6/05/2002 ULTRA EDGE SEQUENTIAL TABLE OF CONTENTS DESCRIPTION PAGE 1 INTRODUCTION ..................................................................................................................................... 3 2 THEORY OF OPERATION.................................................................................................................... 3 2.1 MECHANICAL ASSEMBLY........................................................................................................... 3 2.
6/05/2002 ULTRA EDGE SEQUENTIAL RECEIVING INSPECTION BEFORE REMOVING UNIT FROM ITS PACKAGING, CHECK FOR VISUAL DAMAGE, ESPECIALLY IF CRATE, SKID, OR CARTON HAS BEEN DAMAGED IN TRANSIT. ANY DAMAGE CAUSED IN SHIPMENT SHOULD BE IMMEDIATELY REPORTED TO THE CARRIER. IF UNIT APPEARS IN SATISFACTORY CONDITION, REMOVE ALL PACKING AND WIPE RUST PREVENTIVE FROM ROLLERS WITH MILD SOLVENT.
6/05/2002 ULTRA EDGE SEQUENTIAL All Ultra Edge Sequential controls are conveniently located on the front side of the electrical enclosure 2.3 CONTROL/DEVICE DESCRIPTION Power On/Reset button Turns controller on, resets the servo drive. In Position indicator light, white Turns on when move is complete and motor is holding position. Cycle Start illuminated button, green Puts controller into “Auto” mode from “Manual” mode, starts Auto cycling.
6/05/2002 ULTRA EDGE SEQUENTIAL Example: If a feed pitch/length of 11.138 inches is entered into the feeder, this will result in exactly one revolution of the feed rolls. The motor will accelerate and turn 2.909 turns. This will produce (2.909 x 1048576 = 3050307) pulses of the encoder. The feeder will decelerate and stop, when 3050307 pulses are detected. The feeder is now in position. The result is an accurately positioned strip exactly 11.138 inches from its starting point.
/05/2002 ULTRA EDGE SEQUENTIAL P/A Industries Really Cool Feed Version 1.10 SEQ Hit any key to cont. NOTE: The OPERATOR terminal has five mode keys, they are: ● “OPER” ● “TOOLS” ● “SETUP” ● “F1” ● “F2” NOTE: ▓ The flashing cursor is waiting for the value to be entered. NOTE: < The pointer prompts to press the “ENTER” key. NOTE: To confirm any ENTRY, press “ENTER”. 3.1 “OPER” KEY “OPER” key controls toggles between two screens: FEED STATUS screen and OPERATOR screen.
6/05/2002 ULTRA EDGE SEQUENTIAL • Current mode of the feed • Batch Count, current and total OPERATOR screen shows Batch Count parameter and Step Status command and allows editing batch count: Count Cont.Run Step Status < Press OPER to exit Count is the number of cycles that should be performed. It is a numeric entry with a range of 0 to 9999999. Entering “0” will result in a continuous run.
6/05/2002 ULTRA EDGE SEQUENTIAL NOTE: Tool number can contain up to seven digits. If “Activate Tool” operation is chosen, then the desired tool will be activated and a message will be displayed for a few seconds: Tool Activated The display will then show the FEED STATUS screen. Tool#1 Spd:384 Auto Mode 30 / Cont.
6/05/2002 ULTRA EDGE SEQUENTIAL Length is a distance in inches (or millimeters) of the “Feed Length”. It is a numeric entry with a range of 0 to the 999999. Gags is a combination of the outputs that are activated (fired) at the step. It is a binary entry. Five digits represent five outputs, starting from the right, 0 represents inactive output, 1 - active. T#1 S#1 /24 Repeat 2 Exit editing < TOOLS-next BKSP-Prev Repeat is the number of times the step must be repeated.
6/05/2002 ULTRA EDGE SEQUENTIAL T#1 30 Auto Mode / Cont.Run Press a Mode Key If saving is skipped, then the next screen allows deleting the tool being edited. Press “TOOLS” to open it. Press the “ENTER” key, the warning message will be displayed, press “1” key to confirm deleting or any key to abort. T#1 Delete Tool < TOOLS-next BKSP-Prev Delete Tool#1 Press 1 to confirm Another key to abort The corresponding message on the next screen confirms the chosen command execution.
