Dynamatic 015-000248-2002 Instruction Manual Download Page 17 | Manualshive

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EC-2000-CES MANUAL

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Figure 5

: Keypad Dimensions (to Scale)

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Summary of Contents for 015-000248-2002

Page 1: ...EC 2000 CES Stamping Press Position Controller Instruction Manual Sturtevant Wisconsin USA 53177 Telephone 262 554 7977 Fax 262 554 7041 Toll Free 800 548 2169 www dynamatic com sales dynamatic com ...

Page 2: ...ility 11 3 10 Codes and Standards 11 SECTION 4 CONTROL OPERATION MODES 13 4 1 Control Modes 13 4 2 Mode of Operation 13 SECTION 5 Inputs Outputs 14 5 1 Analog Inputs 14 5 2 Digital Inputs 14 5 3 Analog Outputs 14 5 4 Digital Outputs 14 SECTION 6 INSTALLATION 15 6 1 Panel Keypad Layouts 15 6 2 Mounting Hardware 18 6 3 Wiring 18 6 4 Hardware Jumper Potentiometer Setup 19 SECTION 7 KEYPAD 22 SECTION ...

Page 3: ... 2 PRESS SPEED CONTROL 43 10 3 BRAKE CONTROL BOARD 43 10 4 CLUTCH CONTROL BOARD 44 10 5 PRE START UP PROCEDURE 44 10 6 START UP PROCEDURE 46 SECTION 11 FAULT LISTING DESCRIPTIONS 48 11 00 FAULT LIST 48 11 01 LEVEL 100 FAULTS 48 11 02 LEVEL 200 FAULTS 48 11 03 LEVEL 300 FAULTS 50 SECTION 12 PRESS CONTROL INTERFACE SERIAL PORT 52 12 0 SERIAL PORT PRESS CONTROL INSTRUCTIONS 52 12 1 SERIAL PORT PARAME...

Page 4: ... 13 45 The speed range is limited doesn t reach maximum speed 65 13 46 High Voltages Fuses blow on power up 66 13 47 High Voltages Fuses blow while running 66 13 48 Low Voltages Fuses on clutch control board blow 66 13 49 Low Voltages Fuses on brake control board blow 66 13 50 Unstable Speed Running 66 13 51 Unstable Speed Slowing or Braking 67 Table of Figures Figure 1 Eddy Current Drive Block Di...

Page 5: ... in Green 19 Table 3 Follower Set Point Jumper Settings 19 Table 4 Brake Control Board Programmable Jumpers 21 Table 5 Keypad Button Descriptions 22 Table 6 Mechanical Unit Tach Pulses REV Setting 24 Table 7 Parameter Locations 40 Table 8 Press Run Data Format 53 Table 9 Control Fault Data Format 55 Table 10 Control Monitor Data Format 56 ...

Page 6: ...ng based on press position and feedback magnitude with drive speed and torque being based on the operational mode and load requirements Speed control mode with tachometer or resolver feedback will regulate within 0 5 of set speed Preset speeds and external reference inputs are available as standard parameter selections with the EC 2000 CES control The EC 2000 CES uses digital technology to provide...

Page 7: ...EC 2000 CES MANUAL 7 Figure 1 Eddy Current Drive Block Diagram ...

Page 8: ...EC 2000 CES MANUAL 8 Figure 2 EC 2000 CES Keypad Display ...

Page 9: ...equired Input Voltage 50 60 Hz Notes 015 000248 2002 300VDC 135A 600V 1ph SCRs in F W bridge rectification 015 000248 2003 300VDC 80A 600V 1ph SCRs in F W bridge rectification 015 000248 2004 300VDC 32A 600V 1ph SCRs in F W bridge rectification Field Forcing to 600V Transformer sold separately Input Voltage with step up Isolation Transformer ...

Page 10: ... with keypad user interface Recorded and displayed faults RS422 485 Com port Remotely programmable speeds and angles Ethernet IP add on to be available 3 2 Power and Load Ratings Input voltage 200 230 460 575V AC Output Currents 24 to 135 Amp See Table 1 Output Voltage 300VDC Field Forcing to 750 VDC with Inversion Solid State Relay Outputs 5 Normal Stop Stop on Top Stop Now Stop Motor Control Fau...

