DSP3000 Expansion Unit Manual - FEC-USA

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DSP3000 Expansion Unit Manual

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About This Manual

Thank you for purchasing our Digital Servo Press DSP3000 System. This Operation Manual describes installation, wiring, handling and remedies for trouble of the Digital Servo Press DSP3000 System.

◆ Make sure that this Manual reaches persons who finally use this product.

◆ Interpret that what is not described in this Manual “cannot be carried out.”

◆ Contents of this Manual, specifications and appearance of this product may be subject to change

without prior notice due to improvements.

◆ A part or all of the content of this Manual shall not be copied without permission.

◆ Thoroughly read the “Safety precautions” at first to understand the descriptions as well as to follow

all items.

◆ Thoroughly read this Manual to fully understand the functions and performance of the servo press

and use properly.

◆ Qualified technicians shall carry out wiring and setting of parameters.

◆ Be sure to describe the following in an Operation Manual for machines using this product.

Danger because of high voltage equipment

Danger of being pinched

◆ Never carry out withstand voltage testing and mega testing for this product.

Check the following when unpacking at delivery.

◆ Has the ordered form been met ?

◆ Are the packed products sufficient? (System component specification list)

◆ Was there any damage during transportation ?

◆ Anybus is a registered trademark or trademark of HMS Industrial Networks AB.

◆ CC-Link is a registered trademark or trademark of the CC-Link Partner Association (CLPA).

◆ CompactFlash and CF are registered trademarks or trademarks of SanDisk Corporation of the U.S.

◆ Device Net and EtherNet/IP are registered trademarks or trademarks of the ODVA (Open Device Net

Vendor Association).

◆ Ethernet is a registered trademark or trademark of Fuji Xerox Co., Ltd.

◆ MELSEC-Q and GX-Developer are registered trademarks or trademarks of Mitsubishi Electric

Corporation.

◆ Microsoft Excel and Windows are registered trademarks or trademarks of Microsoft Corporation in the

U.S. and other countries.

◆ PROFIBUS-DP and PROFINET IO are registered trademarks or trademarks of the PROFIBUS

Organization. The trademarks and product trademarks of the respective companies shall be fully respected even when these are not noted in particular. Besides the above, all product names and company names mentioned in this manual are registered trademarks or trademarks of the respective companies.

Items to be followed for use

Items to be checked when unpacking

Trademarks

We hereby declare that the following product conforms with the essential health and safety requirements of EC Directives and that the product can be incorporated into end-machinery. To maintain this declaration, the product must not be put into service until the end-machinery has been declared in conformity with the provisions of the Directives.

Product : Electric Servo Press Model No. : DSP3000 Manufacturer : DAI-ICHI DENTSU LTD. Directives : Machinery Directive 2006/42/EC EMC Directive 2004/108/EC

The above product has been evaluated for conformity with above directives using the following European standards. The technical construction file (TCF) for this product is retained at the above manufacturer’s location and complies according to ANNEX Ⅶ part B. Machinery Directive EN ISO12100:2010, EN 60204-1:2006+A1:2009 EMC Directive EMI EN61000-6-4: 2007+A1:2011 EMS EN61000-6-2: 2005 Low Voltage Directive EN 61800-5-1:2007 Second Edition Safety of Machinery EN60204-1:2006+A1:2009

Introduction

CE Declaration

Safety Precautions (Please be sure to read.)

Be sure to thoroughly read this Operation Manual before use in order to use safely and correctly. Be familiar with all of the equipment knowledge, safety information and precautions before use. Safety precautions are classified into ranks of “DANGER” and “CAUTION.” Items which must be observed are described as follows in order to prevent hazards to the user and other persons and damage to property before they happen.

◆ Extent of hazards and damages which occur as a result of disregard of descriptions and improper

use are classified and described by the following indications.

Further, even items described under may lead to serious results depending on the status. All describe important meanings, therefore, be sure to observe them.

Kinds of meanings you must observe are classified by the following pictorial indications for description.

Improper handling may cause a dangerous state and the risk of

death or serious injury is assumed.

Danger of being

pinched Danger of fire

Caution of

electric shock

Grounding

Prohibition

Caution of high

temperature

Disassembly

prohibited

Compulsory

Danger of

electric shock

Caution of

fire

Improper handling may cause a dangerous state and moderate

injury or minor injury, or physical damage only is assumed.

DANGER

CAUTION

CAUTION

Safety Precautions

Never touch output axis of tool during operation. Injury may result. Make sure that a part of your body never enters into a dangerous limit of a movable part even while the equipment is at rest. The output axis of the tool may lower by some cause, resulting in injury. When carrying out maintenance or inspection, be sure to secure the output axis with a safety block to avoid lowering. Do not remove the motor or gear case of the tool. The output axis of the tool may lower, resulting in injury.

Never repair, disassemble and rework. Otherwise, injury, electric shock, fire or failure may result.

Do not use in a place where water splashes, in a corrosive atmosphere or close to an atmosphere of flammable gas. Otherwise, fire may result. Do not touch connectors while power is on or for some time after power shuts off. Otherwise, electric shock may result.

Qualified technician should carry out wiring, maintenance and inspection. Otherwise, electric shock or injury may result.

Turn off power for wiring, maintenance and inspection. Otherwise, electric shock or injury may result.

Do not damage cable, apply unnecessary force or pinch. Do not use damaged power cable. Otherwise, electric shock or fire may result. Be sure to establish third class grounding for FG terminal. Otherwise, electric shock may result. If any abnormal odor, abnormal sound or operational abnormality occurs, immediately stop operation and turn off the power. Otherwise, injury or fire may result. Install a stop device on the machine side in order to secure safety. Otherwise, injury may result. Install an emergency stop circuit on the outside in order to allow for immediate operational stop. Otherwise, injury may result. Do not get close to the machine because it may suddenly restart after recovery from instantaneous power failure. Take measures to secure safety to person even if it restarts. Otherwise, injury may result.

DANGER

Safety Precautions

Transport the product by the proper method according to its weight.

Otherwise, injury or failure may result.

Transport by ship under the following conditions.

Ambient temperature: -5C to +55C (Not frozen)

Ambient humidity: 50% RH or less (not condensed)

Packing method: Complete sealing

Rustproof measure: Apply grease or oil on tool

Otherwise, electric leakage or failure may result.

Do not grab cable or output axis when transporting the tool.


Do not grab displayer on the front panel when transporting the axis unit.

The displayer may be removed and fall.

Injury or failure may result.

Store under the following environmental condition.

Ambient temperature: -5C to +55C (Not frozen)


Atmosphere: Indoor (in a place where it is not exposed to direct sunlight)

Free from corrosive gas or flammable gas.

Free from oil mist, dust, water, salt or powdered iron.

In a place where vibration or shock does not directly transmit.


CAUTION

Transportation, storage

Safety Precautions

Securely install the tool in a place which can endure weight and maximum load at operation.


Securely install the axis unit in the control panel with the designated screws.

Otherwise, failure may result.

Use the tool and axis unit in the designated combination.

Otherwise, fire or failure may result.

Keep the axis unit the specified distance away from the inner face of the control panel and

other equipment.


Do not block the draft port of the axis unit.

Make sure that foreign matter does not intrude into the product.


Take safety measures such as a breaker or circuit protector on the power input part.


Do not use a tool or axis unit which is damaged or whose components are insufficient.

Otherwise, fire, injury or malfunction may result.

Do not climb on the product or place any heavy object on the product.


Do not give strong impacts.


Do not disconnect cables with power being ON or it may cause damages to units.

Be sure to turn the power OFF when disconnecting cables.

Carry out wiring correctly and securely.

Otherwise, injury, malfunction or failure may result.

Use with power voltage within the standard.

Otherwise, injury, electric shock, fire or failure may result.

Take sufficient shielding measures when using in the following places.

A place where noise occurs

A place where strong electric field or magnetic field occurs

A place where a power line passes in the vicinity


Installation, wiring

CAUTION

Safety Precautions

Do not operate with wet hands.

Otherwise, electric shock may result.

Do not touch radiating fin for SAN unit or motor of the tool while power is on or for some time

after power shuts off because they may be hot.

Otherwise, burn may result.

Use under the following environmental condition.

Ambient temperature: 0C to +45C (Not frozen)


Atmosphere: Indoor (in a place where it is not exposed to direct sunlight)

Free from corrosive gas or flammable gas.

Free from oil mist, dust, water, slat or powdered iron.

In a place where vibration or shock does not directly transmit.


Check and adjust each parameter before operation.

Unexpected running may occur depending on the machine.


Never carry out extreme adjustment or setting change, which may cause unstable operation.


Check that start signal is turned off and reset because the equipment may restart if resetting

is carried out while the start signal is on.

Otherwise, injury may result.

Do not turn on and off the power frequently.


Do not carry out operation which exceeds the maximum load of the tool.

Otherwise, temperature rise due to overload may reduce its life or cause breakage.

The magnetic brake is for holding, therefore, do not use for normal braking.


The magnetic brake may not hold due to expiration of its life.

Install a braking structure on the machine side to secure safety.


If any abnormality occurs, eliminate its cause to secure safety and reset, then restart.


Operation, adjustment

CAUTION

Revision History

Rev. Date Manual No. Content of Revision

5/2016 DSP3000-HW-1 Initial Release

3/2018 DSP3000-HW-1 Added CE Declaration

Table of Contents

Chapter 1: Outline

1-1. How to Use this Instruction Manual................................................................................. 1－1

1-2. Function Overview…………………………...................................................................... 1－2

1-3. Description of Functions.................................................................................................. 1－3

1-4. Precautions for Use……………………............................................................................ 1－4

Chapter 2: Specifications

2-1. Specifications.................................................................................................................. 2－1

2-1-1. Duty Cycle Calculation............................................................................................. 2－1

2-1-2. Press Controller Specifications................................................................................ 2－2

2-1-3. Fieldbus Specifications............................................................................................. 2－4

2-1-4. Expansion Unit Type……......................................................................................... 2－4

2-2. Performance.................................................................................................................... 2－5

2-3. Press Method.................................................................................................................. 2－6

2-3-1. Load Control............................................................................................................. 2－6

2-3-2. Distance Control....................................................................................................... 2－6

2-3-3. Specified Point Load Judgment................................................................................ 2－7

2-3-4. Load Rise Detection................................................................................................. 2－8

2-3-5. Specified Range Peak Load Judgment.................................................................... 2－8

2-3-6. Time Controlled Press.............................................................................................. 2－9

2-3-7. Load Drop Detection................................................................................................ 2－9

2-3-8. Load Drop Detection Point Stop............................................................................... 2－10

2-3-9. Distance Control With Load Limit............................................................................. 2－10

2-3-10. Distance Control With Load Rise Detection........................................................... 2－11

2-4. Speed Control................................................................................................................. 2－12

2-5. Judgment Operation........................................................................................................ 2－13

2-5-1. Interference Check................................................................................................... 2－13

2-5-2. Load Inhibit Check.................................................................................................... 2－13

2-5-3. Three Checks for Part.............................................................................................. 2－14

Chapter 3: System Description

3-1. Part Names..................................................................................................................... 3－1

3-1-1. Press Controller Front Panel Switches and Connectors.......................................... 3－1

3-1-2. Controller Front Panel LED...................................................................................... 3－3

3-1-3. Controller Top and Bottom Panel Switches and Connectors................................... 3－4

3-1-4. Controller Side Panel Connectors............................................................................ 3－5

3-1-5. Controller Display, Switches and LED….................................................................. 3－6

3-1-6. Expansion Unit…….................................................................................................. 3－7

3-2. Connection Diagram....................................................................................................... 3－8

3-2-1. DPS Tool.................................................................................................................. 3－8

3-2-2. DPT Tool................................................................................................................... 3－10

3-2-3. DPM Tool.................................................................................................................. 3－12

3-3. Cable Specification......................................................................................................... 3－13

Table of Contents

Chapter 4: Installation and Wiring

4-1. Installation Procedures.................................................................................................... 4-2

4-2. External Dimensions and Installation Requirements....................................................... 4-3

4-2-1. External Dimensions................................................................................................ 4-3

4-2-2. Installation Requirements......................................................................................... 4-5

4-2-3. Cable Installation Guidelines.................................................................................... 4-6

4-2-4. Considerations for Cable Trolleys............................................................................ 4-7

4-2-5. Considerations for Flexible Cable Tracks.............................................................. 4-7

4-2-6. Considerations for Cable Trays and Ladder............................................................. 4-7

4-3. Input Power Source Connection..................................................................................... 4-8

4-3-1. Motor Power............................................................................................................. 4-8

4-3-2. Control Power.......................................................................................................... 4-10

4-4. Standard I/O Connection................................................................................................. 4-11

4-5. Expansion I/O or Fieldbus Connection............................................................................ 4-11

4-5-1. Jog Mode: Timing Chart........................................................................................... 4-12

4-5-2. Sequence Mode: Timing Chart................................................................................. 4-13

4-6. Controller Switch Settings............................................................................................... 4-14

4-6-1. Press Address Switch Settings................................................................................ 4-14

4-6-2. Special Function SW1 Switch Settings.................................................................... 4-14

4-6-3. Bottom Panel SW2 Switch Settings......................................................................... 4-15

4-7. External Monitoring Output............................................................................................. 4-16

4-8. ETHERNET Interface...................................................................................................... 4-17

4-9. AUX. Interface (STOP).................................................................................................... 4-18

4-10. AXIS LINK IN/OUT Interface......................................................................................... 4-18

4-11. Standard RS232C Interface.......................................................................................... 4-19

