is not used for judgment.

Load

Distance


[12] Load Low Limit

[14] Target Load

[39]Detection

Start Distance

[30] Final Distance High Limit

Final Judgment Zone

[32]Distance High Limit


(DS)

[19] Load Change

DetectionRange


(Rev 4) PAGE 6－32


♦ Load Drop Detection – Point Stop (Method 7) This Load Control press method is similar to Method 3 (Load Drop Detection) except, once [19: Load Change] has been detected, the press will stop. The press will attempt to detect this value until it reaches [14: Target Load]. During the press cycle, checks are performed for “Interference Check” / “Part Check”, Load and Distance. If any of these values are compromised, the press will stop and return as programmed. Final Judgment is based on the distance of the peak load (DS/PS) prior to where the decreasing change in press force equals or exceeds [19: Load Change]. **If JUDGMENT OPERATION is set to “1” or “3” final load will also be judged. (See corresponding sections for Interference Check and Part Check explanations.)

[19: Load Change] is a “control” function and is not used for judgment.

Load

Distance


[12] Load Low Limit

[14] Target Load

[39]Detection

Start Distance

[30] Final Distance High Limit

Final Judgment Zone

[32]Distance High Limit


(DS)

[19] Load Change

DetectionRange


PAGE 6－33 (Rev 4)


♦ Distance Control with Load Limit (Method 8) Upon start of cycle, the press will operate until it achieves [33: Target Distance]. During the press cycle, after achieving [14: Target Load], the press rate will be current controlled to hold [14: Target Load] until [33: Target Distance] is reached. During the press cycle, checks are performed for “Interference Check” / “Part Check”, Load and Distance. If any of these values are compromised, the press will stop and return as programmed. (See corresponding sections for Interference Check and Part Check explanations.)

Load

Distance


[12] Load Low Limit

[14] Target Load

[31] Distance

Low Limit


Final Judgment Zone

[33] Target Distance


(Rev 4) PAGE 6－34


Data Number 10 - Calibration Load

The tool load value is set automatically when the tool type is selected. However, depending on the application characteristics or applications which attach weighted fixtures on the end of the press ram, the value of the applied load and the load displayed by the SAN Unit may be mismatched. In this case it is possible to adjust the Full Scale Load (CAL) value so the displayed load matches the load registered by an external load cell (Master).

The CAL value can be adjusted up to 10% of the Full Scale Load Value. Use the following formula on a collection of at least 10 press cycles when a calibration is necessary.

New CAL value = Master load cell mean/FEC load cell mean * present CAL value Example: For Tool DTP-501R4

Master Load mean value: 48.0 [KN] FEC Load mean value: 49.0 [KN] Present Calibration load: 49.0 [KN]

(48.0 [KN] / 49.0 [KN]) x 49.0 [KN] = 48.0 [KN]

The Calibration load is changed to 48.0 [KN].

Data Number 11 - Final Load High Limit (Methods 2, 3, 4, 6 and 7) Data Number 12 - Load Low Limit Data Number 13 - Load High Limit

Minimum and maximum acceptable limits for Target Load. In Distance Control, if [13: Load High Limit] is reached before achieving [33: Target Distance], the press will stop. When Final Load High Limit is used it acts as the Load High Limit at operation end. A setting is possible from 0 to 110% of full-scale value.

Maximum Operating Load for Different Tools

Tool Name

Maximum Load

[TON]

Maximum Load

F-Type [KN]

Maximum Load

P-Type [KN]

ＤＰＴ－０２１＊＊－＊＊０．２１．９６１．９６ＤＰＴ－０５１＊＊－＊＊０．５４．９０４．９０ＤＰＴ－１０１＊＊－＊＊１．０９．８０９．８１ＤＰＴ－１５１＊＊－＊＊１．５１４．７１４．７１ＤＰＴ－２０１＊＊－＊＊２．０１９．６１９．６１ＤＰＴ－３０１＊＊－＊＊３．０２９．４２９．４２ＤＰＴ－５０１＊＊－＊＊５．０４９．０４９．０３ＤＰＴ－７０１＊＊－＊＊７．０６８．６６８．６４ＤＰＴ－１０２＊＊－＊＊１０．０９８．１９８．１ＤＰＴ－２０２＊＊－＊＊２０．０１９６．１１９６．１

Data Number 14 - Target Load

In Load Control Methods, this is the target load value. (Example: If Target Load is 10KN, press will attempt to operate until 10KN is achieved.) A setting is possible from 0 to full-scale value.

Data Number 16 – Press Speed 1 Start Load

The load value at which the speed of the press will change to [53: Press Speed 1]. A setting is possible from 0 to full-scale value.

If Press Speed 1 or 2 Start Load is detected, even if the press has not reached the Approach Distance, the speed will change to Press Speed 1 or 2.

UNIT：

1N= 0.101972 1kgf = 9.80665 N

Load Settings


PAGE 6－35 (Rev 4)


Data Number 17 – Press Speed 2 Start Load The load value at which the speed of the press will change to [54: Press Speed 2].

A setting is possible from 0 to full-scale value.

Data Number 18 – Distance Measurement Start Load The starting point of calculation of [33: Target Distance]. If set to 0, distance is calculated from start. This should normally be set to zero. A setting is possible from 0 to full-scale value.

For example, if [18: Distance Measurement Start Load] is set to 1KN and [33: Target Distance] is 10mm:

When using the Part Check 3 function, this is the value at which the press will start measuring [44: Part Check 2 Start Distance], [45: Part Check 2 End Distance], [46: Part Check 3 Start Distance] and [47: Part Check 3 End Distance]. See Page 6-36 for Part Check 3 explanations.

Data effected by [18: Distance Measurement Start Load] are [30: Final Distance High Limit], [31: Distance Low Limit], [32: Distance High Limit], [33: Target Distance], [34: Judgment Load Detection Point], [37: Press Speed 1 Start Distance], [38: Press Speed 2 Start Distance], [44: Part Check 2 Start distance], [45: Part Check 2 End Distance], [46: Part Check 3 Start Distance] and [47: Part Check 3 End Distance]. All other distance data is calculated from the [41: Job Start Position].

Data Number 19 - Load Change (Methods 6 and 7)

It sets the load value for detecting force drop when the operation method is [Load Yielding Point] or [Load Yielding Point Stop]. If 1 KN is set, it detects the 1KN force drop of the previous peak value. A setting is possible from 0 to full-scale value.

Data Number 19 - Load Rate Change (Method 3) It sets the load value for detecting the load rate increase when the operation method is

[Load Rise Detection]. (See Page 6-28)

Load Rate Change = (Load @ (DS+.1mm) - Load @ (DS)) x 10

Data Number 20 - Time Start Load (Method 5) The load at which the press begins measuring [42: Press Time].

A setting is possible from 0 to full-scale value.

Data Number 21 - Return Load When using the “Load Return” Return Operation, the press will attempt to decompress

the load to this value after the pressing operation. See Page 6-45 “Load Return”. A setting is possible from 0 to full-scale value.

Load

Distance

Distance Measurement

Start Load = 1KN

10mm

Target Load


(Rev 4) PAGE 6－36


Data Number 30 - Final Distance High Limit (Methods 3, 6 and 7) In special press methods which may be judging two different zones, this is the final target

distance high limit. A setting is possible from 0 to stroke distance limit.

Data Number 31 - Distance Low Limit Data Number 32 - Distance High Limit

Minimum and maximum acceptable distance limits for the target distance or load. In Load Control, if [32: Distance High Limit] is reached before achieving [14: Target Load], the press will stop. A setting is possible from 0 to stroke distance limit.

Data Number 33 - Target Distance

In Distance Control Methods, this is the target distance value. (Example: If Target Distance is 100mm, press will attempt to operate until 100mm is reached.) A setting is possible from 0 to stroke distance limit.

Data Number 34 - Judgment Load Detection Point (Method 2)

In the [Specified Point Load Judgment] method, this is the distance at which the load will be judged. Judgment is carried out at the end of the cycle. A setting is possible from 0 to stroke distance limit.

Data Number 35 - Approach Distance

The distance of Approach Speed operation. This distance is measured from [41: Job Start Position], not from end of [60: Slow Start Time]. A setting is possible from 0 to approach distance limit.

Data Number 37 - Press Speed 1 Start Distance

The distance at which Part Search Speed will change to Press Speed 1. A setting is possible from 0 to stroke distance limit.

Data Number 38 - Press Speed 2 Start Distance The distance at which Press Speed 1 will change to Press Speed 2.

A setting is possible from 0 to stroke distance limit.

