lju documents

ST794-3M-PS-SI-SB TF Trolley Controller

Costumer: Rofa

End costumer: Vinamilk

Plant: SSI Schäfer

WNR: 628231

Version: 1.0

Software-description

LJU Automatisierungstechnik GmbH

© LJU Automatisierungstechnik GmbH

Am Schlahn 1

DE 14476 Potsdam

Tel.: +49 (0) 33201 / 414-0

Fax: +49 (0) 33201 / 414-19

E-Mail: [email protected]

Internet: www.ljuonline.de | www.grenzebach.com

The standard names, trade names, product names etc. used in this documentation may also be brand names even when not specially indicated and as such subject to the statutory stipulations.

May 2011

Software description ST 794-3M-PS-SI-SB-TR V1.0

Table of contents

BV89073_02_en.doc 3

Table of changes Subject to changes

We reserve the right to make changes in the information contained in this document, which arise from our constant effort to improve our products.

Project : Rofa / SSI-Schäfer Vinamilk Order No.: 120645 BV No.: 89073

Date :10.08.2012

Programmer: Hein

Version Date Author Chapter Remarks / Index

1.0 10.08.12 Hein First version 1.1 29.08.12 Hein various Error correction 1.2 08.09.12 Hein General Entry for INI6030 1.3 24.09.12 Hein 6.2 Description Ini6012-1 Inputs 1.4 20.12.12 Hein 3.2 Description of parameter INF

Software description ST 794-3M-PS-SI-SB-TR

V1.0

Table of contents

BV89073_02_en.doc 4

Table of contents

1 General ..................................................................................... 7

1.1 Program description ................................................................ 8

1.1.1 Automatic mode ............................................................... 8

1.1.2 Position sensing with the OLM 708 ...................................... 8

1.1.3 The conveying process ...................................................... 8

1.1.4 Service mode ................................................................... 9

1.1.5 Manual mode ................................................................... 9

2 Error Messages ........................................................................ 10

2.1 Overview ............................................................................. 10

2.2 Description of error messages ................................................ 12

2.2.1 Message -0- .................................................................. 12

2.2.2 Error -1-: Sequence stop switch ....................................... 12

2.2.3 Error -14/ -15/ -16: Error 24 V initiator board.................... 12

2.2.4 Errors -17/ -18/ -19: Monitoring of brakes ........................ 12

2.2.5 Error -21: Inverter phase failure ...................................... 13

2.2.6 Error -23/ -24: Inverter over-voltage ................................ 13

2.2.7 Error -25/ -26: Inverter under-voltage .............................. 13

2.2.8 Errors -27/ -28/ -29: Fuses ............................................. 14

2.2.9 Error -30 Non-equivalence bypass switch .......................... 14

2.2.10 Error -32: No code strip .................................................. 14

2.2.11 Error -33: Stop position overdrive .................................... 15

2.2.12 Error -34: Code reading error .......................................... 15

2.2.13 Error -35: Monitoring OLM speed ...................................... 15

2.2.14 Error -36/ -37: Monitoring conveyor free profile ................. 16

2.2.15 Error -38: Code gap ........................................................ 16

2.2.16 Error -3A: Drive direction command ................................. 16

2.2.17 Error -41/ -43: Motor over-temperature ............................ 17

2.2.18 Errors -51/ -52/ -53: Motor over-current ........................... 17

2.2.19 Error -54/ -55: Inverter overload ..................................... 17

2.2.20 Error -56/ -57: Inverter over-current ................................ 18

2.2.21 Error -61: PLC command plausibility ................................. 18

2.2.22 Error -62: PLC command without release rail ..................... 18

2.2.23 Error -63/ -64: Conveyor runtime ..................................... 19

2.2.24 Error -65/-66: Relay defect ............................................. 19

2.2.25 Error -67: Soiled OLM or bar code tape ............................. 19

2.2.26 Error -68: Drive position outside range ............................. 19

2.2.27 Error -69: Drive direction ................................................ 20

2.2.28 Error -6A: Drive motor standstill monitoring ...................... 20

2.2.29 Error -71 / -72: High-level stage error of inverter ............... 20

2.2.30 Error -74/ -75: Inverter over-temperature ........................ 21

2.2.31 Error -77/ -78: Chopper overload ..................................... 21

2.2.32 Error -8-: Tables CRC incorrect ........................................ 21

2.2.33 Error -81: Safety relay defect .......................................... 22

2.2.34 Error -87: System table error .......................................... 22

2.2.35 Error -9-: Parameter error ............................................... 22

2.2.36 Error -91 /-92 /-94 .. /-98: Communication error ............... 22


Table of contents

BV89073_02_en.doc 5

2.2.37 Error -99: Rail bus communications error .......................... 23

2.2.38 Error - Par ..................................................................... 24

2.3 Trolley-specific error codes from the data concentrator .............. 25

2.3.1 Message 88: Position not in system table .......................... 25

3 Parameter ............................................................................... 26

3.1 General ............................................................................... 26

3.2 Parameter overview .............................................................. 26

3.3 Parameter descriptions .......................................................... 28

3.3.1 Start delay [T0] ............................................................. 28

3.3.2 Acceleration and braking ramps [T1-T4/T6/T7] .................. 28

3.3.3 Speed factor [GED / GEF] ................................................ 28

3.3.4 Scaling of position sensor [SC1] ....................................... 29

3.3.5 IxR compensation [M1D/M3D/M1F] .................................. 29

3.3.6 Cut-off frequency [M2D/M4D/M2F] ................................... 30

3.3.7 Nominal current motor [InD/InF] ...................................... 30

3.3.8 Configuration of OLM [CNF] ............................................. 30

3.3.9 Safe speed [VSF] ........................................................... 31

3.3.10 Positioning ramp [ACL/ACV] ............................................ 31

3.3.11 Positioning window of Drive [WIN] .................................... 31

3.3.12 Positioning window of standstill [TL1] ............................... 31

3.3.13 Tolerance [TL2] .............................................................. 31

3.3.14 Slow drive empty / full window [WIN] ............................... 32

3.3.15 Configuration distance regulation [CNF] ............................ 32

3.3.16 Stopping distance [ABA] .................................................. 32

3.3.17 Ramp distance regulation [ACA] ....................................... 32

3.3.18 Trolley length [FzL] ........................................................ 33

3.3.19 Frequency for releasing or applying brakes [BOx/BCx] ........ 33

3.3.20 Standstill tolerance [FST] ................................................ 33

3.3.21 Time delay to speed control error [TSM] ............................ 33

3.3.22 Timeout conveying [T8] .................................................. 33

3.3.23 Minimum runtime [T11] .................................................. 33

3.3.24 Time to conveyer slow [T12] ............................................ 34

3.3.25 Delay stop loading [T13] ................................................. 34

3.3.26 Waiting time “conveyor empty” [T14] ............................... 34

3.3.27 Waiting time after releasing stop button [T5] ..................... 34

3.3.28 Sequence stop button configuration [CNF] ......................... 34

3.3.29 Signal lamp configuration [CNF] ....................................... 34

3.3.30 Configuration of vacuum cleaner [CCl] .............................. 34

3.3.31 Runtime cleaner after stop of trolley [T15] ........................ 35

3.3.32 Rated voltage [CUN] ....................................................... 35

3.3.33 Intermediate circuit frequency [CZF] ................................ 36

3.3.34 Release number [PAR] .................................................... 36

3.3.35 Offset [Off] .................................................................... 36

3.3.36 Configuration test outputs ............................................... 36

3.3.37 Configuration remote control [CNF] .................................. 37

4 Configuration ........................................................................... 38

4.1 General ............................................................................... 38


V1.0

Table of contents

BV89073_02_en.doc 6

4.2 Configuration overview .......................................................... 38

4.3 Description ........................................................................... 39

4.3.1 Motor temperature ......................................................... 39

4.3.2 IxR compensation measurement by the controller .............. 39

4.3.3 No error display ............................................................. 40

4.3.4 Unconditional manual mode ............................................. 40

4.3.5 Plausibility monitored ...................................................... 40

4.3.6 Error -62 ....................................................................... 40

4.3.7 Invert Conveyer motor direction ....................................... 40

4.3.8 Monitoring speed ............................................................ 40

4.3.9 FAB .............................................................................. 41

4.3.10 Overrun stop position ..................................................... 41

4.3.11 Profile is monitored ......................................................... 41

5 Tables ..................................................................................... 42

5.1 Speed table .......................................................................... 42

5.2 Clearance table ..................................................................... 43

6 Display ................................................................................... 44

6.1 General ............................................................................... 44

6.2 Display modes ...................................................................... 44

6.3 Other displays ...................................................................... 52

7 FB-606 remote control .............................................................. 54

7.1 General ............................................................................... 54

7.2 Button functions (Standard IR Konfiguration) ........................... 54

8 MU705 .................................................................................... 55

9 Display of Input Signals or Control Flags ..................................... 57


General

BV89073_02_en.doc 7

1 General

Read this description carefully before you use the device! It will ensure smooth operation of the system and prevention of er-rors, defects and damage to the system. If a controller ever needs to be replaced, please return it along with an error description that is as accurate as possible. This will help us minimize repair times and return the controller to you in the short-est possible time.