4-11-1. Communication Specifications................................................................................4-19

4-12. Electromagnetic Brake.................................................................................................. 4-20

4-12-1. DPS Tool.................................................................................................................4-20

4-12-2. DPT Tool (DDK Model)........................................................................................... 4-21

4-12-3. DPT Tool (FEC Model)........................................................................................... 4-22

Chapter 5: Power-on and Test Run

5-1. Checks before Power ON............................................................................................... 5-1

5-2. Checks at Power ON....................................................................................................... 5-1

5-3. Initial Setting Values........................................................................................................ 5-2

5-4. Checks after Power ON.................................................................................................. 5-2

5-5. Test Run.......................................................................................................................... 5-3

Chapter 6: Operations

6-1. RUN Mode...................................................................................................................... 6-1

6-1-1. Indication.................................................................................................................. 6-1

6-1-2. Mode Change........................................................................................................... 6-2

6-2. BYPASS Mode................................................................................................................ 6-8

6-2-1. Mode Change........................................................................................................... 6-8

6-2-2. Set Value Selection Mode........................................................................................ 6-8

6-2-3. Set Value Editing Mode............................................................................................ 6-9

6-2-4. Parameter Copy....................................................................................................... 6-10

Table of Contents

Chapter 7: Parameter Setup

7-1. Parameter Structure........................................................................................................ 7-1

7-2. System Parameters......................................................................................................... 7-2

7-2-1. Press Controller Information 1.................................................................................. 7-5

7-2-2. System Parameters.................................................................................................. 7-7

7-2-3. Connected Tool Settings...........................................................................................7-10

7-2-4. Press Controller Information 2.................................................................................. 7-11

7-2-5. Expansion Unit 1 Information................................................................................... 7-12

7-2-6. Expansion Unit 2 Information................................................................................... 7-14

7-2-7. Touch Panel............................................................................................................ 7-15

7-3. Press Parameters......................................................................................................... 7-16

7-3-1. Press Mode............................................................................................................ 7-17

7-3-2. Load, Distance, Position, Time, Speed.................................................................... 7-22

7-3-3. Example of setting procedures of parameters.......................................................... 7-28

7-3-4. Example of setting for Home Return by Distance Control........................................ 7-31

Chapter 8: Maintenance

8-1. Items to be Checked....................................................................................................... 8-1

8-1-1. Tools (Motor Part)..................................................................................................... 8-1

8-1-2. Cables...................................................................................................................... 8-1

8-1-3. Controller.................................................................................................................. 8-1

8-2. Servo Press Maintenance............................................................................................... 8-2

8-2-1. DPT Tool................................................................................................................... 8-2

8-2-2. DPM Tool.................................................................................................................. 8-6

8-2-3. DPS Tool...................................................................................................................8-8

8-2-4. Calibrate Load Cell................................................................................................... 8-11

Chapter 9: Troubleshooting

9-1. Abnormal Operation Indications...................................................................................... 9-1

9-2. Details of Abnormality / Cause and Countermeasures................................................... 9-2

9-2-1. A.01: Load Cell Error................................................................................................ 9-2

9-2-2. A.03: Pre-amplifier Error........................................................................................... 9-3

9-2-3. A.04: System Memory Error..................................................................................... 9-3

9-2-4. A.05: Servo Reply Error........................................................................................... 9-4

9-2-5. A.06: Servo Type Error............................................................................................. 9-4

9-2-6. A.08: Servo Amplifier Error....................................................................................... 9-4

9-2-7. A.09: Setting Data Error........................................................................................... 9-6

9-2-8. A.10: Multi System Error.......................................................................................... 9-8

9-3. Press Controller Judgment: Confirmation of REJECT status.......................................... 9-9

9-4. RTC................................................................................................................................. 9-10

Chapter 1: Outline

1

Chapter 1: Outline

Page 1-2

1-1. How to Use this Instruction Manual

This instruction manual describes the system configuration, specification, and handling

method of the DSP3000.

Chapter Item Contents

1 Outline Description of functions and precautions for use

2 Specifications DSP3000 specifications

3 System Description Description of part names and functions of the Press Controller and Tools

4 Installation and Wiring Installation and wiring

5 Power-on and Test Run Description of prior confirmation for power application and commissioning procedures

6 Operations Displayed parameters and setting up for press operations

7 Parameters Setup Description of functions and parameter list

8 Maintenance Description of check items and inspection methods.

9 Troubleshooting Description of abnormal operational indications, and corrective actions

10 Warranty and Service Description of warranty period and servicing

System Type List Tool models and Press Controller models

Tool List Specifications of Tools

Chapter 1: Outline

Page 1-3

1-2. Function Overview

DSP3000 system is a simplified, electrically operated servo press developed for use in a variety of applications for low cost pressing/press-fitting operations. This servo press system now allows a flexible response to current evolving future-oriented production facilities by integrating the functions of the main unit into the existing Press Controller, enhancing the multi-control (Multi Press) system features and external communication capability.

☆ Reduced start up time

Control of the multi-control (Multi Press) system does not require knowledge of PLC ladder logic or other complexities. Integration of the pressing sequence is achieved by selecting from simple setting instructions requiring no specialized knowledge, bringing significant improvements to operations in the field.

☆ Easy to change parameter settings

Pressing parameters, the pressing sequence, and various other settings are easily implemented by the use of the DSP3000 User Console.

☆ Diversification of external control interface

By means of the Expansion Controller, the unit can be connected to various communication bus protocols, enabling control and communication between external devices and the system.

☆ Saving result data in CF card

With the expansion unit installed, pressing operation data and graphical data can be saved to a Compact Flash (CF) card. For example, a CF card with capacity of 8GB saves approximately 1.8 million data items for the standalone system, 900000 data items for the dual-controller system, 600000 data items for the 4-controller system, and 400000 data items for the 8-contoller system.

☆ High-speed communication with the host system

Ethernet connections are used for communication with PCs enabling significant data communication time savings, as has the application of a communication system specific to the Press Controller.

☆ Power supply I/O compatible with variety of safety measures

Incorporation of an independent emergency stop signal enables interruption of the pressing operation in case of an emergency. Since the Controller operates with a control power supply voltage of 24V DC, the status of the system can still be communicated to the host system in case of interruption of the driving power supply in an emergency.

☆ Multiple functionalities within the Controller

By incorporating multi-controller functions to the functions of the existing Press Controller, a significant downsizing of the installation space is realized, enabling a single system to correspond to the sequence control or the Fieldbus specification

Chapter 1: Outline

Page 1-4

1-3. Description of Functions

(1) Pressing Function

This function enables pressing/press-fitting operation through controlling and monitoring of load and distance.

(2) BYPASS Function

PLC I/O Input signal “BYPASS”: "ON" or RUN/BYPASS switch: BYPASS side In the BYPASS state, the BYPASS red LED turns on. The operation will not start if the START signal is turned from "OFF" to "ON" in the BYPASS state. If the BYPASS state is selected during pressing, this will stop the operation.

(3) Abnormal Signal Output Function

In case any abnormal status is detected during the system check, connection or overload checks, an abnormal signal output occurs and the red STATUS LED of the Press Controller turns on. A sub code specifying the abnormality is displayed on the indicator of the Press Controller.

(4) Tool Type Checking Function

This function performs verification of the tool model set for the Press Controller and the tool model being connected when the power is turned on, or at the time of replacement of the Tool. If the tool type is different to that expected, "Tool Type Error" A.03-02 will be generated

(5) Self-checking Function

When the control power supply voltage is turned on, values for the ZERO voltage and the CAL voltage are acquired. These values will be the basis for the press loading. The values for the ZERO voltage and the CAL voltage of the load cells are obtained prior to start of the pressing operation. Then self-checking is performed by comparing the reference value obtained at power on and the measured value obtained prior to the start of the pressing operation.

(6) Load Curve Display Function

DSP3000 User Console enables the display of load curves of the pressing operations.

(7) Error History Recording Function

In cases where a system error occurs and an abnormality indication is generated, the Press Controller saves the data as error records.

(8) Stored Curve Data Function

100 cycles for the Stored Curve Data and the Stored Reject Curve Data of the pressing results will be saved respectively.

(9) Stored Data Function

Up to 12000 data results can be stored within the Press Controller.

・Maximum number of data items that can be stored in the multi configured system

Number of system

controllers 1 2 3 4 5 6 7 8 9 10

Max. no. of stored data

items 5880 3936 2952 2376 1968 1704 1488 1320 1176 1080

Chapter 1: Outline

Page 1-5

1-4. Precautions for Use

Be sure to follow the precautions described below in order to use the Press Controller in its optimal condition.

☆ Installation

Perform installation of the tool in an area as per the specification using designated fasteners, since the tool can generate heavy loads, applying an equivalent force to the mounted area of the tool. The tool consists of mechanical components and electronic components with sensors: Do not apply heavy vibration or shock. Ensure the installation uses designated mounting hardware for the Press Controller to avoid instability due to vibration or malfunctions.

☆ Pressing Operation

Avoid performing press operations that exceed the maximum load for the tool. Even when performing operations within the maximum load, use a duty cycle (the ratio of operating time to downtime) within the specified range. For details, refer to” 2-1-1. Duty Cycle Calculation”.

☆ Cable Connection

For the power supply to the Press Controller, use cables meeting the specification. To secure the cables, be sure to clamp the correct portion of each connecting cable. When multiple Press Controllers are used, be sure to connect the Press Controller to the tool with its corresponding cables. Turn off the power before connecting or disconnecting cables: failure to do so may cause system breakdown. As for the Grounding Terminal (FG), ensure an isolated Class D grounding, avoiding grounding alongside high voltage circuits or common ground.

☆ Installation Environment

Ensure installation of the Press Controller within a dust-protected housing (control panel) Performing installation in any of the locations described below may cause malfunction or failure. Avoid such locations or take countermeasures, such as installing forced cooling. Areas exposed to direct sunlight or where the ambient temperature of the installation location is outside the range of 0 to 50 ºC Areas where relative humidity exceeds the range of 20% to 90% or where there is an abrupt temperature change that may cause dew condensation. Do not perform installation in the following areas (Contact us if it believed there is such a possibility): ◆Areas where conductive substances such as iron powder, oil mist, saline matter, or organic

solution may be excessive. ◆Areas where corrosive gases or combustible gases are present. ◆Areas where intense electric fields or strong magnetic fields can be generated. ◆Areas where strong vibration or shock can be directly transferred to the Press Controller or the

tool.

☆ Measures against Static Electricity Since there is extensive use of electronic components, pay attention to static electricity hazards. Excessive static electricity may occur in dry areas. Before touching the operating switch on the front panel, for example, be sure to ground yourself by touching grounded metals first.

☆ Cleaning

Never use any organic solvents such as thinners to remove stains on the outer surface of the Press Controller or the tool: use of such solvents can infiltrate the mechanism and may cause breakdown and failure. Wipe off stains lightly using a cloth dampened with warm water or alcohol.

☆ Protection against Noise

Do not place magnetic switches or other electromagnetic devices on the periphery of the dust-protected housing (control panel), in which the Press Controller is housed. When installing relays or magnetic switches in the housing (control panel), be sure to include a noise suppression device such as a surge suppressor. Avoid confusing cables connecting the Press Controller to the tool with other wiring including power lines inside cable conduits.

Chapter 1: Outline

Page 1-6

Memo


2


Page 2-2

2-1. Specifications

Driving Power Supply

Voltage Three-phase, 200 to 230V AC ± 10%

Frequency 50/60 Hz

Control Power 24V DC ± 10%, 0.5A

Installation Environment

Press Controller to be installed in a dust-protective

enclosure (control panel).

Additional cooling/warming devices are required when operated out of the Operating Range described below.

Use

Ambient Temperature

0º to +45ºC (no congelation, heat convection required)

Ambient Humidity

Below 90 % RH (no dew condensation)

Altitude

No greater than 2000 m CAUTION: If located at a height of 1000m or more, heat dissipation is reduced by approx. 20% due to decreased air density.

Operating Range

Duty cycle within 50 % (*) (Within the specified value for one cycle time) (*) For press-fitting Tool (Type F) only

Refer to “Duty Cycle Calculation”

Storage

Ambient Temperature

-5º to +55ºC (no congelation)

Ambient Humidity

90 % RH or less (no dew condensation)

Vessel Transportation

Ambient Temperature

-5 º to + 55 ºC (no congelation)

Ambient Humidity

50 % RH or less (no dew condensation)

Packaging Completely sealed. *Tools to be lubricated with grease/oil.

Ambient Atmosphere Indoors (no exposure to direct sunlight) Free from corrosive gas, flammable gas, oil mist, dust, and dirt.

2-1-1. Duty Cycle Calculation

Duty (%) = Operating time / (Operating time + Downtime) × 100 The given time for each single cycle differs depending on the type of Tool. Confirm the specification of each Tool.

Do not use the Press Controller in a sealed environment. It may excessively

heat the motor and shorten the Tool life.

This value is an approximation which is to be regarded as a reference.

Contact us if detailed operating pattern is known.


