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marposs P7WB Programming Manual

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PROGRAMMING MANUAL
Wheel Balancing / GAP&Crash
Manual Code: D291W001UD
P7_D291W001UD_44.doc 22/04/09

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Summary of Contents for marposs P7WB

  • Page 1 PROGRAMMING MANUAL Wheel Balancing / GAP&Crash Manual Code: D291W001UD P7_D291W001UD_44.doc 22/04/09...
  • Page 2 Marposs S.p.A., Via Saliceto 13, Bentivoglio (BO) Italy SSUED BY MARPOSS S.p.A. does not take on the obligation of notifying possible further changes to the product. The descriptions reported in this book do not authorize any tampering by non-authorized personnel.
  • Page 3 The Directive explicitly excludes from its scope of application finished products such as those manufactured and sold by Marposs. It is still indeed a widely debated matter whether the complete removal of the regulated substances could affect the reliability of the product.
  • Page 4 – Programming Manual...

  • Page 5: Table Of Contents

    TABLE OF CONTENTS 1. INTRODUCTION ......................10 1.1. Interface between Gauge and User ................10 1.2. Programming manual ....................10 2. FRONT PANEL ........................ 11 2.1. Keys..........................13 2.2. Keypad ........................13 2.3. Combination of keys ....................14 2.4. Panel test / Viewing the software version ..............14 3.
  • Page 6 8.4. “External Info” folder ..................36 9. MENU MAPS (AUTOMATIC MODE ) ................. 37 9.1. “View” folder ...................... 37 9.2. “Inputs & Outputs” folder ................... 38 UNIT SET-UP ......................39 10.1. Home position ....................41 10.2. Manual balancing procedure with weights ............
  • Page 7 13.3.1. Programming wheel vibration tolerance limits ..............81 13.3.2. Programming a limit on acceleration value............... 83 13.3.3. Type of balancing algorithm....................83 13.3.4. Programming asymmetric filter on vibration signal ..........84 13.4. Programming the integrated Gap&Crash ............85 13.4.1. Selecting a Frequency Band..................... 85 13.4.2.
  • Page 8 Fatal errors at power-on..................159 ROUTINE MAINTENANCE ..................160 25.1. Cleaning the electronic unit ................... 160 25.2. Forced air cooling system maintenance..............160 25.3. Fans replacement ....................162 25.4. Data back-up batteries ..................162 25.5. Calling Marposs Service ..................164 – Programming Manual...
  • Page 9 – Programming Manual...

  • Page 10: Introduction

    INTRODUCTION The Wheel balancing & Supervision process control allows continuous monitoring of the grinding wheel condition with immediate compensation of possible unbalance during the cycle. It can be customized to a variety of applications and balancing heads. 1.1. Interface between Gauge and User The software uses graphics and/or icons to show the various functions and make comprehension and use easy and intuitive.

  • Page 11: Front Panel

    FRONT PANEL The front panel allows the programmer to customize the gauge system to a specific measurement application. The keypad is used to access the various program pages. Three types of front panel are available: Standard panel (in local or remote version) 3HE 19"...
  • Page 12 3HE 19" front panel Manual/Automatic F keys Display Keypad Hot key menu NOT enabled key F keys Shift key 3HE ½19" front panel Manual/Automatic key Shift key NOT enabled key Keypad Hot key menu F keys Display F keys 2. Front Panel –...

  • Page 13: Keys

    2.1. Keys UNCTION F1 to F6 keys can be used in two ways: as Hot keys or as Function keys. Hot keys are shortcuts for moving through the various pages and can be assigned by the operator F Keys using the keypad, see section 4.1.1. Function keys are predefined to do a one task on page.

  • Page 14: Combination Of Keys

    Increase data values one digit at a time (with autorepeat function). Plus In case of predefined data, allow scrolling parameters or icons to view the desired one. 2.3. Combination of keys OMBINATION OF KEYS UNCTION In Manual mode enable the Wheel/Cycle selection. Shift Upon programming they abort all the changes made Shift...

  • Page 15: How The System Is Organized

    The pages for programming/changing data are protected by password. There are two password levels: System Password (access to system data). This password is always active and cannot be disabled by Programmer (reserved to Marposs’ or Technical Personnel). At the password request, press to access data viewing. User’s Password (access to application data).

  • Page 16: Folders

    3.2.2. Folders The following folders are available: OLDER ICON UNCTION Access the following environments: Viewing viewing of programmed data, viewing of measurement values and cycles stages. Access the following environments: Utilities unit setup, measurement adjustment, viewing of programmed data. Access to the environment where the Programming cycles are parameterized.

  • Page 17: Sub-Folders

    3.2.3. Sub-folders The sub-folders are the second level of the software structure and contain pages with similar functions. Enter to highlight the sub-folder icon and press to access. The message in the lower left is the name of the highlighted sub-folder. Selected Sub-folders sub-folder...

  • Page 18: Messages And Info Section

    3.2.5. Messages and info section UNCTION Either the name of the highlighted icon or button or Message instructions on which button to press. Currently selected wheel number The software can Wheel number handle up to 16 different wheels. Currently selected cycle number. The software can Cycle number handle up to 16 different cycles.

  • Page 19: Use

    4.1. F keys keys on the front panel can be used either as Function keys or Hot keys. Note: Function keys have an F number in the upper left corner of the icon. Function key Hot key F number Function Keys Function keys are only available on a specified page.

  • Page 20: Defining The Hot Keys

    folder sub-folder page 4.1.1. Defining the HOT keys Get to the desired page using the menu maps. Highlight the page icon. Press and hold the desired “F#” key down until the icon is no longer highlighted, about 5 seconds. Release “F#”: the Hot Key is now defined. 4.1.2.

  • Page 21: Getting Around The Program

    4.2. Getting around the Program There are three ways of moving through the program: Using the cursor controls. Shortcuts via the Hot Keys. Home key to the default screen. 4.2.1. Cursor controls keys move the cursor at the same level between folders, sub- folders or pages.

  • Page 22: Hot Keys

    Enter Press to go to the page level of the program. If there are more pages on at the same level, press Enter highlight the icon of the page. Press to access the page. 4.2.2. Hot keys To use the shortcuts method of getting around the program: Turn on Hot key menu by pressing Press the F1 - F6 hot key associated with the desired page icon.

