FEC DSP1500 User Manual
DSP1500E-HM-4
51327 Quadrate Drive Phone: (586) 781-2100
Macomb, MI. 48042 Fax: (586) 781-0044
Web: www.fec-usa.com
enFORCE
DSP1500 Main Unit
Hardware M an u a l
SECOND Edition October 2008
Automation Systems
E-mail: support@fec-usa.com
WARNING
All applicable national and local codes must be followed when installing and operating the equipment detailed in
this manual.
FAILURE TO ABIDE BY THESE CODES AND THE SPECIFICATIONS DESCRIBED IN THIS MANUAL
CAN RESULT IN SERIOUS INJURY TO PERSONNEL AND/OR DAMAGE TO THE EQUIPMENT!
Any questions regarding the contents of this document or any related matter should be
directed to FEC INC. at (586) 781-2100, faxed to (586) 781-0044 or emailed to support@fec-usa.com
The information set forth in the following docu ment is the prop er ty of FEC INC.
This document shall not be released to or c opied for any person and/or organization
Without the expressed prior consent of FEC INC.
Unauthorized reproduction or distribution of this manual is strictly prohibited.
Please contact FEC INC. if you require additional copies.
.
ii
A
Revision
3 01/2007 Initial Release
4 10/2008
DSP1500 = Servo Press
DSP1500 = Servo Press
AFC1500 = Nutrunner
AFC1500 = Nutrunner
FUSION = DC Hand Tool
FUSION = DC Hand Tool
E = English Version
S = Spanish Version
I = Italian Version
*Japanese Version f urn ished b y DDK
uses DDK numbering convention.
Revision
Date
Revision His tory
dded References for Ethernet Version. Added User Console Ethernet
Port. Expanded on Control Interfaces information.
Manual Numbering Convention
DSP1500E-HM-4
Ver sion Nu mber
(Major Revision Level)
HS = SAN Unit Hardware
Operation Manual
HM = Multi / Main Unit Hardware
Operation Manual
HM-ENET = Ethernet Manual for
Multi / Main Unit
SW = Software Manual
iii
Introduction
Thank you for purchasing our Electric Servo Press - DSP1500 System.
This instruction manual describes the procedures for installation, wiring, handling and
actions to be taken in case of any failure.
◆ This instruction manual shall be delivered to the end user who operates the equipment.
◆ Read all instructions before use and always keep this instruction manual with the
equipment.
◆ Items not described in this instruction manual shall be considered “unavailable”.
◆ The product specification and appearance described in this instruction manual is subject to
change without notice.
◆ All rights reserved. Any disclosure, copying, distribution, or use of the information
contained herein for other than its intended purpose, is strictly prohibited.
◆ It is important for you to read all “Safety Precautions” before using the equipment, and
understand and observe all instructions and recommendations included in this manual.
◆ Read all instructions and recommendations included in this manual, understand the
functions and performance of this servo press, and correctly use this machine.
◆ Wiring and para meter setting shall only be conducted by a qualified professional.
◆ Never conduct a withstand voltage test or insulation resistance test on this equipment.
◆ Indicate the following on all instruction manuals that use this equipment.
”This equipment is capable of high voltages hazardous to human life.”
Please confirm the following when unpacking this equipment:
◆ Ensure that you received the correct model as ordered.
◆ Ensure that there are no missing parts.
◆ Check for any damage caused during transportation.
For the safety of operator and equipment
Points to check when unpacking
iv
Introduction
Warranty Period
The standard warranty period is one year from the date of purchase or one year from delivery to
the designated End User (not to exceed 18 Months). Actual terms are order specific.
Provision of warranty
If at any time during the warranty period your product proves to be defective, it will be repaired
free of charge as long as it was used properly in accordance with this instruction manual.
However, t he customer will be required to pay for repair charges in the following cases even if the
defects occurred within the warranty period.
1. Any defect due to improper conditions, improper circumstances and improper handling.
2. Any defect due to modifications or repairs performed by the customer.
3. Any defect caused by other equipment.
4. Any defect caused by customer failing to meet the equipment’ s speci fication.
5. Any defect due to natural disasters and accidents.
This warranty shall be limited to repairing or replacing this product. Any liability for indirect or
consequential loss or damage of any kind incurred or suffered by the customer due to a defect of
the product is excluded.
Warranty
v
Safety Precau tion s
Read all instructions before operating the equipment in order to use this equipment safely and correctly.