Data Number 39 - Detection Start Distance (Methods 3, 4, 6 and 7) In certain special press methods, this is the distance at which the press will begin looking

for the programmed judgment value. A setting is possible from 0 to stroke distance limit.

Data Number 40 - Detection End Distance (Method 4)

In [Specified Range Peak Load Judgment] method, this is the distance at which the press will stop looking for the programmed judgment value. A setting is possible from 0 to stroke distance limit.

Data Number 41 - Job Start Position

The press will go back to this position after operating when a Return Operation is set. A setting is possible from 0 to stroke distance limit.

If a Return Operation is set and the Start signal goes low (OFF), the press will move to this position.

Distance Settings


PAGE 6－37 (Rev 4)


Data Number 60 - Slow Start Time Ramp up time value at start of cycle. [70: Slow Start Speed] is performed during Slow

Start Time. A setting is possible from 0 to 999.9.

Data Number 61 - Load Hold Time The press will hold the [14: Target Load] or [33: Target Distance] for the amount of

time set. If 999.9 (1 figure below the decimal) or 9999 (no decimal point) is set, Load Hold Time is set to no limitation. It finishes operating when the START signal goes OFF. If using the “Advanced” signal, a time must be set. The “Advanced” signal will stay on for this set time. A setting is possible from 0 to 999.9.

The set time for “F-type” tools should generally be kept to 1 second or less unless duty cycle calculations have been done and the tool is oversized for the application. If it is set and operated over 1 second, abnormal 8-10 (overload abnormal) may occur.

The press uses [74: Press Speed 2] to control the holding of the target load or distance. Depending on the forces acting against the press ram, if this speed is set too fast it may cause the holding operation to fluctuate more than desired due to reaction timing and inertia. To avoid this keep [74: Press Speed 2] set low.

Data Number 62 - Press Time (Method 5)

The amount of time the press will run after reaching [20: Time Start Load]. Operation will stop if this time is exceeded A setting is possible from 0 to 327.6.

Data Number 63 - Press Time Low Limit (Method 8) Data Number 64 - Press Time High Limit (Method 8)

In [Distance Control with Load Limit] method, this is the min. and max. time limits. A setting is possible from 0 to 999.9.

[35]Approach Distance

[61] Load Hold Time

[70] Slow Start Speed

[37] Press Speed 1 Start Distance

Or [16] Press Speed 1 Start Load

[60] Slow Start Time

[33] Target

Distance Or

[14] Load

[73] Press Speed 1

[72] Part Search Speed

[71] Approach Speed

[75] Decompression Speed

Time/ Distance

[74] Press Speed 2

[38] Press Speed 2 Start Distance

Or [17] Press Speed 2 Start Load

[76] Return Speed

Speed

Time Settings

klowery

Line

klowery

Line


(Rev 4) PAGE 6－38


Data Number 70 - Slow Start Speed Ramp up speed value at start of cycle. Slow Start Speed is performed during [60: Slow

Start Time]. A setting is possible from tool minimum speed to tool maximum speed.

Data Number 71 - Approach Speed Higher speed value used for the “no-load” portion of the press operation. The

press will run at this speed until [35: Approach Distance], [37: Press Speed 1 Start Distance], [16: Press Speed 1 Start Load], [38: Press Speed 2 Start Distance] or [17: Press Speed 2 Start Load] is reached. Begins after [60: Slow Start Time] has passed. A setting is possible from tool minimum speed to tool maximum speed.

Data Number 72 - Part Search Speed (Recommended less than 50mm/sec. or 1/4 or less of the tool’s maximum speed)

Slower speed value used when nearing the part. The press will run at this speed until [37: Press Speed 1 Start Distance], [16: Press Speed 1 Start Load], [38: Press Speed 2 Start Distance] or [17: Press Speed 2 Start Load] is reached. Begins after [35: Approach Distance] is reached.

Data Number 73 - Press Speed 1 (Recommended less than 20mm/ sec. or 1/4 or less of the tool’s maximum speed)

Slowest speed value used for the “load” portion of the press operation. Begins after [37: Press Speed 1 Start Distance] or [16: Press Speed 1 Start Load] is reached.

Data Number 74 - Press Speed 2 (If unused set equal to Press Speed 1)

(for distance accuracy set <=3mm/sec.) Slowest speed value used for the “load” portion of the press operation. May be used in

conjunction with [73: Press Speed 1] to slow the press even more to obtain distance accuracy. Begins after [38: Press Speed 2 Start Distance] or [17: Press Speed 2 Start Load] is reached. This speed is also used to control the press during [61: Load Hold Time]. If not used, set same as [73: Press Speed 1].

Data Number 75 - Decompression Speed

After completing the press operation, the press will return at this speed until the load has reached a value close to zero then will switch to [76: Return Speed]. The press operates at this speed when performing a “Load Return” operation. On “F-type” presses the time the press can operate under load at this speed is approximately 1 sec. A setting is possible from tool minimum speed to tool maximum speed.

Data Number 76 - Return Speed

Speed at which the press will return to the [41: Job Start Position] after the pressing operation is complete and the load has been released (decompressed). A setting is possible from tool minimum speed to tool maximum speed.

Speed Settings


PAGE 6－39 (Rev 4)


Data Number 15 - Interference Check Load Data Number 36 - Interference Check Distance

These settings may be used together to detect foreign substances (early load) along the press path. If the press senses [15: Interference Check Load] before exceeding [36: Interference Check Distance], an “Interference Check” reject will occur and press operation will stop. A setting is possible from 0 to 105% of full-scale value. * Interference Check Distance must be set lower than Part Check 1 Distance Low Limit.

Data Number 22 - Part Check 1 Load A preliminary “Check” load used to verify the condition of the part before the final

pressing stage occurs. A setting is possible from 0 to 105% of full-scale value.

Data Number 42 - Part Check 1 Distance Low Limit Data Number 43 - Part Check 1 Distance High Limit

Minimum and maximum acceptable limits for [22: Part Check 1 Load]. If the press senses [22: Part Check 1 Load] before reaching [42: Part Check 1 Low

Distance Limit], a “Part Check 1 Distance Low” reject will occur and press operation will stop.

If the press reaches [43: Part Check 1 High Distance Limit] before achieving [22: Part Check 1 Load], a “Part Check 1 Distance High” reject will occur and press operation will stop. A setting is possible from 0 to stroke distance limit. * Interference Check Distance must be set lower than Part Check 1 Distance Low Limit.

If a Part Check interference occurs before the Interference Check Distance is reached it will not be judged.

Interference Check

Interference Check [Interference Check Reject]

Load

Distance

[15] Interference Check Load

Interference Check Distance [36] [35] Approach Distance

Part Check

High Tolerance or Double Feed Part

Low Tolerance or Missing Part

Load

Distance

[22] Part Check 1

Load

[43] Part Check 1 Distance High Limit

[42] Part Check 1

Distance Low Limit

Approach Distance [35]


(Rev 4) PAGE 6－40


Part Check 3 settings are available when the Judgment Operation is set to 1 or 3. Set these values if additional Check Limits are required during the load portion of the press operation.

Data Number 23 - Part Check 2 Load Low Limit Data Number 24 - Part Check 2 Load High Limit

The minimum and maximum acceptable limits for the measured load value occurring between [44: Part Check 2 Start Distance] and [45: Part Check 2 End Distance]. A Low Limit setting is possible from 0 to full-scale value. A High Limit setting is possible from 0 to 110% of full-scale value.

Data Number 44 - Part Check 2 Start Distance

The distance at which “Part Check 2” starts. This distance is measured from the [18: Distance Measurement Start Load] value. A setting is possible from 0 to stroke distance limit.

Data Number 45 - Part Check 2 End Distance

The distance at which “Part Check 2” ends. This distance is measured from the [18: Distance Measurement Start Load] value. A setting is possible from 0 to stroke distance limit.

Data Number 25 - Part Check 3 Load Low Limit Data Number 26 - Part Check 3 Load High Limit

The minimum and maximum acceptable limits for the measured load value occurring between [46: Part Check 3 Start Distance] and [47: Part Check 3 End Distance]. A Low Limit setting is possible from 0 to full-scale value. A High Limit setting is possible from 0 to 110% of full-scale value.

Data Number 46 - Part Check 3 Start Distance

The distance at which “Part Check 3” starts. This distance is measured from the [18: Distance Measurement Start Load] value. A setting is possible from 0 to stroke distance limit.

Data Number 47 - Part Check 3 End Distance

The distance at which “Part Check 3” ends. This distance is measured from the [18: Distance Measurement Start Load] value. A setting is possible from 0 to stroke distance limit.

