User manual FAGOR NC-200 PB - INSTALLATION MANUAL

FAGOR NC-200 PB NC FOR PRESS BRAKES INSTALLATION MANUAL Manual version: 0111 INDEX Declaration of conformity ................................................................................... 4 Safety conditions ............................................................................................... 5 Warranty terms ................................................................................................... 7 Material returning terms ...................................................................................... 8 Description of the different models (they may be selected with PAR64) ................ 9 Diagram of a typical press brake ....................................................................... 10 1. 1.1 1.2 1.3 2. 2.1 2.2 2.3 2.3.1 2.3.2 2.3.3 2.3.3.1 2.3.3.2 2.3.3.3 2.3.3.4 2.3.4 2.3.5 2.4 2.4.1 2.4.2 2.4.3 2.4.4 2.4.5 2.5 2.6 2.7 3. 3.1 Unit description .............................................................................. 11 Front panel (See operation manual) .....................................................11 Rear panel .........................................................................................11 General technical characteristics......................................................... 12 Connections and characteristics .................................................... 13 connection of the feedback systems ................................................... 13 Input/Output characteristics (X2) ....................................................... 14 Input/output Connection (X2). ........................................................... 15 Input description. .............................................................................. 15 Output description ............................................................................ 17 Input/output connection .................................................................... 18 Input/output connection. Model A ..................................................... 18 Input/output connection. Model A1 ................................................... 19 Input/output connection. Model B ..................................................... 20 Input/Output connection. Model C .................................................... 21 Block change synchronism. Models A, A1 ......................................... 22 Block change synchronism. Model B ................................................. 24 Machine reference (home) search....................................................... 26 X axis home search ........................................................................... 26 Y axis reference (home) search. Models A and A1 ............................. 27 Y axis home search. Model "B" ......................................................... 28 Y axis home search. Model "C"......................................................... 29 Precautions when home searching ...................................................... 30 RS-232-C connection (connector X7) ............................................... 31 Power and machine connection.......................................................... 32 Turning the unit on and off ................................................................ 32 Installation Parameters .................................................................. 33 Parameter setting ............................................................................... 34 Page: 2 - Installation Manual - NC-200 PB 4. 4.1. 4.2 5 5.1 5.1.1 5.2 5.2.1 5.2.2 5.2.3 Operation with the RS-232-C serial line ....................................... 49 Saving and restoring data ...................................................................49 Parameter transmitting format .............................................................49 SETUP ............................................................................................ 50 Test mode .........................................................................................50 Direct access to the parameters ..........................................................53 Axis setting........................................................................................54 Open loop without analog voltage output. P46(3)=0, P46(5)=0 ............54 Open loop with analog voltage output. PAR46(3)=1, PAR46(5)=0 .......55 Closed loop. PAR 46(3)=1, PAR46(5)=1 ............................................55 Appendix ........................................................................................................ 57 Error codes ......................................................................................................57 Maintenance......................................................................................................58 Warning: Before starting up the DRO, carefully read the instructions of Chapter 2 in the Installation Manual. The DRO must not be powered-on until verifying that the machine complies with the "89/392/CEE" Directive. NC-200 PB - Installation Manual - Page: 3 DECLARATION OF CONFORMITY Manufacturer: Fagor Automation, S. Coop. Barrio de San Andrés s/n, C.P. 20500, Mondragón -Guipúzcoa (ESPAÑA) We hereby declare, under our responsibility that the product: NC Fagor NC-200 PB meets the following directives: SAFETY: EN 60204-1 Machine safety. Electrical equipment of the machines. ELECTROMAGNETIC COMPATIBILITY: EN 50081-2Emission EN 55011 EN 55011 Radiated. Class A, Group 1. Conducted. Class A, Group 1. EN 50082-2 Immunity EN 61000-4-2 Electrostatic Discharges. EN 