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DANGER HIGH VOLTAGE  

Motor control equipment and controllers are connected 

to hazardous line voltage.  When servicing drives and 

electronic controllers, there may be exposed 

components with their cases and protrusions at or above 

line potential.  Extreme care should be taken to protect 

against shock.  Stand on an insulating pad and make it a 

habit to use only one hand when checking Components.  

Always work with another person in case an emergency 

occurs.  Disconnect power whenever possible to check 

controllers or to perform maintenance.  Be sure 

equipment is properly grounded.  Wear safety glasses 

whenever working on an electronic controller or electrical 

rotating equipment. 

 

CAUTION 

Rotating shafts and above ground electrical potentials 

can be hazardous.  Therefore, it is  strongly 

recommended that all electrical work conform to National 

Electrical Codes and local regulations.  Installation, 

alignment and maintenance should be performed only by 

qualified personnel. 

 

Factory recommended test procedures, included in the 

instruction manual, should be followed.  Always 

disconnect electrical power before working on the unit 

 

REFER TO OSHA RULES AND REGULATIONS.  

PARAGRAPH 1910.219 FOR GUARDS ON 

MECHANICAL POWER TRANSMISSION APPARATUS. 

NOTE: 

Since improvements are continually being made to 

available equipment, the enclosed data is subject to 

change without notice.  Any drawings are for reference 

only, unless certified.  For additional information contact 

your nearest Eddy Current Representative listed in the 

Yellow pages under “Power Transmission Equipment”.  

Or you can call DSI/Dynamatic®

 

at 1-800/548-2169. 

 

IMPORTANT NOTICE 

The printed contents in this manual are to be used for 

reference only.  Due to periodic engineering design 

changes and the addition of modifications, this material 

is provided as a guide only. 

 

Refer to engineering drawings for your specific unit.  If 

you do not have your units engineered drawings, please 

contact the publications department at the factory. 

 

For additional information regarding contents, direct your 

request to one of the following areas: 

 

Instruction Material 

Sales/Marketing 

Technical/Operational Questions 

Engineering 

Parts/Order Inquiry 

Customer Service 

 

This notice is provided to clarify the Intent of the 

instruction book contents and to inform  our customers 

how to obtain appropriate technical assistance from the 

proper source. 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

©Copyright DSI/Dynamatic®, 2002 

Summary of Contents for CES

Page 1: ...E S Stamping Press Controller INSTRUCTION MANUAL Revised 2019 7900 Durand Avenue Bldg 3 Sturtevant WI USA 53177 Toll Free 800 548 2169 Phone 262 554 7977 Fax 262 554 7041 Email sales dynamatic com Web www dynamatic com ...

Page 2: ...re working on the unit REFER TO OSHA RULES AND REGULATIONS PARAGRAPH 1910 219 FOR GUARDS ON MECHANICAL POWER TRANSMISSION APPARATUS NOTE Since improvements are continually being made to available equipment the enclosed data is subject to change without notice Any drawings are for reference only unless certified For additional information contact your nearest Eddy Current Representative listed in t...

Page 3: ...rface Serial 13 Signals for Customer s Recorder 13 Analog Meters 13 Brake Contactor 13 Press Operating Modes 13 Press Control Parameters 18 SECTION 3 OPERATION Purpose 21 Constant Energy System 21 Stamping Press Operation 21 Eddy Current Clutch and Brake 21 Variable Speed Press Drives 21 Power Amplifier 22 CES Logic Board 23 Logic Power Supply Inputs 23 Logic Control Lines 23 LEM Current Feedback ...

Page 4: ...r maintenance TRAINING Training programs are an essential part of safe and correct operation Training provides the knowledge necessary to obtain top performance from your equipment DSI Dynamatic recognizes this fact and conducts training schools to educate your plant personnel in safe maintenance and operating procedures Training schools are held at company headquarters in Sturtevant Wisconsin The...