Load

[44] Part Check 2 Start Distance

Final Position

Time/ Distance

[45]Part Check 2 End Distance

[46]Part Check 3 Start Distance

[25] Part Check 3 Load Low Limit

[24] Part Check 2 Load High Limit

[23] Part Check 2 Load Low Limit

[26] Part Check 3 Load High Limit

[47] Part Check 3 End Distance

[18] Distance Measurement

Start Load

Part Check 3


PAGE 6－41 (Rev 4)


These settings are used to turn the Advance/Return (Timing) Position Signal Output on and off. These settings and output signals 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.

Data Number 50 - Advance Position ON Distance Data Number 51 - Advance Position OFF Distance

When set to a number other than zero, these settings control the “On” and “Off” of the Advance/Return Position Signal output while the press is advancing. *When the press is set up for Negative Load direction, Advance Position is output while the press is returning (moving toward target).

Data Number 52 - Return Position ON Distance Data Number 53 - Return Position OFF Distance

When set to a number other than zero, these settings control the “On” and “Off” of the Advance/Return Position Signal output while the press is returning. *When the press is set up for Negative Load direction, Return Position is output while the press is advancing (returning from target).

50

53

ON

OFF

51 OFF

ON 52

0mm

150mm

Example #1

[50: 50.0mm] [51: 120.0mm] [52: 150.0mm] [53: 100.0mm]

50

53

ON

OFF

150mm

Example #2

[50: 50.0mm] [51: Max Distance] [52: Max Distance] [53: 100.0mm]

0mm

Advance / Return Position Signal Output


(Rev 4) PAGE 6－42


(Requires Main firmware version 1.06 and/or San Unit firmware version 3.11 minimum) *Setup should be performed using the DSP User Console Software. Only use the Programming Display Panel if changes are required and a User Console PC is not available. This special function allows the user to define a high and low limit “band” around a known good part curve signature and use for part judgment. Once defined, a part will be determined “good” only if its curve signature falls within the set band limits. Band Check is enabled in the System Settings. Once enabled, options 4 and 5 can be entered in the Judgment Operation parameter. After the appropriate Judgment Operation has been set, data numbers 80 through B9 become available for setting up the High and Low Limit Band set points.

Data Number 80 - L1 Set Point Load Setting

L1 (Low Limit Band - Setting 1) Load Limit Setting Data Number 81 - L1 Set Point Distance Setting

L1 (Low Limit Band - Setting 1) Distance Limit Setting

Data Number 82 - L2 Set Point Load Setting L2 (Low Limit Band - Setting 2) Load Limit Setting

Data Number 83 - L2 Set Point Distance Setting L2 (Low Limit Band - Setting 2) Distance Limit Setting

Data Number 84 - L3 Set Point Load Setting

L3 (Low Limit Band - Setting 3) Load Limit Setting Data Number 85 - L3 Set Point Distance Setting

L3 (Low Limit Band - Setting 3) Distance Limit Setting













Band Check


PAGE 6－43 (Rev 4)




Data Number A0 - H1 Set Point Load Setting H1 (High Limit Band - Setting 1) Load Limit Setting

Data Number A1 - H1 Set Point Distance Setting H1 (High Limit Band - Setting 1) Distance Limit Setting

Data Number A2 - H2 Set Point Load Setting

H2 (High Limit Band - Setting 2) Load Limit Setting Data Number A3 - H2 Set Point Distance Setting

H2 (High Limit Band - Setting 2) Distance Limit Setting



Data Number A6 - H4 Set Point Load Setting

H4 (High Limit Band - Setting 4) Load Limit Setting Data Number A7 - H4 Set Point Distance Setting

H4 (High Limit Band - Setting 4) Distance Limit Setting



Data Number B0 - H6 Set Point Load Setting H6 (High Limit Band - Setting 6) Load Limit Setting

Data Number B1 - H6 Set Point Distance Setting H6 (High Limit Band - Setting 6) Distance Limit Setting








Data Number B9 - H10 Set Point Distance Setting H10 (Low Limit Band - Setting 10) Distance Limit Setting


(Rev 4) PAGE 6－44


Final Load Low Limit Judgment Disable [ 0 ] Judgment of a “Low Load” condition at the end of the press cycle will not be reported. All other judgments will be performed.

Final Load Low Limit Judgment Enable [ 1 ] Judgment of a “Low Load” condition at the end of the press cycle will be reported. All other judgments will be performed.

Final Load Low Limit Judgment Disable + Part 3 Check [ 2 ] Judgment of a “Low Load” condition at the end of the press cycle will not be reported. This selection also enables the “Part Check 3” functionality. (See Page 6-36 for Part Check 3 Explanation)

Final Load Low Limit Judgment Enable + Part 3 Check [ 3 ] Judgment of a “Low Load” condition at the end of the press cycle will be reported. This selection also enables the “Part Check 3” functionality. (See Page 6-36 for Part Check 3 Explanation)

Because “High Load” conditions have the potential to destroy the parts and/or press, they are ALWAYS judged. If a Part 3 Check is set to be performed near the target and the press speed is set too fast, then the judgment may not be performed until the final distance. If using Part Check during the Time Controlled Press Method, the Part Check will not be performed after the press has sensed Time Start Load.

Final Load Low Limit Judgment Disable + Band Check [ 4 ]

This selection is only possible if “Band Check” is enabled in the System Settings. Judgment of a “Low Load” condition at the end of the press cycle will not be reported. This selection also enables the “Band Check” setup functionality.

Final Load Low Limit Judgment Enable + Band Check [ 5 ] This selection is only possible if “Band Check” is enabled in the System Settings. Judgment of a “Low Load” condition at the end of the press cycle will be reported. This selection also enables the “Band Check” setup functionality.

Positive Load [ 0 ] (Default) Pressing under a load condition will be performed while the press ram is advancing.

Negative Load [ 1 ] Pulling under a load condition will be performed while the press ram is returning.

This selection is set according to the type of press that has been purchased and should not be changed.

Judgment Operation

Loading Direction


PAGE 6－45 (Rev 4)


Return After both an ACCEPT or REJECT judgment the load will be released, then the press will move to the position set in [41: Job Start Position].

[ACCEPT] Return, [REJECT] No Return When the judgment is an ACCEPT, the press will move to the position set in [41: Job Start Position]. When the judgment is a REJECT, the press will stop and the load will be released.

[ACCEPT] No Return, [REJECT] Return When the judgment is an ACCEPT, the press will stop and the load will be released. When the judgment is a REJECT, the press will move to the position set in [41: Job Start Position].

Jog Return During the Return Operation, if the START signal is turned OFF, the operation will stop and if it is turned ON, the operation will start from the position where the press ram stopped. If a load exist at the stop point it will be released.

Keep Load When the judgment is an ACCEPT, the operation will stop at the target load or distance position without the load being released. When the judgment is a HIGH REJECT, the load will be released to near zero and stop. When the judgment is a LOW REJECT, the operation will stop at the point of reject. This Mode is very useful when used in “Step Press” operations. See “Step Press Operation” on page 6-46 for explanation and setup.

Load Ignore Return After both an ACCEPT or REJECT judgment, the press will ignore any load built up in the cylinder and return to the position set in [41: Job Start Position].

When the system is returning the cylinder in normal operation, any load will be released before returning to [41: Job Start Position]. If the cylinder reaches [41: Job Start Position] and it still has load, it will pass the [41: Job Start Position] and go to the Press Home Position (zero position). This Return Method ignores the cylinder load while returning.

No Return

After both an ACCEPT or REJECT judgment, the press will stop and the load will be released.

In No return mode, when a load is being detected, the releasing operation of the load is done until the load is almost zero, but the press will not return to the operation finish return position. If you want to stop the operation with the press on the target position without releasing the load, select the Keep Load Operation.

Load Return (software version 1.94 and later) After both an ACCEPT or REJECT judgment, the press will decompress the load at [75: Decompression Speed] until the load has dropped below the value set in [21: Return Load]. On “P-type” presses this “decompression” is limited to 20 seconds. On “F-type” presses this “decompression” is limited to approximately 1 second due to the load holding limitation.

If decompressing with an excessive load acting against the ram increase [75: Decompression Speed], otherwise an Abnormal 9-7 may occur. If the load is being decompressed too fast decrease [75: Decompression Speed]. If, after reaching the target, the load sensed is less than the value programmed in [21: Return Load], the press will stop at the target position.