  • Page 23: How To Program

    HOW TO PROGRAM Programmable parameters are within dotted lines. 5.1. Selecting predefined values The values that can be given to some parameters are selected from a predefined list (numerical value or icon). to highlight the desired parameter. Press to scroll through the values or icons available to the desired one.

  • Page 24: Resetting All The Programmed Data

    5.4. Resetting all the programmed data Beware !! This operation will delete all the sets and the corresponding programmed data. Hold down the key at the system power-on: the following appears: <ENTER> TO RESET ALL DATA <ESCAPE> TO CONTINUE Enter Press to reset all data.

  • Page 25: Defining The Sets

    DEFINING THE SETS The work data are associated to a Set number: each Set is defined by the combination of two numbers, each one programmable from 1 to 16, totaling 256 combinations (256 Sets). Set no. (1 - 16) Set no. (1 - 16) Each Set can be combined with different types of wheels and/or numbers of cycle based on the programming of the machine logic.
  • Page 26 Enter Set selection Set no. Set no. Enter If 1/1 is the Set to be defined, press , otherwise use Enter to change the Set number, then press Enter A dialog box is displayed with “Yes” highlighted: press The application programming page is displayed. Press Enter Another dialog box is displayed with “Yes”...

  • Page 27: How To Define A New Set

    6.2. How to define a new Set • In Manual mode and in Programming only. Access the Programming environment and go to the programming page Shift relevant to the desired type of application. Press to highlight the Set selection box. Set selection Enter to change the Set number, then press...

  • Page 28: How To Select An Already Defined Set

    6.3. How to select an already defined Set Note: Select the Set prior to any programming procedure. Manual mode only Shift Press to highlight the Set selection box on bottom. The current Set appears. Note: If the Set selection box is not highlighted, it means that just one Set was defined.

  • Page 29: How To Delete A Set

    6.4. How to delete a set • In Manual mode and in Programming only. Shift Access the Programming environment . Press to highlight the Set selection box. Enter Press to view the Set to be deleted, then press to confirm the selected Set.

  • Page 30: Enabling The P.i.p. Window (Picture In Picture)

    ENABLING THE P.I.P. WINDOW (PICTURE IN PICTURE) Shift Press the keys to make a P.I.P. (Picture In Picture) window appear on display. The P.I.P. window views the main information relevant to each process control present in the application. P.I.P. window The P.I.P.
  • Page 31 • Press the Shift keys to confirm the selection. How to move the P.I.P. window on the screen • Press Shift to highlight the window (a dotted line is displayed on the window outline). • Press to move the window to the desired position. •...

  • Page 32: Menu Maps (Manual Mode )

    MENU MAPS (MANUAL MODE 8.1. “Utilities” folder Manual operating mode Unit setup Measure setup View data (Section 11, page 3) (Section 12, page 3) See next page Balancing limits (Section 12.2, page 3) Asymmetric filter on Integrated Gap & Crash Supervision values vibration signal control data...
  • Page 33 “Utilities” folder (continued….) Manual operating mode Unit setup Measure setup View data (Section 10, page 3) … Search for home position Manual balancing Spectral analysis Spectral analysis archive (Section 10.1, page 3) procedure with weights procedure (Section 10.4, page 3) (Section 10.2, page 3) (Section 10.3, page 3) RPM sensor control...

  • Page 34: Programming" Folder

    8.2. “Programming” folder Manual operating mode Request for **User’s password** (if active) Simple set programming Double set programming (Section 13.1, page 3) (Section 13.2, page 3) Integrated Gap & Crash Unbalance value programming Supervision programming programming (Section 13.3, page 3) (Section 13.5, page 3) (Section 13.4, page 3) Programming of asymmetric filter...

  • Page 35: Inputs & Outputs" Folder

    8.3. “Inputs & Outputs” folder Manual operating mode Gap & Crash Folder icon present only if the independent version of the Gap & Crash function is present in the P7. Pls. see the Voltage setup Motors test relevant description in (Section 16, page 3) the section 23, page 3.

  • Page 36: External Info" Folder

    8.4. “External Info” folder Manual operating mode Heads connection Balancing heads info Machine data (Section 17, page 3) (Section 18, page 3) (Section 19, page 3) Parameters of balancing Heads Heads programming. Balancing algorithm with weights. parameterization (Sec. 18.3, page 3) parameters.

  • Page 37: Menu Maps (Automatic Mode )

    9. MENU MAPS (AUTOMATIC MODE 9.1. “View” folder Automatic operating mode View measurements View programmed sets (Section 21, page 3) (Section 20, page 3) Balancing thresholds (Section 12.2, page 3) Asymmetric filter on Integrated Gap & Crash Supervision values vibration signal control data (Section 12.4, page 3) (Section 12.2.1, page 3)

  • Page 38: Inputs & Outputs" Folder

    9.2. “Inputs & Outputs” folder Automatic operating mode Gap & Crash Folder icon present only if the independent version of the Gap & Crash function is present in the P7. Pls. see the relevant description in the section 23, page I/O byte test I/O bit test Fieldbus test (Section 14.3, page 3)

  • Page 39: Unit Set-Up

    10. UNIT SET-UP Manual operating mode. Select the Utilities folder and press Should more sets be programmed, use to highlight the set selection area: use key to select the set to be set-up and press Press to select the Unit setup sub-folder and press Home position page (section 10.1, page 3).
  • Page 40 Spectral analysis procedure page (section 10.3, page 3). Press to go to the page; press to switch to the Spectral Analysis Archive folder. Spectral Analysis Archive page (section 10.4, page 3). Press to go to the page. 10. Unit Set-up –...

  • Page 41: Home Position

    10.1. Home position The Home cycle consists in bringing the masses of the balancing head to neutral position. Stop Home position Start Home position Measurement selection (1) Vibration value (2) (logical channel) No. of physical channel Wheel rotation value (1) Measurement selection: present only in the applications with two logical channels. With the field highlighted, press to select the desired measurement (the number of the corresponding physical channel is displayed).
  • Page 42 See section 17 “Heads connection ”, page 3. Static Home cycle The Home cycle is performed with the wheel NOT rotating (0 rpm). Vibration value Wheel rotation value Dynamic Home cycle The Home cycle is performed with the wheel rotating at a low number of revolutions (approximately lower than 800 RPM), as a function of the features of the balancing head.
  • Page 43 Search for Home position in progress is indicated by the oscillation of the mass symbols . Home position reached is shown as follows: Home position reached If the Home position is not reached within a pre-determined time, or other causes do not allow reaching it, the corresponding alarm messages are displayed.

