enFORCE Digital Servo Press DSP1500 (SAN3) SYSTEM OPERATION MANUAL FIRST Edition SECOND Edition June 2003 July 2005 Automation Systems 51327 Quadrate Drive Macomb, MI. 48042 Web: www.fec-usa.com Phone: (586) 781-2100 Fax: (586) 781-0044 E-mail: sales@fec-usa.
**WARNING** All applicable national and local codes must be followed when installing and operating the equipment detailed in this manual. FAILURE TO ABIDE BY THESE CODES AND THE SPECIFICATIONS DESCRIBED IN THIS MANUAL CAN RESULT IN SERIOUS INJURY TO PERSONNEL AND/OR DAMAGE TO THE EQUIPMENT. WARNING THIS EQUIPMENT IS CAPABLE OF HIGH PRESS FORCE & VOLTAGES HAZARDOUS TO HUMAN LIFE. DO NOT operate the press WITHOUT all safety guards and/or devices in place and operational.
Revisions Revised date Revision History 06/2003 enFORCE DSP1500 (SAN3) First Edition 07/2005 enFORCE DSP1500 (SAN3) Second Edition
Table of Contents Chapter 1: 1.1 1.2 1.3 1.4 Outline About this Operation Manual ..…..………………………………………………1-2 Features ………………………………………………………………………….. 1-3 Safety Precautions …. ………………………………………………………….. 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 ..……………………..
Table of Contents 4.11 Firmware Flash Connector....…………………………………………..……….. 4-22 4.12 Cable Installation Guidelines...………………………………………………….. 4-23 4.12.1 Considerations for Cable Trolleys …………………………………………. 4-24 4.12.2 Considerations for Flexible Cable Track ………………………………….. 4-24 4.12.3 Considerations for Cable Trays & Ladders ……………………………….. 4-24 4.13 Tool Connections ………………………………………………………………… 4-25 4.14 Brake Option ……………………………………………………………………… 4-26 Chapter 5: 5.1 5.
Table of Contents Chapter 7: Maintenance & Inspection 7.1 Inspection Items…….. ………………………………………………………….. 7-2 7.1.1 Press Tool ……………………………………………………………………. 7-2 7.1.2 Press Fixture…………………………………………………………………. 7-2 7.1.3 Homerun Cables…………………………………………………………….. 7-2 7.1.4 SAN Unit……………………………………………………………………….7-3 7.1.5 Air Handling Unit…………………………………………………………….. 7-3 7.2 Basic Operational Tests..……………………………………………………….. 7-4 7.2.1 Load Cell……………………………………………………………………… 7-4 7.2.2 Resolver……………………………………………………………………… 7-4 7.
Table of Contents Appendix A: Reference Drawings Power Wiring Reference - AC…..…………………………………………………….. A-2 PLC I/O Wiring Reference – Allen Bradley (SLC)………………….………………. A-3 PLC I/O Wiring Reference – Omron...…………………………………………..…… A-4 PLC I/O Wiring Reference – Mitsubishi................................................................. A-5 PLC I/O Wiring Reference – GE 90-30……….……………….…………………….. A-6 PLC I/O Wiring Reference – Modicon 984…………………………………………… A-7 SAN Unit Connection Reference……………………………..
Chapter 1: Outline Page １－1
Chapter 1: Outline enFORCE Operation Manual 1.1 About this Operation Manual This manual details the configuration, specifications and the operation of the enFORCE Digital Servo Press System. The following table outlines the contents of each chapter. Title Chapter Contents 1 Outline Basic characteristics and requirements of the enFORCE System. 2 Specifications General specifications of the enFORCE System. 3 System Description Description of SAN Unit and Tools and their instructions.
Chapter 1: Outline enFORCE Operation Manual 1.2 Features enFORCE is a Digital Servo Press System designed for use in both pressing and bonding applications in a low cost package. The system is a culmination of over twenty years of servo motor expertise based on our electric fastening system integrated with the latest digital servo technology. ☆ Compact Design As the result of miniaturization circuit technology, the compact units maintain a maximum width of 123.
Chapter 1: Outline enFORCE Operation Manual 1.3 Safety Precautions To ensure the most effective and extended use of all equipment, adhere to the following precautions: ¾ 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.
Chapter 1: Outline enFORCE Operation Manual ¾ 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.
Chapter 1: Outline enFORCE Operation Manual SAN3-24S SAN3-120S Page １－6
Chapter 2: Specifications PAGE ２－1
Chapter 2: Specifications 2.1 enFORCE Operation Manual System Specifications Power Supply Voltage 180VAC ~ 242VAC, 3 phase, 50/60Hz Operating Conditions Temperature: Humidity: Operating Range Duty Cycle less than 60% Storage Conditions Temperature: Humidity: -5 ~ 55℃ (23 ~ 131℉) Below 90%, no condensation Shipping Conditions Temperature: Humidity: -5 ~ 55℃ (23 ~ 131℉) Below 90%, no condensation Press Accuracy From 1/2 to full scale - 3σ less than 3% scatter of target load.