Page 5: ...tored equipment even if all procedures are followed damage or deterioration may still occur Equipment storage is not covered by warranty ELECTRICAL PART NUMBERING SYSTEM The numbering system for electrical component and assembly part numbers contains some useful data that could be of value to the technician working with or troubleshooting the controller The number is twelve digits arranged in a tw...

Page 6: ...r in this family is a 54 000045 0102 The last four digits describe a specific part within the family and may be assigned in numerical sequence or may describe the specific part value The following table lists those part categories where the last four digits have a significant meaning to the technician Category Part Name Parameter Described 23 Capacitor Capacitance 32 Fuses Ampere rating 49 Potenti...

Page 7: ...7 ...

Page 8: ...transformer T1 Fuses FU5 and FU6 protect T1 against short circuits and internal grounds Capacitors C3 C4 and C5 along with the impedance of the autotransformer serve to filter the incoming power to prevent line noise from affecting the controller and to reduce line disturbances by the controller The autotransformer steps up the line voltage from 480 VAC to 600 VAC FU1 FU2 and FU3 are fast acting s...

Page 9: ...TTING DIODE LED INDICATORS In addition to the LED noted for the keypad programmer LED indicator lights are also located on the printed circuit boards where operating circuit conditions need to be known The printed circuit boards that have LED s are described below LOGIC INTERFACE INDICATOR PCB 15 242 57 Refer to Figure 2 2 for the identification of the LEDs found on this printed circuit board CLUT...

Page 10: ...s only called upon to function during periods where there is no power applied to the control Therefore the life of the battery may greatly exceed the ten year period if there are no extensive periods where the control is actually turned off Once the parameter values have been set the system may be run by activating the appropriate signals in the control circuitry High voltage input and output sign...

Page 11: ...ain of events that provides for the integrity of the enable signal given by the press control to the CES controller Redundant CES inputs are provided to ensure that the enable signal is present and that the receiver is not shorted The enable signals consist of two press control contact closures that put the 115 VAC of the press control into the I O board CLUTCH CONTACTOR ON INPUT In addition to th...

Page 12: ...nt solid state output signals that function as contact closures and contact openings according to the conditions called for The output signals that occur during different phases of operation are as follows Normal Stop Stop Main Motor Fault Stop Now Fault Stop on Top Fault Control Failure Fault Clutch ON and TD Relay NORMAL STOP OUTPUT The normal stop signal from the CES controller indicates that t...

Page 13: ...rating parameters They are as follows 1 Clutch ammeter 2 Brake ammeter 3 Speed indication SPM 4 Elapsed time for clutch ON time BRAKE CONTACTOR A brake contactor is provided which will be closed under simultaneous conditions of control power ON being available and brake current fault not being present The brake contactor is opened 10 seconds after stopping on top when a brake current fault is pres...

Page 14: ...a 5 manual Run Speed trim pot while still others function without any speed pot Both pots are effective when the press starts up and after the press passes Angles No 1 II INCH FORWARD MODE RUN AT The CES controller will be in the inch forward mode if the following conditions exist 1 Enable signal is present 2 No fault is present 3 Reverse is not present 4 Inch is present 5 Micro inch is not presen...

Page 15: ... the enable signal The micro inch forward mode will be indicated by the Micro Inch LED on the keypad and display board V MICRO INCH REVERSE MODE RUN AT The CES controller will be in the micro inch reverse mode if the following conditions exist 1 Enable signal is present 2 No fault is present 3 Reverse is present 4 Inch is not present 5 Micro inch is present 6 Clutch contactor ON signal is present ...

Page 16: ...n the clutch coil when CR1 is de energized a clutch current delay fault will be issued 0206 Press Movement in Wrong Direction Fault Press movement detected to be in a direction opposite of that commanded based upon degrees of opposite rotation after enabled The number of degrees of rotation before causing this fault is adjustable from 0 to 10 degrees at the keypad Set for minimum degrees without c...

