PA Industries SRF-M12, SRF-18, SRF-24, SRF-32, SRF-36 Installation Manual
...
®
Installation and Operating Instructions
MAGNUM SERVO FEED
MODELS SRF-M12 / 18 / 24 / 32 / 36 / 48
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 1-860-242-4870
Website http://www.pa.com • E-Mail service@pa.com
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 A MAGNUM
SERVO FEED OPERATES .................... 2
3. INSTALLING YOUR MAGNUM
SERVO FEED ........................................ 3
3.1 MECHANICAL INSTALLATION ......... 3
3.2 ELECTRICAL INSTALLATION .......... 3
3.3 ELECTRICAL CONNECTIONS ........ 3
3.4 MAGNUM MOUNTING HOLES ........ 4
4. PROGRAMMING THE MAGNUM
SERVO FEED SYSTEM ........................ 4
4.1 PROGRAM A NEW FEED
LENGTH, COUNT, SPEED ............... 5
4.2 PROGRAM A NEW BATCH
COUNT ............................................. 6
4.3 PROGRAM A NEW SPEED
FOR THE FEED ................................ 6
5. OPERATING THE FEED ....................... 6
5.1 PRIORITY MODE .............................. 7
5.2 SET-UP MODE .................................. 7
5.3 AUTO/MANUAL MODE ..................... 7
5.4 LOADING THE FEED ........................ 7
5.5 RUNNING THE FEED ....................... 9
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. MAGNUM MECHANICAL
PARTS LIST AND DIAGRAM................14
9. CASCADE WITHOUT ENCODER
PARTS LIST AND DIAGRAM................17
1. INTRODUCTION
The P/A Industries 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 has led to
many of the design features found in the Magnum.
A high strength cast iron frame forms the core of
the Magnum. Large diameter 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
the heart of the Magnum. The new drive incorporates
all the latest motor control, tuning, and protection
features available. Standard features of the Magnum
controller include: Jog-To-Feed Length; Press Or
Feed Priority Selection, Press/Feeder Synchronous
Checking; Hand Held Jog Pendant with Roll
Release Selector; and many more.
The mechanical simplicity, accuracy, and ease of use
of your new Magnum Heavy Duty Servo Roll
Feeder should help you improve your quality and
production for years to come.
2. HOW A MAGNUM SERVO
FEED OPERATES
The Magnum Servo Roll Feed consists of:
2.1 THE MECHANICAL COMPONENTS
(Refer to Figure 1)
1) Feeder Housing & Feed Rolls
2) Worm-Gear Speed Reducer
3) Servo Motor
4) Air Actuated Roll Release
5) Cascade Guide Rolls
6) OPTIONAL-Cascade Guide Rolls
With Strip Encoder
2.2 THE ELECTRICAL CONTROL
ENCLOSURE ASSEMBLY
(Refer to Figure 1)
7) Operators Control Panel & Data Entry Terminal
8) 24 VDC Logic Power Supply (For Controls)
9) Cabling
10. CASCADE WITH ENCODER
PARTS LIST AND DIAGRAM .............. 18
WARNING .....................................................20
SAFETY PROGRAM ....................................20
WARRANTY .................................................20
DRAWING 17573-01
Figure 1.
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 amount. This will accurately position
the strip.
Fifteen and one-half revolutions of the servo motor
shaft produce 1 revolution of the feed rollers. The
motor-mounted optical encoder produces 8000
"pulses" for each revolution of the motor. The
circumference of the lower roll is 14.842 inches.
Example: If a feed pitch/length of 14.842 inches is
entered into the feeder, this will result in exactly
one revolution of the feed rolls. The motor will
accelerate and turn 15.5 turns. This will produce
(15.5 x 8000) =124,000 pulses of the encoder.
The feeder will decelerate and stop when 124,000
pulses are detected. The feeder is now on position.
This entire process happens very quickly, the end
result is an accurately positioned strip exactly
14.842 inches from its starting point. This entire
process happens in milliseconds.
Quick connectors. 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 cabling is adequate to reach the feeder. It is not
recommended that the Electrical Enclosure be
mounted directly to the press. The vibrations
caused by the press may result in damage to the
control system.
3.3 ELECTRICAL CONNECTIONS
For more detailed wiring information, refer to
Electrical Schematic A-17514-01 for 220 VAC
or 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.
3. INSTALLING YOUR
MAGNUM SERVO FEED
3.1 MECHANICAL INSTALLATION
The Magnum Servo Roll Feed is supplied with
a height adjustable mounting bracket for the feeder.