Chapter 2: Specifications enFORCE Operation Manual 2.2 SAN Unit Specifications 32 bit RISC (Reduced Instruction Set CPU) RS485 (2 Ports) – 1 for DSP User Console Software Flash ROM CPU: Data Communication: Parameter / Firmware Storage: SAN Unit Type SAN3 - 24S Motor Type SAN Unit Input Power SAN Unit Frequency MAX.
Chapter 2: Specifications enFORCE Operation Manual 2.2.2 SAN Unit Dimensions SAN3-24S, SAN3-40S Mounting: Top Bottom Weight: SAN3-24S SAN3-40S 1 place 2 places - #8-32 screw #8-32 screw 1.4 kg 1.8 kg Note: The diagram shown above reflects dimensions for the SAN3-40S. The SAN3-24S does not have a heat sink plate so the width is 60mm as opposed to 74mm.
Chapter 2: Specifications enFORCE Operation Manual SAN3-120S Mounting: Top Bottom 2 places #8-32 screw 2 places #8-32 screw Weight: SAN3-120S - 3.6kg.
Chapter 2: Specifications 2.3 enFORCE Operation Manual 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 (A) PRESS FORCE 050=50kg 151=1.5ton 202=20ton (B) MOTOR 1 = RM1A 2A = RM2A 3 = RM3A 4H = RM4HB (B=INTERNAL BRAKE) 5 = RM5B, RM5 (B=INTERNAL BRAKE) (C) STROKE 15 = 150mm 25 = 250mm (D) PRESS TYPE F = PRESSING (Holding time <1sec.) P = BONDING (Holding time >1sec.
Chapter 2: Specifications enFORCE Operation Manual 2.3.
Chapter 2: Specifications enFORCE Operation Manual 2.3.3 Tool Dimensions Drawing Shown For Reference Only TOOL NUMBER STROKE DPT-021R1-**F 150 DPT-051R2A-**F 250 DPT-101R3-**F 250 DPT-101R4H-**P 250 DPT-151R3-**F 250 DPT-201R3-**F 250 DPT-301R4H-**F 250 DPT-501R4H-**F 250 DPT-501R5B-**P 250 DPT-701R4H-**F 250 A 430 665 690 740 690 690 744 885 885 885 B 60 85 110 110 110 110 128 152 155 155 C 126 160 205 221.
Chapter 2: Specifications enFORCE Operation Manual 2.4 Functions • Pressing Function The following press control methods can be selected for the enFORCE System. 1. 2. 3. 4. 5. 6. 7. 8. Load Control Distance Control Specified Point Load Judgment / Load Inflection Detect Time Controlled Press Load Drop Detection Specified Distance Peak Load Detection Load Drop Detection (Point Stop) Distance Control with Load Limit Load, Distance, Press Rate and Time can be monitored in any configuration.
Chapter 2: Specifications enFORCE Operation Manual PAGE ２－10
Chapter 3: System Description PAGE ３－1
Chapter 3: System Description 3.1 enFORCE Operation Manual System Block Diagram ♦ The enFORCE system can consist of a stand alone unit or combined in a multiple press configuration. Discrete 24VDC (Sinking) I/O on the SAN unit provides direct communication with the PLC for individual or multiple press control. In a multiple press configuration, SAN units can perform synchronous pressing using the SYNC signal.
Chapter 3: System Description enFORCE Operation Manual 3.2 DSP1500 Front Panel (enFORCE Controller) 3.2.1 DSP1500 Front Panel Switches and Connectors ＤＳＰ１５００ CON1 SW1 POWER CON1: For Display Unit (SAN-DP*S) connection. SW1: Sets press number and special configuration features.（See Section 4.8） RUN/BYPASS: RUN: BYPASS: Controller Enable/Disable switch. Enable Bypass Mode（Disable） RS485: Bi-directional Communication ports. RESOLVER: Resolver connection for tool Motor/Resolver cable. MON.
Chapter 3: System Description enFORCE Operation Manual 3.2.2 DSP1500 Front Panel Condition Display LED’s ＤＳＰ１５００ POWER LED (Yellow) Lights when 180~242VAC input power is applied to the controller. CON1 SW1 POWER BUSY SV. BYPASS RUN BUSY LED (Orange) Lights up when in cycle Blinks when returning Blinks when running in MANUAL Lights up when powering on and initializing ABN. ACC. REJ . RS 485 SV. [SERVO] LED (Red) Lights up when a servo amplifier fault condition exists. ABN.