Read this instruction manual carefully and fully understand the equipments functions, safety precautions
and instructions prior to using the equipment. Safety precautions in this manual are marked with two
symbols [Warning] and [Caution].
To prevent danger to the user and other persons as well as property damage, instructions that must be
fully observed are marked with the symbols below.
◆ This instruction manual uses the followi ng two sy mbols according to the deg ree o f damage that may
be caused when the instruction is not observed.
Even instructions that are marked with may result in severe damage if they are
not observed according to conditions.
Contents marked with the above symbols are very important instructions. For your safety, follow all
instructions and especially those marked with these symbols.
◆ This instruction manual uses the following additional symbols for instructions that shall be observed.
Warning
Caution
Warning:
Pinch Point
Caution:
Fire
Prohibited
Required
This symbol indicates that failure to observe instruction marked
with this symbol may result in severe personal injury or death.
This symbol indicates that failure to observe instruction marked
with this symbol may result in minor personal injury or material
damage.
Caution
Warning:
Electric shock
Caution:
Electric shock
Warning:
Fire
Caution:
High Temperature
Do not disassemble
Ground
vi
Safety Precautions
Never touch press ram during operation.
Failure to do so may cause injury.
Make sure t hat no part of you r body gets near any moving par t of the tool e ven while the
equipment is at r est. The press ram m ay lower for som e r eason resulting in injury.
When performin g maintenance or inspectio n, be sure to secure the press ram with safety
blocks to prohibit the ram from lowering.
Do not remove the motor and gear case of tool.
The press ram may lower resulting in injury.
Do not repair, disassemble , or modify the equipment individual components of the system.
Failure to obser v e this instruction may cause injur y, electric shock , f ir e, and malfunction.
Never operat e the equipm ent where it i s exposed to water, near a corros ive atmospher e or
flammable gases. Failure to observe this instruction may cause fire.
Keep fingers away from the connectors while the equipment is turned ON and for a while
after the equipment is turned OFF. Failure to observe this instruction may cause electric
shock.
Wiring operation and maintenance work shall be conducted by a qualified professional.
Failure to obser v e this instruction may cause electric s hock and injury.
Turn OFF the power when conducting wiring operation and maintenance. Failure to observe
this instruction may cau se ele ctr i c sho ck and injur y.
Never damage the cables, apply excess stress to cables, or squeeze the cables. Never use
damaged cables. Failure to observe this instruction may cause electric shock and fire.
Conduct type-3 grounding of FG terminals.
Failure to observ e this instruction may cause electric s hock.
In case of an abnormal odor, noise, or operation error occurrence, stop operation
immediately and turn OFF the power source. Failure to observe this instruction may cause
injury and fire.
Install a Power shutdown device in order to ensure the safety of equipment.
Failure to observ e this instruction may cause injury.
Install an emergency stop circuit on the outside of equipment in order to stop operation
promptly. Failure to observe this instruction m ay cause injury.
Keep away from the equipment during recovery from a temporary blackout, and ensure
safety measur es are condu c ted after restarting the equipment. The equip m ent may suddenly
restart. Failure to observe this instruction may cause injury.
Warning
vii
Safety Precautions
Transportation / Storage
Transport the equipme nt properly according to its weight.
Failure to obser v e this instruction may cause injury and malfunction.
The conditions when transporting the equipment by ship is as below.
◆Ambient temperature: -5°C～+55°C (Avoid freezing)
◆Ambient humidity: 50% RH or lower (Avoid moisture)
◆Package: Tight seal
◆Rust prevention measure: Apply grease or oil on tools.
Failure to obser v e this instruction may cause earth lea kage and malfunct ion.
Do not hold cables or press ram when transport ing the tools.
Failure to obser v e this instruction may cause injury and malfunction.
Do not hold the indictor on the front panel when transporting the SAN Unit.
The indicato r may come off and d rop from the front panel.
Failure to obser v e this instruction may cause injury and malfunction.
The equipment shall be stored under the following conditions.
◆Ambient temperature: -5°C～+55°C (Avoid freezing)
◆Ambient humidity: 90% RH or lower (Avoid moisture )
◆Atmosphere: Indoors (Avoid direct sunlight)
No
No oil m ist, dust, water, salt, iron powder
◆Avoid direct vibration or shocks
Failure to obser v e this instruction may cause earth lea kage and malfunct ion.
corrosive gases or flammable gases
Caution
viii
Safety Precau tion s
g
Installation / Wirin
Install the tools in a place that can support the weight and maximum load during operation.
