Expert SmartTurn Installation And Operating Instructions Manual
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Expert SmartTurn Installation And Operating Instructions Manual

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Inhaltsverzeichnis
2016-08-15
Installation and operating instructions
Turntable control
SmartTurn
"Original operating instructions"
Dok-ID:EXPERT-0003-EN-2011

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  • Page 1 Inhaltsverzeichnis 2016-08-15 Installation and operating instructions Turntable control SmartTurn “Original operating instructions” Dok-ID:EXPERT-0003-EN-2011...
  • Page 2 © Expert-Tünkers GmbH Seehofstr. 56-58 64653 Lorsch Tel.: +49 (0) 6251 592-0 Fax: +49 (0) 6251 592-100 E-Mail: sales@expert-tuenkers.de info@expert-tuenkers.de Internet: www.expert-tuenkers.de Dok-ID:EXPERT-0003-EN-2011...

  • Page 3: Table Of Contents

    Turntable control SmartTurn Table of contents General Information ............... 5 Information about this manual ........5 Explanation of symbols ..........6 Disclaimer ..............7 Copyright ................ 7 Replacement parts ............8 Guarantee terms ............8 Customer service ............8 Safety ..................9 Responsibility of the customer ........
  • Page 4 Change mode (changed rotary direction) ..62 6.3.6 Changed lock angle ........63 6.3.7 Wrong rotary direction (direction forward / backward) .............64 6.3.8 Internal device fault (secure state) ....65 Start up after corrected fault ........66 SmartTurn – spare parts ............67 Index ..................69 Dok-ID:EXPERT-0003-EN-2011...

  • Page 5: General Information

    Turntable control SmartTurn General Information Pos : 1.1 /Standardmodule/1 Allgemeines/1 Allgemei nes @ 0\mod_1192538340958_38.doc @ 132 1 General Information Pos : 1.2 /SmartTur n/1.1 Info z ur Anl eitung @ 1\mod_1221483643050_38.doc @ 8502 1.1 Information about this manual This manual enables safe and efficient maintenance of the device.

  • Page 6: Explanation Of Symbols

    Turntable control SmartTurn General Information 1.2 Explanation of symbols Warnings Warnings are indicated by symbols in this operating manual. The warnings are introduced by signal words that express the scope of the hazard. The warnings must be strictly heeded, you must act prudently to prevent accidents, personal injury, and property damage.

  • Page 7: Disclaimer

    Turntable control SmartTurn General Information 1.3 Disclaimer All information and instructions in this operating manual have been provided under due consideration of applicable guidelines, the current state of technology, as well as our many years of experience. The manufacturer assumes no liability for damages due to: ...

  • Page 8: Replacement Parts

    Turntable control SmartTurn General Information Pos : 1.8 /Standardmodule/1 Allgemeines/1.5 Ersatzteile @ 0\mod_1192626437050_38.doc @ 275 1.5 Replacement parts WARNING! Safety risk if the wrong replacement parts are used! Incorrect or defective replacement parts can cause damage, malfunction, or total failure; they can also impair safety.

  • Page 9: Safety

    Turntable control SmartTurn Safety 2 Safety This section provides an overview of all the important safety aspects for optimal protection of personnel, as well as for safe and trouble-free operation. Significant hazards can occur if the handling instructions and safety instructions in this manual are not complied with.

  • Page 10: Personnel Requirements

    Turntable control SmartTurn Safety Pos : 2.5 /SmartTur n/2_ Personalanforderungen @ 1\mod_1219047099489_38.doc @ 6876 2.2 Personnel requirements 2.2.1 Qualifications WARNING! Danger of injury due to insufficient qualification! Improper handling can cause serious injury or material damage. Therefore: – Only have activities performed by personnel who are qualified to perform these activities.

  • Page 11: Intended Use

    The customer is solely liable for all damage in the case of non- intended use. The SmartTurn turntable controller is only designed to operate Turntable controller - SmartTurn EXPERT-TÜNKERS turntables with fixed indexing and lock angles of 20, 30, 40 and 60 degrees. The step time must be greater than 1.5s.