Page 2-3

2-1-2. Press Controller Specifications

Press Controller Type

MFC—S024S

Connecting Motor Type

RM1 RM2 RH1

Motor Rating 60W 80W 80W


MFC-S060S MFC-S120S

Connecting Motor Type

RM3 RM4H RM5

Motor Rating 200W 1500W 3000W


MFC-S024S MFC-S060S MFC-S120S

Indicator 6 letters × 2 lines and 7 segments of LED indicator

Number of Function switches: 9

Switch

Bypass slide switch: RUN/BYPASS

Setting switch: for user settings (Front side of Press Controller)

Press setting switch：A maximum of 32 can be set. (1 to 32)

Internal setting switch: 8bit For adjustment at the manufacturer's site (Bottom side of Press Controller)

LED MULTI/MAIN LED, STATUS LED, JUDGE LED, COM. LED, BYPASS LED

CONTROL POWER LED, Ethernet LED

CPU SH-2A

RS232C Communication

38400 bps (Factory Set Values) / 19200 bps/9600 bps, Single port

External Analog Monitoring Output

Load analog voltage Position pulse signal Position CW/CCW signal

Axis Link (Multi-controller communication)

Dedicated communication port for “Axis Link” (Multi-controller communication) (Maximum number of connections: 32)

ETHERNET PC Communication Port IEEE 802.3 compliant (100BASE-T)

Standard

I/O

Input

Bi-directional photocoupler input 12V DC 5mA / 24V DC 10mA, Number of input points:12ch *Connection type available:

NPN (sink・(-) common) / PNP (source・(+) common)

Output

Photo MOS Relay contact 24V DC, 30mA, Number of input points: 12ch

*Connection type available:

NPN (sink・(-) commom) / PNP (source・(+) common)


Page 2-4

(*1) Acceptable current value at a continuously driven constant output current (constant load torque)

Mainly the limiting value that gives heat sink temperature increase. (*2) Life expectancy at full rated voltage until soft charge resistor fusing occurs. (*3) Limiting value in cases of long-time continuous operation (no limitation when the frequency of

performed cycle time is low)


MFC-S024S MFC-S060S MFC-S120S

RTC Time display: year, month, day, hour, min., sec.

Retention interval: 30 days (at full charge, ambient temp. 20ºC)

Protective Features

Overload: duty ratio of 100% or more Heat applied to driver: Heat sink temperature of 80 ºC or more

Overcurrent (short-circuit protection)：Excessive current due to output short-

circuit or ground fault. Drop in control power supply voltage: Control power supply voltage not within 24 ± 2.4 V DC Soft charging incomplete: Charging of driving power supply capacitor not completed. Resolver error: Disconnection of wire, tracking error

CPU error：CPU watchdog timer

Insulation Resistance

50MΩ or more / 500V DC

Dielectric Voltage 1500V AC /10mA or less

Current Value at

Driving Power Supply 22A max 22A max 40A max

Current Value at

Control Power Supply 15A max

(Convegence Time:36ms)

15A max (Convegence Time:36ms)

15A max (Convegence Time:36ms)

Continuous Drive Current (*1)

2.0 Arms 4.0 Arms 5.2 Arms

Momentary Maximum

Output Current 17.0 Arms 42.4 Arms 84.8 Arms

Max. count of power switch-on/off (*2)

10 million times 3 million times 2.5 million times

Max. cycle of driving power switch-on/off

(*3) 10 sec 10 sec 15 sec

Radiation fan - - Provided (two)

Heat sink at back side - Provided Provided

Weight (kg) 1.66 2.02 4.92

[Driving Power-on Cycle] ・Input power circuit for the Controller is of a capacitive input type: An integrated circuit

controls the applied current at power-on and performs charging through a resistor until the internal voltage reaches a fixed reference.

・Inrush current limiting resistor has a limited mechanical life: When performing on/off duty cycle operation for driving the power supply at a certain frequency, a power-on cycle for the driving power supply voltage may be considered by referring to the “Max. cycle of driving power switch-on/off” in the above table.

[Controller] Since there is extensive use of electronic components in the Controller, pay attention to static electricity hazards. Excessive static electricity may occur in dry areas. Before touching the operating switch on the front panel, for example, be sure to first ground yourself by touching grounded metal.

http://www.linguee.jp/%E8%8B%B1%E8%AA%9E-%E6%97%A5%E6%9C%AC%E8%AA%9E/%E7%BF%BB%E8%A8%B3/heat+sink+temperature.html


Page 2-5

2-1-3. Fieldbus Specifications

Fieldbus Type I/O In/Out Message In/Out

PRESS→PLC PLC→PRESS PRESS→PLC PLC→PRESS

CC-Link V1.10 14 bytes

(112 points) 14 bytes


(16 words) 30 bytes

(15 words)

CC-Link V2.00 110 bytes


(880 points) 144 bytes (72 words)

142 bytes (71 words)

DeviceNet 32 bytes


(96 points) 2048 Ch.

(4096 bytes) 16 Ch.

(32 bytes)

PROFIBUS DP-V1 32 bytes


(96 points) 2048 words (4096 bytes)

16 words (32 bytes)

ErherNet/IP 32 bytes


(96 points) 2048 words (4096 bytes)

16 words (32 bytes)

PROFINET IO 32 bytes


(96 points) 2048 Ch.

(4096 bytes) 16 Ch.

(32 bytes)

2-1-4. Expansion Unit Type

Expansion Unit Type Application

MFC-DT-S Expansion I/O (Input:32ch / Output:32ch)

MFC-CC-S CC-Link V2 / V1

MFC-DN-S DeviceNet

MFC-PB-S PROFIBUS DP-V1

MFC-EN-S EtherNet/IP

MFC-PN-S PROFINET IO

MFC-CF-S Compact Flash Card

Expansion RS232C (2 Port)

MFC-CFEN-S

For Server PC Ethernet

Compact Flash Card

Expansion RS232C (1 Port)


Page 2-6

2-2. Performance

Load Positioning Accuracy

For DPT/DPM Tool Within the range: 50 to 100% of the rated load

3 σ/Χ―

Within 3% Within the range: 25 to 50% of the rated load

3 σ/Χ―

Within 4% For DPS Tool

Within the range: 25 to 100% of the rated load

3 σ/Χ―

Within 1.5%

(σ: standard deviation, Χ―

: mean value,

3 σ/Χ―

: load positioning accuracy)

n

i

ixn

x1

1,

2

1

)(1

1

n

i

i xxn

{ n : total no. of pressing data, ix (i=1,2,3,…, n) : each pressing data}

Load resolution Approx. 1/1000 of Calibration Load

Load control range 25% to 100 % of Calibration Load

Load judgment range 10% to 100 % of Calibration Load

Distance positioning accuracy

-0 to +0.02mm

Distance internal control unit 0.001 mm

Load cell accuracy ±1% (fs)

Load cell linearity ±0.5% (fs)

Pressing Method Load Control / Distance Control

Ram Tip Pendant Allowable Load

Not exceeding 1/6 of max. Load of the Tool (2kN max.) (when brake is applied) For DPS-051**-** and DPS-101**-** Tool, 0.6 kN max.

For press-fitting Tool (Type F)

Used for operations requiring instantaneous loading. This is achieved by generating the maximum load by operating above the rated torque of the servo motor. The operation will be performed at the full-rated speed although this Tool is unsuitable for use in continuous operation.

For press Tool (Type P)

Used for operations requiring extended duration of the loading process. The Servo motor is designed to generate maximum load with rated torque enabling constant generation of the maximum load.

For details, refer to the Tool list.

Load / distance stopping accuracy figures should be interpreted according to the measurement methods given in our regulations. Distance stopping accuracy will be as in the case of a compressed spring load under

the operating conditions given in our regulations.


Page 2-7

2-3. Press Method

2-3-1. Load Control

The system performs the press operation until [Target Load] is achieved, and judges the distance obtained. The press operation stops when the [Load High Limit] or the [Distance High Limit] is exceeded.

2-3-2. Distance Control

Pattern 1 (when “Disable Final Load Low Limit” is unchecked)


Page 2-8

Pattern 2 (when “Disable Final Load Low Limit” is checked)

The system performs the press operation until [Target Distance] is achieved, and judges the maximum load during the operation. The operation stops when the [Load High Limit] or the [Distance High Limit] is exceeded.

2-3-3. Specified Point Load Judgment

The system performs the press operation until [Target Load] is achieved, and performs a sampling process with the load obtained at [Judgment Load Detection Point], and uses the result for initial judgment. The obtained distance is monitored during the pressing operation. The press operation stops when [Final Load High Limit] or [Distance High Limit] is exceeded.


Page 2-9

2-3-4. Load Rise Detection

The system performs the press operation until [Target Load] is achieved. During the operation, as soon as [Detection Start Distance] is achieved, a rate calculation begins based upon the load seen at a distance of 0.1 mm before [Detection Start Distance] and will continue to be calculated in 0.1 mm increments until [Load Rate Change] is exceeded. Load Rate is calculated by taking the (load at measured distance – load at 0.1mm before the measured distance) and multiplying that value by 10. During this pressing operation to achieve the [Target Load], distance is also monitored. The press operation stops when [Final Load High Limit] or [Final Distance High Limit] is exceeded.

2-3-5. Specified Range Peak Load Judgment

The system performs the press operation until [Target Load] is achieved. It then attempts to detect the Peak Load between the [Detection Start Distance] and the [Detection End Distance], on which the Judgment will be based. If positive numbers are entered for Detection Start and End Distance, then the distance will be measured from zero. If negative values are entered, they will be measured from the Final Distance position. During this pressing operation to achieve the [Target Load], distance is also monitored.

The press operation stops when [Final Load High Limit] or [Final Distance High Limit] is exceeded.


Page 2-10

2-3-6. Time Controlled Press

After achieving the [Time Start Load], the press continues to achieve the [Target Load] in proportion to the time specified in the [Press Time]. The press operation stops when [Load High Limit] or [Distance High Limit] is exceeded.

2-3-7. Load Drop Detection

The system performs the press operation until [Target Load] is achieved. By comparison of the load before and after every 0.1 mm increment, it then detects the decreasing change in the press force (the distance of the peak point where the decreasing change equals or exceeds [Load Change]). Judgment will be based on the peak load obtained before this detection. The press operation stops when [Final Load High Limit] or [Final Distance High Limit] is exceeded.


Page 2-11

2-3-8. Load Drop Detection Point Stop

The system performs the press operation, attempting to achieve the [Target Load], however it stops once it detects the decreasing change in [Load Change] that has been set by comparison of the load before and after every 0.1 mm increment. Judgment will be based on the peak load obtained before this detection. The press operation stops when [Final Load High Limit] or [Final Distance High Limit] is exceeded.

2-3-9. Distance Control with Load Limit

The system performs the press operation until [Target Distance] is achieved. During this operation, the press rate will be controlled to hold [Target Load] until [Target Distance] is achieved. Its basic operation is “Distance Control”, but with a load limiting function. The operation stops when [Distance High Limit], [Load High Limit] or [Press Time High Limit] is exceeded. Judgment is performed for the transit time between the detected [Distance Measurement Start Load]


Page 2-12

point to [Target Distance].

2-3-10. Distance Control with Load Rise Detection

During the operation, as soon as [Detection Start Distance] is achieved, a rate calculation begins based upon the load seen at a distance of 0.1 mm before [Detection Start Distance] and will continue to be calculated in 0.1 mm increments until [Load Rate Change] is exceeded. The system will then press to a [Target Distance], which is a distance relative to the Load Rate Change point. *Load Rate is calculated by taking the (load at measured distance – load at 0.1mm before the measured distance) and multiplying that value by 10. The press operation stops when [Final Load High Limit] or [Final Distance High Limit] is exceeded.


Page 2-13

2-4. Speed Control

[Slow Start Time]: Execution time for slow start speed

[Slow Start Speed]: Pressing speed at slow start

[Approach Distance]: No load high speed pressing distance

[Approach Speed]: No load high speed pressing speed

[Part Search Speed]: Medium pressing speed

[Press Speed 1 Start Load]: Load 1 to switch pressing speed

[Press Speed 1 Start Distance]: Distance 1 to switch pressing speed

[Press Speed 1]: Speed 1 for pressing operation

[Press Speed 2 Start Load]: Load 2 to switch pressing speed

[Press Speed 2 Start Distance]: Distance 2 to switch pressing speed

[Press Speed 2]: Speed 2 for pressing operation

[Decompression Speed]: Speed for decompression operation

[Return Speed]: Return pressing speed

[Precautions on Speed Settings] For proper use of the Press Tool, set [Part Search Speed] no higher than 50mm/sec or 25% of the maximum speed, whichever is lower. For [Press Speed 1] and [Press Speed 2], set no higher than 20mm/sec or 25% of the maximum speed, whichever is lower. Shock due to contact with the Part and/or Fixture may shorten the life of the

mechanical components of the Press Tool.


Page 2-14

2-5. Judgment Operation

2-5-1. Interference Check

This function detects pinching of foreign matter. When detecting [Interference Check Load] before [Interference Check Distance] is achieved, the “Interference Check Reject” state occurs to stop the press operation.

2-5-2. Load Inhibit Check

Used where a large ramp up of the load value sensed at start up is not to be used for judgment by [Load High Limit] Load settings exceeding [Load Inhibit Limit] which are detected after the operation startup until it reaches [Load Inhibit Distance] are to be ignored.


Page 2-15

2-5-3. Three Checks for Part

Part Check 1

This function enables detection of Part faults (IE: no Part, misalignment, etc.) during initial phase of the pressing operation. It enables judgment of both the “Distance High Limit” and the “Distance Low Limit” for the distance detecting [Part Check 1 Load]. Check 1 is enabled after [Interference Check Distance] is exceeded. Even if [Interference Check Load] is set as larger than [Part Check 1 Load], Part Check judgement is not performed unless [Interference Check Load] is exceeded as long as the distance is within [Interference Check Distance]. The press operation stops as it detects NG (reject), unless the “Disable Part Check Reject Stop” function is set beforehand.

