TPC ERN 100T Operating Instructions Manual Download Page 1

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COIL WINDING MACHINE ERN T-VERSION

OPERATING INSTRUCTIONS

ERN 100T, 200T

TPC s.r.o
Pálenica 53/79
03301 Liptovský Hrádok
SLOVAKIA

Tel.: +421-44-5221366
Fax: +421-44-5222088
E-mail: [email protected]

www.tpc.sk

Version: 1.3

Date: 11.6.2019

Summary of Contents for ERN 100T

Page 1: ...G MACHINE ERN T VERSION OPERATING INSTRUCTIONS ERN 100T 200T TPC s r o P lenica 53 79 03301 Liptovsk Hr dok SLOVAKIA Tel 421 44 5221366 Fax 421 44 5222088 E mail tpc tpc sk www tpc sk Version 1 3 Date...

Page 2: ...ptosensor 5 9 Winding corrections 5 9 1 Spindle reference position setting 5 9 2 Wire guide relative position setting 5 9 3 Number of turns correction 5 9 4 Total counter 5 9 5 Wire guide correction 5...

Page 3: ...Menu 10 1 Programme locking 10 2 Error messages 10 3 Model selection 10 4 Display language 10 5 Winding machine number 10 6 Access PIN code setting 10 7 Zero spindle position mode 11 Firmware and upg...

Page 4: ...i chamber coils trapezoidal or asymetric windings AC servo that is used like a spindle drive assures excellent dynamical parameters constant torque and accurate positioning wire guide on ball bearings...

Page 5: ...ire guide adjustable for round and flat wire support with spool holders and dereelers optional accessories Winding cycle linear acceleration max speed linear deceleration and stop is running automatic...

Page 6: ...OP disconnects power in emergency 3 POWER ON indicator 4 START button starts the winding cycle 5 STOP button interrupts the winding cycle 6 JOYSTICK 7 MANUAL button 8 Connector for foot pedal 9 Indust...

Page 7: ...4 ERN T V 1 3 COM1 MANUAL I 0 JOYSTICK 1 2 3 4 5 6 7 POWER EMERGENCY STOP 0 I Monitor cables assembly Control elements...

Page 8: ...5 ERN T V 1 3 UPS POWER MAN I 0 TOTAL STOP BRAKE 8 9 10 11 12...

Page 9: ...ing window Switching from Winding to Programming window it is necessary to touch central display place Switching back touch ENTER button Winding window Programming window In order to work with a PC we...

Page 10: ...N PE400V 230V 50 Hz TN S with tolerance 5 and max power consumption 7 kVA Before plug in the connection cable make sure that electric power accordance with technical requirements Only professional sta...

Page 11: ...machine switch over to the stand by after few second After renewing electric power supply the machine returns to the initial regime but in the position like after pressing the STOP button Keep always...

Page 12: ...login see chap 13 OPERATOR LOGIN 20 4 2011 8 30 OPERATOR operator 1 OPERATOR 1 4 7 0 START 2 5 8 3 6 9 5 WINDING OPERATION 5 1 Switching the machine on and gear setting After switching on 1 the start...

Page 13: ...e guide is shifted to left home zero position zero number of turns step 0 and the last programme is set 10 ERN T V 1 3 1 2 The gear change requires the use of password Master code listed in the warran...

Page 14: ...ivation of this function MEM POS ON will be updated with values as they were before the electricity drop IN ORDER TO USE THIS FUNCTION THE MACHINE MUST BE EQUIPPED WITH THE UNINTERRUPTIBLE POWER SUPPL...

Page 15: ...ing on the machine and pressing ENTER or after a step finished Starting from this state will shift the programme one step forward Eg If we are in the step 0 after pressing START step 1 will be running...

Page 16: ...VOLATILE MEMORY Data store in the working part of memory will remain there even if power is disconnected PC SSD disc PART D LAN 5 6 Start and Stop of winding cycle programme Winding cycle is initiated...

Page 17: ...n ramp can be set up by PEDAL button Speed set up in this way is applicable only for the current programme It is independent of the speed programmed in a specific programme step Eg maximum speed set u...

Page 18: ...ng START button 4 cycle continues Winding cycle can continue seamlesly without interruption 5 8 Security measure OPTO SENSOR OPTO SENSOR TURCK type QMT42VN6FF1000 with range of 1 m 2 m which logs body...

Page 19: ...gs Reference zero spindle position is set up as follows switch the brake off by the switch 6 turn the spindle manually to the required position and return the switch 6 to the former position press EXI...