61000-4-4 Bursts and fast transients. EN 61000-4-5 Power surges EN 61000-4-11 Voltage fluctuations and Outages. ENV 50140 Radiofrequency Radiated Electromagnetic Fields. ENV 50141 Conducted disturbance induced by radio frequency fields. As instructed by the European Community Directives on Low Voltage: 73/23/EEC, on Machine Safety 89/392/EEC and 89/336/EEC on Electromagnetic Compatibility. In Mondragón, on April 1st, 2001 Page: 4 - Installation Manual - NC-200 PB SAFETY CONDITIONS Read the following safety measures in order to prevent damage to personnel, to this product and to those products connected to it. Fagor Automation shall not be held responsible for any physical or material damage derived from the violation of these basic safety regulations. Do not open this unit Only personnel authorized by Fagor Automation may open this unit. Do not handle the connectors with the unit connected to AC power. Before handling the connectors (mains, feedback, etc.) make sure that the unit is not connected to AC power. Use proper Mains AC power cables To avoid risks, use only the Mains AC cables recommended for this unit. Avoid electrical overloads In order to avoid electrical discharges and fire hazards, do not apply electrical voltage outside the range indicated in chapter 2 of this manual Ground connection In order to avoid electrical discharges, connect the ground terminals of all the modules to the main ground terminal. Before connecting the inputs and outputs of this unit, make sure that all the grounding connections are properly made. Before powering the unit up, make sure that it is connected to ground In order to avoid electrical discharges, make sure that all the grounding connections are properly made. Ambient conditions Respect the temperature and humidity ranges specified on the chapter about technical characteristics in this manual (1.3). Do not work in explosive environments In order to avoid risks, damage, do not work in explosive environments. NC-200 PB - Installation Manual - Page: 5 Working environment This unit is ready to be used in Industrial Environments complying with the directives and regulations effective in the European Community Install the unit in the right place It is recommended, whenever possible, to instal the DRO so its power switch of the back panel is at a distance between 0.7 m (27.5 inches) and 1.7 m (5.6 ft) off the floor and away from direct sunlight, hot air, coolants, chemical products, blows as well as from relays, or high electromagnetic fields (about 0.5m or 20 inches) that could damage it. This unit complies with the European directives on electromagnetic compatibility. Nevertheless, it is recommended to keep it away from sources of electromagnetic disturbance such as. - Powerful loads connected to the same AC power line as this equipment. - Nearby portable transmitters (Radio-telephones, Ham radio transmitters). - Nearby radio / TC transmitters. - Nearby arc welding machines. - Nearby High Voltage power lines. - Disturbance generating elements of the machine. - Etc. Safety symbols Symbols which may appear on the manual WARNING. symbol It has an associated text indicating those actions or operations may hurt people or damage products. Symbols that may be carried on the product WARNING. symbol It has an associated text indicating those actions or operations may hurt people or damage products. "ELECTRICAL SHOCK" symbol It indicates that point may be under electrical voltage "GROUND PROTECTION" symbol It indicates that point must be connected to the main ground point of the machine as protection for people and units. Page: 6 - Installation Manual - NC-200 PB WARRANTY TERMS WARRANTY All products manufactured or marketed by Fagor Automation has a warranty period of 12 months from the day they are shipped out of our warehouses. The mentioned warranty covers repair material and labor costs, at FAGOR facilities, incurred in the repair of the products. Within the warranty period, Fagor will repair or replace the products verified as being defective. FAGOR is committed to repairing or replacing its products from the time when the first such product was launched up to 8 years after such product has disappeared from the product catalog. It is entirely up to FAGOR to determine whether a repair is to be considered under warranty. EXCLUDING CLAUSES The repair will take place at our facilities. Therefore, all shipping expenses as well as travelling expenses incurred by technical personnel are NOT under warranty even when the unit is under warranty. This warranty will be applied so long as the equipment has been installed according to the instructions, it has not been mistreated or damaged by accident or negligence and has been manipulated by personnel authorized by FAGOR. If once the service call or repair has been completed, the cause of the failure is not to be blamed the FAGOR product, the customer must cover all generated expenses according to current fees. No other implicit or explicit warranty is covered and FAGOR AUTOMATION shall not be held responsible, under any circumstances, of the damage which could be originated. SERVICE CONTRACTS Service and Maintenance Contracts are available for the customer within the warranty period as well as outside of it. NC-200 PB - Installation Manual - Page: 7 MATERIAL RETURNING TERMS When returning the DRO, pack it in its original package and with its original packaging material. If not available, pack it as follows: 1.- Get a cardboard box whose three inside dimensions are at least 15 cm (6 inches) larger than those of the unit. The cardboard being used to make the box must have a resistance of 170 Kg (375 lb.). 