Return Operation


(Rev 4) PAGE 6－46


6.5 Step Press Using Time Controlled Press A Step Press is a press operation that is done in multiple phases using multiple parameters. This operation works best when used in conjunction with the “Keep Load” Return Operation. For best results set up as follows:

For a smooth curve, set [20: Time Start Load] equal to the previous step’s [14: Target Load].

Turn On the Self Check Off signal before starting each cycle. After the end of each phase, start the next phase as soon as possible. Because load

hold is not used, the press motor will turn off and the press will begin releasing the load gradually.

The present load value will be fixed to 0 point and operate unless the SELF-CHECK signal is turned OFF for this operation. *There is a possibility to destroy the equipment. This press can be done with the F type tool but make sure not to overload.

Load

Parameter 1

Final Position

Time/ Distance

Parameter 2 Parameter 3 Parameter 4


PAGE 6－47 (Rev 4)


6.6 Return Parameter Setup It is recommended that, if the return of the press is done with a parameter, use Distance Control. However, if Target Distance is set to 0 without a return operation, the press will reject because the Distance Low value is zero (a value less than zero is not possible). Refer to the following for setting up a Return Parameter. Adjustments can be made according to the individual application.

D-NO DATA SETTING

00 Press Operation ０００１ (Distance Control＋Return Operation)12 Load Low Limit ０ 13 Load High Limit Maximum Load of the Tool 15 Interference Check Load Maximum Load of the Tool 16 Press Speed 1 Start Load 1 or Maximum Load of the Tool 17 Press Speed 2 Start Load Same as Press Speed 1 Start Load 18 Distance Measurement Start Load ０ 22 Part Check 1 Load ０. １ 31 Distance Low Limit ０ 32 Distance High Limit ２ 33 Target Distance １ (setting to 0 will cause a reject) 35 Approach Distance １０ (may need to set larger for higher speeds) 36 Interference Check Distance ０ (unless required) 37 Press Speed 1 Start Distance ３ 38 Press Speed 2 Start Distance ２ 41 Job Start Position ０ 42 Part Check 1 Distance Low Limit ０ 43 Part Check 1 Distance High Limit Maximum Stroke of the Tool 50 Advance Position ON Distance ０ 51 Advance Position OFF Distance ０ 52 Return Position ON Distance ０ 53 Return Position OFF Distance ０ 60 Slow Start Time ０. １ 61 Load Hold Time ０ 70 Slow Start Speed １ 71 Approach Speed １００ 72 Part Search Speed １０ 73 Press Speed 1 ３ 74 Press Speed 2 １ 75 Decompression Speed ５ 76 Return Speed ５


(Rev 4) PAGE 6－48


Blank Page

－1

Chapter 7: Maintenance & Inspection


(Rev 4) PAGE 7－2


7.1 Inspection Items

A scheduled inspection is recommended to keep the enFORCE System in the best running condition. A preventive maintenance routine should be set-up. Recommended inspection schedules are given for each item.

Follow Lockout/Tagout and other safety precautions when connecting or disconnecting cables, wiring, and equipment. When performing the following inspections, verify that the System is disabled prior to touching any moveable components.

7.1.1 Press Tool

Recommended Schedule: Quarterly

It is important to keep the tool clean and properly adjusted to ensure correct press and accurate system outputs. Inspect each tool, and ensure the following conditions exist:

• All environmental conditions are within the specified ranges. • The duty cycle is within specifications, and the motor is producing normal heat levels. • The tool is producing normal levels of noise and vibration. • The tool is free from excessive contamination and foreign matter. • The tool is securely mounted, with mounting bolts properly tightened. • The homerun cables are securely connected to the tool.


PAGE 7－3 (Rev 4)


7.1.1.1 Lubrication

Recommended Schedule: 1 year or 1 million cycles minimum *

* Depending on environmental conditions, it may be required to lubricate more often. Inspect press ram at start up for appearance of excessive lubricant deposits.

When required, lubricate according to the following guidelines:

• Use only Mobil Mobilith® SCH PM or Lube USA Luber® FS grease. • DPT-301-** & smaller - ram must be advanced to 120mm to access ball screw through

hole. • DPT-501-** & larger - a grease fitting is provided for ball screw nut lubrication. • DPM-050-** - ram must be advanced to 80mm to access ball screw through hole. • Apply 1/3 of the quantity shown. Cycle the press 3 - 4 times, then repeat.

Press Model Gear Grease Fitting Gear Access Hole Ball Screw Nut

Grease Fitting/Hole Ram Grease

Fitting or SurfaceDPT-021R*-15* 10ml. 10ml. 10ml. 10ml. DPT-051R*-25* 10ml. 10ml. 10ml. 10ml. DPT-101R*-25* 10ml. 10ml. 10ml. 20ml. DPT-151R*-25* 10ml. 10ml. 10ml. 20ml. DPT-201R*-25* 10ml. 10ml. 10ml. 20ml. DPT-301R*-25* 10ml. 10ml. 10ml. 20ml. DPT-501R*-25* 15ml. 15ml. 15ml. (3 fittings) 20ml. DPT-701R*-25* 15ml. 15ml. 15ml. (3 fittings) 20ml. DPS-101R*-20* - - 10ml. 10ml. (on surface) DPS-301R*-20* - - 10ml. 10ml. (on surface) DPM-050R*-10* - - 10ml. 10ml. (on surface)


(Rev 4) PAGE 7－4


7.1.1.2 Ball Screw Inspection (DPT Series)

Recommended Schedule: 1 year or 1 million cycles.

Inspect of the ball screw by removing the CW switch. Do the following with power off: 1. Mark the position of the CW switch (closest to the press ram) like what is shown in

section 7.2.3.3 for re-attachment reference. 2. Remove CW switch. 3. Inspect Ball Screw to verify that it is not scored and that the grease is not abnormally dirty

or containing metal debris. 4. Re-attach CW switch using reference marks.

7.1.1.3 Belt Tension Verification and Adjustment (DPS & DPM Series)

DPS and DPM series tools use a belt for motor torque transmission to the ball screw. The belt tension is adjusted before shipment for optimal performance and long life, but may require periodic tension verification and adjustment.

For maintenance purposes, the resolver position should be recorded at initial tool installation to be used as a baseline reference (See 7.2.2). If, after time on periodic inspections, the resolver count on a DPS tool drops by more the 500 points or out of the 1000~3000 range the belt tension may need to be adjusted. If this occurs on a DPM tool contact FEC.

Inspection of the belt is done by removing the safety cover. Do the following with power off: 1. Loosen the safety cover bolts and remove

cover. 2. Verify that the motor fixing bolts are tight. 3. Check tension using a tension

measurement device. a. Preferred device is a wave-style belt

tension meter (Ex: Gates Unitta Asia P/N: U-507).

If the belt requires adjustment do according to the following procedures:

1. Loosen Motor fixing bolts. Do not loosen too much.

2. Turn the tension bolt to adjust belt tension. a. Tension is raised when motor is

drawn toward side and lowered when drawn towards press body.

3. Tighten the motor fixing bolts. (Tension will rise a little as bolts are tightened)

4. Check tension using a tension measurement device.

a. Preferred device is a wave-style belt tension meter (Ex: Gates Unitta Asia P/N: U-507).

5. Re-install safety cover. ※Tension range is 50 ~ 200% of specified value

Tool Model Belt Model Tension [N]※

DPM-051R1* 3GT-9 44

DPS-101R3* EV5GT-25 178

DPS-301R4* EV8YU-25 294

DPS-501R4* EV8YU-40 500

テンションボルト

安全カバー

固定ボルト（4ヵ所）

モータ

テンション大小

駆動ベルト

DPS-301R4H-**F

Fixed bolt（Four places）

High ← Tension → Low

Drive belt

Tension bolt

Safety cover

MOTOR

Example:


PAGE 7－5 (Rev 4)


7.1.2 Press Fixture

Recommended Schedule: Daily

• Ensure all light curtains and safety devices are operating properly - immediately shut down press if any problem is found and do not operate until safety devices are in proper working order.

• Ensure any fixture is securely attached to the press ram (and/or press base) and all fasteners are tight.

7.1.3 Homerun Cables


These cables connect the tool to the SAN unit. Ensure the following conditions are met:

• The cables are free from unnecessary force and tension. • The cables are secured away from any movement. • The cables are in good condition, sufficiently insulated with no indication of broken wires. • The cables are free from excessive contamination and foreign matter. • The cables are securely connected to the SAN unit and to the press. • The cables are free from heat distortion, and are not warm or hot to the touch. • The cables, cable connectors, and connector screws are securely and correctly fastened.

