PA Industries SRF-5, SRF-8, SRF-12, SRF-16, SRF-20 User Manual

®

Installation and Operating Instructions

ADVANTAGE SERVO FEED

Models SRF-5 / 8 / 12 / 16 / 20 / 24 / 28 / 32 / 36

(for Serial Numbers 7610697 and higher)

P/A INDUSTRIES INC.
522 Cottage Grove Road • Bloomfield, Connecticut 06002-3191 U.S.A.
Toll Free 1-800-243-8306 • Worldwide 1-860-243-8306 • Fax [phone]
Website http://www.pa.com • E-Mail [e-mail]

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 by

shipping 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.

TABLE OF CONTENTS

DESCRIPTION PAGE

1. INTRODUCTION ................................... 2

2. HOW AN ADVANTAGE

SERVO FEED OPERATES ................... 2

2.1 MECHANICAL ASSEMBLY .............. 2

2.2 ELECTRICAL CONTROL

ENCLOSURE ASSEMBLY ............... 2

3. INSTALLING YOUR ADVANTAGE

SERVO FEED ........................................ 3

3.1 MECHANICAL INSTALLATION ........ 3

3.2 ELECTRICAL INSTALLATION .......... 3

3.3 ELECTRICAL CONNECTIONS ........ 3

3.4 ADVANTAGE MOUNTING HOLES ... 4

4. PROGRAMMING THE ADVANTAGE

SERVO FEED SYSTEM ........................ 4

4.1 PROGRAM A NEW FEED

LENGTH, COUNT, SPEED .............. 6

4.2 PROGRAM A NEW BATCH

COUNT ............................................. 6

4.3 PROGRAM A NEW SPEED

FOR THE FEED ............................... 6

5. OPERATING THE FEED ....................... 7

5.1 PRIORITY MODE .......... .................. 7

5.2 SET-UP MODE ................................. 7

5.3 AUTO/MANUAL MODE .................... 7

5.4 LOADING THE FEED ....................... 8

5.5 RUNNING THE FEED ....................... 8

6. TROUBLESHOOTING GUIDE ..............11

6.1 PRO-200 MOTION

CONTROL CARD ERRORS ............12

6.2 DDM DRIVE ERROR MESSAGES ..13

6.3 RUN TIME ERROR CODES ........... 13

6.4 POWER-UP ERROR CODES ......... 13

7. MAINTENANCE ................................... 13

8. ROLL FEED PARTS LIST

AND DIAGRAM ....................................14

WARNING .................................................... 16

SAFETY PROGRAM ................................... 16

WARRANTY ................................................ 16

1. INTRODUCTION

The P/A Industries Advantage Servo Roll Feed is
a state of the art AC Servo feed which eases operator
adjustments to feed pitch, feeder speed, and feed
acceleration. These operator adjustments are entered
into the control memory by key pad input. 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 release, when to open the rolls for piloting.

The mechanical simplicity, accuracy, and ease of use of
the Advantage Servo Roll Feed should help to improve
your quality and production for years to come.

2. HOW AN ADVANTAGE
SERVO FEED OPERATES

The Advantage Servo Roll Feed consists of:

2.1 MECHANICAL ASSEMBLY

(Refer to Figure 1)

1) Adjustment/Mounting bracket

2) Feeder

3) Motor

4) Mechanical pilot release actuator

2.2 ELECTRICAL CONTROL

ENCLOSURE ASSEMBLY

(Refer to Figure 1)

1) Control switches/buttons

2) Power supply, 24 VDC (for controls)

3) Motor / Axis control module
(inside electrical enclosure)

4) Data entry terminal

5) Cabling

MECHANICAL PILOT

CONTROL

ENCLOSURE

Figure 1.

RELEASE ACTUATOR

ADJUSTABLE

MOUNTING

BRACKET

DATA
TERMINAL

CABLES

The introduction of servomotor technology to the
press roll feed has pushed the limits of accuracy,
adjustability, and performance to levels previously
unattainable.

Each revolution of the servo motor 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

11.142 inches.

DRAWING 17415

2

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 11.142 inches is
entered into the feeder, this will result in exactly
one revolution of the feed rolls. The motor will
accelerate and turn 2.909 turns. This will produce
(2.909 x 8000 = 23,272) pulses of the encoder.
The feeder will decelerate and stop when 23,272
pulses are detected. The feeder is now on position.
The end result is an accurately positioned strip
exactly 11.142 inches from its starting point. This
entire process happens in milliseconds.