Page 11: ...rt 15B of federal regulation 47 as a Class A digital device when operated in a defined enclosure and installed in accordance with our instructions third party verification is required EMI Susceptibility Complies with IEC 801 1984 3 class 2 It operates without fault or disturbance under the specified level of radiated EMI Performance Criteria 1 3 6 Enclosures Enclosures available upon request lead ...

Page 12: ...EC 2000 CES MANUAL 12 ...

Page 13: ...tween an automatic signal i e 4 20mA or 0 10V and the control potentiometer in Speed Mode Start Stop Utilizes Enable High Enable Low Clutch Contactor Six Preset Angles and Speeds o Programmable through the keypad Top Stop Utilizes Creep angle Creep Speed Stop Angle Adjustable Braking Ramp Control Loss of Follower User Process Units Programmable SPM and Gear Ratio Tach Pulses Forward Reverse Speed ...

Page 14: ...for setpoints 5 2 Digital Inputs Clutch On Enable High Enable Low Inch High Inch Low Reverse Continuous Mode Fault Reset 5 3 Analog Outputs Tach Pulses 5 4 Digital Outputs Clutch Contactor On Relay NO o 2A 115VAC Solid State Relays 120VAC o Normal Stop o Stop on Top o Stop Now o Stop Motor o Control Fault ...

Page 15: ...EC 2000 CES MANUAL 15 SECTION 6 INSTALLATION 6 1 Panel Keypad Layouts Figure 3 Standard Panel Dimensions Not to scale ...

Page 16: ...EC 2000 CES MANUAL 16 Figure 4 Keypad Cutout Template to Scale Inches ...

Page 17: ...EC 2000 CES MANUAL 17 Figure 5 Keypad Dimensions to Scale ...

Page 18: ...ds adhering to the National Fire Protection Association s NFPA 70 National Electrical Code codes and standards for proper branch protection SCCR ratings and ampacity ratings o https www nfpa org codes and standards all codes and standards list of codes and standards detail code 70 Terminal Block Tightening Torque o TB 25 lb in o TB1 8 8 lb in o TB2 6 lb in ...

Page 19: ...17 Tach Generator TB2 18 19 J3 Process Feedback Not Used on CES Control 0 TO 20VDC 0 TO 5 10V J4 Speed Control Feedback From Resolver TB2 2 Tach Generator TB1 G1 G2 J5 Clutch Current Feedback Scaling 72 AMP or less Output 100 Amp Output J6 Brake Current Feedback Scaling 36 AMP or less Output 50 Amp Output J7 Gating Pulse Train Standard and High Power Controls CES Press Drive Control Only J8 Sync B...

Page 20: ...EC 2000 CES MANUAL 20 Figure 6 Clutch Control Board Layout Location of Jumpers on the Clutch power Board Note that Jumpers J3 and J6 are located under the logic circuit board if it is installed ...

Page 21: ...r Reference Internal Power Supply External Power Supply J3 Resolver Reference Internal Power Supply External Power Supply J4 Clock Reference Internal Oscillator External Oscillator J5 Processor Mode Run Test J6 Tachometer Pulse Divisor Low Divisor High Divisor J7 Programmable Switch Open Closed Potentiometers R1 Measure TP1 to TP4 Adjust R1 for 5Volts 1 R35 SCR Pulse Position R174 Analog Input Sca...

Page 22: ...Table 5 Keypad Button Descriptions Key Function Notes ENTER Allows user into a menu or submenu confirms value change EXIT Allows user to back out of a menu or submenu F1 F2 Turns Display light on and off Allows user to cycle through menus or values in ascending order Shift Allows user to change between individual digits Allows user to cycle through menus or values in descending order Figure 8 Keyp...

Page 23: ...CURRENT Select the output range of the controller Choose the closest value to the coil rating for scaling purposes 5 5 Amps 8 Amps 16 Amps 24 Amps 36 Amps 54 Amps 72 Amps 80 Amps 100 amps Default 135 amps 3 CLUT COIL RATING Locate the clutch coil rating on the nameplate of the mechanical unit and enter it The value should be equal or less than the previous parameter 2 Controller Current Default 10...

