Coretec BS Series, BS100 Series, BS200 Series, BS-M3A-1B Instruction Manual

BS Controller for AC SERVO PRESS

BS Controller for AC SERVO PRESS Instruction Manual

Introduction

Request

Instruction Manual Ver1 .08 BS-M3A-1B

Thank you very much for purchasing our Servo press.

This manual describes the hardware scheme, installation procedures, connections,

running, operations, communication, status display and daily inspections.

Make sure to thoroughly understand the contents and use the product properly.

We have taken all possible measures to ensure the contents of this instruction

manual, however, please contact us if you have any questions or find any errors.

The product names, etc. are generally registered trademarks of various companies.

* To secure safety and quality, never fail to refer to this manual.

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BS Controller for AC SERVO PRESS

1. For safe use ................................................................................................................. 7

2. Before use .................................................................................................................. 11

3. Specifications .............................................................................................................13

4. Construction ..............................................................................................................16

5. Installation ................................................................................................................18

Instruction Manual Ver1 .08 BS-M3A-1B

Table of contents

1.1. Regarding symbols .................................................................................................. 7

1.2. Observe the following for safety ............................................................................. 7

1.3. Caution on attachment and use. .......................................................................... 8

1.4. Make sure to observe for sequencer circuit ........................................................... 9

1.5. EMC directive .......................................................................................................... 9

1.6. Others ....................................................................................................................... 9

1.7. The relation with the Mitsubishi Electric servo system ..................................... 10

2.1. Characteristics of Servo press ............................................................................... 11

2.1.1. Possible to record program execution result ................................................. 11

2.1.2. Programmable action possible ....................................................................... 11

2.1.3. Display of load and stroke during program execution and Graph display . 11

2.2. The suiting tool ....................................................................................................... 11

2.3. Accompanying items .............................................................................................. 11

2.4. About the model name and the version ............................................................... 12

2.4.1. Anybus option ................................................................................................. 12

3.1. Specifications of BS-M3A-1B ................................................................................ 13

3.2. Specifications fo brake .......................................................................................... 13

3.3. Common specification of MR-J3A ........................................................................ 14

3.4. Specification peculiar to the tool type .................................................................. 14

3.4.1. BS100 series ................................................................................................... 14

3.4.2. BS200 series ................................................................................................... 15

4.1. Name of each part of the controller ...................................................................... 16

4.2. Outline .................................................................................................................... 17

4.3. Connection figure (include options) ..................................................................... 18

5.1. Procedures for installing to control panel ............................................................ 20

5.1.1. Designing conditions for control box ............................................................. 20

5.1.2. Cautions when installing BS ......................................................................... 20

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BS Controller for AC SERVO PRESS

6. Installing lines ...........................................................................................................21

7. Timing Chart .............................................................................................................31

8. Concept of stroke .......................................................................................................36

Instruction Manual Ver1 .08 BS-M3A-1B

5.1.3. The interval with MR-J3A ............................................................................. 20

5.1.4. Noise Filter of MR-J3A .................................................................................. 20

6.1. Load cell i/f(CN31) ................................................................................................. 21

6.2. Origin sensor i/f(CN32) ......................................................................................... 21

6.3. MR-J3A parallel i/f(CN33) .................................................................................... 21

6.4. Emergency stop(CN34) ......................................................................................... 21

6.5. RS-232C(CN4) ....................................................................................................... 22

6.6. RS-232C(CN5) ....................................................................................................... 22

6.7. RS-485(CN6,7) ....................................................................................................... 22

6.8. Ethernet(CN8) ....................................................................................................... 23

6.9. Parallel I/O (CN9) .................................................................................................. 23

6.9.1. Bit assignment ............................................................................................... 24

6.9.2. PIO connector pin assignment ...................................................................... 27

6.9.3. Wiring by the side of input ............................................................................ 27

6.9.4. Wiring by the side of output .......................................................................... 28

6.10. Control power supply (CN10) ........................................................................... 28

6.11. Backup battery（CN11） ...................................................................................... 28

6.12. Anybus .................................................................................................................... 28

6.13. Brake ...................................................................................................................... 29

6.14. Motor cable ............................................................................................................. 30

6.15. Encoder Cable ........................................................................................................ 30

7.1. Power supply injection .......................................................................................... 31

7.2. Alarm reset ............................................................................................................ 31

7.3. Origin ..................................................................................................................... 31

7.4. JOG ......................................................................................................................... 32

7.5. Program execution ................................................................................................. 32

7.6. Program execution using Post Judge ................................................................... 33

7.7. Writing of a product name and a serial number ................................................. 34

7.8. Post Judge .............................................................................................................. 35

8.1. Semi closed loop ..................................................................................................... 36

8.2. Direction ................................................................................................................. 36

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BS Controller for AC SERVO PRESS

9. Connection with Personal Computer ........................................................................38

10. Starting ..................................................................................................................44

Instruction Manual Ver1 .08 BS-M3A-1B

8.3. System home position ........................................................................................... 36

8.4. User home position ................................................................................................ 36

8.5. System stroke limit ............................................................................................... 36

8.6. User stroke limit .................................................................................................... 36

8.7. If the stroke limit is exceeded ............................................................................... 37

8.8. A motion of the ram at the time of servo off ........................................................ 37

9.1. Spindle number setup ........................................................................................... 38

9.2. IP address setup of BS controller ......................................................................... 38

9.3. IP address setup of a personal computer ............................................................. 38

9.4. LAN cable ............................................................................................................... 39

9.5. Communicative check ........................................................................................... 39

9.5.1. Setup of operational authoority .................................................................... 39

9.5.2. Setup of receive filter ..................................................................................... 40

9.5.3. Collection setup .............................................................................................. 40

9.5.4. Check of status ............................................................................................... 40

9.6. Starting of two Configurators ............................................................................... 41

9.7. Use of two or more network interface cards ........................................................ 42

9.8. Arbitrary IP address setup ................................................................................... 42

9.8.1. Notes ............................................................................................................... 42

9.8.2. The communication method with an IP address unknown controller ....... 43

10.1. Starting procedure of BS controller ..................................................................... 44

10.1.1. Attachment to equipment .............................................................................. 44

10.1.2. Wiring .............................................................................................................. 44

10.1.3. Control power supply injection ..................................................................... 44

10.1.4. Attachment of a backup battery ................................................................... 44

10.1.5. Parameter setup of MR-J3A .......................................................................... 44

10.1.6. Parameter setup of BS ................................................................................... 44

10.1.7. Re-starting of a power supply ....................................................................... 44

10.1.8. Check of a brake ............................................................................................. 44

10.1.9. Check of an emergency stop .......................................................................... 44

10.1.10. Origin .......................................................................................................... 44

10.1.11. Build a program. ......................................................................................... 44

10.1.12. Execution of a program .............................................................................. 45

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BS Controller for AC SERVO PRESS

11. Troubleshooting .....................................................................................................53

12. Regeneration ..........................................................................................................61

13. Absolute encoder system ........................................................................................62

14. Load-Sensor-less System .......................................................................................63

15. Tool Type Discernment ..........................................................................................64

16. Stole .......................................................................................................................65

17. Others ....................................................................................................................66

18. Article of Consumption ..........................................................................................67

Instruction Manual Ver1 .08 BS-M3A-1B

10.2. Parameter setup of MR-J3A ................................................................................. 45

10.3. Parameter setup of BS controller ......................................................................... 49

10.4. Re-injection of a control power supply ................................................................. 50

10.5. Check of the brake ................................................................................................. 50

10.6. Check of emergency stop ....................................................................................... 51

10.7. Origin ..................................................................................................................... 51

10.8. Program creation ................................................................................................... 51

10.9. Execution of a program ......................................................................................... 52

11.1. The state display by LED ..................................................................................... 53

11.2. Alarm code table .................................................................................................... 54

12.1. Lowering regeneration frequency ........................................................................ 61

12.2. Regeneration option .............................................................................................. 61

13.1. Setup....................................................................................................................... 62

13.1.1. Setup to BS controller .................................................................................... 62

13.1.2. Setup to MR-J3A ............................................................................................ 62

13.1.3. Wearing of a backup battery ......................................................................... 62

13.2. The alarm release method .................................................................................... 62

17.1. The options of the servo press .............................................................................. 66

18.1. Battery ................................................................................................................... 67

18.1.1. The detection method ..................................................................................... 67

18.1.2. The exchange method .................................................................................... 67

18.1.3. Management ................................................................................................... 67

18.1.4. Clock setup ..................................................................................................... 67

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BS Controller for AC SERVO PRESS

19. Maintenance of Tool ...............................................................................................68

20. Cautions on abandonment .....................................................................................68

Instruction Manual Ver1 .08 BS-M3A-1B

18.2. Parts having service lives of MR-J3A .................................................................. 67

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BS Controller for AC SERVO PRESS

1. For safe use

1.1. Regarding symbols

1.2.

Observe the following for safety

This symbol assumes the possibility that accidental death or serious injury may occur immediately to the user, if the symbol is neglected and the product is incorrectly handled.

The power source is as high as 200V. Look out for electric shock.

This symbol assumes that there is a potential for personal death or injury if this expression is ignored and this product is mishandled.

In a case where the product is used in an application in which an accident resulting in

as installing a fail-safe device.

Do not use around combustible gas. If disregarded, it may lead to an explosion.

In a case of handling cables and connectors, etc., cut off the power temporarily without fail. If disregarded, it may lead to an electric shock.

Do not remove the cover, disassemble, repair or modify the product. If disregarded, it may lead to an electric shock.

Make sure to connect the protection conductor terminal to ground. Electric shock might be caused.

Do not touch the power supply terminal in this equipment within five seconds after the power is turned off. It could cause the electric shock.

Do not forcibly twist, pull or scratch the power cord or cord of the AC plug.

DANGER

WARNING

Instruction Manual Ver1 .08 BS-M3A-1B

Symbols are used to provide warnings in this instruction manual and for indication for

proper product use and to prevent danger to the user or other people and damage to

property from occurring. Understand the indication meanings before reading this

manual.

death or injury or a serious expansion of damage is predictable, take safety measures such

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BS Controller for AC SERVO PRESS

This symbol assumes that there is a potential for personal death or injury if this expression is ignored and this product is mishandled.

Please use this product under the environment of overvoltage category II specified in IEC 60664-1.

Please use this product under the environment of Pollution Degree II specified in IEC 60664-1.

For the operation, stop, and emergency stop shall be done in the final machinery into which this equipment is incorporated.

This product will surely be in a servo off state, when it is in an alarm state. However, battery alarm is excepted.

Set up the emergency stop and interlock circuit with the external circuit. This allows to prevent expansion of damage.

Use the input voltage, frequency and output voltage, and current within the standard. If disregarded, it may lead to an accident or electric shock.

Do not use the product at over the specified ambient temperature. If disregarded, it may lead to fire or electric shock.

Use in an environment without condensation due to water or moisture. If disregarded, it may lead to an electric shock.

When output cannot be obtained, or any other abnormality is found during operation, stop

the product or our company’s sales office without fail.

1.3.

Caution on attachment and use.

This symbol assumes that there is a potential for personal death or injury if this expression is ignored and this product is mishandled.

Installation, connection, driving and operation, check and failure diagnosis shall be done by a qualified technician.

Do not move, install, connect and check this equipment while the power is on. Please make sure the power is turned off for conducting these works.

For installation requirements of this equipment, protection against electric shock is class

sure this equipment is grounded when installed. (PE should be marked at the protective earthing terminal.)

This equipment shall be stored in a dustproof and drip-proof controlled box. (IP54 class) If

proof is not strong enough, dielectric strength shall

be decreased, and the potential of dielectric breakdown shall be increased.

The cross-sectional area of the protective bonding conductor shall be the same size as the input power wire for this equipment.

Do not tighten the Servo press control cable excessively with binding band. Malfunction might be caused.

The electric shock protection from the power supply terminal block of this equipment to final machinery shall be provided in the final machinery.

For 24 VDC power supply, use SELV power supply which comply with IEC standard.