3. INSTALLING YOUR
ADVANTAGE SERVO FEED

3.1 MECHANICAL INSTALLATION

The Advantage Servo Roll Feed is supplied with an
adjustable mounting bracket. The feed should be
securely mounted to the press frame. (A transition
bracket is sometimes required in certain
applications.) The feed should be centered, square,
and perpendicular to the pass line of the press.
It should be mounted at a height that will
accommodate the appropriate die sets. The feed has
a pass line height adjustment of ±1.2 inches.
(Note: The centerline of the Feeder is NOT the
centerline of the rolls.) Refer to Figure 2 on
Page 4 for dimensioning.

The feeder may be used to push or pull strip stock
through the die.

If pilot locating pins are used in your die sets, the
optional mechanical roll release bracket should be
attached to the press ram. It must be mounted in
such a way as to provide roll release at the proper
time and be adjustable for different die sets.

If the optional electro-pneumatic piloting is
used, another cam switch will be necessary for
controlling feed roll opening and closing.

3.3 ELECTRICAL CONNECTIONS

For more detailed wiring information refer to
Electrical Schematic A-17556-01 for 220 VAC and
Electrical Schematic A-17556-02 for 440 VAC.

The main power for the feed system requires a
"clean" 220 VAC single phase 20 ampere source.
A terminal strip is provided in the main control
enclosure to facilitate wiring connections. It is
recommended that #12 MTW (Machine Tool Wire)
be used for the primary power supply input.

IMPORTANT!

A #12 MTW grounding conductor must be
installed for proper machine grounding.

NOTE:

All connections should be made in accordance
with National Electrical Code (NEC)
requirements and must comply with all local
ordinances.

NOTE:

A word about electrical “noise”. Most pressroom
environments contain considerable electrical noise.
It is emitted from electro-mechanical press relays,
contacts, and solenoids. While the Advantage
Servo Roll Feed has been designed to minimize
“self generated” electrical noise, it is difficult to
provide protection for all applications. If erratic
system behavior is experienced, then the source
of the "noise" must be suppressed with either a
resistive/capacitive type of suppressor on AC
coils, or “Avalanche” type diodes on DC coils.

NOTE:

The Advantage Servo Roll Feed is fully
protected by line fuses. If it becomes necessary
to replace the fuses, use only exact equivalent fuse
types to prevent serious damage to the system.

3.2 ELECTRICAL INSTALLATION

The Advantage Servo Roll Feed has been designed
to make electrical connections quickly and easily. All
that is required is a "clean" 220 VAC single phase
20 ampere source. The inputs and outputs to your
press control (i.e. Emergency Stop, Feed Advance
Cam Contact, Pilot Release Cam Contact,
Continue Cam Contact, End of Strip Input) must
also be connected for proper operation. The motor
connects by factory installed "Amphenol" (Military
Specifications) Quick connectors.

NOTE:

The electrical control enclosure is supplied with
a stand/support which may be placed in any
convenient location. The enclosure may also be
mounted in any fixed location as long as the
cabling is adequate to reach the feed. It is not
recommended that the electrical enclosure be
mounted directly to the press. The vibrations
caused by the punch press can result In
damage to the control system.

3

3.4 ADVANTAGE
MOUNTING HOLES

4. PROGRAMMING THE
ADVANTAGE SERVO FEED
SYSTEM

PASS LINE

CENTER LINE OF RAM

D

TAP X 1”(25mm) DEEP

TYPICAL MOUNTING ON GAP FRAME PRESS

E REF

A REF

BOLSTER

C

L

C

B

D

PASS LINE

BOLSTER

ADJUSTABLE
CAM BAR

DRAWING 17147-03

PASS LINE

ADJUSTMENT

E

A

IMPORTANT !

Before turning the system on for the first time,
verify that the main input voltage is correct
(220 VAC single phase) and inspect all
connections for tightness, shorts, etc.

STEP #1:

Turn on the main power disconnect switch. This
applies power to the control power supply. Press the
amber ‘

POWER ON’ push-button. The button will

illuminate and the data input display will be visible:

☞

STEP #2:

P/A INDUSTRIES

SERVO ROLL FEED

VERSION 1.00

HIT KEY TO CONT__

Press any key on the terminal, the display will show:

☞

LENGTH 00008.000
COUNT 100000
SPEED 0062/SEC

ENCODER FAULT

Figure 2.