2.- When sending it to a Fagor Automation office for repair, attach a label indicating the owner of the unit, person to contact, type of unit, serial number, symptom and a brief description of the problem. 3.- Wrap the unit in a polyethylene roll or similar material to protect it. 4.- Pad the unit inside the cardboard box with poly-utherane foam on all sides. 5.- Seal the cardboard box with packing tape or industrial staples. Page: 8 - Installation Manual - NC-200 PB DESCRIPTION OF THE DIFFERENT MODELS (THEY MAY BE SELECTED WITH PAR64) A. Controlling only the final position of the bend. The foot switches and the hydraulic circuit are not controlled by this NC. The intermediate positions of the ram are detected by electrical microswitches. A1. Same as model "A" with footswitch treatment and outputs for governing the hidraulic valves for the 4 EXECUTION modes. The rapid approach feed is not managed. Especially indicated for conventional down-stroke machines. B. Same as model "A" with a linear encoder or potentiometric scale for decoding the intermediate ram or bed positions affecting the bending approach speed and depth: With outputs to relays or to a PLC: STOP - Top dead point overrun S9 S29 S28 Fast ram approach. Slow speed controlled by the footswitches. Ram retraction. With internal processing: (without external output). · · Going through "Y=sheet thickness" position to withdraw the X axis. Bend position reached to start bending timing on upstroke models that do not have a presostat. C- Control of the actual ram/bed position. With internal processing of all the intermediate positions. The footswitches control directly the position of the bending tool, Y axis. NC-200 PB - Installation Manual - Page: 9 DIAGRAM OF A TYPICAL PRESS BRAKE + Y - X + Page: 10 - Installation Manual - NC-200 PB 1. UNIT DESCRIPTION This unit is especially designed to be used on punch presses. It allows displaying the position of the X and Y axes, controlling them as well as the raising device (H), editing and executing part programs etc. The axes may also be moved manually from the dro keyboard or externally with footswitches. 1.1 1.2 FRONT PANEL (SEE OPERATION MANUAL) REAR PANEL 1 2 3 Dimensions of the Built-in model (in mm): On the back of the unit, the following items may be found: 1.- Power switch. 2.- Three-prong power connector for AC and ground connection. 3.- M6 mm terminal for general machine ground connection. NC-200 PB - Installation Manual - Page: 11 X2.- SUB-D type 37 pin female connector to connect the digital inputs and outputs as well as the analog outputs. X3.- SUB-D HD type 15-pin female connector for X axis feedback device. X4.- SUB-D HD type 15-pin female connector for Y axis feedback device. X5.- SUB-D HD type 15-pin female connector for 2nd axis feedback device. auxiliary Y' axis (only on model "B"). X7.- SUB-D type 9 pin male connector for the RS-232-C serial line connection. WARNING Do not handle the connectors while the unit is under power. Before handling the connectors (mains, feedback, etc.) make sure that the unit is not under power. It is NOT enough to turn the display off by using the at the keyboard. key 1.3 GENERAL TECHNICAL CHARACTERISTICS Universal Power Supply between 100V AC and 240V AC ±10% at a mains frequency between 45 Hz and 400Hz, between 120Vdc and 300Vdc Mains frequency of 0 Hz (DC) and from 45 Hz to 400 Hz. Power outages of up to 20 milliseconds. 10-year memory backup of installation parameter even when the unit is off. The operating temperature inside the DRO enclosure must be between 5º C and 45º C (41ºF and 113ºF). The storage temperature inside the DRO enclosure must be -25º C and +70º C (-13º F and 158º F). Maximum relative humidity: 95% non condensing at 45ºC (113ºF). Front Panel Sealing: IP54 (DIN 40050), Rear panel: IP4X (DIN40050) except for built-in models in which case is: IP20. Page: 12 - Installation Manual - NC-200 PB 2. CONNECTIONS AND CHARACTERISTICS The connection for the RS-232 serial line (optional X1 connector) is not described in this manual; but in a supplement for it. 2.1 CONNECTION OF THE FEEDBACK SYSTEMS The feedback systems (scales or encoders) are connected via SUB-D HD type 15-pin female connectors: X3 and X4. Characteristics of feedback inputs: X3, X4 and X5: +5V input consumption: 250 mA Admits square-wave signal (TTL). (A, B, Io) Maximum frequency: 250 KHz, minimum separation between flanks: 950 nsec. Phase shift 90º ±20º, hysteresis 0.25 V, Vmax 7V, maximum input current: 3 mA. High threshold (logic state 1) Low threshold (logic state 0) Pin 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 2.4V < VIH < 5V 0.0V < VIL < 0.8V Signal A /A * B /B * Io /Io * Alarm /Alarm * +5V Not connected 0V Not connected Not connected Not connected Chassis Feedback alarm Power for feedback Not being used at this time Power for feedback Not being used at this time Not being used at this time Not being used at this time Shield Reference signal Feedback signals Function 1 * They depend on the type of feedback and may not be connected NC-200 PB - Installation Manual - Page: 13 2.2 INPUT/OUTPUT CHARACTERISTICS (X2) A 37-pin female connector is used. Signal characteristics of connector "X2": The supply voltage is at +24V (±25%), thus the threshold between a "0" and a "1" will be about +6V. Characteristics of the inputs at 24V : - Maximum load current: 100mA - Minimum DC voltage: 18V - Maximum DC voltage: 30V The main characteristics of the digital outputs are: (optocoupled with solid state relay with a normally open