A breaker that comply with IEC Standard shall be installed in the final machinery into which this equipment is incorporated,for the short-circuit protection of this equipment.

The methods of the ground fault protection of this equipment are as follows: b) For the TN grounded system: Use an over current breaker generally. (The fault loop

CAUTION

WARNING

Instruction Manual Ver1 .08 BS-M3A-1B

use immediately. It may lead to electric shock. Contact the distributor where you purchased

Ⅰ，and equipment mobility is a stationery equipment for indoor installation. Please make

the performance of dustproof and drip-

a) For the TT grounded system: Use an earth leakage breaker (Type A or B shall be used)

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BS Controller for AC SERVO PRESS

impedance in the final equipment shall satisfy the overcurrent characteristics of the

This symbol assumes that there is a potential for personal death or injury if this expression is ignored and this product is mishandled.

When attaching the CPS body, allow a space of 25 mm or more for the right and left directions and 80 mm or more for up and down directions for cooling.

Do not apply more load on the Servo press tool than allowed. The life might be considerably shortened.

For connection to the protective earthing terminal, one wire should be provided for each terminal.

The insulation’s color of the protective earthing conductor shall be green-and-yellow.

Design the sequencer circuit under consideration of safety measure such as emergency stop.

1.4.

Make sure to observe for sequencer circuit

This symbol assumes that there is a potential for personal death or injury if this expression is ignored and this product is mishandled.

Insert or pull off the connector only after turning off the power. Otherwise, controller might fail.

Improper understanding of stroke might cause serious accident. Please understand the Section 8 in this manual to handle.

1.5.

EMC directive

1.6.

Others

WARNING

CAUTION

Instruction Manual Ver1 .08 BS-M3A-1B

breaker so that the breaker shall be interrupted within 0.4s or less when earth fault is occurred.)

Safety measure

The EMC directive applies not to the servo units alone but to servo-incorporated

machines and equipment.

This requires the EMC filters to be used with the servo-incorporated machines and

equipment to comply with the EMC directive.

Please ask a concrete solution to our office.

This equipment is classified into the partly completed equipment according to

Machinery Directive (2006/42/EC). Therefore, after this equipment is incorporated into

the final machinery, conformity with Machinery Directive (2006/42/EC) shall be needed

in the final machinery.

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BS Controller for AC SERVO PRESS

1.7. The relation with the Mitsubishi Electric servo system

Instruction Manual Ver1 .08 BS-M3A-1B

CE marking based on Machinery Directive is not done to the partly completed

machinery. Therefore, for the case that circulates by the partly completed machinery

until this equipment is incorporater into the final machinery in Europe. It is necessary

for the declaration of incorporation and the manual of this equipment to be appended to

this equipment

BS controller works as a higher rank controller of Mitsubishi Electric servo system

MR-J3A.

Please refer to the manual of the Mitsubishi Electric issue about the details of a

MR-J3A system.

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BS Controller for AC SERVO PRESS

2. Before use

2.1. Characteristics of Servo press

2.1.1. Possible to record program execution result

2.1.2. Programmable action possible

2.1.3. Display of load and stroke during program execution and Graph display

2.2. The suiting tool

Tool type

Adaptation load (kN)

Servo amplifier

Motor BS100 series

100

MR-J3-500A

HC-RP503(B)K

BS200 series

200

MR-J3-700A

HF-SP702(B)K

2.3. Accompanying items

Instruction Manual Ver1 .08 BS-M3A-1B

The Servo press provides new production controls, press methods and other actions

by programmable operations, controls and monitoring of the load and stroke

amount. The characteristics are given below.

Up to 2700 pieces of data of press results can be recorded inside the BS

Controller.

By using communications software, infinite data can be recorded.

Among factors such as speed, load stroke, time and communications with

external I/O, the programmable factor is what primarily concerns the

customer.

(Refer to the BS Configurator Instruction Manual)

By using special communications software, the values of load and stroke can

be monitored. The electric current can also be monitored by selecting the

details screen. A graph can be displayed after actions and detailed

information can be obtained.

Big-sized servo press controller BS-M3A works as a higher rank controller of

Mitsubishi Electric servo amplifier MR-J3A. The combination of servo amplifier

and a motor is decided according to the adaptation load of a tool.

 BS-M3A-1B main body  A set of plug for CN34 (EMERGENCY)

Maker：Phoenix contact Model：MC1.5/2-STF-3.81

 A set of plug for CN10 (DC power supply)

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BS Controller for AC SERVO PRESS

2.4.

About the model name and the version

2.4.1. Anybus option

Code

None

No Anybus option,PIO

CC

CC-Link

DV

DeviceNet

PF

Profibus DP

EI

EtherNet/IP

PN

PROFINET I/O

Instruction Manual Ver1 .08 BS-M3A-1B

Maker：Phoenix contact Model：MC1.5/3-STF-3.81

 Backup battery(CR2032WK13)  Operating manual(CD-R)  MR-J3A

The characters which follow the basic model name are explained. At

BS-M3A-1B-zz, zz expresses Anybus option.

説明

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BS Controller for AC SERVO PRESS

3. Specifications

3.1. Specifications of BS-M3A-1B

Items

Contents

Outline

Refer to outline diagram on the Appendix（Section 4

Environ ment

Temperature

0～50℃

Humidity

85% or less (No condensation)

Altitude

Altitude 1000 m or lower

Installing location

Harmful places with corrosive gas, cutting oil, metal powder, oil etc., are not allowed.

Power for control

DC24V±10%

Power consumption [W]

6 *1

Installing procedures

Installing on back panel

Vibration proof

0.5G（10～50Hz）

Shock proof

5G

Serial communications RS-485

115.2kbps occupied by MR-J3A

Serial communications RS-232C

19.2～76.8kbps dedicated protocol

Ethernet

UDP/IP Fixed IP address

Load cell accuracy

1.5％@Tool rating (in a state without an overhang load)

Load sensor resolution

12Bit

Input signals

Start,Reset,P-No. Select,User in etc. Capacity of photo coupler 24V, 4.8mA, Filter time constant 50ms

Output signals

Ready,Run,Judge,Alarm,User out etc. Capacity of photo coupler 24V、30mA

Status indicator

LEDs(Charge,Status,Code,OK,NG,DC Power,Ethernet)

Cable length

Maximum 30 m

Executing program

31 points

Executing result storing function

For 2700 times

3.2. Specifications fo brake

Tool type

Power consumption

Maintenance force [kN]

Instruction Manual Ver1 .08 BS-M3A-1B

）

±

*1 It is only BS-M3A-1B. MR-J3A is not included.

A tool can be equipped with the brake for position maintenance as an option.

The brake is released by electric current at DC24V after 0.2 second from

turning on it. Control of a brake is not performed by BS controller. Please

control by PLC side.

BS100 24V/7W 2.5 BS200 24V/19.4W 23.4

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BS Controller for AC SERVO PRESS

3.3. Common specification of MR-J3A

Power supply

Voltage/frequency

3-phase 200 to 230VAC, 50/60Hz

Permissible voltage fluctuation

AC170～253V

Permissible frequency fluctuation

Within 5%

Control circuit

Voltage, frequency

1-phase 200 to 230VAC, 50/60Hz

Permissible voltage fluctuation

AC170～253V

Permissible frequency fluctuation

Within 5% Input

45W

Inrush current

30A (Attenuated to approx. 0A in 3ms)

Interface power

Voltage, frequency

DC24V±10%

Power supply capacity

300mA

Control System

Sine-wave PWM control, current control system

Dynamic brake

Built-in

Protective functions

Over current shut-off, regenerative over

protection

MR-J3- A

3.4. Specification peculiar to the tool type

3.4.1. BS100 series

Servo motor

HC-RP503(B)K

Servo amplifier

MR-J3-500A

Power supply capacity

7.5kVA

Servo

heat[W]

At rated torque

195W

With servo off

25W

Area required for heat dissipation

3.9m2

Power supply Inrush Currents (A0-p)

44A (Attenuated to approx. 20A in 20ms)

Instruction Manual Ver1 .08 BS-M3A-1B

Specification common to MR-J3-500A and MR-J3-700A is indicated. *1

power supply

supply

voltage shut-off, overload shut-off (electronic thermal relay), servo motor overheat protection, encoder error protection, regenerative error protection, under voltage, instantaneous power failure protection, over speed protection, excessive error

*1 It is posting from the data of Mitsubishi Electric. Please refer to the

SERVO AMPLIFIER INSTRUCTION MANUAL for details.

amplifier-generated

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BS Controller for AC SERVO PRESS

3.4.2. BS200 series

Servo motor

HF-SP702(B)K

Servo amplifier

MR-J3-700A

Power supply capacity

10.0kVA

Servo

heat[W]

At rated torque

300W

With servo off

25W

Area required for heat dissipation

6.0m2

Power supply Inrush Currents (A0-p)

88A (Attenuated to approx. 20A in 20ms)

Instruction Manual Ver1 .08 BS-M3A-1B

amplifier-generated

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BS Controller for AC SERVO PRESS

4. Construction

4.1. Name of each part of the controller

OK/NG LED

ID SW

CN6,7 RS-485

CN9 Ethernet

CN10 PI/O

CN10 Control power CN34

CN33 MR-J3A Parallel

CN32 Origin sensor

CN31 Load cell

Status LED

Instruction Manual Ver1 .08 BS-M3A-1B

Code LED

Extended bus(Anybus)

CN4 RS-232C CH1

CN5 RS-232C CH2

Emergency stop

Control

Power LED

CN11 Backup battery

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BS Controller for AC SERVO PRESS

4.2. Outline

Instruction Manual Ver1 .08 BS-M3A-1B

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BS Controller for AC SERVO PRESS

AC Power *10

AC200V 3φ

PLC

DC Power *10

DC24V

Emergency Stop *11

Servo Amp.

MR-J3-500A

BS Controller *3

BS-M3A-1B

BS100 Tool

Sequence cable

CCKSQ-3M *4

Parallel I/F cable *2

CBSPIF-**M

Serial Com. cable *2

CBS422-**M

Origin Sensor cable *1

CBSGS-**M

Load Cell cable *1

CBSLC-**M

Encoder cable *1 *8

MR-J3ENSCBL**M-L

Motor cable *1 *7

CBSMT10-**M

Brake cable

CBSBK-**M *1 *11

LAN cable(cross) *5

CCKLANC-5M

RS-232C cable CCK232-3M *9

FA Network

Board

Application software

Regen. Reg. *12

MR-RB31 MR-RB51

PC

LED Display

LDS-24

ＬＥＤ Display cable CCKDSP-**M　*6

4.3. Connection figure (include options)

4.3.1. BS100

Instruction Manual Ver1 .08 BS-M3A-1B

Fig.4-3-1 BS100 Series

*1 The length of a cable is selectable from 5,10 and 20m. The junction cable is not

prepared.

*2 The length of a cable is selectable from 0.5 and 1m.

*3 The connectors in a dashed line are included to the controller set.

*4 This is unnecessary when using a FA Network Board.

*5 The type of LAN cable may not be crossing when using a HUB.

*6 The length of a LED Display cable is selectable from 5 and 10m.

*7 The model name of movable cable is CBSMT10R-**M.

*8 The model name of movable cable is MR-J3ENSCBL**M-H.

*9 Detail of the model name is different for each PLC type.

*10 A customer prepares cables.

*11 A customer controls this line.

*12 A external regeneration resister is an option.

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BS Controller for AC SERVO PRESS

AC Power *

11

AC200V

3φ

PLC

DC Power *11

DC24V

Emergency Stop *12

Servo Amp.