Display: 4-stellig (4x7 Segment) Parameter set: ST794-3MPS-SI-SB MU 705: 89073_90 DKZ: 89073_00 Components

Name BV WNR BG

IPM-1.6-TF -----_-- 181114 53586_04 IPM-2.5-TF -----_-- 181161 53543_04 CPU-805-6-TF Bootloader 94018_02 181189 51296_01

BIOS 94083_18 User 94071_08

CPU-IPM-MB3-TF Bootloader 94088_02 181159 51522_01 BIOS 94105_04 USER

IRDA-805-5-TF -----_-- 18754 56064 INI-6030-TF Adr.: 0 86546_00 18683 55267 INI-6012-TF Adr.: 0 86133_00 18698 55574 INI-6012-TF Adr.: 1 86133_00 18698 55571 ESB-1-TF -----_-- 181014 57438 PHÜ-1.6.1-TF -----_-- 181229 57901 BÜ-1-TF -----_-- 18968 57178


V1.0

General

BV89073_02_en.doc 8

1.1 Program description

1.1.1 Automatic mode

In automatic mode the trolley receives command flags in a cyclic data ex-change from the data concentrator or the PLC, to either drive or convey. Since the data concentrator knows the position of all the trolleys, it in-forms each trolley of the free route available to it in the drive direction. Flags in the system table are used to stop the trolley at a particular point. The PLC must set a bypass flag/bridging flag in order for the trolley to continue driving after a stop.

1.1.2 Position sensing with the OLM 708

A bar code scanner is used to determine the actual position. A barcode is placed in the system, which is read by the scanner. The positions are coded as absolute values in the system. For more infor-mation, please refer to the manufacturer’s handbook. If the scanner detects an error in the code (breaks), it signals this and the controller software continues to incrementally count the position of the trolley for a specific time period. The counting speed is based on the trol-ley speed, due to which the correct position is determined even in this case.

1.1.3 The conveying process

LS1 – Gap control LS2 – Stop when loading from left

After switching on, an initial check is made of whether the conveyor is occupied by a pallet. If the light barriers for the position occupancy (LS2) are not free, then the conveyor is detected as occupied and an “o” (occupied) appears in the dis-

Conveyer

Direction

LJU

LS 1

Conveyer

LS 2


General

BV89073_02_en.doc 9

play. If only one of these light barriers is occupied, then the load status is detected as undefined and a “u” (undefined) appears in the display. If profile monitoring has been selected (see parameter description), then the profile is monitored during the drive. If the conveyor is occupied, then it is monitored for possible pallet shifting (LS1 is occupied). If the convey-or is free, no light barriers may become blocked and the display shows a ”_” to signalize conveyor free. Various signals are used to synchronize an external conveyor with the conveyor on the trolley. The commands to load/unload are checked for plausibility. (See error descriptions.)

1.1.4 Service mode

In service mode, drive and convey commands can be set in the trolley us-ing the PLC. During the drive, the trolley direction and speed may be se-lected. Trolley distance monitoring and relaying of the routing tables re-main activated. The service module position is not monitored!

The chain conveyor can only drive at slow speed in this operating mode. The light barriers and the load are not monitored!

1.1.5 Manual mode

- Manual mode allows access to the various controller functions. - In the manual mode, the controller works with limited error analysis. - When the manual mode is activated or deactivated, all the errors are

reset. - !! In manual mode, the controller does not respond to data concentra-

tor commands!!


V1.0

Error Messages

BV89073_02_en.doc 10

2 Error Messages

2.1 Overview

Display DCN Display Meaning

-0- 1 Bypass safety circuit - 1 - 10 Sequence stop - 14 14 24 volt initiator board 6030 - 15 15 24 volt initiator board 6012-1 - 16 16 24 volt initiator board 6012-2 - 17 17 Drive motor brake - 18 18 Conveyer1 motor brake - 19 19 Conveyer2 motor brake - 21 21 Inverter phase error - 23 23 Inverter 1 over-voltage 1) - 24 24 Inverter 2 over-voltage 2) - 25 25 Inverter 1 under-voltage 1) - 26 26 Inverter 2 under -voltage 2) - 27 27 Fuse, initiator board 6030 - 28 28 Fuse, initiator board 6012-1 - 29 29 Fuse, initiator board 6012-2 - 30 30 Non-equivalence bypass switch - 32 32 No code strip - 33 33 Stop position overdrive - 34 34 Code reading error - 35 35 Monitoring OLM speed - 36 36 Monitoring conveyor1 free profile - 37 37 Monitoring conveyor2 free profile - 38 38 Code gap -3A 39 Drive direction command - 41 41 Motor over-temperature drive/ conveyor 1 - 43 43 Motor over-temperature conveyor 2 - 51 51 Drive motor over-current - 52 52 Conveyor1 motor over-current - 53 53 Conveyor2 motor over-current - 54 54 Inverter 1 overload 1) - 55 55 Inverter 2 overload 2) - 56 56 Inverter 1 over-current 1) - 57 57 Inverter 2 over-current 2) - 61 61 PLC command plausibility - 62 62 PLC command without release rail


Error Messages

BV89073_02_en.doc 11

- 63 63 Conveyor 1 runtime - 64 64 Conveyor 2 runtime - 65 65 Drive motor relay - 66 66 Conveyer 1 motor relay - 67 67 Soiled OLM / bar code tape - 68 68 Drive position outside range - 69 69 Drive direction - 6A 6A Drive motor standstill monitoring - 71 71 High-level stage error of inverter 1 1) - 72 72 High-level stage error of inverter 2 2) - 74 74 Inverter 1 over-temperature - 75 75 Inverter 2 over-temperature - 77 77 Overload chopper inverter 1 - 78 78 Overload chopper inverter 2 - 8 - 80 Tables CRC incorrect - 81 81 Safety-relay defect - 87 87 System table error - 9 - 90 Parameter error - 91 91 Inverter 1 offline 1) - 92 92 Inverter 2 offline 2) - 94 94 Initiator board 6030 offline - 95 95 Initiator board 6012-1 offline - 96 96 Initiator board 6012-2 offline - 97 97 OLM offline - 98 98 FAB offline - 99 99 Rail bus communications error PAR A0 Controller not enabled

1) Inverter 1 = Drive / Conveyor1

2) Inverter 2 = Conveyor2

The control box is sending the error numbers in hex.


V1.0

Error Messages

BV89073_02_en.doc 12

2.2 Description of error messages

Only negative flashing numbers are error messages!

2.2.1 Message -0-

Cause: - The switch for bypass the safety is activated

Solution:

- Release the switch

2.2.2 Error -1-: Sequence stop switch

Cause: - The palm button has been pressed.

- No connection exists between shut-off switch and controller. Solution:

- Unlock palm button switch; the trolley continues the drive after the parameterized follow-up time has expired. - Check that the cable connection between palm button switch and controller is well seated.

2.2.3 Error -14/ -15/ -16: Error 24 V initiator board

Cause: - No 24 volt supply to the input boards.

Solution:

- Verify 24-volt supply voltage by measurement. - Check that the ribbon cables are well seated.

2.2.4 Errors -17/ -18/ -19: Monitoring of brakes

Cause: - Fuses for the brake defect - Brake lock defective - Brake line from motor missing - Incorrect cable type for motor cable -Mechanical jamming


Error Messages

BV89073_02_en.doc 13

Solution: - Check fuses for the brake on the inverter board - Check / replace brake locks - Check motor line - Check brakes

2.2.5 Error -21: Inverter phase failure

Cause: - At least one phase of the 460-volt supply voltage has failed.