  • Page 44: Manual Balancing Procedure With Weights

    10.2. Manual balancing procedure with weights Manual balancing of wheel vibration with angular positioning of two weights on the wheel flange. This procedure can be performed under two different conditions: • Balancing head not present • Balancing head present, provided the masses have been previously taken to Home (execution of a Home cycle).

  • Page 45: Rpm Sensor Control

    Manual balancing with variable weights / variable angles (section 10.2.3, page 3) A determined number of holes is programmed in the “Number of holes” datum. This allows getting (F1 key) to the programming of the available weight values, as described in section 18.1.3 “Weight value”, page 3.

  • Page 46: Manual Balancing Procedure With Fixed Weights/Variable Angles

    10.2.2. Manual balancing procedure with fixed weights/variable angles Page B7 of the “Utilities” folder menu map (section 8.1, page 3). Wheel balancing through angular positioning of two weights with pre-defined value on the wheel flange. Through a guided menu P7 supplies the angular values where the weights are to be positioned in order to compensate the wheel unbalance.
  • Page 47 Indexed scale Wheel rotation direction (RPM) direction Programmed Magnetic disk for condition RPM sensor Compensation weights Wheel Indexed scale 360° Execution of manual balancing procedure with weights The wheel rotation speed must be the same in the various steps of the procedure. Wheel NOT rotating.
  • Page 48 • Evaluate the residual unbalance and, in case, define the correction values by pressing F5 The absolute angular values to which the weights shall be moved for compensating the residual unbalance are displayed next to β1 and β2. Wheel NOT rotating. •...
  • Page 49 Move the weights to the angular positions indicated, then change the wheel rotation speed bringing it to the work speed. Stage 2 – balancing at work speed Press F5 (finishing of residual unbalance): the display shows the message “Balancing RPM not constant: repeat balancing procedure keeping the current positions?": confirm with “Yes”...

  • Page 50: Manual Balancing Procedure With Variable Weights /Fixed Angles

    10.2.3. Manual balancing procedure with variable weights /fixed angles Page B7 of the “Utilities” folder menu map (section 8.1, page 3). Wheel balancing using commercial dowels, with different weight, that are screwed on the wheel flange where a number of equally spaced threaded holes were previously made (by Customer).
  • Page 51 Wheel rotation → clockwise Holes angular positioning → counter-clockwise Wheel rotation → counter-clockwise Holes angular positioning → counter-clockwise (3) The vibration value can be viewed as width ("micron" or "inches") or as speed ("mm/sec" or "inches/sec"). The display modality is defined upon the application configuration.

  • Page 52: Procedure For Frequency Spectral Analysis

    10.3. Procedure for frequency spectral analysis Page C7 of the “Utilities” folder menu map (section 8.1, page 3). The procedure for frequency spectral analysis makes it possible to gauge the unbalance due to frequencies different from the wheel rotation ones (noise frequencies).
  • Page 53 Acquisition stops automatically when elaboration is performed or on user request with the same F4 key A cursor is available to scan each bar X position (rpm) and the Y value (“g” or “µm”). The following is an example of frequency analysis acquisition for a wheel speed of 3993 rpm, centered as required at 10000 rpm.
  • Page 54 Enter Shift Pressing the keys simultaneously changes not programmed values “No” (default) to programmable ones and vice versa. Example: Values programming is recommended if comparison of plots at different acquisition time is necessary, in order to acquire and plot data in the same condition. Value programming: press to highlight the involved field, press view the desired value, then...

  • Page 55: Archive Of Frequency Spectral Analysis

    10.4. Archive of frequency spectral analysis Page D7 of the “Utilities” folder menu map (section 8.1, page 3). Up to three archives (Arch.1, Arch.2, Arch.3) are available where frequency analysis acquisitions were previously stored: to select an archive press to highlight the corresponding field, press to view the desired archive, then press confirm.
  • Page 56 The following example shows the data acquired stored in archive 3, channel 1. Channel 1 Channel 2 Delete the selected archive Delete data from archive: select the archive (use to bring the cursor next to Arch.1, Arch.2 or Arch.3 and press ), then press the F6 key or use to highlight and press...

  • Page 57: Measurement Adjustment

    11. MEASUREMENT ADJUSTMENT Manual operating mode Select the Utilities folder and press Should more Sets be programmed, use highlight the set selection area: press to select the set on which measurement adjustment operations will be performed and press Press to select the Measurement Adjustment sub-folder and press Manual Balancing page (section 0, page 3).

  • Page 58: Manual Balancing

    Double Automatic Balancing page (balancing on 2 channels simultaneously) (section 11.3, page 3). Note: page displayed only if: - P7 system with “Two Channels Simultaneously” balancer card - the ”Dual Plane Balancing” software function (system configuration) is enabled - a two-channel set is selected.
  • Page 59 Motor speed Wheel rotation speed Vibration value Measurement selection: present only in the applications with two logical channels. With the field highlighted, press to select the desired measurement (the number of the corresponding physical channel, 1 or 2, is displayed). (2) The vibration value can be displayed either as width (unit of measure "micron"...
  • Page 60 Motor of mass 1 Motor of mass 2 forward forward Motor of mass 2 Motor of mass 1 backward backward The masses can also be moved simultaneously and with opposite sign (example -1 with +2 11. Measurement adjustment – Programming Manual...

  • Page 61: Automatic Balancing

    11.2. Automatic balancing Page B5 of the “Utilities” folder menu map (section 8.1, page 3). Automatic wheel balancing cycle with manual control of start cycle (function possible only when the proper logic enabling signal is present). Measurement selection- A or B (1). Vibration value (2) (logical channel) Vibration value...

  • Page 62: Double Automatic Balancing

    11.3. Double automatic Balancing Page C5 of the “Utilities” folder menu map (section 8.1, page 3). Automatic balancing cycle on two channels simultaneously, with manual start cycle control (function possible only if the proper enabling logical signal is present). Note: The procedure of double automatic balancing can be performed (the page is displayed) only if: - P7 system with “Two Channels Simultaneously”...

