ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
TABLE OF CONTENTS
DESCRIPTION PAGE
1 INTRODUCTION........................................................................................................................................... 3
2 THEORY OF OPERATION ......................................................................................................................... 3
2.1 MECHANICAL ASSEMBLY................................................................................................................... 3
2.2 ELECTRICAL CONTROL ENCLOSURE ASSEMBLY...................................................................... 3
2.3 SERVOMOTOR/DRIVE OPERATION................................................................................................. 4
2.4 TOOL STORAGE OPERATION ........................................................................................................ 5
2.5 PLS OPERATION (OPTIONAL) ........................................................................................................... 5
2.6 STRIP ENCODER-OPERATION (OPTIONAL) .................................................................................... 6
3 PROGRAMMING THE ULTRA ADVANTAGE SERVO ROLL FEED SYSTEM - OVERVIEW........ 7
3.1 “OPER” KEY ............................................................................................................................................ 8
3.2 “TOOLS” KEY .......................................................................................................................................... 8
3.3 “SETUP” KEY......................................................................................................................................... 13
4 HOW TO ….................................................................................................................................................. 16
4.1 HOW TO CREATE A NEW TOOL................................................................................................... 16
4.2 HOW TO EDIT AN EXISTING TOOL ............................................................................................. 19
4.3 HOW TO CREATE A NEW TOOL USING AN EXISTING ONE.................................................... 21
4.3 HOW TO DELETE A TOOL.............................................................................................................. 24
4.4 HOW TO ACTIVATE A TOOL.......................................................................................................... 25
4.5 HOW TO EDIT “SETUP” PARAMETERS ...................................................................................... 26
4.7 HOW TO EDIT LENGTH FROM OPERATOR SCREEN ............................................................... 26
4.8 HOW TO EDIT COUNT FROM OPERATOR SCREEN ................................................................. 27
4.9 HOW TO MICRO ADJUST LENGTH USING LENGTH ADJUSTMENT...................................... 27
4.10 HOW TO SYNCHRONIZE PRESS AND PLS .................................................................................. 27
4.11 HOW TO SET CAM “ON”/“OFF” PARAMETER............................................................................... 28
5 OPERATING THE ULTRA ADVANTAGE SERVO FEED.................................................................... 28
5.1 PROGRAMMING .................................................................................................................................. 28
5.2 PRIORITY MODE.................................................................................................................................. 28
5.3 “JTL” (JOG TO LENGTH) MODE ...................................................................................................... 28
5.4 “AUTO / MANUAL” MODE................................................................................................................... 29
5.5 STRIP ENCODER OPERATION ......................................................................................................... 29
5.6 TROUBLESHOOTING GUIDE............................................................................................................ 32
5.7 ERROR CODES.................................................................................................................................... 33
WARNING ....................................................................................................................................................... 35
SAFETY PROGRAM ..................................................................................................................................... 35
WARRANTY.................................................................................................................................................... 35
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ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
RECEIVING INSPECTION
BEFORE REMOVING UNIT FROM ITS PACKAGING, CHECK FOR VISUAL DAMAGE,
ESPECIALLY IF CRATE, SKID, OR CARTON HAS BEEN DAMAGED IN TRANSIT. ANY
DAMAGE CAUSED IN SHIPMENT SHOULD BE IMMEDIATELY REPORTED TO THE CARRIER.
IF UNIT APPEARS IN SATISFACTORY CONDITION, REMOVE ALL PACKING AND WIPE RUST
PREVENTIVE FROM ROLLERS WITH MILD SOLVENT.
1 INTRODUCTION
IMPORTANT
Before turning the system on for the first time, verify that installation has been completed according to the
Installation manual and the main input voltage is 220 VAC, single phase.
The P/A Industries Ultra Advantage Servo Roll Feed is a state of the art AC Servo feed, which simplifies Operator
adjustments to feed parameters. These Operator adjustments are entered into the control memory through the keypad.
With the use of positional limit switches, the press signals the feeder when to begin moving the strip, when the feed pitch
must be completed, when the press has completed its down stroke, and with optional pneumatic pilot release, when to
open the rolls for piloting.
The mechanical simplicity, accuracy, and ease of use of the Ultra Advantage Servo Roll Feed will help to improve your
quality and production for years to come.
2 THEORY OF OPERATION
2.1 MECHANICAL ASSEMBLY
Mechanical assembly consists of:
1) Adjustment/Mounting bracket
2) Feeder
3) Servomotor
4) Mechanical pilot release actuator (optional)
5) PLS – Programmable Limit Switch (optional)
2.2 ELECTRICAL CONTROL ENCLOSURE ASSEMBLY
Electrical control enclosure consists of:
1) Control switches/buttons/relays
2) Power supply, 24 VDC/5 VDC
3) Servo drive
4) Data entry terminal
5) Cabling
6) Jog Pendant
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ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
ALL ULTRA ADVENTAGE SERVO ROLL FEED CONTROLS ARE CONVENIENTLY LOCATED
ON THE FRONT SIDE OF THE ELECTRICAL ENCLOSURE
CONTROL/DEVICE DESCRIPTION
Power On/Reset button Turns controller on, resets the servo drive.
In Position indicator light, white Turns on when move is complete and motor is holding position.
Cycle Start illuminated button, green Turns controller into “Auto” mode from “Manual” mode, starts cycling.
Cycle Stop button, red: Stops cycling and returns the controller into “Manual” mode.
“JTL / Manual-Auto” mode selector
switch:
Emergency Stop mushroom button, red Shuts controller off
Operator terminal Displays controller’s data and enters data into controller.
“Programming Locked / Unlocked” keyswitch
Forward / Reverse remote jog pendant Pendant is attached to the enclosure through retractile cable.
Turns controller into “Manual” or “JTL” (Jog To Length) mode.
Locks access to programming.
2.3 SERVOMOTOR/DRIVE OPERATION
The introduction of servomotor technology to the press roll feed has pushed the limits of accuracy, adjustability, and
performance to levels previously unattainable.
The following example is based on the Ultra Advantage Servo Roll Feed Standard, US model. The actual numbers for
Heavy Duty or metric models are different.
Each revolution of the servomotor produces 8000 encoder pulses. Every 10.24 revolutions of the servo motor shaft
produce 1 revolution of the feed rollers. The circumference of the lower roll is approximately 11.138 inches.
When a new feed pitch is entered into the system, the built in computer calculates the correct number of electronic
“pulses” it must receive from the motor mounted encoder in order to rotate the feed rolls the correct distance.
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ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
Example: If a feed pitch/length of 11.138 inches is entered into the feeder, this will result in exactly one revolution of the
feed rolls. The motor will accelerate and turn 10.24 turns. This will produce (10.24 x 8000 = 81,920) pulses of the
encoder. The feeder will decelerate and stop, when 81,920 pulses are detected. The feeder is now in position. The result
is an accurately positioned strip exactly 11.138 inches from its starting point. This entire process happens in milliseconds.
2.4 TOOL STORAGE OPERATION
The tool storage feature allows for storing of parameters that are different from tool to tool. It takes just a few seconds to
activate feeding parameters associated with a certain tool number. Maximum 200 tools can be stored. Tools are organized
by Tool number, which is user definable and can contain up to 7 digits.
Each tool consists of the following parameters:
-Length;
- Batch Count;
- Speed;
- Dwell;
- Accel;
- Decel;
- Feed Cam “On”;
- Feed Cam “Off”;
- Reset Cam “On”;
- Reset Cam “Off”;
- Pilot Release Cam “On”;
- Pilot Release Cam “Off”;
- Aux1. Cam “On”;
- Aux1. Cam “Off”;
- Aux2. Cam “On”;
- Aux2. Cam “Off”;
- Aux3. Cam “On”;
- Aux3. Cam “Off”;
NOTE: Cam settings are available only with PLS version of software.