Failure to observe this instruction may cause injury and malfunction.
Install the MAIN and/or SAN Units fir m ly inside the con trol panel using the s pecified screws.
Failure to observe this instr uction may cause m alfunction.
Use the specified tool for the SAN Unit.
Failure to observe this instr uction may cause fire and malfunction.
The MAIN and/or SAN Units shall ma intain the specified distance from other devices.
Failure to observe this instr uction may cause fire and malfunction.
Do not block the ventilation hole of the MAIN and/or SAN Units.
Avoid any foreign body from entering inside the equipment.
Failure to observe this instr uction may cause fire and malfunction.
The power source shall be provided with safety measures such as breakers and circuit
protectors. Failure to observe this instruction may cause fire and malfunction.
Do not use too ls or MAIN and/o r SAN Units that are damaged or have missing parts.
Failure to observe this instr uction may cause fire, injury, and malfunction.
Do not climb on top of the equipm ent or place he avy objects on the top of equipment.
Failure to observe this instruction may cause injury, and malfunction.
Do not subject the equipment to excess shock and impact.
Failure to observe this instr uction may cause m alfunction.
Conduct wiring properly and firmly.
Failure to observe this instr uction may cause injury, false operation, and malfunction.
Operate the equipment within the specified po wer supply voltage.
Failure to observe this instruction may cause injury, electric shock, fire, and malfunction.
When operat ing the equ ipment in the follow ing condit ion s, tak e sufficien t mea sures t o shie ld
the equipment .
◆Locations where electrical nois e is generated.
◆Locations where the equipment is subjected to a strong electric field or magnetic field.
◆Locations near high power wiring.
Failure to observe this instr uction may cause injury, false operation, an d malfunction.
Caution
ix
Safety Precautions
Operation / Adjustment
Never operate the equipme nt with wet hand s.
Failure to observe this instruction may cause e l ectric shock.
Keep fingers aw ay from the SAN U nit radiating f ins and tool motor while the equipment is
turned ON or for a while after the equipment is turned OFF. These parts may become very
hot. Failure t o observe this instr uction may cause bur ns.
Use the equipment under the following conditions.
◆Ambient temperature: 0°C～+45°C (Avoid freezing)
◆Ambient humidity: 90% RH or lower (Avoid moisture)
◆Atmosphere: Indoors (Avoid direct sunlight)
No
No oil mist, dust, water, salt, iron powder
◆Avoid direct vibration or shocks
Failure to observe this inst r uction may cause earth leak age and malfunction.
Confirm and adjust all parameters before operation in order to prevent unexpected
movement of t he equipmen t.
Failure to observe this in str uction may ca use injury, false operation and malfunction.
Never conduct extreme adjustments or setting changes that may cause instability of
operation.
Failure to observe this in str uction may ca use injury, false operation and malfunction.
The equipment may restart suddenly when the equipm ent is reset with the start signal ON.
Always ensure that the start signal is O FF before resettin g the equipment.
Failure to observe this in st r uction may ca use injury.
Do not turn ON and OFF the equipment repeatedly.
Failure to observe this instr uction may cause m alfunction.
Do not use the equipment at l oads higher than the maximum lo ad.
Failure to observe this instruction may shorten equipment life or cause malfunction due to the
high temperature caused by overload.
The magnetic brake is for holding the press ram when performing maintenance procedures.
Do not use for normal braking otherwise failure m ay result.
The magnetic brake may fail to hold near the end of its life expectancy due to wear.
Secondary braking structures should be installed on the machine side to safely secure
otherwise injury may result.
In case any abnormality occurs, remove the cause and ensure safety before resetting and
restarting the equipment.