  • Page 63: View Acceleration

    11.4. View acceleration Page D5 of the “Utilities” folder menu map (section 8.1, page 3). The acceleration value is a signal directly coming from the vibration sensor (accelerometer): this makes it possible to improve the system reaction in case of an alarm condition.

  • Page 64: Noise Measurement

    11.5. Noise measurement Page C6 of the “Utilities” folder menu map (section 8.1, page 3). LED: status of Gap control Noise value of Gap control No. of physical channel Measurement selection - A or B (1). (logical channel) Noise value of Crash control LED: status of Crash control Measurement selection: present only in the applications with two logical...

  • Page 65: Gap&Crash Graphic Representation And Dynamic Set-Up

    11.6. Gap&Crash graphic representation and dynamic set-up Page D6 of the “Utilities” folder menu map (section 8.1, page 3). Page emulating the oscilloscope function, in manual operating mode, for: • viewing the noise signal coming from the acoustic sensor of each logical channel (channel 1 and/or channel 2).
  • Page 66 Out-of-screen trace indicators Should the trace(s) be not contained in the screen, two arrows appear to indicate the trace position (above or below its zero trace). Example (trace out of the screen on upper side). Selection of the set to be displayed to highlight the set selection area: and keys to select the set, then press...

  • Page 67: Time Base

    Below there are reported the specific data for each control. If you want to change the data value act as follows: • press to highlight the desired field • press to display the desired value • press to confirm. The change just made is displayed in real time. 11.6.1.
  • Page 68 Channel 1 trace vertical zoom factor (10% to 5000%) Channel 2 trace vertical zoom factor (10% to 5000%) 11. Measurement adjustment – Programming Manual...

  • Page 69: Trace Source And Position

    11.6.3. Trace Source and Position Zero trace Definition of channel 1 trace vertical position on screen (zero trace). Move the cursor with keys F4 key for resetting channel 1 trace position Definition of channel 2 trace vertical position on screen (zero trace). Move the cursor with keys F5 key for resetting channel 2 trace position 11.6.4.

  • Page 70: Gap&Crash Graphical Thresholds

    Channel 2 values Maximum value of channel 1 signal Minimum value of channel 1 signal F4 key for resetting channel 1 minimum and maximum values The indications are similar for channel 2. Note: Stop display (F3 key ): at the display start (F3 key ) it is asked whether the minimum and maximum values must be reset.

  • Page 71: View Data

    Graphic representation of Graphic representation of channel 1 Gap&Crash channel 2 Gap&Crash thresholds thresholds Crash threshold value (C) per channel 1 Gap threshold value (G) for channel 1 Gap threshold value (G) for channel 2 Crash threshold value (C) for channel 2 The thresholds can be programmed between 0.0 and 99.9 decibel (0.1 db resolution).
  • Page 72 Should more Sets be programmed, press to highlight the set selection area: use to select the set whose data are to be viewed and press . Use to select the View data sub-folder and press Application with 2 channels: press to select Channel 1 or Channel 2.

  • Page 73: Viewing Data Relevant To Set (Wheel/Cycle)

    12.1. Viewing data relevant to set (wheel/cycle) Page D3 of the “Utilities” folder menu map (section 8.1, page 3). Application with 2 channels: press to select Channel 1 or Channel 2. The data displayed have the following meaning: Channel Number of the physical channel associated to the logical channel Source of the RPM signal: INT= internal signal (rpm sensor on balancing head);...

  • Page 74: Viewing Asymmetric Filter On Vibration Signal

    Limit L3: wheel vibration value within which balancing is considered UNACCEPTABLE (vibration OUT OF TOLERANCE). When limit L3 is exceeded it means there is an out-of-control situation: an alarm condition (High Vibration) is activated with the Vibration Alarm signal at output. Acceleration limit: when this limit is exceeded, the Vibration Alarm signal is activated.

  • Page 75: Viewing Data Of Integrated Gap & Crash Function

    12.3. Viewing data of integrated Gap & Crash function Page C4 of the “Utilities” folder menu map (section 8.1, page 3). Type of receiver/transmitter unit: E78N/E82 or Type of receiver/transmitter unit: MINI CT Compact Area of Gap Area of Crash Area of Gap Area of Crash control data...

  • Page 76: Gap Control Data

    12.3.1. Gap control data Gap control Gap control limit (S1) trigger modality Delay on Gap control limit Reference of Gap control limit Value of the filter on the Gap background noise Gap control self-locking Reference of Gap control limit Gap control limit value = absolute value Gap control limit value = relative value Gap control trigger modality The Gap output control is triggered when the noise level exceeds limit S1.

  • Page 77: Viewing Supervision Data

    Crash control trigger modality The Crash output control is triggered when the noise level exceeds limit The Crash output control is triggered when the noise level drops below limit S1. Crash control self-locking Self-locked control. Once supplied the Crash output control is reset only at the successive Crash control enabling.

  • Page 78: Programming

    13. PROGRAMMING Select the Programming folder and press Request for **User’s password** (if active): • type password press program/change the data ( • Pressing without password gives access to data viewing ( Press to access the Simple Set Press to access the Double Set Programming (Sec.

  • Page 79: Programming A Simple Set (1 Logical Channel)

    13.1. Programming a simple set (1 logical channel) Page A2 of the “Programming” folder menu map (section 8.2, page 3). This page allows defining the combination of logical channel and physical channel for the selected set. Press to access the page. Data relevant to the set Set (Wheel/Cycle) selection Press...

  • Page 80: Programming A Double Set (2 Logical Channels)

    13.2. Programming a double set (2 logical channels) Page C2 of the “Programming” folder menu map (section 8.2, page 3). This page allows defining the source of the RPM signal for each logical channel. Press to select Channel 1 or Channel 2; press to confirm the selection and access the page.

  • Page 81: Programming Unbalance Limit Values

    13.3. Programming unbalance limit values Page A4 of the “Programming” folder menu map (section 8.2, page 3). In this stage it is possible to program the wheel vibration tolerance limits (defining whether the wheel balancing must be considered as optimum, acceptable or unacceptable).
  • Page 82 Three tolerance limits for wheel vibration may be defined: Limit L1 (0 to 50 µm or 0 to 50mm/sec): wheel vibration value within which balancing is considered OPTIMUM. Limit L2 (0 to 50 µm or 0 to 50mm/sec): wheel vibration value within which balancing is considered ACCEPTABLE.