6/05/2002 ULTRA EDGE SEQUENTIAL Add Step < Delete Step Insert Step Press F1 for next Position the cursor on desired line, using “↑” and “↓” keys and press the “ENTER” key. Press “F1” to open the next screen. Press “ENTER” key to perform a step copy.
6/05/2002 ULTRA EDGE SEQUENTIAL The Insert command allows a step to be placed before or after the current step. T#1 S#20 /24 Length 60.000 Gags 00011 Press TOOLS for next Press F1, then position the cursor next to Insert Step command and press Enter key: Add Step Delete Step Insert Step < Press F1 for next Position the cursor next to desired command and press Enter key: Insert Step Before Step 20 < After Step 20 Press BKSP for prev.
6/05/2002 ULTRA EDGE SEQUENTIAL 3.4 “SETUP” KEY “SETUP” key controls the appearance of setup screens. Seven screens contain parameters of the feed that are not changed often or are never changed. Press “SETUP” key three times to open the first screen. Position the cursor on the desired line, using “↑” and “↓” keys , enter in desired value and press the “ENTER” key. Press “SETUP” key to open the next screen or “ BKSP” – the previous. Speed 72.00 Accel 400.00 Decel 400.
6/05/2002 ULTRA EDGE SEQUENTIAL top position sensors/cam switches. When the material is fed, the Gag outputs are activated for the duration of Dwell time (must be long enough for the punches to go all the way down or the press to pass BDC-bottom dead center, meaning the press is running in its Single Stroke mode) Scale 7355.00 Direction (1/0) CW Debounce(ms) 1 SETUP-Next BKSP-Prev Scale is the encoder scaling parameter used to define the number of encoder counts/inch (or mm). It is a numeric entry.
6/05/2002 ULTRA EDGE SEQUENTIAL If any value is assigned for this parameter, the feed will move material back for the distance that equals Back Length when: -In the Press application, the cutter bottom position sensor turns on between the end of the Feed Cam signal and the beginning of the Reset Cam signal, while only one Gag output is active (fired) in the current step. -In the Punch application, the cutter bottom position sensor turns on within Dwell time and the Feed signal remains on.
6/05/2002 ULTRA EDGE SEQUENTIAL Position cursor next to desired parameter, enter appropriate value, and press the “ENTER” key. Press “TOOLS” key to open next screen. T#1 S#1 /1 Length 60.000 Gags 00011 Press TOOLS for next To save a newly created tool, position the cursor next to Exit editing command and press the “ENTER” key.
6/05/2002 ULTRA EDGE SEQUENTIAL Position cursor next to desired parameter, enter the new value, and press the “ENTER” key. T#1 S#1 /24 Length 60.000 Gags 00011 Press TOOLS for next T#1 S#1 /24 Repeat 2 Exit editing < TOOLS-next BKSP-Prev To navigate between multiple steps use “TOOLS” and “BKSP” keys to scroll or move the cursor to the first line, next to S#, enter the desired step number and press “ENTER” key. Press “F1” key to modify the existing tool using Add, Insert and Copy commands.
6/05/2002 ULTRA EDGE SEQUENTIAL 4.4 HOW TO INSERT A STEP BETWEEN OTHER STEPS Open the Tool for editing: T#1 S#1 /24 Length 60.000 Gags 00011 Press TOOLS for next Bring up the step before or after which you need to insert a new step and press “F1” key, T#1 S#16 /24 Length 60.000 Gags 00011 Press TOOLS for next position the pointer next to INSERT STEP command and press the “ENTER” key.
6/05/2002 ULTRA EDGE SEQUENTIAL Step copied! 4.6 HOW TO DELETE A STEP Open the Tool for editing: T#1 S#1 /24 Length 60.000 Gags 00011 Press TOOLS for next Bring up the step that is to be deleted press “F1” key, T#1 S#16 /24 Length 60.000 Gags 00011 Press TOOLS for next position the pointer next to DELETE STEP command and press the “ENTER” key. Add Step Delete Step < Insert Step Press F1 for next Delete Step 16 Press 1 to confirm Another key to abort Step 16 deleted! or Aborted! 4.