Consider the tool storage as a part of the servo drive’s NVRAM memory that is dedicated to storing information of all the
existing tools. In order to run a tool, it must be activated. Tool activation is an internal drive procedure of making a copy
of the tool, and placing it in a different memory location. This copy, not the tool in the tool storage, is used to perform
material feeding. “Tool #NNN is active” means only that the feed running parameters are copied from this tool.
A tool in the tool storage area and its copy, are edited independently, with the difference, that only two of the copy’s
parameters are accessible – Length and Batch Count. These are accessible from the Operator screen. In order to edit the
rest of the parameters of the tool, the tool in tool storage must be edited, and then, reactivated.
NOTE: Deleting an active tool from the tool storage causes deletion of its copy as well.
NOTE: An active tool remains active after power recycling.
2.5 PLS OPERATION (OPTIONAL)
The PLS, Programmable Limit Switch consists of an intelligent encoder and the cable that connects the encoder to the
servo drive. The encoder is mounted on the press and its shaft is coupled or belted to the crankshaft with a one to one
(1:1) ratio. On every power-up, the encoder turns into the intelligent mode (for approximately 10 msec) to read its actual
position and store it in the servo drive.
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ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
The encoder then turns into the incremental mode, sending the count signals to the servo drive proportionally to the
angle of the move (1024 counts per revolution). The servo drive software, having the start point position of the encoder
shaft, constantly calculates (updates) its current position. The position of the press crankshaft is determined through the
offset parameter, which is the position of the encoder shaft when the press is in its 0 degree position (TDC).
Thus, at every point of the stroke, the servo drive knows where the crankshaft is. The servo drive controls six cams
simultaneously, turning them on and off accordingly to the cam settings.
Since the PLS encoder is connected directly to the servo drive, there is no need to wire connections for the Feed Cam and
the Reset Cam outputs. These outputs are software type outputs.
The rest of the cam outputs are hardware type and require wiring of output relays to the desired mechanisms, such as a
pilot release solenoid, parts blow-off, tool lubricator, etc. The cam settings (On/Off angles) are set through the operator
terminal. They are part of the tool settings.
NOTE: All PLS outputs are active as soon as SRF power is turned on.
2.6 STRIP ENCODER-OPERATION (OPTIONAL)
The Strip Encoder assembly consists of:
a. 300mm diameter knurled measuring wheel
b. 10,000 pulses per revolution encoder
c. Air valve with manual actuator
d. Air cylinder slide
e. Magnetic sensor
The encoder measuring wheel is coupled to the encoder and both are mounted on the slide. The slide can be moved up and
down by applying air pressure (80-100 PSI) to the air cylinder. The magnetic sensor is used to indicate the up/down
position of the measuring wheel.
The encoder output results in 40,000 pulses (counts) per revolution for a final resolution of 3386 counts per inch of linear
strip movement.
While the measuring wheel is in its up position, the servo roll feed acts as if there is no strip encoder attached to it, and all
of the SETUP parameters associated with a strip
The Strip Encoder may be used to control or to check the position of the material strip.
The P/A Industries® servo roll feed with optional Strip Encoder comes standard with the ability to function in one of the
two modes.
encoder operation are inactive.
1. CONTROL MODE
In this mode the position control of the material motion is done through Strip Encoder feedback. The velocity control is
based on data coming from both, Strip Encoder and Motor Mounted Encoder.
This mode provides relatively slower speed performance, due to the increase in computation of the velocity control
algorithm.
2. CHECK MODE
In this mode the full control of the material motion (Acceleration, Deceleration, Speed and positioning) is done through
the Motor Mounted Encoder. When a move is complete, the Strip Encoder positioning control checks if the material is
within the Length Check tolerance, if it is not, "Position Error" is displayed, and Auto mode is turned off.
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ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
3 PROGRAMMING THE ULTRA ADVANTAGE SERVO ROLL FEED SYSTEM OVERVIEW
NOTE: Before attempting any programming, make sure that the “PROGRAMMING LOCKED / UNLOCKED”
key switch is in the “Unlocked” position.
NOTE: After power shutdown, WAIT for 10 seconds before powering up the Feed.
Turn on the main power disconnect switch. This applies power to the control power supply. Press the green Power On
push-button. The button will illuminate and the OPERATOR terminal display will be visible.
Wait for the IN POSITION light to illuminate.
Press any key to begin.
P /A I n du s tr i es
R ea l ly Co o l F eed
V er s io n 1 . 00 std
H i t an y k e y t o c o nt .
NOTE: The OPERATOR terminal has three mode keys, they are:
● “OPER”
● “TOOLS”
● “SETUP”
NOTE: ▓ The flashing cursor is waiting for the value to be entered.
NOTE: < The pointer prompts to press the “ENTER” key.
NOTE: To confirm any value, press “ENTER”.
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ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
3.1 “OPER” KEY
“OPER” key controls appearance of two screens: STATUS screen and OPERATOR screen.
STATUS screen shows:
T o o l #1 P os : 18 2
Ma n u al Mo d e
3 0 / Co n t .R u n
P re s s a M o de Ke y
• Active tool number. In case there is no active tool “No Tool!” message is displayed instead
• Current press position in degrees. Available only on PLS model
• Current mode of the feed
• Batch count, current and commanded
NOTE: When the feed is turned into Auto mode it displays current press speed (in strokes per minute) instead of
current press position.
T o o l #1 S pd : 38 4
A u t o M od e
3 0 / Co n t .R u n
P re s s a M o de Ke y
OPERATOR screen shows and allows editing the following parameters:
L e n g th 1 . 00 0
C o u n t C o nt . Ru n
L e n g th Ad j u st m en t <
P r e ss OP E R t o e x it
• Length
• Batch count command
• Length micro adjustment
Every time the “OPER” key is pressed it toggles between the STATUS screen and the OPERATOR screen.
3.2 “TOOLS” KEY
“TOOLS” key controls appearance of TOOL STORAGE screens. Press the “TOOLS” key to open the first screen.
This allows the Operator to chose a Tool Storage operation: “Edit Tool”, “Activate Tool”, or “Create New Tool”.
E d i t T o ol
A c t i va t e T o ol <
C r e a te Ne w
P r e s s T OO L S t o e x it
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ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
Position the pointer on desired line, using “↑” and “↓” keys , and press the “ENTER” key.
Enter in the tool number or select it from the tool list using “↑” and “↓” keys and press the “ENTER” key again.
E d i t T o ol # 1
A r r o w k ey s to sc r ol l
P r e s s T OO L S t o e x it
A c t i va t e
T oo l # 1
A r r o w k ey s to sc r ol l
P r e s s T OO L S t o e x it
C r e a te To o l #
P r e s s T OO L S t o e x it
NOTE: Tool number can contain up to seven digits.
If “Activate Tool” operation is chosen, then the desired tool will be activated and message will be displayed for a few
seconds:
T oo l A ct i v at e d
Display will show STATUS screen.
T o o l #1 S pd : 38 4
A u t o M od e
3 0 / Co n t .R u n
P re s s a M o de Ke y
If “Activate Tool” or “Edit Tool” operation is chosen and the entered tool number doesn’t exist, the following message
will be displayed:
T o o l d o es n ‘t e xi s t!
The display will show the previous screen.
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ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
E d i t To o l#
A r r o w k e ys t o s cr o ll
P r e s s T O OL S to ex i t
Or
A c t i v at e
T oo l #
A r r o w k e ys t o s cr o ll
P r e s s T O OL S to ex i t
If “Edit Tool” or “Create New Tool” operation is chosen, then the next three (nine - with PLS option) screens will allow
editing of the tool parameters. Position the cursor on desired line, using “↑” and “↓” keys , enter in the desired value, and
press the “ENTER” key. Press “TOOLS” to open the next screen or “BKSP” – the previous.