  • Page 83: Programming A Limit On Acceleration Value

    13.3.2. Programming a limit on acceleration value Acceleration is a signal directly coming from the vibration sensor (accelerometer) and allows improving the system reaction in case of alarm conditions (excessive vibration). Acceleration limit: acceleration value beyond which the Vibration Alarm signal is activated. This datum can be programmed with values within 0.01g and 3.50g, and 0.01g resolution.

  • Page 84: Programming Asymmetric Filter On Vibration Signal

    Type selection: use to highlight the involved field, press to view the desired value, then to confirm. 13.3.4. Programming asymmetric filter on vibration signal Page A5 of the “Programming” folder menu map (section 8.2, page 3). From the page for programming tolerance limit values, press function key F4, or to highlight , and press Asymmetric filter on vibration signal that opportunely stabilizes the vibration value...

  • Page 85: Programming The Integrated Gap&Crash

    13.4. Programming the integrated Gap&Crash Select the Programming folder and press With **User’s password** active, the password is asked: • type the password and press Press Application with 2 channels: press to select Channel 1 or Channel 2. Press function key F2 or to highlight and press to access the data programming page.

  • Page 86: Gain Selection

    STG balancing heads (type of receiver/transmitter unit: compact) Band (filter) 1: filtering of the signal already demodulated to about 320 Hz. Band (filter) 2: filtering of the signal already demodulated to about 160 Hz. Band (filter) 3: filtering of the signal already demodulated to about 80 Hz. Frequency band selection: press to highlight the involved field, press to view the desired icon, then press...

  • Page 87: Programming Gap Control Data

    13.4.3. Programming Gap control data Page B4 of the “Programming” folder menu map (section 8.2, page 3). Gap control Gap control limit trigger modality Delay on Gap control limit Reference of Gap control limit Value of the filter on the Gap background noise Gap control self-locking Gap control limit...
  • Page 88 noise S1 = 0.75 x (RM1 - RM0) time Note: When changing the working conditions (wheel, workpiece, etc.) we recommend to verify the programming of S1. Setting range for S1: 0 to 99.9 decibel (resolution 0.1 decibel). Value programming: press to highlight the involved field, press view the desired value, then to confirm.
  • Page 89 Gap control trigger modality The Gap output control is triggered when the noise level exceeds limit The Gap output control is triggered when the noise level drops below limit S1. noise noise Data programming: press to highlight the involved field, press to view the desired condition, then to confirm.

  • Page 90: Programming Crash Control Data

    13.4.4. Programming Crash control data Page B4 of the “Programming” folder menu map (section 8.2, page 3). Crash control limit Crash control trigger modality Delay on Crash control limit Crash control self-locking Crash control limit Setting of the trigger limit (S2) of Crash control. The value programmed must always be intended as absolute.
  • Page 91 Crash control trigger modality The Crash output control is triggered when the noise level exceeds limit The Crash output control is triggered when the noise level drops below limit S2. noise noise Data programming: press to highlight the involved field, press to view the desired condition, then to confirm.

  • Page 92: Supervision Programming

    13.5. Supervision programming Select the Programming folder and press With **User’s password** active, the password is asked: • type the password and press Press Application with 2 channels: press to select Channel 1 or Channel 2. Press function key F4 or to highlight and press to access the data programming page.
  • Page 93 Note: With the RPM datum enabled the procedure of manual balancing with weight cannot be correctly performed (section 10.2, page 3). Data programming: press to highlight the involved field, then: method 1 press to view the desired value, then press to confirm.

  • Page 94: I/O Test

    14. I/O TEST The I/O test can be performed in Manual and Automatic mode: Manual mode: viewing of Inputs status viewing and/or changing of Outputs status Automatic mode: viewing of Inputs and Outputs status Manual operating mode Enter Select the Inputs and Outputs folder and press Press to select the icon indicated and...

  • Page 95: I/O Byte Test

    Field Bus test (Section 14.3) Pages viewed only in case of application with Field Bus Functionality Although it is possible to configure as wished how many and which inputs must be viewed and how many and which outputs must be modified, the software automatically carries out the following tests in order to prevent incorrect operations: Based on the total number of I/O bits present on the card (or cards), the Operator is not allowed to configure the screen with I/O bits that actually are not present.
  • Page 96 14. I/O test – Programming Manual...
  • Page 97 Type of I/O port The meaning of the icons used is the following: 1 input bit (byte) 8 input bits (word) 16 input bits (double word) 32 input bits 1 output bit (byte) 8 output bits (word) 16 output bits (double word) 32 output bits no I/O port has been selected.

  • Page 98: I/O Bit Test

    Value of I/O port Viewing of the hexadecimal value of the I/O port being considered. Inputs: (Manual/Automatic) it is only possible to read the value of the input port. Outputs: (Manual) it is possible to change the hexadecimal value by forcing the output port to take a determined configuration.
  • Page 99 Number of the logical I/O bit Selection of the number of the logical bit to be viewed/changed. Note: The correspondence between logical bit number and no. of pins of the I/O connector(s) is reported on the “I/O list” relevant to the application in use, present in the corresponding “Installation Manual”.

  • Page 100: Field Bus Test

    14.3. Field Bus test The aim of this page is viewing any input byte of the communication channel used and to view and/or change any output byte of the same channel. Moreover it is possible to view and/or change all the I/O’s in groups of 16 bits (word) and 32 bits (double word).
  • Page 101 With the color display the input ports are green and the output ports are red. To select the port (input, output, byte, word or dword) to be viewed or changed, press to highlight the desired field, press to view the desired type of port, then to confirm.
  • Page 102 In Manual mode, it is possible to change the number of the current Slave Address. Press : the field relevant to the current Slave Address number is highlighted. Press to display the desired number (1 to 126) and press Press to highlight and press to enable the selection.

  • Page 103: Motors Test

    15. MOTORS TEST This function allows viewing the instant value, maximum and minimum, of current absorbed by the motors that actuate the balancing masses, while moving to the selected direction. The current input value is expressed in mA. Manual operating mode. Select the Inputs and Outputs folder and press to select the Motor Test sub-folder and press Motor of mass 1...
  • Page 104 to control the movement of the motors relevant to the movement of the masses to the desired direction. It is possible to control just one movement at a time. During the motors movement the following is displayed: Motor of mass 1 Motor of mass 2 Maximum current Maximum current...