7.1.4 SAN Unit


The SAN Unit requires careful use and handling. Inspect each SAN unit and ensure the following requirements are met:

• The environmental conditions are within specifications. • There is no moisture, oil, or foreign matter on the unit. • The unit is securely mounted, with appropriate clearance on all sides. • All screws (for the cover of the unit and for mounting) are correctly tightened. • The input power remains within specifications at all times. • The unit is not producing any abnormal (excessive) heat. • Unit cables (on the front and the underside) are securely fastened and without damage.

7.1.5 Air Handling Unit

Recommended Schedule: Every 2 months (sooner if external environment is harsh i.e. machining area with coolant mist in air)

Equipment supporting the enFORCE System's environment must be sufficiently maintained. Internal electrical enclosure (which the SAN units are housed) heat load can be calculated using the internal power consumption data in table 2.3. Verify support equipment meets the following requirements, as applicable to the unit type:

• The unit is free from dust, oil, and foreign matter. • All filtration devices are clean, and air flow is not impeded. • The unit is securely and correctly mounted. • The input power remains within specifications at all times. • All fans are functioning properly with no abnormal sound or vibration.


(Rev 4) PAGE 7－6


7.2 Basic Operational Tests

Follow Lockout/Tagout and other safety precautions when connecting or disconnecting cables, wiring, and equipment. When performing the following inspections, verify that the System is disabled prior to touching any moveable components.

7.2.1 Load Cell

The system can perform a load cell check before each press cycle, comparing the values from the load cell (zero and calibration) to the data stored in the system memory. The system is maintenance free, however it can be manually checked as follows:

• Be sure that the enFORCE is in the READY mode.(powered up and not running with a STOP signal applied)

• Check that the load display shows 0 when the keyboard-display unit RESET key is being pressed.

• At the same time as 2 (above), check that the ACCEPT LED is lit. • Check that the display is showing the full scale load value when the SAN unit CAL key is

being pressed. • At the same time as 4 (above), check that the ACCEPT LED is lit. • If any of these checks fail internal limits, an ABNORMAL will be generated and the ABN

LED will light. See Chapter 8 for troubleshooting.

7.2.2 Resolver The resolver feedback is automatically checked while the press motor is turning. No manual steps can be taken to manually check the resolver since it is totally enclosed and there is no access to the motor to manually turn it. However, the resolver position (in pulses) in relation to the return proximity switch can be checked to verify it is within the acceptable range of 1000 ~ 3000.

• Be sure that the enFORCE is in the READY mode.(powered up and not running with a STOP signal applied)

• Perform a “Home Position Search” using the attached Programming Display. After the press has performed this operation, a number will be shown for 1 second. This is the resolver position.

• If it is out of the 1000 ~ 3000 range, see 7.2.3.2 “Motor Tuning” for steps on how to adjust.


PAGE 7－7 (Rev 4)


7.2.3 Motor If doubts about the condition of the motor exist, the windings can be manually checked with an Ohm meter. To check the motor, measure the winding's resistance and the isolation resistance.

• Power down the system. • Disconnect the motor connector from the tool assembly. • Measure the resistance between windings. (See Below) • Measure the isolation resistance between each pair and the frame.

Insulation resistance: Using a megohmmeter, 500 VDC, 50 Mohms or more, test the insulation resistance between the motor windings and the motor case. The values should register in excess of 50 Mohms for each winding.

Motor Winding Resistance* MOTOR SIZE Pins J - K Pins K - L Pins L - J

60W (M1) 15.6Ω 15.6Ω 15.6Ω 200W (M3) 1.6Ω 1.6Ω 1.6Ω 1500W (M4) .9Ω .9Ω .9Ω 3000W (M5) .3Ω .3Ω .3Ω

Resolver Winding Resistance

MOTOR SIZE Pins A - B Pins C - D Pins E - F 60W (M1) 100 −115 Ω 90 − 100 Ω 90 − 100 Ω

200W (M3) 100 −115 Ω 90 − 100 Ω 90 − 100 Ω1500W (M4) 30 − 40 Ω 50 − 65 Ω 50 − 65 Ω 3000W (M5) 30 − 40 Ω 50 − 65 Ω 50 − 65 Ω

Insulation Resistance

MOTOR SIZE Pins J - K Pins K - L Pins L - J

60W (M1)

More than 50 megohms at 500 VDC 200W (M3)

1500W (M4) 3000W (M5)

Tolerance + / - 10%


(Rev 4) PAGE 7－8


7.2.3.1 Motor Replacement Procedure

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. Before performing the following procedure, tie up or block press ram to prevent it from falling after motor is removed.

1. If possible, run a “Home Position Search” by holding down the manual button and pressing

the start button on the Program Display Panel. 2. Note the number that appears on the display for a few seconds after the search has been

performed. 3. Power down machine and disconnect Power/Resolver Cable from motor. 4. Remove the motor by unscrewing the 4 bolts holding it to the gear housing (or brake if an

external brake is used). 5. Bolt new motor to gear housing using 4 existing bolts. 6. Connect Power/Resolver Cable to motor and power up machine. 7. Perform a “Home Position Search” and note the number that appears on the display for a

few seconds after the search has been performed. *This number should be between 1000 and 3000. If it is not, then a motor tuning procedure must be performed (Refer to the following sections or contact FEC).


PAGE 7－9 (Rev 4)


7.2.3.2 Home Position Search Explanation

1. Press RAM moves in return direction. 2. CCW Proximity Switch turns off. * 3. Press RAM moves in forward direction. * 4. CCW Proximity Switch turns on. * 5. Motor stops at the first time Z-phase is reached after CCW Proximity Switch turns on. *

The number of pulses between steps 4 and 5 will be displayed for a few seconds after the Home Position Search has been performed. *There is no CCW proximity switch on DPM series. CCW is an internal stop sensed by the load cell.

7.2.3.3 Motor Tuning

If after performing a Home Position Search, the number displayed is out of the 1000~3000 range, the following must be done:

1. Power down the machine and disconnect Power/Resolver cable from motor. 2. Remove the motor by unscrewing the 4 bolts holding it to the gear housing (or brake if

an external brake is used). 3. Rotate the motor shaft. (Display number will change by approximately 1000 for

every 90 turned) **If using a motor with an internal brake, apply 24V across brake leads to

disengage before adjusting. 4. Bolt motor back onto gear housing. 5. Connect Power/Resolver Cable to motor and power up machine. 6. Perform a “Home Position Search” and note the number that appears on the display

for a few seconds after the search has been performed. 7. If this number is still out of the 1000~3000 range, perform steps 1 through 6 again.

If the displayed number is excessively out of range (<1000 or >3000) adjustment can be made by moving the CCW (return) proximity switch as shown on the following page.

⑤ Z

② ③ ④ ①

4096 0

1000 3000

CCW LMT

OFF

ON ①

②

③

④

⑤


(Rev 4) PAGE 7－10


Mark X & Y position for Ref. Mark X & Y position for Ref.

Press Part Number If reading is

(0～1000), move If reading is

(3000～4095), move Move for every 1000

pulses (approx) DPT-021R1-**F Down Up 0.75mm DPT-021R3-**P Down Up 0.31mm DPT-051R2A-**F Up Down 0.42mm DPT-051R3-**P Up Down 0.14mm DPT-101R3-**F Up Down 0.42mm DPT-101R4H-**P Up Down 0.42mm DPS-101R3-**F Down Up 0.33mm DPT-151R3-**F Up Down 0.42mm DPT-151R4H-**P Up Down 0.36mm DPT-201R3-**F Up Down 0.25mm DPT-201R4H-**P Up Down 0.25mm DPT-301R4H-**F Down Up 1.00mm DPT-301R4H-**P Up Down 0.20mm DPS-301R4H-**F Down Up 0.63mm DPT-501R4H-**F Down Up 0.63mm DPT-501R5B-**P Up Down 0.25mm DPS-501R4H-**F Down Up 0.50mm DPT-701R4H-**F Down Up 0.42mm DPT-701R5-**P Up Down 0.18mm

Presses larger than 10 ton cannot be adjusted this way because of the use of the Origin switch. “Up” is a movement towards the gear housing and “Down” is a movement towards the press ram.

－1

Chapter 8: Troubleshooting


(Rev. 4) PAGE 8－2


8.1 Abnormal Display

When an abnormal condition is detected by the system, the affected press stops and lights the ABNORMAL LED. For ease of troubleshooting the nature of the abnormal, the system provides an abnormal code in the [PARM] display and an abnormal sub-code in the [D-NO] display.