Page 17: ...from 3 to 20 seconds and the current allowable is 20 The CES controller cannot be enabled until cool down tine has expired 0317 Inch Change Fault If the inch command signal is changed while enable is present an inch change fault will exist 0318 Micro Inch Change Fault If the micro inch command is changed while enable is present a micro inch change fault will exist 0319 Reverse Change Fault If the ...

Page 18: ...g the following 1 Issuing a brake ON command 2 Setting reference to 0 3 Setting feedback to 100 In the brake test mode the brake is de energized by doing the following 1 Setting parameter No 62 to OFF down arrow 2 Exiting the test mode or 3 Entering the clutch test mode De energizing the brake test mode initiates the following 1 Reference and feedback are set to 0 Test Mode Faults Receiving an ena...

Page 19: ...er the CES controller has received the stop on top contact closure 4 The eighth angle will be the 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 d...

Page 20: ...1 180 degrees 2 Manual Speed pot 16 SPM 3 Angle No 2 115 degrees 4 Speed No 2 10 SPM 5 Angle No 3 360 degrees 6 Speed No 3 10 7 Angle No 4 360 degrees 8 Speed No 4 10 9 Angle No 5 360 degrees 10 Speed No 5 10 11 Angle No 6 360 degrees 12 Speed No 6 10 13 Creep Angle 305 degrees 14 Stop Angle 356 5 degrees 15 On the keypad enter Creep Speed 3 SPM ...

Page 21: ...r an eddy current clutch rotor and a brake rotor assembly directly connected to the press drive shaft Driving torque is developed through an electromagnetic force between the flywheel and clutch rotor Braking torque is developed through a similar force between the stationary brake field assembly and the brake rotor Electromagnetic coils in the flywheel or brake field assembly are energized to esta...

Page 22: ... the opposite effect takes place The tachometer feedback voltage then exceeds the reference and the clutch error amplifier drives the clutch power amplifier off This puts a positive input on the brake error amplifier driving the brake power amplifier on By braking to slower speeds the tachometer feedback voltage is reduced in direct proportion to the reduction of the press speed until the speed re...

Page 23: ...prevent overlap by producing a high on the control line Any high on the control line inhibits further operation A high on the control line can also be caused by other factors For the clutch it can be caused by the absence of a run signal input clutch contactor not pulled in DMR inhibit signal present 120 rated clutch coil current or 85 rated line voltage or missing phase For the brake it can be ca...

Page 24: ...Speed of press SPM 36 Angle No 4 0 359 9 Degrees 37 Speed No 4 Speed of press SPM 38 Angle No 5 0 359 9 Degrees 39 Speed No 5 Speed of press SPM 40 Angle No 6 0 359 9 Degrees 41 Speed No 6 Speed of press SPM 42 Creep Angle Degrees 43 Stop Angle 5 Degrees 44 Creep Speed 5 SPM 45 Micro Inch Speed 25 of max SPM 46 Inch Speed 50 of max SPM 47 Inch Accel Rate 1 100 SPM Sec 48 Initial Value of Linear Ac...

Page 25: ...ector Parameters are selected for viewing by first selecting either the top or bottom display window called the active display and then entering the 2 digit code for that parameter in the parameter number field The top display windows are selected by pressing the Top button on the keypad and similarly the bottom display windows are selected by pressing the Bot key When the display windows become a...

Page 26: ...ow button for a period longer than one second the up down function will revert back to normal speed of operation A faster up down function is also available By first pressing the key and then either the Up or Down arrow button the increment of change will be by 100 units per increment Any attempt to change a non alterable display parameter will be ignored ...

Page 27: ...s will Stop On Top In other words if the signal is present when the set Creep Angle is reached the press will continue at Run Speed into the next stroke This is the equivalent of the continuous mode of operation If the signal is not present at this point the press will go to Creep Speed If after being programmed to Creep Speed the signal is present when the press reaches the set Stop Angle the pre...