  • Page 12: Environmental Protection

    Turntable control SmartTurn Safety Pos : 2.8 /SmartTur n/2._U mwelts chutz @ 1\mod_1219048921572_38.doc @ 6898 2.4 Environmental protection CAUTION! Environmental hazard due to incorrect handling! Incorrect handling of environmentally hazardous substances, particularly improper disposal, can cause significant environmental damage. Therefore: –...

  • Page 13: Technical Data - Turntable Controller

    Turntable control SmartTurn Technical data - turntable controller 3 Technical data - turntable controller SmartTurn sensor: Dimensions (without plug-in connector) Approximately 130x 75x 32mm WHD -25 to +70 ℃ Ambient temperature Enclosure material Degree of protection IP67 Operating voltage 18-30 V DC...

  • Page 14: Structure And Function

    Pos : 4.1 /SmartTur n/SmartT urn-N eu- 02.2011/4 aufbau + funktion - übersiocht @ 3\mod_1311931545664_38.doc @ 28180 4 Structure and function 4.1 Overview Sensor Fig. 1 Sensor Control unit Fig. 2 Control unit The SmartTurn turntable controller consists of the components:  Inductive sensor, incl. Position encoder.  Control unit.  Sensor cable.

  • Page 15: Device Description

    Turntable control SmartTurn Structure and function Pos : 4.2 /SmartTur n/SmartT urn-N eu- 02.2011/4.1.1 Ger ätebesc hr eibung @ 2\mod_1296729895005_38.doc @ 25805 4.1.1 Device description Sensor, Fig. 1 The sensor is equipped with:  A connection for the control unit.

  • Page 16: Functional Description

    Turntable control SmartTurn Structure and function 4.2 Functional description The SmartTurn turntable controller is used to control Expert- Tünkers fixed indexing turntables with any desired indexing. The turntable can be operated in reverse mode and continuous mode. The drive motors can be actuated directly via contactors or frequency converters.

  • Page 17: Standard Mode

    Securely connect input E4 to 24 V DC.  Set lock angle on switch S1 to setting 1 - 4 in accordance with EXPERT specification, see chap. 4.2.7. Pos : 4.5 /SmartTur n/SmartT urn-N eu- 02.2011/4.2 - b R evesier betrieb @ 2\mod_1296744168196_38.doc @ 25856 Reverse mode...

  • Page 18: Special Mode

    Turntable control SmartTurn Structure and function 4.2.2 Special mode The turntable rotates depending on the selection via the PLC, 1 to 4 cycles forward or backward per activation. It can be rotated forward or backward as often as desired. The lock angle in special mode is fixed at 30º.
  • Page 19 Pos : 4.7 /SmartTur n/SmartT urn-N eu- 02.2011/4.2 - d Funkti onsprinzip - Grafi k @ 2\mod_1296801075498_38.doc @ 25890 Functional principle diagram Fig. 3 Functional principle A: PLC plant controller B: SmartTurn – control unit   1 "Start forward"...

  • Page 20: 0-Position Optimization

    Turntable control SmartTurn Structure and function Pos : 4.8 /SmartTur n/4.2.1 aa Opti mierung 0- Stell ung @ 1\mod_1219134976670_38.doc @ 6980 4.2.3 0-position optimization With "Forward on" or "Backward on" the turntable controller checks the activated direction and the momentary position. If the result is OK, the output "Forward start"...
  • Page 21 Turntable control SmartTurn Structure and function Pos : 4.9 /SmartTur n/4.2.1_a O- Stellung-Grafi k @ 1\mod_1219136730145_38.doc @ 6991 0-position and switch-off angle at the sensor Switch-off angle forward 0-position Switch-off angle backward Position encoder Fig. 4 0-position - sensor Pos : 4.10 /SmartT urn/4.2.1_b @ 1\mod_1219137280849_38.doc @ 7002...

  • Page 22: Brake Wear Monitor

    Turntable control SmartTurn Structure and function 4.2.4 Brake wear monitor If the switch off angle reaches the end of the lock movement, then the warning "End lock angle" is output to the PLC. CAUTION! Warning "End lock angle"! Increased brake wear or abnormal conditions (e.g.

  • Page 23: Overrun Monitor

    Turntable control SmartTurn Structure and function Pos : 4.14 /SmartT urn/SmartTur n-Neu-02.2011/4.2.3 Ü ber wac hung Überlauf @ 2\mod_1296811195609_38.doc @ 25907 4.2.5 Overrun monitor If the 0-position is overrun during a rotation the warning "Overrun forward" or "Overrun backward" is output.