Chapter 3: System Description enFORCE Operation Manual 3.2.3 DSP1500 Detachable Keypad Buttons START MANUAL CAL ( SEARCH) RESET Operating Button START Button MANUAL Mode Button CAL Manual Button RESET Button DATA DSP1500 D-NO PARM MODE DATA SET ( HOME) BYPASS RUN Data Display / (Operating) Button MODE Button SET Button（Home Return） DATA UP Cursor Button（Manual Return） DATA DOWN Cursor Button (Manual Advance) ABN. ACC. REJ . RS 485 RESOLVER MON.
Chapter 3: System Description enFORCE Operation Manual 3.2.4 DSP1500 Detachable Keypad Condition Display START MANUAL CAL ( SEARCH) RESET DATA Display (4 figure) Data Display (Load, Distance, etc.） DATA PARM Display (2 figure) Parameter Number Display Or Abnormal Number Display DSP1500 D-NO PARM MODE DATA SET ( HOME) BYPASS RUN D-NO Display (2 figure) Data Number Display Press Unit Number Display Or Abnormal Sub-Code Number Display ABN. ACC. REJ . RS 485 RESOLVER MON.
Chapter 3: System Description enFORCE Operation Manual 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.
Chapter 3: System Description enFORCE Operation Manual 3.4 Connection Diagram Controller Tool TO PLC OR I/O DEVICE CON1 BRAKE BRAKE CABLE MOTOR ※ CCW *ORG RESOLVER RES. RS485 RESOLVER RS485 CONNECT TO COMPUTER, PC OR NEXT SAN UNIT LOAD CELL CABLE PREAMPLIFIER MON MOTOR T/D MOTOR CABLE CW PLC AC 200-220V CONNECT TO PLC OR I/O DEVICES INPUT POWER CABLE 3 PHASE 180-242VAC 50/60Hz I/O & LIMIT SENSOR CABLE LOAD CELL CABLE *ORG Connection is for special applications.
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 4.4 enFORCE Operation Manual 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 4.6 enFORCE Operation Manual 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 – NEAR ORG/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 *See “4.7.4 Synchronization” for SYNC signal connections. All enFORCE inputs and outputs are active true low. All interface devices must accommodate active true low connection (NPN) for correct operation. When an input card with high input resistance is used, it may not normally receive OUT DATA signals depending on the external environment and other conditions.
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.
Chapter 4: System Setup and Wiring enFORCE Operation Manual ♦ Output Signals Outputs are rated at +12~24VDC, 200ma. When activated, open collector sink outputs (normally high) pull the input device low (0VDC). OUTPUT BANK 1: Bank0 – Off / Bank1 - Off REJECT: [OUT DATA7] Press REJECT (NG) Signal Output when the press result exceeds the press limits. Output remains active until the start or reset signal is input.
Chapter 4: System Setup and Wiring enFORCE Operation Manual TIMING SIGNAL: [OUT DATA9] (Special Function) This signal is active if Parameter 00, D-No. 0A (Option Output Signal) is set to a number other than 0. When activated, D-No. 30, 31, 32 and 33 of Parameters 1~32 (normally Rate 1 and Rate 2 limits) will be used to set ON and OFF limits for the Timing Signal.
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 Synchronized Press Operation SYNC: Synchronized Press Signal For using multiple numbers of press units, connect parallel with SYNC common.
Chapter 4: System Setup and Wiring 4.7.5 enFORCE Operation Manual Operation Timing Chart Timing to set the START signal OFF, it is voluntary if the BUSY is Automatic Mode OFF. OFF STOP ON ON READY OFF ON RESET OFF ON START OFF Condition Operating Operating ON BUSY OFF ON ACCEPT OFF ON REJECT Above 10ｍｓ OFF ON ABNORMAL OFF WORK SELECT Parameter select fixed Parameter select fixed 0～4 MANUAL Mode ON MANUAL OFF ON START OFF ON WORK SEL. 0 OFF ON WORK SEL.1 OFF ON WORK SEL.
Chapter 4: System Setup and Wiring enFORCE Operation Manual 4.8 SW1 - Axis Unit Number Setting In a multiple SAN Unit system, it is necessary to address each unit for communication purposes. The number is set with the front DIP switch (4 thru 8) of the SAN Unit. If the display unit is installed, it must be removed to access the DIP switches. No two units can share the same number. However, units may be skipped or started from a number besides one.
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 4.11 enFORCE Operation Manual 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 Brake Option Reference Circuit Diagram Brake Unit: Permanent Magnet type - Brake normally engaged Power Requirements: RM1 ~ RM4 Motor RM5 Motor (Internal Brake) RM5 Motor (External Brake) 24VDC, 0.5 Amps 24VDC, 0.7 Amps 24VDC, 1.2 Amps In the example circuit above, the brake is disengaged (ON) while the motor is rotating because the BUSY signal is output. Once Origin has been defined (Org.