MR-J3-700A

BS Controller *3

BS

-

M3

A-

1

B

BS200 Tool

Sequence cable

CCKSQ-3M *4

Parallel I

/F cable

*

2

CBSPIF-

**M

Serial Com. cable *2

CBS422-**M

Origin Sensor cable *1

CBSGS-

**M

Load Cell cable *

1

*14

CBSLC-**M

Encoder cable *1 *8

MR

-J3

ENSCBL**M-L

Motor cable *1 *7

CBSMT

10-**

M

Brake cable

CBSBK

-

**M

*1

*

12

LAN cable(cross) *5

CCKLANC-5M

RS-

232

C cable

CCK232

-

3M

*10

FA Network

Board

Application

Software

Regen.Reg. *13

MR-RB31 MR-RB51

PC

LED Display

LDS-24

LED Display cable CCKDSP-**M　*6

Load Cell *9

4.3.2. BS200

Instruction Manual Ver1 .08 BS-M3A-1B

Fig.4-3-2 BS200 Series

*1 The length of a cable is selectable from 5,10 and 20m. The junction cable is not

prepared.

*2 The length of a cable is selectable from 0.5 and 1m.

*3 The connectors in a dashed line are included to the controller set.

*4 This is unnecessary when using a FA Network Board.

*5 The type of LAN cable may not be crossing when using a HUB.

*6 The length of a LED Display cable is selectable from 5 and 10m.

*7 The model name of movable cable is CBSMT20R-**M.

*8 The model name of movable cable is MR-J3ENSCBL**M-H.

*9 The load cell is an option.

*10 Detail of the model name is different for each PLC type.

*11 A customer prepares cables.

*12 A customer controls this line.

*13 A external regeneration resister is an option.

*14 A model without a load cell needs a load cell cable to recognize a tool type.

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BS Controller for AC SERVO PRESS

5. Installation

5.1. Procedures for installing to control panel

5.1.1. Designing conditions for control box

5.1.2. Cautions when installing BS

5.1.3. The interval with MR-J3A

5.1.4. Noise Filter of MR-J3A

Instruction Manual Ver1 .08 BS-M3A-1B

Please be advised that the control box meets the general safety specifications.

Take the following into consideration.

1． The control box to house the BS should be a dustproof and drip-proof

structure.

2． Temperature in the control box should be from 0 to 50°C.

Heat generating amount of the BS depends on the operating status of

the Servo press. Install a fan, heat exchanger and heat radiation fin

according to the heat generating amount in the control panel.

3． Make sure to apply sealing to the cable outlet and window portion. 4． Consider mounting of the BS so that maintenance such as inspection and

removal is easily carried out.

When installing the main body of the BS, secure space of more than 25 mm (for

cooling) on both sides and more than 80 mm (for removal) above and under the

main body. Moreover, space 100mm or more is required for a front side because

of connectors.

Please make BS controller and MR-J3A adjoin. A connection cable should give

50cm or less as a standard.

Please be sure to insert a line noise filter in AC power supply of MR-J3A.

- 20 -

BS Controller for AC SERVO PRESS

6. Installing lines

6.1. Load cell i/f(CN31)

6.2. Origin sensor i/f(CN32)

6.3. MR-J3A parallel i/f(CN33)

6.4. Emergency stop(CN34)

Instruction Manual Ver1 .08 BS-M3A-1B

It is used for the communication with strain gauge amplifier. The signal level

is an equivalent for RS-422. There is no necessity for connection in the system

without a load cell. Cable type：CBSLC-**M(Basic Cable)

Cable type：JCBSLC-**M(Joint Cable)

An origin sensor is connected. Although, as for this system, absolute encoder

specification is also prepared, all tools are equipped with the origin sensor for

the initial position setup. Cable type：CBSGS-**M

It connects with CN1 of MR-J3A. The position detection pulse of a motor and

the position instruction pulse to MR-J3A are contained. In order to avoid the

influence of a noise, short wiring is recommended as much as possible. Cable type：CBSPIF-**M

An emergency stop SW is connected. The logic is normally closed. If it is made

opened, an emergency stop will be output to MR-J3A.

- 21 -

BS Controller for AC SERVO PRESS

6.5. RS-232C(CN4)

number

Signal

name

Contents

1

Rｘｄ

2

Tｘｄ

3

RTS

4

CTS

5

S-GND

Signal GND

6

7

P-

Power GND

8

２４Ｖ

Power

6.6. RS-232C(CN5)

number

Signal

name

Contents

1

Rｘｄ

2

Tｘｄ

3

4

5

S-GND

Signal GND

6

7

P-

Power GND

8

２４Ｖ

Power

6.7. RS-485(CN6,7)

MI-232C**M

Instruction Manual Ver1 .08 BS-M3A-1B

It is a general-purpose serial communication port. Since DC24V power supply

is assigned, it is dangerous if it connects except an exclusive cable here. A

setup of a protocol and a baud rate is performed from CPS SP Configurator. Controller side connector typr：HR12-10R-8SDL（HIROSE）

ＧＮＤ

Cable type：CCK232-**M(General)

：CCK232M-**M(Only for Mitsubishi Electric PLCs)

Usage：Connection with RS-232C unit of PLC etc.

It is a general-purpose serial communication port. Since DC24V power supply

is assigned, it is dangerous if it connects except an exclusive cable here. A

setup of a protocol and a baud rate is performed from CPS SP Configurator. Controller side connector type：HR12-10R-8SDL（HIROSE）

ＧＮＤ

It connects with CN3 of MR-J3A. Although two connectors are prepared for

cascade connection, it cannot be used by 1:1. Please connect either of CNs 6

- 22 -

BS Controller for AC SERVO PRESS

number

Signal

name

Contents

1

RD＋

2 RD- 3

TD+ 4

TD- 5

S-GND

Signal GND

6

S-GND

Signal GND

6.8. Ethernet(CN8)

6.9. Parallel I/O (CN9)

CBS422-**M

Instruction Manual Ver1 .08 BS-M3A-1B

and 7.

The potential difference of GND for signals is permissible to 7V. When

communication is not stabilized, please turn on GND for signals of the pin

numbers 5 and 6 . If the metal cover of a right-hand side is removed toward BS

controller and 3 and 4 of the dip switch SW4 on the substrate are turned on

(above), GND for signals will become effective. Cable type：

Controller side connector type：53462(Moｌex)

Cable type：CBS422-**M

It connects with a personal computer and exclusive application BS

Configurator performs a setup of BS controller etc. The protocol is UDP/IP.

They are 10 / 100M automatic change. It is necessary to make LAN setup of a

personal computer into a fixed IP address.

The example of a setting IP address 192:168:1:1

Subnet mask 255:255:0:0

Please use a cross cable, when you connect a personal computer and CPS

controller directly. Please use a straight cable, when you connect via a HUB.

It connects with a sequencer etc. and BS is controlled.

Cable type：CCKSQ-**M

（Refer to the wiring diagram for CPS<=>PLC connection.）

Connector：54306-3611(MOLEX)

- 23 -

One side is cut.

BS Controller for AC SERVO PRESS

6.9.1. Bit assignment

Bit number

Signal name

Contents

0

STOP

Program execution is interrupted, then a scram is carried

in a servo off state.

1

RESET

Alarm release and judgment output reset.

2

ORIGIN

Origin is started. Original position information disappears by start of origin.

3

START

Program execution is started.

4

USER_SEL

User output selection.

5

JOG_SPD1/U_IN0

Bit 0 of JOG speed specification binaries/user input 0,

When JOG_ENA is ON, JOG speed is

JOG_ENA is off, it becomes the user input 0.

6

JOG_SPD2/U_IN1

Bit 1 of JOG speed specification binaries/user input 1, are superposed.

7

JOG_ENA

JOG operation is permitted. Moreover, the output bit 3 is changed to BAT.ALARM.

8

PNO1/JOG+

The bit 0 of the binary value which specifies an execution

JOG_ENA is ON, JOG operation is carried out in the direction of +.

9

PNO2/JOG-

The bit 1 of the binary value which specifies an execution

. When JOG_ENA is ON, JOG operation is carried out in the direction of -.

10

PNO4

The bit 2 of the binary value which specifies an execution program number.

11

PNO8

The bit 3 of the binary value which specifies an execution program number.

12

PNO16

The bit 4 of the binary value which specifies an execution program number.

13

SERVO_ON

Servo-on is directed to MR-J3A. In operation by PI/O,

at all.*1

14

U_IN2

User input 2.

15

U_IN3

User input 3.

Instruction Manual Ver1 .08 BS-M3A-1B

Input

out. After performing speed zero for 0.2 seconds, it will be

are superposed. specified in four stages with the input bit 6. When

program number/+ Direction JOG are superposed. When

program number/- Direction JOG are superposed

unless it is in a servo-on state, a system does not operate

*1 On the tool operation screen and a program execution screen of BS Configurator,

SERVO_ON signal are ignored.

- 24 -

BS Controller for AC SERVO PRESS

Bit number

Signal name

Contents

0

ALARM(N.C)

Alarm. It is normalｙ closing. It turns off in the state of alarm.

1

ALM_MR(N.C)

The alarm state of MR-J3A is shown. It is normal

closing.

2

READY

The completion of operation preparation.

3

IN_ORIGIN/BAT.ALARM

In origin mode/Battery alarm are superposed. BAT.ALARM is chosen when JOG_ENA is ON.

4

RUN

It turns on during program execution.

5

OK

O.K. judging output. The output timing of

program.

6

NG

NG judging output.

7

IN_JOG/AREA1

Under JOG operation/Area signal1 are

ON.

8

P_ANS1/U_OUT0

The response of the bit 0 of binary value which

when USER_SEL is ON. It is the same to the bit

12.

9

P_ANS2/U_OUT1

The response of the bit 0 of binary value which

output 1 are superposed.

10

P_ANS4/U_OUT2

The response of the bit 1 of binary value which

output 2 are superposed.

11

P_ANS8/U_OUT3

The response of the bit 2 of binary value which

output 3 are superposed.

12

P_ANS16/U_OUT4

The response of the bit 3 of binary value which

output 4 are superposed.

13

U_OUT5

User output 5.

14

U_OUT6

User output 6.

15

USER_SEL_ANS

The response of USER_SEL.

16

BAT.ALARM

It is an output only for battery alarms. *1

17

ORIGIN_END

It turns on, when origin is completed. It turns off, when origin is required. *1

18

PJ _WA IT

When using a post judgment, it turns on in the state of waiting a judgement from a PC.

19

AREA2

Area signal 2.

20

AREA3

Area signal 3.

21

AREA4

Area signal 4.

22-31

RESERVED

Instruction Manual Ver1 .08 BS-M3A-1B

Output

ｙ

O.K./NG is a time of executing jdg command in a

superposed. IN_JOG is chosen when JOG_ENA is

specifies an execution program number/User output 0 are superposed. User outputs are chosen

specifies an execution program number/User

* Above bit16 can be used only when Anybus option is chosen. It is that PI/O (CN9)

- 25 -

BS Controller for AC SERVO PRESS

Instruction Manual Ver1 .08 BS-M3A-1B

suits from bit0 to bit15.

BS controller of version 1.02.23 or more is needed to use bit16 to bit18.

BS controller of version 1.02.31 or more is needed to use bit19 to bit21.

- 26 -

BS Controller for AC SERVO PRESS

6.9.2. PIO connector pin assignment

PIN No.

Bit

Color

Signal name

PIN No.

Bit

Color

Signal name

1

I0

Gn

STOP

19

O0

LB/W

ALARM

2

I1

Br

RESET

20

O1

R/Bk

ALARM_MR

3

I2

Bl

ORIGIN

21

O2

Gn/Bk

READY

4

I3

Gy

START

22

O3

Br/Bk

IN_ORIGIN/BAT.ALA RM

5

I4

Or

USER_SEL

23

O4

Bl/Bk

RUN

6

I5

Pr

JOG_SPD1/U_IN0

24

O5

Gy/Bk

OK 7 I6

Pn

JOG_SPD2/U_IN1

25

O6

Or/Bk

NG

8

I7

LB

JOG_ENA

26

O7

Pn/Bk

IN_JOG/AREA

9

I8 W PNO1/JOG+

27

O8

LB/Bk

P_ANS1/U_OUT0

10

I9

Gn/W

PNO2/JOG-

28

O9

W/Bk

P_ANS2/U_OUT1

11

I10

Bw/W

PNO4

29

O10

Gn/R

P_ANS4/U_OUT2

12

I11

Bl/W

PNO8

30

O11

Br/R

P_ANS8/U_OUT3

13

I12

Gy/W

PNO16/U_IN4

31

O12

Bl/R

P_ANS16/U_OUT4

14

I13

Or/W

SERVO_ON

32

O13

Gy/R

U_OUT5

15

I14

Pr/W

U_IN2

33

O14

Or/R

U_OUT6

16

I15

Pn/W

U_IN3

34

O15

Pn/R

USER_SEL_ANS

17 R

+24V

35 Bk

0V

18 R/W

+24V

36 Bk/W

0V

6.9.3. Wiring by the side of input

BS

17,18

DC24V

IN

Instruction Manual Ver1 .08 BS-M3A-1B

A pin number, the wiring color of PIO cable, and a signal name are shown.