T o o l # 1
L e n g t h 6 0. 0 00
C o u n t Co n t. R un
P r e s s T O OL S fo r n e xt
Length is a distance in inches (or millimeters) of the “Feed Length”. It is a numeric entry with a range of 0 to the
Maximum Length.
Count is the number of feed indexes that should be performed. It is a numeric entry with a range of 0 to 9999999.
Entering “0” will result in a continuous run.
T o o l # 1
S p e e d 72
D w e l l 0
T O O L S -n e x t B K S P- P re v
Speed is the maximum velocity of the material in in/sec (or mm/sec). It is a numeric entry with a range of 0 to 72 in/sec
(1828 mm/sec) for Standard model and 0 to 41 in/sec (1041 mm/sec) for Heavy Duty models.
Dwell controls the “On” duration of the “Permit Press” output while the control is in Single Stroke mode. The next feed
length will not be started until Dwell time is expired. It is a numeric entry with a range of 0 to 100000 msec.
T o o l # 1
A c c e l 40 0 .0
D e c e l 40 0 .0
T O O L S -n e x t B K S P- P re v
Accel is the rate of acceleration in in/sec2 (or mm/sec2). It is a numeric entry with a range of 0-to 1000 in/sec2 (25400
mm/sec
Decel is the rate of deceleration in in/sec
mm/sec
2
). Normally set to 400 in/sec2 (10160 mm/sec2).
2
2
). Normally set to 400-in/ sec2 (10160 mm/sec2). Enter “0” to duplicate Accel rate.
(or mm/sec2). It is a numeric entry with a range of 0-to 1000 in/sec2 (25400
NOTE: The following six screens are part of the optional PLS package and displayed only if the corresponding
software is loaded.
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ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
NOTE: Each of the following six PLS screens (Feed Cam, Reset Cam, Pilot Release, Auxiliary 1,2,3) has a press
current position shown at the top right corner.
T o o l # 1 P o s: 3 54
F e e d C am On 2 60
F e e d C am Of f 9 0
T O O L S -n e x t B K S P- P re v
FeedCam On indicates the position of the press when the feed cam switch turns on and the feed starts feeding the
material.
FeedCam Off indicates the position of the press where the feeding must be completed. Otherwise, the servo drive will
generate Synch Fault Signal, display the corresponding message in the screen, and stop feeding.
T o o l # 1 P o s: 3 54
R e s e t Ca m O n 1 80
R e s e t Ca m O f f 2 00
T O O L S -n e x t B K S P- P re v
ResetCam On indicates the position of the press when the reset cam switch turns on.
ResetCam Off indicates the position of the press when the reset cam switch turns off.
T o o l # 1 P o s: 3 54
P i l o t Re l O n 1 25
P i l o t Re l O f f 2 40
T O O L S -n e x t B K S P- P re v
Pilot Release On indicates the position of the press when the pilot release cam switch turns on to open the rolls.
Pilot Release Off indicates the position of the press when the pilot release cam switch turns off to close the rolls.
T o o l # 1 P o s: 3 54
A u x 1 On 0
A u X 1 Of f 1 20
T O O L S -n e x t B K S P- P re v
T o o l # 1 P o s: 3 54
A u x 2 On 1 2 0
A u X 2 Of f 2 40
T O O L S -n e x t B K S P- P re v
T o o l # 1 P o s: 3 54
A u x 3 On 2 4 0
A u X 3 Of f 0
T O O L S -n e x t B K S P- P re v
Auxiliary 1 (2, 3) On indicates the position of the press when the auxiliary cam switch turns on.
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ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
Auxiliary 1 (2, 3) Off indicated the position of the press when the auxiliary cam switch turns off.
Tool information can be saved on the next screen.
NOTE: Up to 200 tools can be saved.
T o o l #
S a v e <
S a v e as
T O O L S -n e x t B K S P- P re v
Use SAVE to save the tool being edited. Press the “ENTER” key.
T o o l# 1 S a ve d
Use SAVE AS to create a new tool using the one being edited. Press the “ENTER” key, enter desired tool number, and
press the “ENTER” key again.
S a v e As To o l #
P r e s s T O OL S to A b or t
S a v e As #1 2 3 45 6 7
T o o l #1 2 34 5 6 7 S av e d
The display will show the STATUS screen.
T o o l # 1 S p d: 3 84
A u t o M od e
3 0 / Co n t. R un
P r e ss a M o de Ke y
If saving is skipped, then the next screen allows deleting the tool being edited. Press “TOOLS” to open it. Press the
“ENTER” key, the warning message will be displayed, press “1” key to confirm deleting or any key to abort.
T o o l #
D e l e t e T oo l <
T O O L S -n e x t B K S P- P re v
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ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
D e l e t e T oo l # 1
P r e s s 1 t o co n fi r m
A n o t h er ke y to ab o rt
The corresponding message on the next screen confirms the chosen command execution.
T oo l # 1 D el e te d
or
A b or t e d!
Display will show STATUS screen.
T o o l # 1 S p d: 3 84
A u t o M od e
3 0 / Co n t. R un
P r e ss a M o de Ke y
NOTE: To exit tool editing at any time, press the “OPER” key. Changes will not be saved.
3.3 “SETUP” KEY
“SETUP” key controls the appearance of setup screens. Seven screens contain parameters of the feed that are not
changed often or never are changed. Press “SETUP” key three times to open the first screen. Position the cursor on the
desired line, using “↑” and “↓” keys , enter in desired value and press the “ENTER” key. Press “SETUP” key to open
the next screen or “ BKSP” – the previous.
J o g S pe e d % 5
J o g A c ce l 10 . 0
J o g D e ce l 1 0 .0
P r e s s S E TU P fo r n e xt
Jog speed is the maximum jogging speed. It is a numeric entry with a range of 0 to 99 percent of the Speed parameter.
Normally set between 1-5%.
2
JogAccel is the rate of jogging acceleration. It is a numeric entry with a range of 0-to 300-in/sec
2
in/sec
.
JogDecel is the rate of jogging deceleration. It is a numeric entry with a range of 0-to 300-in/sec
2
in/sec
.
. Normally set 10
2
. Normally set 10-
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ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
I n P o s it i on 0 .0 2 00
P r i o r it y ( 1 / 0) F BP
A d j u s tm e nt S t ep 0. 0 01
S E T U P -N e xt B KS P -P r ev
InPosition is a tolerance window around the final position. This is used to verify the feed index accuracy is within
acceptable limits before continuing onto the next function. It is a numeric entry with a range of 0 to 100 inch. Normally
set 0.02 inch.
Priority is a parameter that selects whether the feeder indexes before the press starts “FBP” or the press starts before the
feeder indexes “PBF”. Entering a “0” selects “PBF” mode and a “1” selects “FBP” mode.
AdjustmentStep is an increment of the Length adjustment. It is a numeric entry with a range of 0 to 1 inch. Normally
set 0.001 inch.
S c a l e 7 3 55 . 00
D i r e c ti o n ( 1/ 0 ) C W
D e b o u nc e (m S ) 1
S E T U P -N e xt B KS P -P r ev
Scale is the encoder scaling parameter used to define the number of encoder counts/inch (or mm). It is a numeric entry.
Standard model value is 7355 cnts/inch (289.56 cnts/mm). Heavy Duty model value is 12871 cnts/inch (506.73 cnts/mm).
Direction controls the direction of positive motor rotation. Entering “0” selects CW and a “1” selects CCW.
Debounce is the amount of time each input should stay HI or LOW, in order to be recognized. It is a numeric entry, with
a range of 0 to 999 msec. It is normally set to 1.
K p 20 0
P g a i n 1 2 00
I g a i n 1
S E T U P -N e xt B KS P -P r ev
Kp is proportional gain of the position loop. This is a tuning parameter, in order to change its value consult P/A
Industries Service Department.