Solution:

- Measure phase voltage. - Check system for short circuit. - Check fuses.

2.2.6 Error -23/ -24: Inverter over-voltage

If the controller is working in the generating mode, the intermediate cir-cuit voltage increases. If it exceeds a certain value, the error is produced.

Cause: - Defective chopper resistance.

Solution:

- Replace controller

2.2.7 Error -25/ -26: Inverter under-voltage

If the intermediate circuit voltage is under a defined limit. The Limit de-pends on the parameter for the rated voltage.

Cause: - Wrong parameter value for rated voltage - Phase missing - Defective controller

Solution:

- Check the parameters - Check the three phases - Replace controller


V1.0

Error Messages

BV89073_02_en.doc 14

2.2.8 Errors -27/ -28/ -29: Fuses

A multi-fuse on the initiator board has tripped. Cause:

- Short circuit in an external device connected to the input board. Solution:

- Check the connected sensors and/or external devices (initiators, sequence stop buttons etc.) for short circuits.

2.2.9 Error -30 Non-equivalence bypass switch

If so configured both contacts of the bypass switch are monitored if they are open or closed simultaneously. Cause:

- The initiator /switch is not designed to be non-equivalent, alt-hough it is configured as such.

- There is no configured initiator or the cable connections are loose.

- If it is a non-equivalence initiator / switch, the contacts are both simultaneously open or closed (initiator defective).

Solution:

- Check the parameters of the initiator (see MU parameters). - Install an initiator or check that the connecting plug is securely

seated. - Replace initiator.

2.2.10 Error -32: No code strip

The OLM has not found a valid code after the segment end+1000 mm of a segment in which the trolleys have to drive without any code strip. Cause:

- Incorrectly adjusted OLM - Area without code strip too big - Missing flag for no code strip

Solution:


Error Messages

BV89073_02_en.doc 15

- - Check adjustment of the OLM - Clean OLM and code stripe - Check system table

Note: Not used in this project!

2.2.11 Error -33: Stop position overdrive

In the positioning software, there is an option for a trolley to reverse and position itself within a certain range in case it overshoots its stop position. However if the trolley has overshot even this range, an error is generated. Cause:

- The controller or positioning has incorrect parameters (e.g. gear factor, positioning ramp)

- Dirt or defective OLM - Dirt or ill-adjusted barcode strip

Solution:

- Verify parameters - Check OLM - Check barcode strip

2.2.12 Error -34: Code reading error

This error occurs if the controller does not receive any valid position for more than 1000 mm. (position was only counted incrementally) Cause:

- Declutched/disengaged gear - Loose driving wheel - Incorrectly adjusted or dirt OLM

Solution:

- Check the position of the clutch lever - Check that the drive wheel is firmly seated - Check the adjustment of the OLM and the rails - Clean the rails and OLM

2.2.13 Error -35: Monitoring OLM speed

The trolley controller monitors whether the actual speed matches with the specified value. This error indicates a deviation. Cause:


V1.0

Error Messages

BV89073_02_en.doc 16

- Incorrectly adjusted or dirty OLM - Loose driving wheel, declutched gear, … - Gear factor has incorrect parameters

Solution:

- Check that the driving wheel is firmly seated - Check the position of the clutch lever - Check parameters (see MU parameters)

2.2.14 Error -36/ -37: Monitoring conveyor free profile

If profile monitoring is selected, then profile freedom is monitored while the trolley has a conveyor command. If the conveyor is empty, no light barriers may become blocked. If the conveyor is full, none of the gap con-trols may become blocked. Cause:

- Shifted pallet - Foreign object blocking the gap-control light barrier

Solution:

- Check pallet position - Check region in which the fault occurred for foreign objects

2.2.15 Error -38: Code gap

This error occurs if the OLM has not sent two sequentially increasing or decreasing positions for a span of 700 mm. Cause:

- Incorrectly adjusted OLM - Dirt OLM or code strip

Solution:

- Check adjustment of the OLM - Clean OLM and code strip

2.2.16 Error -3A: Drive direction command

It is only monitored if the corresponding software switch has been activat-ed (see Configuration section). This error occurs if the controller got a drive backward command from the PLC.


Error Messages

BV89073_02_en.doc 17

. Cause:

- Wrong Configuration (SW11) - Wrong PLC drive direction command - Automatic mode active

Solution:

- Check configuration - Execute backward drive commands only in service mode

2.2.17 Error -41/ -43: Motor over-temperature

Cause: - Motor has no temperature probe - Motor has incorrect parameters - Incorrect cable type for motor cable - Mechanical jamming - Motor defective

Solution:

- Check motor’s type plate - Check parameters (see MU parameters) - Check the motor cable (Thermistor cabling must be shielded) - Check motor and mechanics

2.2.18 Errors -51/ -52/ -53: Motor over-current

Cause: - Motor has incorrect parameters - Mechanical jamming - Motor defective

Solution:

- Check parameters (see MU parameters) - Check motor and mechanics

2.2.19 Error -54/ -55: Inverter overload

The maximum power of the inverter was exceeded. Cause:

- Inverter capacity too low for the required power - Mechanical jamming

Solution:


V1.0

Error Messages

BV89073_02_en.doc 18

- Check the load on the trolley - Check mechanics

2.2.20 Error -56/ -57: Inverter over-current

In normal mode, the output current has exceeded the inverter module’s nominal current. With automatic IxR compensation selected, an error is triggered if the current lies 200% above the nominal current parameter set for the motor. Cause:

- Defective drive motor (short to winding) - Parameter for the motor’s nominal current incorrectly set

Solution:

- Check motor - Check parameter for the motor’s nominal current (set value from

motor’s type plate)

2.2.21 Error -61: PLC command plausibility

Cause: - PLC sending simultaneous drive and convey commands - PLC sends simultaneous load and unload commands

Solution:

- Check PLC program, only one command may be received at a time

2.2.22 Error -62: PLC command without release rail

In order to work must supply (L1) on the 5th Rail / rail-sharing. Monitor-ing of this error can be selected or deselected. (See section configuration).

Cause:

- SPS gives a driving instruction although the release rail is not connected

Solution: - Check the PLC program


Error Messages

BV89073_02_en.doc 19

2.2.23 Error -63/ -64: Conveyor runtime

This error is only monitored if the corresponding software switch has been activated (see configuration section). Within a certain amount of time the trolley was not loaded or unloaded despite a pending command. The monitoring time is set via a parameter in a range of 0-32 s (see parameters section). Cause:

- Broken chain - Tipped pallet

Solution:

- Check chain - Check conveyor - Check motor action

2.2.24 Error -65/-66: Relay defect

In the controller, it is monitored whether only the particular activated re-lay is activated (checked whether it is not stuck). Cause:

- A relay reports ‘activated’ though it is not activated Solution:

- Check relay - Replace controller

2.2.25 Error -67: Soiled OLM or bar code tape

Cause: - OLM report a dirt error

Solution:

- Check OLM - Check code strip

2.2.26 Error -68: Drive position outside range

The controller software monitors whether the positions returned by the OLM lie within the allowed position range. Cause: - OLM returns an incorrect position


V1.0

Error Messages

BV89073_02_en.doc 20

- Incorrect or damaged barcode strip Solution:

- Check OLM - Check barcode strip

2.2.27 Error -69: Drive direction

This error occurs, if the driving motor is defective or turning in the wrong direction. Cause:

- The driving motor is defective - Incorrect parameters - The motor is connected incorrectly

Solution: - Check cables - Check parameters (see MU parameters)

Check if the motor is defective

2.2.28 Error -6A: Drive motor standstill monitoring

The error is output if the trolley is moving without a drive command. The range that is accepted can be adjusted by a parameter. Cause:

- Open clutch - Defective break - Wrong parameters

Solution: - Check clutch and break - Check parameters (see MU parameters)

2.2.29 Error -71 / -72: High-level stage error of inverter

The frequency inverter’s starting current was too high. Cause:

- Mechanical jamming - Failed phase at drive motor - Motor brake not released


Error Messages

BV89073_02_en.doc 21

Solution: - Check mechanics - Check cable connections to motor terminal board - Check brake

2.2.30 Error -74/ -75: Inverter over-temperature

Temperature probes for monitoring the chip temperature are integrated into the semiconductor components of the power circuit for driving the motor (skips). In particular, if it is necessary to drive synchronously over long distances, the skips can be subject to temperature increases. Cause:

- Inverter capacity too low for the required power - Inverter has incorrect parameters

Solution:

- Install an inverter of the next higher power class - Check the load on the trolley - Check parameters (see MU parameters)

2.2.31 Error -77/ -78: Chopper overload

If the controller is working in generating mode, the intermediate circuit voltage increases. If it exceeds a certain value, the intermediate circuit is discharged through a chopper resistor. Cause:

- Inverter capacity too low for the required power - Defective chopper

Solution:

- Check the load on the trolley - Replace controller

2.2.32 Error -8-: Tables CRC incorrect

A checksum (CRC) is saved with the tables in the data concentrator and in the trolley. These are compared with one another to determine any changes. Cause:

- Defective memory Solution:


V1.0

Error Messages

BV89073_02_en.doc 22

- If the error occurs repeatedly replace controller

2.2.33 Error -81: Safety relay defect

The 5th Signal Rail is switched but the internal safety relay remains active Cause:

- Incorrect positions in the system table Solution:

- Replace safety relay

2.2.34 Error -87: System table error

The trolley attempts to assign itself to a segment of the system table based on its position. If it is unable to do this within a certain window, the trolley is stopped and an error is displayed. Cause:

- Incorrect positions in the system table Solution:

- Check system table

2.2.35 Error -9-: Parameter error

Cause: - The controller is new and no parameters have been imported

yet Solution:

- Import the parameters with the MU

2.2.36 Error -91 /-92 /-94 .. /-98: Communication error

Cause: - A controller component is not registering itself on the bus - The software switch for the FAB is selected, but no FAB is con-

nected (-98) Solution:

- Check that the bus cables are securely seated


Error Messages

BV89073_02_en.doc 23

- Replace controller (component defective) - Check software switch settings

2.2.37 Error -99: Rail bus communications error

Cause: - An unregistered trolley is in the data concentrator area - A cable to the data bus is loose or unplugged from the modem - No 24-volt power supply to the data concentrator

Solution:

- Check whether all the trolleys in the data concentrator area are registered.

- Check that cabling is securely connected - Check supply voltage


V1.0

Error Messages

BV89073_02_en.doc 24

2.2.38 Error - Par

Cause: - The release code for the controller is incorrect

Solution:

- Set correct code in the parameters in the MU, and then import it into the controller (see MU parameters)

If a controller ever needs to be replaced, then while returning the control-ler, we request that you include an error description that is as accurate as possible. This will help us to minimize repair times and return the control-ler to you in the shortest possible time.


Error Messages

BV89073_02_en.doc 25

2.3 Trolley-specific error codes from the data

concentrator

There are certain error situations that the trolley controller cannot detect automatically. In these situations, the data concentrator is able to gener-ate trolley-specific error messages. These error messages are then sent in the error byte of the respective trolley to the PLC. Because the trolley con-troller itself does not detect the error, it cannot display it in the control-ler’s display.

Error

number

Meaning

88 Position not in system table

2.3.1 Message 88: Position not in system table

Cause:

- The trolley reports a position to the Data concentrator, which is not present in the system table.

- There are errors in the system table. Solution:

- Correct the system table and re-send it to the data concentra-tor.


V1.0

Parameter

BV89073_02_en.doc 26

3 Parameter

3.1 General

The parameters are used to influence the controller’s major features. The smallest possible value for a parameter is zero. The maximum possible is 65535. For some parameters, this value range has been restricted to a range of allowed values. If a value that is below the lower limit is entered for a parameter, then the minimum value for this parameter will be used. If the set value is higher than the maximum permitted value, then the maximum permitted value will be used. Despite these limitations, changes to the parameter settings should be made only if their effect can be estimated.

3.2 Parameter overview

No. Name Value Unit Meaning 1 T0 ms Delay on start 2 T1 ms/Hz Acceleration ramp of drive motor empty 3 T2 ms/Hz Decceleration ramp of drive motor empty 4 T3 ms/Hz Acceleration ramp of drive motor full 5 T4 ms/Hz Decceleration ramp of drive motor full 6 BOL 1/10Hz Frequency open brakes of drive motor empty 7 BCL 1/10Hz Frequency close brakes drive motor empty 8 BOV 1/10Hz Frequency to open brakes of drive motor full 9 BCV 1/10Hz Frequency to close brakes of drive motor full 10 InD 100mA Nominal current of drive motor 11 M1D % IxR compensation of drive motor 12 M2D Hz Cutoff frequency of drive motor 13 M3D % IxR compensation of drive motor at VSF 14 M4D Hz Cutoff frequency of drive motor at VSF 15 GED cm/min Speed at 50Hz drive motor 16 SC1 cm/kinc Scaling position encoder 17 G %/Inc Servo resolution * 18 Gmn % Servo amplification * 19 ABS servo regulation max regulation fault * 20 CNF Configuration OLM 21 VSF cm/min Save speed 22 ACL xm/s^2 Positioning ramp empty 23 ACV xm/s^2 Positioning ramp full


Parameter

BV89073_02_en.doc 27

No. Name Value Unit Meaning 24 Win mm Positioning window on movement 25 TL1 mm Positioning window on stand still 26 TL2 mm Max. way backward forpositioning 27 Win mm Slow drive windows empty 28 Win mm Slow drive windows full 29 CNF Configuration Distance control 30 ABA mm Stopping distance 31 FzL mm Length of vehicle 32 ACA xm/s^2 Ramp for distance control 33 FST mm Standstill tolerance 34 TSM ms Time delay to speed control error 35 T6 ms/Hz Acceleration ramp conveyor motor 36 T7 ms/Hz Decceleration ramp conveyor motor 37 BOF 1/10Hz Frequency to open brakes of conveyor motor 38 BCF 1/10Hz Frequency to close brakes of conveyor motor 39 Inf 100mA Nominal current of conveyor motor 40 M1F % IxR compensation of conveyor motor 41 M2F Hz Cutoff frequency of conveyor motor 42 GEF xm/min Speed at 50Hz conveyor motor 43 VF0 xm/min Slow speed of conveyor motor 44 VF1 xm/min Fast speed of conveyor motor 45 T8 ms Maximum Runtime conveyor motor 46 T11 ms Minimum Runtime conveyor motor 47 T12 ms Time to change in slowly 48 T13 ms Delay stop loading 49 T14 ms Waiting time “conveyor empty” 50 T9 ms Reserved 51 T10 ms Reserved 52 CNF Reserved 53 T5 ms Waiting time after stop button 54 CNF Configuration stop button 55 CNF Configuration stop button Lamp 56 Cun Configuration Nominal voltage 57 CZF kHz+1 Intermediate circuit frequency Drive 58 PAR Release code of control box 59 CNF Configuration remote control 60 CCl Vacuum cleaner Configuration 61 T15 ms Vacuum cleaner overrun time 62 tst Test outputs

*Not used in this Project


V1.0

Parameter

BV89073_02_en.doc 28

3.3 Parameter descriptions

3.3.1 Start delay [T0]

During this time, all the controller components are contacted and initial-ized. During the start delay, error messages are suppressed. Especially when external components are used (OLM, FAB, Extension Box etc.), it should be ensured that the power supply is setup, the participant has reg-istered on the bus and its current status (inputs, position etc.) is evaluat-ed. If the configured time is too short, the controller will receive various error messages each time it is switched on, which can simply be acknowl-edged. The start time must be bigger than 5,5 s. The OLM need this time for the initialization.

3.3.2 Acceleration and braking ramps [T1-T4/T6/T7]

These ramps specify the step-width for the frequency change, if the de-sired frequency changes. They considerably influence the trolley’s drive pattern. (Breaking and acceleration distances) In the interest of careful operation of the controllers, the ramps should not be set as steep as pos-sible, rather as steep as necessary. The figure below serves to illustrate this. It shows an acceleration ramp of 10 ms/Hz.

3.3.3 Speed factor [GED / GEF]

This factor specifies the speed at which the trolley drives at 50 Hertz. It depends on the rated motor speed, the diameter of the drive wheel, and the transmission ratio. In particular, the speed factor for the drive gear must be determined accurately. The factor is taken into the calculation of the current position during incremental counting and is determined for controlling the synchronous drive. The factor can be determined in the following manner.

min/**

Uinnmmindi

dnGED

π=

Frequency

Time [ms]

[Hz]

50

500


Parameter

BV89073_02_en.doc 29

The result gives the speed factor in mm/min. To get the value in cm/min it must divided by 10 If a different scaling is desired, the units must be changed accordingly (possibly using correction factors). The value determined in this way can now be entered into the MU as the speed factor value and fed into the controller.

