gefran ADV200 Instruction Manual
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gefran ADV200 Instruction Manual

Flying shear for roll forming machines application
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ADV200 - Flying Shear for Roll
Forming machines Application
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Instruction manual

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Summary of Contents for gefran ADV200

  • Page 1 ADV200 - Flying Shear for Roll Forming machines Application English Instruction manual...
  • Page 2 Keep the manual in a safe place and available to engineering and installation personnel during the product functioning period. Gefran Drives and Motion S.r.l. has the right to modify products, data and dimensions without notice. The data can only be used for the product description and they can not be understood as legally stated properties.
  • Page 3 Flying Shear for Roll Forming machines – Instruction manual Pag. 3 / 29...

  • Page 4: Table Of Contents

    Symbols used in the manual ....................... 5 Installing the application ......................... 6 Application key ............................ 7 General description ..........................9 Sizing and commissioning ........................10 Machine Data ............................ 10 ADV200 configuration ........................11 4.2.1 Basic parameters configuration ....................12 4.2.2 Digital I/O ........................... 13 4.2.3 Encoder ............................

  • Page 5: Introduction

    1.1 Information about this manual This document describes the Flying Shear for Roll Forming machines software, supplementing what is described in the ADV200 drive manual (for asynchronous and synchronous motors) and the optional boards for encoder acquisition and input expansion.

  • Page 6: Installing The Application

    _..._A1 application was loaded Application 2 if the rffs _..._A2 application was loaded Save and reset the drive. At the start, the drive will show the message, “ADV200 rffs V…” on the display to confirm that the drive has been loaded. •...

  • Page 7: Application Key

    Write down the Serial Number indicated in Regulation S/N (PAR 12106, ROLL FORMING FS \ About menu). • Contact Gefran support and provide the serial number you just read to obtain the application unlock key. Enter the unlock code in the Application key parameter field (PAR 572, CONFIG DRIVE menu).
  • Page 8 • Save and reset the drive. At the start, the drive will no longer show the “Key Expiring” message on the display, confirming that the drive has been unlocked. Flying Shear for Roll Forming machines – Instruction manual Pag. 8 / 29...

  • Page 9: General Description

    3 General description The blade or cutting assembly is fixed onto a carriage that can move forwards and backwards, piloted by the application. The application measures the length of the material to be cut by a metric wheel binding onto the material.

  • Page 10: Sizing And Commissioning

    4 Sizing and commissioning 4.1 Machine Data The data in table 1 must be known before commissioning the shear. This table can be used as a reminder and completed before or after commissioning. UNIT OF NAME VALUE PARAMETER MEASURE Line Kmec (PAR 11804), Metric wheel advancement menu LINE / Trolley Kmec (PAR 11702),...

  • Page 11: Adv200 Configuration

    4.2 ADV200 configuration See the connection diagrams proposed for asynchronous or synchronous motors: Figure 2: Typical connection diagram (Asynchronous motor) Figure 3: Typical connection diagram (Synchronous motor) Flying Shear for Roll Forming machines – Instruction manual Pag. 11 / 29...

  • Page 12: Basic Parameters Configuration

    The following drive configurations are required: • Basic parameters configuration • Digital I/O • Encoders • Field bus 4.2.1 Basic parameters configuration After loading the default application parameters (Load default, PAR 11100), the basic drive parameters are configured. Table 2 shows the configurations loaded. PARAMETER SETTING MENU...

  • Page 13: Digital I/O

    4.2.2 Digital I/O The drive hardware enable input must be connected to digital input 7. The high and low blade inputs are used to indicate blade position. These are connected to sensors on the blade as shown in figure 4: Figure 4: High and low blade sensor operating logic The output that controls the cut is the output listed in the table::...
  • Page 14 Suppose we have a cutting system with these specifications: • The carriage advances 36 mm per motor revolution. The encoder on the carriage motor has 1024 ppr. • • The advancement of the metric wheel on the material is 314 mm. In this case, an encoder with 8192 ppr is suitable.

  • Page 15: Fieldbus

    4.2.4 Fieldbus After loading the default application parameters (Load default, PAR 11100) the fieldbus is configured as shown in table 4: PARAMETER SETTING COMMUNICATION PARAMETER MENU Fieldbus M->S enable 4010 FIELDBUS CONFIG Enable 4020 FIELDBUS M->S Fieldbus M->S1 PAR 11800 Required cut size [m] Fieldbus M->S1 sys 4022...
  • Page 16 Command mapping word The word sent by the PLC containing the commands is written in the Dig word decomp parameter (PAR 4450). The different function commands are linked to the word bits by selecting the appropriate “bitxx decomp mon”. WORD WORD DECOMP DECOMP DESCRIPTION...