Page 24: ...20 180 Tach From Resolver See Notes Below Tachometer From Resolver Place clutch driver board jumper J4 in the A position The resolver outputs a pulse 4096 times per revolution This output is connected to the pulse input term 1 2 on the clutch driver board after being scaled by jumper J6 with a divisor of 2 low or 8 high The default is 8 high HZ 4096 Divisor 60 at one stroke per minute 4096 pulse 8...

Page 25: ...h current controls Typical 8 amp control is 0 Typical 100 amp control 500 10 CUR FILTER Filter for the current feedback loop 1 64 Each Increment 8 3 ms Has no effect if current loop disabled Otherwise current response is dampened Default 16 11 SPD FILTER AVER Allows for taking an average of the speed feedback readings This is primarily used for non standard speed feedback configurations noise affe...

Page 26: ...egral derivative feedback loop PID It is recommended to only adjusting the speed feedback parameters 4 5 and 6 And try to keep parameter 6 as low as possible as high DIFF values can cause a control speed to run away over time and adjust parameters 4 and 5 until stable results are achieved 1 CURR PROP GAIN Current Proportional Gain is the amount of response times a constant to the current and is pr...

Page 27: ...ult 0 7 ENABLE CURRENT LOOP The EC 2000 CES has two PID loops as seen in the previous parameters speed and current where the speed PID loop is fed into the current PID loop This parameter allows the user to disable the current PID loop This is typically is used in Systems with fast changing outputs that require very quick response While a bit of speed accuracy is given up control response and stab...

Page 28: ...sponse that is calculated based on the rate at which the current value is approaching the set point value This slows the response to avoid over shoot Normally only needed in systems with a very slow response Default 0 6 BRK SPD PROP GAIN Speed Proportional Gain is the amount of response times a constant to the current and is proportional to the amount of that error Default 100 Default 80 7 BRK SPD...

Page 29: ...s per minute All of the speeds set in process are multiplied by the gear ratio to establish an operating speed Note the control can also display an output speed is strokes per minute from the resolver This can be used to correct the gear ratio if the proper value is not known to obtain the proper output speed Max RPM Gear Ratio Max SPM 1 INCH SPEED 0 to Max SPM 2 MICRO INCH SPEED 0 to Max SPM 3 AN...

Page 30: ...ormal stop 18 RESOLVER OFFSET Enter degrees to correct resolver reading to actual press position 0 360 degrees 19 RESOLVER DIR REV o ENABLE o DISABLE default 20 GEAR RATIO Enter Gear Ratio from Press Drive to Press Default 25 8 6 Menu G FAULT 1 CURRENT FAULT Allows the user to see the current fault read only 2 PRIOR FAULT 1 Allows the user to see the previous fault read only 3 PRIOR FAULT 2 Allows...

Page 31: ... On Signal must be on together within the programmed time Missing Enable Low Fault 210 Missing Enable High Fault 213 Missing Clutch On Fault 208 Default 500 MS 3 ENA CONT MISSING Once controller accepts a run command if one of the enables or clutch on or clutch contactor is missing for the programmed time a fault will be generated Missing Clutch on Fault 208 Missing Clutch Contactor Fault 218 Clut...

Page 32: ... Micro Inch On Together Fault 212 Reverse command without Inch command Fault 317 Inch Command Change Fault 318 Micro Inch Command Change Fault 319 Reverse Command Change Default 300 MS 7 CL OVER CUR TIME Timer for clutch overcurrent above current rating Fault 315 Default 2500 MS 8 BR OVER CUR TIME Timer for brake overcurrent above current rating Fault 316 Default 2500 MS 9 CL BR OVERLAP TIME Timer...

Page 33: ...f max brake current for on too long timer Fault 321 Default 30 14 CL COOL DOWN Timer for brake current on too long Fault 227 Default 30 SEC 15 BR COOL DOWN Percentage of max brake current for on too long timer Fault 228 Default 30 SEC 16 OVR SPD TRIP TIME Over Speed Trip Timer Fault 101 Default 2000 MS 17 OVR SPD TRIP Over Speed Trip Fault 101 Default 30 18 UND SPD TRIP TIME Under Speed Trip Timer...

