Chapter 4: System Setup & Wiring PAGE 4 - 1
Chapter 4: System Setup and Wiring enFORCE Operation Manual 4.1 Design and Build Guidelines Review Chapters 1 and 2 prior to designing a System. If requirements and specifications in these two chapters are not addressed, there is a possibility for degraded system performance. № ITEM COMMENTS Section Reference 1 Select the correct tool size Keep force range between 50% and 75% of tool capability for press performance. 2 Design tool mounting plate and press fixtures.
Chapter 4: System Setup and Wiring enFORCE Operation Manual 4.2 SAN Unit Design and Mounting Dimensions SAN units must be mounted with a minimum clearance of 12mm on each side to allow proper heat dissipation. Cable connections on the front of the units require 100mm of clearance. Allow a minimum of 100mm clearance on the bottom of each controller for cable hook up when updating firmware. SAN units must be located a minimum of 600mm from any high transient voltage power source.
Chapter 4: System Setup and Wiring enFORCE Operation Manual SAN3-120S Mounting: Top (2) places Bottom (2) places Weight: SAN3-120S - #8-32 screw #8-32 screw 3.
Chapter 4: System Setup and Wiring enFORCE Operation Manual 4.3 Calculating Circuit Protection RATED VALUES FOR CALCULATING CIRCUIT PROTECTION MOTOR # OF SAN3 UNITS KVA PER MOTOR TYPE WATTAGE SAN3 UNIT PER 1 KVA SAN3 UNIT R1 60 SAN3-24S 8 .125 R2 80 SAN3-24S 6 .167 R3 200 SAN3-40S 2.5 .40 R4 1500 SAN3-120S 0.5 2.0 R5 3000 SAN3-120S 0.25 4.0 The chart above shows nominal motor ratings for standard press motors, along with the power requirements for each SAN unit.
Chapter 4: System Setup and Wiring enFORCE Operation Manual 4.4 Input Power Supply Connection Adequate circuit protection must be provided for the SAN unit input power. Recommended conductor size should be a minimum of #16AWG. Suggested color code (FEC standard): U – Red, V – White, W – Black, FG – Green. Wiring Chart SAN3-24S, 40S ４：Ｕ ３：Ｖ ２：Ｗ １：ＦＧ T/ D MOTOR 3-Phase 180 ~ 242VAC 50/60Hz.
Chapter 4: System Setup and Wiring enFORCE Operation Manual 4.5 Motor Power-Resolver Connections The motor connector provides control power to the motor. The resolver connector handles the signals that define the rotation of the motor. The controller provides a signal to the winding of the rotor. As the rotor spins two sets of stators, electrically shifted 90 degrees, generate a sine wave and a cosine wave signal. Both signals are processed by the controller to define position and speed of the motor.
Chapter 4: System Setup and Wiring enFORCE Operation Manual 4.6 Pre-Amplifier Connection The pre-amplifier connector links the SAN controller to the tool load cell in order to perform the following functions: 1. Reads the load voltage values from the pre-amplifier. 2. Tests the pre-amplifier condition by generating a voltage signal for full scale load by the Calibration function. 3. Tests the Pre-amplifier Zero level by the Zero Level Check function. See Section 4.
Chapter 4: System Setup and Wiring enFORCE Operation Manual 4.7 External-Control Signal Connection Mating Plug Manufacturer：Honda Tsushin Kougyo (HONDA) Vertical Housing Part No.: MR-34L Male Insert Part No.: MR-34M (See Appendix A for connecting cable part numbers) 4.7.1 ＰＬＣ Ｉ／Ｆ（ＡＸＩＳ Ｉ／Ｏ）Signal Pin No.
Chapter 4: System Setup and Wiring enFORCE Operation Manual System Parameter 00, D-No. 08 – HOME SENSOR/BANK1 signal is normally “BANK 1”. To enable Output Banks 2 & 3, set Parameter 00-08 to ‘2’. (See Page 6-22) If using the CYCLE OK signal, BANK 1 output is not available in Bank 1. The BUSY signal is normally used to operate the brake. When changing Banks, the meaning of the BUSY signal will change when a bank other than Bank 1 is selected. (See Section 4.
Chapter 4: System Setup and Wiring enFORCE Operation Manual 4.7.2 Input and Output Ｈ／Ｗ Recommended Connecting Circuit Ｉ／ＯConnector All enFORCE inputs and outputs are active true low. All interface devices must accommodate active true low connection (NPN) for correct operation. When an input card with high input resistance is used, it may not normally receive OUT DATA signals depending on the external environment and other conditions.
Chapter 4: System Setup and Wiring 4.7.3 ♦ enFORCE Operation Manual Input and Output Signal Explanation Input Signals Inputs are sourced (normally high) and activated when pulled low (0VDC). START：Cycle Start signal (Normally Open) The unit reads the WORK SELECT signal and SELF-CHECK signal at the start (“OFF”-> “ON”) of this signal and starts pressing. This signal must be maintained until the cycle is complete. The press unit will be in BUSY (in cycle) status after start of press.