6/05/2002 ULTRA EDGE SEQUENTIAL Edit Tool < Activate Tool Create New Press TOOLS to Exit Enter the desired tool number or select it from the tool list using “↑” and “↓” keys and press the “ENTER” key again. Edit Tool# Arrow keys to scroll Press TOOLS to exit Edit Tool#1 Arrow keys to scroll Press TOOLS to exit Modify the existing tool and then choose Exit editing command and press the “ENTER” key. T#1 S#1 /24 Length 60.
6/05/2002 ULTRA EDGE SEQUENTIAL 4.8 HOW TO DELETE A TOOL NOTE: Make sure that the PROGRAMMING “LOCKED / UNLOCKED” key switch is in “Unlocked” position and FEED STATUS screen is displayed. If the current screen is not FEED STATUS one then press the “OPER” key to bring it up. Press “TOOLS” key, position the pointer next to EDIT TOOL command and press the “ENTER” key.
6/05/2002 ULTRA EDGE SEQUENTIAL Delete Tool#1 Press 1 to confirm Another key to abort Press “1” key. Tool#1 Deleted 4.9 HOW TO ACTIVATE A TOOL NOTE: Make sure that the PROGRAMMING “LOCKED / UNLOCKED” key switch is in “Unlocked” position and FEED STATUS screen is displayed. If the current screen is not FEED STATUS one then press the “OPER” key to bring it up. Press “TOOLS” key, position the pointer next to Activate tool command and press the “ENTER” key.
6/05/2002 ULTRA EDGE SEQUENTIAL Press “SETUP” key three times, position cursor next to desired parameter, enter in new value, and press the “ENTER” key. Speed 72.00 Accel 400.00 Decel 400.00 Press SETUP for next Press “OPER” key if editing is done or press “SETUP” key to open next screen. 4.11 HOW TO EDIT COUNT FROM OPERATOR SCREEN Locate the OPERATOR screen, position cursor next to the Count, enter new value, and press the “ENTER” key. Enter “0” for continuous run. Count Cont.
6/05/2002 ULTRA EDGE SEQUENTIAL - the current step carries only one Gag output assigned to the cutting device. If more than one Gag output gets fired, the feed will not make a backup move – it will proceed to the next step displaying an error message that will remain on the screen until Operator clears it out by pressing “ENTER” key: T#1 Auto Mode Step 32 Backup error Press a Mode Key The Back Length is compensated on the next move, so it has no affect on the Length parameter.
6/05/2002 ULTRA EDGE SEQUENTIAL 5.3 TROUBLESHOOTING GUIDE The chart that follows contains the most frequently encountered issues. Symptom Cause or Remedy No power indication when Power On button is pressed 1. 2. 3. 4. 5. No display on power up 6. Check the cabling connection between display and the servo drive. 7. Check 5 VDC power supply. 8. Check if IN POSITION indicator is off. Check parameters. Check drive for Error Codes. 9. Check the FAULT in display i.e. DRIVE FAULT # ABC.
6/05/2002 ULTRA EDGE SEQUENTIAL 5.4 ERROR CODES Error Code Problem or Symptom 04 Motor Over Temperature 05 IPM Fault 09 Bus Under Voltage 10 Bus Over Voltage 11 Illegal Hall State 20 Motor Encoder State Error Possible Cause(s) Action/Solution Motor thermostat trips due to: High motor ambient temperature, and/or Excessive RMS torque. Bad encoder cable or connection. Motor cables shorted. Motor winding shorted internally. Ultra5000 Servo drive temperature too high.
6/05/2002 ULTRA EDGE SEQUENTIAL Error Code Problem or Symptom Possible Cause(s) Action/Solution 21 Auxiliary Encoder state Error The auxiliary encoder encountered an illegal transition. 22 Motor Thermal Protection Fault 23 IPM Thermal Protection Fault The internal filter protecting the motor from overheating has tripped. The internal filter protecting the IPM at slow speed has tripped. 24 Excess velocity Error Velocity error limit was exceeded Use shielded cables with twisted pair wires.
6/05/2002 ULTRA EDGE SEQUENTIAL WARNING This equipment offers various means of operating or controlling machines. The operator must not be in or near the point-ofoperation of the machine, or the operating parts of any equipment installed on the machine, or bodily injury could result. The EMPLOYER must post adequate warning signs onto the machine with proper warnings for his machine and the specific application to which the machine and equipment are being applied.