  • Page 105: Value Of The Temperature Between Transmitter And Receiver

    15.1. Value of the temperature between transmitter and receiver The value of the temperature (#°C) between transmitter and receiver (transmission area) is displayed in case of balancing heads with transmitter/receiver unit type “Compact” or “MINI CT”. Transmitter/receiver unit type “Compact” The operating maximum temperature for an optimal operation: 55°C (130°F) Threshold of alarm (maximum value admitted) of the inner temperature of the rotor: 71°C (159.8°F).

  • Page 106: Voltage Setup

    16. VOLTAGE SETUP Note: This function is present and the corresponding pages are displayed only with balancing heads with “E78N/E82” and “MINI CT”. transmission system. It is not present with heads with “Contactless compact” transmission system. Manual operating mode Select the Inputs and Outputs folder and press to select the Voltage setup sub-folder and press View receiver supply voltage page (section 16.1, page 3).

  • Page 107: Viewing The Receiver Supply Voltage

    16.1. Viewing the receiver supply voltage Page C3 of the “Inputs & Outputs” folder menu map (section 8.3, page 3). This page views the value of the voltage between transmitter and receiver (receiver supply voltage) with motors standing still. No. of physical channel RPM sensor control Measurement selection –...

  • Page 108: Rpm Sensor Checking

    16.1.1. RPM sensor checking Page C4 of the “Inputs & Outputs” folder menu map (section 8.3, page 3). From the Voltage setup page either press the F3 function key or use to highlight , then press LED of RPM sensor On this page a virtual LED warns when the RPM sensor is aligned with the slot on the rotary portion of the balancing head.
  • Page 109 With the field highlighted, press to select the desired measurement (the number of the corresponding physical channel, 1 or 2, is displayed). To perform the test, simultaneously press the keys or . In this way the movement of the pair of motors is controlled. –...

  • Page 110: Heads Connection

    You are asked to insert the **System Password**: press to access data viewing ( ) (programming/modification of these data is reserved for Marposs’ or Technical Personnel). Connection heads page (section 17.1, page 3). Press F1 or F2 to access the Balancing channel info page.

  • Page 111: Connection Of Balancing Channels

    17.1. Connection of balancing channels Page A6 of the “External Info” folder menu map (section 8.4, page 3). This page shows the connections between balancing channels and balancing heads. Type of balancing head Balancing channels Presence of external RPM / Accelerometer Presence flag of balancing Number of balancing head channel/balancing head...

  • Page 112: Characteristics Of Heads Connected To Balancing Channels

    External RPM sensor / accelerometer presence flags The following indications near each balancing head mean: External RPM sensor present for the corresponding balancing head External RPM sensor NOT present for the corresponding balancing head. Accelerometer present for the corresponding balancing head Accelerometer NOT present for the corresponding balancing head.

  • Page 113: Balancing Heads Info

    18. BALANCING HEADS INFO Manual operating mode. Select the External Info folder and press Press to select the Balancing heads Info sub-folder and press Parameters for balancing with weights page (section 18.1, page 3). Request for **User’s password** (if active): •...
  • Page 114 Note: All the parameters present in the pages where the **System password** is requested are defined upon the configuration stage and can be changed only by Marposs’ or Technical Personnel after entering the password. 18. Balancing heads Info – Programming Manual...

  • Page 115: Parameters For Manual Balancing With Weights

    18.1. Parameters for manual balancing with weights Page A3 of the “External Info” folder menu map (section 8.4, page 3). The meaning of the displayed parameters is as follows: No. of holes and weights Channel selection (1) Wheel rotation direction (RPM) / Angle evaluation direction (°) (1) Channel selection: with the field highlighted, press to view the desired...

  • Page 116: Number Of Holes

    Parameter programming: press to highlight the field of interest, press to view the desired value, and to confirm. 18.1.2. Number of holes Number of equally spaced threaded holes present on the wheel flange (made by Customer) in which commercial dowels with different weight are screwed for the manual balancing procedure with variable weights / fixed angles.

  • Page 117: Weight Value

    18.1.3. Weight value Page A4 of the “External Info” folder menu map (section 8.4, page 3). The “number of holes” datum is programmed to a value between 6 and 90 (see section 18.1.2 ”Number of holes“, page 3) : press the F1 key to access the page for programming the value of the available weights.

  • Page 118: Copy Data

    18.1.3.1. Copy data In order to avoid repeating the whole weight value programming stage, it is possible to press the F2 key, copy the table of weight values of the other channel into the one of the current channel. 18.1.4. Test weight Page A4 of the “External Info”...

  • Page 119: Heads Parameterization

    18.2. Heads parameterization Page B3 of the “External Info” folder menu map (section 8.4, page 3). The parameters displayed have the following meaning: Measurement viewing resolution Channel selection (1) Measurement viewing modality Head information Type of noise scale (1) Channel selection: with the field highlighted, press to view the desired channel.

  • Page 120: Heads Programming

    18.3. Heads programming Page C3 of the “External Info” folder menu map (section 8.4, page 3). This page shows the type of head connected to the selected channel (type defined when configuring the application). Channel selection (1) Type of balancing head connected Type of receiver/transmitter unit...
  • Page 121 Note: The F6 key (Reset the algorithm original parameters) is NOT enabled upon data display. Selecting the algorithm type With the field highlighted, press to select the type of algorithm. When the type of algorithm is changed, the values of the corresponding parameters are shown. The following types of balancing algorithm are available, corresponding to parameters pre-defined based on the type of grinder.

  • Page 122: Machine Data

    19. MACHINE DATA Manual operating mode. The Machine data concern the whole system, regardless the active (selected) control process. Select the External Info folder and press Press to select the Machine Data sub-folder and press Hardware unit info. Unit of measure and View software codes.
  • Page 123 – Programming Manual 19. Machine data...

  • Page 124: Selecting Unit Of Measure And Language

    19.1. Selecting unit of measure and language Page A5 of the “External Info” folder menu map (section 8.4, page 3). Language selection field Unit of measure selection field Press to reach the page. 19.1.1. Selecting unit of measure (micron/inch) The System can accommodate the use of either measurement system based on the application requirements.