The adjustment is (±2.0 inch) from middle
position. The feeder should be securely mounted to
the press frame. A transition bracket is sometimes
required in certain applications requiring more
adjustment.
The feeder should be centered, square, and
perpendicular to the pass line of the press. Use the
24 millimeter square keys on the front mounting
plate for alignment and leveling the feeder. The
feeder should be mounted at a height that will
accommodate the appropriate die sets. Refer to
Figure 2 on Page 4.
The feeder can be used to push or pull stock.
3.2 ELECTRICAL INSTALLATION
The Magnum Servo Roll Feed has been designed
to make electrical connections quickly and easily.
A clean 220 VAC single phase 20 ampere source is
required for trouble free operation. The inputs and
outputs to your press control (i.e. Emergency stop,
Feed advance cam contact, Continue cam contact,
Pilot Release Cam Contact (if used), and Taut
or No Loop Input) must be connected according
to the electrical schematic instructions included
with machine. The motor connects by a factory
installed "Amphenol" (Military Specifications)
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 Magnum
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 Magnum Servo Roll Feed is fully protected
by a disconnect switch and line fuses. If it
becomes necessary to replace the fuses, use only
exact equivalent fuse types to prevent serious
damage to the system.
3
3.4 MAGNUM MOUNTING HOLES
PASS LINE
HEIGHT
ADJUSTMENT
±
2.0”
4.3” (109mm)
DRAWING 17573-02
D
PASS LINE
5.9”
(150mm)
3.1” (80mm)
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 0060/SEC
ENCODER FAULT
A
B
C
ø0.67” (ø17mm)
(4) MOUNTING
HOLES
Figure 2.
MAGNUM MOUNTING HOLES
for drawing 17573-02
INCHES
MODEL A B C D
SRF-M12 12.2 24.4 26.4 18.4
SRF-M18 15.3 30.5 32.5 24.4
SRF-M24 18.2 36.4 38.4 30.4
SRF-M32 22.3 44.5 46.5 38.3
SRF-M36 24.2 48.4 50.4 42.4
SRF-M48 30.1 60.2 62.2 54.2
MILLIMETERS
MODEL A B C D
SRF-M12 310 620 670 467
SRF-M18 387 775 825 619
SRF-M24 462 925 975 772
SRF-M32 565 1130 1181 972
SRF-M36 615 1230 1280 1076
SRF-M48 765 1529 1580 1377
4. PROGRAMMING THE MAGNUM
SERVO FEED SYSTEM
IMPORTANT !
Before turning the system on for the first time,
verify that the main input voltage is correct
(220vac single phase) and inspect all connections
for tightness, shorts, etc.
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
the ‘
JOG FORWARD’ button, or jogged in reverse
by pressing the ‘
JOG REVERSE’ button.
The Magnum Servo Roll Feed has six viewable
screens. Only the first operator screen (shown
above) will be operator editable/programmable.
This screen displays the length, count, and speed
parameters. These parameters may only be changed
while the program is stopped (indicated by lack of
‘
CYCLE START’ or set up light). The other
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 Magnum Servo Roll Feed are printed
on the operator panel below the operator terminal.
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:
• LENGTH: Distance in inches (or millimeters) of
the feed length. Maximum value of 999.750
inches.
• COUNT: The number of pieces required to run
in the batch. Maximum value of 999,999 pieces.
4
• SPEED: The maximum velocity of the material
in inches/second (or millimeter/second).
Maximum value of 60 inches/second.
ACCEL 000402/SEC^2
☞
• ACCEL: The rate of acceleration in
inches/second2(or millimeter/second2).
Maximum value of 1000 inches/second2.
• 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.
DWELL 00.00
DBNC 1 X 3.75MS
BDC) switch and the cycle can be
PRIORITY PBF
BACKLIGHT ON
☞
• 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.
1’.
INPOSN 000.0200
FELIM 5.000
FETIM 0.500
SYSTEM RESET
• PRIORITY: This parameter selects whether the
feeder indexes before the press starts ‘FBP’
(Feed-Before-Press), or the press starts before
the feeder indexes ‘PBF’ (Press-Before-Feed).
Entering a ‘0’ selects ‘PBF’ mode or a ‘1’ selects
‘FBP’ mode.
• BACKLIGHT: This turns on the backlight in the
display, which enhances the viewing.