• Abnormal code display. When an Abnormal condition occurs (ABNORMAL LED is lit), the display mode will automatically change to the STATUS mode. (If the display is not in the STATUS mode, depress the MODE button until a blinking “A” appears in the [PARM] display area) A code number appears at the right side of the blinking character. This code refers to some specific type of failure detailed in the tables shown in the following sections.

• Abnormal Sub-code display. The number shown at the most right position in the [D-NO] display area is a sub-code that can be used in conjunction with the Abnormal failure code to further narrow down the cause of the fault. See the following sections. The main Abnormal codes are: ABNORMAL

CODE

DESCRIPTION 1 Load Cell Error. 2 Offset Load Error. 3 Tool EEPROM error. 4 System Memory Error. 5 Servo Amplifier Reply Error. 6 Servo Type Mismatch Error. 7 Internal Error. 8 Servo Amplifier Error. 9 Parameter Error.

Abnormal sub-codes and specific actions for troubleshooting are detailed in the following section.


PAGE 8－3 (Rev. 4)


8.2 Load Cell Abnormals [ A1_* ]

• Code A1_0 - LOAD CELL / ZERO VOLTAGE ERROR

Zero level does not match master level read from tool EEPROM during power on initialization. CAUSE: 1. When the tool load cell is sensing excessive force due to forces on the press shaft. 2. If the controller or the load cell cable is located in an electric or magnetic noise field. 3. When the load cell, load cell cable or the controller malfunctions. RECOVERY: 1. Check that the press shaft has no external force applied to it. (Nothing touching the press

shaft assembly or that anything mounted to it does not bind.) 2. Verify that the cable or controller are not located near any high voltage transient power

sources. Relocate as required and reinitialize. 3. Exchange load cell cable, tool and/or controller with known working units. Reinitialize the

system after each exchange, and make note of any change in the location of the abnormal. 4. Replace the defective component.

• Code A1_1 - LOAD CELL / CAL VOLTAGE ERROR

Calibration voltage error during power on initialization. CAUSE: 1. When the tool load cell is sensing excessive load due to forces on the press shaft. 2. If the controller or the load cell cable is located in an electric or magnetic noise field. 3. When the load cell, load cell cable or the controller malfunctions. RECOVERY: 1. Check that the press shaft has no external force applied to it. (Nothing touching the press

shaft assembly) 2. Verify that the cable or controller are not located near any high voltage transient power



• Code A1_2 - LOAD CELL / ZERO CHECK ERROR

Zero level voltage loaded to memory from tool EEPROM during initialization does not match the actual zero level during a self check (while the self check function is DISABLED). CAUSE: 1. When the tool load cell is sensing excessive force due to pressure or vibration during the

press cycle start. 2. If the controller or the load cell cable is located in an electric or magnetic noise field. 3. When the load cell, load cell cable or the controller malfunctions. RECOVERY: 1. Check that the press shaft has no external force applied to it. 2. Verify the tool mounting bolts are tight and nothing is causing excessive vibration to the tool. 3. Verify that the cable or controller are not located near any high voltage transient power

sources. Relocate as required and attempt again the press start input. 4. Exchange load cell cable, tool and/or controller with known working units. Input the start

signal after each exchange, and make note of any change in the location of the abnormal. 5. Replace the defective component.


(Rev. 4) PAGE 8－4


• Code A1_3 - LOAD CELL / CAL SELF CHECK ERROR

Calibration level voltage error after a press start was attempted. CAUSE: 1. When the load cell is sensing excessive force due to pressure or vibration during the press

cycle start. 2. If the controller or the load cell cable is located in an electric or magnetic noise field. 3. When the load cell, load cell cable or the controller malfunctions. RECOVERY: 1. Check that the press shaft has no external force applied to it. 2. Verify the tool mounting bolts are tight and nothing is causing excessive vibration to the tool. 3. Verify that the cable or controller are not located near any high voltage transient power

sources. Relocate as required and attempt again a press start input. 4. Exchange load cell cable, tool and/or controller with known working units. Input the start

signal after each exchange, and make note of any change in the location of the abnormal. 5. Replace the defective component.

• Code A1_4 - LOAD CELL / STARTED ON ZERO ERROR CONDITION

The start signal was input while a Zero voltage abnormal condition existed. RECOVERY: 1. Interlock the PLC circuit to disable the start signal during an existing abnormal condition. 2. Follow the ZERO VOLTAGE ERROR abnormal help procedure.

• Code A1_5 - LOAD CELL / STARTED ON CAL ERROR CONDITION

The start signal was input while a Cal voltage abnormal condition existed. RECOVERY: 1. Interlock the PLC circuit to disable the start signal during an existing abnormal condition. 2. Follow the CAL VOLTAGE ERROR abnormal help procedure.

• Code A1_6 - LOAD CELL / ZERO LEVEL SELF CHECK ERROR

Zero level voltage loaded to memory from tool EEPROM during initialization does not match the actual zero level during a self check with the self check function enabled. CAUSE: 1. When the load cell is sensing excessive force due to pressure on the press shaft. 2. If the controller or the load cell cable is located in an electric or magnetic noise field. 3. When the load cell, load cell cable or the controller malfunctions. RECOVERY: 1. Check that the press shaft has no external force applied to it. 2. Verify that the cable or controller are not located near any high voltage transient power




PAGE 8－5 (Rev. 4)


8.3 Offset Load Abnormals [ A2_* ] • Code A2_0 - OFFSET LOAD ABNORMAL

High load was detected during an initial stage of press. CAUSE: 1. Excessive binding in the press shaft or press fixture. 2. The load cell is sensing excessive force due to pressure or vibration during the initial stage of

press cycle. 3. The controller or the load cell cable is located in an electric or magnetic noise field. RECOVERY: 1. Repair or replace mechanism which is binding. 2. Check that the press shaft has no external force applied to it. 3. Verify that the cable or controller are not located near any high voltage transient power

sources. Relocate as required and reinitialize.


(Rev. 4) PAGE 8－6


8.4 Preamplifier Errors [ A3_* ] • Code A3_0 - PREAMPLIFIER / TOOL ID CHECKSUM ERROR

Communication data checksum error between the load cell preamplifier and the SAN Unit. Data is not reliable due to data error. CAUSE: 1. If the controller or the load cell cable is located in an electric or magnetic noise field. 2. When the load cell, load cell cable or the controller malfunctions. RECOVERY: 1. Verify that the cable or controller are not located near any high voltage transient power

sources. Relocate as required and reinitialize the system. 2. Exchange load cell cable, tool and/or controller with known working units. Reinitialize the


• Code A3_1 - PREAMPLIFIER / TOOL TYPE ERROR

The connected tool type does not match the tool type programmed into the controller. This error may occur in the multi-tool type application or when controllers are replaced and not reprogrammed with the correct configuration. RECOVERY: 1. Verify the tool type name from the tool identification tag 2. Compare the tool tag name with the setup value located on Data Display (see Page 6-24) 3. Program proper tool number into SAN Unit or change tool to proper tool.

• Code A3_2 - STARTED WITHOUT TOOL CONNECTED

The start signal was applied while a TOOL IS NOT CONNECTED abnormal condition existed. RECOVERY: 1. Interlock the PLC circuit to disable the start signal during an existing abnormal condition. 2. Follow the TOOL IS NOT CONNECTED (Code 3-3) abnormal help procedure.

• Code A3_3 - PREAMPLIFIER / TOOL IS NOT CONNECTED

Communications error between the load cell preamplifier and the controller. CAUSE: 1. The load cell cable is not connected 2. If the controller or the load cell cable is located in an electric or magnetic noise field. 3. When the load cell, load cell cable or the controller malfunctions. RECOVERY: 1. Verify that the load cell cable is connected 2. Verify that the cable or controller are not located near any high voltage transient power

sources. Relocate as required and reinitialize the system. 3. Exchange load cell cable, tool and/or controller with known working units. Reinitialize the



PAGE 8－7 (Rev. 4)


• Code A3_4 - CCW SENSOR POSITION ABNORMAL

The resolver count is out of the 1000 ~ 3000 range after performing a Home Position Search. (See Section 7.2.3.2 for an explanation of Home Position Search) Note: The press unit will still be able to operate with this abnormal but be warned that, if using Distance Control press methods, the distance value may fluctuate. CAUSE: 1. The motor was changed and not “tuned” or tuned incorrectly. 2. The RETURNED switch (CCW) has moved. 3. An offset value was entered in the “Resolver Position” System Parameter [00-09] that caused

the resolver count to become out of range. 4. If using a DPS or DPM series tool, the belt tension may need adjustment. RECOVERY: 1. Perform a “tuning” procedure on the motor. (See Section 7.2.3.3) 2. Verify that the RETURNED switch (CCW) mounting screws are tight. If loose, tighten and

perform a “tuning” procedure on the motor. 3. Enter a value of zero into the “Resolver Position” System Parameter [00-09] and download to

the controller. Perform a Home Position Search and verify that the resolver count is between 1000 ~ 3000. If it is slightly out of range, an offset value may be entered in the “Resolver Position” System Parameter [00-09]. (See Section 6.4.5.1 for an explanation of the “Resolver Position” System Parameter [00-09])

4. Verify that the motor fixing bolts on the DPS or DPM tool are tight and the belt is at the correct tension. (See Section 7.1.1.3)

• Code A3_5 - ORIGIN SEARCH TIMEOUT

The Home Position Search operation did not finish in the time specified in System Parameter 00-30. (See Section 7.2.3.2 for an explanation of Home Position Search) RECOVERY: 1. Increase the Home Position Search Time Out specified in System Parameter 00-30.