Part Check 2 and 3

This function enables detection of Part faults (i.e. pinching) during the pressing phase. Monitoring is available, confirming that the load values between [Part Check 2 Start Distance] and [Part Check 2 End Distance] are within the range of [Part Check 2 Load Low Limit] and [Part Check 2 Load High Limit]. Monitoring is also available, confirming that the load values between [Part Check 3 Start Distance] and [Part Check 3 End Distance] are within the range of [Part Check 3 Load Low Limit] and [Part Check 3 Load High Limit]. The press operation stops as it detects NG (reject), unless the “Disable Part Check 2 Reject Stop” or “Disable Part Check 3 Reject Stop” function is set beforehand.


Page 2-16

Memo


3


Page 3-2

3-1. Part Names

3-1-1. Press Controller Front Panel Switches and Connectors

1: Indicator Mounting Connector

3: ETHERNET Connector for PC Communication

6: Standard I/O Connector

(Input: 12ch/ Output: 12ch)

4: Control Power Source Connector

5: Standard RS232C Connector

C: RUN/BYPASS Switch

RUN: Operation mode

BYPASS: Bypass mode 7: Sensor Connector (Resolver/Transducer)

7: Motor Connector 8: Motor Power

Source Connector MFC-S060Ｓ

A: Special Function SW1 Switches

3000 Series

B: Controller Address (Press No.) Switches

2: Axis Link (Press Communication) IN/OUT Connectors


Page 3-3

●Controller Front Panel Items List ・・・・Connectors List

No. Items Details Reference

Page

1 Indicator Mounting Connector

For connection to the MFC-DP01 Display －

2 Axis Link (Press communication) IN/OUT Connectors

Communication port between Press Controllers. Page 4-15

3 PC Communication

Connector Communication port for User Console and touch panel.

Page 4-14

4 Control Power Source

Connector Connection for Control Power Source: 24 V DC

Page 4-7

5 Standard RS232C

Connector Outputs Pressing Data Aux. Connection for updating Firmware

Page 4-16

6 Standard I/O Connector

Input: 12ch/ Output: 12ch

Connection for input and output signals. Available signals vary depending on Master Controller or Slave Controller.

Page 4-8

7 Sensor Connector

Connection for Tool cable. Page

3-8~12 Motor Connector

8 Motor Power Source Connector

Connection for driving power supply.

200 to 230V AC(±10％), 50/60Hz

Page 4-5

・・・・Switches List


Page

A Special Function SW1 Switches

Sets Special Functions. Page 4-11

B Press Address Switches Sets Press No. for Press Controller communication. Page 4-11

C RUN/BYPASS Switch

Enable or disable switch for Press Controller

RUN: Enable

BYPASS: Bypass mode

－


Page 3-4

3-1-2. Controller Front Panel LED

No. Name Color Status Details

1 MULTI/MAIN LED

Green

・SEQ Judgment: Accept ・ZERO/CAL Voltage Check

Total: Accept

・Sequence result judged as Accept. ・ZERO/CAL Voltage Check value is within the

acceptable range for all Press Controllers

Orange SEQ in Operation Sequence command is being performed.

Red

・SEQ Judgment: Reject ・ZERO/CAL Voltage Check

Total: Reject ・Total Abnormal Occurred

・Sequence result judged as Reject. ・ZERO/CAL Voltage Check value is outside the

acceptable range for at least one of the Press Controllers. ・At least one of the Press Controllers is in an

abnormal state.

2 STATUS LED

Green Press Ready Ready for pressing operation when receiving external input signal.

Orange Press in operation Manual or automatic parameter is in operation.

Red Press Abnormal Occurred Abnormal status has occurred in the system or during a pressing operation.

3 JUDGE LED

Green

・Press Judgment: Accept ・ZERO/CAL Voltage Check:

Accept

・Parameter pressing result value is within the

range of judgment limits. ・ZERO/CAL Voltage Check value is within the

acceptable range.

Red

・Press Judgment: Reject ・ZERO/CAL Voltage Check:

Reject

・Parameter pressing result value is outside

the range of judgment limits. ・ZERO/CAL Voltage Check value is outside

acceptable range.

4 COM. LED Orange Data communicating During data communication between Press Controllers or PCs.

5 BYPASS LED

Off RUN(Enable) State Press Controller is in RUN (Enable) state.

Orange BYPASS(Bypass mode) State Press Controller is in BYPASS (Bypass mode).

Red Driving Power Supply: Off Driver power supply is not turned on.

6 CONTROL POWER LED

Green Control Power Supply applying power.

Control Power Supply is turned on and applying power.

Red Abnormality. Press Controller Error.

Fatal error in the Press Controller.

1：MULTI/MAIN LED

2：STATUS LED

3：JUDGE LED

4：COM. LED

5：BYPASS LED

6：CONTROL POWER LED


Page 3-5

3-1-3. Controller Top and Bottom Panel Switches and Connectors

Top

Bottom

Controller Lower and Upper Panel Switches and Connectors List


Page

1 External Monitoring Device Output Connector

Output monitoring signals; load analog voltage, distance pulse, etc.

Page 4-13

2 Externally-Attached Regenerative Resistor Connector

Intended for manufacturer’s adjustment －

3 External STOP (Enable) Signal Connector

Pressing operation can be forced to stop by dropping

the external STOP signal.

(Set the SW2 switch No. 1 to “ON” to enable)

Page 4-15

4 Aux. Sensor Connector Intended for manufacturer’s use －

5 BOOT Communication Connector

Intended for manufacturer’s adjustment －

6 Lower Panel SW2 Switch Enables settings changes for functions of the Press Controller.

Page 4-12

1: External Monitoring Device Output Connector

2: Externally-Attached Regenerative Resistor Connector

3: External STOP Signal Connector

4：Aux. Sensor

Connector

5: BOOT

Communication

Connector

6: Bottom Panel

SW2 Switch


Page 3-6

3-1-4. Controller Side Panel Connectors

Controller Side Panel Connectors List

Items Details Reference

Page

Fieldbus Expansion I/O Connector The Expansion Module 1 can be installed here. Page 3-7

CF Card Expansion RS232C Connector The Expansion Module 2 can be installed here.

Fieldbus Expansion I/O

Connector

CF Card Expansion RS232C

Connector


Page 3-7

3-1-5. Controller Display, Pushbuttons and LED

Installation of display for the Press Controller enables parameter setting and confirmation of Press Results. The indicator can be directly attached to the CON connector on the front panel of the Press Controller, and is detachable even after control power supply voltage is turned on.

No. Items Details

1 DATA Display LED (6 digits) Displays the pressing results, setting data, and status.

2 PAR No. Display LED

(3 digits)

・Displays the display mode and parameter numbers. ・Displays status in manual operation. ・Displays an Abnormality code when an abnormal condition occurs.

3 D-No. Display LED

(3 digits)

・Displays the number of data displayed on the DATA display. ・Displays the status of the parameter being used in an operation.

・Displays an Abnormality sub code when an abnormal condition occurs.

4 START / SEARCH

Pushbutton

・When the pushbutton for the Master Controller only is turned ON, operation

for the selected sequence number will be performed. If released during this operation, the operation will stop. ・If this pushbutton is turned ON while holding down the MAN. pushbutton, the

Home Position Search operation will start. (For the Master Controller: All connecting Controllers, for the Slave Controller: the Slave Controller itself only) Home Position Search will not stop even if the pushbutton is being released during the operation.

5 MAN. Pushbutton Goes to manual mode while holding down this pushbutton.

6 CAL Pushbutton Performs check for CAL voltage while pressing this pushbutton. (Available for

the Master Controller: All connecting Controllers, for the Slave Controller: the

Slave Controller itself only)

7 RESET Pushbutton

・Performs check for Zero voltage while pressing this pushbutton. ・Stops the pressing operation and resets the system.

(For the master Controller: All connecting Controllers, for the Slave Controller:

the Slave Controller itself only)

8 Pushbutton Used to change display modes and set digits.

9 ▲ ▼ Pushbutton

・Used to change display data and setting data. ・Pressing this pushbutton while pressing the MAN. pushbutton enables jog

advancing and reversing operation. (For the Master Controller: All connecting Controllers, for the Slave Controller: the Slave Controller itself only)

10 SET / HOME Pushbutton

・Used to confirm the setting data. ・Pressing this pushbutton while pressing the MAN. pushbutton enables to

start the Home Position Search operation. (For the master Controller: All connecting Controllers, for the Slave Controller: the Slave Controller itself only)

Home Position Search will not stop even if the switch being released during the operation.

10：SET / HOME

Pushbutton

4：START / SEARCH

Pushbutton

1：DATA Display

LED (6 digits)

7：RESET Pushbutton

6：CAL Pushbutton

3：D-No.Display LED (3 digits)

8： Pushbutton

8： Pushbutton

9：▲ Pushbutton

9：▼ Pushbutton

5：MAN. Pushbutton

2：PAR No. Display

LED (3 digits)


Page 3-8

3-1-6. Expansion Module

●Expansion Module 1 (MFC-DT-S, MFC-FB-S, MFC-CC-S,

MFC-DN-S, MFC-PB-S, MFC-EN-S,

MFC-PN-S)

●Expansion Module 2 (MFC-CF-S)

Expansion Module Functions List

Function Details Reference

Fieldbus Connector Slot The connector for external control is connected here.

Expansion Module Manual

Expansion D-I/O Connector For connection of input signals and output signals from the

outside.

CF Card Slot For insertion of a CompactFlash (CF) card. This can be used

to store cycle data, curves and press programs

CF ACCESS LED Indicates the state of the CF card by the color of the LED.

Expansion RS232C Input Connector For input of ID data (barcode scanner, etc.).

Expansion RS232C Output Connector For output of Pressing Results Data

Fieldbus Connector Slot ・CC-Link Ver2.00(Ver1.10) ・DeviceNet ・Ethernet/IP ・PROFIBUS DP-V1 ・PROFINET IO

Expansion D-I/O Connector (MFC-DT-S)

Input: 32ch/Output: 32ch

CF Card Slot

Expansion RS232C Input Connector

Expansion RS232C Output Connector


Page 3-9

3-2. Connection Diagram

3-2-1. DPS Tool


Page 3-10

DPS Tool Cable List

No.

Cable Name

DP

S-*

**R

1*

DP

S-*

**R

2*

DP

S-*

**R

3*

DP

S-*

**R

4H

*

DP

S-*

**R

5*

Cable Model

1

MFC-S024S / S060S Motor Power Cable (10 foot) ○ ○ ○ FEB-1260

MFC-S120S RM4 Motor Power Cable ○ FEB-1607A

MFC-S120S RM5 Motor Power Cable

○ FEB-1607

2 Control Power Cable (Note) ○ ○ ○ ○ ○ FEB-1632 (Ref:)

3

RM1,RM2,RM3 Mtr/Res Cable ○ ○ ○ FEB-1251-*

RM4H Mtr/Res Cable ○ FEB-1605-*

RM5 Motor Cable ○ FEB-1603-*

RM5 Resolver Cable ○ FEB1604-*

4 Transducer Cable ○ ○ ○ ○ ○ FEB-1173-*

5 1500 to 3000 Series Resolver/Transducer Cable Adapter

○ ○ ○ ○ ○ FEB-1648

6 I/O Limit Sensor Adapter ○ ○ ○ ○ ○ FEB-1649-G01

7 Limit Sensor & Brake Y-Cable ○ ○ ○ ○ ○ FEB-1624-M*

Limit & Brake Extension Cable (Optional) ○ ○ ○ ○ ○ FEB-1626-M*

8 Brake Cable (2 meters) ○ ○ ○ ○ ○ FEB-1625 ○: Adaptable cable

・・・・” * ” in Tool Type represents a unique number. ・・・・” * ” in Cable Model represents cable length. (i.e. “M2:2m”) ・・・・Standard length of power cable: 10 feet

Standard length for field cables: 15 to 50 feet (15M). Maximum length of field cables is 100 feet (30M). Control Power connector & Auxiliary E-Stop connector is supplied with the controller. Wiring of those connectors is the responsibility of the end user.


Page 3-11

3-2-2. DPT Tool


Page 3-12

DPT Tool Cable List

No.

Cable Name

DP

T-*

**R

1*

DP

T-*

**R

2*

DP

T-*

**R

3*

DP

T-*

**R

4H

*

DP

T-*

**R

5*

Cable Model

1

MFC-S024S / S060S Motor Power Cable (10 foot) ○ ○ ○ FEB-1260

MFC-S120S RM4 Motor Power Cable ○ FEB-1607A

MFC-S120S RM5 Motor Power Cable

○ FEB-1607

2 Control Power Cable (Note) ○ ○ ○ ○ ○ FEB-1632 (Ref.)

3

RM1,RM2,RM3 Mtr/Res Cable ○ ○ ○ FEB-1251-*

RM4H Mtr/Res Cable ○ FEB-1605-*

RM5 Motor Cable ○ FEB-1603-*

RM5 Resolver Cable ○ FEB1604-*

4 Transducer Cable ○ ○ ○ ○ ○ FEB-1173-*


○ ○ ○ ○ ○ FEB-1648

6

I/O Limit Sensor Adapter (0.2 thru 10 Ton) ○ ○ ○ ○ ○ FEB-1649-G02

I/O Limit Sensor Adapter (15 and 20 Ton) ○ ○ ○ ○ ○ FEB-1649-G01

7 Limit Sensor Cable (2 meter) ○ ○ ○ ○ ○ FEB-1613

8 Limit Sensor Extension Cable ○ ○ ○ ○ ○ FEB-1612-M*

9 Brake Cable (Optional) ○ ○ ○ ○ ○ FEB-1314-* ○: Adaptable cable

・・・・” * ” in Tool Type represents a unique number. ・・・・” * ” in Cable Model represents cable length. (IE: “M2 = 2 meter”) ・・・・Standard length of power cable: 10 feet

Standard length for field cables: 15 to 50 feet (15M). Maximum length of field cables is 100 feet (30M). Control Power connector & Auxiliary E-Stop connector is supplied with the controller. Wiring of those connectors is the responsibility of the end user.