Failure to observe this inst r uction may cause injury.
corrosive gases or flammable gases
Caution
x
Table of Contents
Chapter 1: Outline
1.1 About this Manual......................................................................................... 1-2
1.2 Functions...............................…..……………………………………………… 1-3
1.3 Safety Precautions……….....…..………………………………………………. 1-4
Chapter 2: Specifications
2.1 Specifications.........................………………………………………………….. 2-2
2.2 Unit Dimensions……….................................…….…………………………… 2-3
Chapter 3: System Description
3.1 System Block Diagram...........………………………………………………….. 3-2
3.2 Unit Description…….....................................…….…………………………… 3-3
Chapter 4: Installation & Wiring
4.1 Unit Dimensions.....................………………………………………………….. 4-2
4.2 Installation…….............................................…….…………………………… 4-3
4.3 Power Wiring Reference........………………………………………………….. 4-4
4.4 Input Power Connection........………………………………………………….. 4-5
4.5 RS485 Connection…….........………………………………………………….. 4-5
4.6 Serial Communication Ports..………………………………………………….. 4-6
4.6.1 PC Port………............................………………………………………….. 4-7
4.6.2 Display Port…............................………………………………………….. 4-7
4.6.3 Data-Out (1) Port........................………………………………………….. 4-7
4.6.3.1 Available Output Data...........………………………………………….. 4-8
4.6.3.2 Output Data Format..............………………………………………….. 4-9
4.6.4 Data-Out (2) Port........................………………………………………….. 4-10
4.6.5 Data-In Port…............................………………………………………….. 4-10
4.6.6 Serial Communication Cables….………………………………………….. 4-11
4.7 User Console Ethernet Connection..…… ……… …………………………….. 4-12
4.8 PLC Interface Communication (I/O).………………………………………….. 4-13
4.8.1 External I/O Disable Switch…....………………………………………….. 4-14
4.9 Firmware Flash Connector………….………………………………………….. 4-14
Chapter 5: Control Interfaces
5.1 Interface Board Setup……….………………………………………………….. 5-2
5.2 Signal Timing Chart…..................................…….…………………………… 5-3
5.2.1 Sequence Operation..................………………………………………….. 5-3
5.2.2 Jog (Manual) Operation.............………………………………………….. 5-4
xi
Table of Contents
5.3 Discrete I/O Interface….........………………………………………………….. 5-5
5.3.1 Sinking Type (NPN)…................………………………………………….. 5-5
5.3.1.1 Discrete Signal Connection (Sinking Type)………………………….. 5-6
5.3.2 Sourcing Type (PNP)..................………………………………………….. 5-7
5.3.2.1 Discrete Signal Connection (Sourcing Type).……………………….. 5-8
5.3.3 Input Signals (PLC-IN)................………………………………… ……….. 5-9
5.3.4 Output Signals (PLC-OUT).........………………………………………….. 5-11
5.3.4.1 Output Data Banks.…...........………………………………………….. 5-15
5.4 Interbus S
5.4.1 Component Descriptions............………………………………………….. 5-18
5.4.2 User Console Software Settings ………………………………………….. 5-19
5.4.3 Input Signals (Reference Layout)..……………………………………….. 5-20
5.4.4 Output Signals (Reference Layout)……………………………………….. 5-22
5.5 DeviceNet
5.5.1 Component Descriptions...........………………………………………….. 5-25
5.5.2 User Console Software Settings ………………………………………….. 5-26
5.5.3 Input Signals (Reference Layout)..……………………………………….. 5-27
5.5.4 Output Signals (Reference Layout)……………………………………….. 5-29
5.6 Profibus
5.6.1 Component Descriptions............………………………………………….. 5-32
5.6.2 User Console Software Settings ………………………………………….. 5-33
5.6.3 Input Signals (Reference Layout)..……………………………………….. 5-34
5.6.4 Output Signals (Reference Layout)……………………………………….. 5-36
5.7 Modbus Plus
5.7.1 Component Descriptions............………………………………………….. 5-39
5.7.2 User Console Software Settings ………………………………………….. 5-41
5.7.3 Input Signals (Reference Layout)..……………………………………….. 5-42
5.7.4 Output Signals (Reference Layout)……………………………………….. 5-44
5.8 CC-Link
5.8.1 Component Descriptions........... ………………………………………….. 5-47
5.8.3 Input Signals (Reference Layout)..……………………………………….. 5-49
5.8.4 Output Signals (Reference Layout)……………………………………….. 5-51
5.9 CC-Link
5.9.1 Component Descriptions............………………………………………….. 5-54
5.9.2 User Console Software Settings ………………………………………….. 5-56
5.9.3 Input Signals (Reference Layout)..……………………………………….. 5-57
5.9.4 Output Signals (Reference Layout)……………………………………….. 5-59
5.10 Allen-Bradley Remote I/O Interface………………………………………….. 5-60
5.10.1 Component Descriptions...........………………………………………….. 5-62
5.10.2 User Console Software Settings .……………………………………….. 5-63
5.10.3 Input Signals (Reference Layout).……………………………………….. 5-64