Page 34: ...for Resolver Speed Update Default 100 MS 23 SERIAL COMM FAULT Timer For EC 2000 Communication Fault Fault 231 Default 5000 MS 24 MISSING STPT TIME Timer For EC 2000 to acknowledge a set point If the control fails to receive a set point after a run or inch command is issued this fault will be issued Fault 204 Default 2000 MS 8 8 Menu I POSITION ERROR SETUP 1 TOP STOP ERROR If the error in stopping ...

Page 35: ...d SPM Clutch Amps Brake Amps EC RPM Feedback Resolver or Tachometer in RPM EC Set Point in RPM Set point seen by the control RPM EC Ramp In RPM Acceleration Ramp in RPM 8 10 Menu K SERIAL OPTIONS 1 EC 2000 MENUS Speed Controller Menu Access Consult Factory Allows Direct Access to Speed Controller Menus Need Item 2 Enabled as well for this to work Use only for trouble shooting Choices Are ENABLE DI...

Page 36: ...lutch contactor in the programmed time delay in parameter D 10 The controller responds to this removal of enable with a normal stop signal output signal The enable contact closures must be given only after all safety features of press operation have been determined to be in a GO status by the press control Redundant inputs are provided to ensure that the enable signal is present and that the recei...

Page 37: ...lt reset command is a signal from the press control to reset any fault condition in the controller allowing for continuation of operation If the condition is a result of a clutch current fault or a brake current fault it will be necessary to wait the on the setting of parameters H 14 for the clutch and H 15 for the brake before resetting otherwise another fault will be generated This delay is nece...

Page 38: ...control board of the CES controller opens a solid state relay contact LED On for the stop on top fault signal to the press control This signifies a 300 Level Fault CONTROL FAILURE FAULT OUTPUT The control failure fault is generated by either of two conditions One is when the main microprocessor watchdog timer senses a microprocessor failure The other is when the secondary clutch brake controller f...

Page 39: ...N MODE NORMAL The controller is in the run mode if the following conditions exist 1 Enable signals are present 2 NO fault is present 3 Reverse is not present 4 Inch is not present 5 Micro inch is not present 6 Clutch contactor ON is present 7 Brake contactor is closed When in the run mode the CES controller functions in the following manner A clutch ON command closes the clutch contactor Upon init...

Page 40: ...without any speed pot INCH FORWARD MODE SET UP The controller will be in the inch forward mode if the following conditions exist 1 Enable signals are present 2 No fault is present 3 Reverse is not present 4 Inch is present 5 Micro inch is not present 6 Clutch contactor ON signal is present 7 Brake contactor is closed When in the inch forward mode the controller functions in the following manner A ...

Page 41: ...ol removing clutch on or the internal brake delay timing out parameter D 10 The inch reverse mode will be indicated by simultaneous display of the Inch H and Reverse on the keypad display MICRO INCH FORWARD MODE SET UP The controller will be in the micro inch forward mode if the following conditions exist 1 Enable signals are present 2 No fault is present 3 Reverse is not present 4 Micro Inch is p...

Page 42: ...re the Fault display and Fault LED s While in the fault mode the fault is displayed on the top line of the display regardless of the display assignment for that line The fault can also be read at parameter G 1 The fault mode is entered if any fault is generated Once the fault mode has been entered by the initiation of a fault the controller remains in the fault mode until the fault mode is remotel...

Page 43: ...d a circuit breaker for over current protection An autotransformer steps the 480 volt line voltage up to 600 volts for the required forcing voltage The clutch suppressor and brake suppressor printed circuit boards provide isolation and amplification of the SCR firing pulses 10 2 PRESS SPEED CONTROL The press control provides closed loop speed control operation with inner speed loops on both the cl...

Page 44: ...nt and various other items to the brake board via serial port 10 5 PRE START UP PROCEDURE Use a digital multi meter such as a Fluke 87 with 1 or better accuracy for all measurements required during start up Turn the circuit breaker to the OFF position Turn all incoming signals OFF Make sure the press motor is off Check all terminal screws for tightness Make certain that All plugs are properly seat...

Page 45: ... 3 times 23 Press the local remote key The control can now be operated from the keypad 24 Press the set point key 25 Use the up arrow to set the set point to 1000 26 Press the set point key 27 Connect a clip on DC Ammeter to one of the clutch leads 28 Press the run key to energize the clutch Press the stop key to de energize the clutch The current should ramp up and limit at the set current limit ...