Page 3-13

3-2-3. DPM Tool

DPM Tool Cable List

No. Cable Name Cable Model

1 MFC-S024S Motor Power Cable FEB-1260

2 Control Power Cable (Note) FEB-1632 (Ref:)

3 RH1 Tool Cable FEB-1524-M*


FEB-1648

Maximum tool cable length: 30m Control Power connector & Auxiliary E-Stop connector is supplied with the controller. Wiring of those connectors is the responsibility of the end user.


Page 3-14

3-3. Cable Specification

■ MFC-S024S, S060S Motor Input Power Cable (Part #：FEB-1260) 10 Feet Long

●Minimum bending radius：120mm

●Cable Drawing

●Connector Model

Type Manf. Model No.

D3200S Receptacle・Housing AMP 1-178128-4

Receptacle Contact (Pin) (Crimp type)

AMP 1-175218-3 ■ MFC-S120S RM4 Motor Input Power Cable (Part #：FEB-1607A) 10 Feet Long


●Cable Drawing

●Connector Model TypeTypeTypeType Manf.Manf.Manf.Manf. Model No.Model No.Model No.Model No.

D3200M Receptacle・Housing AMP 1-917659-5


AMP 1-175218-3

Controller Side

Controller Side


Page 3-15

■ MFC-S120S RM5 Motor Input Power Cables (Part #：FEB-1607) 10 Feet Long


●Cable Drawing

●Connector Model TypeTypeTypeType Manf.Manf.Manf.Manf. Model No.Model No.Model No.Model No.

D3200M Receptacle・Housing AMP 1-917659-5


AMP 1-175218-3

■ Control Power Cable (Model: FEB-1632)

●Cable Drawing (Reference Only)

●Connector Model (Controller side)


Connector Phoenix Contact MC 1.5/2-STF-3.81 *Note: Connector is supplied with controller – wiring is the responsibility of the end user.

Controller Side


Page 3-16

■ STOP Signal Cable (Model: FEB-1633)

●Cable Drawing (Reference Only)

●Connector Model (Controller side)


Connector Phoenix Contact MC 1,5/2-STF-3,81 *Note: Connector is supplied with controller – wiring is the responsibility of the end user. ■ 1500 to 3000 Series Resolver/Transducer Cable Adapter (Model: FEB-1648)

PHOENIX MC 1.5/2-STF-3.81


Page 3-17

■ RM1, RM2, RM3 Motor/Resolver Cable (Model: FEB-1251-*)

●Part #：FEB-1251-x x = Length in feet (5-100 in 5 foot increments)

●Minimum bending radius：6.0”

●Nominal Cable Diameter：0.50”

■ RM4 Motor/Resolver Cable (Model: FEB-1605-*) ●Part #：FEB-1605-x x = Length in feet (5-100 in 5 foot increments)




Page 3-18

■ Resolver Cable for RM5(B) (MODEL: FEB-1603-*) ●Part #：FEB-1603-x x = Length in feet (5-100 in 5 foot increments)



■ Motor Cable for RM5(B) (MODEL: FEB-1604-*) ●Part #：FEB-1604-x x = Length in feet (5-100 in 5 foot increments)



MOLEX 5557-10R

Amphenol PT06A14-12S(SR)

AMP 1-178289-5

DDK MS3101A-18-10S

Tool Side Controller

Tool Side Controller


Page 3-19

■ RH1 Tool Cable (Model: FEB-1524-M*)

●Part #：FEB-1524-Mx x = Length in Meters (5, 10, 15, 20, 25, 30 meter)


●Nominal Cable Diameter：15.5mm

AMP 178288-5

DDK WEBSP2528F-1-D


Page 3-20

■ DPT Tool I/O Limit Switch Cable (Model: FEB-1649-G02)

• Min. Bend Radius: 64mm

■ DPS Tool I/O Limit Switch Cable (Model: FEB-1649-G01)



Page 3-21

■ DPT Tool (0.2 thru 10 ton) Limit Switch Extension (Model: FEB-1612-M*)


■ DPT Tool (15 & 20 ton) Limit Switch Extension (Model: FEB-1612A-M*)


■ DPT Tool (0.2 thru 10 ton) 2 Meter Limit Switch Cable (Model: FEB-1613)


■ DPT Tool (15 & 20 ton) 2 Meter Limit Switch Cable (Model: FEB-1613A)



Page 3-22

■ DPS Tool Brake/Position Switch Y-Cable (Model: FEB-1624-M*)


■ DPS Tool Brake/Position Switch Extension Cable (Model: FEB-1626-M*)



Page 3-23

■ DPT Tool Brake Cable (Model: FEB-1314-*)


■ DPT Tool Brake Extension (Model: FEB-1314-*)


■ DPS Tool Brake Cable (Model: FEB-1625)


Amphenol PT06A-8-2S(SR)

Outside diameter: φ4.6mm

OMRON XS2H-D421-CA0-A

Outside diameter:φ6mm


Page 3-24

■ ETHERNET Cross Cable (Model: FEB-1331)

■ ETHERNET Straight Cable (Model: FEB-1268-7)


Page 3-25

■ Controller Communication Cable (Model: FEB-1635)

■ Controller Communication Connector (Model: C30-AL2)


Page 3-26

■ RS232C Communication Cable (Model: C30-TU1-M*)

[CONTROLLER] OMRON XM3A-0921 D-SUB9 XM2S-0911 OMRON XM3D-0921 D-SUB9 XM2S-0913


Page 3-27

■ Expansion I/O Cable (Model: FEB-1643-M*)

Pin No.

Wire Color* Details Pin No.

Wire Color* Details

1 Orange ･ Black 1 IN COMMON1 35 Orange ･ Red 1 OUT COMMON1

2 Grey ･ Black 1 IN COMMON2 36 Grey ･ Red 1 OUT COMMON2

3 White ･ Black 1 IN DATA1 37 White ･ Red 1 OUT DATA1

4 Yellow ･ Black 1 IN DATA2 38 Yellow ･ Red 1 OUT DATA2

5 Pink ･ Black 1 IN DATA3 39 Pink ･ Red 1 OUT DATA3

6 Orange ･ Black 2 IN DATA4 40 Orange ･ Red 2 OUT DATA4

7 Grey ･ Black 2 IN DATA5 41 Grey ･ Red 2 OUT DATA5














21 Orange ･ Black continuous IN DATA19 55 Orange ･ Red continuous OUT DATA19

22 Grey ･ Black continuous IN DATA20 56 Grey ･ Red continuous OUT DATA20

23 White ･ Black continuous IN DATA21 57 White ･ Red continuous OUT DATA21

24 Yellow ･ Black continuous IN DATA22 58 Yellow ･ Red continuous OUT DATA22

25 Pink ･ Black continuous IN DATA23 59 Pink ･ Red continuous OUT DATA23

26 Orange ･ Long Black 1 IN DATA24 60 Orange ･ Long Red 1 OUT DATA24

27 Grey ･ Long Black 1 IN DATA25 61 Grey ･ Long Red 1 OUT DATA25

28 White ･ Long Black 1 IN DATA26 62 White ･ Long Red 1 OUT DATA26

29 Yellow ･ Long Black 1 IN DATA27 63 Yellow ･ Long Red 1 OUT DATA27

30 Pink ･ Long Black 1 IN DATA28 64 Pink ･ Long Red 1 OUT DATA28

31 Orange ･ Long Black 2 IN DATA29 65 Orange ･ Long Red 2 OUT DATA29

32 Grey ･ Long Black 2 IN DATA30 66 Grey ･ Long Red 2 OUT DATA30

33 White ･ Long Black 2 IN DATA31 67 White ･ Long Red 2 OUT DATA31

34 Yellow ･ Long Black 2 IN DATA32 68 Yellow ･ Long Red 2 OUT DATA32

HIROSE DX31A-68P(50) DX-68-CV1


Page 3-28

Memo


4


Page 4-2

4-1. Installation Procedures

Refer to the following items when using the DSP 3000 Stand-alone System.

№ Item Content Reference

Section

1 Selection of cooling/heating

installation

Install air-conditioning equipment applicable to the

environment especially ambient temperatures.

Page

2-1

2 Selection of circuit

protection and noise filter Install them for each Press Controller

Page

4-6

3 Switch setting for the Press

Controller

According to the factory settings

(Confirm before installing the Press Controller.)

Page

4-11

4 Installation of the Press

Controller

Install the Press Controller inside the control panel

according to the external dimensions, mounting

dimensions, and installation requirements.

Page

4-2~4

5 Connection for input power Connect power cables using the connectors supplied

with the Press Controller. Page

4-5

6 Cable wiring for the Tool Perform cable wiring and Tool installation. Page

3-8~12

7 Brake cable wiring Perform brake cable wiring and installation. Page

4-17~19

8 Checks before power ON Confirm cable connection, wiring, and power voltage. Page

5-1

9 Parameter setting Set Parameter, Sequence, and PLC Output Layout

on the User Console. －

10 Test run Test the initial operation. Page

5-3


Page 4-3

4-2. External Dimensions and Installation Requirements

External Dimensions

Mounting: Upper bracket: one slotted hole, Thread: M4 (Top part)

Bottom bracket: two open-ended slots, Thread: M4 (Bottom part)

Weight: MFC-S024S: 1.66 kg

MFC-S060S: 2.06 kg

MFC-DT-S/CC-S/DN-S/PB-S/PN-S/EN-S: 0.42 kg

MFC-CF-S: 0.48 kg

Press Controller Model

Average Heating Value Heating Value during

Standby

MFC-S024S Approx. 32W Approx. 15W


*Power dissipation values vary depending on the operating conditions: these values are presented as reference only.

MFC-S024S / S060S

100 mm Min.


Page 4-4

Mounting: Upper bracket: two slotted holes Thread: M4 (Top part)

Bottom bracket: two open-ended slots Thread: M4 (Bottom part)

Weight: MFC-S120S: 4.92 kg

MFC-DT-S/CC-S/DN-S/PB-S/PN-S/EN-S: 0.42 kg

MFC-CF-S: 0.48 kg

軸ユニット型式軸ユニット型式軸ユニット型式軸ユニット型式平均発熱量平均発熱量平均発熱量平均発熱量待機中の発熱量待機中の発熱量待機中の発熱量待機中の発熱量ＭＦＣ－Ｓ１２０Ｓ約１３７Ｗ約１５Ｗ

Press Controller Model

Average Heating Value Heating Value during

Standby


*Power dissipation values vary depending on the operating conditions: these values are presented as reference only.

MFC-S120S

100 mm Min.


Page 4-5

Installation Requirements

Mounting inside the Control Panel

TOP

BOTTOM

100 mm Min. 25 mm

Min. 25 mm

Min. 100 mm Min. 100 mm Min. 100 mm Min.

25 mm Min. 25 mm

Min.

100 mm Min. 25 mm Min. 25 mm

Min. 25 mm Min.

・・・・Install a fan or cooling unit in the enclosure so that the ambient temperature inside

the enclosure is kept below 45 ºC.... ・・・・Mount the Press Controller leaving adequate clearance on the top side for proper

heat dissipation. ・・・・Ensure the Press Controller is free from contamination and foreign matter.


Page 4-6

4.2.3 Cable Installation Guidelines

Improper installation of cables can reduce cable life expectancy drastically. The following guidelines should be used when installing cables.

• The cables must be prepared for installation without twists, bends or kinks. Upon unpacking the cables, any tie wraps used in shipping should be removed.

• Before inserting the cables in the cable tray, cable track or other overhead suspension, it is important that the cables be laid out or hung prior to installation long enough to relax any stresses and remove any “memory” resulting from packaging, transit or storage. If the cables cannot be relaxed, they should be shook out by grasping the cable length at its mid-point and shaking the cables as you move to each end. Then, wrap the end of each cable with masking tape and make alignment marks on the top of each end. Maintain this alignment throughout the installation to assure cable is not being twisted.

• The minimum recommended bending radius of the cable should not be exceeded. The minimum bend radius is calculated by multiplying the cable’s outer diameter by ten (Rmin = O.D. x 10). When multiple cables are run together, the largest diameter cable in the bundle should be used for calculating bend radius. Minimum bend radius must be increased when repeated flexing occurs at a given point on the cables.

• Use the most direct path when routing cables.

• Do not weave cables between or wrap around one another.

• Route cables and connectors away from liquid of any type.

• Protect cable connectors from any impact or abrasion that may cause damage (IE: pulling cables through cable tray and dropping cables to the floor).

• Check cable route for possible chafing or abrasion points. Re-route or protect cable at these points with a nylon cable wrap or similar means to avoid future cable damage.

• The use of plastic cable ties (ty-wraps) should be avoided if possible. The use of Velcro straps is preferable. If the use of plastic cable ties cannot be avoided, the following practices should be followed:

o Cables should not be tied so tight as to cause indentations in the cable jacket. Flexible cables are designed to move inside their cable jacket. If this movement is restricted, wires in the cable may become stressed and break.

o Plastic cable ties around grouped cables should be used minimally so that cables have the ability to move individually rather than all as one.

o An acceptable method is to include the use of a flexible tubing or sleeve between the plastic cable tie and the cable(s).