Page 20: ...allows you to correct the wire guide position to be in accordance with the bobbin or winding tool Default 5 mm rel pos 9mm rel pos 5mm rel pos 1mm the same wire guide coordinate depending on relative...

Page 21: ...dequate spindle turn leads to the loss of reference position Pressing the RESET button will change the actual number count to zero 1 2 5 9 4 Total counter We can switch between TOTAL COUNTER and COUNT...

Page 22: ...you to correct the wire guide position during the winding process Holding any of the the buttons pressed cca 0 5 s moves the wire guide continuously 5 9 6 Wire guide direction change This allows you t...

Page 23: ...achine will return to the STANDSTILL state 5 9 8 Back winding This allows you to wind back the required number of turns We can wind back the number of turns required only by using the pedal The number...

Page 24: ...ightly faster than programmed deceleration ramp This is controlled by the software CODE TIME s 1 1 0 2 1 3 3 1 8 4 2 3 Presentated values are valid for max speed 5 2 8 6 3 8 7 5 8 8 7 8 2 1 Code table...

Page 25: ...a four way JOYSTICK which provides the following actions wire guide corrections RIGHT WIRE GUIDE MOVING LEFT WIRE GUIDE MOVING step change RETURN TO WIRE GUIDE CORRECTION NEXT STEP PREVIOUS STEP GO BA...

Page 26: ...ck and wire guide direction change RETURN ONE STEP BACK this action returns winding programme to the end of the previous step and sets correct positions of the wire guide and the spindle JOYSTICK retu...

Page 27: ...r use the numeric keyboard Created programme is saved to the working part of memory programme in this memories is designated as an ACTUAL PROGRAMME We can either overwrite or modify the already existi...

Page 28: ...e of cycle type of cycle shift shift winding winding step 1 step 4 step 3 step 2 Joining to the next step is defined by the type of cycle If the type of cycle END is programmed within a specific step...

Page 29: ...mp spindle is not turning and the wire guide is shifting from its position to the left or right in accordance with the programmed value Delay spindle and wire guide are idle the duration of the pause...

Page 30: ...sh program starts the next step automatically without pressing the START button Winding step decelerates to zero at first Continual cycle without deceleration After step finish program starts the next...

Page 31: ...irection after start Cancelation of the previous number of turns CANCEL previous counted number of turns is cancelled after START UP of the winding step type NOT CANCEL counted number of turns is not...

Page 32: ...etween 1 and 8 for acceleration and deceleration according to the table below CODE 1 2 3 4 5 6 7 8 ACCEL DECEL 3 0 3 5 4 0 5 0 6 0 7 0 8 0 9 0 3 0 3 5 4 0 5 0 6 0 7 0 8 0 9 0 s s Protection shield pro...

Page 33: ...Pitch Left reversal point 30 ERN T V 1 3 780 00 0 000 PROGRAM PROGRAM PROGRAM PROGRAM 2 2 2 2 1 2 1 Right reversal point 1 PROGRAM PROGRAM 2 2 2 1...

Page 34: ...uring programming The wire guide shifting can be switched OFF by pressing the SHIFTING ON OFF button during programming PROGRAM 2 PROGRAM 2 Type of cycle Set the type of cycle and choose how to contin...

Page 35: ...7 2 4 Wire guide jump Lenght of jump and direction 32 ERN T V 1 3 1 2 PROGRAM Type of cycle 2 1 PROGRAM PROGRAM 3...

Page 36: ...Type of cycle 33 ERN T V 1 3 1 2 7 2 5 Delay Time of delay PROGRAM PROGRAM PROGRAM 2 1 3...

Page 37: ...be switched as follow The layer number of every step can be assigned according to winding instruction The same number of layer can be assigned to a few consecutive steps While winding the assignment...

Page 38: ...corrections An empty step can be inserted anywhere within the programme It can then be completed with the required parameters Subsequent steps are shifted in value 1 automatically 2 2 1 PROGRAM 2 2 E...

Page 39: ...in value 1 automatically Step which we wish to cancel can be chosen by buttons or 1 2 4 3 JUMP EMPTY STEP 1 2 3 7 4 3 Copy step Each already programmed step can be copied to another step previous or...

Page 40: ...e of the same type Eg if the current step is winding the chosen parameter will be changed in all subsequent winding steps This is valid for all other step types SHIFT JUMP PAUSE The pitch is changed i...

Page 41: ...correction provides offset for all coordinates in the programme to the left or right of the entered value 39 ERN T V 1 3 All programmed coordinates left right reversal points and shifts are increased...