3.3.4 Scaling of position sensor [SC1]

This specifies the resolution used by the positioning system. The scaling uses the relation “way/1000incr”. At 1000 mm/kincr, the position can be resolved to exactly 1 mm. If the speeds are specified in cm/min, the scal-ing must be specified in 100 cm/kincr. CRU Unit Speed at 50Hz (GEX) Value PLS3 + DLS2 cm/min 200 PLS3 mm/min 2000 PLA14 cm/min 100 PLA14 mm/min 1000 OLM in cm cm/min 100 OLM in mm mm/min 1000 OLM in 0,1 mm cm/min 10 OLM in 0,1 mm mm/min 100

3.3.5 IxR compensation [M1D/M3D/M1F]

This parameter should be determined with the automatic IxR measure-ment (see SW switch description). It influences the modulation curve depending on the frequency. General explanation of the IxR compensation using an example of a con-figured IxR compensation of 0 % and 10 %:

Frequency

100 % modulation

IxR-Compensation = 10 %

IxR-Compensation = 0 %

Cut-off fre-


V1.0

Parameter

BV89073_02_en.doc 30

If the drive seems to lack power, one can attempt to make up for this with a higher IxR compensation. If the IxR compensation is set too high this leads to motor heating!

3.3.6 Cut-off frequency [M2D/M4D/M2F]

This specifies the frequency at which 100 % modulation is reached. (See IxR compensation example.) It is either included in the motor’s data sheet (operating with frequency inverter) or is determined by the manner in which the motor is connected. Delta motors: 87 Hz Star motors: 50 Hz

3.3.7 Nominal current motor [InD/InF]

Here you need the nominal current from the type plate of the motor. If the motor current exceeds 140% of the nominal current, the trolley stops with a fault message.

3.3.8 Configuration of OLM [CNF]

Value Function

0 Operation without special functions +1 Position resolution 0.1mm1 +2 Invert counting direction +4 Controller saves a variable reference value2 +8 Calculate reference value at switching edge of a reference

initiator2 +16 Allow for position overrun in reference value2 +32 Error in message from encoder +64 Error in plausibility of encoder position2 +128 Error in area of encoder position² +256 Error in speed monitoring +512 Error in direction monitoring +1024 Error in stationary monitoring +2048 Referencing is done externally2 1 Resolution in this project 1mm!

2 Not used in this project


Parameter

BV89073_02_en.doc 31

3.3.9 Safe speed [VSF]

This parameter specifies the speed at which the trolley drives, when the system controller does not send the bit for the release of segment-based speeds.

3.3.10 Positioning ramp [ACL/ACV]

The positioning ramp differs from the braking ramp or acceleration ramp. The progress of the ramp is not linear, but drops severely at the beginning of the positioning, and trails off flatly towards the end. The shape of this ramp enables the speed to be reduced quickly and the exact positioning to be executed towards the end.

3.3.11 Positioning window of Drive [WIN]

This value sets the permissible deviation between the current trolley posi-tion and the required stopping position and nevertheless a message that the trolley is positioned is sent.

3.3.12 Positioning window of standstill [TL1]

This value sets the permissible deviation between the current trolley posi-tion and the required stopping position. It nevertheless sends a message that the trolley is positioned. This parameter is active only if the trolley is stationary and the inverter is off.

3.3.13 Tolerance [TL2]

If a trolley has driven past its stopping position, then up to a certain dis-tance from this position it can attempt to reach the position by driving backwards. The tolerance parameter sets the area in which this reverse drive may take place.

Destination position

Positioning window

Monitoring

Tolerance

Drive direction


V1.0

Parameter

BV89073_02_en.doc 32

3.3.14 Slow drive empty / full window [WIN]

It specifies the area in which the trolley drives at minimal speed while po-sitioning. A distinction is made between empty and full trolleys. The size of the window depends on the mechanical conditions of the trolley. It must be dimensioned such that the trolley does not overshoot its position during the positioning. In case of conveyors without sensors, only the parameter “slow drive win-dow full” is used.

3.3.15 Configuration distance regulation [CNF]

Value Function 0 Distance maintaining without regulation ramp � full speed

until stop distance 1 Distance maintaining with regulation ramp � reducing speed

until stop distance +2 higher speed to close gaps (when the

function is enabled in system table and the gap is smaller than Parameter “trolley length”)

Only with function 1 and synchronous drive

+4 Given distance is drive distance (nor-mally it is the stopping distance)

+8 Regulation with hysteresis +16 Not used +32 Not used +64 Compensation for driven distance

since the last distance value. Only active with asynchronous drive

128 No distance maintaining

3.3.16 Stopping distance [ABA]

It sets the distance between two trolleys. The distance should be dimen-sioned such that there are no contacts.

3.3.17 Ramp distance regulation [ACA]

For keeping the stopping distance the control box uses a calculation, which works similar to the positioning routine.

Trolley 1 Trolley 2 Stopping distance


Parameter

BV89073_02_en.doc 33

The deceleration way is calculated by actual speed and ramp. This way is added to the stopping distance.

3.3.18 Trolley length [FzL]

To ensure correct operation, it is necessary to determine this parameter very precisely. Along with the stopping distance parameter (ABA), it sig-nificantly influences the calculation of free path and distance maintenance.

3.3.19 Frequency for releasing or applying brakes

[BOx/BCx]

If a trolley must begin drive on upward slopes, then it makes sense to ap-ply current to the motor a bit before releasing the brake. This parameter sets the frequency to drive the motor, to enable the release of the brake. The reverse case is the frequency at which to pre-apply the brake, mean-ing if the frequency falls below the set value, then the brake is applied. Thus it is also possible to stop at an exact point even on upward slopes.

3.3.20 Standstill tolerance [FST]

The parameter specifies the maximum movement of a trolley without a drive command. If the movement exceeds the value of this parameter an error is given.

3.3.21 Time delay to speed control error [TSM]

The parameter specifies the time delay for drive speed error.

3.3.22 Timeout conveying [T8]

If a convey command is pending for longer than this period of time, the error message “conveyor running time” will be generated. The running time will not be monitored, if the software switch SW3 is set [-].

3.3.23 Minimum runtime [T11]

The parameter specifies the minimum time the conveyor should have run before the ‘empty’ status can be set.


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Parameter

BV89073_02_en.doc 34

3.3.24 Time to conveyer slow [T12]

This parameter specifies a time delay for changing from fast to slow speed. The time starts if the palette reaches the stop light barrier of the opposite site to the actual conveying direction.

3.3.25 Delay stop loading [T13]

This parameter specifies how long the conveyor motors must continue to run if the pallet has reached the stop light barrier.

3.3.26 Waiting time “conveyor empty” [T14]

This parameter specifies how long the conditions for an empty conveyer must be given before the control box is sending the status empty.

3.3.27 Waiting time after releasing stop button [T5]

If the stop switch is activated and released again, then the trolley is once again set in motion after this time expiries.

3.3.28 Sequence stop button configuration [CNF]

Value Functionality

0 Not present 1 Stop without error message to master 2 Stop with error message to master 3 Switched stop without error message to master 4 Switched stop with error message to master +128 Activation of stop button initialized the conveyer

The sequence stop also resets all errors.

3.3.29 Signal lamp configuration [CNF]

Set value Functionality 0 Normally off, flashing on error, on during sequence stop 1 Normally on, flashing on error, slowly flashing during se-

quence stop

3.3.30 Configuration of vacuum cleaner [CCl]


Parameter

BV89073_02_en.doc 35

Depending on the requirement, the vacuum cleaner can be configured in its function.

Value Function

0 No vacuum cleaner 1 Activation during motor running and overrun time T15 2 Activation during motor running +64 During the servo control, the vacuum cleaner remains off * +128 During the manual mode, the vacuum cleaner remains off

*Not used in this project

3.3.31 Runtime cleaner after stop of trolley [T15]

In some modes the cleaner has to run longer than the drive motor.