ADVANTAGE MOUNTING HOLES

for drawing 17147-03

ENGLISH

DIMENSION SRF-5 SRF-8 SRF-12 SRF-16/20/24/28/32/36

A 1.97 1.97 1.97 1.97
B 3.15 3.94 3.94 3.94
C 6.30 7.87 7.87 7.87
D – – – 5.91

TAP M14 M16 M16 M16

E MIN. 2.2 2.2 2.4 2.4

PASS LINE +2.4 +2.4 +2.4 +2.4

ADJUSTMENT -0.0 -0.0 -0.0 -0.0

METRIC

DIMENSION SRF-5 SRF-8 SRF-12 SRF-16/20/24/28/32/36

A505050 50
B 80 100 100 100
C 160 200 200 200
D – – – 150

TAP M14 M16 M16 M16

E MIN. 56 56 60 60

PASS LINE +60 +60 +60 +60

ADJUSTMENT -00.0 -00.0 -00.0 -00.0

STEP #3:

The ‘POWER ON’ push-button has a ‘FAULT

RESET

POWER ON’ button to clear the ‘ENCODER

‘

FAULT

’ function built into the button. Press the

’ message at the bottom line of the display.

The feed may now be jogged forward by pressing

JOG FORWARD’ button, or jogged in reverse

the ‘
by pressing the ‘

JOG REVERSE’ button.

The Advantage Servo Roll Feed has six viewable
screens. Only the first operator screen (shown
above) will be operator editable/program-mable.
This screen displays the length, count, and speed
parameters. These parameters may only be changed
while the program is stopped (indicated by lack

CYCLE START’ or set up light). The other

of ‘
viewable screens are shown on the following page.

These five other screens will be viewable at all times,
but are "locked" out of programming via run/prog
switch located on the electrical panel inside the
electrical enclosure. The factory set parameter
values for the Advantage Servo Roll Feed are printed
on the operator panel below the operator terminal.

4

These parameters are set from the factory for
average feeding applications and they seldom
require any changes. The five screens and a brief
explanation of the parameters are described below:

• CNTS/UNIT: This is the encoder scaling

parameter used to define the number encoder
counts/inch (or counts/millimeter).

• LENGTH: Distance in inches (or millimeters) of

the feed length. Maximum value of 1140 inches.

• COUNT: The number of pieces required to run

in the batch. Maximum value of 999,999 pieces.

• SPEED: The maximum velocity of the material in

inches/second (or millimeters/second). Maximum
value of 72 inches/second. (Maximum value of
54 inches/second for SRF-28/32/36).

ACCEL 000402/SEC^2

☞

• ACCEL: The rate of acceleration in

inches/second
Maximum value of 1000 inches/second

• DWELL: The time delay, which controls the ‘ON’

duration of the cut output relay. The dwell is used
when the press or shear, lacks a continue Bottom
Dead Center (
controlled by the dwell parameter.

• DBNC: This is the debounce parameter, which

is used to ignore contact bounce on the feed
signals.

☞

• PRIORITY: This parameter selects whether the

feeder indexes before the press starts ‘
(Feed-Before-Press), or the press starts before
the feeder indexes ‘
Entering a ‘
‘

FBP’ mode.

DWELL 00.00
DBNC 1 X 3.75MS

2

(or millimeters/second2).

2

.

BDC) switch and the cycle can be

PRIORTY PBF
BACKLIGHT ON

FBP’

PBF’ (Press-Before-Feed).

0’ selects ‘PBF’ mode or a ‘1’ selects

• TIME BASE: Time scaling parameter for various

parameters. This is always set to ‘
entering ‘

• JOG SPEED: The rate of jogging speed in

percent of the ‘
between 1 - 5%.

• DIRECTION: This parameter controls the

direction of positive motor rotation. 0 = CCW,
and 1 = CW.

☞

• KP: Proportional gain parameter for the motion

control. It controls the transitions between the
starting and stopping of the rolls. A lower value
provides a smoother (slower) transition.

• KD: This parameter is not used.

• KFF: Velocity feed forward gain. This is used to

reduce following error of the system.

• AUTO OFFSET: This parameter turns the

automatic offset on. Turn this feature on by
entering ‘

☞

• INPOSN: In-position parameter 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.

0’.

SPEED’ parameter. Normally set

KP 0.30
KD 0.00
KFF 0.50
AUTO OFFSET ON

1’.

INPOSN 000.0200
FELIM 5.000
FETIM 0.500
SYSTEM RESET

/SEC’ by

• BACKLIGHT: This turns on the backlight in the

display, which enhances the viewing.

CNTS/UNIT 7353

☞

TIME BASE /SEC
JOG SPEED 5%
DIRECTION CCW

• FELim: Follower error limit. FELim is the

maximum allowed position error. When this limit
is exceeded for the amount of time specified by
the FETime, the control will execute an
emergency stop.

• FETime: Follower error time. FETime is the

5