Pgain is proportional gain of the velocity loop. This is a tuning parameter, in order to change its value consult P/A
Industries Service Department.
Igain is integral gain of the velocity loop. This is a tuning parameter, in order to change its value consult P/A Industries
Service Department.
F F 1. 0
K f f 0 .0
C u r r e nt Li m i t 30
S E T U P -N e xt B KS P -P r ev
FF is an acceleration feed-forward gain of the velocity loop. This is a tuning parameter, in order to change its value
consult P/A Service Department.
Kff is a feed-forward gain of the position loop. This is a tuning parameter, in order to change its value consult P/A Service
Department.
Current Limit is a maximum positive and negative current the drive may output to the motor. This is a tuning parameter,
in order to change its value consult P/A Service Department.
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ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
B a c k Le n gt h 0. 0 00
K e r f 0. 0 00
M a x L e ng t h 6 0. 0 00
S E T U P -N e xt B KS P -P r ev
Back Length is used for Cut-to-Length application to protect the material against bending up by the blade. If any value is
assigned for this parameter, the feed will move material back for the distance that equals Back Length when Reset Cam
input is turned “On” by the blade bottom position sensor. The Back Length is compensated on the next move, so it has
no affect on the Length parameter. It is a numeric entry, with a range of 0 to 1 inch.
Kerf is a cutting tool width and used for Cut-to-Length application to compensate for a loss of the Length caused by
width of the tool. It is a numeric entry, with a range of 0 to 10 inches.
Max length is a Length limit and protects against accidental entering extra digits, for example: 100 inch instead of 10
inch. It is a numeric entry, with a range of 0 to 999999. (This value is factory set to 20.000.)
NOTE: The following screen is part of the optional PLS package and displayed only if the corresponding software
is loaded.
P L S C ou n ts / R ev 1 0 24
P r e s s O f fs e t 3 21
S E T U P -E x it B KS P -P r ev
PLS Counts/Rev is an amount of pulses the PLS encoder produces per revolution. This is a tuning parameter. In order to
change its value, consult P/A Industries Service Department.
Press Offset is a difference between PLS and Press absolute positions in degrees. It is a numeric value, with a range of 0
to 360. See HOW TO SYNCHRONIZE PRESS AND PLS section of this manual for further details.
L e n g t h M od e Co n tr o l
L e n g t h C he c k 0 . 01
S t r i p S c al e 3 3 86 . 30
S E T U P -N e xt B KS P -P r ev
Length Mode is a parameter that selects whether the feeder works in the Control or Check mode. Entering a "0" selects
Control mode and "I" selects Check mode.
Length Check is a parameter that defines the Check mode tolerance. It is a numeric entry with a range of 0.00 to
5.00 inch.
Strip Scale is the Strip Encoder scaling parameter used to define the number of encoder counts/inch. It is a numeric
entry with a factory value 3386.17.
P r o f i le L i ne a r
B a n d w id t h 3 00
K p M ul t i pl i er 1. 3
S E T U P -N e xt B KS P -P r ev
Profile: is a parameter that defines whether the feed motion profile is Linear or S-Curve. In other words, the motion
profile is triangle or trapezoidal with linear acceleration / deceleration, or acceleration / deceleration is S-shaped. (Refer to
the picture below) The S-Curve becomes handy on applications with possible-material slippage between the rolls of the
feed. Entering a "0" selects Linear mode and "I" selects S-Curve mode.
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ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
Bandwidth is a tuning parameter, before changing its value consult the P/A Industries Service Department
Kp Multiplier is a parameter that defines a proportional gain of the position loop of the Strip Encoder and based on the
value of the motor encoder's Kp proportional gain. This is a tuning parameter, before changing its value, consult the
P/A Industries Service Department.
LINEAR
ACCELERATION
S-CURVED
ACCELERATION
NOTE: To exit setup editing at any time, press the “OPER” key. Changes will be saved.
4 HOW TO …
4.1 HOW TO CREATE A NEW TOOL
NOTE: Make sure that the PROGRAMMING “LOCKED / UNLOCKED” key switch is in “Unlocked”
position and OPERATOR screen is displayed. If the current screen is not OPERATOR one then press the
“OPER” key to bring it up.
Press the “TOOLS” key.
Position the pointer next to Create new tool command and press the “ENTER” key.
E d i t To o l
A c t i v at e T o o l
C r e a t e N ew <
P r e s s T O OL S to Ex i t
Enter new tool number and press the “ENTER” key again.
16
ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
C r e a t e T oo l #
P r e s s T O OL S to Ex i t
C r e a t e # 1
T oo l C r e at e d
Position cursor next to desired parameter, enter appropriate value, and press the “ENTER” key.
T o o l # 1
L e n g t h 1. 0 00
C o u n t Co n t. R un
P r e s s T O OL S fo r n e xt
Press “TOOLS” key to open next screen. Position cursor next to desired parameter, enter appropriate value, and press
the “ENTER” key.
T o o l # 1
S p e e d 72
D w e l l 0
T O O L S -n e x t B K S P- P re v
Press “TOOLS” key to open next screen. Position cursor next to desired parameter, enter the appropriate value, and
press the “ENTER” key. Enter “0” for Decel to use Accel value or an actual desired value.
T o o l # 1
A c c e l 40 0 .0
D e c e l 40 0 .0
T O O L S -n e x t B K S P- P re v
NOTE: The following six screens are part of the optional PLS package and displayed only if the corresponding
software is loaded.
Press “TOOLS” to open the next screen. Position cursor next to desired parameter, enter new value, and then press
“ENTER” key.
17
ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
T o o l # 1 P o s: 3 54
F e e d C am On 2 60
F e e d C am Of f 9 0
T O O L S -n e x t B K S P- P re v
Press “TOOLS” to open the next screen. Position cursor next to desired parameter, enter new value, and press “ENTER”
key.
T o o l # 1 P o s: 3 54
R e s e t Ca m O n 1 80
R e s e t Ca m O f f 2 00
T O O L S -n e x t B K S P- P re v
Press “TOOLS” to open the next screen. Position cursor next to desired parameter, enter new value, and press “ENTER”
key.
T o o l # 1 P o s: 3 54
P i l o t Re l O n 1 25
P i l o t Re l O f f 2 25
T O O L S -n e x t B K S P- P re v
Press “TOOLS” to open the next screen. Position cursor next to desired parameter; enter new value, and press “ENTER”
key.
T o o l # 1 P o s: 3 54
A u x 1 On 0
A u X 1 Of f 1 20
T O O L S -n e x t B K S P- P re v
Press “TOOLS” to open the next screen. Position cursor next to desired parameter, enter new value, and press “ENTER”
key.
T o o l # 1 P o s: 3 54
A u x 2 On 1 2 0
A u X 2 Of f 2 40
T O O L S -n e x t B K S P- P re v
Press “TOOLS” to open the next screen. Position cursor next to desired parameter, enter new value, and press “ENTER”
key.
T o o l # 1 P o s: 3 54
A u x 3 On 2 4 0
A u X 3 Of f 0
T O O L S -n e x t B K S P- P re v
Press “TOOLS” key to open next screen. To save changes, choose the SAVE command and press the “ENTER” key.
T o o l #
S a v e <
S a v e as
T O O L S -n e x t B K S P- P re v
18
ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
T o o l# 1 S a ve d
4.2 HOW TO EDIT AN EXISTING TOOL
NOTE: Make sure that the PROGRAMMING “LOCKED / UNLOCKED” key switch is in “Unlocked”
position and OPERATOR screen is displayed. If the current screen is not OPERATOR one then press the
“OPER” key to bring it up.
Press “TOOLS” key, position the pointer next to EDIT TOOL command and press the “ENTER” key.