(See Page 6-21) 2. Increase the Home Position Search Speed specified in System Parameter 00-31. 3. Verify that the Home Position Sensor setting specified in System Parameter 00-36 is set

correctly.


(Rev. 4) PAGE 8－8


8.5 System Memory Errors [ A4_* ] • Code A4_0 - SYSTEM MEMORY ERROR / FLASH ROM WRITE ERROR

Communications error to internal SAN Flash ROM during WRITE attempt. CAUSE: 1. Metal chips and/or debris have migrated inside SAN Unit through vent holes. 2. Flash ROM IC chip has malfunctioned. RECOVERY: 1. Remove SAN Unit and blow or shake out debris. 2. Replace and return unit to FEC for repair.

• Code A4_1 - SYSTEM MEMORY ERROR / FLASH ROM READ ERROR

Communications error to internal SAN Flash ROM during READ attempt. CAUSE: 1. Metal chips and/or debris have migrated inside SAN Unit through vent holes. 2. Flash ROM IC chip has malfunctioned. RECOVERY: 1. Remove SAN Unit and blow or shake out debris. 2. Replace and return unit to FEC for repair.

• Code A4_2 - SYSTEM MEMORY ERROR / SERVO AMP FLASH ROM ERROR

Communications error to internal SAN Servo Amp flash ROM. CAUSE: 1. Metal chips and/or debris have migrated inside SAN Unit through vent holes. 2. Flash ROM IC chip has malfunctioned. RECOVERY: 1. Remove SAN Unit and blow or shake out debris. 2. Replace and return unit to FEC for repair.


PAGE 8－9 (Rev. 4)


8.6 Servo Amplifier Response Errors [ A5_* ] • Code A5_0 - SERVO AMPLIFIER REPLY ERROR / NO REPLY FROM RESOLVER

The controller is attempting to turn the motor, but is not receiving any signals back from the resolver to indicate that the tool is actually turning. CAUSE: 1. The motor/resolver cable is damaged or not connected 2. When the resolver, motor, or the controller malfunctions. 3. If there is excessive binding in the transmission or the press shaft assembly keeping the

motor from turning. 4. System Parameter 00-06 (No Load Current) is not set to the correct value. 5. When running short cycle times the brake reaction time may not be fast enough causing the

brake to drag during the first few milliseconds of the press cycle. RECOVERY: 1. Verify that the motor cable is connected and not damaged. 2. Connect all spare tool cables to the existing tool. 3. Exchange tool and/or controller with known working units. Reinitialize the system after

exchanges. 4. Verify that system parameter 00-06 is set to the correct default value. If weight is installed on

the press ram and this abnormal occurs, the value may have to be increased. 5. Inspect and correct any binding in the transmission or press shaft. 6. Verify that the brake is operating correctly. 7. For item 5 above: The brake is designed to be used for maintenance, not for control. Set

Parameter 00, Data No. 36 to “Dynamic Hold - On” (this allows motor to control holding of press). See Page 4-28 for brake setup. If brake must be used for control on short cycle time applications, incorporate a timer to delay the start until the brake has time to react.


(Rev. 4) PAGE 8－10


8.7 Servo Type Error [ A6_* ] • Code A6_0 - SERVO TYPE ERROR / SERVO TYPE MISMATCH

The SAN Unit model does not match the connected motor type. RECOVERY: 1. Verify the servo type tag with the motor type tag. 2. There are 3 types of SAN Units (controllers) available & they must be connected to the

correct motor size as shown in the tables in sections 2.1 and 2.2. Tool Type Part Number Breakdown R1 motor = SAN3/4-24S R1H motor = SAN3/4-24HS R2 motor = SAN3/4-24S R3 motor = SAN3/4-40S R4 motor = SAN3/4-120S R5 motor = SAN3/4-120S Example: Tool Type DPT-151R3-**FS R3 is motor size


PAGE 8－11 (Rev. 4)


8.8 Servo Amplifier Errors [ A8_* ]

• Code A8_1 - SERVO AMPLIFIER ERROR / SERVO IS OVER HEATED

The SAN controller servo circuit has overheated. CAUSE: 1. The controller servo drive circuit has failed. 2. If the environment temperature is more than 122 degrees Fahrenheit (50 degree centigrade)

without any air flow. 3. Source voltage is very close to the limit (242 VAC) and the environment temperature is also

close to the limit. RECOVERY: 1. Replace the controller. 2. Provide additional cooling to the enclosure. 3. Verify and correct the source voltage as required.

• Code A8_4 - SERVO AMPLIFIER ERROR / OVER CURRENT

The SAN controller servo circuit experienced a current overload. CAUSE: 1. The controller servo drive circuit has failed. 2. If the environment temperature is more than 122 degrees Fahrenheit (50 degree centigrade)

without any air flow. 3. Source voltage is very close to the limit (242 VAC) and the environment temperature is also

close to the limit. 4. Maximum force is being run or exceeded by the tool every cycle. 5. Speed may be too low or too high during load speed. RECOVERY: 1. Replace the controller. 2. Verify proper cooling for the enclosure. 3. Verify and correct the source voltage as required. 4. Verify proper load or work piece. 5. Adjust load speed setting.

• Code A8_5 - SERVO AMPLIFIER ERROR / INTERNAL POWER SUPPLY

The SAN controller servo power supply circuit is not working properly or the input voltage is above the maximum limit. CAUSE: 1. The controller internal power supply has failed. 2. Source voltage is very close to the limit (242 VAC) and the environment temperature is also

close to the limit. RECOVERY: 1. Replace the controller. 2. Provide additional cooling to the enclosure. 3. Verify and correct the source voltage as required.


(Rev. 4) PAGE 8－12


• Code A8_6 - SERVO AMPLIFIER ERROR / INPUT VOLTAGE ABNORMAL

The SAN3 controller servo power supply circuit or SAN4 controller control power circuit has detected improper input voltage either above or below the specified limits. CAUSE: 1. The controller internal power supply has failed. 2. Source voltage is out of the limit (180-242 VAC) and/or the environment temperature is also

close to the limit. 3. One or more phases of input power are missing. RECOVERY: 1. Replace the controller. 2. Provide additional cooling to the enclosure. 3. Verify and correct the source voltage as required (SAN3 - between 180-242 VAC 3 phase,

SAN4 - between 180-242 VAC 1 phase).

• Code A8_7 - SERVO AMPLIFIER ERROR / DRIVE VOLTAGE ABNORMAL (SAN4)

The SAN4 controller motor power supply circuit has detected improper input voltage either above or below the specified limits. CAUSE: 1. The controller internal power supply has failed. 2. Source voltage is out of the limit (180-242 VAC) and/or the environment temperature is also

close to the limit. 3. One or more phases of input power are missing. RECOVERY: 1. Replace the controller. 2. Provide additional cooling to the enclosure. 3. Verify and correct the source voltage as required (between 180-242 VAC 3 phase).

• Code A8_9 - SERVO AMPLIFIER ERROR / OVER SPEED.

The resolver signal received at the SAN controller indicates an over speed condition. CAUSE: 1. The resolver cable or resolver has failed. RECOVERY: 1. Check resolver using method in 7.2.3. 2. Replace resolver cable with spare cable. 3. Replace tool assembly.