Page 46: ...ck for presence of LED on brake control board and on the keypad display 3 Reverse Check for presence of LED on brake control board and on the keypad display 4 Stop On Top Check for presence of LED on the brake control board 5 Clutch Contactor ON and Enable Check for presence of LEDs on the brake control board Since the motor is not running an under speed fault 313 will result and a stop on top fau...

Page 47: ...4 Speed 1 Set to 10 Strokes Per Minute 3 Set Items 5 7 9 11 13 to 360 DEG These Speeds will be skipped 4 Set Item 15 CREEP ANGLE to 300 DEG 5 Set Item 16 CREEP SPEED to 4 0 Strokes Per Minute 6 Set Item 17 STOP ANGLE to 355 DEG o Run the press through several cycles o Use the stop on top function to stop the press Readjust the creep speed creep angle and stop angle if necessary to attain the prope...

Page 48: ...es in the reverse direction past the degree amount programmed this fault is set o Degrees Parameter Group I Item 3 FAULT 207 Low or Lost AC Voltage o This fault is set if the control supply voltage becomes unstable or is reduced to less than 80 of 120 VAC FAULT 208 Missing Clutch On Signal o If the two enables are closed during starting or running and the clutch on input is opened or remains open ...

Page 49: ...tem 4 FAULT 224 Top Stop Out Of Range o When operating in single stroke mode if the control fails to perform a top stop within the programmable degree range _ degrees this fault is set o Degree error Parameter Group I Item 1 o Top Stop Degrees Parameter Group F Item 17 FAULT 225 Clutch Contactor Removed Early o The clutch contactor needs a time delay on stopping to dissipate clutch current This de...

Page 50: ...FAULT 314 Clutch and Brake Current Overlap o If both the clutch and brake values exceed 20 of max current at the same time for the time set in the programmed parameter a fault is set o Time Parameter Group H Item 9 FAULT 315 Clutch Over Current o If the clutch current exceeds the maximum limit value for the programmed period of time this fault is set o Time Parameter Group H Item 7 FAULT 316 Brake...

Page 51: ...med time limit a fault is generated o Time Parameter Group H Item 10 Parameter Group H Item 11 FAULT 321 Brake Current On Too Long o If the control brake current is above the programmed of max current for the programmed time limit a fault is generated o Time Parameter Group H Item 12 Parameter Group H Item 13 ...

Page 52: ... codes CC Send monitor data DD Begin using parameters down loaded with last AA commands EE Echo back last AA parameters The press control may have constraints on changing of speeds and press drive parameters while the press is running The CES controller will change parameters as directed by the press control Press control parameters are sent by the press control in a packet of bits representing AS...

Page 53: ...he angle to initiate the contact that will allow the press control to set the friction brake after the press has been at creep speed and reaches this stop angle 5 The angles will be four digits with an implied decimal point in tenths of a degree ranging from 0 to 359 9 degrees 6 The speeds will be four digits with an implied decimal point in hundredths of a stroke per minute 7 The press run data s...

Page 54: ... press control will send a two character packet to the CES controller instructing the DMR to execute the new parameters The two ASCII characters in this packet of bits will be DD All characters in the packet will be 8 bit ASCII the most significant bit being zero with one start one stop and no parity In the run mode the new parameters will take effect immediately after the receipt of the DD comman...

Page 55: ... to complete the 68 character packet Numbers in the monitor data will be four digits with an implied decimal point 12 7 SERIAL PORT MONITOR DATA PACKET CONTENT The CES monitor data packet will contain the following information 1 ASCII characters CC 2 Acceleration and deceleration rates will be four digits with an implied decimal point in tenths of a stroke 3 The speeds will be four digits with an ...

Page 56: ... Old 324 RX 94 Old 325 The Proper baud rate must also be set It is 9600 Packet Number Data 1 through 2 CC 3 through 6 Inch Speed 7 through 10 Micro Inch Speed 11 through 14 Creep Speed 15 through 18 Auto acceleration rate 19 through 22 Auto deceleration rate 23 through 26 Manual acceleration rate 27 through 30 Manual deceleration rate 31 through 34 Stop Deceleration Rate 35 through 68 Zeros ...