  • Page 24: Device Settings - Control Unit

    Turntable control SmartTurn Structure and function Pos : 4.16 /SmartT urn/SmartTur n-Neu-02.2011/4.2.5 Ger äteei nstellung Steuer einheit-S1 @ 2\mod_1296813371510_38.doc @ 25924 4.2.7 Device settings - control unit There are three setting possibilities on the control unit, S1, S2, and S3. They are behind a screw-fastened cover.
  • Page 25 Turntable control SmartTurn Structure and function Pos : 4.18 /SmartT urn/4.2.5_b S3 @ 1\mod_1219401222930_38.doc @ 7251 Rotary direction clockwise rotation - counter-clockwise rotation, drive roller R = clockwise rotation (default value) L = counter-clockwise rotation Fig. 6 The rotary movement of the turntable plate depends on the rotary direction of the drive motor, and on the incline of the drive roller.
  • Page 26 Turntable control SmartTurn Structure and function With the reversal of rotary direction, the rotary direction check of the drive roller can be reversed. Clockwise is the factory setting. If the rotary direction of the drive roller does not agree with the setting, then this is detected as a fault at activation and the fault "Wrong rotary direction"...

  • Page 27: Connections

    Designation Connection Description / plug-in connector Flange plug-in connector, M23x1, 19-pin Power Flange connector M12x1, 4-pin Sensor Flange socket, M12x1, 4-pin Diagnostics Flange connector M12x1, 5-pin, B-coded Fig. 8 Pos: 4.22 /SmartTurn/SmartTurn-Neu-02.2011/4.3.1.1 Pin Belegung -Steuereinheit @ 3\mod_1296814485562_38.doc @ 25984 Dok-ID:EXPERT-0003-EN-2011...

  • Page 28: Pin Assignment Control Unit

    Turntable control SmartTurn Structure and function 4.3.1.1 Pin assignment control unit X1 – PLC interface Pin assignment Function 24 V DC supply Reference potential Protective conductor Fig. 9 Pin assignment control unit – X1 Input slow on Reference potential Input mode...
  • Page 29 Turntable control SmartTurn Structure and function Pos : 4.23 /SmartT urn/SmartTur n-Neu-02.2011/4.3.1.1_a Pin- belegung Steuerungsei nheit @ 3\mod_1296815568589_38.doc @ 26001 X2 – inputs/outputs power unit Inputs Forward on Backward on Outputs Forward start Fig. 10 Pin assignment control unit – X2 Backward start X3 –...

  • Page 30: Sensor, See Fig. 1

    Turntable control SmartTurn Structure and function 4.3.2 Sensor, see Fig. 1 Designation Connection Description / plug-in connector Control unit Flange connector M12x1, 5-pin Pos : 4.25 /SmartT urn/4.3.2.1 Pin Beleg ung - Sens or @ 1\mod_1219300377502_38.doc @ 7122 4.3.2.1 Pin assignment sensor...

  • Page 31: Optional Components And Accessories

    Turntable control SmartTurn Structure and function 4.4 Optional components and accessories Position sensing - standard For simple position sensing without safety requirement up to a max. of 15 positions. Contactless detection of turntable position through sensors and actuators based on transponder technology, thus wear-free and maintenance free.

  • Page 32: Installation And Commissioning

    Turntable control SmartTurn Installation and commissioning Pos : 5.1 /SmartTur n/5 Ins atllation und Ersti nbetriebnahme @ 1\mod_1219310963810_38.doc @ 7190 5 Installation and commissioning CAUTION! Danger due to defective installation and commissioning! Installation and commissioning errors can cause significant material damage.

  • Page 33: Mounting Instructions

    Pos : 5.3 /SmartTur n/5.2 Montagehinweis e @ 1\mod_1219310064423_38.doc @ 7173 5.2 Mounting instructions Expert-Tünkers mounts the sensor and the position encoder on the drive shaft during the manufacturing process. The customer can mount the control unit at suitable and easily accessible points with the connections facing down.