Chapter 4: System Setup and Wiring enFORCE Operation Manual WORK SELECT 0 thru 4: Parameter Select signal (Normally Open) These 5 inputs [WORK SELECT 1-4] form a binary code which is capable of selecting up to 32 different sets of press parameters. *Allow at least 10ms from the time this signal is turned on before turning on the START signal. Do not turn this signal off at least until BUSY goes “HIGH”. WORK WORK WORK WORK WORK Param MANUAL mode SELECT 4 SELECT 3 SELECT 2 SELECT 1 SELECT 0 No.
Chapter 4: System Setup and Wiring ♦ enFORCE Operation Manual Output Signals Outputs are rated at +12~24VDC, 200ma. When activated, open collector sink outputs (normally high) pull the input device low (0VDC). OUTPUT BANK 1: Bank0 – Off / Bank1 - Off REJECT: [OUT DATA7] Press REJECT (NG) Signal Output when the press result exceeds the press limits. This signal turns on just before BUSY goes “LOW”. Output remains active until the start or reset signal is input.
Chapter 4: System Setup and Wiring enFORCE Operation Manual TIMING SIGNAL: [OUT DATA9] (Special Function) This signal is active if Parameter 00-0A (Option Output Signal) is set to a number other than 0. When activated, D-No. 30, 31, 32 and 33 of Parameters 1~32 will be used to set ON and OFF limits for the Timing Signal.
Chapter 4: System Setup and Wiring enFORCE Operation Manual OUTPUT BANK 2: Bank0 – On / Bank1 - Off WORK SELECT 4: [OUT DATA3] Work Select 4 Input Echo Signal Output when the WORK SELECT 4 input is high (On). WORK SELECT 3: [OUT DATA4] Work Select 3 Input Echo Signal Output when the WORK SELECT 3 input is high (On). WORK SELECT 2: [OUT DATA5] Work Select 2 Input Echo Signal Output when the WORK SELECT 2 input is high (On).
Chapter 4: System Setup and Wiring enFORCE Operation Manual 4.7.4 Operation Timing Chart Automatic Mode Timing to set the START signal When the START or RESET OFF, it is voluntary if the BUSY is signal is turned ON the ACCEPT OFF. and REJECT signals turn OFF.
Chapter 4: System Setup and Wiring enFORCE Operation Manual 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.
Chapter 4: System Setup and Wiring enFORCE Operation Manual 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 Disabled The speeding up and slowing down is done rapidly. It is used to gain cycle time, etc.
Chapter 4: System Setup and Wiring enFORCE Operation Manual 4.9 MON. Signal (External Monitor Signal) This auxiliary connector is used to output Load, Position, Current and Speed signals to external equipment for monitoring purposes. This connection is not required for the system to operate. enFORCE outputs 1 digital pulse per 0.1mm moved distance and press proportionate to load by the MON>OUT connectors.
Chapter 4: System Setup and Wiring enFORCE Operation Manual 4.10 RS485 Interface Connection The enFORCE system communication is performed via the RS485 port. These ports are provided to link each SAN Unit together by “jumpering” from one controller to the next or for connecting to a PC equipped with DSP User Console software. Both connectors are identical and are internally connected. There is no order (upper or lower connection) in how the cables must be connected from SAN Unit to SAN Unit.
Chapter 4: System Setup and Wiring enFORCE Operation Manual 4.11 Firmware Flash Connector (CN8) Upgrades or revisions to Firmware are handled easily with the on board Flash connector located on the bottom of each SAN Unit. There is no need to remove or disassemble the unit. A Flash adapter (SAN-ROM) containing the new firmware can be connected to connector CN8 with the power off to the unit. The power is then cycled on and off with the adapter in place and the firmware is automatically updated.
Chapter 4: System Setup and Wiring enFORCE Operation Manual 4.12 Cable Installation Guidelines Improper installation of cables can reduce cable life expectancy drastically. The following guidelines should be used when installing cables. • The cables must be prepared for installation without twists, bends or kinks. Upon unpacking the cables, any tie wraps used in shipping should be removed.
Chapter 4: System Setup and Wiring enFORCE Operation Manual 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.
Chapter 4: System Setup and Wiring enFORCE Operation Manual 4.13 Tool Connections Tools are connected to the SAN controller using three or four cables. The first cable connects to the Load Cell Force Transducer preamp. Second is a combination Motor / Resolver Cable. The third cable connects the position proximity switches for home and advanced position indication. A fourth cable is for an external brake if ordered.
Chapter 4: System Setup and Wiring enFORCE Operation Manual 4.14 Maintenance Lock Option Reference Circuit Diagram #1 This circuit not recommended when a significant load is attached to the press ram. Reference Circuit Diagram #2 Maintenance Lock Unit: Permanent Magnet type - Lock normally engaged Power Requirements: RM1 ~ RM3 Motor RM4H Motor RM5 Motor 24VDC, 0.5 Amps 24VDC, 0.8 Amps 24VDC, 1.