Chapter 5: Power Up & Initial Checks PAGE ５－1
Chapter 5: Powering Up and Initial Checks enFORCE Operation Manual WARNING DO NOT operate the press WITHOUT all safety guards and/or devices in place and operational. NEVER enter the press ram area with power applied to the press unit. Follow Lockout/Tagout and other safety precautions when performing maintenance or connecting / disconnecting cabling, wiring, and equipment. There is a possibility of receiving an electrical shock from this equipment, if used improperly. 5.
Chapter 5: Powering Up and Initial Checks enFORCE Operation Manual • Check the Input Voltages (2.1, 4.4) Verify that the Input Power Connector is properly wired and that the voltage to be applied is within the specified range. Verify that the 24VDC and 0VDC common wires are properly connected. Damage may occur if wired improperly. Be sure to check the previously mentioned items before turning the power on.
Chapter 5: Powering Up and Initial Checks 5.2 enFORCE Operation Manual Initial Data Setting (Display Module Required) After the previous items have been completed, turn on the power supply and then verify that the necessary parameter data required for pressing has been entered and is correct (IE: distance, load, speed, etc). To perform these checks, the following signals from external control equipment (PLC, selector switch, etc) to the SAN unit must be set. STOP signal must be set high.
Chapter 6: System Operation PAGE ６－1
Chapter 6: System Operation enFORCE Operation Manual 6.1 Display and Programming Unit (DP*S) An optional detachable display / programming unit is available for the SAN Unit. The display unit allows the viewing of press results as well as viewing / programming of press parameters if the optional DSP software is not being used. The DP1S & DP2S are for the SAN3-24S/40S and the DP3S & DP4S are for the SAN3-120S.
Chapter 6: System Operation enFORCE Operation Manual 6.1.1 DP2S & DP4S Serial Connection Connector: DB-9P (Male) Mating Connector: DB-9S (Female) PIN No. Signal 1 Signal Description Not Used 2 ＲＸＤ Not Used 3 ＴＸＤ Output data for printer 4 ＤＴＲ ON output (always) 5 ＧＮＤ 6 Signal ground 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.
Chapter 6: System Operation enFORCE Operation Manual 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 SAN –DP2S/SP4S installed. Use SAN –IF unit if you want to output multiple results.
Chapter 6: System Operation enFORCE Operation Manual Data format when the judgment is a REJECT 1 2 3 4 5 6 7 8 COUNT Number 30H ０ 17 31H １ 33 20H 49 30H 30H ０ ０ 18 31H 20H １ 19 20 PEAK LOAD 32H 2EH 33H ２ ． ３ 34 35 36 FINAL LOAD 21 22 23 24 Judg ment 34H 20H 20H 20H ４ 37 38 33H 20H ３ 50 53 30H 2EH 31H 32H ０ ． １ ２ 65 10 11 Axis Number 20H 20H 20H 30H 31H 20H ０ １ 31H 2EH 32H １ ． ２ 51 52 2ND RATE 66 67 68 2ND TIME 20H 20H 9 39 40 25 54 55 56 Judg ment 33H 20H 20H 20H ３ 13 14 PARM Numbe
Chapter 6: System Operation enFORCE Operation Manual 6.2 Function of Display and Operating Panel Manual Operation Buttons [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.
Chapter 6: System Operation enFORCE Operation Manual 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.
Chapter 6: System Operation enFORCE Operation Manual 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 Press Condition Display until the end of cycle. At that time the display switches to the Press Result Display Mode.
Chapter 6: System Operation enFORCE Operation Manual 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 [Press Condition Display] is displayed.
Chapter 6: System Operation 6.3.4 Real Time Display Mode enFORCE Operation Manual D-NO: 1 figure The following data is displayed on the screen in the Real Time Display Mode. The [D-NO] changes by pressing the [↑] and [↓] buttons.
Chapter 6: System Operation enFORCE Operation Manual 6.3.5 Press Result Display Mode D-NO：left side figure The following is displayed on the screen in the Press Result Display Mode. The [D-NO] changes by pressing the [↑] and [↓] buttons.
Chapter 6: System Operation 6.3.6 Parameter Display Mode enFORCE Operation Manual D-NO: 2 figure display The following data is displayed on the screen in the Parameter Display Mode. By pressing the [↑] and [↓] buttons, the [D-NO] changes and the value of the data number is displayed in the [DATA] area. If [↓] is pressed at the first data number of each parameter number, [PARM] parameter number will decrement by 1.