• Do not tie or hang anything, whatsoever, from tool cables.

• Avoid running cables directly next to high voltage or high frequency lines.

• Cables must be supported near connectors in panel and at tool to avoid strain on connection points.

• Certain tool operations may have foreseeable cable damaging aspects which are unavoidable. In these situations a shorter “extension” cable can be provided with the expectation of replacing this intermediate, less expensive cable as required. The use and proper placement of an “extension” cable will also make cable replacement less time consuming.


Page 4-7

4.2.4 Considerations for Cable Trolleys

• Cables hung by festooning type systems must be secured to the individual cable trolley and positioned to avoid sharp bends and eliminate or minimize any torsion twisting.

• Restraint cords should be used in between cable trolleys to limit movement and reduce the stress on cables as they are extended. Restraint cord lengths must always be shorter than the length of cable hung between trolleys.

• Cable loops should be consistent in length, typically not exceeding 5 feet in depth between trolleys. Sufficient number of trolleys should be used in a system to support the entire length of moving cable and to allow relaxed stacking/festooning of cable loops when tool is in the retracted position.

• One trolley should be fixed to the runway rail to eliminate tugging on or stretching of cables.

4.2.5 Considerations for Flexible Cable Tracks

• Cables must under no circumstances have the opportunity to tangle. Therefore the clearance height of a track compartment with several similar cables next to one another must not amount to more that one and a half times the cable diameter.

• There should be an “all around” minimum clearance between cables of 10% of the cable’s diameter.

• Cables and hoses with very different diameters should be laid separately. Separation is achieved by using Flexible Track separators. The following rules should be followed for cable separation:

o If (Cable 1 Diameter) + (Cable 2 Diameter) > 1.2 x Track Inner Height, then no separation is necessary.

o If (Cable 1 Diameter) + (Cable 2 Diameter) ≤ 1.2 x Track Inner Height, then a horizontal or vertical separator must be used to reduce the inner height, thereby preventing the entanglement of the cables.

• The cable weight should be symmetrically distributed along the width of the track.

• Cables must be able to move freely along the radius.

• The cables must be secured with strain relief at both ends. In exceptional cases, the cables may be fixed with strain relief at the moving end only. Unless using a Flexible Cable Track with integrated strain relief, a gap of 10~30 x cable diameter between the end of the bending segment and the fixed point is recommended for most cables.

• Under no circumstances should excess cable be put into a Flexible Cable Track.

4.2.6 Considerations for Cable Trays & Ladders

• Cable drop out panels should be used where cables enter and exit a tray or ladder system. Sharp bends need to be avoided whenever possible.

• Cables should be secured at both entry and exit points of a tray or ladder.

• Avoid running high voltage or high frequency cables in the same tray or ladder as signal or control cables unless cables are designed for such environments.

• If excess cable is to be stored in a tray or ladder, do not tightly coil cable. Cable should be laid in as large of a loop as possible.


Page 4-8

4-3. Input Power Source Connection

Motor Power

Supply power through the [MOTOR POWER] connector located on the lower-right of the Press Controller. Driving power cables are provided as accessories.

４ R ３ S ２ T １ E

５ R ４ S ３ T ２ NC １ E ＡＢ 3-phase AC Power

AC200~230V

MFC-S024S / S060S MFC-S120S

3-phase AC Power

AC200~230V

* Be sure to connect to ground.

* Be sure to connect to ground.

* Wire both row A and B.

Manufacturer: AMP Type: D3200S RISE housing Model No.: 1-178128-4 (keying X) Type: RISE contact (Crimp type) Model No.: 1-175218-3

Manufacturer: AMP Type: D3200S RISE housing Model No.: 1-917659-5 (keying X) Type: RISE contact (Crimp type) Model No.: 1-917511-3 ・Connect the Grounding Terminal (FG) separately by the Class D grounding, avoiding

grounding alongside or sharing a common ground with high voltage circuits. ・Power lines shall be provided with a circuit protector. ・Install a noise filter for noise reduction.


Page 4-9

Rated Values for Calculating Circuit Protection for 200-230VAC 3 phase

Controller

Model Motor Type

Motor

Wattage

Presses

per KVA Transformer Capacity

MFC-S024S RM1 60W 8 0.125 KVA × Number of Presses

RM2/RH1 80W 5 0.2 KVA × Number of Presses



RM5 3000W 1 1.0 KVA × Number of Presses

The chart above shows nominal motor ratings for standard motors, along with the power requirements (200-230VAC 3 phase in KVA) for each spindle. (These already have a safety factor calculated in) Use the formula below to compute transformer secondary fuse or circuit breaker sizing:

Example:

* Use a fuse or circuit breaker with next available highest rating. Due to the high inrush current at power up, it is recommended to use SLOW BLOW type fuses or fuses rated for motor loads such as Bussman® FRS/FRN type.

1.5 XTRANSFORMER (VA)

SECONDARY VOLTAGE

.

. 3 = SECONDARY FUSE SIZE

1.5 X1000 (VA)

200 VAC

.

. 3 = 4.3 AMP (USE 5 AMP FUSES)*


Page 4-10

Control Power

Supply the control power via the CONTROL POWER connector at the middle left part of the Controller.

The control power connector is provided with the equipment. Wiring is the responsibility of the end user.

Control Power Wiring Procedures

(1) Prepare the wires and rod terminals (ferrules). ･ Compatible wire size ･･･ AWG 20 ~ 22 (0.3mm2 ~ 0.5mm2) ･ Recommended rod terminals (ferrules) ･･･ Type: AI 0,5-6NU (Phoenix Contact)

(2) Peel off the insulating coating of the wirings (be sure to adhere to the dimension in the drawing below).

(3) Conduct crimping using a crimping tool. After crimping, cut the wire at a point of the same length

as the rod terminal or at a point approximately 0.5mm longer than the rod terminal. ･ Recommended crimping tool ･･･ Model: CRIMPFOX6 (Phoenix Contact)

(4) Loosen the screws of the insertion slots of the connector and insert the rod terminals into the

insertion slots. Insert a single rod terminal into a single insertion slot of the connector.

(5) Fasten the screws of the insertion slots of the connector and connect the cable to the CONTROL

POWER connector at the middle left part of the controller.

1 24V

2 0V

3 FG

Direct-current Power DC 24V

* Be careful of the polarity when wiring.

Manufacturer: Phoenix Contact

Type: Cable connector

Model : MC 1,5/3-STF-3,81

Specifications: Applicable wire size AWG 20 ~ 22 or

0.3mm2 ~ 0.5mm2

1. Be sure to ground the power supply.

2. Select the rod terminals in accordance with the wire size used. If the rod terminal size is incorrect, a gap will form during crimping and the wire will detach from the terminal easily. 3. Be careful not to mistake the polarity of the control power source (24 volts DC).

Mistaken polarity may cause electric shock or a malfunction of the Controller.


Page 4-11

4-4. Standard I/O Connection

NO: Normal Open

Servo ON

Output is active ("ON") when Servo Control Loop is on.

Release the brake while in the "ON" state. Page 4-17~19

When manual or automatic operation is started, Servo ON output is active ("ON").

Inputs of the signals [Stop], [Reset], or [Bypass] or any abnormality will change Servo ON to "OFF".

4-5. Expansion I/O or Fieldbus Connection

Please refer to [DSP3000 Expansion Unit Manual].

Pin No. Signal Name IN/OUT Function and application explanation

1 Input Signal Common Bipolar NPN (Sink Type)： +24V DC

PNP (Source Type)： 0V DC

2 CW Limit Signal IN From Tool Proximity Cable

3 CCW Limit Signal IN From Tool Proximity Cable

4 Near Origin Limit Signal IN From Tool Proximity Cable (on 15 & 20 Ton Models only)

14 Output Signal Common Bipolar NPN (Sink Type)： 0V DC

PNP (Source Type)：+24V DC

15 Servo ON OUT

NO Output is active (“ON”) while Servo is “ON”. *Used in braking circuit

Adaptable Plug

Manufacturer: Sumitomo 3M Type: Cable connector Model: 10126-3000PE Specifications: Applicable wire size AWG 24 ~ 30 or 0.2mm2 ~ 0.05mm2 Type: Cable connector case Model: 10326-52A0-008

Expansion I/O Fieldbus

CC-Link

DeviceNet

EtherNet/IP

PROFIBUS-DP V1

PROFINET IO


Page 4-12

Jog Mode: Timing Chart

ON Jog OFF Jog Speed ON

Select OFF

ON Start OFF

ON Return OFF Operation ON Busy OFF

ON Ready OFF Press Select 0~4 Press Select 0~4

System Parameter

[059] Jog High Speed

Jog Operation Press No. Input

Jog Mode

Jog Advance Jog Return

* Interlock

Output

System Parameter

[060] Jog Medium Speed

Jog Operation Press No.


Page 4-13

Sequence Mode: Timing Chart

Emergency OFF Stop ON

ON Ready OFF

ON Reset OFF

ON Home Set OFF

ON Home OFF

ON Start OFF Operation ON Busy OFF

ON Total Accept OFF

ON Total Reject OFF

Press ON Abnormal OFF

ON End OFF Seq. Select 0~5 Seq. Select 0~5

100ms or more OFF

Sequence No.

Sequence No.

Sequence No.

Sequence No.

* Turn the [Start] signal from ON to OFF after the [Busy] signal turns OFF.

* Interlock

* When the [Start] signal is turned ON, the [Ready] [Total Accept] [Total Reject] [End] signals are turned OFF and the [Busy] signal is turned ON.

Input

Output

Home Position Search

Home Return Sequence Sequence


Page 4-14

4-6. Controller Switch Settings

Address (Press No.) Switch Settings

Set the Address of each Controller via the rotary switch at the front of the Press Controller. If the display device is to be attached, unscrew and remove the screws at the two locations of the display bottom.

No. Setting No. Setting No. Setting No. Setting

01 Press 1 09 Press 9 17 Press 17 25 Press 25








*Press Address cannot be duplicated. The Press No. other than "01-32" cannot be set.

Special Function SW1 Switch Settings

If a customized feature is desired, set via the switch SW1. If the display device is to be attached, unscrew and remove the screws at the two locations of the display bottom.

No. Factory Setting

Function Setting Details

1 OFF

Zero voltage

Effective range

expansion

Home Position will vary, for example, when a heavy tool is installed. Set to ON if abnormality occurs.

2 ON Front I/O connector-

sensor configuration ON – Front Sensor configured to North America Standard OFF – Front Sensor configured to Japan Standard

3 ~ 7

OFF Not for use

8

Press No.

1：ON

2~32：OFF

Press controller

setting for

communication

(Master / Slave)

·ON: functions as the master controller of the multi-controller

communication. Communication with PC and PLC needs to be

performed from the master controller. ·OFF: functions as a slave controller of the multi-controller

communication. Communication with PC and PLC needs to be

performed via the master press controller.

ones digit

tens digit


Page 4-15

Bottom Panel SW2 Switch Settings

No. Factory Setting

Function Setting Details

1 OFF

AUX. STOP

(Enable) signal

Connector valid

If set to ON, 24V must be maintained to this connector or

the press/controller will Stop. For more information on the

STOP signal, refer to the "AUX. Interface".

2 OFF

Controller

RUN / BYPASS

Switch invalid

If set to ON, the RUN / BYPASS switch on the front of the

controller cannot be used to switch to BYPASS. If set to

ON, switching to BYPASS state can be available only via

the PLC I/O signal, "BYPASS".

3 OFF

STOP signal

Always ON

(STOP signal release)

If set to ON, the PLC I/O input "STOP" signal will be permanently ON. To operate the machine, be sure to set this function to OFF.

4 OFF Not for use

5 OFF Not for use

6 OFF Not for use For adjustment by manufacturer




Page 4-16

4-7. External Monitoring Output

Pin No. Signal Name IN/OUT Details

1 EA2 OUT Not Used

2 EB2 OUT Not Used

3 POSITION PULSE OUT Position pulse monitor output (5V TTL signal)

4 POSITION CW/CCW OUT CW / CCW monitor output (5V TTL signal)

5 GND - Monitor signal output GND

6 TD2 OUT Not Used

7 MON1 OUT Current monitor output (10V: Controller max. current)

8 MON2 OUT Speed monitor output (10V: Tool maximum rotation speed)

9 LOAD OUT OUT Load analog voltage monitor output

LOAD OUT: Load analog voltage signal

Monitor output is represented by a potential difference of approximately 2.5 V from zero load to Calibration Load. The origin voltage is defined as the voltage at the point where the press tool head is stopped.

POSITION PULSE: Position pulse signal (5V TTL signal)

Pulse position outputs are, one pulse with respect to a motion distance of 0.1mm.

POSITION CW/CCW: CW/CCW pulse signal (5V TTL signal) During forward rotation the motor unit will output HI, and during reverse rotation the motor unit will output LOW.

Manufacturer: OMRON Type: Connector plug Model: XM3A-0921 Specifications: D-SUB 9-pin plug, soldered type Type: Connector hood Model: XM2S-0913 Specifications: Inch thread (#4-40), maximum outer diameter of

compatible cable: 9φ

Adaptable Plug Top view of the controller

Highest rate of output will be 1250 pulses / sec. When operating at a speed of 125mm / sec or more, the exact number of

pulses cannot be output.

Position pulse

0.1mm

CW/CCW pulse

Operation CW (Advance) Stop Stop

CCW (Return)

Forward rotation of the motor (CW) may sometimes translate to reverse direction depending on the tool.