E d i t To o l <
A c t i v at e T o o l
C r e a t e N ew
P r e s s T O OL S to Ex i t
Enter desired tool number or select it from the tool list using “↑” and “↓” keys and press the “ENTER” key again.
E d i t To o l#
A r r o w k e ys t o s cr o ll
P r e s s T O OL S to ex i t
E d i t To o l# 1
A r r o w k e ys t o s cr o ll
P r e s s T O OL S to ex i t
Position cursor next to desired parameter, enter the new value, and press the “ENTER” key.
T o o l # 1
L e n g t h 2 0. 0 00
C o u n t Co n t. R un
P r e s s T O OL S fo r n e xt
Press “TOOLS” key to open next screen. Position cursor next to desired parameter, enter new value, and press the
“ENTER” key.
T o o l # 1
S p e e d 72
D w e l l 1 50
T O O L S -n e x t B K S P- P re v
Press “TOOLS” key to open next screen. Position cursor next to desired parameter, enter new value, and press the
“ENTER” key.
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ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
T o o l # 1
A c c e l 40 0 .0
D e c e l 40 0 .0
T O O L S -n e x t B K S P- P re v
NOTE: The following six screens are part of the optional PLS package and displayed only if the corresponding
software is loaded.
Press “TOOLS” to open the next screen. Position cursor next to desired parameter, enter new value, and then press
“ENTER” key.
T o o l # 1 P o s: 3 54
F e e d C am On 2 60
F e e d C am Of f 9 0
T O O L S -n e x t B K S P- P re v
Press “TOOLS” to open the next screen. Position cursor next to desired parameter, enter new value, and press “ENTER”
key.
T o o l # 1 P o s: 3 54
R e s e t Ca m O n 1 80
R e s e t Ca m O f f 2 00
T O O L S -n e x t B K S P- P re v
Press “TOOLS” to open the next screen. Position cursor next to desired parameter, enter new value, and press “ENTER”
.
key
T o o l # 1 P o s: 3 54
P i l o t Re l O n 1 25
P i l o t Re l O f f 2 40
T O O L S -n e x t B K S P- P re v
Press “TOOLS” to open the next screen. Position cursor next to desired parameter; enter new value, and press “ENTER”
key.
T o o l # 1 P o s: 3 54
A u x 1 On 0
A u X 1 Of f 1 20
T O O L S -n e x t B K S P- P re v
Press “TOOLS” to open the next screen. Position cursor next to desired parameter, enter new value, and press “ENTER”
key.
T o o l # 1 P o s: 3 54
A u x 2 On 1 2 0
A u X 2 Of f 2 40
T O O L S -n e x t B K S P- P re v
Press “TOOLS” to open the next screen. Position cursor next to desired parameter, enter new value, and press “ENTER”
key.
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ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
T o o l # 1 P o s: 3 54
A u x 3 On 2 4 0
A u X 3 Of f 0
T O O L S -n e x t B K S P- P re v
Press “TOOLS” key to open next screen. To save changes choose SAVE command and press the “ENTER” key.
T o o l #
S a v e <
S a v e as
T O O L S -n e x t B K S P- P re v
T o o l# 1 S a ve d
4.3 HOW TO CREATE A NEW TOOL USING AN EXISTING ONE
NOTE: Make sure that the PROGRAMMING “LOCKED / UNLOCKED” key switch is in “Unlocked”
position and OPERATOR screen is displayed. If the current screen is not OPERATOR one then press the
“OPER” key to bring it up.
Press “TOOLS” key, position the pointer next to EDIT TOOL command and press the “ENTER” key.
E d i t To o l <
A c t i v at e T o o l
C r e a t e N ew
P r e s s T O OL S to Ex i t
Enter desired tool number or select it from the tool list using “↑” and “↓” keys and press the “ENTER” key again.
E d i t To o l#
A r r o w k e ys t o s cr o ll
P r e s s T O OL S to ex i t
E d i t To o l# 1
A r r o w k e ys t o s cr o ll
P r e s s T O OL S to ex i t
Position cursor next to desired parameter, enter new value, and press the “ENTER” key.
T o o l # 1
L e n g t h 2 0. 0 00
C o u n t Co n t. R un
P r e s s T O OL S fo r n e xt
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ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
Press “TOOLS” key to open next screen. Position cursor next to desired parameter, enter new value, and press the
“ENTER” key.
T o o l # 1
S p e e d 72
D w e l l 1 50
T O O L S -n e x t B K S P- P re v
Press “TOOLS” key to open next screen. Position cursor next to desired parameter, enter new value, and press the
“ENTER” key.
T o o l # 1
A c c e l 40 0 .0
D e c e l 40 0 .0
T O O L S -n e x t B K S P- P re v
NOTE: The following six screens are part of the optional PLS package and displayed only if the corresponding
software is loaded.
Press “TOOLS” to open the next screen. Position cursor next to desired parameter, enter new value, and then press
“ENTER” key.
T o o l # 1 P o s: 3 54
F e e d C am On 2 60
F e e d C am Of f 9 0
T O O L S -n e x t B K S P- P re v
Press “TOOLS” to open the next screen. Position cursor next to desired parameter, enter new value, and press “ENTER”
key.
T o o l # 1 P o s: 3 54
R e s e t Ca m O n 1 80
R e s e t Ca m O f f 2 00
T O O L S -n e x t B K S P- P re v
Press “TOOLS” to open the next screen. Position cursor next to desired parameter, enter new value, and press “ENTER”
key.
T o o l # 1 P o s: 3 54
P i l o t Re l O n 1 25
P i l o t Re l O f f 2 40
T O O L S -n e x t B K S P- P re v
Press “TOOLS” to open the next screen. Position cursor next to desired parameter; enter new value, and press “ENTER”
key.
T o o l # 1 P o s: 3 54
A u x 1 On 0
A u X 1 Of f 1 20
T O O L S -n e x t B K S P- P re v
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ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
Press “TOOLS” to open the next screen. Position cursor next to desired parameter, enter new value, and press “ENTER”
key.
T o o l # 1 P o s: 3 54
A u x 2 On 1 2 0
A u X 2 Of f 2 40
T O O L S -n e x t B K S P- P re v
Press “TOOLS” to open the next screen. Position cursor next to desired parameter, enter new value, and press “ENTER”
key.
T o o l # 1 P o s: 3 54
A u x 3 On 2 4 0
A u X 3 Of f 0
T O O L S -n e x t B K S P- P re v
Press “TOOLS” key to open next screen. To save changes as a new tool, choose the SAVE AS command and press the
“ENTER” key.
T o o l #
S a v e
S a v e as <
T O O L S -n e x t B K S P- P re v
Enter the new tool number and press the “ENTER” key again.
S a v e as To o l #
P r e s s T O OL S to Ab o rt
S a v e as #5
T o o l# 5 S a ve d
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ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
4.3 HOW TO DELETE A TOOL
NOTE: Make sure that the PROGRAMMING “LOCKED / UNLOCKED” key switch is in “Unlocked”
position and OPERATOR screen is displayed. If the current screen is not OPERATOR one then press the
“OPER” key to bring it up.
Press “TOOLS” key, position the pointer next to EDIT TOOL command and press the “ENTER” key.
E d i t To o l <
A c t i v at e T o o l
C r e a t e N ew
P r e s s T O OL S to Ex i t
Enter desired tool number or select it from the tool list using “↑” and “↓” keys and press the “ENTER” key again.
E d i t To o l#
A r r o w k e ys t o s cr o ll
P r e s s T O OL S to ex i t
E d i t To o l# 1
A r r o w k e ys t o s cr o ll
P r e s s T O OL S to ex i t
T o o l # 1
L e n g t h 2 0. 0 00
C o u n t Co n t. R un
P r e s s T O OL S fo r n e xt
Press the “TOOLS” key four (ten – with PLS option) times scrolling through the editing screens.
