WEISS HP140 Operating Instructions Manual
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WEISS HP140 Operating Instructions Manual

Was.handling, electro documentation, 1x208...230v, 3x208...230v, 3x400...480v
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04/2010

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Summary of Contents for WEISS HP140

  • Page 1 04/2010...
  • Page 2 WEISS GmbH reserves the right to make alterations to this documentation (also without prior notice). WEISS GmbH is not liable for any technical or printing errors in this document. We accept no liability for damages directly or indirectly related to the provision or use of this documentation.

  • Page 3: Table Of Contents

    Table of contents 1 Safety Instructions ............................1 1.1 Description of Symbols ..........................1 1.2 Safety Instructions.............................2 2 Product description............................5 2.1 Overview ..............................5 2.2 Technical Data ............................6 2.3 Terminology.............................10 3 Installation ..............................11 3.1 Installation of ACOPOS drives ........................11 3.2 Electrical installation ACOPOS drive.......................15 3.3 Installation of external I/O-Module ......................22 3.4 Electrical installation of I/O-Module ......................23 3.5 Connection Diagram for control cables ....................24...

  • Page 4: Safety Instructions

    1 Safety Instructions 1.1 Description of Symbols Warnings are emphasized by a safety symbol and are shown as follows depending on the degree of risk: Imminent danger. Fatal injury, death or substantial material damage can be caused if the appropriate safety measures are not taken! Danger ! Minor injuries may occur if the appropriate safety measures are not taken.

  • Page 5: Safety Instructions

    The operating instructions must be kept in a safe place for further use and must be passed on to every subsequent owner, user and end customer. The HP140 may only be started up when the whole machine and control system, in particularly the safety system, correspond to the machinery directive 98/37/EC.
  • Page 6 WEISS devices conform to the relevant VDE regulations. The VDE regulations must also be observed in the case of modification or extension of the devices. This documentation contains instructions for EMC installation - including screening, earthing and installation of the lines. Compliance with the limit values stipulated by EMC legislation is the responsibility of the manufacturer of the system or machine.
  • Page 7 Adequate protective devices, e.g. covers, protective grids, light curtains or stop sensor must be installed for operation in order to protect the operating personnel from injury by the HP140. Danger! The clamp “Enable” at the ACOPOS drive (terminal X1/9) is implemented as a so-called “secure restart inhibit”...

  • Page 8: Product Description

    2 Product description 2.1 Overview The device consists of the following assemblies: • mechanic mains connection • drive controls • cable set drive control drive control • option: digital I/O Y-Axis Z-Axis Eingänge des Verstärkers: - Enable (Not-Aus) - Quickstop - 24V Versorgung customer interface: digital outputs...

  • Page 9: Technical Data

    2.2 Technical Data 2.2.1 Drive control – power section: Depending on customer requirement, one of the following drive controls is used: Model: ACOPOS 8V1010.50-2 ACOPOS 8V1022.50-2 Permitted temperature ranges: storage: -25° C...+55° C operation: 0° C...+40° C vertical Installation position: 5 to 95%, without condensation Air humidity: 3 x 110 VAC to 230 VAC ±...
  • Page 10 In one of the drive controls, there is a Slot –PLC of type AC140 or AC141 integrated. These modules have an exchangeable program memory in the form of a compact flash card as well as a separate backup battery. The AC140 is equipped with Profibus and the AC141 with CAN-bus This Slot-PLC represents the hard- and software interface to customers PLC.
  • Page 11 Slot-PLC AC141.61.3 Processor clock 100MHz SRAM 32kB DRAM 32MB Interface IF1 Interface type RS232 Potential separation Design 9pol. DSUB-plug max. baud rate 115,2 kBaud Indications X1 LED Interface IF2 Interface type RS232 Potential separation Design 9pol. DSUB-plug max. baud rate 115,2 kBaud Indications X1 LED...
  • Page 12 2.2.3 I/O – Module CX408 (Option): level <5V Digital Inputs: HIGH >15V input current ca. 4mA at 24V input filter <2ms Digital Outputs: output current A1-A12 max. 0.4A each output output current A13 – A16 max. 2.0A each output CE, C-UL-US, GOST-R Certifications: 5 - 95%, without condensation Air humidity:...