contact) - Maximum AC or DC voltage: - Maximum load current: - Maximum internal resistance: - Maximum peak current: - Through current when open: - Leak current: - Galvanic isolation voltage: - Activation time: - Deactivation time: 48V 150 mA 24Ohm 500mA for 100ms at 25ºC 1µA 200nA (Vload=100V) 1500V for 1 minute 3ms 3ms Main characteristics of the analog outputs Voltage range: ±10V Maximum current: 10mA Impedance: Resolution: 4.88mV Offset: ±30mV 120 Ohm referred to GND Page: 14 - Installation Manual - NC-200 PB 2.3 Pin I/O 1 2 I 3 I 4 O 5 O 6 O 7 O 8 I 9 O 10 O 11 I 12 I 13 I 14 I 15 I 16 I 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 I/O I/O I I O I O O O O O O I I I I I I I O INPUT/OUTPUT CONNECTION (X2). Common signals Chassis 0V External 24V External 24V User X enable 1 = X fast, 0 = X slow X direction Model "A" Model "A1" Model "B" Model "C" Not being used Buzzer Height H, 1 = up X limit + (Io X) X- limit New block BCD 1 switch External key 1 Chassis Pressure or scale input X analog output 0V Analog. 0V External 24V External 24V User Emergency Y enable 1 = Y fast, 0 = Y slow Y direction Manual mode Presostat External key RETURN footswitch Fast approach Buzzer Not being used Manual station "BCD 2" EXECUTION mode selector X, Y in position Y limit + (Io Y) Y- limit Ram retract Feed ram Bend slowly Not used Not used X forward / retract BCD 2 switch Y disable Semiautomatic External key External key Y analog voltage X forward Not used BEND footswitch "BCD 1" EXECUTION mode 2.3.1 INPUT DESCRIPTION. Section 2.3.3 shows the electrical diagrams for the indicated models. The parameters mentioned there are described in chapter 3 of this manual. The inputs are active high at 24V (PAR21 and PAR22 = 1....1). Pin 18 may be configured as an analog input with a 0V to +10V range. When installing a linear potentiometer, it should be supplied with the 5V from the digital feedback devices (pin 5 of X3, X4). NC-200 PB - Installation Manual - Page: 15 PIN FUNCTION DESCRIPTION In MANUAL mode, they limit the movement in the corresponding direction. In EXECUTION mode, they abort the program. In HOME SEARCH mode, they respond as home switches in the positive direction 11, 12, 30, 31 Limit switches. Hardware 23 EXTERNAL EMERGENCY Disables the axes Disables the outputs Displays error 20 1 - Continuous feed 14, 33, 34 5-position BCD selector in MANUAL mode - PAR32 2, 3, 4 - Incremental feed with the pitch set by PAR 32 5 - Y axis disable in EDITOR / TEACH-IN mode. It only displays it. It allows withdrawing the punch by external means in "C" mode. Semiautomatic in EXECUTION mode Models A1, B and C 36, 16 "BCD" selector 1 2 3 4 - RUN 1 - RUN 2 - SET - JOG 36 0 0 1 1 16 0 1 0 1 35, 36, 16 Model A External key simulation. PAR 31 Model A1, B and C footswitch connection Models A, A1 Allows duplicating any 3 keys that may be selected - PAR 31 8, 35 They respond according to the logic defined with the "BCD" selector If PAR65.1=1, requires previous input at I32 Confirmation of RAM at top dead position. Make sure that I13=1 to begin the home search (A, A1, B) F1 - Retracts the backstop X if there 's a conflict when bending, conditioned by the editing attribute B in the slow speed stage F2 - Forced X axis feed at the beginning of the bending sequence if PAR65.2 = 1 Only F2 13 Next block Models A, A1 Double function F1 + F2 32 Model B The X backstop automatically retracts at the position: Y = sheet thickness A - Electrical signal from the pressure sensor A1 - Confirmation that the programmed maximum pressure has been exceeded to begin the delay "D". Not connected. if the machine does not have a pressure sensor. Model A, A1 Pressure sensor section 2.3.4 15 Mode B, C FAST approach before the bend conditioned to the maneouver safety that requires "busy hands". The change to SLOW is forced at a previous programmable position Page: 16 - Installation Manual - NC-200 PB 2.3.2 OUTPUT DESCRIPTION If any of the outputs is going to be connected to some highly inductive device, a "1N4000" type diode must be installed in antiparallel. It is not required on auxiliary relays of less than 20 mA. The drives are enabled with auxiliary relays (section 5.2). PIN 5, 6, 7, 24, 25, 26 FUNCTION Axis enable FAST/SLOW DIRECTION PAR46 DESCRIPTION Enabling drives or frequency inverters for open loop control. 18, 37 Analog voltage outputs. PAR 64, PAR65 To control drives in closed loop drives. When installing a pressure transducer or potentiometric scale, connect it to pin 18 and change the position of the internal jumper. MANUAL mode selection confirmation. It activates the auxiliary output to raise the X axis backstop. R axis function, ON /OFF conditioned by the "H" editing attribute. A - Retraction control by trigger time of the thermostat conditioned by the "D" attribute. A1, B - Forced retraction up to the top dead point. Bending time conditioned by the "D" attribute. Signal to the electrical cabinet to enable the FAST approach buttons or SLOW bend footswitch. Single output. The FAST/SLOW change is handled with external resources from the electrical cabinet that manages the FAST buttons and the change switch. At all models, it is reset with : I32 (A, A1) or Y = e (B, C) at the beginning of the bend if attribute B I15 when exceeding the bending pressure 27 MANUAL mode 10 H output Models A, A1, B 28 Ram retraction. Section 2.3.4 Model A Axes in position Model A1 29 Approach and bending Model B SLOW approach. Section 2.3.4 9 Model B Fast movement handling. Ram approach. Model A, A1, C It resets in the programmable change position that forces the slow motion output O29. Buzzer to warn the operator about "permission to bend" NC-200 PB - Installation Manual - Page: 17 Encoder Encoder MOTOR CONTROL M X3 X4 M MOTOR CONTROL LIMIT X+ LIMIT X- LIMIT Y+ X2 EMERGENCY x50 x100 x1 Y Dis. FREE EXTERNAL KEY SIMULATION ß Semiauto BCD 24V USER Page: 18 - Installation Manual - NC-200 PB 11 12 X ENABLE 5 X SPEED 6 X DIRECTION 7 ANALOG X 18 GNDA 30 31 Y ENABLE Y SPEED Y DIRECTION ANALOG Y GNDA 2.3.3 INPUT/OUTPUT CONNECTION 19 LIMIT Y- I rf nte ace 24 25 26 37 19 MANUAL 27 H AXIS 10 IN POSITION NC- 200 PB 0V 24V EXTERNAL 24V RETRACT RAM BUZZER NEXT BLOCK FEED/RETRACT X AXIS 2 20 3 21 PRESSURE SENSOR 2.3.3.1 INPUT/OUTPUT CONNECTION. MODEL A Without footswitch connection or ram controlling outputs. 