The shield line of a cable is connected to the connector shell by the side of a

controller. Connector（MOLEX：54306-3611）

Connector shell（MOLEX：54331-0361）

Cable（SUN LIGHTSX 0.2×18P）

- 27 -

Common voltage is DC24V and serves as a photo-coupler input.（Current is

about 5mA / 1 circuit.）

BS Controller for AC SERVO PRESS

6.9.4. Wiring by the side of output

6.10. Control power supply (CN10)

6.11. Backup battery（CN11）

Please attach for a red lead to upside.

6.12. Anybus

BS

DC24V

L

OUT

17,18

35,36

Instruction Manual Ver1 .08 BS-M3A-1B

Open collector output (30mA / 1 circuit)

Control power supply 24V are connected.

The exclusive battery for SRAM backup is connected. Please connect a backup

battery in the state of control power supply ON. Although the life of a battery

is about five years, it changes a lot according to a use state and environment. If

battery voltage is less than 2.1V, BAT.ALARM (parallel output 3) turns on.

Even in such a case, inside information is held unless a control power supply is

turned off.

If the metal cover of the right side is removed toward CPS controller, the

- 28 -

BS Controller for AC SERVO PRESS

6.13. Brake

RED(+24V)

WHITE(0V)

Instruction Manual Ver1 .08 BS-M3A-1B

connector for Anybus will appear. If it equips with Anybus card which HMS

offers, control equivalent to PI/O will be attained by networks, such as

CC-Link.

Although a tool with a brake can be chosen as an option, brake control is not

performed by BS controller. Please control a brake by the user system side. A

brake will be released if current is passed between a No. 1 pin and a No. 2 pin.

The brake is completely released in 0.2 seconds after turning on the current.

Please do not move the ram until the brake is released.

An option brake is an object for position maintenance to the last, and is not

applicable to dynamic braking.

If a jig weight added to the ram exceeds several percent of the tool maximum

thrust, the ram may fall naturally. In such a case, please use the brake for

position keeping.

MR-J3A builds in the dynamic brake. A sudden stop is possible if an emergency

stop (CN34) is opened.

Cable type：CBSBK-**M

- 29 -

BS Controller for AC SERVO PRESS

6.14. Motor cable

6.15. Encoder Cable

Sield

Instruction Manual Ver1 .08 BS-M3A-1B

Please fully perform measure against a noise about the motor cable of MR-J3A.

Noise filters, such as a ferrite core, need to be attached.

The cables for BS100 series Cable type：CBSMT10-**M

Cable type：CBSMT10R-**M (Cable for movable)

Cable type：CBSMT10L-**M

The cables for BS200 series Cable type：CBSMT20-**M

Cable type：CBSMT20R-**M (Cable for movable)

Cable type：CBSMT20L-**M

Cable type：MR-J3ENSCBL**M-L

Cable type：MR-J3ENSCBL**M-H (Cable for movable)

- 30 -

BS Controller for AC SERVO PRESS

Timing Chart

7.1. Power supply injection

7.2. Alarm reset

Alarm may not be canceled unless it outputs RESET twice.

7.3. Origin

O READY

O ALARM

I RESET

MR-J3A CTRL PW

0.5s

MR-J3A AC PW

BS CTRL PW 0.2s

O

READY

I

SERVO_ON

I ORIGIN

I STOP

I JOG_ENA

O IN_ORIGIN

/BAT.ALARM

O SERVO_ON

O ORIGIN_END

Origin is interrupted by STOP.

Orign normal end

Instruction Manual Ver1 .08 BS-M3A-1B

7.

The timing chart of fundamental operation is shown.

- 31 -

BS Controller for AC SERVO PRESS

O READY_RUN

I START

I PRG.NO

O RUN

O ANS

O OK/NG

I RESET

7

55 4 4 8

8

7.4. JOG

7.5. Program execution

I SERVO_ON

I

JOG_ENA

I PNO1/JOG+

I PNO2/JOG-

I JOG_SPD1/U_IN0

I JOG_SPD2/U_IN1

O

IN_JOG/AREA

Instruction Manual Ver1 .08 BS-M3A-1B

When you turns on JOG_ENA, it is required for PNO1/JOG+, and PNO2/JOG-

to be in the state of off. It will become alarm if JOG_ENA is turned ON when

either of those signals is ON.

- 32 -

BS Controller for AC SERVO PRESS

7.6.

Program execution using Post Judge

O READY_RUN

I START

Anybus

Setting Post Judge No.

I PRG.NO

O RUN

O PJ_WAIT

Collecting Waveform data

Judgement of PC

Ethernet

O ANS

O OK/NG

I RESET

5

4

5

4

Instruction Manual Ver1 .08 BS-M3A-1B

"Post Judge" is the function to take in waveform data to PC, to perform a

special analysis in PC, and to return judgment to BS controller. This function

can perform judgment processing which cannot be realized only by the

real-time operation within BS controller. Please refer to a BS_Configurator

handling description for details.

- 33 -

BS Controller for AC SERVO PRESS

7.7.

Writing of a product name and a serial number

PLC

BS

PC

A product name, a serial number, etc. are set to each spindles via AnyBus I/f.

Start each spindles

The status sense to each spindles. A numerical and waveform data are collected from the ended spindles. Data is saved.

Instruction Manual Ver1 .08 BS-M3A-1B

The flow chart in the case of recording a product name, a serial number, etc.

to numerical data using Anybus i/f is shown

- 34 -

BS Controller for AC SERVO PRESS

7.8.

Post Judge

PLC

CPS

PC

PLC

BS

PC

A post judg number is set up vis AnyBus I/f.

Start each spindles

The status sense to each spindles. A numerical and waveform data are collected from the ended spindles.

When using Post Judge, waveform analysis is performed according to the specified judgment number. A result is returned to BS.

O.K./NG is outputted considering the judgment from PC, and an internal judgment.

Instruction Manual Ver1 .08 BS-M3A-1B

"Post Judge" is the function to take in waveform data to PC, to perform special

analysis in PC, and to return a judgment to BS controller. This function can

perform judgment processing which cannot be realized only by the real-time

operation within BS controller. Please refer to a BS_Configurator handling

description for details.

- 35 -

BS Controller for AC SERVO PRESS

8. Concept of stroke

8.1. Semi closed loop

8.2. Direction

8.3. System home position

8.4. User home position

8.5. System stroke limit

8.6. User stroke limit

Instruction Manual Ver1 .08 BS-M3A-1B

When using the Servo press, an incorrect setting of stroke will cause a

serious accident.Please be sure to understand concept of stroke well before

using the servo press. then design user programs, sequence, and system

after that.

The stroke value of a servo press is calculated from the encoder pulse of a

motor, and may not show the exact position of the ram always.

The right stroke value cannot be outputted before an origin return.

In proportion to load, a tool is distorted slightly. It is about 0.3mm at the

maximum load

When the mechanism of a timing belt or others breaks down, the actual

position and stroke value of the ram are-less correlating.

When the position of the ram has serious influence for operation of a system ,

we recommend you to form the sensor which detects the position of the ram

uniquely.

The direction where ram is extended is the direction of +.

It is used when adjusting offset of the whole system. It is set as a controller

using BS Configurator. When tools are exchanged, adjustment of an

attachment position can be easily performed by change of a system home

position.

It is the offset which can be arbitrarily set up in a user program. It specifies

using a home position table. It is set up on the basis of a system home position.

The stroke value of 32 pieces is prepared for the home position table. The

contents of a home position table can be changed by BS Configurator.

The stroke value treated in a user program starts from a user home position.

It is the maximum stroke value set to the tool table.*1 A setup can be

arbitrarily changed in the range exceeding it. The stroke value starts from an

origin sensor.

It is the stroke limit which can be described in a user program. The stroke

- 36 -

BS Controller for AC SERVO PRESS

8.7. If the stroke limit is exceeded

8.8. A motion of the ram at the time of servo off

Instruction Manual Ver1 .08 BS-M3A-1B

value starts from a user home position.

If one of stroke limits is exceeded, a controller turns off READY and will be in

a servo off state. Please input RESET, in order to restore. If ON of READY is

checked, please move ram into a stroke limit by manual operation.

At the moment of servo-off, a ram may shift from various factors slightly. The amount of shift is 1mm or less. In order to prevent the shift, please stop

servo-off or use the brake for position keeping.

*1 A tool table is the file various setting value about a tool is indicated to be. It

exists under the installation folder of BS Configurator. If a tool type is chosen

on a tool selection screen, the contents of a tool table will be displayed.

- 37 -

BS Controller for AC SERVO PRESS

9. Connection with Personal Computer

9.1. Spindle number setup

The spindle number setting method

BS front

In the left figure, the spindle number

indle number in one

Please set up the number between

31.In the other setup, it becomes

an error.

9.2. IP address setup of BS controller

9.3. IP address setup of a personal computer

0

5

1

4

2

3

6

9

87

0

5

1

4

2 3

6

9

87

IDx10

IDx1

Instruction Manual Ver1 .08 BS-M3A-1B

In order to set up BS controller, exclusive application BS Configurator is

started, and it is necessary to connect with a personal computer. The procedure

is explained.

BS controller is connectable with the same communication system to 31 sets.

In this case, in order to discriminate each controller, it is necessary to set up a

spindle number.

is set as 5.

ID x 10 is 10 digits. ID x 1 is 1 digit.

Please set up a sp communication system not to overlap. Duplication of a spindle number causes a communication error.

01-

When a spindle number is changed, a spindle new number becomes effective

after a re-injection of a power supply.

The IP address of BS controller is set up like this 192:168: (master number

+14) : (spindle number).

A master number is set up by the SW1 bits 0-3 on CPU board. A master

number adds 1 to the binary value of 4 bits of SW1 low ranks. SW1 is visible if

the cover of an expansion bus is removed. A front panel side is a low rank bit.

The master number is set as 1 at the time of shipment. The controller of a

different master number is not connectable with one communication system.

The default gateway is 192.168.1.1.

In order to communicate with BS controller, it is necessary to set a fixed IP

- 38 -

address for a personal computer in the communication method of Ethernet.

Since the setting methods of a fixed IP address differ for every OS, refer to

BS Controller for AC SERVO PRESS

9.4. LAN cable

9.5. Communicative check

9.5.1. Setup of operational authoority

Instruction Manual Ver1 .08 BS-M3A-1B

other data for them.

An example of a setting of an IP address

IP address 192.168.1.1(The default gateway of BS)

Subnet mask 255.255.0.0

Since it is not connectable with the Internet environment in almost all cases,

the personal computer set as the fixed IP address should be careful.

Please use a cross cable, when you link a BS controller and a personal

computer directly. Please use a straight cable, when you go via a hub.

If connection is completed, BS Configurator will be started and communication

will be checked. In the following explanation, the spindle number shall be set

as No. 1.

Operation authority can be set to BS Configurator. All operations are attained

by setting it as "All ". If setup-operation authority is chosen with a pull down

menu, an operation authority screen (Fig. 9-1) will be displayed. The radio

button of “All” is turned ON, a password is inputted, and O.K. button is clicked.

The initial value of a password is "2".