Chapter 6: System Operation enFORCE Operation Manual Item System Tool Data Tool Type Load Distance Rate Time Speed Special Setting Parameter Number PARM ００ ００ ００ ００ ００ ００ ００ ００ ００ ００ ００ ００ ００ ００ ００ ００ ００ ００ ００ ００ ００ ００ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ ０１～３２ Data Number DNo ００ ０１ ０２ ０３ ０４ ０５ ０６ ０７ ０８ ０９ ０Ａ ０Ｂ ０Ｃ ０Ｄ ０Ｅ ０Ｆ １０ １１ １２ １３ １
Chapter 6: System Operation 6.3.7 enFORCE Operation Manual Operating Condition Display Speed conditions are shown on the display when in operation.
Chapter 6: System Operation enFORCE Operation Manual 6.3.
Chapter 6: System Operation enFORCE Operation Manual 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.
Chapter 6: System Operation enFORCE Operation Manual 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).
Chapter 6: System Operation enFORCE Operation Manual 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.
Chapter 6: System Operation enFORCE Operation Manual 6.4.
Chapter 6: System Operation enFORCE Operation Manual Organization of Parameter 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] Bank Select Enable SP Version Manual Speed Preamp Version Tool Type No Load Current Special Settings, etc. Parameter Parameter Parameter Parameter Parameter Parameter 5 4 3 2 1 Full-Scale Load Minimum Load Maximum Load Target Load . . .
Chapter 6: System Operation enFORCE Operation Manual 6.4.5 Data Number Definitions 6.4.5.1 System Parameter: Parameter Number 0 0 ¾ Data Number 0 0 Load Unit 0: Load Unit [KN] * Fixed to 0. No changes can be made. ¾ Data Number 0 1 S P Version This is the Unit Software Version. No changes can be made. However, the [DATA] fields are made available for Parameter Copying.
Chapter 6: System Operation ¾ Data number 0 8 □ □ □ enFORCE Operation Manual Near Origin Sensor Availability／Bank Select Enable □ 0: No Near Origin sensor (Default) 1: Near Origin sensor attached (on presses 10 ton and larger) 2: Bank Select enable (enable output signal banks 2 & 3) 0: Enable Distance High Limit Stop (Default) 1: Disable Distance High Limit Stop 0: 0.1mm distance sampling 1: 0.01mm distance sampling 2: 0.
Chapter 6: System Operation enFORCE Operation Manual ¾ Data Number 0 B Free Run Distance Limit／Load Transducer Availability This data field sets the maximum free run distance and availability of the load transducer. □ □ □ □ Load Transducer Availability 0: With Load Cell 1: Without Load Cell Free Run Distance Limit If you set 200, the free run distance will be up to 200mm. *Example: If the load transducer is available and the free run distance limit is 200mm, the setting will be 2000.
Chapter 6: System Operation enFORCE Operation Manual ¾ Data Number 2 0 Tool Number The connected tool number is set from the following tool table. Tool Number 30 44 31 32 33 43 34 42 35 40 41 37 38 39 9 13 14 16 17 47 Tool Number Maximum Load [KN] DPT-021R1-**F 1.96 DPT-021R2A-**F 1.96 DPT-051R2A-**F 4.90 DPT-101R3-**F 9.81 DPT-151R3-**F 14.70 DPT-201R3-**F 19.60 DPT-301R4-**F 29.40 DPT-301R4H-**F 29.40 DPT-501R4-**F 49.00 DPT-501R4H-**F 49.00 DPT-701R4H-**F 68.60 DPT-102R5-**F 98.00 147.
Chapter 6: System Operation enFORCE Operation Manual 6.4.5.2 Work Parameters: Parameter Number 0 1 to 3 2 Load Settings Rate Settings Speed Settings Distance Settings Time Settings Special Settings ¾ Data Number 0 0 Operation Mode（Operation Method＋Operation Step＋ Operation Finish Mode） This data field will set the operation method, operation step and operation finish mode.
Chapter 6: System Operation enFORCE Operation Manual Operation Methods ♦ Load Control (Method 0) Upon start of cycle, the press will operate until it achieves [13: Standard Load]. During the press cycle, checks are performed for “1ST Judgment Zone”, 1ST Rate, 2ND Rate, Load, Distance, 1ST Time and 2ND Time. If any of these values are compromised, the press will stop and return as programmed. (See corresponding sections for Time, Rate, 1ST Zone and Speed explanations.
Chapter 6: System Operation enFORCE Operation Manual ♦ Distance Control (Method 1) Upon start of cycle, the press will operate until it achieves [22: Standard Distance]. During the press cycle, checks are performed for “1ST Judgment Zone”, 1ST Rate, 2ND Rate, Load, Distance, 1ST Time and 2ND Time. If any of these values are compromised, the press will stop and return as programmed. (See corresponding sections for Time, Rate, 1ST Zone and Speed explanations.