Page 42: ...er each wound layer The machine will stop after each layer at both left and right reversal points This will continue until the programmed number of turns is reached If the assigned layer is displayed...

Page 43: ...int The machine will stop in desired layer in desired reversal point and the entire winding step terminates 41 ERN T V 1 3 7 5 3 Warnings This function allows to write important warning for any step I...

Page 44: ...er is wound eg from left to the right press the wire guide correction button and correct the wire guide position This corrected position is saved by pressing SAVE AS RIGHT CORRECTION button Likewise i...

Page 45: ...Maximum value for wire guide correction can not be greater than 10 mm after a layer is wound Value higher than this will be ignored 43 ERN T V 1 3 2 3 1...

Page 46: ...urns have been completed In the manual regime the winding is done by the foot pedal The value of the pitch is taken from the current step The wire guide direction is controlled by WIRE GUIDE DIRECTION...

Page 47: ...rapezoid OFF right trapezoid X X left trapezoid OFF right trapezoid X X left trapezoid X X right trapezoid OFF left trapezoid X X right trapezoid X X left trapezoid X X right trapezoid OFF left trapez...

Page 48: ...xiliary digital outputs and 4 digital inputs Digital inputs and outputs are galvanically isolated Relay is applied in standard equipment 7 6 1 Window for inputs and outputs Controller ERN Auxiliary eq...

Page 49: ...YCLE START winding cycle start is done if input is high 12 V CYCLE START BLOCKED start is blocked while duration of high 12V 47 ERN T V 1 3 7 6 3 Digital outputs programming The following 3 parameters...

Page 50: ...48 ERN T V 1 3 Delay 1 2...

Page 51: ...49 ERN T V 1 3 8 STEPS LIST Steps list displays view of programmed steps and provides the following possibility for programming and corrections Parameter correction...

Page 52: ...50 ERN T V 1 3 780 00 0 000 PROGRAM 2 1 Each parameter can be changed in this way Insert empty step empty step 2 1...

Page 53: ...51 ERN T V 1 3 Copy step 1 2 Pressing of button COPY STEP ends copying...

Page 54: ...52 ERN T V 1 3 Delete step 1 2...

Page 55: ...dium PC memory space is divided into two partitions C and D The operating system is installed on C Access to partition C is blocked Partition D is used for manufacturer application programmes and wind...

Page 56: ...54 ERN T V 1 3...

Page 57: ...mme saving Each programme can have a maximum of 350 steps Once a programme is created it can then be saved Provide a name for the programme and save it into directory or subdirectory 55 ERN T V 1 3 2...

Page 58: ...56 ERN T V 1 3 9 3 Programme copy This function allows to copy programmes already created 1 2 1 2...

Page 59: ...locking Model selection Language selection PIN code setting Machine number setting Display layer Spindle zero position Accelerations decel 10 1 Programme locking Programming can be locked or unlocked...

Page 60: ...tion press ENTER and correct either spindle speed or pitch ERROR Wire guide position out of range Winding width is out of range Solution press ENTER and correct either relative position or reversal po...

Page 61: ...10 3 Model selection 10 4 Display language 59 ERN T V 1 3 Allows a selection of display language 1 2 3 1 2...

Page 62: ...rk identification 10 6 Access PIN code setting Available codes for user MASTER code allows you to change all settings in menu This code is fixed by producer and is referred to guarantee certificate PI...

Page 63: ...et Absolute zero spindle position ON zero spindle position as set during reset is kept for all winding steps and manual spindle handling Absolute zero spindle position OFF zero spindle position starts...

Page 64: ...Upgrade of the application programme Procedure of the application programme upgrade is as follows copy unpack received upgrade file connect flash disc keyboard and mouse to the USB ports of the PC cl...

Page 65: ...on log is created The names and codes information are stored in the file C TPC OperatorNames ini this can be edited never change the header it has to remain on the first row in the form MenaObsluhy al...

Page 66: ...file After pressing the button a dialog box appears for the file saving and a preset file name is proposed TabProd_ERN_num_X where X numerical code of the winding machine The production log can be tr...

Page 67: ...logical operation description is displayed on the winding machine monitor automatically This information comes from the winding procedure and it can be represented in form of texts or images Applicati...

Page 68: ...onnected online with a winder It allows the creation of complicated long programs with an overview of the position of the wire guide and has special features such as layer spread or correction 66 ERN...

Page 69: ...the ball bearings have permanent grease filling no lubrication is needed 18 WARRANTY PERIOD AND SERVICE Warranty period is 24 months from the date of delivery Warranty and after warranty repairs are...

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