Page 28: ...ng 450 ms Time Delay 27 Max AC Line Voltage 0226 Clutch Contactor On w o Enable 28 Max Cl Cur Scaling Factor Amps 0227 Enable Before Cool Down Expired 29 Max Br Cur Scaling Factor Amps 0228 Creep Sp Not Reached Before Stop Angle 30 Angle 1 DEG 0313 Under speed 31 Speed 1 SPM 0314 Clutch and Brake Current Overlap 32 Angle 2 DEG 0315 Clutch Current 33 Speed 2 SPM 0316 Brake Current 34 Angle 3 DEG 03...

Page 29: ...oltage 0224 Stop On Top Not Performed 28 Max Cl Cur Scaling Factor Amps 0225 Cl Contactor On Removed w o Removing 29 Max Br Cur Scaling Factor Amps Enable or During 450 ms Time Delay 30 Angle 1 DEG 0226 Clutch Contactor On w o Enable 31 Speed 1 SPM 0227 Enable Before Cool Down Expired 32 Angle 2 DEG 0228 Creep Sp Not Reached Before Stop Angle 33 Speed 2 SPM 0313 Under speed 34 Angle 3 DEG 0314 Clu...

Page 30: ... used to fire the SCRs that provide the power required to maintain the set speed 2 Limits the clutch current to a value equal to the rating of the mechanical unit 3 Limits the brake current to a value equal to the rating of the mechanical unit 4 Provides adjustable velocity damping to the clutch circuitry 5 Provides adjustable velocity damping to the brake circuitry 6 Provides clutch free wheel co...

Page 31: ...ON position h The DMR will remember that it is in the test mode 60 On will reappear in the top row of display i The test mode will be indicated by the Test LED on the keypad and display board 5 Enter the clutch test mode a While in the test mode the clutch test mode can be entered by setting the clutch test mode parameter No 61 to ON Proceed as follows 1 Press the Bot key This will activate the bo...

Page 32: ... fault will be generated Check this LED on the I O board Since the press is not rotating it will not get to the creep angle or the stop angle therefore a stop now fault will be generated Check this LED on the 1 0 board 6 Send the clutch contactor ON signal without the enable signal A stop now fault will be generated 7 Send the enable signal without the clutch contactor ON signal A stop now fault w...

Page 33: ... the Inch pushbutton for this jog function 14 Check the Remaining Faults APPROXIMATE PARAMETER SETTINGS Approximate parameter settings which are furnished for trial only are indicated in Table 4 1 Actual settings will be determined during the press set up If for security reasons the customer removes the ribbon cable connecting the keypad to the DMR care must be exercised in removing the power to t...

Page 34: ...0 0 52 100 0 58 5 0 54 5 0 55 100 0 56 100 0 57 100 0 58 5 5 59 5 5 60 Off 61 Off 62 Off 63 Clear 64 10 0 65 10 0 66 300 0 67 2 0 68 2 0 69 10 0 70 3 0 71 1 72 1 0 73 9600 0 74 10 0 75 120 0 76 See resolver adjustments under Start Up Section 77 See resolver adjustments under Start Up Section 78 See press specifications 79 See speed reference section 80 Self Explanatory 81 150 0 82 170 0 83 3 0 NOT...

Page 35: ...ds at the controller terminal strip and check the resistance of the coil and resistance to ground Check the drive nameplate or contact the Field Service Department at the factory for the coil resistance Resistance to ground should be about 20 megohms When using a megger make sure both coil leads are disconnected from the controller Do not megger any portion of the controller If the drive is errati...

Page 36: ...eplacement Technical assistance is available over the telephone and field service engineers are available for start up troubleshooting and training You may inquire about rates and scheduling from the factory The company maintains a Repair Service Department and work is done on a time and material basis All replacement boards will carry a new factory warranty Refer to Tables 2 1 and 2 2 for DMR ass...

Page 37: ...Page is intentionally blank ...

Page 38: ...DRIVE SOURCE INTERNATIONAL INC 7900 Durand Avenue Bldg 3 Sturtevant WI USA 53177 Toll Free 800 548 2169 Phone 262 554 7977 Fax 262 554 7041 Email sales dynamatic Web www dynamatic com ...

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