T o o l # 1
S p e e d 72
D w e l l 1 50
T O O L S -n e x t B K S P- P re v
T o o l # 1
A c c e l 40 0 .0
D e c e l 40 0 .0
T O O L S -n e x t B K S P- P re v
T o o l # 1 P o s: 3 54
F e e d C am On 2 60
F e e d C am Of f 9 0
T O O L S -n e x t B K S P- P re v
T o o l # 1 P o s: 3 54
R e s e t Ca m O n 1 80
R e s e t Ca m O f f 2 00
T O O L S -n e x t B K S P- P re v
24
Press “ENTER” key.
ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
T o o l # 1 P o s: 3 54
P i l o t Re l O n 1 25
P i l o t Re l O f f 2 40
T O O L S -n e x t B K S P- P re v
T o o l # 1 P o s: 3 54
A u x 1 On 0
A u X 1 Of f 1 20
T O O L S -n e x t B K S P- P re v
T o o l # 1 P o s: 3 54
A u x 2 On 1 2 0
A u X 2 Of f 2 40
T O O L S -n e x t B K S P- P re v
T o o l # 1 P o s: 3 54
A u x 3 On 2 4 0
A u X 3 Of f 0
T O O L S -n e x t B K S P- P re v
T o o l # 1
S a v e
S a v e as <
T O O L S -n e x t B K S P- P re v
T o o l # 1
D e l e t e T oo l <
T O O L S -n e x t B K S P- P re v
D e l e t e T oo l # 1
P r e s s 1 t o co n fi r m
A n o t h er ke y to ab o rt
Press “1” key.
T o o l # 1 D e le t ed
4.4 HOW TO ACTIVATE A TOOL
NOTE: Make sure that the PROGRAMMING “LOCKED / UNLOCKED” key switch is in “Unlocked”
position and OPERATOR screen is displayed. If the current screen is not OPERATOR one then press the
“OPER” key to bring it up.
Press “TOOLS” key, position the pointer next to Activate tool command and press the “ENTER” key.
25
ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
E d i t To o l
A c t i v at e T o o l <
C r e a t e N ew
P r e s s T O OL S to ex i t
A c t i v at e T o o l#
A r r o w k e ys t o s cr o ll
P r e s s T O OL S to ex i t
Enter desired tool number or select it from the tool list using “↑” and “↓” keys and press the “ENTER” key again.
A c t i v at e # 1 2 34 5 67
A r r o w k e ys t o s cr o ll
P r e s s T O OL S to ex i t
T oo l Ac t iv a te d
4.5 HOW TO EDIT “SETUP” PARAMETERS
NOTE: Make sure that the PROGRAMMING “LOCKED / UNLOCKED” key switch is in “Unlocked”
position and OPERATOR screen is displayed. If the current screen is not OPERATOR one then press the
“OPER” key to bring it up.
Press “SETUP” key three times, position cursor next to desired parameter, enter in new value, and press the “ENTER”
key.
J o g S pe e d % 5
J o g A c ce l 10 . 0
J o g D e ce l 1 0 .0
P r e s s S E TU P fo r n e xt
Press “OPER” key if editing is done or press “SETUP” key to open next screen.
4.7 HOW TO EDIT LENGTH FROM OPERATOR SCREEN
Locate the OPERATOR screen, position cursor next to the Length, enter new value, and press the “ENTER” key.
L e n g t h 1. 0 00
C o u n t Co n t. R un
L e n g t h A dj u s tm e nt
P r e s s O PE R to ex i t
26
ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
4.8 HOW TO EDIT COUNT FROM OPERATOR SCREEN
Locate the OPERATOR screen, position cursor next to the Count, enter new value, and press the “ENTER” key. Enter
“0” for continuous run.
L e n g t h 1. 0 00
C o u n t Co n t. R un
L e n g t h A dj u s tm e nt <
P r e s s O PE R to ex i t
4.9 HOW TO MICRO ADJUST LENGTH USING LENGTH ADJUSTMENT
Locate the OPERATOR screen, position pointer next to the Length Adjustment and press the “ENTER” key.
L e n g t h 1. 0 00
C o u n t Co n t. R un
L e n g t h A dj u s tm e nt <
P r e s s O PE R to ex i t
L e n g t h 1. 0 00
U s e Ar r ow K ey s t o
A d ju s t L e ng t h
P r e s s O PE R to ex i t
Adjust Length using “↑” and “↓” keys and then press “OPER” to exit adjusting.
4.10 HOW TO SYNCHRONIZE PRESS AND PLS
Open Set-Up screens, find Press offset parameter, and verify its value is set to “0” and if it is not, set it so. Recycle the
.
power
P L S C ou n ts / R ev 1 0 24
P r e s s O f fs e t 0
S E T U P -E x it B KS P -P r ev
Jog the press to its “0” degree (TDC) position, open status screen and read PLS position.
T o o l # P o s: 3 24
M an u al M od e
3 0 / C o nt . Ru n
P r e ss a M o de Ke y
Go back to Press offset parameter and change it to match PLS reading.
P L S C ou n ts / R ev 1 0 24
P r e s s O f fs e t 3 24
S E T U P -E x it B KS P -P r ev
Recycle the power. Read PLS position from the status screen, it should be the same as the press’, “0” degrees.
27
ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
T o o l # P o s: 0
M an u al M od e
3 0 / C o nt . Ru n
P r e ss a M o de Ke y
At this point the press and PLS are synchronized and you can start setting cam On/Off parameters.
4.11 HOW TO SET CAM “ON”/“OFF” PARAMETER
Open the screen that displays desired cam settings, jog the press to position where cam should turn on, read the exact
value of the press current position and enter this value for Cam On parameter.
T o o l # 1 P o s: 3 54
F e e d C am On 2 60
F e e d C am Of f 9 0
T O O L S -n e x t B K S P- P re v
Follow the same procedure to set Cam Off parameter.
5 OPERATING THE ULTRA ADVANTAGE SERVO FEED
5.1 PROGRAMMING
There is no need to program anything if the “Tool Storage” is properly set up. It is only a matter of activating the needed
tool, although the OPERATOR screen allows the Operator to edit two basic parameters.
OPERATOR screen is the only one that is Operator editable. This screen displays Length, Count, and Length
Adjustment. Length and Count can be changed only when cycling is stopped, although Length can be adjusted by
using the LENGTH ADJUSTMENT command even while the feed is running.
When Length and Count are edited or adjusted from OPERATOR screen, they override the stored tool Length and
Count and will be active until current tool is reactivated or another tool is activated.
Activate tool is the only command that is Operator accessible and can be executed only when the feed is not cycling.
5.2 PRIORITY MODE
The Ultra Advantage Servo Roll Feed has two modes of automatic cycle starting. The choice can be made between
“Press – Before – Feed” (“PBF”) and “Feed – Before – Press” (“FBP”) operating mode.
When “PBF” mode is selected and the Cycle Start button is pressed on the control panel, the feeder causes the “Auto”
and “Permit Press” relays to turn on thus enabling the start of continuous cycling on the press.
When “FBP” is selected and Cycle Start button is pressed on the feed control, the material/strip will be fed forward
before the press is started. The Operator may verify that the strip is in position before starting the press.
The Ultra Advantage Servo Roll Feed will now follow the press until it is stopped by the Operator, counter, emergency
stop, or feed error.
5.3 “JTL” (JOG TO LENGTH) MODE
“JTL” mode is used primarily during the threading of the strip through the die. This mode allows the Jog – To – “Feed
Length” operations to be performed. While in the “JTL” mode, the strip may be moved using the remote Jog Pendant.
If the “Jog Forward” is stopped before the “Feed Length” is reached, then either the “Jog Forward” or the “Jog
Reverse” Operator buttons will work. The “Jog Reverse” will not allow the strip to go backwards beyond the initial
“Feed Length” starting point.