  • Page 34: Electrical Installation

    Turntable control SmartTurn Installation and commissioning 5.3 Electrical installation Connect the sensor and control unit via sensor cables. Only use the specified sensor cable. Connect control unit and plant controller via cable to X1 and X2. Install the cables separate from high-voltage cables.

  • Page 35: Description - Plc Signals

    Outputs A3 to A7 can be loaded with a maximum of 0.25A at 24VDC (6W). Pos : 5.7 /SmartTur n/5.3.1_a Bes chr eibung SPS @ 1\mod_1219645308201_38.doc @ 7301 SmartTurn power supply The permissible operating voltage for the SmartTurn control unit is between 18 and 30 V DC. Connection +24 V DC supply 0 V DC, reference potential inputs/outputs Pos : 5.8 /SmartTur n/SmartT urn-N eu- 02.2011/5.3.1.1 Ei ngänge @ 3\mod_1297779264522_38.doc @ 26071...
  • Page 36 Turntable control SmartTurn Installation and commissioning CAUTION! Damage to drive elements at operating speed! Material damage can occur on the drive elements! Therefore: – Do not start the turntable from a non-defined position. E4 – operating mode (pin7) The input must be permanently wired with 24 V or 0 V.

  • Page 37: Outputs

    Turntable control SmartTurn Installation and commissioning 5.3.1.2 Outputs Inputs – power unit – X2 A1 – forward start (pin 2) Turntable rotation forward is enabled. Output A1 is switched on when input E1 is activated. Output A1 remains switched on until the turntable has reached the calculated switch-off angle in order to optimally come to a stop in the 0-position.
  • Page 38 Turntable control SmartTurn Installation and commissioning The overrun faults forward/backward A4 and A5 are set together if the two inputs forward on (E1) and backward E2 are simultaneously activated for longer than 120 ms. In this case the outputs forward start (A1) and backward start (A2) are switched off and blocked until E1 and E2 are off again.
  • Page 39 Turntable control SmartTurn Installation and commissioning A6 – system faults (pin 11) Output A6 is switched on if faults are detected that compromise safe operation of the turntable. System faults can only be acknowledged on the turntable controller via the reset button.

  • Page 40: System Integration In The Plant Control System

    Switch the brake directly and not via the PLC. The respectively valid safety guidelines for motor-brake activation must be complied with. When using SEW motors, Expert-Tünkers recommends the use of a type BMKB1.5 brake rectifier. If a brake rectifier, other than type BMKB1.5 is used, then it must always be wired on the direct current and alternating current sides so that the brake can work with fast application.
  • Page 41 Fig. 16. The SmartTurn power unit must only be directly wired into the plant controller from power contactors, if for operating the turntable no safety functions in accordance with DIN EN ISO 13849-1 are required, see Fig.
  • Page 42  H: "Turntable slow" NOTE! The SmartTurn control unit is not a safety component as defined in the Machinery Directive. If when operating the turntable, risks can occur that demand the use of safety functions in accordance with DIN EN ISO 13849-1, then safety switching...
  • Page 43 Turntable control SmartTurn Installation and commissioning Example Fig. 17 Direct activation of the power contactors NOTE! Direct activation of the power contactors is only permitted if safety functions in accordance with DIN EN ISO 13849-1 are not necessary.  ...
  • Page 44 Turntable control SmartTurn Installation and commissioning Pos : 5.13 /SmartT urn/SmartTur n-Neu-02.2011/5.3.2_b Anschl üss e Steuerteil @ 3\mod_1297858059196_38.doc @ 26178 Connections control unit Fig. 18 SmartTurn outputs   N: "System fault" A: PLC plant controller   B: SmartTurn control unit P: „End lock angle"...
  • Page 45 Turntable control SmartTurn Installation and commissioning Pos : 5.14 /SmartT urn/SmartTur n-Neu-02.2011/5.3.2 b-2 SPS-Sig nal e _2 Grafi k @ 3\mod_1297853619915_38.doc @ 26161 Fig. 19 SmartTurn inputs   B: SmartTurn control unit U: „"Pre-select cycles bit 1"  ...