Origin voltage may not be 0V. (It should be within the range of -2V ~ + 2V) Also, there can be a different origin voltage with the same type of tool. For example, when the origin voltage is -0.5V, the voltage at the time of full-scale load becomes close to + 2.0V,

Voltage change is approximately ⊿⊿⊿⊿2.5V....


Page 4-17

Calibration method for external monitoring equipment

When CAL switch on the Controller indicator is pressed, load voltage is outputted on the LOAD OUT

in a potential difference of approximately ∆2.5V. Load value which the Controller recognizes at this time is displayed on the DATA display part. Make an adjustment so that the same load value is displayed at this load voltage with the external monitoring equipment. * The load voltage at zero load is not 0V.

The load voltage depends on tools, therefore, correction for zero point is required by external monitoring equipment.

Output Circuit ● Load Voltage Output Part ● Position pulse, CW/CCW pulse Output Part

4-8. ETHERNET Interface

The ETHERNET interface is the TCP/IP ETHERNET port dedicated to communication with the DSP3000 User Console installed in a PC with Windows® or Touch Panel (option).

A commercially available LAN cable (cross/straight) can be used as the cable.

IP Address 192.168.11.10 (factory setting)

Subnet Mask 255.255.255.0 (factory setting)

Default Gateway 192.168.11.1 (factory setting)

Communication Protocol IEEE 802.3 compliant

ETHERNET Standard 100BASE-T

Communication Speed 100Mbps

Cable Category 5 or higher (category 5 is recommended)

Connector Shape RJ-45

Op amp output: 0 ~ ±5V TTL (5V) output


Page 4-18

4-9. AUX. (STOP) Interface

The system can be stopped forcibly by dropping the STOP signal via the AUX. connector on the bottom

panel part of the Controller.


1 STOP＋ IN STOP signal input + (DC24V)

2 STOP－ IN STOP signal input – (DC 0V)

4-10. AXIS LINK IN/OUT Interface

Communication between press controller units is performed via a dedicated communication port.

The AXIS LINK OUT connector of one controller and the AXIS LINK IN connector of another controller

are connected in a chain by the axis link cable.

Also, axis link terminators are connected to the AXIS LINK IN connector of the first controller and the

AXIS LINK OUT connector of the last controller.

Manufacturer: Phoenix Contact

Type: Cable connector

Model: MC 1,5/2-STF-3,81

Adaptable Plug

Applicable Connector: RJ-45

<Example of Wiring of 4 Presses>

Term

inator Wiring b

Term

inator Wiring a

Press 1 Press 2

Press 3 Press 4


Page 4-19

4-11. Standard RS232C Interface

Communication Specifications

Synchronizing Method Asynchronous

Communication Mode Half-duplex

Error Control None Shipment setting

Communication Speed 9600, 19200, 38400bps 38400bps [SYS-208] Parity Even, Add, None None [SYS-209]

Stop Bits 1 bit, 2 bits 1 bit [SYS-210]

Data Bits 7 bits, 8 bits 8 bits [SYS-211]


1 N.C. - Not Used

2 RxD IN

3 TxD OUT Press Result Data Output

4 DTR OUT Always ON Output

5 GND - Signal Ground

6 DSR - Not Used

7 RTS OUT Always ON Output

8 CTS - Not Used

9 N.C. - Not Used

Manufacturer: OMRON Type: Connector socket Model: XM3D-0921 Specifications: D-SUB 9-pin socket, soldered type Type: Connector hood Model: XM2S-0913 Specifications: Inch thread (#4-40), maximum outer diameter of

compatible cable: 9φ

Adaptable Plug


Page 4-20

4-12. Electromagnetic Brake

DPS Tool

Non-excitation Electromagnetic Brake

*Varistor is built into the tool brake circuit.

* Directly, driving RY with the Servo ON signal, is possible.

Power Voltage 24V DC Brake Release at Energization

Current consumption

BS10(For 5kN & 10kN tool) 0.4A

BS30(For 30kN tool) 0.6A

BS50(For 50kN tool) 1.0A

BS80(For 80kN tool) X

BS100(For 100kN tool) X

1. This brake is just for “holding” to maintain the stop state for maintenance. Therefore, never use this for general “braking.”

2. For emergency stop, be sure to turn OFF the STOP signal. 3. Because the brake may eventually fail due to wear, use it in combination with other securing methods.

Brake

Tool

0V 24V

Reference Circuit

Controller

Y001 Brake Release

PLC

15 Servo ON

PLC I/F

X000 Servo ON

* Any address of X and Y is allowed.

1 2

BRK

RY


Page 4-21

DPT Tool (DDK Model)


*Varistor is built into the tool brake cable.



Current Consumption

BK1F(For RM1,2) 0.5A

BK3F(For RM3) 0.5A

BK4F(For RM4H) 0.8A

BK5F(For RM5) 1.2A

1 2

BRK

Tool

RY

Brake

Red (Red / Green)

Reference Circuit




0V 24V

Controller

Y001 Brake Release

PLC

15 Servo ON

PLC I/F

X000 Servo ON

Black (Blue / Green)


Page 4-22

DPT Tool (FEC Model)


* Please connect the varistor provided on brake cable.



Current Consumption

BK1F(For RM1,2) 0.5A

BK3F(For RM3) 0.5A

BK4F(For RM4H) 0.8A

BK5F(For RM5) 1.2A

A B

BRK

Tool

RY

Brake

Varistor

Reference Circuit




0V 24V

Controller

Y001 Brake Release

PLC

15 Servo ON

PLC I/F

X000 Servo ON

Red (Red / Green)

Black (Blue / Green)


5


Page 5-2

5-1. Checks before Power ON

(1) Checking power voltage

Ensure correct wiring by referring to [4-3. Input Power Source Connection]. Confirm that the Motor Power Voltage is three-phase, 200 to 230V AC, 50/60Hz, and the Control Power Voltage is 24V DC.

(2) Checking connection between Press Controller and Tool

Ensure correct connection of the resolver/motor/preamplifier cables and the limit sensor cable between the Press Controller and Tool. Confirm no excessive force has been applied to any cable.

(3) Checking wiring for Press Controller and PLC I/F (Power of 24 VDC and control signals)

Confirm that the input/output signal of the Press Controller has been correctly wired to the PLC.

5-2. Checks at Power ON

Confirm that the display indication transits as follows after the control power is turned ON.

For an abnormality indication as follows, check wiring between the Press Controller and Tool.

RUN

For Approx. 1 sec

Control power ON

BYPASS

[Precautions when recovering the drive power]

After the drive power is OFF, be sure to wait (1 minute recommended) before turning ON the power again. Power recovery with no pause or an insufficient pause may cause the following problems:

・Inrush current protective circuit may not work, resulting in an abnormal current flow into the primary power circuit. This could cause the circuit protector to trip.

・The power circuit of the Press Controller detects the abnormality, and automatically shuts down the circuit. The power circuit is deactivated (remaining OFF) even after drive power re-connection.

When the drive power cannot be successfully recovered, first turn off the power, and be

sure to wait for 5 minutes or more, before turning ON.

For Approx. 1 sec


Page 5-3

Checking I/O wiring after power ON

The input/output condition of each signal can be checked in [I/O Monitor] on the User Console.

When STOP/RESET/BYPASS signals are input, the Press Controller displays as follows:

■ STOP signal OFF ■ RESET signal ON ■ BYPASS signal ON When the following display appears, even after using the Jog Return Operation, check the wiring of

CW limit sensor: When the following display appears, even after using the Jog Advance Operation, check the wiring of

CCW limit sensor:

5-3. Initial Setting Values

Setting values necessary for a test run can be input. The already programmed factory settings enable initial operation. If necessary, these values can be edited by referring to “Chapter 6 Operations” and “DSP3000 User Console Manual”

5-4. Checks after Power ON

(1) Checking load cell Home Position level Press the RESET of the Press Controller, and confirm that the load display shows zero. At this time, check that the JUDGE LED lights up green.

(2) Checking CAL voltage Press the CAL switch of the Press Controller, and confirm that the load display shows the full scale value. At this time, check that the JUDGE LED lights up green.

(3) Checking cable wiring For multi-controller systems, ensure each cable has been securely connected. Disconnect the preamplifier cable on the Tool side, turn ON the power, and confirm that the

corresponding Press Controller generates a Tool Unconnected Error. Disconnect the resolver cable on the Tool side, turn ON the power, and confirm that the corresponding Press Controller generates a Resolver Error.


Page 5-4

5-5. Test Run

Activate the [Emergency Stop] signal to enable the controller.

Single System Activate all the [Parameter Select] signals to turn ON.

*At least, wiring for [Emergency Stop], [Input Signal Common], and [Output Signal Common] is

necessary.

For a multi-controller system, be sure to first confirm that the cable between the Press Controller and the Tool has been securely connected before starting the test run

(1) Manual mode: Checking Home Search Operation

(2) Manual mode: Checking Advance/Return Operation

(3) Automatic mode: Checking Automatic Operation (Single System) Press the START switch, and confirm that automatic operation starts. Turn ON the START signal from the PLC, and confirm that automatic operation is correctly working

Pressing the SEARCH pushbutton while pressing the MAN. pushbutton starts the Home Position search operation. After Home Position Search, the resolver position in which the limit sensor turns from OFF to ON is displayed for one second on the [D-NO] display.

When the resolver position is out of the range of 1000 to 3000, the home position can be shifted. Re-adjust the CCW limit sensor position.

(DPT tool: Page 8-5, DPS tool: Page 8-10）

If the re-adjustment does not improve the situation, contact FEC.

While pressing the MAN. pushbutton, press the▼,▲ pushbutton to perform JOG Advance/Return first one way and then the other. Check that the connected Tool (s) operates accordingly. Confirm that there is no interference within the movable range. (1) Turn the RUN/BYPASS switch of all the controllers to the BYPASS

side. (2) Turn only one Press Controller to the RUN side, perform Jog

Advance/Return, and confirm that the Tool of the corresponding Press No. operates accordingly. Check the operations of all the Controllers one by one.

(3) While pressing the MAN. pushbutton, press the ▲ pushbutton to perform Return. Confirm there is no interference until the CCW limit position is reached.


6


Page 6-2

6-1. RUN Mode

In the RUN mode, the pressing operation can be executed. The pressing results, abnormality status, press No., parameters, etc., are indicated on the display.

6-1-1. Indication

DATA Indication Part

Displays the results of press operations and the parameter values. In Real Time Mode, the load signal of the load cell is displayed. When there is a STOP / limit signal loss on the input, "SToP" is displayed.

PAR No. Indication Part

Displays the current parameter (sequence) number and running status. When an error occurs, an abnormality code is displayed.

D-No. Indication Part

Displays the number of the display data to the DATA display unit and running status. When an error occurs, an abnormality sub-code is displayed.

■ Real Time Monitor Mode ■ Press Result Mode ■ Pressing ■ Parameter Setting Mode ■ System Setting Mode ■ Abnormal





Page 6-3

Mode Change

Each time the pushbuttons is pressed, the Press Controller cycles around Real Time Mode, Press Result Mode, and Parameter Setting Mode. During the press operation, the system turns into Operation Status Mode.

When an error occurs or the STOP / limit signal input is OFF, the system enters "Status Mode".

Real Time Mode Press Result Mode

PAR No.

Mon.

D-No. SLo: Slow Start Speed

APP: Approach Speed

SEA: Part Search Speed

Pr1: Press Speed 1

Pr2: Press Speed 2

dEC: Decompression Speed

rEt: Return Speed

Power ON

PAR No.

r.**

Start pressing operations End pressing operations

System Setting Mode Parameter Setting Mode

PAR No.

SyS.

PAR No.

P.**

Pressing Mode

Real Time Mode

Parameter Setting

Mode

System Setting Mode

Parameter Setting Mode

Status Mode

Abnormal occurrence, or STOP/limit signal input is OFF

PB

PB

PB PB

PB

PB

PB PB

PB

PB

PB

PB

PB PB PB PB

PB PB PB PB

PAR No.

Mon. PAR No.

r.**

PAR No.

SyS.

PAR No.

P.**


Page 6-4

In Real Time Mode, the following data is displayed. Pressing the ▲,▼pushbuttons increments or decrements the "D-No." display.

D-No. DATA Unit

0 Load value display

Load currently loaded to the load cell is displayed in real time. Press the [CAL] switch to display the full-scale load value.

kN

1

Load voltage value display Load signal voltage across the load cell for the current load is displayed in real time. Pressing the [CAL] switch displays the load voltage with the potential difference of

approximately ⊿2.5V.

mV

2 Maximum load value display (Maximum Hold)

From the last press of the [RESET] pushbutton - the peak load is recorded and displayed here.

kN

3 Press stroke distance display

Shows the absolute distance from the home position. mm

4 Load factor display

The motor load factor is displayed in real time. If this quantity exceeds 100, Abn.08-10 Overload Error occurs.

%

5 Current value display

The present current value is displayed. A

6

Parameter number / Sequence number Single system:

Displays the parameter number in selection (P.001 to 128). Multi System:

Master: Displays the sequence number in selection (S.01 to 64). Slave: Displays the parameter number in selection (P.001 to 128).

SW2(switch of Press Controller): If position number 3 is ON, data will be displayed with a preceding under bar "_" .

7

ZERO / CAL abnormal voltage warning If a ZERO voltage and the CAL voltage is abnormal warning value and displays the "V Warn". When reset, "------" is displayed.

8 Tool movement speed display

The speed of movement of the tool during operation is displayed.

mm/sec

9 Resolver position display (0-4095)

The current position of the resolver is displayed.