  • Page 13: Terminology

    2.3 Terminology HP140 Type Motor coil Measurement system Design WAS.handling Electro Documentation...

  • Page 14: Installation

    3 Installation 3.1 Installation of ACOPOS drives The ACOPOS drive may only be used in environments corresponding to pollution level II (non-conductive contamination). The maximum operating temperature of 40 ° C (104° F) specified in the technical data as well as the protective type IP20 must be observed on installation of the devices.
  • Page 15 Drilling template: Fixing screws M5 WAS.handling Electro Documentation...
  • Page 16 3.1.2 Model for 400VAC Dimensions: 2 piece of Acopos 8V1022.50- Air output Air input 2) A free space of 80 mm must be provided above and below the ACOPOS drive to ensure adequate air circulation. For permitting an easy wiring, there must be a space of at least 100mm below the ACOPOS drive. WAS.handling Electro Documentation...
  • Page 17 Drilling template: Fixing screws M5 WAS.handling Electro Documentation...

  • Page 18: Electrical Installation Acopos Drive

    3.2 Electrical installation ACOPOS drive The ACOPOS drive may only be operated on earthed, three-phase industrial networks (TN, TT network). The mains is connected via the terminals X3 - For single phase connection use clamps: L1, N, PE. - For three phase connection use clamps: L1, L2, L3, PE Use lines of at least 1.5 mm²...
  • Page 19 3.2.1 Connecting diagram ACOPOS 1010 three phase connection single phase connection 3 x 208V - 230V~ 1 x 208V - 230V~ WAS.handling Electro Documentation...
  • Page 20 ACOPOS 1022 three phase connection 3 x 400V – 480V~ WAS.handling Electro Documentation...
  • Page 21 3.2.2 Circuits for EMERGENCY STOP The customer must assign the Pick & Place to a safety category that corresponds to the risk potential for the whole machine. For the interruption of the energy supply in the case of an E-Stop, below we have provided examples of three options.
  • Page 22 Version 2a: Interruption of the motor line Trigger 1 Quickstop COM (1, 2) ACOPOS Shield Endlagenschalter + NOT-AUS Endlagenschalter - Referenzschalter Enable Enable COM (8, 9) COM (8, 9) n.c. 24V OUT Slot 1 Slot 2 Slot 3 +24V +24V Encoder +24V AC120...
  • Page 23 Version 3a: Interruption of terminal X1/9 at the ACOPOS drive Trigger 1 Quickstop COM (1, 2) ACOPOS Shield Endlagenschalter + Endlagenschalter - NOT-AUS Referenzschalter Enable Enable COM (8, 9) COM (8, 9) n.c. 24V OUT Slot 1 Slot 2 Slot 3 +24V +24V Encoder...
  • Page 24 (clamp X 1/9). The delay time is set to the calculated time for the stop ramp (max. 0,1s for the horizontal Axes of the HP140).

  • Page 25: Installation Of External I/O-Module

    3.3 Installation of external I/O-Module The optional available I/O-Module can be mounted directly or onto a DIN-rail. The Dimensions are as follows: WAS.handling Electro Documentation...

  • Page 26: Electrical Installation Of I/O-Module

    3.4 Electrical installation of I/O-Module One or two I/O-Modules can be applied. The connection to the drives takes place via the internal CAN-Bus. Adequate cables are within the shipment. One Module has 16-In- and 16-Outputs, 24VDC. Outputs 1-12 can supply up to 0,4A, the Outputs 13-16 can supply up to 2A. The sum of all currents is max. 10A.

  • Page 27: Connection Diagram For Control Cables

    3.5 Connection Diagram for control cables 3.5.1 CAN-Bus – without I/O-Module The drive controls will be connected to each other with the preconfigured cable 563-200000200. Terminal resistors are inside the plugs. CAN-Adresses: Slot PLC: “0A“ Plug-In Module AC110: “1B“ 3.5.2 CAN-Bus – with one I/O-Module Both drive controls and the I/O-Module will be connected together via cable 563-200000202.

  • Page 28: Motor Connection

    3.6 Motor connection The delivered Lines are completely pre-configured. To prevent interchanging the lines of the two axis, the lines are signed as follows: Vertikal axis: left drive control (with Slot-PLC “AC140“) Horizontal axis: blue right drive control (with module “AC110“) The wires of the motor lines are signed with specified indications.

  • Page 29: Customers Interface

    3.7 Customers interface 3.7.1 Profibus D-Sub – Socket Description Function (female) DATA Data CNTRL Transmit Enable Profibus_GND Profibus_GND (potential separated) +5V / 50mA +5V Supply / 50mA (potential separated) DATA\ Data\ CNTRL\ Transmit Enable\ 3.7.2 CAN Bus D-Sub – Plug (male) Description Function CAN_L...
  • Page 30 3.7.3 Digital In- and Outputs The Slot PLC is equipped with one digital Output and two digital Inputs. This is enough for a lubrication pump or one gripper. For more complex wiring, one or two I/O-Modules can be connected. All In- and Outputs are freely configurable via Software. For this reason, here is no circuit shown. For connecting more powerful devices, the Outputs 13-16 onto the additional I/O-Module are available.
  • Page 31 Digital In- and Outputs I/O-Module: Inputs: Clamp on Function Description I/O-extension (CX408) X1-1 GND (0V) 24V-Supply of Inputs X1-2 +24V / 24V-Supply of Inputs DC_OK X1-3 E 1.1 Configurable via Windows-Program X1-4 E 1.2 Configurable via Windows-Program X1-5 E 1.3 Configurable via Windows-Program X1-6 E 1.4...
  • Page 32 Terminal block HP140 Tool-Connector SBS4 As described before, the use of In- and Outputs is freely configurable. For connecting I/O’s with the HP140, there is a preconfigured cable delivered. If pneumatic valves and Tool-Connector are requested, the wiring is as follows:...