Fig.9-1 Operational authority screen

- 39 -

BS Controller for AC SERVO PRESS

9.5.2. Setup of receive filter

9.5.3. Collection setup

9.5.4. Check of status

Instruction Manual Ver1 .08 BS-M3A-1B

If a setup-data collection-receiving filter is chosen with a pull down menu, a

receiving filter screen will be displayed. Please set up, as shown in Fig. 9-3.

Fig.9-3 Receive filter screen

At the pull down menu, check is put into setup-data collection-collection. (refer

to Fig. 9-4.)

Fig.9-4 Collection setup

If the status bar of the screen lower part is displayed as shown in Fig. 9-5,

communication is performed normally. Although various alarms are displayed

when no setup for BS controller is performed, there is no problem. As shown in

- 40 -

BS Controller for AC SERVO PRESS

9.6.

Starting of two Configurators

Instruction Manual Ver1 .08 BS-M3A-1B

Fig. 9-6, when status is displayed, communication is not performed normally.

Please improve a setup from the beginning of Chapter 9.

Fig.9-5 Status bar Alarm state

Fig.9-6 Status bar Communication error state

It is also possible to install two BS Configurators in one PC, and to start

simultaneously. Starting of the 2nd Configurator displays the message "the

port cannot be used." It is because the 1st Configurator has already used the

port number 5008 (default value). Then, at the 2nd Configurator, it is set up so

that the port number except 5008 may be used. In the menu of the 2nd

Configurator,Setup-Data collection-Communication is chosen, and the

communication setting screen is opened.

Please choose 5009 at the list-box of All Port No. button, and click O.K. button.

Please re-start the 2nd Configurator. Two Configurators can be used if the

message about a port is not displayed. If two Configurators are used, data can

be displayed by the station.

Fig. 9-5 Communication Setup screen

- 41 -

BS Controller for AC SERVO PRESS

9.7.

Use of two or more network interface cards

9.8.

Arbitrary IP address setup

9.8.1. Notes

Instruction Manual Ver1 .08 BS-M3A-1B

If LAN Interface Card Name in the Communication Setup screen of Fig. 9-5 is

used, the communication route between a PC and controllers can be specified.

Mixture of a network is avoidable if this function is used when using two or

more network interface cards. Moreover, if two Configurators are started and

data collection is performed by the separated network interface card, the time

of data collection can be shortened.

As shown in Fig. 9-5, the network interface card names are displayed in a

floating window by right click of the lower part of LAN Interface Card Name.

A setup will become effective, if LAN Interface Card Name of you wish is

chosen and O.K. button is clicked.

Arbitrary IP addresses can be set up now to the controller of a version 1.02.26

or later. On Fig. 9-5 Communication Setup screen if IP Address button is

clicked, Fig.9-6 IP Address Setup screen will open. The IP address of

Configurator and the IP address of a controller can be arbitrarily set up on this

screen. Address 4 is decided by the

spindle number. A spindle number

is set up with the rotary SWs of the

front upper part of a controller. The

setting range of a spindle number is

Fig.9-6 IP Address Setup screen

from 1 to 31.

Communication is impossible unless Configurator and a controller are the

same IP addresses. Moreover, it is necessary to also change the IP address of

the network interface card used with a personal computer. Please setup

addresses 1 and 2 with the same addresses of a controller.

A setup of a controller becomes effective after a re-injection of a power supply.

- 42 -

BS Controller for AC SERVO PRESS

9.8.2. The communication method with an IP address unknown controller

Instruction Manual Ver1 .08 BS-M3A-1B

Please use a default fixed IP address to the controller with an unknown setup

of an IP address. When a spindle number is set as 71 to 99 with the rotary SW

of the upper part in front of a controller, the IP address of the controller is as

follows.

192.168.15.(spindle number - 70) A new IP address becomes effective by re-injection of a power supply.

- 43 -

BS Controller for AC SERVO PRESS

10. Starting

10.1. Starting procedure of BS controller

10.1.1. Attachment to equipment

10.1.2. Wiring

10.1.3. Control power supply injection

10.1.4. Attachment of a backup battery

10.1.5. Parameter setup of MR-J3A

10.1.6. Parameter setup of BS

10.1.7. Re-starting of a power supply

10.1.8. Check of a brake

10.1.9. Check of an emergency stop

10.1.10. Origin

10.1.11. Build a program.

Instruction Manual Ver1 .08 BS-M3A-1B

The outline procedure in the case of actually using BS controller is shown

below. The item which needs details is indicated after [2].

BS controller,MR-J3A and a tool are fixed to equipment.

Please wire with reference to a wiring diagram.

Only a control power supply is switched on. Please refer Section7 Timing Chart

7-1 Power supply injection.

The backup battery for holding the contents of a setting is attached.

The parameter of MR-J3A is set up. (It is required work only when MR-J3A is

purchased alone.)

Tool type selection, a setup of a stroke limit, etc. are performed from exclusive

PC application BS Configurator.

After a setup of a parameter, a power supply is turned off at once and only a

control power supply is switched on again. If alarm has not occurred, AC power

supply is also switched on. When alarm has occurred, please remove a cause

with reference to troubleshooting.

When a mechanical brake is chosen as an option, it checks that a brake is

taken off in the state of operation.

Please perform emergency stop operation and check that an emergency stop

operates.

Large restriction is applied to speed and output load when origin has not been

completed.

Build a program which suited the purpose using BS Configurator, and

transmit to BS controller.

- 44 -

BS Controller for AC SERVO PRESS

10.1.12. Execution of a program

10.2. Parameter setup of MR-J3A

Caution 1

Caution 2

Caution 3

Parameter A

No.

Symbol

Name

Setting

Unit

Range

Change

required

PA01

*STY

Control mode

0000

0000-0235h

*

PA02

*REG

Regenerative option

0000

0000-000Ah

*

PA03

*ABS

Absolute position detection system

0000

0000-0004h

*

PA04

*AOP01

Function selection A-1

0000

0000-0011h

PA05

*FBP

Number of command input pulses per revolution

16384

0/1000-50000

*

PA06

CMX

Electronic gear numerator (Command pulse multiplying factor numerator)

1

1-1048576

*

PA07

CDV

Electronic gear denominator

ommand pulse multiplying factor

denominator)

1

1-1048576

*

PA08

ATU

Auto tuning

0001

0000-0003h

PA09

RSP

Auto tuning response

12

1-32

PA10

INP

In-position range

100

pulse

0-10000

PA11

TLP

Forward torque limit

100.0

%

0.0-100.0

PA12

TLN

Reverse torque limit

100.0

%

0.0-100.0

PA13

*PLSS

Command pulse input from

0010

0000-0712h

PA14

*POL

Rotation direction selection

0

0-1 * PA15

*ENR

Encoder output pulses

16384

pulse/rev

1-100000

*

PA16

For manufacturer setting

0000

0000-FFFFh

PA17

*MSR

For manufacturer setting

0000

0000-FFFFh

PA18

*MTY

For manufacturer setting

0000

0000-FFFFh

PA19

*BLK

Parameter write inhibit

000C

0000-FFFFh

*

Instruction Manual Ver1 .08 BS-M3A-1B

If you run a program and there is an inconvenient portion, please add

correction and raise the completeness of a program.

When purchased in lump sum with a tool, the parameter of MR-J3A is already

set up.

About PA05 and PA15, those are setups for SP200 series. It is set

to 8192 in SP100 series. As for the parameter by which a setup is changed into

BS systems, * mark is attached to the Change required item.

About PA02, it is a setup of standard regeneration resistance.

When equipping with regeneration resistance of an option, a setup needs to be

changed.

About PA03, it is a setup of an incremental system. When you use

it by the absolute encoder system, please set it as 2.

- 45 -

(C

BS Controller for AC SERVO PRESS

Parameter B

No.

Symbol

Name

Setting

Unit

Range

Change

required

PB01

FI LT

Adaptive tuning mode (Adaptive filter )

0000

0000-0002h

PB02

VRFT

Vibration suppression control filter

(Advanced vibration suppression control)

0000

0000-0002h

PB03

PST

Position command

(Position smoothing)

10

ms

0-20000

*

PB04

FFC

Feed forward gain

0 % 0-100

PB05

FFCF

For manufacturer setting

500

rad/s

10-4500

PB06

GD2

Ratio of load inertia moment to servo motor inertia moment

0.8

times

0.0-300.0

PB07

PG1

Model loop gain

38

rad/s

1-2000

PB08

PG2

Position loop gain

58

rad/s

1-1000

PB09

VG2

Speed loop gain

327

rad/s

20-50000

PB10

VIC

Speed integral compensation

21.5

ms

0.1-1000.0

PB 11

VDC

Speed differential compensation

980

0-1000

PB12

OVA

For manufacturer setting

0 % 0-100

PB13

NH1

Machine resonance suppression filter 1

4500

Hz

100-4500

PB14

NHQ1

Notch form selection 1

0000

0000-0330h

PB15

NH2

Machine resonance suppression filter 2

4500

Hz

100-4500

PB16

NHQ2

Notch form selection 2

0000

000-0331h

PB17

NHF

Automatic setting parameter

000E

0000-031Fh

PB18

LPF

Low-pass filter

3141

rad/s

100-18000

PB19

VRF1

Vibration suppression control vibration frequency setting

100.0

Hz

0.1-100.0

PB20

VRF2

Vibration suppression control resonance frequency setting

100.0

Hz

0.1-100.0

PB21

VRF3

For manufacturer setting

0.00

0.00-1.00

PB22

VRF4

For manufacturer setting

0.00

0.00-1.00

PB23

VFBF

Low-pass filter selection

0000

0000-0011h

PB24

*MVS

Slight vibration suppression control selection

0000

0000-0021h

PB25

*BOP1

Function selection B-1

0000

0000-1F12h

PB26

*CDP

Gain changing selection

0000

0000-0014h

PB27

CDL

Gain changing condition

10

0-9999

PB28

CDT

Gain changing time constant

1

ms

0-100

PB29

GD2B

Gain changing ratio of load inertia

moment

7.0

0.0-300.0

PB30

PG2B

Gain changing position loop gain

37

rad/s

1-2000

PB31

VG2B

Gain changing speed loop gain

823

rad/s

20-50000

PB32

VICB

Gain changing speed integral compensation

33.7

ms

0.1-5000.0

Instruction Manual Ver1 .08 BS-M3A-1B

tuning mode

acceleration/deceleration time constant

moment to servo motor inertia

倍

- 46 -

BS Controller for AC SERVO PRESS

PB33

VRF1B

Gain changing vibration

setting

100.0

Hz

0.1-100.0

PB34

VRF2B

Gain changing vibration

setting

100.0

Hz

0.1-100.0

PB35

VRF3B

For manufacturer setting

0.00

0.00-1.00

PB36

VRF4B

For manufacturer setting

0.00

0.00-1.00

PB37

VP1

For manufacturer setting

100

pulse

0-32767

PB38

TGW1

For manufacturer setting

0.0

0.0-20.0

PB39

TGW2

For manufacturer setting

0.0

0.0-20.0

PB40

TGW3

For manufacturer setting

0.0

0.0-20.0

PB41

VRFF1

For manufacturer setting

112 5

Hz

1-1125

PB42

VRFF2

For manufacturer setting

112 5

Hz

1-1125

PB43

VRFQ

For manufacturer setting

0004

0000-0304h

PB44

For manufacturer setting

0000

0000-FFFFh

PB45

For manufacturer setting

0000

0000-FFFFh

Parameter C

No.