3.3.32 Rated voltage [CUN]

Value Mains voltage

0 480V 1 460V 2 440V 3 420V 4 400V 5 380V 6 360V 7 340V 8 320V 9 300V 10 280V 11 260V 12 240V 13 220V 14 60V 15 40V


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Parameter

BV89073_02_en.doc 36

3.3.33 Intermediate circuit frequency [CZF]

Value Intermediate circuit frequency

3 4kHz 4 5kHz 5 6kHz 6 7kHz 7 8kHz 8 9kHz 9 10kHz 10 11kHz 11 12kHz 12 13kHz 13 14kHz 14 15kHz 15 16kHz

3.3.34 Release number [PAR]

Before you can work with the controller, you must set the parameters ac-cording to the operating conditions of your installation. To make the controller ready for operation, set the “Key” parameter to the value: 8231.

3.3.35 Offset [Off]

If higher trolley numbers are required than the number that can be set with the FAB (max. 255), then an offset can be set with this parameter. This is added to the number set by the FAB to give the resulting trolley number. This parameter is only valid when FAB is used! (FAB selected – see

following section)

3.3.36 Configuration test outputs

Only for testing do not set this parameter for normal operation!

Bit 0…7 sets the outputs 0…7 of the ini6012-1 Bit 8…13 sets the outputs of the ini6012-0 Bit 14,15 sets the outputs of the ini6030 X7_5 & X10_5 Value Meaning 0 The outputs are set by software


Parameter

BV89073_02_en.doc 37

1 Inverter release 2 Relay Q1 +(drive motor) 4 Relay Q2 +(conveyor 1 motor) 8 16 Enable PKR 32 Enable SICK 64 128 256 512 1024 2048 4096 8192 16384 X7_5 Error lamp 32768 X10_5 Vacuum cleaner

3.3.37 Configuration remote control [CNF]

The function of the remote control can be parameterized in a range of possibilities. Value Meaning 0 No special function 1 � Drive forward with V14 and positioning 2 �� Drive forward with V15 and positioning 64 Change direction of conveyer 1) 128 Change direction of drive 1)

Combination of the values is possible.

1) Only in Hand mode


V1.0

Configuration

BV89073_02_en.doc 38

4 Configuration

4.1 General

The Configuration helps in selecting or deselecting particular functions in the controller software. There are up to 16 Configuration switches sup-ported [SW1…16]. They will be transmitted to the controller along with the parameters.

4.2 Configuration overview

Bit Name Meaning 2^15 Motor tem-

perature [+] Motor temperature monitoring selected [-] Motor temperature monitoring deselected

2^14 Auto IxR [+] IxR compensation – automatic measurement se-lected

[-] IxR compensation – automatic measurement dese-lected

2^13 SW 14 2^12 No error

display [-] Error-code display selected [+] Error-code display deselected

2^11 Uncondi-tional man-ual mode

[+] Unconditional manual mode [-] Conditional manual mode

2^10 Error if au-tom. backw.

[+] Error message on backward drive (Automatic) [-] No error message on backward drive (Automatic)

2^9 Plausibility monitored

[+] PLC Plausibility enabled [-] PLC Plausibility disabled

2^8 Error -62 [+] Error -62 is monitored [-] Error -62 is not monitored

2^7 Nonequiva-lence bypass safety circuit

[+] enabled [-] disabled

2^6 SW 7 2^5 SW 6 2^4 Invert Con-

veyer motor direction

[+] Invert conveyer motor direction [-] Normal conveyer motor direction

2^3 FAB [+] FAB available [-] FAB not available; trolley number must be set via

MU


Configuration

BV89073_02_en.doc 39

2^2 Overrun stop pos

[+] Stop position overrun monitored [-] Stop position overrun is not monitored

2^1 SW2 [+] Conveyor Empty flag delayed

2^0 Profile moni-tored

[+] Profile is monitored [-] Profile is not monitored

1Not used in this project

4.3 Description

4.3.1 Motor temperature

If activated the temperature of the connected motor is monitored. If the temperature is too high (or the motor is not properly connected) a error is generated.

4.3.2 IxR compensation measurement by the controller

4.3.2.1 Preconditions

- The appropriate parameter for the motor’s rated current (GRx)

must be set to the rated current (can be read from the motor’s type plate).

- To take the measurement, activate the corresponding display mode of IxR compensation of the respective motor.

- Preset the appropriate parameter Mx for motor IxR compensa-tion to a value that approximately corresponds to the required IxR compensation.

- Recommended starting value: 10%

4.3.2.2 Operation:

Before the drive begins, the inverter generates a voltage corresponding to 2/3 of the set IxR compensation with a frequency of 0 Hz. This voltage value is then increased (by internally increasing the configured IxR com-pensation) until the motor current reaches the parameter setting for the rated motor current. Using the IxR compensation attained at that mo-ment, the motor begins drive in accordance with the given drive com-mand. If the voltage increases such that it equals 200 % of the set IxR compen-sation and the motor current has not reached the rated motor current, then the inverter outputs the error “Inverter over current”.


V1.0

Configuration

BV89073_02_en.doc 40

As long as the corresponding software switch remains selected, this measurement is repeated for each new drive command before the motion begins. 4.3.2.3 Follow-up action:

After successfully measuring the IxR compensation, the displayed value must be entered as the new parameter Mx for the IxR compensation us-ing the MU.

4.3.3 No error display

As per standard, the error messages superimpose over the ‘normal’ dis-plays. To make a diagnosis with the help of displays in the event of error, the error displays can be deactivated with the help of the software switch. This does not deactivate the error evaluation! After completion of the work, the error messages should necessarily be reactivated.

4.3.4 Unconditional manual mode

In absolute manual operation, all software limit switches and most of the error evaluations are deactivated and it is possible to move a trolley de-spite error messages. All hardware limit switches (emergency end posi-tions) continue to be active.

4.3.5 Plausibility monitored

With this switch, the plausibility analysis of the PLC command can be acti-vated or deactivated.

4.3.6 Error -62

This switch activates the monitoring of error -62.

4.3.7 Invert Conveyer motor direction

If selected the transport direction for unload/ upload is inverted.

4.3.8 Monitoring speed

This switch activates the monitoring of drive speed.


Configuration

BV89073_02_en.doc 41

4.3.9 FAB

If this option is activated, then the controller accepts the number set in FAB as its current trolley number. If the option is active and no FAB is connected, then a communication error is displayed. If this option is deactivated, the communication is not monitored and the trolley number must be set with the MU.

4.3.10 Overrun stop position

This setting activates or deactivates the error -33.

4.3.11 Profile is monitored

If the switch is activated, the conveyor profile is monitored based on the load state and the load state is displayed in the controller’s display.


V1.0

Tables

BV89073_02_en.doc 42

5 Tables

The tables in the MU correspond to the system table in the following man-ner: Set MU = system-table index + 1

5.1 Speed table

A correct speed table is absolutely necessary for trouble-free op-

eration of the trolleys!

Set Index Value: Valid for:

1 0 2 1 3 2 4 3 5 4 Automatic Fast Speed Driving 6 5 7 6 8 7 9 8 10 9 11 10 12 11 Min speed 13 12 Service mode slow 14 13 Service mode fast 15 14 Manual mode with remote control slow 16 15 Manual mode with remote control fast

All Speeds must be calculate in cm/min


Tables

BV89073_02_en.doc 43

5.2 Clearance table

Set Index Value: Valid for:

1 0 Default 2 1 3 2 4 3 5 4 6 5 7 6 8 7 9 8 10 9 11 10 12 11 13 12 14 13 15 14 16 15


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Display

BV89073_02_en.doc 44

6 Display

6.1 General

Using the various display modes, a very accurate diagnosis of the control-ler state can be carried out. The display consists of a four-digit display in the controller. If it is necessary to carry out a diagnosis for a pending er-ror, then the error display must be deselected (see Configuration), since it permanently overwrites the normal display.