  • Page 46: Plc Programming

    Turntable control SmartTurn Installation and commissioning 5.3.3 PLC programming Reverse mode The following diagram shows the signal exchange with the PLC as an example. Switch S1 in position 1-4 Function Signal Pin Operating mode Forward on Forward start Backward on...
  • Page 47 Turntable control SmartTurn Installation and commissioning Continuous mode The following diagram shows the signal exchange with the PLC as an example. Switch S1 in position 1-4 Function Signal Operating mode Forward on Forward start Backward on Backward start Slow on...
  • Page 48 Forward start Backward on Backward start Slow on 0-position Position forward Position back In the lock angle System fault Motor is turning Position Fig. 22 Sequence graphic – special mode Pos: 5.18 /SmartTurn/SmartTurn-Neu-02.2011/5.2 Erstinbetriebnahme - Beschreibung @ 3\mod_1297939041601_38.doc @ 26270 Dok-ID:EXPERT-0003-EN-2011...

  • Page 49: Commissioning

    Turntable control SmartTurn Installation and commissioning 5.4 Commissioning NOTE! The turntable is commissioned in the factory by EXPERT-TÜNKERS. When the turntable is commissioned it is tested and the mode is adjusted to customer specifications in reverse mode, continuous mode or special mode.
  • Page 50 Turntable control SmartTurn Installation and commissioning Pos : 5.19 /SmartT urn/SmartTur n-Neu-02.2011/5.2 Abl auf der Inbetriebnahme @ 3\mod_1297939267607_38.doc @ 26287 Commissioning sequence Movement range “B” backward “F” forward Fig. 23 Example: Movement range Turn drive roller (position encoder) in the movement range (1), at least 45 degrees outside of the 0-position.
  • Page 51 Turntable control SmartTurn Installation and commissioning Pos : 5.20 /SmartT urn/SmartTur n-Neu-02.2011/5.2 -b Ablauf der Inbetriebnahme @ 3\mod_1315556372255_38.doc @ 30130 Position of the position encoder when commissioning in reverse mode. Blocked area +/- 45 degrees in front of 0-position. Permitted range.

  • Page 52: Re-Commissioning In The Plant

    Turntable control SmartTurn Installation and commissioning 5.4.1 Re-commissioning in the plant When re-commissioning the turntable in the plant the settings made during the commissioning process must be checked and any adaptations to local conditions must be executed. Re-commissioning sequence Switch on the operating voltage.

  • Page 53: Faults

    The fault tables below are provided to help you localize and rectify the fault. Or contact one of the EXPERT-TÜNKERS service addresses. Pos : 6.4 /SmartTur n/SmartT urn-N eu- 02.2011/6.2.1 Überlauf Vorwärts / R üc kwärts @ 3\mod_1297939864245_38.doc @ 26304 6.2.1 Overrun forward / backward...
  • Page 54 Turntable control SmartTurn Faults The fault is also generated if the two inputs forward on (E1) and backward on (E2) are simultaneously activated by the controller for longer than 120 ms. In this case the outputs forward start (A1) and backward start (A2) are switched off and blocked until E1 and E2 are off again.

  • Page 55: Warning End Lock Angle (Lock Angle Reserve)

    Turntable control SmartTurn Faults Reset fault NOTE! Eliminate cause. In reverse mode the fault is deleted by activation of the opposite direction and leaving the overrun. In continuous mode and in special mode the fault is deleted with a subsequent "Forward on" activation.

  • Page 56: End Of Lock Angle Reserve Reached (End Of Lock Angle Reserve)

    Turntable control SmartTurn Faults Pos : 6.6 /SmartTur n/6.2.3 Ende Ras twinkel r eser ve erreic ht @ 1\mod_1219744044028_38.doc @ 7538 6.2.3 End of lock angle reserve reached (end of lock angle reserve) If the switch-off angle is more than 5 degrees outside of the lock movement, the warning "End lock angle"...

  • Page 57: Input Forward And Backward On (Both Inputs On)

    The diagnostics data will remain accessible until the system fault is deleted on the turntable controller. Use of the tool requires consultation with Expert Tünkers. Pos : 6.9 /SmartTur n/SmartT urn-N eu- 02.2011/6.3.1 Sens orfehl er @ 3\mod_1297944274847_38.doc @ 26338 Dok-ID:EXPERT-0003-EN-2011...

  • Page 58: Sensor Fault (Sensor Defect)

    Turntable control SmartTurn Faults 6.3.1 Sensor fault (sensor defect) Possible causes Measures Sensor is defective Check sensor and replace if necessary Position encoder is defective or is not in the Check the position sensor, replace if necessary detection range of the sensor...