Symbol

Name

Setting

Unit

Range

Change

required

PC01

STA

Acceleration time constant

0

ms

0-50000

PC02

STB

Deceleration time constant

0

ms

0-50000

PC03

STC

S-pattern acceleration/deceleration time constant

0

ms

0-1000

PC04

TQC

Torque command time constant

500

ms

0-20000

PC05

SC1

Internal speed command 1

100

r/min

0-50000

PC06

SC2

Internal speed command 2

500

r/min

0-50000

PC07

SC3

Internal speed command 3

1000

r/min

0-50000

PC08

SC4

Internal speed command 4

200

r/min

0-50000

PC09

SC5

Internal speed command 5

300

r/min

0-50000

PC10

SC6

Internal speed command 6

500

r/min

0-50000

PC 11

SC7

Internal speed command 7

800

r/min

0-50000

PC12

VCM

Analog speed command maximum speed

0

r/min

0-50000

PC13

TLC

Analog torque command maximum output

100.0

%

0.0-1000.0

PC14

MOD1

Analog monitor output 1

0000

0000-041Fh

PC15

MOD2

Analog monitor output 2

0001

0000-041Fh

PC16

MBR

Electromagnetic brake sequence output

100

ms

0-1000

PC17

ZSP

Zero speed

50

r/min

0-10000

PC18

*BPS

Alarm history clear

0000

0000-0001h

PC19

*ENRS

Encoder output pulses selection

0000

0000-0021h

PC20

*SND

Station number setting

0

station

0-31

PC21

*SOP

Communication function selection

0040

0000-0150h

*

PC22

*COP1

Function selection C-1

0000

0000-1111h

PC23

*COP2

Function selection C-2

0000

0000-1511h

PC24

*COP3

Function selection C-3

0000

0000-0061h

Instruction Manual Ve r1 .08 BS-M3A-1B

suppression control vibration frequency

suppression control resonance frequency

- 47 -

BS Controller for AC SERVO PRESS

PC25

*COP4

For manufacturer setting

0000

0000-0111h

PC26

*COP5

Function selection C-5

0000

0000-0111h

PC27

*COP6

For manufacturer setting

0000

0000-1111h

PC28

*COP7

For manufacturer setting

0000

0000-0000h

PC29

*COP8

For manufacturer setting

0000

0000-0001h

PC30

STA2

Acceleration time constant 2

0000

ms

0-50000

PC31

STB2

Deceleration time constant 2

0

ms

0-50000

PC32

CMX2

Command pulse multiplying factor numerator 2

0

1-65535

PC33

CMX3

Command pulse multiplying factor numerator 3

1

1-65535

PC34

CMX4

Command pulse multiplying factor numerator 4

1

1-65535

PC35

TL2

Internal torque limit 2

1 % 0.0-100.0

PC36

*DMD

Status display selection

100.0

0000-011Fh

PC37

VCO

Analog speed command offset

0000

mV

-999-999

PC38

TPO

Analog torque command offset

1

mV

-999-999

PC39

MO1

Analog monitor 1 offset

0

mV

-999-999

PC40

MO2

Analog monitor 2 offset

0

mV

-999-999

PC41

MOSD1

For manufacturer setting 0

pulse

-1048576-1048 576

PC42

MOSD2

For manufacturer setting 0

pulse

-1048576-1048 576

PC43

For manufacturer setting

0000

0000-FFFFh

PC44

For manufacturer setting

0000

0000-FFFFh

PC45

For manufacturer setting

0000

0000-FFFFh

PC46

For manufacturer setting

0000

0000-FFFFh

PC47

For manufacturer setting

0000

0000-FFFFh

PC48

For manufacturer setting

0000

0000-FFFFh

PC49

For manufacturer setting

0000

0000-FFFFh

PC50

For manufacturer setting

0000

0000-FFFFh

Parameter D

No.

Symbol

Name

Setting

Unit

Range

Change

required

PD01

*DIA1

Input signal automatic ON selection 1

0C00

0000-0FFFh

*

PD02

*DIA2

For manufacturer setting

0000

0000-0000h

PD03

*DI1

Input signal device selection 1 (CN1-15)

00020202

00000000-003F 3F3Fh

PD04

*DI2

Input signal device selection 2 (CN1-16)

00212100

00000000-003F 3F3Fh

PD05

*DI3

Input signal device selection 3 (CN1-17)

00070704

00000000-003F 3F3Fh

PD06

*DI4

Input signal device selection 4 (CN1-18)

00080805

00000000-003F 3F3Fh

PD07

*DI5

Input signal device selection 5 (CN1-19)

00030303

00000000-003F 3F3Fh

PD08

*DI6

Input signal device selection 6 (CN1-41)

00202006

00000000-003F 3F3Fh

Instruction Manual Ve r1 .08 BS-M3A-1B

- 48 -

BS Controller for AC SERVO PRESS

PD09

*DI7

For manufacturer setting

00000000

00000000-0000 0000h

PD10

*DI8

Input signal device selection 8 (CN1-43)

00000A0A

00000000-003F 3F3Fh

PD11

*DI9

Input signal device selection 9 (CN1-44)

00000B0B

00000000-003F 3F3Fh

PD12

*DI10

Input signal device selection 10 (CN1-45)

00232323

00000000-003F 3F3Fh

PD13

*DO1

Output signal device selection 1 (CN1-22)

0004

0000-3F3Fh

PD14

*DO2

Output signal device selection 2 (CN1-23)

000C

0000-3F3Fh

PD15

*DO3

Output signal device selection 3 (CN1-24)

0008

0000-3F3Fh

*

PD16

*DO4

Output signal device selection 4 (CN1-25)

0007

0000-3F3Fh

PD17

*DO5

For manufacturer setting

0003

0000-3F3Fh

PD18

*DO6

Output signal device selection 6 (CN1-49)

0002

0003-0003h

PD19

*DIF

Response level setting

0002

0000-3F3Fh

PD20

*DOP1

Function selection D-1

0000

0000-0011h

PD21

*DOP2

For manufacturer setting

0000

0000-0111h

PD22

*DOP3

Function selection D-3

0000

0000-0211h

PD23

*DOP4

For manufacturer setting

0000

0000-0111h

PD24

*DOP5

Function selection D-5

0000

0000-FFFFh

PD25

For manufacturer setting

0000

0000-FFFFh

PD26

For manufacturer setting

0000

0000-FFFFh

PD27

For manufacturer setting

0000

0000-FFFFh

PD28

For manufacturer setting

0000

0000-FFFFh

PD29

For manufacturer setting

0000

0000-FFFFh

PD30

For manufacturer setting

0000

0000-FFFFh

10.3. Parameter setup of BS controller

Instruction Manual Ve r1 .08 BS-M3A-1B

A parameter required in order to start a program is only tool type selection.

Please setup a stroke limit, acceleration time, and deceleration time if needed.

These can be set up from the tool selection screen of exclusive PC application

BS Configurator. The tool selection screen is shown in Fig. 10-3-1.

Fig. 10-3-1 Tool selection screen

- 49 -

BS Controller for AC SERVO PRESS

10.4. Re-injection of a control power supply

10.5. Check of the brake

Instruction Manual Ve r1 .08 BS-M3A-1B

Tool type setting procedure is explained.

1) Choose a spindle number.

2) Choose a suitable tool name from the pull down list of tool types.

3) A click of the display area of the maximum stroke displays a numerical input

screen. The maximum stroke of a system is inputted. A positive numerical

value smaller than a default numerical value can be set up. If the Max. stroke

is set as longer 5-10mm than the actually used maximum stroke value, the

crash by incorrect operation etc. may be able to be prevented.

4) Set up deceleration time by the same method. Deceleration time is time

required for a tool to stop from top speed. Although a cycle time will be

shortened if deceleration time is shortened, the rate of regeneration load rises.

5) Set up acceleration time by the same method. Acceleration time is time until

a tool reaches top speed from a stop state. Although a cycle time will be

shortened if acceleration time is shortened, large current flows at the time of

acceleration. Since it leads to a rise of the rate of execution load, please be

careful.

6) A click of a send button displays a check screen. A click of O.K. sends the

contents of a display to BS controller.

7) After changing a tool type, a power supply needs to be re-supplied. Please

re-switch on a control power supply after equipping with a backup battery.

The control power supply of MR-J3A is switched on first. It is displayed on the

display area of MR-J3A as AL E6, and blinks. Since the power supply of BS

controller is not on, this shows that MR-J3A is in an emergency stop state. If

the power supply of BS controller is switched on, MR-J3A will be in a normal

state. Supposing MR-J3A is in an alarm state at this time, please specify a

cause from the contents of an alarm display, and remove the cause. In addition,

when alarm is generated, please remove a cause with reference to

troubleshooting.

When a mechanical brake is chosen as an option, please check that a brake is

taken off at the time of operation. Please control a brake by the sequencer

which controls a system. BS system is not equipped with the control and the

interlock function about a brake. Since there is a case where the system was

- 50 -

BS Controller for AC SERVO PRESS

Cautions 1

Cautions 2

10.6. Check of emergency stop

Note

10.7. Origin

If origin is again started from the completion position of origin, ram will once

move in the minus direction. Please design a mechanism so that rum can

operate in the 10mm or more minus direction from the origin point.

10.8. Program creation

Instruction Manual Ve r1 .08 BS-M3A-1B

worked, having forgotten brake release as an example of a trouble, plentifully,

please be careful enough.

and closing. Since the noise control circuit is added to the brake control circuit

of CPS controller, it is not necessary to prepare a serge killer etc. by the user

side.

position maintenance. Please do not use it for braking.

Please check that the emergency stop input (CN33) of BS controller is released,

and MR-J3A will be in the emergency stop state. As for MR-J3A, a dynamic

brake operates in the state of an emergency stop.

In an incremental encoder system, whenever it switches on a control power supply, a

origin is needed. Moreover, also in an absolute encoder system, origin is surely required

at once. Execution of a program cannot be performed in the state of

un-completing an origin. Moreover, in the state of un-completing an origin ,

even in manual operation, the speed of a tool and an output are restricted

A serge noise generates a mechanical brake at the time of opening

The mechanical brake which is an option article is an object for

A dynamic brake is not applicable to position maintenance.

sharply. Speed is restricted to origin speed. An output is restricted to about

10% of the maximum output. Where the load exceeding it is applied, origin

cannot be performed.

There are the following as indispensable data at the time of creating a

program.

1. Contact position with a work

2. Permission Maximum Stroke

3. Permission Maximum Load

These parameters are greatly concerned with the safety of a system. Please

pay careful attention and define a numerical value.

Refer to the applicable item of the operation description of BS Configurator

for program language specification. We recommend you for the more

unfamiliar one to use the program automatic generation function of BS

- 51 -

BS Controller for AC SERVO PRESS

10.9. Execution of a program

Instruction Manual Ve r1 .08 BS-M3A-1B

Configurator. If the numerical value is set up according to the guide screen, a

program will be generated automatically.

Please send the created program to a BS controller.

Although execution of a program is usually performed by PI / O operation, it is

possible even if it uses the program execution function of BS Configurator.

When wiring of PI/O and a control system are incomplete, it is effective as a

check means of operation.

We recommend use of the numerical monitor of BS Configurator, or a

waveform monitor function to debugging of a program. Please refer to the

applicable item of a BS Configurator operation description about those details.

- 52 -

BS Controller for AC SERVO PRESS

11. Troubleshooting

11.1. The state display by LED

LED3

LED4

The state of a

Note

STATUS

CODE

Color

State

Color

State

off off

Power supply off

It may be, when CPU is not operating normally.

off

Green

Blink

Servo off

It is in the state of servo off.

Green

on off

READY

It is in the state in which program execution is possible.

Orange

on off

Under program execution

Blink

-

Battery alarm

Blink of STATUS is not based on a color but means battery alarm. Even when LED3 is off, it is compulsorily green and blinks.

Red

on

Green

on

Slight alarm

It is the alarm resulting from I/O operation and timing.

Red

on

Orange

on

Middle alarm

It is alarm to be set up according to CPS SP Configurator.

Red

on

Red

on

Serious alarm

It is the alarm resulting from the environment of a controller, and hardware.

Instruction Manual Ve r1 .08 BS-M3A-1B

Alarm is generated in many cases in multiplex, and the contents of a display

machine etc. are overwritten by the newest alarm. In order to know the details of

alarm, we recommend you to use the alarm history function of BS Configurator. In

an alarm history function, a monitor is possible for the alarm history of BS

controller and MR-J3A.