• Code A8_10 - SERVO AMPLIFIER ERROR / OVER LOAD (I SQUARE T)

The duty cycle of the press application is too severe for this size of tool, or for the parameters currently set up. RECOVERY: 1. Reduce duty cycle - Increase tool “downtime or off time” and/or increase Press Speed and

Part Search Speed to reduce the amount of time running at high load/slow speed. 2. Increase the Press Speed Start Load or Press Speed Start Distance at which Part Search

Speed shifts to Press Speed. 3. If using Load Hold, try decreasing the hold time. 4. If the problem remains, a larger tool assembly may be required for this application. Please

contact FEC. 5. If this happens while performing a “Home Position Search”, verify that the brake is operating

correctly.


PAGE 8－13 (Rev. 4)


• Code A8_11 - SERVO AMPLIFIER ERROR / RESOLVER SIGNAL ERROR.

The resolver signal received is not correct. RECOVERY: 1. Check the cable and look for loose connectors or visible damages to the cable. 2. Replace with known good tool.


(Rev. 4) PAGE 8－14


8.9 Parameter Errors [ A9_* ] • Code A9_0 - PARAMETER ERROR / MISSING SPEED PRESET

Some speed preset is not set up in the parameter number selected or the wrong parameter number has been selected by the PLC. RECOVERY: 1. Verify that the parameter number that is being selected by the PLC is configured in the

controller. 2. Check that the speed presets are not <0> or out of the specified speed range of the tool.

• Code A9_1 - PARAMETER ERROR / MISSING TIME or SPEED PRESET

Some Time or Speed preset is not setup in the parameter number selected or the wrong parameter number has been selected by the PLC. RECOVERY: 1. Verify that the parameter number that is being selected by the PLC is configured in the

controller. 2. Check that the time or speed presets are not set as <0> or out of the specified speed range

of the tool.

• Code A9_2 - PARAMETER ERROR / PARAMETER SELECT ERROR

The parameter selected was empty. RECOVERY: 1. Verify that the parameter number that is being selected by the PLC is configured in the

controller. 2. Check that the press presets are not <0> or out of the specified range for the tool.

• Code A9_3 - PARAMETER ERROR / MISSING RETURN SPEED

The Return Speed preset is missing. RECOVERY: 1. Verify that the parameter number that is being selected by the PLC is configured in the

controller. 2. Check that the Return Speed is not set as <0> or out of the specified range for the tool.

• Code A9_4 - PARAMETER ERROR / PRESS SPEED NOT SET

The Press Speed preset is missing. RECOVERY: 1. Verify that the parameter number that is being selected by the PLC is configured in the

controller. 2. Check that the Press Speed is not set as <0> or out of the specified range for the tool.

• Code A9_5 - PARAMETER ERROR / LOAD SETUP ERROR

One of the Load presets is out of range. RECOVERY: 1. Verify that the Load presets are in range for the tool size. 2. Check that the load presets are not <0> or setup as specified in 6.4.5.2.


PAGE 8－15 (Rev. 4)


• Code A9_6 - PARAMETER ERROR / DISTANCE SETUP ERROR

One of the Distance presets is out of range RECOVERY: 1. Verify that the Distance presets are in range for the tool size. 2. Check that the Distance presets are not <0> or setup as specified in 6.4.5.2.

• Code A9_7 - PARAMETER ERROR / RETURN LOAD OVER.

The Return Load is more than 1/6 of the Full Scale Load. RECOVERY: 1. Verify there is no excessive binding in the press shaft or press fixture while running in the

return portion of the press stroke. 2. Verify that the brake has been released while running a return operation. 3. If heavy tooling is attached to the press ram causing an excessive load to be seen, set the

“Self Check Off” signal high (on) before sending a “Start” signal.

• Code A9_8 - PARAMETER ERROR / ADVANCE JOG LOAD OVER.

The Advance Jog Load is more than 1/6 of the Full Scale Load. RECOVERY: 1. Verify there is no excessive binding in the press shaft or press fixture while jogging forward in

manual mode. 2. Verify that the brake has been released while performing a forward jog operation.

• Code A9_9 - PARAMETER ERROR / HOME SEARCH LOAD OVER.

The Home Search Load is more than 1/6 of the Full Scale Load. RECOVERY: 1. Verify there is no excessive binding in the press shaft or press fixture while performing a

Home Position Search. 2. Verify that the brake has been released while performing a Home Position Search.

• Code A9_10 - PARAMETER ERROR / HOME RETURN LOAD OVER.

The Home Return Load is more than 1/6 of the Full Scale Load. RECOVERY: 3. Verify there is no excessive binding in the press shaft or press fixture while performing a

Home Return operation. 4. Verify that the brake has been released while performing a Home Return operation.


(Rev. 4) PAGE 8－16


8.10 Questions & Answers Q1: Does home position search have to be performed every time the power is turned on? A1: Yes.

Home position search may also need to be performed after a catastrophic abnormal has occurred.

Q2: REJECT was output but the reason in unclear. A2: See “Press Result Display Mode” in Section 6.3.5.

Contents of the REJECT is shown from ‘ 6 ’ to ‘ 9 ’. Q3: Is it possible to press while jogging in Manual Mode? A3: No. Abnormal 9-8 will occur when 1/6 of the full-scale load is detected. It is possible to jog using a parameter.

When you want to JOG operate, set the operation finish mode to JOG RETURN and turn the START signal ON and turn it OFF when you want to stop. It will start from the present position if it is turned ON again.

When set to Jog Return Mode, if a load is detected when the START signal goes off, the load will be released.

If you do not want the load to be released, set to Keep Load Mode. Also, turn on the Self Check Off signal before starting again or when returning or an abnormal will be generated due to a force being present at START.

When the Self Check signal is turned off, the present load is set to the 0 load value, so be careful. ** It is a possible to destroy the equipment using this method. ** This method can be used with F type tools, but make sure it is not overloaded.

A-1

Appendix A: Reference Drawings


(Rev. 4) A-2


Power Wiring Reference (SAN3)


A-3 (Rev. 4)


Power Wiring Reference (SAN4)

Saf

ety

Rel

ay

Saf

ety

Rel

ay

Saf

ety

Rel

ay

Saf

ety

Rel

ay


(Rev. 4) A-4


System Transformers


A-5 (Rev. 4)


Motor / Resolver Homerun Cable (DPT & DPS) – (RM1, RM2 & RM3 Motors)


(Rev. 4) A-6


Motor / Resolver Homerun Cable (DPT & DPS) – (RM4 Motor)


A-7 (Rev. 4)


Motor Homerun Cable (DPT & DPS) – (RM5 Motor)


(Rev. 4) A-8


Resolver Homerun Cable (DPT & DPS) – (RM5 Motor)


A-9 (Rev. 4)


Load Cell Homerun Cable (DPT & DPS) – (RM1, RM2, RM3, RM4 & RM5 Motor)


(Rev. 4) A-10


Motor / Resolver / Load Cell Homerun Cable (DPM Series)


A-11 (Rev. 4)


Motor/Resolver Extension Cable (DPT & DPS) - (RM1, RM2, RM3 & RM4 Motor) (RM5 Resolver)


(Rev. 4) A-12


Motor Extension Cable (DPT & DPS) – (RM5 Motor)


A-13 (Rev. 4)


Load Cell Extension Cable (DPT & DPS) – (RM1, RM2, RM3, RM4 & RM5 Motor)


(Rev. 4) A-14


Motor / Resolver / Load Cell Extension Cable (DPM Series)


A-15 (Rev. 4)


SAN3/4-24S/24HS/40S Power Cable


(Rev. 4) A-16


SAN3/4-120S Power Cable


A-17 (Rev. 4)


SAN4 Control Power Cable


(Rev. 4) A-18


I/O Connection Cable


A-19 (Rev. 4)


I/O Proximity Switch Breakout Adapter (DPT & DPS Series)


(Rev. 4) A-20


Proximity Switch Homerun Cable (DPT Series)


A-21 (Rev. 4)


Proximity Switch Tool Extension Cable (DPT Series)


(Rev. 4) A-22


Brake Unit (Maintenance Lock) Homerun Cable (DPT Series)


A-23 (Rev. 4)


Brake Unit (Maintenance Lock) Extension Cable (DPT Series)


(Rev. 4) A-24


External Brake Unit (Maintenance Lock) Cable (DPT Series)


A-25 (Rev. 4)


Proximity Switch & Brake Extention Cable (DPS Series)


(Rev. 4) A-26


Proximity Switch & Brake “Y” Cable (DPS Series)


A-27 (Rev. 4)


Brake Cable (DPS Series)


(Rev. 4) A-28


RS-485 Jumper Cable


A-29 (Rev. 4)


RS-485 to RS-232 PC Converter Cable

enForce SAN for Version 3.x Intro - FEC-USA€¦ · DSP1500 SAN Unit Operation Manual (for Firmware...

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