Chapter 6: System Operation enFORCE Operation Manual ♦ Specified Point Load Judgment (Method 2 – Type 1) This Load Control press method allows judgment of a load (PS) at a given distance [13: Standard Distance]. Type 1 Control is active if [22: Standard Distance] is set to a number other than 0. Upon start of cycle, the press will operate until it achieves [13: Standard Load]. During the press cycle, checks are performed for “1ST Judgment Zone”, 1ST Rate, 2ND Rate, Load, Distance, 1ST Time and 2ND Time.
Chapter 6: System Operation enFORCE Operation Manual ♦ Load Rise Detection (Method 2 – Type 2) This Load Control press method allows judgment of a distance (DS) at a given load [18: Crossover Load] and press rate [33: Rate 2 High]. Type 2 Control is active if [22: Standard Distance] is set to 0. Upon start of cycle, the press will operate until it achieves [13: Standard Load].
Chapter 6: System Operation enFORCE Operation Manual ♦ Time Controlled Press (Method 3) This Load Control press method allows a pressing operation to be performed based off of a given time [42: 2ND Time]. Upon start of cycle, the press will operate until it achieves [13: Standard Load].
Chapter 6: System Operation enFORCE Operation Manual ♦ Load Drop Detection (Method 4) This Load Control press method allows judgment of a load “drop off” or yielding point [63: Δ f]. Upon start of cycle, the press will operate until it achieves [13: Standard Load]. During the press cycle, as soon as [18: Crossover Load] is achieved, the press will begin looking for a yield in press force [63: Δ f]. The press will attempt to detect [63: Δ f] until [13: Standard Load] has been reached.
Chapter 6: System Operation enFORCE Operation Manual ♦ Specified Range Peak Load Judgment (Method 5) This Load Control press method allows judgment of a peak load (PS) at a certain distance (DS). Upon start of cycle, the press will operate until it achieves [13: Standard Load]. During the press cycle, as soon as [18: Crossover Load] is achieved, the press will begin looking for a peak in press force (PS). The press will attempt to detect (PS) until [24: Crossover Distance] has been reached.
Chapter 6: System Operation enFORCE Operation Manual ♦ Load Drop Detection – Point Stop (Method 6) This Load Control press method is similar to Method 3 (Load Drop Detection) except, once [63: Δ f] has been detected, the press will stop. The press will attempt to detect this value until it reaches [13: Standard Load]. During the press cycle, checks are performed for “1ST Judgment Zone”, 1ST Rate, Load, Distance, 1ST Time and 2ND Time.
Chapter 6: System Operation enFORCE Operation Manual ♦ Distance Control with Load Limit (Method 7) Upon start of cycle, the press will operate until it achieves [22: Standard Distance]. During the press cycle, after achieving [13: Standard Load], the press rate will be current controlled to hold [13: Standard Load] until [22: Standard Distance] is reached. During the press cycle, checks are performed for “1ST Judgment Zone”, 1ST Rate, 2ND Rate, Load, Distance, 1ST Time and 2ND Time.
Chapter 6: System Operation enFORCE Operation Manual Operation Steps 1 Step Operation Performs the series of operations without stopping. Distance value is counted from [16: SNUG Load] and, it will stop counting if it is less than SNUG Load. [16: SNUG Load] is automatically set to 0 for other control methods. 1 Step Operation (using Distance Control) The distance value will not be counted if the SNUG load is low.
Chapter 6: System Operation enFORCE Operation Manual 1 Step Operation - 1ST H/L Check At [23: 1ST Step Distance], the judging of an abnormally high or low load is possible. If a load value greater than [15: 1ST Step Load] is sensed before the press exceeds [23: 1ST Step Distance], a “1ST Rate Low” reject will occur and press operation will stop. Upon reaching [23: 1ST Step Distance], if [17: Threshold Load] has not been reached, a “1ST Rate High” reject will occur and press operation will stop.
Chapter 6: System Operation enFORCE Operation Manual Operation Finish Modes Return After both an ACCEPT or REJECT judgment, the press will move to the position set in [62: Return Position]. [ACCEPT] Return, [REJECT] No Return When the judgment is an ACCEPT, the press will move to the position set in [62: Return Position]. When the judgment is a REJECT, the press will stop and the load will be released.
Chapter 6: System Operation enFORCE Operation Manual ¾ Data Number 10 - Calibration Load The tool load value is set automatically when the tool type is selected. However, when 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.
Chapter 6: System Operation enFORCE Operation Manual ¾ Data Number 13 - Standard Load In Load Control Methods, this is the target load value. (Example: If Standard Load is 10KN, press will attempt to operate until 10KN is achieved.) A setting is possible from 0 to 105% of full-scale value. ¾ Data Number 14 - Speed Change Load The load value at which press speed will change to [53: Load Speed]. A setting is possible from 0 to 105% of full-scale value.