29 28 9 13 32 15 23 8 35 36 16 14 33 34 4 22 Encoder Encoder MOTOR CONTROL M X3 X4 M MOTOR CONTROL LIMIT X+ LIMIT X- LIMIT Y+ X2 11 12 X ENABLE 5 X SPEED 6 X DIRECTION 7 ANALOG X 18 GNDA 30 31 Y ENABLE Y SPEED Y DIRECTION ANALOG Y GNDA 19 LIMIT Y- In fa ter ce 24 25 26 37 19 MANUAL H AXIS FEED RAM NC- 200 PB 0V RETRACT RAM BUZZER NEXT BLOCK FEED/RETRACT X AXIS PRESSURE SENSOR 2 20 3 21 4 22 24V 24V EXTERNAL 2.3.3.2 INPUT/OUTPUT CONNECTION. MODEL A1 27 10 29 28 9 13 32 15 23 8 35 36 16 14 EMERGENCY 33 34 RUN 2 RUN 1 SET JOG x50 x100 x1 Y Dis. ß "BCD" Semiauto BCD 24V USER With footswitch connection. Manual control and ram controlling outputs. NC-200 PB - Installation Manual - Page: 19 "RETRACT" FOOTSWITCH "BEND" FOOTSWITCH Encoder Encoder MOTOR CONTROL M X3 X5 X4 M MOTOR CONTROL LIMIT X+ LIMIT X- LIMIT Y+ X2 EMERGENCY RUN 2 RUN 1 SET JOG x50 x100 x1 Y Dis. ß "BCD" Semiauto BCD 24V USER "RETRACT" FOOTSWITCH "BEND" FOOTSWITCH Page: 20 - Installation Manual - NC-200 PB 11 12 X ENABLE 5 X SPEED 6 X DIRECTION 7 ANALOG X 18 GNDA 30 31 Y ENABLE Y SPEED Y DIRECTION ANALOG Y GNDA 19 LIMIT Y- I rf nte ace 24 25 26 37 19 MANUAL H AXIS RAM SLOW RETRACT RAM RAM FAST TABLE TRAVEL LIMIT FEED X AXIS MANUAL STATION FAST FEED NC- 200 PB 0V 2 20 3 21 4 22 14 33 34 2.3.3.3 INPUT/OUTPUT CONNECTION. MODEL B With footswitch connection. Manual control and ram controlling outputs. 27 10 29 28 9 13 32 15 23 8 35 36 16 24V 24V EXTERNAL Encoder Encoder MOTOR CONTROL M X3 X4 M MOTOR CONTROL VALVE LIMIT X+ LIMIT X- LIMIT Y+ X2 11 12 X ENABLE 5 X SPEED 6 X DIRECTION 7 ANALOG X 18 GNDA 30 31 Y ENABLE Y SPEED Y DIRECTION ANALOG Y GNDA 19 LIMIT Y- In fa ter ce 24 25 26 37 19 MANUAL H AXIS BUZZER NC- 200 PB 0V With footswitch connection and manual control. 2 20 3 21 4 22 24V 24V EXTERNAL 2.3.3.4 INPUT/OUTPUT CONNECTION. MODEL C FREE FREE FREE FREE MANUAL STATION FAST FEED 27 10 9 29 28 13 32 15 23 8 35 36 16 14 EMERGENCY 33 34 RUN 2 RUN 1 SET JOG x50 x100 x1 Y Dis. ß "BCD" Semiauto BCD NC-200 PB - Installation Manual - Page: 21 "RETRACT" FOOTSWITCH "BEND" FOOTSWITCH 24V USER 2.3.4 BLOCK CHANGE SYNCHRONISM. MODELS A, A1 Description of the diagrams according to positions a, b and c. There are three ways to synchronize when going from one block to the next at the end of a bend. If a pressure gage (transducer) is installed, P64.6 = 1, the editor offers the possibility to program the work pressure on the header page N0. 1. With the transducer connected to input I18 (P64.7=0), this positioning dro (NC) compares the active pressure with the one programmed and provokes the block changing sequence. 2. If the comparator is external (P64.7=1), this positioning dro (NC) waits for a signal at I15 that confirms that the programmed pressure has been exceeded in order to begin the change sequence. In either case: a. Output O29 is deactivated (INPOS) in order to prevent the ram from going down. It starts the delay "D", bending time, at maximum programmed pressure. b. At the end of the bend, output O28 is activated to force the ram to return automatically and it resets the analog output for pressure. c. When it reaches the top dead point I13=1, it resets O28 and goes on to the next block. If PAR65.1=1, it requires a flank at I32 to confirm the contact of the punch with the sheet. 3. With pressure sensor signal, P64.6=0, connected to I15 and programmable delay for RAM UP. When the pressure sensor triggers: a. It deactivates O29 (INPOS) to prevent the ram from going down. It activates O28 to force the ram to return automatically. It is affected by the timer (PAR29 + D). As a precaution, a minimum delay is forced (PAR29). b. It resets O28 and it goes on to the next block. There are three possibilities: b1 With a "D" value too high, the ram reaches the top dead point, it activates I13 before the delay is over. b2 If D = 0, after the PAR29 delay. b3 If the delay is over (PAR29 + D), it forces it to go to the next block without waiting for I13. In the "b1" and "b2" modes, I13 resets the timer and O28. If it reaches the top dead point, it goes on to the next block. If PAR65.1=1, it requires a previous flank at I32. Page: 22 - Installation Manual - NC-200 PB 1- Pressure analog input I18 Analog Input P ar64 (6) = 1 P ar64 (7) = 0 (A) IN_POS O29 BN ED R T R O8 EU N 2 CHANGE I13 BLOCK a b P ar64 (6) = 1 P ar64 (7) = 1 c 2- Pressure analog output I18 Analog Output I15 Pressure level (A) IN_POS O29 BN ED R T R O8 EU N 2 CHANGE I13 BLOCK a b P ar64 (6) = 0 c 3- Pressure gage input I15 Pressure level (A) IN_POS BN ED O29 R T R O8 EU N 2 BLOCK I13 CHANGE Block change a b1 b2 b1 b3 NC-200 PB - Installation Manual - Page: 23 2.3.5 BLOCK CHANGE SYNCHRONISM. MODEL B Description of the diagram according to positions 1 through 6: 1. With X and Y axis already in position, the FAST approach is activated from the MANUAL control station IE15 or only SLOW from the "BEND" footswitch (I8). 