  • Page 59: Short Circuit At Output

    Turntable control SmartTurn Faults 6.3.2 Short circuit at output Possible causes Measures Activated contactor coil defective Check the contactor coil, replace if necessary Excessive power consumption of the activated Only use contactor coils with a max. power contactor coil consumption of 14 W at 24 V DC...

  • Page 60: Invalid Sensor Data (Changed Sensor Position)

    Turntable control SmartTurn Faults 6.3.3 Invalid sensor data (changed sensor position) If after switching on the operating voltage, a deviation from the last saved position is detected, this results in a fault. Possible causes Measures Turntable has been dismantled and no longer has...

  • Page 61: Change Mode (Changed Rotary Mode)

    Turntable control SmartTurn Faults 6.3.4 Change mode (changed rotary mode) The mode deviates from the saved mode or impermissible level change on input E4 "Mode" Change from position 9 to position 1-4 or vice versa on rotary switch S1. Possible causes...

  • Page 62: Change Mode (Changed Rotary Direction)

    Turntable control SmartTurn Faults 6.3.5 Change mode (changed rotary direction) Rotary direction deviates from the saved rotary direction or change rotary direction right/left on switch S3. Possible causes Measures Reverse mode / change S3 Reverse mode:  Turn drive roller (position encoder) a min. 45 degrees outside of the 0-position in the movement range between the positions "Front"...

  • Page 63: Changed Lock Angle

    Turntable control SmartTurn Faults 6.3.6 Changed lock angle Lock angle setting deviates from the saved lock angle setting or change of the lock angle on switch S1. Possible causes Measures Reverse mode / continuous mode Continuous mode, reverse mode ...

  • Page 64: Wrong Rotary Direction (Direction Forward / Backward)

    Turntable control SmartTurn Faults 6.3.7 Wrong rotary direction (direction forward / backward) At each start the rotary direction of the drive roller is checked against the setting on switch S3 clockwise/counter-clockwise. Possible causes Measures The actual rotary direction of the drive roller does...

  • Page 65: Internal Device Fault (Secure State)

    Faults Pos : 6.16 /SmartT urn/SmartTur n-Neu-02.2011/6.3.8 Interne Ger ätefehl er @ 3\mod_1297949053644_38.doc @ 26423 6.3.8 Internal device fault (secure state) Possible causes Measures SmartTurn control unit defective Replace SmartTurn control unit. Apply S1, S3 – settings. Reverse mode: ...

  • Page 66: Start Up After Corrected Fault

    Turntable control SmartTurn Faults 6.4 Start up after corrected fault After correcting the fault execute the following steps to start up again: Reset the emergency-stop devices. Acknowledge the fault on the controller. Ensure that that no one is in the danger zone.

  • Page 67: Smartturn - Spare Parts

    Turntable control SmartTurn SmartTurn – spare parts 7 SmartTurn – spare parts Designation Part number Sensor 502765 Sensor actuator 504480 Control unit, SmartTurn 2011 510937 Sensor cable 5 m 504775 Diagnostics cable 2 m 517719 Position sensing - standard for max. 8 positions: ...
  • Page 68 Part number Coupling M12x1, 4-pin with connecting cable 4x0.75 527651 mm² for plug X2, length=20 m Coupling M12x1, 4-pin, for self-assembly for plug X2 X* X* Contact one of the EXPERT-TÜNKERS service addresses. ===== Ende der Stüc kliste ===== Dok-ID:EXPERT-0003-EN-2011...

  • Page 69: Index

    Turntable control SmartTurn Index 8 Index Input forward and backward on (Both Inputs On) 0-position optimization ........20 ................57 Inputs ..............35 Brake wear monitor ..........22 Installation and commissioning ......32 Intended use ............11 Change mode (changed rotary direction) ... 62 Internal device fault (secure state) .....65...
  • Page 70 System monitoring ..........23 Sequence faults ..........53 Service ..............8 Technical data - turntable controller....13 SmartTurn – spare parts ........67 SmartTurn power supply ........35 Warning end lock angle (lock angle reserve) ..55 Special mode ............. 48 Wrong rotary direction (direction forward / backward) ............

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