There are four LEDs in the front panel upper part of BS controller. Among

those, two pieces are assigned to STATUS and CODE and display the internal

state of CPS controller in the state of these lightings.

controller

－

- 53 -

BS Controller for AC SERVO PRESS

11.2. Alarm code table

Alarm code

Name

Meaning/correspondence

001

The abnormalities

Abnormalities were discovered by the data of the backup

The domain containing abnormalities

Consumption of a

he omission of the connector of a

. When a backup file

backup)

002

The abnormalities

The output is over tolerance level at the time of the calibration of a load cell. Please check calibration value

Configurator handling

has been

, calibration value may be out of order. In this

case, repair is required.

003

The abnormalities

The no-load output value of a load cell is over tolerance

y the monitor

output value may be out of order. In this case, repair is required. Moreover, it may become abnormalities in

the cause of load.

006

Program

The specified user program does not exist in a controller. Please check that an appointed program number is in a controller.

007

Tool

A tool type has not been registered. Please set a suitable tool type as a controller. Consumption of a backup battery

he omission of the connector of a backup battery is

Configurator need to be set up. When a backup file exists,

backup)

008

Origin error

Abnormalities occurred during origin and origin was not

ings can be considered as a

STOP signal is inputted, Excessive load exists. Please remove these causes and perform origin operation again.

009

The abnormalities in SG amplifier

The communication with a tool is unusual. Please check the connection of an encoder cable(CN31).

010

The abnormalities

The typeｓ of the tool connected with the tool type set as

Instruction Manual Ve r1 .08 BS-M3A-1B

An alarm code cannot be known only with a controller. Please use BS

Configurator or the below-mentioned option article.

Basic alarm code

in RAM backup

in CAL

in ZERO

domain of SRAM. is shown by the detailed alarm code. backup battery or t backup battery is suspected(CN11) exists, restoration can restore easily. (Refer BS_Configurator handling description 7-6-2

by manual operation. (Refer BS description 4-3 proofreading) When a tool crashed

level. Please check a load cell output b function. (Refer BS Configurator handling description 4-3 proofreading) When a tool has been crashed, no-load

ZERO if a program is started when load is applied to a tool. In this case, please start a program after removing

un-registering.

or t suspected(CN11). All itmes of thr setup menu in BS

restoration can restore easily. (Refer BS Configurator handling description 7-6-2

completed. The following th factor which bars origin,

- 54 -

BS Controller for AC SERVO PRESS

in a tool type

the controller differ. Please set the right tool type to the controller.

011

The abnormalities

Abnormalities were discovered at the contents of

Configurator. Please consult with a operating window, when there is an unusual numerical value.

013

Basic parameter

The parameter which accompanies a tool has not been

Configurator need to be set up. When a backup file exists,

backup)

014

The abnormalities in the contents of

The parameter exceeding rating is contained in the program under execution. Please check the contents of a user program. When each table is being referred to with speed, the position, and the load parameter, please check the contents of each table.

016

The abnormalities in a driver

It is the alarm about a motor driver. Please refer to a detailed alarm code.

017

AC power supply is OFF state.

AC power supply is in off state. Please check the state of power supply.

018

The abnormalities in origin

A program was started in the state of un-completing an origin.

019

The abnormalities in a data

Access for data collection was not made from PC during user program execution. The abnormalities of data collection PC and Ethernet cable are suspected. When

please set this

function off.

020

Emergency stop

STOP signal of a general-purpose input operated. Please turn off STOP signal and perform reset operation.

021

Tool type

error

The tool type of the performed program differs from the

022

Power supply

demand

Since the backup file was restored, a power supply needs 023

Backup area partial error

The checksum error occurred in a part of backup domain.

024

The abnormalities in JOG operation signal

When JOG_ENA is turned on, JOG+ or JOG- has already

025

It was started in AC power supply OF F.

It was going to work the controller in spite of OFF state

026

Since it is

, it

cannot start.

It was going to start the program in spite of the state of 027

Under operation of JOG or origin

It was going to start the program during JOG operation or origin.

029

Anybus

It failed in initialization of the card which was equipped

Instruction Manual Ve r1 .08 BS-M3A-1B

in EEPROM

or gain parameter un-registering.

Program

EEPROM. Please check the numerical value of each item on the maintenance information screen of BS

registered. All itmes of thr setup menu in BS

restoration can restore easily. (Refer BS Configurator handling description 7-6-2

collection failure

mismatching

re-injection

JOG_ENA ON

you do not perform data collection,

tool type set to the controller.

to be re-supplied.

turned on.

of AC power supply.

ON of JOG_ENA.

- 55 -

BS Controller for AC SERVO PRESS

initialization error

to Anybus. Please check the Anybus card.

030

Tool change error

The power supply is not re-switched on after change of a tool type. A power supply is re-switched on.

031

Anybus error

Abnormalities have occurred in Anybus.

032

A collision of PC

While opening the tool proofreading screen or the tool operation screen of BS Configurator,, program start operation was made via I/O. Please close the tool

a tool operation screen of BS

Configurator at the time of program execution.

033

The error of

kind

The kind of board equipped to Anybus is wrong. Please

set to the controller, and the

kind of actual board.

034

Absolute position

The encoder information of MR-J3A was lost. The

onsumption of the

isconnection of an encoder

This alarm is not resettable unless the power

of a power supp l y, it needs origin operation.

035

The abnormalities

initialization

It failed in communication initialization with MR-J3A.

J3A is on.

check a power supply injection sequence.

036

The abnormalities

The communication with MR-J3A is impossible. Please

J3A is on. Moreover, please check a communication cable. Please check a power supply injection sequence.

037

Torque restriction

value is inaccurate.

The setting value of DAC for a torque restriction voltage 038

Alarm

in

Alarm is generated in MR-J3A. The contents of alarm of

J3A can be checked by the alarm history function of

BS Configurator, or the MR-J3A alarm history function.

040

Servo-off starting error

Origin, JOG, or the program was started in the state of Servo-off. Please start after turning on SERVO_ON.

041

MR-J3 ABS setup

Some error is in a parameter setup of MR-J3A. Encoder

correctly.

042

MR-J3 ABS type

It failed in reading of encoder specification at initialization after a power supply injection of a

Please check the communication cable which

J3A with CN6 or CN7 of

BS-M3A-1B.

051

Post judgment

Although the post judgment was used, PC did not answer within regulation time. Please check that PC is in a data collection state. Moreover, about a setup of the response

Configurator handling

description 7-7-7 others.

053

Anybus

The communication with the master of a network

Instruction Manual Ve r1 .08 BS-M3A-1B

and PLC

proofreading screen or

Anybus board

is lost

in MR-J3A communication

proofreading

MR-J3A.

check the kind of Anybus

following causes can be considered-c backup battery of MR-J3A,d cable. supply of BS system is re-switched on. After a re-injection

Please check whether the power supply of MRMoreover, please check a communication cable. Please

check whether the power supply of MR-

output is over the range.

MR-

error

specification is not set as the absolute type via serial communication. Please set up the parameter of MR-J3A

read error

controller. connects CN3 of MR-

response error

time from PC, please refer BS

- 56 -

BS Controller for AC SERVO PRESS

communication error

stopped. The omission of the communication cable or the abnormalities of the master are suspected.

098

The abnormalities in a battery

Backup battery voltage fell. A battery needs to be exchanged.

Alarm code

Name

Meaning/correspondence

102

FPGA error.

They are the abnormalities of a logic IC. Repair is required.

103

Updating timing violation of a basic parameter.

A tool type setup was performed during servo-on. Please do not perform a tool type setup during program execution.

104

Origin isn’t finished.

Positioning operation was performed for orogin not to be performed. Please perform origin.

200

The abnormalities

Abnormalities were discovered by the contents of a motor table. Please refer to the details of a motor table.

202

Outside of the

current.

Abnormalities were discovered by the contents of a motor table. Please refer to the details of a motor table.

203

Rated current is outside of the range.

Abnormalities were discovered by the contents of a motor table. Please refer to the details of a motor table.

204

Outside of the

Abnormalities were discovered by the contents of a motor table. Please refer to the details of a motor table.

207

Outside of the

max rated

current.

Abnormalities were discovered by the contents of a

a motor

table.

211

Outside of the

direction.

Abnormalities were discovered by the contents of a

212

Outside of the

direction.

Abnormalities were discovered by the contents of a

213

Outside of the

resolution.

Abnormalities were discovered by the contents of a 214

Outside of the range-origin speed.

Abnormalities were discovered by the contents of a tool table. Please refer to the details of a tool table.

215

Outside of the range-creep speed.

Abnormalities were discovered by the contents of a tool table. Please refer to the details of a tool table.

216

Outside of the

sensor logic.

Abnormalities were discovered by the contents of a

217

Outside of the

Abnormalities were discovered by the contents of a

Instruction Manual Ve r1 .08 BS-M3A-1B

Detailed alarm code

It is a detailed alarm code in the case of the abnormalities in a driver

in a motor type

range-rated

range-max speed.

range-

range-encorder

range-origin

range-encorder

motor table. Please refer to the details of

tool table. Please refer to the details of a tool table.

range-origin

tool table. Please refer to the details of a tool table.

- 57 -

BS Controller for AC SERVO PRESS

range-load cell type.

tool table. Please refer to the details of a tool table.

218

Outside of the

limit.

Abnormalities were discovered by the contents of a

308

Outside of the

stop speed

ratio.

Abnormalities were discovered by the contents of a 309

Outside of the range-deceleration.

Abnormalities were discovered by the contents of a tool table. Please refer to the details of a tool table.

310

Outside of the

ratio.

Abnormalities were discovered by the contents of a

400

Outside of the

They are the abnormalities of a control mode

on of a microcomputer is suspected. Repair is required, if, so that it may occur frequently.

401

Over limit-target

Since there was a possibility of the stroke limit having been exceeded or exceeding, it went into the stop mode.

402

Over limit-target speed.

The speed target value exceeding the limit was set up.

404

Inconsistency of pulus limits.

- side of stroke restriction value was set up more greatly than + side.

410

Outside of the

The parameter in the positioning mode is unusual. Incorrect operation of a microcomputer is suspected. Repair is required, if, so that it may occur frequently.

411

Outside of the

time.

The setting value of acceleration time is over the

le or check

a tool setup.

530

Z phase ditected

The encoder incorrect-counted. Incorrect operation by the abnormalities in an encoder cable and the noise can be considered. Please add filters, such as a ferrite core, to a noise generation source.

532

ABZ of encoder alarm.

Disconnection detection of an encoder cable operated. Please check the plug of a connector.

536

Z-phase lost

Z phase of the encoder was not detected more than a

The failure relevant to an encoder cable or

an encoder is suspected.

540

Limit over-stroke.

The stroke limit was exceeded. Please move by manual operation after reset at within the limits.

550

Limit over-current

Current restriction value was exceeded at the time of

, the big load at the time of

should set the concerned part of a tool table as

proper value.

551

Limit over-stroke

The stroke range currently assumed by origin

originsensor is suspected.

load in

Please check

Load cell recieve

The communication state with load cell amplifier is not good.

Instruction Manual Ve r1 .08 BS-M3A-1B

range-current

range-

range-deceleration

range-control mode.

stroke.

range-stroke mode.

tool table. Please refer to the details of a tool table.

parameter. Incorrect operati

range-acceleration

wrong timing.

in origin mode.

552 Limit over-

origin mode

553

range. Please improve a setup of a tool tab

fixed term.

origin. In such a case origin

sequence was exceeded. The abnormalities of an

Load restrictions worked before origin finished. whether there is any nothing that bars a motion of ram.

- 58 -

BS Controller for AC SERVO PRESS

re against a noise is required. It is, when the load

1001-1031

The abnormalities in a program

Abnormalities were detected in the program number (detailed alarm code -1000).

1101-1131

The abnormalities in Judge Table

Abnormalities were detected in Judge Table number (detailed alarm code -1100).

1201-1231

The abnormalities in Zone Table

Abnormalities were detected in Zone Table number (detailed alarm code -1200).

1301

The abnormalities in Position Table

Abnormalities were detected in Position Table.

1302

The abnormalities in Load Table

Abnormalities were detected in Load Table.