Chapter 6: System Operation enFORCE Operation Manual ¾ Data Number 15 [1ST Load] ¾ Data Number 23 [1ST Distance] Ending point of calculation of 1ST Rate. In a 2 step operation, ending of 1ST step. A setting is possible from 0 to 105% of full-scale value. [1ST Judgment] These two settings may be used together to detect foreign substances (early load). If the press reaches [15: 1ST Load] before exceeding [23: 1ST Distance], a “1ST Rate Low” reject will occur and press operation will stop.
Chapter 6: System Operation enFORCE Operation Manual ¾ Data Number 17 - Threshold Load The starting point of calculation of 1ST Rate. This also sets the “Low” value when using 1st Step Hi/Low check. A setting is possible from 0 to 105% of full-scale value. Load 1ST Rate１Maximum Rate１Minimum Threshold Distance If rate supervision is not needed, set Threshold to the Full Scale Load value. Threshold will not be detected, so rate supervision will not be performed.
Chapter 6: System Operation enFORCE Operation Manual ¾ Data Number 20 - Low Distance Limit ¾ Data Number 21 - High Distance Limit Minimum and maximum acceptable limits for [22: Standard Distance]. In Load Control, if [21: High Distance Limit] is reached before achieving [13: Standard Load], the press will stop. ¾ Data Number 22 - Standard Distance In Distance Control Methods, this is the target distance value.
Chapter 6: System Operation enFORCE Operation Manual ¾ Data Number 51 - Freerun Speed Higher speed value used for the “no-load” portion of the press operation. The press will run at this speed until [60: Freerun Distance], [24: Crossover Distance] or [14: Speed Change Load] is reached. Begins after [40: Initial Time] has passed. ¾ Data Number 52 - Slowdown Speed Slower speed value used to approach the part.
Chapter 6: System Operation enFORCE Operation Manual ¾ Data Number 62 - Return Position The press will go back to this position after operating. If a Return Operation is set and the Start signal goes low (OFF), the press will move to this position. ¾ Data Number 63 - Δ f It sets the load value for detecting force drop when the operation method is [Load Yielding Point] or [Load Yielding Point Stop]. A setting is possible from 0 to 105% full-scale value.
Chapter 6: System Operation enFORCE Operation Manual Step Press Operation 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 [18: Crossover Load] equal to the previous step’s [13: Standard Load]. Turn On the Self Check Off signal before starting each cycle.
Chapter 6: System Operation 6.5 enFORCE Operation Manual External LVDT Sensor In applications which require the use of an external sensor to measure when actual part contact is made and THEN determine what the final press distance would be, the use of an external LVDT is required. The enFORCE System allows external distance data to be input from an LVDT controller via an RS232 connection.
Chapter 7: Maintenance & Inspection PAGE ７－1
Chapter 7: Maintenance & Inspection 7.1 enFORCE Operation Manual 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.
Chapter 7: Maintenance & Inspection enFORCE Operation Manual 7.1.4 SAN Unit Recommended Schedule: Quarterly 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.
Chapter 7: Maintenance & Inspection enFORCE Operation Manual 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.
Chapter 7: Maintenance & Inspection enFORCE Operation Manual 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.
Chapter 7: Maintenance & Inspection enFORCE Operation Manual 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.
Chapter 7: Maintenance & Inspection enFORCE Operation Manual 7.2.3.2 Home Position Search Explanation ⑤ OFF Z 4096 0 ③ CCW LMT ② ④ 1000 3000 ① ON ④ ① 1. 2. 3. 4. 5. ⑤ ② ③ Press RAM moves in return direction. CCW Proximity Switch turns off. Press RAM moves in forward direction. CCW Proximity Switch turns on. Motor stops at the first time Z-phase is reached after CCW Proximity Switch turns on.
Chapter 7: Maintenance & Inspection enFORCE Operation Manual PAGE ７－8
Chapter 8: Troubleshooting PAGE ８－1
Chapter 8: Troubleshooting 8.1 enFORCE Operation Manual 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.
Chapter 8: Troubleshooting enFORCE Operation Manual 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.
Chapter 8: Troubleshooting enFORCE Operation Manual • 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.
Chapter 8: Troubleshooting enFORCE Operation Manual 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.
Chapter 8: Troubleshooting 8.4 enFORCE Operation Manual 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.
Chapter 8: Troubleshooting enFORCE Operation Manual 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.
Chapter 8: Troubleshooting enFORCE Operation Manual 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.
Chapter 8: Troubleshooting enFORCE Operation Manual 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.
Chapter 8: Troubleshooting 8.8 enFORCE Operation Manual Internal Errors [ A7_* ] • Code A7_0 - INTERNAL ERROR / INTERNAL POWER SUPPLY ABNORMAL The controller internal power supply circuit is not working properly. CAUSE: 1. The controller internal power supply has failed. 2. If the environment temperature is more than 122 degrees Fahrenheit (50 degrees centigrade). 3. Source voltage is very close to the limit (242 VAC) and the environment temperature is also close to the limit. RECOVERY: 1.