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ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
The “Jog Forward” Operator button will function until the end of the “Feed Length” is reached. During “JTL” mode,
the bottom line on the display will show “Waiting for Jog”. When the “Feed Length” is reached, the jog buttons
become inactive and the message on display will show “Waiting for Press”. The jog buttons will not become active
again until after the press has made a cycle.
5.4 “AUTO / MANUAL” MODE
“Auto” Mode is used for production running of the UltraAdvantage Servo Roll Feed. When “Manual” mode is selected
via the 2-position selector switch, the control can be put in “Auto” mode by pressing Cycle Start button.
During “Manual” mode, the feeder can be jogged infinitely in either direction. After the Cycle Start button is pressed,
the jog buttons are inactive, and the feeding of the strip follows the cam signals from the press.
During “Auto” mode, the control keeps check on synchronization of the feeder and the press. If the feeder does not
complete the index within the feed cam window, the message “SYNC FAULT” displays.
The Ultra Advantage Servo Roll Feed has 2 modes of automatic cycling. The feeder can operate with Single Stroke or
Continuous modes. The mode is selected through an input to the feed controller. The Press single stroke/continuous
mode switch should be interfaced to that input for proper operation. During single stroke mode operation, the “Permit
Press” relay is activated upon the completion of each feed index.
The “Permit Press” relay remains activated until the reset cam signal turns on, or for the duration of the Dwell, if the
Dwell parameter is programmed. The “Permit Press” relay may be used to signal the press when to initiate the single
stroke cycle. The automatic cycling of the press and feeder will continue until the batch is completed, or the cycle is
stopped by the Operator, or an error occurs.
During “Continuous Press” mode, the “Permit Press” relay turns on at the beginning of the indexing.
The “Permit Press” relay remains activated until the automatic cycling is stopped by either “Cycle Stop” button, “Batch
Complete” internal command, “Sync Fault” or any other drive related error. Under “Cycle Stop” or “Batch Complete”
stopping, the output will turn off at the beginning of the Feed Cam Signal. This should allow the press to stop near the top
of the stroke. Under “Sync Fault” or other drive fault conditions, the “Permit Press” relay will turn off immediately
upon detection of the error.
5.5 STRIP ENCODER OPERATION
The control is designed such that if there is no Strip Encoder attached to the Servo Drive or the measuring wheel
is lifted, the Servo Drive and the whole feed acts as regular feed, operation of which is described in this Manual.
The measuring wheel must be lowered and the Length Mode must be set up before Cycle Start button is pressed.
Refer to STRIP ENCODER-OPERATION section of this manual for Length Mode description.
There are four additional SETUP parameters that take care of proper Strip Encoder operation. They are as follows:
Length Mode is a parameter that selects whether the feeder works in the Control or Check mode. Entering a "0" selects
Control mode and "I" selects Check mode.
Length Check is a parameter that defines the Check mode tolerance. It is a numeric entry with a range of 0.00 to
5.00 inch.
Strip Scale is the Strip Encoder scaling parameter used to define the number of encoder counts/inch. It is a numeric
entry with a factory value 3386.17.
Kp Multiplier is a parameter that defines a proportional gain of the position loop of the Strip Encoder and based on the
value of the motor encoder's Kp proportional gain. This is a tuning parameter, before changing its value, consult the
P/A Industries Service Department.
29
ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
L e n g t h M od e Co n tr o l
L e n g t h C he c k 0 . 01
S t r i p S c al e 3 3 86 . 30
S E T U P -N e xt B KS P -P r ev
P r o f i le L i ne a r
B a n d w id t h 3 00
K p M ul t i pl i er 1. 3
S E T U P -N e xt B KS P -P r ev
NOTE: The following speed performance charts represent theoretical calculations based on parameter values most
commonly used. Higher performance for specific applications can be reached by custom tuning the control.
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ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
Figure 6 SPEED PERFORMANCE CHART
Velocity (in/sec) 72.00 Feed Window (degrees)
Accel (in/sec2) 400.00 Strokes per minute
Feed(in) Feed Time(sec)
0.25 0.070 214 429 643
0.50 0.091 165 331 496
0.75 0.107 141 281 422
1.00 0.120 125 250 375
2.00 0.161 93 186 279
3.00 0.193 78 155 233
4.00 0.220 68 136 205
5.00 0.244 62 123 185
6.00 0.265 57 113 170
7.00 0.285 53 105 158
8.00 0.303 50 99 149
9.00 0.320 47 94 141
10.00 0.336 45 89 134
12.00 0.366 41 82 123
14.00 0.394 38 76 114
16.00 0.422 36 71 107
18.00 0.450 33 67 100
20.00 0.478 31 63 94
22.00 0.506 30 59 89
24.00 0.533 28 56 84
26.00 0.561 27 53 80
28.00 0.589 25 51 76
30.00 0.617 24 49 73
35.00 0.686 22 44 66
40.00 0.756 20 40 60
45.00 0.825 18 36 55
50.00 0.894 17 34 50
55.00 0.964 16 31 47
60.00 1.033 15 29 44
Velocity (in/sec) 41.00 Feed Window (degrees)
Accel (in/sec2) 400.00 Strokes per minute
Feed(in) Feed Time(sec)
0.25 0.070 214 429 643
0.50 0.091 165 331 496
0.75 0.107 141 281 422
1.00 0.120 125 250 375
2.00 0.161 93 186 279
3.00 0.193 78 155 233
4.00 0.220 68 136 205
5.00 0.244 61 123 184
6.00 0.269 56 112 167
7.00 0.293 51 102 153
8.00 0.318 47 94 142
9.00 0.342 44 88 132
10.00 0.366 41 82 123
12.00 0.415 36 72 108
14.00 0.464 32 65 97
16.00 0.513 29 59 88
18.00 0.562 27 53 80
20.00 0.610 25 49 74
22.00 0.659 23 46 68
24.00 0.708 21 42 64
26.00 0.757 20 40 59
28.00 0.805 19 37 56
30.00 0.854 18 35 53
35.00 0.976 15 31 46
40.00 1.098 14 27 41
45.00 1.220 12 25 37
50.00 1.342 11 22 34
55.00 1.464 10 20 31
60.00 1.586 9 19 28
90 180 270
90 180 270
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ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
5.6 TROUBLESHOOTING GUIDE
The chart that follows contains the most frequently encountered issues.
Symptom Cause or Remedy
No power indication when
Power On button is pressed
No display on power up 1. Check the cabling connection between display and the servo drive.
Feed will not jog 1. Check if the Feed is in “JTL” mode. Waiting for press?
Power On indicator is lit. Feed
will not operate.
Feed will not accept new “Feed
Length” or other parameters
Inaccurate feeding 1. Adjust the rolls for the correct material thickness; the tip of the roll release lever
Feed runs backwards 1. Verify that the direction parameter has been set properly (CW or CCW).
Drive Fault This is a generic display prompt indicating a fault on the Servo Drive.
1. Check the main power supply for proper voltage.
2. Check the supply circuit breakers.
3. Verify that the main disconnect switch is on.
4. Verify that the E-Stop is not engaged (E-Stop Loop closed.)
5. Check the bulb in Power On push button.
2. Check 5 VDC power supply.
2. Check if IN POSITION indicator is off. Check parameters. Check drive for
Error Codes.
3. Check the FAULT in display i.e. DRIVE FAULT # ABC. Check for Error
descriptions. See Section 5.2 of the “Ultra 5000 Intelligent Positioning Drives”
Installation manual.
1. Check that the IN POSITION indicator is lit. If not, check parameters.
2. Check that the Error message is in the Display. If so, check error description in
Section 7.2
3. Move selector switch to “Manual”, press the Power On button, release the Power
On button, and then try to jog feeder.