1303

The abnormalities in Speed Table

Abnormalities were detected in Speed Table.

1304

The abnormalities

Table

Abnormalities were detected in Home Position Table. 1400

The abnormalities in Tool Table

Abnormalities were detected in Home Tool Table.

1601

The abnormalities in Numerical data

Abnormalities were detected in the pointer of Numerical data.

1602

The abnormalities in Numerical data

Abnormalities were detected in Numerical data.

1603

The abnormalities in Waveform data

Abnormalities were detected in the pointer of Normal Waveform data.

1604

The abnormalities in Waveform data

Abnormalities were detected in Normal Waveform data.

1605

The abnormalities in Waveform data

Abnormalities were detected in the pointer of NG Waveform data.

1606

The abnormalities in Waveform data

Abnormalities were detected in NG Waveform data.

1701

The abnormalities in Alarm history

Abnormalities were detected in the pointer of Alarm history.

1702

The abnormalities in Alarm history

Abnormalities were detected in Alarm history.

1801

The abnormalities in Backup time

Abnormalities were detected in Backup time.

1802

The abnormalities

times

Abnormalities were detected in Total running times.

1803

The abnormalities

Total running

distance

Abnormalities were detected in Total running 1901-1904

The abnormalities in Others

Abnormalities were detected in Others.

1905

The abnormalities in JOG speed

Abnormalities were detected in JOG speed

1906

The abnormalities in Load/Stroke output interval

Abnormalities were detected in Load/Stroke output

Instruction Manual Ve r1 .08 BS-M3A-1B

error The measu

sensor connector has fallen out.

in Home Position

in Total running

in

distance.

interval.

- 59 -

BS Controller for AC SERVO PRESS

1907

The abnormalities in Others

Abnormalities were detected in Others.

1908

The abnormalities in Load Rate Parameters

Abnormalities were detected in Load Rate 2001-2010

The abnormalities

in Unused area

Abnormalities were detected in Unused area.

Instruction Manual Ve r1 .08 BS-M3A-1B

Parameters.

- 60 -

BS Controller for AC SERVO PRESS

12. Regeneration

Caution

12.1. Lowering regeneration frequency

12.2. Regeneration option

Instruction Manual Ve r1 .08 BS-M3A-1B

The regeneration electric power which occurs by rapid slowdown is changed

into heat by regeneration resistance. In BS Configurator, a monitor is possible

for the rate of regeneration load. If the rate of regeneration load exceeds 85%,

it will become the alarm of the abnormalities in regeneration (caution). There

are two methods in avoiding the abnormalities in regeneration. The first is the method of lowering regeneration frequency.、The second is the method of using

more nearly mass regeneration resistance.

rate of regeneration load exceeds 85%, by BS controller, warning is also treated

as alarm.

Although there are a method of lengthening slowdown time, and a method of

taking long operation pause time in order to lower regeneration frequency ,in

all a cycle time becomes long.

The larger regeneration option is prepared by Mitsubishi Electric than the

regeneration resistance built-in MR-J3A. Refer to the technical data of MR-J3A

for the details of a regeneration option.

When it corresponds to the regeneration of high frequency by the

regeneration option, it is necessary to consider the temperature rise in a

control board. I ask measure, such as attaching a cooling device so that the

temperature in a control box may not exceed 50 degrees C, of you.

Although it is the warning of fault regeneration as MR-J3A when the

- 61 -

BS Controller for AC SERVO PRESS

13. Absolute encoder system

13.1. Setup

13.1.1. Setup to BS controller

13.1.2. Setup to MR-J3A

13.1.3. Wearing of a backup battery

13.2. The alarm release method

Important

Instruction Manual Ve r1 .08 BS-M3A-1B

MR-J3A corresponds to the absolute encoder system. Therefore, BS system can also

be equivalent to the absolute encoder system.

In the tool type of absolute encoder system, "A" is attached to the end of tool

type form.

PA03 is set as 0002 by parameter setup. In the 1st power supply injection after

performing this setup, the alarm of AL.25-" absolute position disappearance"

will be generated at MR-J3A. The release method of the alarm is mentioned

later.

Please equip CN4 of MR-J3A with the backup battery of exclusive use.

The alarm of AL.25 "absolute position disappearance" will occur in MR-J3A by

a power supply injection of the first time after absolute encoder system setup,

consumption of a backup battery and disconnection of an encoder cable. AL.25

will be canceled if the power supply of MR-J3A is re-switched on after

removing some causes of alarm.

power supply of BS controller is switched on when AL.25 occur, BS controller

will be in the state where origin is not completed. In this case, execution of a

program etc. cannot be performed unless origin operation is completed. When

AL.25 occurs, please perform origin operation after re-switching on a power

supply.

If wiring connection of the BS system is made normally and the

- 62 -

BS Controller for AC SERVO PRESS

14. Load-Sensor-less System

Item

load-sensor-less

with load sensor

Load value

It computes from motor current.

Load cell value Accuracy

15%@Tool rating

2%@Tool rating

Renewal cycle of load value

1ms

At the time of

It has no problem to the

system.

A load cell carries out plastic modification in about 150% of its rating.

Disconnection

No

It is detected by ZERO and CAL alarm.

Price

Only the part without a load cell is cheaper.

Only the part of a load cell is more expensive.

Instruction Manual Ve r1 .08 BS-M3A-1B

The load-sensor-less tool is also prepared in this system. The special feature is

shown in a comparison table.

±

crash

Since there are the above special features, please choose the system according to

the use.

amount of -proof of a tool and a

±

- 63 -

BS Controller for AC SERVO PRESS

15. Tool Type Discernment

Instruction Manual Ve r1 .08 BS-M3A-1B

Information, such as a tool type name and load cell proofreading value, is written in

BS tool. It will become alarm if the tool name different from the tool linked to BS

controller is set up.

About connection of BS controller and MR-J3A, there is no function to recognize the

capacity of MR-J3A in BS controller. Therefore, incorrect connection is not detected.

In multi-spindles composition, I ask sufficient consideration for connection of BS

controller, MR-J3A, and a motor of you.

- 64 -

BS Controller for AC SERVO PRESS

16. Stole

Instruction Manual Ve r1 .08 BS-M3A-1B

A stole can be carried out with arbitrary load value by executing a load restriction

command on a program. Load accuracy is a 15%@FS grade. In the case of a stole,

droop pulses occurs at a maximum of 2 rotations on a motor. If the procedure of

canceling load restrictions is mistaken, ram will operate abruptly, and there is a

risk of causing breakage of a work and a system. Please cancel load restrictions

after solving droop pulses.

- 65 -

BS Controller for AC SERVO PRESS

17. Others

17.1. The options of the servo press

BS Configurator

It is exclusive application software which operates on Windows of IBM

etup of a

user program, data collection, etc. can

LED DISPLAY This is two steps of 6 figure display

232C port of a

controller. Monitors, such as a

Electromagnetic brake It is effective when preventing the slide

off. A

BS Configurator

Instruction Manual Ve r1 .08 BS-M3A-1B

The options of the servo press are shown below.

compatible machine. S controller, a maintenance, and editing a

be performed.

machines by 7 segment LED. It connects with RS-

numerical result, can be done.

of the ram at the time of servo brake is not controlled by BS controller.

- 66 -

BS Controller for AC SERVO PRESS

18. Article of Consumption

18.1. Battery

18.1.1. The detection method

18.1.2. The exchange method

18.1.3. Management

18.1.4. Clock setup

18.2. Parts having service lives of MR-J3A

Part name

Life guideline

Smoothing capacitor

10 years

Relay

Number of power-on and number of

stop times : 100,000 times

Cooling fan

10,000 to 30,000hours (2 to 3 years)

Absolute position battery

Approx. 10,000 hours (battery life with power off)

Instruction Manual Ve r1 .08 BS-M3A-1B

The visual check of the abnormalities in a battery can be carried out by blink of

LED3 STATUS in the front panel upper part of a controller.

Moreover, since a battery unusual signal is outputted also from a

general-purpose output, it is detectable also by PLC.

Although the life of a backup battery is about five years, it varies greatly

according to a state of operation and environment of operation. If the

abnormalities in a battery occur, please exchange a backup battery quickly.

Battery exchange is carried out in the state of power supply ON. If batteries

are exchanged in the state of power supply off, a backup circuit will not operate

normally but consumption of a battery will progress remarkably.

Exchange date of a backup battery is memorized in a controller by BS

Configurator, and a monitor of it is possible. Moreover, calculation of the net

backup time is count. Please use it for management of a backup battery.

This controller is equipped with the clock function. In the case of battery

exchange, we recommend you to setup of a date and time.

Please refer to the collection of servo amplifier technical data of MR-J3A for

details.

emergency

- 67 -

BS Controller for AC SERVO PRESS

19. Maintenance of Tool

20. Cautions on abandonment

Revision history

CORETEC Fastening Innovators

500 Akahama,Soja City,

Okayama Pre 719

Sales Dept. TEL 0866

Instruction Manual Ve r1 .08 BS-M3A-1B

About a tool, we recommend you implementation of a periodical maintenance.

By BS controller, the number of times of operation and the total information on

the mileage of a ball screw are managed. A monitor is possible for these

information by the maintenance information function of BS Configurator. A

near maintenance cycle can be obtained from these information and the load

situation of a program. Please ask for details the window in your duty.

An overhaul must be carried out at our company and any overhaul carried

out by another company falls outside our guaranteed coverage.

If you have any questions on the Servo press, please contact us.

Devices into which electronic equipment is mounted must not be discarded as

domestic waste. Please obey the local laws or regulations effective at present

for electrical and electronic equipment waste.

-1121

-94-9016

- 68 -

Coretec BS Series, BS100 Series, BS200 Series, BS-M3A-1B Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1. For safe use

1.1. Regarding symbols

Observe the following for safety

Caution on attachment and use.

Make sure to observe for sequencer circuit

EMC directive

Others

1.7. The relation with the Mitsubishi Electric servo system

2. Before use

2.1. Characteristics of Servo press

2.1.1. Possible to record program execution result

2.1.2. Programmable action possible

2.1.3. Display of load and stroke during program execution and Graph display

2.2. The suiting tool

2.3. Accompanying items

About the model name and the version

2.4.1. Anybus option

3. Specifications

3.1. Specifications of BS-M3A-1B

3.2. Specifications fo brake

3.3. Common specification of MR-J3A

3.4. Specification peculiar to the tool type

3.4.1. BS100 series

3.4.2. BS200 series

4. Construction

4.1. Name of each part of the controller

4.2. Outline

4.3. Connection figure (include options)

4.3.1. BS100

4.3.2. BS200

5. Installation

5.1. Procedures for installing to control panel

5.1.1. Designing conditions for control box

5.1.2. Cautions when installing BS

5.1.3. The interval with MR-J3A

5.1.4. Noise Filter of MR-J3A

6. Installing lines

6.1. Load cell i/f(CN31)

6.2. Origin sensor i/f(CN32)

6.3. MR-J3A parallel i/f(CN33)

6.4. Emergency stop(CN34)

6.5. RS-232C(CN4)

6.6. RS-232C(CN5)

6.7. RS-485(CN6,7)

6.8. Ethernet(CN8)

6.9. Parallel I/O (CN9)

6.9.1. Bit assignment

6.9.2. PIO connector pin assignment

6.9.3. Wiring by the side of input

6.9.4. Wiring by the side of output

6.10. Control power supply (CN10)

6.11. Backup battery（CN11）

6.12. Anybus

6.13. Brake

6.14. Motor cable

6.15. Encoder Cable

Timing Chart

7.1. Power supply injection

7.2. Alarm reset

7.3. Origin

7.4. JOG

7.5. Program execution

Program execution using Post Judge

Writing of a product name and a serial number

Post Judge

8. Concept of stroke

8.1. Semi closed loop

8.2. Direction

8.3. System home position

8.4. User home position

8.5. System stroke limit

8.6. User stroke limit

8.7. If the stroke limit is exceeded

8.8. A motion of the ram at the time of servo off

9. Connection with Personal Computer

9.1. Spindle number setup