  • Page 33: Getting Started

    4 Getting started 4.1 Drive controls For controlling both Motors, matching drive controls will be delivered. This drive controls are designed for digital stroke and position controlling. The first controller is equipped with the following modules: Slot-PLC “AC140“ or “AC141“ Sin/Cos feedback-Interface “AC120“.
  • Page 34 24 V supply. Take note that multiple faults in the IGBT bridge can lead to a brief jerking. The maximum stroke of the axis depends on the used motor. For the HP140 this is about 5mm.
  • Page 35 A fault in the IGBT bridge can result in a fatal direct voltage at the motor clamps. If electrical work is being carried out on the HP140, the mains line must be cut off by a mains contactor or a master switch.

  • Page 36: Slot-Plc

    4.2 Slot-PLC The PLC is a user-friendly interface between customer interface and ACOPOS drive. It provides the required movement commands at the correct time. Positions and Drive – Sequences are handled and stored by the Slot-PLC. The Slot-PLC is available in two different versions: AC140: with user interface Profibus AC141: with user interface CAN-Bus (also for DeviceNet) The following interfaces are standard included in both PLCs:...

  • Page 37: Mechanics, Motors And Feedback

    4.3 Mechanics, Motors and Feedback The mechanics consists of two linear motors which are coupled to Y/Z-axes. The use of linear motors gives an increase of dynamics. With less load (up to 1.5kg), accelerations up to 40m/s² are possible which however going back with increasing load.

  • Page 38: Machine Zero Position

    Reference run Because the used incremental encoder system is not equipped with a reference signal, a reference search must be done before the first positioning can start. The only possibility which the mechanics offers consists in taking the end of the axis as a reference point (reference on limit stop). For this, the axis moves in a specified direction with slow speed and reduced torque, until it recognizes a block (following error increases).

  • Page 39: Windows User Interface - Software

    For connecting via RS232, there is a so called “Null Modem Cable” necessary. The assignment can be found in the electric manual. This parameterization is only necessary one time after the implementation of the HP140. All important parameters are placed to disposal via Interface to customers PLC.

  • Page 40: Service Und Maintenance

    5 Service und Maintenance 5.1 Battery Replacement The battery of the controller has to be replaced every 4 years to prevent data loss. The control computer monitors the battery voltage and gives a warning (digital output / field bus) if the voltage drops. The replacement of the battery may take place when the control computer is switched of or when the 24 V supply voltage is on.
  • Page 41 5. Push the end of the pullout strip that stands out under the battery, so that it does not extend from the battery compartment. 6. Replace the cover. The recess for the screwdriver should point upwards. Lithium batteries are hazardous waste! Spent batteries have to be disposed of appropriately.

  • Page 42: Appendix

    6 Appendix 6.1 Assignment of Cables The following lines are available in length 5m, 10m, 15m, 20m, 25m. 6.1.1 Assignment of Motor line (563-100000070…74 to 563-100000080…84): Item Description Remark Motor line 4 x1,5mm² + 2 x 2 x 0,75 mm² Circular Connector BSTA 108 FR 19 08 0006 000 Shrink wrap...
  • Page 43 6.1.2 Assignment of Feedback line (563-200000070…74 to 563-200000080…84): Item Description Remark Encoder Cable 5 x 2 x 0,25mm² + 2 x 0,5mm² DSUB-Housing, metallized, 15pin Female DSUB-Housing 45° , metallized, 15pin Male Shrink Wrap for Designation D-Sub – male connector Pin Designation Function Channel A...
  • Page 44 6.1.3 Assignment control cable for valves & gripper (563-200000100…104): 6.1.4 Assignment Null Modem Cable (563-200000010): The Null Modem Cable is used for connecting the Laptop to Slop PLC – X1. WAS.handling Electro Documentation...
  • Page 45 6.1.5 Assignment CAN-Adapter (563-200000200): 6.1.6 Assignment CAN-Adapter (563-200000202): WAS.handling Electro Documentation...
  • Page 46 WAS.handling Electro Documentation...

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