CNTS/UNIT 8396
TIME BASE /SEC
☞
• CNTS/UNIT: This is the encoder scaling
parameter used to define the number encoder
counts/inch (or counts/millimeter).
• TIME BASE: Time scaling parameter for various
parameters. This is always set to ‘/SEC’ by
entering ‘0’.
• JOG SPEED: The rate of jogging speed in
percent of the SPEED parameter. Normally set
between 1 - 5%.
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
maximum amount of time that the following error
limit may be exceeded before executing an
emergency stop.
• SYSTEM RESET: This function clears all
parameters to the factory default conditions. No
program may be running,
(press and hold the ‘
the ‘
PROG/RUN’ switch must be set to ‘PROG’
position. Pressing ‘
SYSTEM RESET line will result in a confirmation
screen being displayed. Pressing ‘
time will reset the parameters to the factory
default values and the power-up screen will be
displayed. Pressing any other key than ‘
result in aborting the system reset.
1’ while the cursor is on the
RESET must be active
POWER ON’ button), and
1’ a second
1’ will
• DIRECTION: This parameter controls the
direction of positive motor rotation. 0 = CCW,
and 1 = CW.
☞
KP 0.30
KD 0.00
KFF 0.30
AUTO OFFSET ON
4.1 PROGRAM A NEW FEED
LENGTH, COUNT, SPEED
To program a new feed pitch/length the program
must be stopped. This may be done by pressing the
‘
POWER ON’ or the ‘CYCLE STOP’ button
(if the press is running). Press the ‘
button to view the following screen:
5
OPERATOR’
LENGTH 00008.000
☞
STEP #1:
The ‘UNDERLINE’ type cursor is located under
the length display whenever this screen is called up.
This indicates that this entry is capable of being
modified.
STEP #2:
Enter a new feed length; for instance...1.253 inches.
Press the ‘
press the ‘
‘
ENTER’ key. The control will now take a moment
to clear the existing length value in its memory and
then "memorize" the new setting. The display
should now show the new feed length setting. The
maximum feed length is limited to 8,388,608
encoder counts or 999.750 inches.
1’ key, press the ‘.’ Key, press the ‘2’ key,
5’ key, press the ‘3’ key, and press the
COUNT 100000
SPEED 0060/SEC
After the first Index/Part is made, the display
will show:
LENGTH 00001.253
COUNT 001000
☞
S
PEED 0060/SEC
000001 / 001000
4.3 PROGRAM A NEW SPEED
FOR THE FEED
STEP#1:
Position the ‘UNDERLINE
PEED with the ◗ key.
S
LENGTH 00001.253
☞
STEP #2:
Enter a new speed value, 60 inches per second is the
maximum speed setting. 1 inch per second is the
minimum speed setting.
COUNT 001000
S
PEED 0060/SEC
’ type cursor under
☞
LENGTH 00001.253
COUNT 100000
SPEED 0060/SEC
4.2 PROGRAM A NEW
BATCH COUNT
STEP #1
Position the ‘UNDERLINE’ type cursor under
C
OUNT. Use the ◗ key.
☞
LENGTH 00001.253
C
OUNT 100000
SPEED 0060/SEC
STEP #2
Enter a new desired batch count. For instance....
1000 pieces. Press the ‘
buttons. The control takes a moment to clear the
existing batch count setting in memory, and then
"memorizes" the new value. Enter a value of ‘
disable the batch counter. The display should now
show:
1’, ‘0’, ‘0’, ‘0’, and ‘ENTER’
0’ to
We will use 50/inches per second as our
example... Press the ‘
The control clears the existing value and inserts
50/seconds into its memory.
The display should now show the new setting:
☞
These (3) parameters may be changed when the
running batch is stopped. All other feeder
parameters are locked out of the editing mode via
‘RUN/PROGRAM’ switch located inside the
electrical enclosure on the panel.
5’, ‘0’, and ‘ENTER’ buttons.
LENGTH 00001.253
COUNT 001000
S
PEED 0050/SEC
5. OPERATING THE FEED
NOTE:
It is very important to remember that the motor
on the Magnum Servo Feed System is only
for feeding material. It is not intended to be the
power source for a pull-through straightening
device, or the like. An adequate free loop must
be provided at all times. This will assure
consistent and accurate feeding.
☞
LENGTH 00001.253
C
OUNT 001000
SPEED 0060/SEC
5.1 PRIORITY MODE
The Magnum Servo Roll Feed has (2) modes of
automatic cycle starting. The Operator can
6
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