6.2 Display modes

0: Frequency in Hz with preceding sign 1: Motor current in 100 mA unit W 4: Chip temperature [°C] 5: Intermediate circuit voltage in volts 6: Motor temperature unscaled 7: Inverter power rate 8: Display of inverter control commands

Display Meaning

0001 Selection of parameter set 0002 Selection of parameter set 0004 Selection of parameter set 0008 Monitor I²t 0010 Monitor Overcurrent 0020 Monitor intermediate circuit voltage 0040 Compensate intermediate circuit voltage 0080 No clipping 0100 Neg. half-wave report 0200 Pos. half-wave report 0400 Release brake 0800 Servo drive 1000 Hand-held mode (restricted error evaluation) 2000 Initialize servo trip 4000 Activation command 8000 Release inverter

9: Inverter speed presetting 10: Display IxR compensation [1/10 %]


Display

BV89073_02_en.doc 45

11: Display inverter status

Display Meaning

01 Phase failure 02 Inverter drive release 04 Hardware lock released 08 Load contactor switched on / intermediate circuit loaded 10 Inverter running 20 Parameters OK 40 Inverter warning 80 Inverter error pending

12- 18 Diagnosis repair (LJU - internal) 17: Servo trip 18: Servo modulation (amplitude) 19: Current drive speed 20: Frequency in Hz with preceding sign 21: Motor current in 100 mA unit W 24: Chip temperature [°C] 25: Intermediate circuit voltage in volts 26: Motor temperature unscaled 27: Inverter power rate 28: Display of inverter control commands

Display Meaning

0001 Selection of parameter set 0002 Selection of parameter set 0004 Selection of parameter set 0008 Monitor I²t 0010 Monitor Overcurrent 0020 Monitor intermediate circuit voltage 0040 Compensate intermediate circuit voltage 0080 No clipping 0100 Neg. half-wave report 0200 Pos. half-wave report 0400 Release brake 0800 Servo drive 1000 Hand-held mode (restricted error evaluation) 2000 Initialize servo trip 4000 Activation command 8000 Release inverter

29: Inverter speed presetting 30: Display IxR compensation [1/10 %]


V1.0

Display

BV89073_02_en.doc 46

31: Display inverter status

Display Meaning

01 Phase failure 02 Inverter drive release 04 Hardware lock released 08 Load contactor switched on / intermediate circuit loaded 10 Inverter running 20 Parameters OK 40 Inverter warning 80 Inverter error pending

32-34, 36 Diagnosis repair (LJU - internal) 38: Input ports, initiator board 1 (6030)

Display Terminal Meaning

0001 X5/ 4 0002 X6/ 2 0004 X6/ 4 0008 X9/ 4 0010 X7/ 2 0020 X7/ 4 0040 Initiator board fuse 0080 Monitor output ports for short circuit 0100 X8/ 2 0200 X8/ 4 Sequence stop button 0400 X8/ 5 0800 X10/ 4

39: Output ports, initiator board 1 (6030)


01 X7/ 5 Signal lamp sequence stop 04 X10/ 5 Cleaner


Display

BV89073_02_en.doc 47

40: Input ports, initiator board 1 (6012)


0001 X15/ 10 Reserve 0002 0004 0008 0010 0020 0040 Initiator board fuse 0080 Monitor output ports for short circuit 0100 (Q1_E1) Monitoring Q1 (option)1) 0200 (Q1_E2) Monitoring Q2 (option)1) 0400 X15/ 8 Reserve 0800 X15/ 9 Reserve

1) Function not used in this project



01 02 04 08

42: Input ports, initiator board 2 (6012)


0001 X15/ 7 Light barrier 5 conveyor 2 speed 0002 X15/ 8 Light barrier 6 gap control conveyor 2 0004 Q1 /42 (SICK NO) 0008 Q2 / M1 (PKR) 0010 X16/ 5 Status Safety Switch inactive (NC) 0020 X16/ 6 Status Safety Switch active (NO) 0040 Initiator board fuse 0080 Monitor output ports for short circuit 0100 X15/ 3 Light barrier 1 gap control conveyor 1 0200 X15/ 4 Light barrier 2 conveyor 1 speed 0400 X15/ 5 Light barrier 3 conveyor 1 stop 0800 X15/ 6 Light barrier 4 conveyor 2 stop


V1.0

Display

BV89073_02_en.doc 48



01 Inverter 1 release (SICK) 02 Relay Q1 +(drive motor) 04 Relay Q2 +(conveyor 1 motor) 10 K1_A1 (SICK) 20 K2_A2 (PWR) 44: Inputs of brake voltage monitoring (BÜ-1)


01 B1 Brake activation inverter 1 (drive / conveyor 1 motor) 02 B2 Brake activation Q1 (drive motor) 04 B3 Brake activation Q2 (conveyor 1 motor) 08 B4 Brake activation inverter 2 (conveyor 2 motor)

46: OLM status

Display Meaning

0002 Temperature 0008 No barcode 0010 Error distance to code strip 0020 Soiled OLM 0080 OLM overflow 47: OLM dirty status 48: OLM position (unfiltered position sent directly from the OLM) 49: Trolley number (sent by Prodat) 50: Infrared command (manual remote control) 51: Drive commands

Display Meaning

2 Hand mode slow forward 3 Hand mode slow backward 4 Hand mode fast forward 5 Hand mode fast backward 6 Setup mode forward 7 Setup mode reverse 10 Automatic forward or reverse

52: Drive flags


Display

BV89073_02_en.doc 49

Display Meaning

01 Drive release (MS_Lauf) 02 Direction flag (MS_Dir) 04 Positioning 08 10

53 & 54 : Conveyor commands 1)

Display Meaning

2 Hand mode slow loading 3 Hand mode slow unloading 4 Hand mode fast loading 5 Hand mode fast unloading 6 Service mode loading 7 Service mode unloading 10 Automatic loading 11 Automatic unloading

1) Direction for loading unloading depends on Config_SW5

55: Conveyor flags (Hex)

Display Meaning

01 Conveyor1 running 02 Conveyor1 direction 10 Conveyor2 running 20 Conveyor2 direction

56: Data concentrator number 57: Trolley number (controller) 58: Conveyor load status

Display Meaning

01 Conveyor 1 free 02 Conveyor 1 occupied 04 Conveyor 1 loading 10 Conveyor 2 free 20 Conveyor 2 occupied 40 Conveyor 2 loading 60: Absolute trolley position in the installation (x_pos_ist) 62: Free path in direction of drive (x_freier_weg) 64: Next target for trolley positioning using system table (x_atab_ziel) 65: Trolley target position (x_ziel_pos)


V1.0

Display

BV89073_02_en.doc 50

66: Difference from trolley target position (anz_pos_diff) 67: Last absolute trolley position (used when the controller is switched on

again) 70: Position point of the Routing table 71: Configuration for the actual position point 72: Next positioning point in the Routing table 73: Configuration for the next positioning point in the Routing table 74: Actual value routing pointer. 75: Incrementally counted trolley position (pos_speed) 76: Number of data sets used in the routing table 77: Number of targets 78: Index of the routing table 80: Target position 90: Number of possible sets in the current system table 91: Current value of the system table pointer (processed entry in the sys-

tem table) 92: Next positioning point in the system table 93: First position of the current segment (absolute) 94: Last position of the current segment (absolute) 95: First position of the “Next 1” segment in the system table 96: Last position of the “Next 1” segment in the system table 97: First position of the “Next 2” segment in the system table 98: Last position of the “Next 2” segment in the system table 99: First position of the “Prev 1” segment in the system table 100: Last position of the “Prev 1” segment in the system table 101: First position of the “Prev 2” segment in the system table 102: Last position of the “Prev 2” segment in the system table 103: Number of the “Next 1” segment in the system table 104: Number of the “Next 2” segment in the system table 105: Number of the “Prev 1” segment in the system table 106: Number of the “Prev 2” segment in the system table 110: Current position point 115: Status report A

Display Meaning

01 Vehicle requests table comparison 02 Vehicle in position 04 Speed Conveyor 1 (Slow / Fast) 08 Message see below 10 20 Error has occurred 40 80 New destination


Display

BV89073_02_en.doc 51

10 08 Remark

1 1 Conveyer 1 motor is running 1 0 Conveyer 1 is occupied 0 1 Conveyer 1 empty 0 0 Conveyer 1 undefined

116: Signal flags (Rotating Box)

Display Meaning

01 General error 02 Drive motor is running 04 State of bypass switch 08 Stop due 5th rail 10 Stop due stop button 20 Stop due to anti-collision initiator 40 Stop due to distance maintenance 80 Manual operation (IR- remote operation)

117: Actual Cycle-index DKT-> Trolley 118: Actual Cycle-index Trolley _ DKZ 119: Cycle time of the rail-bus connection Regarding the following points, see also the rail-bus system speci-

fications!

