PA Industries SRF-M12, SRF-18, SRF-48 Operation Manual

ULTRA MAGNUM SERVO ROLL FEED 5/23/2003

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)....................................................................................................... 6

2.6 STRIP ENCODER-OPERATION (OPTIONAL) ............................................................................... 6

3 PROGRAMMING THE ULTRA MAGNUM 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......................................................................................... 18

4.3 HOW TO CREATE A NEW TOOL USING AN EXISTING ONE............................................... 21

4.3 HOW TO DELETE A TOOL......................................................................................................... 23

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............................................................. 26

4.9 HOW TO MICRO ADJUST LENGTH USING LENGTH ADJUSTMENT................................. 26

4.10 HOW TO SYNCHRONIZE PRESS AND PLS ............................................................................. 27

4.11 HOW TO SET CAM “ON”/“OFF” PARAMETER.......................................................................... 27

5 OPERATING THE ULTRA MAGNUM 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.............................................................................................................. 28

5.5 STRIP ENCODER OPERATION .................................................................................................... 29

5.6 TROUBLESHOOTING GUIDE....................................................................................................... 31

5.7 ERROR CODES ............................................................................................................................... 32

WARNING .................................................................................................................................................. 34

SAFETY PROGRAM ................................................................................................................................ 34

WARRANTY............................................................................................................................................... 34

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ULTRA MAGNUM SERVO ROLL FEED 5/23/2003

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 Magnum Heavy Duty Servo Roll Feed combines the latest servo roll feed design
technology with the latest servo drive control technology. Years of testing and experience had led to many of the
design features found in the Ultra Magnum.

A high strength cast iron frame forms the core of the Ultra Magnum. Large diameters textured feed rolls with driven
upper and lower rolls assure positive feeding of the strip without slipping. A precision worm-gear reducer provides the
torque multiplication necessary for optimum pulling capacity required on heavier material.

A brand new high performance digital servo drive is a heart of the Ultra Magnum. The new drive incorporates all the
latest motor control, tuning, and protection features available.

All 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, when to open the rolls for piloting.

The mechanical simplicity, accuracy, and ease of use of the Ultra Magnum 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) Feeder

2) Servomotor

3) Air actuated roll release

4) 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 MAGNUM SERVO ROLL FEED 5/23/2003

ALL ULTRA MAGNUM 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 and Rolls Open/Close
remote jog pendant

Turns controller into “Manual” or “JTL” (Jog To Length) mode.

Locks access to programming.

Pendant is attached to the enclosure through retractile cable.

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 Magnum Servo Roll Feed Standard, US model. The actual numbers for
Heavy Duty or metric models are different.

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ULTRA MAGNUM SERVO ROLL FEED 5/23/2003

Each revolution of the servomotor produces 8000 encoder pulses. Every 25 revolutions of the servo motor shaft
produce 1 revolution of the feed rollers. The circumference of the lower roll is approximately 14.781 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.

Example: If a feed pitch/length of 14.781 inches is entered into the feeder, this will result in exactly one revolution of
the feed rolls. The motor will accelerate and turn 25 turns. This will produce (25 x 8000 = 200,000) pulses of the
encoder. The feeder will decelerate and stop, when 200,000 pulses are detected. The feeder is now in position. The
result is an accurately positioned strip exactly 14.781 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 a tool numbers which are user definable and can contain of 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.

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ULTRA MAGNUM SERVO ROLL FEED 5/23/2003

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.

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.

1. CONTROL MODE

encoder operation are inactive.

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.

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ULTRA MAGNUM SERVO ROLL FEED 5/23/2003

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.

3 PROGRAMMING THE ULTRA MAGNUM 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 d u s t r i e s
R e a l l y C o o l F e e d
V e r s i o n 1 . 0 0 s t d
H i t a n y k e y t o c o n t .

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 MAGNUM SERVO ROLL FEED 5/23/2003

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 o s : 1 8 2
M a n u a l M o d e
3 0 / C o n t . R u n
P r e s s a M o d e K e 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 p d : 3 8 4
A u t o M o d e
3 0 / C o n t . R u n
P r e s s a M o d e K e y

OPERATOR screen shows and allows editing the following parameters:

L e n g t h 1 . 0 0 0
C o u n t C o n t . R u n
L e n g t h A d j u s t m e n t <
P r e s s O P E R t o e x i t

• 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 o l
A c t i v a t e T o o l <
C r e a t e N e w
P r e s s T O O L S t o e x i t

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ULTRA MAGNUM SERVO ROLL FEED 5/23/2003

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 o l # 1

A r r o w k e y s t o s c r o l l
P r e s s T O O L S t o e x i t

A c t i v a t e
T o o l # 1
A r r o w k e y s t o s c r o l l
P r e s s T O O L S t o e x i t

C r e a t e T o o l #

P r e s s T O O L S t o e x i t

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:

To o l A c t i v a t e d

Display will show STATUS screen.

T o o l # 1 S p d : 3 8 4
A u t o M o d e
3 0 / C o n t . R u n
P r e s s a M o d e K e 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 e s n ‘ t e x i s t !

The display will show the previous screen.

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ULTRA MAGNUM SERVO ROLL FEED 5/23/2003

E d i t T o o l #

A r r o w k e y s t o s c r o l l
P r e s s T O O L S t o e x i t

Or

A c t i v a t e
T o o l #
A r r o w k e y s t o s c r o l l
P r e s s T O O L S t o e x 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 0 0
C o u n t C o n t . R u n
P r e s s T O O L S f o r n e x t

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 4 0
D w e l l 0
T O O L S - n e x t B K S P - P r e 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 40
in/sec (1016 mm/sec) for Standard model and 0 to 30 in/sec (762 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 4 0 0 . 0
D e c e l 4 0 0 . 0
T O O L S - n e x t B K S P - P r e 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 MAGNUM SERVO ROLL FEED 5/23/2003

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 5 4
F e e d C a m O n 2 6 0
F e e d C a m O f f 9 0
T O O L S - n e x t B K S P - P r e 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 5 4
R e s e t C a m O n 1 8 0
R e s e t C a m O f f 2 0 0
T O O L S - n e x t B K S P - P r e 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 5 4
P i l o t R e l O n 1 2 5
P i l o t R e l O f f 2 4 0
T O O L S - n e x t B K S P - P r e 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 5 4
A u x 1 O n 0
A u X 1 O f f 1 2 0
T O O L S - n e x t B K S P - P r e v

T o o l # 1 P o s : 3 5 4
A u x 2 O n 1 2 0
A u X 2 O f f 2 4 0
T O O L S - n e x t B K S P - P r e v

T o o l # 1 P o s : 3 5 4
A u x 3 O n 2 4 0
A u X 3 O f f 0
T O O L S - n e x t B K S P - P r e v

Auxiliary 1 (2, 3) On indicates the position of the press when the auxiliary cam switch turns on.

Auxiliary 1 (2, 3) Off indicated the position of the press when the auxiliary cam switch turns off.

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