5.10.4 Output Signals (Reference Layout).…………………………………….. 5-66
Interface..…........………………………………………………….. 5-16
®
Interface.…........………………………………………………….. 5-23
®
Interface.……...... ..………………………………………………….. 5-30
®
Interface.........………………………………………………….. 5-37
®
Interface (Version 1)..……………………………………………….. 5-45
®
Interface (Version 2)..……………………………………………….. 5-52
®
xii
Table of Contents
5.11 Ethernet-I/P Interface…........………………………………………………….. 5-67
5.11.1 Component Descriptions...........………………………………………….. 5-68
5.11.2 User Console Software Settings. .……………………………………….. 5-69
5.11. 3 Input Signals (Reference Layout).……………………………………….. 5-70
5.11.4 Output Signals (Reference Layout)..…………………………………….. 5-72
5.11.5 PLC Message Transfer Setup Example…..…………………………….. 5-73
Chapter 6: Troubleshooting
6.1 Abnormals…………………….………………………………………………….. 6-2
xiii
Blank Page
xiv
Chapter 1: Outline
Chapter 1: Outline
enFORCE DSP1500 Main Unit Hardware Manual
1.1 About this Main Unit Manual
This manual details the configuration, specifications and the operation of the DSP1500 Main Unit.
The following table outlines the contents of each chapter.
Chapter
1 Outline
Title Contents
Basic characteristics and requirements of the DSP1500
Main Unit.
2 Specifications General specifications of the DSP1500 Main Unit.
3 System Description Description of standard and optional system components.
4 Installation and Wiring
5 Control Interfaces
Mounting requirements, wiring connection references
including communication port specifications.
Description of standard Discrete I/O and optional Fieldbus I/O
PLC Interfaces.
6 Troubleshooting Description of Abnormal conditions.
Any questions regarding the contents of this document or any related matter should be
directed to FEC Inc. at (586) 781-2100 or faxed to (586) 781-0044.
The Information set forth in the following document is the property of FEC Inc. This
document shall not be released to or copied for any person and/or organization without
the expressed prior consent of FEC Inc.
Unauthorized reproduction or distribution of this manual is strictly prohibited. Please
contact FEC Inc. if additional copies are required.
Related Docum entation
DSP User Console Manual DSP1500E-SW-*
DSP1500 SAN Unit Operation Manual DSP1500E-HS-*
(Rev. 4.0) PAGE 1 - 2
enFORCE DSP1500 Main Unit Hardware Manual
Chapter 1: Outline
1.2 Functions
The Main Unit is a complimentary controller device to enhance the DSP1500 capabilities by
providing the communication and the sequence control features required by larger or more
sophisticated multi press applications. When a group of DSP1500 Servo Controllers (SAN Units) are
linked to a Main Unit, the Main Unit assumes control (over these presses) of the following functions:
Input-Output (I/O) Connection (including Fieldbus interface)
Sequence Control
Parameter Programming
Pressing Data Monitoring & Communication
General Status Indication
♦ Input-Output Connection (including Fieldbus interface)
The Main Unit assumes control of the control signals (Ex.: STOP, START, RETURN,
BYPASS, etc.) to all of the DSP1500 Servo Controllers linked to it via the RS485
communication port, thus eliminating direct connection & control to the individual presses.
The control signals for the multi-press array can be of different sources: Signals manually
generated by pressing the Control Buttons on the front of the Main Unit or I/O (Input/Output)
signals from a PLC or from a PC Based Controller.
♦ Sequence Control
The Main Unit controls the pressing sequencing eliminating the need for external control
devices (PLC) to perform complicated control sequencing. All pressing sequencing is
handled by the Main Unit. This built in feature allows the Main Unit to control a variety of
complex sequencing strategies including; several pressing steps, reject (retry) strategies,
wait timing, multiple starts, etc.
♦ Parameter Programming
A Windows® compatible computer running the DSP User Console software package can be
connected to the Main Unit in order to upload or download the preset data to all the SAN
(Servo) Controllers connected in the multi press array. This eliminates the need to program
individual presses manually.
♦ Pressing Data Monitoring & Communication
The Main Unit can monitor and process the pressing results collected by the DSP1500 Servo
(SAN) Controllers connected to it. It has four (4) configurable RS232C ports to input and
output pressing data results. Data monitoring / saving is also a function of the DSP User
Console software package.