Page 57: ...ping A logical and effective maintenance program requires keeping a log of any problems and any corrective action taken even if that action was not successful in solving the problem Normal indications In order to be more effective in troubleshooting requires knowledge of normal conditions Normal conditions would include but not be limited to 1 Line voltage 2 Brake current levels 3 Clutch current l...

Page 58: ...the main motor 204 Missing Set point fault Loss of set point after run command issued Possible causes Programming error speed set point Programed at 0 Connection Problem between clutch control and brake control boards Check PL2 plug on clutch control logic board and EC PL plug on brake board Cycle power to the control Serial port failure on clutch control board or brake control board Replace as ne...

Page 59: ...brake control board Low voltage check incoming line 208 Enables without clutch contactor on fault clutch on wire 10 signal is not present within time set in H 2 of receiving enables Possible causes Press control not sending signal Check clutch on LED on brake control board Bad clutch brake board Parameter H 2 Time set too short 209 Clutch contactor on after clutch on is a de energized fault Clutch...

Page 60: ...ter H 2 Possible causes Press control not sending signal Check clutch on LED on brake control board Bad clutch brake control board Parameter H 2 Time set too short 218 Enables Clutch on without clutch contactor fault Clutch contactor not on in time set in H 3 Possible causes Connections on clutch contactor coil Clutch contactor auxiliary contacts CE relay contacts E relay on clutch control board B...

Page 61: ...D 9 Brake gains are too low Creep angle is set too late Creep speed is too high Defective Brake control board not firing SCR s properly 225 Clutch contactor on or clutch contactor removed too soon fault Clutch on signal removed without removing the enable signal or removing clutch on signal during the delay required by the parameter in H 5 before de energizing clutch contactor Possible causes Pres...

Page 62: ...r control and reports current and speed values to the main processor several times per second If no data is received by the master processor for the programmed time a control fault is set Time Parameter Group H Item 23 Possible causes Connections between clutch control board PL2 and brake control board PL EC Clutch control processor crashed Cycle power to the control Defective clutch control logic...

Page 63: ...s expired Possible causes Mechanical binding or overloading of press Increase value of parameter H 7 Insufficient torque due to damaged clutch coils Miss adjustment of tuning parameters Defective clutch control board Defective clutch SCR s Loose belts 316 Brake current fault If brake current is above the current limit set in parameter B 4 for a time determined by parameter H 8 a brake current faul...

Page 64: ...ed limits this fault will occur Possible causes Operator or interface error Defective brake control board Control fault a microprocessor watchdog timer monitors the microprocessor and the power supply for proper operation This fault requires turning power to the control off to reset Possible causes Power supply 5V Adjustment clutch control board Power supply 5V Adjustment brake control board Defec...

Page 65: ...s Check parameters SPM or F 3 F 14 gear ratio F 20 may be too high Check J9 J10 on clutch control board Set to A position Check parameters H 16 H 17 H 20 H 21 These may be set so high that over speed and tach loss faults are disabled Missing Tachometer feedback Check display Check j4 jumper on clutch control board Position A for resolver tach Position B for mechanical unit tach Binding in mechanic...

Page 66: ...be about 18 ohm Try engaging clutch with coil disconnected If fuses blow problem is in the control If not problem is in the mechanical unit Check for press binding causing excess clutch amps Defective clutch control board 13 48 Low Voltages Fuses on clutch control board blow Possible causes Too much load on 120VAC circuit Change 1 amp fuse to 5 amp Defective clutch control board or logic board 13 ...

Page 67: ...rake speed differential gain Parameter B 8 Press Counterbalance not set or working properly Check to see if control is working harder on the down stroke vs the upstroke or visa versa Note The fault menu and conditions are merely troubleshooting aids Drive stops due to automatic Fault detection may be eliminated by changing times or settings in Menu H CAUTION Changing fault times or percentages can...

Page 68: ...rmation disclosed hereon This document is issue in confidence and is not to be reproduced or used to manufacture anything shown hereon without the written permission of Drive Source International Inc Drive Source International Inc Sturtevant Wisconsin USA 53177 Telephone 262 554 7977 Fax 262 554 7041 Toll Free 800 548 2169 www dynamatic com sales dynamatic com ...

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