2. In the change position, Y= PAR33 or programmable, the SLOW speed is activated with the "BEND" footswitch. 3. When pinching the sheet metal, Y = thickness, it resets O29 to wait for the return of the X axis. 4. Once the programmed bending depth has been reached, the auxiliary feedback Y compares the difference Y -Y' < PAR18 to begin the bending delay, "D" attribute. 5. After the delay "D" and depending on the selected cycle, it activates the return: If RUN1, RUN2 - Automatic or when interrupting with I35. If SET- With return footswitch I35. 6. When reaching the final dead point, PAR28 or programmable, it begins the next block. Page: 24 - Installation Manual - NC-200 PB - Position Y' - Auxiliary scale PAR33 Y' = e FAST/SLOW change Programmable top dead point By default: PAR28 D SLOW O29 Retract X programmable By default: P29 Programmed Y coordinate ·I8 ·I8 ·I8 I8 FAST 09 ·I15 I35 in EXEC. RUN1, RUN2 RAM DOWN O28 BEND footswitch 1 2 3 4 5 MANUAL-SET ·I35 JOG 6 X, Y axes IN POSITION. To enable O29, O9 O28 STOP Cut off valve X + Y in motion MANUAL CONTROL STATION I15 Begin bend FOOT CONTROL STATION, BEND I8 Sheet pinched Fina bend position FOOT CONTROL STATION E35 NC-200 PB - Installation Manual - Page: 25 2.4 MACHINE REFERENCE (HOME) SEARCH In this mode, the initial values are preset in a fixed reference position. If PAR14.4 = 1 on any axis, home search is mandatory on that axis every time the machine is turned on. This unit starts in mode. To quit this mode without homing, press and key in the access/exit code: 719200 If PAR14.4 = 0, home search is only required on machine setup. At the beginning, the software limits PAR12 and PAR13 should be opened to their maximum values to prevent this NC from forcing uncontrolled movements in order to position the axes within these travel limits. Should this happen by mistake, the movement may be stopped by pressing . Being PAR14.1 = 1 (Floating home search), if while in this state you press [access code], the affected axis will show the value: PAR12 + PAR26 as initial value. When pressing the relevant key , , it will suggest the PAR10 value by default with an option to select any other as described in later chapters. 2.4.1 X AXIS HOME SEARCH PAR14 establishes how the machine reference (home) search is to be carried out. All models perform this home search in the positive direction. The X axis usually has a travel limit switch: PAR 14 bit 1 = 0 and a rotary encoder. The home searching sequence is as follows: · Set the NC in Home search mode by pressing The led will turn on. . . If the home search for any of the axes is defined as "floating" (P14.1 = 1), it requests the password (719200) after pressing · · Select the Press . axis. The unit will display the text "START". The Axis moves in the positive direction, backwards, in rapid until reaching the positive travel limit switch. Once the switch is pressed, it returns at slow speed until the reference mark (I0) of the rotary encoder is detected. At that point, this unit displays the value set at PAR10 (that will correspond to the real value from the center of the die to the support side of the X axis). See section 2.4.5 Page: 26 - Installation Manual - NC-200 PB 2.4.2 Y AXIS REFERENCE (HOME) SEARCH. MODELS A AND A1 a- If the machine has travel limit switches, the home search procedure is the same as the one described for the X axis; but it is only enabled if I13 = 1, ram at top dead position. b- If the machine does NOT have travel limit switches (which is very common on down stroke models), set PAR14 bit 1 = 1 to indicate that the reference position is floating. The homing sequence is as follows: · In MANUAL mode, move the Y axis in the Y+ direction to make sure that the backlash is properly compensated for. If P17 = 1, the Y- movement will be affected by the unidirectional approach and will return in the Y+ direction. · · · Press the "BEND" footswitch until the ram reaches its final position. Output O27 is active ("A" model) to enable the footswitch. Measure the distance between the support bases of the punch and die. This distance will be the Yref to be preset. Press . The led will turn on. Enter the password (719200). This unit displays the real position and the axis remains on stand by. · Select the axis, (by default, it suggests the PAR10 value) and preset the reference value Yref and press to assume it. It displays the coordinate ( Y = Yref - Hpunch - Hdie) compensating the height of the tools that are active. See section 2.4.5 NC-200 PB - Installation Manual - Page: 27 2.4.3 Y AXIS HOME SEARCH. MODEL "B" Usually, this axis has home switches on UP-STROKE models. · Position the table or the ram at the far-end position activating the limit switch I13. · Press · Select the · Press . The led turns on. axis. It displays the word "START". to reach the home position. · Actuate on the "BEND" footswitch until the punch or the die (on up-stroke models) goes to its final position. a) With a linear encoder: · Press to synchronize the Y axis home value set in PAR10 with that of its associated axis Y'. b) With a linear potentiometer: It requires two synchronization points for the value of the Y axis with the position of the table in order to obtain the V/mm constant of the potentiometer and set an initial reference value. 