  • Page 17: Commissioning

    4.3 Commissioning 4.3.1 Machine development Start up is performed after machine development. The drive is disabled: • Start by inserting the mechanical data and metric wheel: Refers to TROLLEY and LINE menues, and set all the values. • Continue by setting speed and ramp times: Refers to FASTSTOP, JOG, TROLLEY and HOMING and set all the values.
  • Page 18 4.3.2.4 Metric Wheel Advancement Check the correctness of the direction using the metric wheel. If the direction is incorrect use the metric wheel encoder. Flying Shear for Roll Forming machines – Instruction manual Pag. 18 / 29...

  • Page 19: Description Of Functions And Parameter List

    5 Description of functions and parameter list 26.01 Application The menu will display the version of the application installed on the drive. MENU Description Type ACCESS 26.01.01 12000 State mon ENUM Application status monitor: Init Disable Standstill Fast Stop Jog + Jog - Homing Auto...
  • Page 20 MENU Description Type ACCESS Blade simulator activation monitor. Reset line mon 26.01.15 12028 BOOL Material count reset monitor. Cut time mon 26.01.16 12030 FLOAT Cut time monitor, measured as the time elapsed between the command being sent and the blade release. The monitor is updated after a cut in “automatic cut”...

  • Page 21: App Service

    MENU Description Type ACCESS 26.01.29 12056 Pos err FLOAT Position error monitor. Command status word mapping (PAR 12052): DIGITAL OUTPUT DIGITAL OUTPUT DESCRIPTION BIT NUMBER [HEX] Cut alarm 0x0001 Auto Alarm 0x0002 0x0004 Cut length alarm 0x0008 Pos min alarm Pos max alarm 0x0010 Sync alarm...

  • Page 22: Enable

    MENU Description Type ACCESS Speed reference destination generated by the application . Pad 5 Cmds mon dest 26.02.03 11104 ENUM Destination of the status word containing the commands generated by the application (see Table 7). 26.03 Enable This function allows the source of the enabling command software to be set and the possible destination of the command monitor.

  • Page 23: Homing

    MENU Description Type ACCESS 26.05.04 11306 Jog acc FLOAT 0.01 10.0 Acceleration ramp for jog command. 26.05.05 11308 Jog dec FLOAT 0.01 10.0 Deceleration ramp for jog command. 26.06 Homing This function allows the parameters for defining the zero point to be set. MENU Description Type...

  • Page 24: Move

    26.07 Move This function allows the parameters for repositioning the shear at the zero point or at the head of the material to be set, when the Drive is switched on, if the save function for the material present in the machine (PAR 11806) has been activated.

  • Page 25: Trolley

    MENU Description Type ACCESS 26.08.06 11610 Reset pos mat ENUM Decp bit12 Manual reset of the material count. 26.08.07 11612 Max Line Spd m/min FLOAT Setting the maximum line speed. The calculated line speed will be limited to this parameter. 26.09 Trolley This function allows the parameters that manage the trolley and the immediate manual cut to be set..

  • Page 26: Line

    MENU Description Type ACCESS 26.09.13 11718 Blade Close src ENUM Decp bit8 Source of the low blade sensor, i.e. in the end of cut position. 26.09.14 11720 Sens Blade Open BOOL Enabling the high blade sensor. 26.09.15 11722 Blade Open src ENUM Decp bit9...

  • Page 27: Virtual

    MENU Description Type ACCESS Maximum tolerance allowed on the bar cut. If this is exceeded the alarm is tripped by the appropriate bit of the word alarms. Trolley pos max 26.11.03 11904 FLOAT Maximum permissible trolley position. If this is exceeded the alarm is tripped by the appropriate bit of the word alarms.
  • Page 28 MENU Description Type ACCESS 26.13.02 12102 Build date FLOAT Date when the application was compiled. 26.13.03 12104 MDPlc version FLOAT MDPlc version used to compile the application. Regulation S/N 26.13.04 12106 DWORD Serial Number of the control board. Use to activate the application. Flying Shear for Roll Forming machines –...

  • Page 29: Application Alarms

    6 Application alarms The application carries out a series of checks on itself while it is functioning. The information is stored in the Word alarm mon (PAR 12052) parameter. The table shows the application-specific alarms: APPLICATION APPLICATION ALARM CAUSE DESCRIPTION ACTION ALARM CAUSE BIT NUMBER...
  • Page 30 Ph. +91 20 6614 6500 Fax +44 (0) 8452 604556 Fax +91 20 6614 6501 sales@gefran.co.uk gefran.india@gefran.in SENSORMATE AG GEFRAN MIDDLE EAST ELEKTRIK VE GEFRAN INC. ELEKTRONIK SAN. VE TIC. LTD. STI Steigweg 8, 8 Lowell Avenue Yesilkoy Mah. Ataturk...

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