120: current control commands A & B (display: BB AA see following points)


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Display

BV89073_02_en.doc 52

121: Control command A

Display Meaning

01 Speed select 02 Speed select 04 Bypass positioning 08 Error Reset 10 Conveyor release 20 Drive release 40 80 Automatic release

122: Control command B

Display Meaning 01 Forward drive 02 Drive reverse 04 Conveyer 1 load 08 Conveyer 1 unload 10 Conveyer 2 load 20 Conveyer 2 unload 40 Fast speed 80

127: Last received control command A (used for drive without communi-cation) 128: Last received control command B (used for drive without communi-cation) 129: Last calculated free route (used for drive without communication)

6.3 Other displays

Dot in the 1st position from the left: No free path in direction of drive Dot in the 1st (flashing) : Vehicle in position Dot in the 2nd position from the left: IR communication Dot in the 3rd position from the left: OLM position OK Dot in the 4th position from the left: Tables loaded Left two positions in display flashing: Hx (manual mode) 1) Left two positions “o” on the 1st position from the left: Conveyor 1 occupied “_” on the 1st position from the left: Conveyor 1 empty “U” on the 1st position from the left: Conveyor 1 unknown occupancy


Display

BV89073_02_en.doc 53

“o” on the 2st position from the left: Conveyor 2 occupied “_” on the 2st position from the left: Conveyor 2 empty “U” on the 2st position from the left: Conveyor 2 unknown occupancy

Caution! The load status is only shown if profile monitoring is activated (see configuration section).


V1.0

FB-606 remote control

BV89073_02_en.doc 54

7 FB-606 remote control

7.1 General

On pressing a button, the red LED must flash quickly. If not, the remote control is working with an incorrect infrared protocol. To switch to remote control mode, the buttons ��must be pressed simultaneously until the LED flashes quickly. If the LED glows steadily, then the battery is empty.

7.2 Button functions (Standard IR Konfiguration)

The remote control supports three operating modes “H1”,” H2” and “H3”. Switching throw the Modes can be done by pressing the “�” key again af-ter entering the hand held mode.

Button Functionality � Select Hand-held mode # Normal mode � Convey to right slow 1) Convey to left slow 1) �� Convey to right fast 1) � Convey to left fast 1) � Forward drive slow � Reverse drive slow �� Forward drive fast �� Reverse drive fast

1) Accessed conveyor depends on Hand held mode

The three modes differs only which conveyor is accessed by pressing con-vey commands. In mode “H1” conveyer 1 is under control of the remote control. In mode “H2” conveyer 2 is under control of the remote control. In mode “H3” both conveyers 1 & 2 executes the requested convey com-mands. If all buttons on the remote control are released, the last remote control command continues to be processed in the controller for 800 ms. If you want the controller to stop immediately, you have to press the star but-ton.


MU705

BV89073_02_en.doc 55

8 MU705

The software in the MU 705 is organized into menus. A menu item is selected by pressing the corresponding number or by the arrow keys and Enter. You can switch to the next higher menu with the ‘Esc’ key. The MU can be switched off by a long press of ‘Esc’ key. The most important menu commands and paths are as follows: Main menu 1. Parameters

1.1. Write data: To transmit the parameters, the controller and the MU must be set to the same parameter set.

1.2. Read data: Before reading the parameters, it is checked if the parameter set matches.

1.3. Change data: Use the �� keys to switch between the various pa-rameters.

1.3.1. Data: The values for the parameters can be entered here. 1.3.2. Configuration: Different functions can be selected and de-

selected here. 1.3.3. Type: If it is an MU for multiple controller types, these can

be selected here. 1.4. Verify data: Here, the parameters are read out of the controller

and compared with the data in the MU. The checksum is calculat-ed and displayed together with the checksum of the parameters in the MU. This function serves to check whether the parameters in the MU and those in the controller are identical. If they aren’t equal you can search for the values of the different parameters by pressing ‘F1’ (� view).

2. Test 2.1. PCM signal: 1 2.2. Remote control: The MU must be pointed directly at the controller

to perform all the operations described here. (Distance approx. 30 cm)

- The display shows which keys are used for the functions of the remote control. Refer to chapter: FU706 � Function of the keys.

- Only one key can be pressed at the time. Key combinations are realized by saving ‘�’. (When the display shows a Mark at ‘�’, the MU uses the combined remote commands)

2.3. IR test: The MU shows the received Signal from another LJU IR device that is in range.

2.4. BIOS Exceptions: Only LJU internal! 2.5. Error log: The LJU Box saves a log of the last 29 faults. 2.6. Memory: Only LJU internal!


V1.0

MU705

BV89073_02_en.doc 56

3. Destination/number:

3.1. Tag: A destination can be read or written here. 3.2. Number: The trolley number can be read or written here. Warn-

ing! If the FAB is activated (see Configuration), the number of the FAB is used!

3.3. Display: The display mode can be read or written here. 3.4. WNR/Ser-No: The plant number and the serial number of the

controller can be written here. Warning! Only LJU-internal! 3.5. HW Configuration: Only LJU internal!

With the following functions it is possible to read, to modify and again write into the various tables of the trolley. You can switch between the ta-ble records using the �� keys. 4. Tables: All tables can be read from and written to the LJU Box. they

can be checked and modified in the MU. 4.1. Some tables are defined in this menu. 4.2. Some tables are summarized in Table groups. By selecting the

Table group you are accessing the next menu level. 4.3. All tables: Here al tables can be read, written or the checksums

compared together. 5. MU Config:

5.1 Language 5.2 Switch off time 5.3 Polling delay 5.4 Display illumination

6. Information 6.1. BIOS info: Provides information about the plant number and seri-

al number of the controller and the transmission time of BIOS 6.2. USER Info: Provides information about the version number, and

the transmission time of user software 6.3. MU Info: Provides information about the version number, and the

transmission time of MU software 7. Program

7.1. Program manager: The firmware can be stored and download-ed to the LJU Box by the MU

7.2. Password: The download is restricted to instructed persons. 7.3. Memory: Only LJU internal!

More information on the MU-705 or the FB-606 has to be taken from the corresponding device operating instructions!


Display of Input Signals or Control Flags

BV89073_02_en.doc 57

9 Display of Input Signals or Control Flags

An input or flag can have one of two states: “0” or “1”. This corresponds to one digit in the binary number system. Computer technology works with bits and bytes. One bit corresponds to one binary digit. Eight bits are combined to one byte. Therefore, one byte corresponds to an eight-digit binary number: e.g. 10010111b. Conversion to a decimal number is carried out bit-by-bit using the formu-la: D = B x 2n. “n” indicates the position in the binary number. The 0 (ze-ro) position is on the right, then we count up moving to the left. The sum of all values equals the decimal number.

1 0 0 1 0 1 1 1 | | | | | | | 20-- 1 x 1 | | | | | | 21-- ------ 1 x 2 | | | | | 22-- ------ ------ 1 x 4 | | | | 23-- ------ ------ ------ 0 x 8 | | | 24-- ------ ------ ------ ------ 1 x 16 | | 25-- ------ ------ ------ ------ ------ 0 x 32 | 26-- ------ ------ ------ ------ ------ ------ 0 x 64 27-- ------ ------ ------ ------ ------ ------ ------ 1 x 128 = 151d

In the hexadecimal number system, a digit can have any one of 16 values (0 .. 9 + A.F). These represent all possible combinations of four bits. A byte can therefore be represented by two hexadecimal digits. The weight or significance of the bits is as follows:

Bit 0: 01 Bit 4: 10 Bit 1: 02 Bit 5: 20

Bit 2: 04 Bit 6: 40 Bit 3: 08 Bit 7: 80 As long as only one of these bits is active, the displayed number can be allocated directly to the input / flag belonging to it. If multiple bits are active, their weights or significance are added togeth-er. For reasons of simplicity only the lower four bits / right hex digit are shown in the following examples. Display: 9 = 1 + 8 => bit 0 and bit 3 are active Display: 7 = 1 + 2 + 4 => bit 0, bit 1 and bit 2 are active The letters A..F stand for the numbers 10 .. 15: Display: A (10) = 2 + 8 Display: d (13) = 1 + 4 + 8 Display: F (15) = 1 + 2 + 4 + 8


V1.0

Display of Input Signals or Control Flags

BV89073_02_en.doc 58

The advantage of this logic is that it is closely related to the way proces-sors operate. In this way, a substantial amount of information can be rep-resented with very little expenditure.

lju documents

Documents

description of error

hein various error correction

description ini6012

program description

table of contents

hein general entry

table of changes subject

product names