1- Pressr , it displays the value of the potentiometer cursor in volts. It enables the MANUAL mode. 2- Press 3- Use to move the Y axis to the far-end position towards Y-. Activate the BEND footswitch again until the final position. Press again. Quit by pressing Page: 28 - Installation Manual - NC-200 PB 2.4.4 Y AXIS HOME SEARCH. MODEL "C" An up-stroke or down-stroke model "C" has a linear encoder and controls the actual (real) position of the ram using foot switches. It usually has travel limit switches. If PAR00 bit 6 = 0, has been set for a linear encoder with a regular reference mark (without distance-coded reference marks), the homing procedure is the same as described in section 2.4.2 (a) If PAR00 bit 6 = 1 has been set for a linear encoder with distance-coded reference marks. The homing sequence is as follows · Set the NC in Home search mode by pressing The · · led will turn on. axis. The unit will display the text "START". . . Select the Press The axis moves upwards in the positive direction until detecting two consecutive reference marks (I0's) and it displays the reference value set at PAR10. PAR10 = D - O + Where D = Distance between the support bases between the punch and the die. O = Offset value indicated on the label of the linear encoder = (See the next section 2.4.4) NC-200 PB - Installation Manual - Page: 29 2.4.5 PRECAUTIONS WHEN HOME SEARCHING The software limits set by PAR12 and PAR13 will indicate the real values referred to machine zero and they will correspond to the + and - limits slightly short of the positions of the travel limit switches or hard stops. The floating-home search on the Y axis (PAR14.1 = 1) is a little risky if the home value is wrong and does not match the actual distance between the supporting sides of the punch and die. The software limits set by the OEM may be overshot. The Y axis tries to recover a position within the software limits with the risk of exceeding the limits of the worm gear mechanism. As a precaution, make sure that the ram is in the upper area (I13 = 1) to make the home search sequence possible. If the machine has home switches (PAR14.1 = 0), the contact point of the microswitch with the cam should not be too close to the position of the first reference mark (I0) of the encoder. The + limit switch is also the reference input that is deactivated when reversing the movement direction. A certain margin should be kept in order to reach a stable slow feedrate before receiving the reference mark (I0) also overshooting the amount of backlash set at PAR16. Standard clamps allow some rotation of the encoder body to make this adjustment easily. Once the home search is finished, the axis moves towards X- until it reaches the software travel limit (always less than the hardware limit set by the X+ home switch) until reaching the position = PAR13 - PAR26. On open-loop controls, the I0 signal sends a stop command; but there is no assurance that the axis will be held at that position. There is a slight overshooting even when selecting a slow home search speed. Selecting the reference value for PAR10 takes three steps: 1- Set PAR10 with any value and execute a home search for a first rough approach. Calculate the "" difference: = PAR10 - final position reached (+ value) 2- The final value for PAR10 will be: The requested distance between the support bases between the punch and the die + . 3- Set the software travel limits PAR12 and PAR13. Page: 30 - Installation Manual - NC-200 PB 2.5 RS-232-C CONNECTION (CONNECTOR X7) The RS-232-C serial communications line uses a 9-pin male SUB-D type connector. Parameter PAR90 sets the transmission speed through this line. See section 3.5 in this manual. The operating mode for this feature is described in chapter 5 of the Operating Manual. Pin Signal Function 1 2 3 4 5 6-9 NC RxD TxD NC GND NC Not connected Receive Data Transmit Data Not connected Ground Not connected NC-200 PB - Installation Manual - Page: 31 2.6 POWER AND MACHINE CONNECTION This NC can be connected to an AC voltage anywhere between 100V AC and 264 V AC ±10% at a frequency between 45 Hz and 400 Hz. Between 120Vdc and 300Vdc without having to select it depending on the country where they are installed thanks to their universal power supply. Always mount it vertically so its keyboard is within operator's reach and its digits are easily visible (at operator's eye level). Do not connect or disconnect this NC connectors while it is under power. Connect all metallic parts to a common point on the machine tool and it to the general ground point. Use cables of enough gage (no thinner than 8 mm2). 2.7 TURNING THE UNIT ON AND OFF Turning the unit ON The unit is turned on by actuating on the power switch of the rear panel This NC runs a self-test and shows on the LCD display the text: "Fagor NC-200PB, Press and the and displays show "Fagor dro" if everything is OK and the error number if otherwise. See the appendix at the end of this manual. Turning the unit OFF If you press this NC turns off the displays while maintaining the power supply to the feedback systems and goes on reading the position of the axes at all times. This is not the case when the equipment is switched off by means of the switch on its rear panel. To reset the displays, just press this basta again, as long as this NC is getting voltage (plugged in and with the switch on the rear panel on). Notes: - Before powering this NC down with the switch on the rear panel or disconnecting it from mains, it is a good idea to press the key in order to store the current position of the axes permanently. - If the unit is powered down with its rear panel switch or there is a power outage without previously having pressed least 30 minutes. - The unit will display ERROR 2 when powered back up if the position reading was lost when turned off while the axes were moving or after the accidental backup period has expired without having saved the current position by previously pressing Page: 32 - Installation Manual - NC-200 PB , this NC will keep the last position of the axes for at . 