As an added feature, the Main Unit stores previous pressing data in RAM (volatile) for
uploading at another time. The number of cycles stored is based on the number of presses
connected (see chart on page 2-2). The data can be uploaded using the DSP User Console
software package.
♦ General Stat us Indi ca tio n
A set of indicator LED’s provide the status for Power On, Busy, Total Accept, Total Reject and
Abnormal conditions.
PAGE 1 - 3 (Rev. 4.0)
Chapter 1: Outline
enFORCE DSP1500 Main Unit Hardware Manual
1.3 Safety Precautions
To ensure the most effective and extended use of all equipment, adhere to the following
precautions:
¾ Wiring
¾ Installation Environment
¾ Static Electricity
¾ Cleaning
¾ Electrical Noise Prevention
¾ Handling and Shipping
(Rev. 4.0) PAGE 1 - 4
• Use only the specified cables for all system connections.
• Do not use a high voltage circuit as a frame ground (FG). Also, the frame ground should be
separate from the power ground. The use of a grounding rod located as close as possible to
the enclosure housing the DSP1500 Main Unit is preferable.
• Circuit breakers or fuses are required on branch circuit power feeds to the Main Unit.
• PLC I/O cables must be run separate from any high voltage sources or cabling, and must not
exceed 50 feet.
• The DSP1500 Main Unit should be placed in a NEMA 12 enclosure.
• Using the equipment in the following locations may lead to malfunction or breakdown. Avoid
using in these areas or use an air conditioner.
Areas under direct sunlight or if the environmental temperature is out of the 32~122℉
(0~50℃) range.
Areas where relative humidity is out of the 20-90% range, the temperature change is
drastic or where the area is exposed to mist and water drops.
• Do not use at the following locations. (Contact FEC Inc. if necessary for clarification)
Areas where conductive powder, oil, mist, salt or organic solvents exist.
Areas that have corrosive or combustible gases.
Areas that have strong electric or magnetic fields.
Areas where strong vibration or shock could be transmitted directly to a Main Unit.
• The DSP1500 Main Unit incorporates many electronic Surface Mounted Devices (SMD). It is
advisable to strictly adhere to practices for safe electrostatic discharge in order to prevent
damage to the system components when handli ng them.
• Do not use any organic solvents, such as thinner, to clean a Main Unit. The solvent could
melt the surface paint, or penetrate inside and cause damage. A cloth dampened with
alcohol or warm water should be used to lightly wipe the components.
• Main Units must be located a minimum of 600mm from high transient voltage sources such
as transformers, motor starters, AC inverters and AC contactors. If it cannot be avoided, the
unit must be shielded.
• If high powered devices are used inside the enclosure, they must use a surge suppression
device.
• Make sure that the power supply lines and cables for connecting the unit and tool are not run
together inside the same duct.
• It is cr itical that DSP1500 System components are properly handled and shipped in order to
maintain the system’s integrity. Adhere to the following requirements for shipping and
handling:
Loose DSP1500 Main Units must be individually packaged and shipped in anti-static
containers or wrap to prevent damage from electrost ati c discharge.
If the Main Unit is to be shipped in an enclosure, tighten all mounting screws to
prevent the unit from being dislodged.
Do not ship or store the unit in environments where the temperature is out of the
23~131℉ (-5~55℃) range or where the humidity is above 90%.
Chapter 2: Specifications
(
)
(
)
Chapter 2: Specifications
2.1 Specifications
Power Supply Voltage 100 to 220 VAC±15%, 1-phase, 50/60 Hz.
Power Consumption 9 Watt/Hour
Operating Current Less than 70 mA
In rush current Less than 160 mA
CPU NEC V53A
Data Communication RS 232C (User Console PC)
RS232C
RS232C (Data Input)
RS232C (Data Output #2)
RS422 (External Remote Display)
RS485 Servo Units Programming/Control
Ethernet - User Console (User Console PC)
Ethernet - Network Communication (2E Version Only)
Control Interfaces Discrete I/O (24Vdc Sink)
Discrete I/O (24Vdc Source)
Allen Bradley Remote I/O 1
Ethernet I/P (includes messaging capabilities)
M-Net
Pressing Sequence
Programming Steps
Pressing
Control Methods
Max. No. of presses 31 per Main Unit
Pressing Parameters 32
Pressing Sequences 32
Data Storage
(non-volatile RAM)
Based on the number of
presses connected.