  • Page 125: Software Codes

    The System Password (access to system data) is always active and cannot be disabled by the Operator (reserved to Marposs’ or Technical Personnel). The User’s Password (access to application data) can be defined, changed or deleted by the Operator.

  • Page 126: Definition Of User's Password

    19.3.1. Definition of User’s Password Note: Once the password has been defined, it is not possible to access the application data programming without entering that password. Press to access the password definition page and highlight the icon corresponding to the user’s password by pressing .

  • Page 127: Changing The User's Password

    User’s password enabled Press to exit the password definition page. 19.3.2. Changing the User’s Password Note: To be able to change the password you must know the current password. Press to access the password definition page and highlight the icon corresponding to the user’s password by pressing .

  • Page 128: Eliminating The User's Password

    19.3.3. Eliminating the User’s Password Note: To be able to eliminate the user’s password you must know the current password. Press to access the password definition page and highlight the icon corresponding to the user’s password by pressing . Press Press to highlight “Yes”...
  • Page 129 Press to confirm the password deletion, then press to exit the password definition page. – Programming Manual 19. Machine data...

  • Page 130: Info About Hardware Unit

    19.4. Info about hardware unit Page D5 of the “External Info” folder menu map (section 8.4, page 3). This page allows verifying the hardware unit of the system and to view the functional characteristics of each card used. No. of system slot Card foreseen for the Card present in the selected slot...

  • Page 131: Programming The Communications

    Viewing of the last 20 alarm messages. Press to highlight the key and press The last 20 alarm messages relevant to the selected slot are displayed (see example to the right). When the system is switched off all the possible alarm messages recorded are reset.

  • Page 132: View Programmed Sets (Automatic Operation)

    20. VIEW PROGRAMMED SETS (AUTOMATIC OPERATION) In this stage it is possible to view the data programmed for the selected set (wheel/cycle) with the system in Automatic operating mode. The set is selected by the machine’s logic. Note: The data displayed are the same of the View Data sub-folder (Utilities folder of Manual operating mode), so consult the corresponding sections for a description of data.

  • Page 133: View Measurements (Automatic Operation)

    21. VIEW MEASUREMENTS (AUTOMATIC OPERATION) to select the View Measurements sub-folder and press Noise Measurement page (section 21.1, page 3). Press to select the Balancing Procedure folder. Balancing Procedure page (section 21.2, page 3). Press to select the Double Balancing Procedure folder. Double Balancing Procedure page (section 21.3, page 3).

  • Page 134: View Noise Measurement

    21.1. View noise measurement Page A5 of the “View” folder menu map (section 9.1, page 3). Viewing of noise value of Gap control and Crash control for the selected channel, with the system in Automatic operating mode. Gap control status Noise value of Gap control No.

  • Page 135: View Automatic Balancing Cycle

    21.2. View automatic balancing cycle Page B5 of the “View” folder menu map (section 9.1, page 3). Viewing of the wheel automatic balancing cycle, for the selected channel. Measurement selection – Vibration value (2) A or B (1). (logical channel) Vibration value Wheel rotation Flag of motors...

  • Page 136: View Double Automatic Balancing Cycle

    21.3. View double automatic balancing cycle Page C5 of the “View” folder menu map (section 9.1, page 3). Automatic balancing cycle on two channels simultaneously. Note: The double automatic balancing procedure can be performed (the page is displayed) only if: - P7 system with “Two Channels Simultaneously”...

  • Page 137: View Acceleration

    21.4. View acceleration Page D5 of the “View” folder menu map (section 9.1, page 3). The acceleration value is a signal that directly comes from the vibration sensor (accelerometer). Vibration value (2) Acceleration value Vibration value Measurement selection - A or Wheel rotation speed B (1).

  • Page 138: Application Examples

    22. APPLICATION EXAMPLES 22.1. Manual balancing with weights Wheel #2 Wheel #1 Weights Weights holding flange holding flange RPM speed sensor (EXT RPM #1) Accelerometer 2 Accelerometer 1( “Balancing with weights” balancer card Programming of double set (two logical channels) Channel 1: EXT RPM #1 1 (accelerometer)

  • Page 139: Automatic Balancing

    22.2. Manual balancing with weights + automatic balancing Balancing head Transmission system Weights holding flange (INT RPM #1) RPM speed sensor (EXT RPM #1) Accelerometer ( 1-channel balancer card Manual balancing with weights (balancing head with masses at Home or head not present) Channel 1: EXT RPM #1 1 (accelerometer)

  • Page 140: Automatic Balancing On Two Channels Simultaneously

    22.3. Automatic balancing on two channels simultaneously • P7 system equipped with “Two channels simultaneously” balancer card • the ”Dual Plane Balancing” software function is enabled (system configuration) • a double set is selected (two logical channels). Independent balancing of two wheel slides Channel 1 Channel 2 Transmission system...
  • Page 141 Balancing of two wheels on the same axis Channel 1 Channel 2 Balancing head 1 Balancing head 2 (RPM INT #2) (RPM INT #1) Wheel #1 Wheel #2 Accelerometer 2 Accelerometer 1 Balancer card “Two channels simultaneously” Channel 1 Channel 2 INT RPM #1 INT RPM #2 (or 1) The balancing cycle is simultaneously performed on the two wheels by programming...

  • Page 142: Gap & Crash Function

    23. GAP & CRASH FUNCTION GAP and CRASH controls carried out through a microphone (piezoelectric transducer) with two independent control channels simultaneously enabled. GAP control Check of contact between wheel and workpiece: the definition of a noise threshold allows to detect the contact between wheel and workpiece to switch from approach speed to feed rate.

  • Page 143: Hardware Setup

    23.1.1. Hardware setup In this section the following parameters are defined: selection of frequency range alarms enabling definition of GAP control characteristics definition of CRASH control characteristics Selection of frequency range Microphone alarm: Cable alarm enabled enabled NOT enabled NOT enabled GAP control area CRASH control area Selection of Frequency Range...
  • Page 144 - record the noise value (NOISE) displayed on the bargraph with the wheel away from the workpiece (rest position) - record the noise value (SIGNAL) displayed on the bargraph during the working cycle (contact condition). Select the band - record NOISE and SIGNAL as indicated above. Select the band - record NOISE and SIGNAL as indicated above.
  • Page 145 Definition of GAP control (GAP control Area) Programming of characteristics of the control associated with GAP control. Definition of type of GAP control GAP control trigger enabling in self-locked control case of Alarm (1) NOT self-locked control control enabled control NOT enabled (1) This programming is possible only if at least one of the two types of alarm (cable alarm / microphone alarm) has been enabled.