1. Make sure that the feed is not in “Auto” Mode.
2. Reset the Feed.
must have a small amount of play/wobble – approx. 1/16’’.
2. Adjust the spring pressure (Do not bottom springs. Catastrophic damage can
occur.)
3. Confirm if the rolls are slipping on the strip. Remove oil from the feed rolls,
reduce acceleration, check the tool for binding/slugs, etc.
4. Adjust the upstream equipment if the upstream equipment not providing
adequate/consistent free loop.
5. Check the roll release for the proper settings
1. Look at the diagnostic display on the Servo Drive. The cause of the fault can be
determined by reading the Error Code.
2. Refer to Sections 7.2. This fault condition can be caused by any one of the errors
in the lists.
3. Check the Error Code first, then reset the Servo Drive by turning the power off,
waiting 10 seconds, and then powering the Servo Drive back on.
4. Verify that the fault will not reset. Call the factory for assistance.
If the problem you are having does not appear in the above chart, or does appear in the chart, and you have questions
about it, call the P/A Service Department for assistance. Please have your Model Number and Serial Number ready.
However, it is advisable to check the basics before calling to be sure the problem is not something simple that may have
been overlooked.
32
5.7 ERROR CODES
Error
Code
Problem or
Symptom
ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
Possible Cause(s) Action/Solution
04 Motor Over
Temperature
05 IPM Fault
10 Bus Over Voltage
20 Motor Encoder
State Error
Motor thermostat trips due to:
High motor ambient
temperature, and/or
Excessive RMS torque.
Bad encoder cable or
connection.
Motor cables shorted. Verify continuity of motor power cable and connector.
Motor winding shorted
internally.
Ultra5000 Servo drive
temperature too high.
Operation above continuous
power rating.
Ultra5000 has a bad IPM,
output short circuit, or over
current.
Low AC line/AC power input. Verify voltage level of the incoming AC power. 09 Bus Under Voltage
100 VAC minimum for safe
Ultra5000 operation.
Excessive regeneration of
power.
When the motor is driven by an
external mechanical power
source, it may regenerate too
much peak energy through the
Ultra5000's power supply. The
system faults to save itself from
an overload.
Excessive AC input voltage. Verify input is below 264V AC.
Output short circuit. Check for shorts.
Motor cabling wires shorted
together.
Internal motor winding short
circuit.
Incorrect phasing. Check cables and connections. 11 Illegal Hall State
Bad connections.
The motor encoder encountered
an illegal transition.
Bad encoder. Replace motor.
Operate within (not above) the continuous torque rating
for the ambient temperature (40'C maximum).
Lower the ambient temperature to increase motor
cooling.
Check the encoder cable connections. Check the
encoder cable for continuity.
Check for short on U,V,W and Gnd windings of the
motor.
Check for clogged vents or defective fan.
Ensure cooling is not restricted by insufficient space
around the unit.
Verify ambient temperature is not too high (above 60'
C). Operate within the continuous power rating.
Replace Ultra5000.
Check AC power source for glitches or line drop (below
90V AC).
Install an uninterruptible power supply (UPS) of the
proper size on your AC input.
Lower the deceleration rate.
Check for shorts.
Check for shorts.
Replace the motor. Check the Pilot Release settings.
Route the cables away from potential noise sources.
Check the system grounds.
33
ULTRA ADVANTAGE SERVO ROLL FEED 2/14/2003
Error
Code
21 Auxiliary Encoder
Problem or
Symptom
state Error
Possible Cause(s) Action/Solution
The auxiliary encoder
encountered an illegal
transition.
Use shielded cables with twisted pair wires.
Route the encoder cable away from potential noise
sources.
Bad encoder - replace motor.
Check the ground connections.
22 Motor Thermal
Protection Fault
23 IPM Thermal
Protection Fault
The internal filter protecting the
motor from overheating has
tripped.
The internal filter protecting the
IPM at slow speed has tripped.
Reduce acceleration rates.
Reduce duty cycle (“On/Off”) of feed indexes.
Increase time permitted for motion. (Check cabling.)
Reduce acceleration rates.
Reduce duty cycle (“On/Off”) of feed indexes.
Increase time permitted for motion.
The servo drive module has built in diagnostics. The current status of the drive is always shown on the 7-segment LED
STATUS display, located on the front of the drive. The normal state of the LED is to actively cycle its edge segments
and an illuminated decimal point that indicates +5 volts. If an error occurs, the LED displays flashing letter E followed
by a two-digit error code, one digit at a time.
Errors can also be viewed on a Personal Computer screen using Ultraware® software package available upon request.
34
WARNING
This equipment offers various means of operating or controlling machines. The operator must not be in or near the point-of-operation
of the machine, or the operating parts of any equipment installed on the machine, or bodily injury could result. The EMPLOYER
must post adequate warning signs onto the machine with proper warnings for his machine and the specific application to which the
machine and equipment are being applied.
Occupational Safety and Health Act (OSHA) Sections 1910.211, 1910.212, and 1910.217 contain installation information on the
distance between danger points and point-of-operation guards and devices. No specific references have been made to which
paragraph of OSHA 1910.211, 1910.212, 1910.217 or any other applicable sections because the paragraphs may change with each
edition of the publication of OSHA provisions.
All equipment manufactured by us is designed to meet the construction standards of OSHA in effect at the time of sale, but the
EMPLOYER installs the equipment so the EMPLOYER is responsible for installation, use, application, training, and maintenance, as
well as adequate signs on the machine onto which this equipment will be installed.
Remember, OSHA says that the EMPLOYER must use operating methods designed to control or eliminate hazards to operating
personnel.
It shall be the responsibility of the EMPLOYER to establish and follow a program of periodic and regular inspections of his machine
to insure that all their parts, auxiliary equipment, and safeguards are in a safe operating condition and adjustment. Each machine
should be inspected and tested no less than weekly to determine the condition of the machine. Necessary maintenance or repair of
both shall be performed and completed before the machine is operated. The EMPLOYER shall maintain records of these inspections
and the maintenance work performed.
Our Company is not responsible to notify the user of this equipment of future changes in State or Federal laws, or construction
standards.
SAFETY PROGRAM
Accident free operation will result from a well developed, management sponsored and enforced safety program. Of vital importance to
any successful program is the proper selection of guards and devices. However, there is no safety device that will bring “automatic”
safety to your operation.
Of equal importance to this proper selection of the guard and the device is the training of your personnel. Each person must be trained
as to the operation of the guard or safety device, highlighting why they have been provided on the equipment. Rules for safe operating
should be written and enforced at all times. A final major concern of an effective safety program is regularly scheduled inspection and
maintenance of all of the equipment.
To ensure continued safety at all times, top management, line supervision, safety engineers and all employees must assume their
proper share of the responsibility in the program. Only as a group, one that knows your own operation and its problems, can you carry
out an effective safety program.
To assist you in the development of and continued use of safety programs, many safety minded groups have made guidelines available
to you. However, you must know when and how to apply these guidelines. The manufacturer provides information to assist you in
properly adjusting and maintaining your equipment. There is no short cut to proper safety; therefore, it is recommended that you
comply with their recommendations at all times.
WARRANTY
We warrant our new parts against defects under normal use and service for a period of 12 months after date of shipment. Our
obligation under this warranty is limited to replacing or repairing (at our option) the defective part without charge, F.O.B. our plant in
Bloomfield, Connecticut. The defective part must be forwarded to our plant, freight prepaid, for our inspection prior to replacement or
repair. EXCEPT AS EXPRESSLY PROVIDED HEREIN, THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING A WARRANTY OF MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE. Furthermore, the seller does not warrant or represent that the equipment complies with the provisions of
any law, particularly including the Occupational Safety and Health Act of 1970, and regulations promulgated thereunder. In no
event shall we be liable for special, indirect incidental or consequential damages, however rising.
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