Installation requirement NEMA12 Enclosure
Operation Temperature 0º to 50 ºC (32 º to 122 ºF)
Operation Humidity 20% to 90%
1) Mitsubishi CC Link & Allen Bradley Remote I/O are proprietary and licensed for use.
2) The number of cycles stored will be reduced if RS232C - DATA IN data is stored with the
pressing data.
enFORCE DSP1500 Main Unit Hardware Manual
Data Output #1
DeviceNet
Interbus-S
Profibus
Mitsubishi CC Link
Modbus Plus
CC Link
DeviceNet
Interbus-S
Profibus
Also Available: Contact FEC for special fieldbus requirements.
100
(99 plus End Step)
Load Control / Distance Control
plus 7 other special methods
Stored
# of
Press
Cycles
1 8322 9 2475 17 1434 25 1012
2 6526 10 2250 18 1350 26 984
3 5289 11 2081 19 1294 27 928
4 4445 12 1941 20 1237 28 900
2
5 3826 13 1828 21 1181 29 872
6 3375 14 1716 22 1125 30 843
7 3010 15 1603 23 1097 31 815
8 2700 16 1519 24 1040
(includes messaging capabilities)
®
®
®
1
®
®
Version 2 (includes messaging capabilities)
®
for ToolsNet®
®
for ToolsN e t®
®
for ToolsNet®
®
# of
Press
Stored
Cycles
# of
Press
Stored
Cycles
# of
Press
Stored
Cycles
(Rev. 4.0) PAGE 2 - 2
enFORCE DSP1500 Main Unit Hardware Manual
2.2 Unit Dimensions
Weight: 1.4 kg
Chapter 2: Specifications
PAGE 2 - 3 (Rev. 4.0)
Chapter 2: Specifications
enFORCE DSP1500 Main Unit Hardware Manual
Blank Page
(Rev. 4.0) PAGE 2 - 4
Chapter 3: System Description
Chapter 3: System Description
enFORCE DSP1500 Main Unit Hardware Manual
3.1 System Block Diagram
The diagram below shows how the DSP1500 Main Unit can be connected to a single unit or combined
in a multiple press configuration. The use of a Main Unit provides one set of PLC I/O for c ontrolling
multiple pressing operations. Along with discrete 24VDC (sinking or sourcing) I/O, various fieldbus
interf ac es are al s o a va i la bl e for dire c t connecti o n t o n e t wo r ks such as Profi bus, AB remote I/O , C CLink,
DeviceNet, etc.
The DSP1500 Main Unit also provides an interface for connection to the User Console PC, serial
printers, barcode readers, display units, etc.
(Rev. 4.0) PAGE 3 - 2
enFORCE DSP1500 Main Unit Hardware Manual
3.2 Unit Description
Chapter 3: System Descriptio n
Standard Version
(RS232C) Data-Out Port #1
(RS232C) Data-Out Port #2
(RS232C) PC Port
(RS422) Display Port
(RS232C) Data-In Port
* Discrete I/O Interface Board Shown.
Interface Board
Power Connector
Ethernet U/C
Status LED
Power ON LED
Busy LED
Accept LED
Reject LED
Abnormal LED
Reset Button
Start Button
Home Button
Calibration Button
RS485 Port
Ethernet U/C Port
Ethernet (E) Version
Ethernet Network Port
Ethernet Reset Button
(RS232C) Data-Out Port
(RS232C) Data-In Port
(RS422) Display Port
Ethernet U/C
Status LED
PAGE 3 - 3 (Rev. 4.0)
Chapter 3: System Description
®
enFORCE DSP1500 Main Unit Hardware Manual
Main Unit Panel Description
Power On LED Indicates when power is applied to the Main Unit.
Busy LED Lights when the unit is performing a self check, Home Search, Home
Return, Sequence operation, Jog operation or is
downloading/uploading data to the DSP Software.
Blinks when clearing stored data in the Main Unit and while
communicating when “Disable Main Unit When Communicating” is
checked in the DSP Software.
Accept LED Lights if a pressing cycle or a self check test falls within acceptable
parameters. (This LED indicates status for ALL connected presses)
Reject LED Lights if a pressing cycle or a self check test is outside of acceptable
parameters. (This LED indicates status for ALL connected presses)
Abnormal LED Lights when a system abnormal condition is detected in the control
system of any connected press. (Does NOT indicate a press reject).