  • Page 146: Software Setup

    detected noise exceeds the threshold and is energized when the noise goes below the threshold. To enable/disable, proceed as follows: highlight the desired field with , then press to change its status. 23.1.2. Software setup This section describes the elements for GAP and CRASH controls programming. Noise display area Icon of control type Bargraph...
  • Page 147 GAP control area Status of GAP control Gain acquisition type Start/Stop gain automatic acquisition Scroll bar for gain value adjustment Status of GAP control The status of GAP control is indicated by a LED: LED lit: GAP control enabled LED not lit: GAP control triggered Type of gain acquisition It is possible to select two different types of gain control procedure: automatic gain control procedure (with variable and oscillating background...

  • Page 148: Gap Control Programming

    Status of CRASH control The status of CRASH control is indicated by a LED: LED lit: CRASH control enabled LED not lit: CRASH control triggered 23.1.2.1. GAP control programming The GAP cycle can be controlled with the definition of an appropriate ultrasonic limit value.
  • Page 149 With the gain adjustment area highlighted, adjust the sensitivity with keys , bringing the noise display on bargraph slightly below the threshold and just before the GAP control LED switches off. To verify the programming perform a few cycles and verify that the GAP control has triggered at the right time.

  • Page 150: Crash Control Programming

    Note: The background noise acquisition time is 300 ms from the start cycle so it is mandatory that the grinding wheel takes more time to reach the workpiece. Note: If the type of wheel, workpiece, etc. is changed it may be necessary to reprogram the system.

  • Page 151: Gap & Crash Control Setting

    23.2. Gap & Crash control setting Setting, in Automatic mode, of GAP and CRASH controls. In Automatic mode select folder Inputs & Outputs Press Press to select the icon of GAP&Crash function. Press Press Setting of Gap & Crash controls Section 23.2.2 page 3 and 23.2.3 page 3.
  • Page 152 Noise display area Icon of control type Bargraph GAP control area CRASH control area Noise display area Noise is displayed through a bargraph, with values increasing from left to right. Symbol on bargraph indicates the control triggering point. Beside the bargraph there is an icon indicating the type of control the noise displayed refers to: GAP control CRASH control...

  • Page 153: Gap Control Setting

    fixed gain control procedure (with stable and repetitive background noise). To select, proceed as follows: highlight the desired field with , display the desired icon with , and press to confirm. Start/Stop gain automatic acquisition Start gain automatic acquisition (enabled only if the automatic gain control procedure has been selected).
  • Page 154 to highlight the gain adjustment area and to set the gain value to zero (scroll bar of the scale completely on the left). GAP control LED Bargraph Fixed gain Scroll bar for gain value adjustment / Key Bring the wheel almost in contact with the workpiece, or with the reference pin if the GAP control is used to check position, etc., as in normal working conditions (wheel spinning at work speed, workpiece rotating, coolant on, etc.).

  • Page 155: Crash Control Setting

    Bring the wheel almost in contact with the workpiece, or with the reference pin if the GAP control is used to check position, etc., as in normal working conditions (wheel spinning at work speed, workpiece rotating, coolant on, etc.). Highlight and press (the icon changes meaning becoming With the gain adjustment area highlighted, adjust the sensitivity with keys...
  • Page 156 to highlight the gain adjustment area and keys to define the sensitivity by setting the gain value approximately at the center of its range (scroll bar of the scale in central position). Simulate a few cycles and all the possible machine conditions (grinding, workpiece loading/unloading, dressing, etc.) to identify the maximum noise condition and adjust the sensitivity to have the noise value displayed on the bargraph scale just below the threshold...

  • Page 157: Diagnostics

    24. DIAGNOSTICS An error or malfunction condition of the system or the execution of incorrect operations is indicated by a message on display, within a dedicated window. The messages display is structured as follows: Message code and title Cause that generated the alarm message Remedy (operations required for restoring the correct operation) The structure of the message code is as follows: T XX Y ZZZ...
  • Page 158 Modality 2 Example of “Warning” Example of "Alarm" key, to completely display the information (CAUSE / REMEDY) relevant to the event displayed: Example Press to exit the error display, and then act as indicated under the item "REMEDY". 24. Diagnostics –...

  • Page 159: Fatal Errors At Power-On

    ESSAGE AUSE EMEDY Timeout on synchronization The Function CPU card, indicated by the Please call Marposs Service. with card # message, has not been programmed by the Master CPU card. The Function CPU card indicated by the Please call Marposs Service.

  • Page 160: Routine Maintenance

    25. ROUTINE MAINTENANCE 25.1. Cleaning the electronic unit Clean the outside of the electronic unit and the front panel using a cloth with denatured alcohol. Do not use solvents or abrasive products. 25.2. Forced air cooling system maintenance The P7 units installed in 3HE racks with sealed case (protection class IP43 or IP54) are fitted with a forced air circulation cooling system.
  • Page 161 Remove the filter protection panel (extract the four fixing screws). Check the felt element and the metal filter, clean them by immersing them in a mild detergent solution, after extracting them from their housing. Alternatively, replace the felt element (Marposs part number 4172000013) Filter Metal filter...

  • Page 162: Fans Replacement

    P7 rack. We advise replacing the fans once every 50,000 working hours (assuming average operating conditions at 40°C). The fans must be replaced by authorised personnel only (Marposs or Customer personnel). Fan located inside the rack Fan located inside the case 25.4.
  • Page 163 Once programmed the P7 unit we suggest to copy the programming data through the “Back-up/Restore Tool” program that can be supplied by any Marposs center throughout the world. This program, to be used with a PC, is based on Windows®...

  • Page 164: Calling Marposs Service

    25.5. Calling Marposs Service When calling for Marposs service, please have available the following information: Gauge name plate information on left side, including: serial #, model #, software unit # (CM1xxxxxxx). The P7 system is identified by labels arranged as follows: A.

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