3. INSTALLATION PARAMETERS These NC's have a number of installation parameters to configure it for a particular application. These parameters may be saved into a peripheral or uploaded from it through the RS-232-C serial communications line. The format for these parameters depends on whether they are general or particular for each axis. . If it affects the axes, press the corresponding axis key to modify it. . If it is a general parameter, the X display will show its current value. . The LCD display will show the description of the parameter and its number. There are several kinds of parameters depending on how to set them: · Binary values (1/0) are displayed in an 8-digit row identified as 1 through 8 from right to left. Their state changes by pressing their associated number key 1 · With decimal values, select the axis and key in the value. · Options, the value is selected by pressing + - which will show the various options in a rollover way. · Simulated key code, by accessing the corresponding key. to 8 . NC-200 PB - Installation Manual - Page: 33 3.1 PARAMETER SETTING Machine parameters PAR50, PAR51 and PAR90 enable special features of this NC. The user may access them directly. In initial mode, press [parameter number] . The rest can only be accessed by installers and technicians. Press and hold press . for at least 2 seconds, when the displays start blinking, Key in the access code: 060496 to access the general parameters. Once on the menu, to access a particular parameter, press: [Parameter number] The LCD display will shows the parameter number and a short description. . If it is a general parameter, its value is only shown on the first display. . If it is an axis parameter, each axis display will show its current value. In this case, select the axis by pressing its key ( new value. - To go to the next parameter saving the changes: Press or to go to the next one. or ) and key in its To return to the previous one, press - Pressing the key of the other axis ( - Pressing or ) saves the value of the previous axis and it goes on to edit the new selected axis. will quit the parameter editing mode. is pressed, the unit will ignore - If while changing the value of a parameter, the new value and will assume the previous one. Page: 34 - Installation Manual - NC-200 PB Binary values (1/0) are displayed in an 8-digit row identified as 1 through 8 from right to left. X 8 PARAMETER FUNCTION PAR00 Feedback configuration, different per axis. Binary type. This parameter sets the specific characteristics of the feedback device (rotary or linear encoder) used to read the axis position. Digit 8 Direction of the distance-coded Io (0 = Increasing, 1 = Decreasing) Fagor offers two types of linear encoders depending on the type of reference marks they use (Io): the standard one with several reference marks every 50 mm and the one with distance-coded reference marks (models with "O", e.g.: MOVX, FOP, etc.). When using a rotary encoder or a standard Fagor linear encoder (without "O") for this axis, this bit must be set to "0". When using an "M" or "F" series Fagor linear encoders with distance-coded reference marks (e.g.: MOVX, FOP) for this axis, this bit must be set to "0". When using a "C" type linear encoder with distance-coded reference marks, (e.g.: COX, COVP) for this axis, this bit must be set to "1". 7 Pitch of the distance-coded Io (0 = 20 mm, 1 = 100 mm) This bit is ignored if bit 6 has been set to "0". When using Fagor M or C series linear encoders, this bit must be "0". When using Fagor F series linear encoders, this bit must be "1". 6 Type of linear scale's Io (0 = Fix, 1 = Coded) Fagor offers two types of linear encoders depending on the type of reference marks they use (Io): the standard one with several reference marks every 50 mm and the one with distance-coded reference marks (models with "O" e.g.: MOVC, COS, etc.). When using a rotary encoder or a standard Fagor linear encoder, this bit must be set to "0". NC-200 PB - Installation Manual - Page: 35 X 7 XX 6 5 X 4 X 3 X 2 X 1 5 Axis units: 0 = mm, 1 = inches These units refer to the feedback and not to the display which may be changed with the key.. 4 3 2 Not being used at this time. It must be set to "0" Not being used at this time. It must be set to "0" Type of feedback signals (0 = TTL) This bit must be set to "0". A value of "1" will be ignored. 1 Counting direction (0 = normal, 1 = reverse) Regulation for press brakes: X axis retraction in the positive direction. Ram up movement in the positive direction. If an axis count increases or decreases in the opposite direction to the one desired, change the value of this digit. It conditions the setting of the sign bit PAR46(2) and the sign of the analog voltage. PAR01 Feedback resolution, independent for each axis, Possible values: factory setting: from 0.0001 mm to 1 mm. From 0.000001 to 0.03937 inch 0.0050 (mm). PAR02 TTL multiplying factor (subdivision). Independent for each axis. Options: x4, x2, x1 and x0.5. The selection of these values rotates by pressing The factory setting is: x4 and it is the one used for FAGOR scales. When using an encoder, its number of pulses should be calculated according to the leadscrew pitch, the desired resolution and the multiplying factor to be applied as per the formula: Encoder (lines/turn) = Leadscrew pitch (mm/turn) Resolution (mm/pulse) x F Where "xF" would be the multiplying factor to be applied. Page: 36 - Installation Manual - NC-200 PB