All operations are halted and cannot be restarted until the Abnormal
condition is corrected. Can be cleared only by the Reset function. (see
DSP1500 SAN Unit Operation Manual for Abnormal Troubleshooting)
RS485 Port RJ45 style connector used to connect to all DSP1500 Servo (SAN)
Units included in the system.
Ethernet U/C Port Communication port for the User Console PC.
Red (TX) Transmitting Data
Ethernet U/C Status LEDs
Reset Button Resets all signal and communication buffers to “clear” conditions.
Start Button Starts the pressingcycle. Must be maintained during complete cycle.
Home Button If any of the connected presses have not been “Homed”, pushing this
Cal Button Performs the Load Transducer shunt calibration test. When pressed,
Power Connector Connects to incoming power: 100 to 220VAC (auto-sensing), Single
Interface Board (I/O) Allocation socket for input/output signal Interface boards. Options
RS232C – PC Port Communication port for the User Console PC.
RS232C – Data Out Port #1 Communication port for pressing result data output to a serial printer.
RS232C – Data Out Port
(Ethernet Version)
RS232C – Data In Port Co mmuni cation port for ASCII data input fro m periphe ral devices. (Ex:
RS232C – Data Out Port #2 Communication port for pressing result data output to a host
RS422 – Display Port Communication Port for an FEC Remote Display Unit
Ethernet Network Port*
Ethernet Reset Button* for resetting the Network Ethernet Port
*On Ethernet Version only.
Yellow 10/100 Link
Green (RX) Receiving Data
Clears the Abnormal signal and performs the Load Transducer Zero
Level Check.
button will cause those presses to perform a “Home Position Search”.
If Home has been set, the connected presses will move to the Home
Position.
the Servo (SAN) Units will display either a green accept LED or red
reject LED indicating status of the individual Calibration test.
phase, 50/60 Hz.
available are Discrete I/O (Sink or Source), Interbus-S
Profibus
, CC-Link® (Version 1 or 2), Modbus Plus®, Allen Bradley
®
, DeviceNe t®,
®
Remote I/O (Rockwell License #199906006) or Ethernet-I/P
Data output format is configured using the User Console (DSP)
Software package.
Communication port for pressing result data output to any external
device, i.e.: host computer, serial printer, etc. Data output format is
configured using the User Console (DSP) Software package.
bar code readers, RF tag, etc.) Allows external ASCII data to be
merged with pressing result data.
computer. Data output format is configured using the User Console
(DSP) Software package.
for Network Connectivity (Toolsnet
, QDAS®,Custom Protocol, etc.)
(Rev. 4.0) PAGE 3 - 4
Chapter 4: Installation & Wiring
Chapter 4: Installation & Wiring
enFORCE DSP1500 Main Unit Hardware Manual
4.1 Unit Dimensions
Main Units must be mounted with a minimum clearance of 13mm on each side to allow proper heat
dissipation. Cable connections on the front of the units require 100mm of clearance. Allow a
minimum of 100mm clearance on the bottom of the unit for flash connector hook up when updating
firmware.
Mounting: Top (1) place #8-32 screw
Bottom (2) places #8-32 screw
Weight: 1.4 kg
(Rev. 4.0) PAGE 4 - 2
enFORCE DSP1500 Main Unit Hardware Manual
Chapter 4: Installation & Wiring
4.2 Installation
The Main Unit should be mounted into a NEMA12 / IP52 enclosure at a minimum and spaced similar
to the DSP1500 SAN Units (Shown Below).
PAGE 4 - 3 (Rev. 4.0)
Chapter 4: Installation & Wiring
enFORCE DSP1500 Main Unit Hardware Manual
4.3 Power Wiring Reference
Even though the Main Unit power input allows it to connect to 120 VAC ~ 220 VAC power lines,
typically the unit is connected to the same power source that the SAN Units are connected to (200 to
220 VAC ± 10%) . In the example wiring diagram shown below there are two power branches; one is
for the control circuitry connected to 120 VAC and the other is for the SAN power circuitry connected
to 220 VAC. For convenience, the Main Unit is wired together with the DSP1500 Servo Controllers.
Note that the Main Unit is using one phase while the Servo Controllers use three phases.
Main Unit Power Reference
Note: Diagram shown with the Main Unit wired using same cable used for SAN Unit for
standardizing components. Pin #2 is not wired internally on the Main Unit.
(Rev. 4.0) PAGE 4 - 4
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