Chapter 8: Troubleshooting enFORCE Operation Manual 8.9 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.
Chapter 8: Troubleshooting enFORCE Operation Manual • Code A8_6 - SERVO AMPLIFIER ERROR / INPUT VOLTAGE ABNORMAL The SAN controller servo 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.
Chapter 8: Troubleshooting enFORCE Operation Manual 8.10 Parameter Errors [ A9_* ] • Code A9_0 - PARAMETER ERROR / MISSING SPEED PRESET. Some 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 speed presets are not <0> or out of the specified speed range of the tool.
Chapter 8: Troubleshooting enFORCE Operation Manual • 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 / MANUAL OR RETURN LOAD OVER. The Manual Load or the Return Load is more than 1/6 of the Full Scale Load. RECOVERY: 1.
Chapter 8: Troubleshooting enFORCE Operation Manual 8.11 Questions & Answers Q1: Does home position search have to be performed every time the power is turned on? A1: Yes. Home position search should also be performed after an abnormal has occurred. Q2: REJECT was output but the reason in unclear. A2: See “Operation 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.
Chapter 8: Troubleshooting enFORCE Operation Manual PAGE ８－16
Appendix A: Reference Drawings A-1
Appendix A: Reference Drawings enFORCE Operation Manual Power Wiring Reference A-2
Appendix A: Reference Drawings enFORCE Operation Manual PLC I/O Wiring Reference – Allen Bradley (SLC) A-3
Appendix A: Reference Drawings enFORCE Operation Manual PLC I/O Wiring Reference – Omron (CS1) A-4
Appendix A: Reference Drawings enFORCE Operation Manual PLC I/O Wiring Reference – Mitsubishi A1S A-5
Appendix A: Reference Drawings enFORCE Operation Manual PLC I/O Wiring Reference – GE 90-30 Series A-6
Appendix A: Reference Drawings enFORCE Operation Manual PLC I/O Wiring Reference – Modicon (984) A-7
Appendix A: Reference Drawings enFORCE Operation Manual SAN3 Unit Connection Reference A-8
Appendix A: Reference Drawings enFORCE Operation Manual enFORCE System Transformers A-9
Appendix A: Reference Drawings enFORCE Operation Manual Motor / Resolver Homerun Cable – (SAN3-24S, SAN3-40S) A-10
Appendix A: Reference Drawings enFORCE Operation Manual Motor / Resolver Homerun Cable – (SAN3-120S with RM4 Motor) A-11
Appendix A: Reference Drawings enFORCE Operation Manual Motor Homerun Cable – (SAN3-120S with RM5 Motor) A-12
Appendix A: Reference Drawings enFORCE Operation Manual Resolver Homerun Cable – (SAN3-120S with RM5 Motor) A-13
Appendix A: Reference Drawings enFORCE Operation Manual Load Cell (Pre-Amplifier) Homerun Cable – (SAN3-24S, 40S, 120S) A-14
Appendix A: Reference Drawings enFORCE Operation Manual Motor/Resolver Extension Cable – (SAN3-24S, SAN3-40S, SAN3-120S with RM4, also as SAN3-120S with RM5 Resolver Ext.
Appendix A: Reference Drawings enFORCE Operation Manual Motor Extension Cable – (SAN3-120S with RM5 Motor) A-16
Appendix A: Reference Drawings enFORCE Operation Manual Load Cell (Pre-Amplifier) Extension Cable – (SAN3-24S, 40S, 120S) A-17
Appendix A: Reference Drawings enFORCE Operation Manual SAN3-24S/40S Power Cable A-18
Appendix A: Reference Drawings enFORCE Operation Manual SAN3-120S Power Cable A-19
Appendix A: Reference Drawings enFORCE Operation Manual I/O Connection Cable A-20
Appendix A: Reference Drawings enFORCE Operation Manual I/O Proximity Switch Breakout Adapter A-21
Appendix A: Reference Drawings enFORCE Operation Manual Proximity Switch Homerun Cable A-22
Appendix A: Reference Drawings enFORCE Operation Manual Proximity Switch Tool / Extension Cable A-23
Appendix A: Reference Drawings enFORCE Operation Manual Brake Unit Homerun Cable A-24
Appendix A: Reference Drawings enFORCE Operation Manual Brake Unit Extension Cable A-25
Appendix A: Reference Drawings enFORCE Operation Manual External Brake Unit Cable A-26
Appendix A: Reference Drawings enFORCE Operation Manual RS-485 Jumper Cable A-27
Appendix A: Reference Drawings enFORCE Operation Manual RS-485 to RS-232 PC Converter Cable A-28