10 Home Return: Resolver position display (0-4095)

Displays the resolver position when CCW limit sensor from "OFF to ON" at the home search operation.

11 Home Set: Resolver position display (0-4095)

Displays the resolver position at the time of home determined at the home search operation.

12 Home Search: Distance value display

Displays the distance value at the time of home determined at the home search operation.

13 Download error parameter number, data number display

Displays the parameter number and data number at the time of setting a download error.

PAR No.: Mon Real Time Mode


Page 6-5

In Press Result Mode, the following data is displayed: Every pressing of the ▲,▼ pushbuttons (increments or decrements) the "D-No." display.

D-No. DATA Unit

00 Judgment Load, Judgment: H/L kN

01 Judgment Distance, Judgment: H/L mm

02 *When Judgment Distance is more than 100mm, Judgment: H/L

03 Final Load, Judgment: H/L kN

04 Final Distance, Judgment: H/L mm

05 *When Final Distance is more than 100mm, Judgment: H/L

06 Distance Measurement Start Distance mm

07 Interference Check Distance, Judgment: Z mm

08 *When Interference Check Distance is more than 100mm, Judgment: Z

09 Cycle Time sec

10 Self-check Sc on: Executed Sc oFF: Not Executed

11 Cause of Press Stop

Blank: Reset/No data/After manual operation

Abn: Abnormal byPASS: Bypass signal rESEt: Reset signal

rEJECt: REJECT ACCEPt: ACCEPT

St-oFF: Start signal OFF C: CW signal CC: CCW signal

12 1st Reject Item

13 Operation Sequence No. S.01～S.32 *Stand-alone system or Slave: “—“

14 Operation Parameter No. P.01～P.32 001～128

15 Press Method 0～9

16 Speed when [Part Check 1 Load] is detected mm/sec

17 Part Check 1 Distance, Judgment: H/L mm

18 *When Part Check 1 Distance is more than 100mm, Judgment: H/L

19 Part Check 2 Minimum Load, Judgment: L kN

20 Part Check 2 Maximum Load, Judgment: H kN

21 Part Check 2 Minimum Distance mm

22 Part Check 2 Maximum Distance mm

23 Part Check 3 Minimum Load, Judgment: L kN

24 Part Check 3 Maximum Load, Judgment: H kN

25 Part Check 3 Minimum Distance mm

26 Part Check 3 Maximum Distance mm

27 Absolute Distance mm

28 Press Time, Judgment: H/L sec

29 Load Factor %

30 Press Cycle Count (×1 million) * “--" if less than 1 million cycles

31 Press Cycle Count (×1)

32 Tool Cycle Count (×1 million) * “--" if less than 1 million cycles

33 Tool Cycle Count (×1)

PAR No. r.** Press Result Mode


Page 6-6

In Parameter Setting Mode, the following data is displayed. Pressing the ▲,▼ pushbuttons (increments or decrements) the "D-No." display. Press the ▼ pushbutton while on the last digit of the data number of each parameter, and the parameter number is incremented +1. Press the ▲ pushbutton while on the first digit of the data number of each parameter, and the parameter number is decremented -1. Holding down either pushbutton ▲ or ▼will cause the numbers to jump by 10.

PAR No. P.01～128 Parameter Setting Mode

０００

D-No.

４０７

０００

００１

００２

４０７

００１

００２

～

Press Method

Press Option 1

Return Speed

Ｐ.０１

PAR

No.

Ｐ.０１

Ｐ.０２

Ｐ.０３

４０７１２８

Press Option 2


Page 6-7

In the System Settings mode, the following data is displayed. Pressing the ▲,▼ pushbuttons (increments or decrements) the "D-No." display. Holding down either pushbutton ▲ or ▼will cause the numbers to jump by 10.

０００

D-No.

Load Unit

５０２

００１

００２

～

ＳｙＳ.

PAR

No.

Software Version

Amplifier Version

PAR No. SyS. System Setting Mode

Touch Panel Function / Language Setup


Page 6-8

In the parameter operation, the following states are displayed. Below is a display example during operation at parameter number 1:

■ On Slow Start Speed ■ On Approach Speed ■ On Part Search Speed

■ On Press Speed 1 ■ On Press Speed 2 ■ On Target Hold Speed

■ On Decompression Speed ■ On Return Speed

During manual operation, the following is displayed.

■ Home Search ■ Home Return

■ Jog Advance (High Speed) ■ Jog Advance (Medium Speed) ■Jog Advance (Low Speed)

■ Jog Return (High Speed) ■ Jog Return (Medium Speed) ■Jog Return (Low Speed)

When an error occurs or the STOP / limit signal input is OFF, the system enters "Status Mode".

■ Abnormal ■ STOP signal OFF input ■CW signal OFF input ■CCW signal OFF input

Pressing Mode

Status Mode


Page 6-9

BYPASS Mode

In BYPASS Mode, setting of parameters can be edited. The display device shows the parameter number, data number, and the set value.


Displays the set value.


Displays the parameter number.


Displays the data number.

Mode Change

Set Value Selection Mode

When Set Value Selection Mode is entered, the cursor (numbers flashing) is displayed in the D-No. display area. Press the ▲ ▼ pushbuttons to increment or decrement the cursor position. The selected parameter number and the data number is displayed in the DATA display area. Press the pushbutton to move the cursor to the PAR No. display area.

SET or RESET SW

or SW

▼ ▼

▼

▼

Set Value Selection Mode Set Value Editing Mode SET SW

▼

Set Value Editing Mode

SET SET

SET

▼ ▲





Page 6-10

Set Value Editing Mode

In the "Setting Value Editing Mode", the cursor (numbers flashing) is displayed in the DATA display. Press the ▲ ▼ pushbuttons to increment or decrement the cursor position. When is pressed, the cursor moves to an adjacent digit of the DATA display.

Pressing the SET pushbutton rewrites the values according to the setting, and the mode is switched to "Set Value Selection Mode". If the input setting is outside the range for the parameter, the rewrite is not performed but the set value is displayed as in the following examples:

How to set the system parameters (PAR No. : SyS.) Press the SET pushbutton, then press ▲or▼ pushbutton within 2 seconds to switch the display from "NO" to "YES". After this, press the SET pushbutton once again to change the setting.

▼ ▼

▼

▼

Set Value Selection

Mode

SET SET

SET

▼ ▲

SET ▲

▼ Within 2 sec.

SET

Within 2 sec.

Change

If the tool number is changed (SYS.200), the initial values are set in the press parameters.

The changed setting value is recorded and stored in the system when the RUN / BYPASS switch is returned to the RUN mode from the BYPASS mode.

If the system power is turned OFF during the setting value editing, all the changes underway are cancelled and the setting of previously set values is retained.

The "NO", "YES" display disappears after two seconds if neither is selected.

The system then returns to its original settings.


Page 6-11

Parameter Copy

Parameter Unit Copy

(1) Set "SYS" in the PAR No. display area and "022" in the D-No. Display area. (2) In BYPASS Mode, press the SET pushbutton. (3) Set the copy source parameter number in the upper three-digits of DATA display area. (4) Set the parameter number of the destination in the lower three digits of the DATA display area. (5) Press the SET pushbutton, and switch from “NO to “YES” within two seconds by using ▲ or▼

pushbutton, and press SET again. This performs parameter unit copy.

Parameter Bulk Copy

(1) Set "SYS" in the PAR No. display area and "022" in the D-No. Display area. (2) In BYPASS Mode, press the SET pushbutton. (3) Set the copy source parameter number in the upper three-digits of DATA display area. (4) Set the lower three digits of DATA display to "999". (5) Press the SET pushbutton, and switch from “NO to “YES” within two seconds by using ▲ or ▼

pushbutton, and press SET again. This performs a parameter bulk copy.

SET

SET

▲

▼ Within 2 sec.

SET

Within 2 sec.

▲

▼ Within 2 sec.

SET

Within 2 sec.

Copy

Copy

Copy source Copy destination

Copy source

Bulk copy


Page 6-12

Memo


7


Page 7-2

7-1. Parameter Structure

Press Parameter : 128






000: Press Method

001: Press Option 1

002: Press Option 2

003: Judgment Operation 1

004: Judgment Operation 2

405: Load Hold Speed

406: Decompression Speed

407: Return Speed

～

～

System Parameter : SYS

000: Load Unit 001: Software Version

002: Amplifier Version

502: Touch Panel Function /

Language Setup

～


Page 7-3

7-2. System Parameters

Par No. Indication: SYS

Item D-No. Contents Setting

change Units

Press

Controller

Information 1

000 Load Unit 0：kN

001 Software Version

002 Amplifier Version

003 System Select SinGLE / MuLti ○

004 Unused

005 For in-house adjustment


007 Communication Press MAStEr / SLAVE

008 Press Cycle Count (×1 million)

009 Press Cycle Count (×1)

010 Controller maximum current

011 IP Address (upper 6 digits) : 192.168 ○

012 IP Address (lower 6 digits) : 11.10 ○

013 Subnet Mask (upper 6 digits) : 255.255 ○

014 Subnet Mask (lower 6 digits) : 128.0 ○

015 Default Gateway (upper 6 digits) : 192.168 ○

016 Default Gateway (lower 6 digits) : 11.1 ○

017 MAC Address (upper 6 digits): 001F98

018 MAC Address(lower 6 digits): 001000

019 RTC: Year/Month/Day “130725” July 25, 2013 ○

020 RTC: Time “123456” 12:34 56 ○

021 Erase Pressing Record /Format CF Card ○

022 Parameter Copy ○




026 Controller Front Panel SW1 Setting State

027 Controller Bottom Panel SW2 Setting State


Page 7-4


change Units

System Parameter

050 Offset Load ○ kN

051 Distance Compensation ○ mm

052 No Load Current Limit ○

053 Current Load Conversion Ratio ○ %

054 Home Position Offset ○ mm

055 Resolver Position ○

056 Home Position Search Time Out ○ sec

057 Home Position Search Speed ○ mm/sec

058 Home Return Speed ○ mm/sec

059 Jog High Speed ○ mm/sec

060 Jog Medium Speed ○ mm/sec

061 Jog Low Speed ○ mm/sec

062 Stroke Distance Limit ○ mm

063 Approach Distance Limit ○ mm

064 Home Returned Signal Output Range ○ mm

065 Advance Load High Limit ○ kN

066 Return Load High Limit ○ kN

067 Load Sampling Interval ○

070 Option 1 ○

071 Option 2 ○

072 Option 3 ○

073 Option 4 ○

Connected Tool Settings

100 Connected Tool No.

101 Connected Tool Information

102 Tool CAL Load Decimal Point Position

103 Tool CAL Load kN

104 Tool CAL Voltage V

105 Tool ZERO Voltage V

106 Tool Internal Gear Ratio (×100)

107 Tool Serial No. (upper 3 digits)

108 Tool Serial No. (lower 4 digits)

109 Tool Rotation Direction

110 Tool Order No. (upper 2 digits)

111 Tool Order No. (lower 5 digits)

112 Tool Cycle Count (×1 million)

113 Tool Cycle Count (×1)


Page 7-5


change Units

Press

Controller

Information 2

200 Press Controller Setting Tool No. ○

201 Press Controller Setting Tool Information

202 Parameter Configuration File Version

203 Sequence Configuration File Version

204 PLC Output Layout Configuration File Version

205 Fieldbus Configuration File Version

206 Fieldbus Message Configuration File Version

207 RS232C Input/Output Configuration File Version

208 Standard RS232C Communication Speed：38400bps ○ bps

209 Standard RS232C Parity：None ○

210 Standard RS232C Stop Bit：1 bit ○ bit

211 Standard RS232C Data Bit ○ bit

Expansion

Unit 1

Information

300 Connected Fieldbus Information

301 ANYBUS-CC Version

302 Unit Setting Fieldbus Information

303 Station No. (Node Address)

304 Communication Speed (0 ~ 4)

305 Occupied Stations (1, 2, 3, 4)

306 Extended Cyclic Setting (1, 2, 4, 8)

307 I/O Setting Byte Length “PLC → PRESS” byte

308 I/O Setting Byte Length “PRESS → PLC” byte

309 Message Block Byte Length byte

310 Message Setting Byte Length “PLC → PRESS” byte

311 Message Setting Byte Length “PRESS → PLC” byte

312 IP Address (upper 6 digits)

313 IP Address (lower 6 digits)

314 Subnet Mask (upper 6 digits)

315 Subnet Mask (lower 6 digits)

316 Gateway (upper 6 digits)

317 Gateway (lower 6 digits)

Expansion

Unit 2

Information

400 CF Card Storage Capacity %

401 Expansion RS232C-2 Communication Speed bps

402 Expansion RS232C-2 Parity

403 Expansion RS232C-2 Stop Bit bit

404 Expansion RS232C-2 Data Bit bit

405 Expansion RS232C-3 Communication Speed bps

406 Expansion RS232C-3 Parity

407 Expansion RS232C-3 Stop Bit bit

408 Expansion RS232C-3 Data Bit bit

409 Upload CF Card Backup File ○

Touch Panel

500 IP Address (upper 6 digits) ○

501 IP Address (lower 6 digits) ○

502 Touch Panel Function / Language Setup ○


Page 7-6

7-2-1. Press Controller Information 1

D-No.000 Load Unit

0 : kN

D-No.001 Software Version

This is the software version of the Press Controller.

D-No.002 Amplifier Version

This is the amplifier version.

D-No.003 System Select

Options of Single System or Multi System are selectable.

Single System Multi System

D-No.007 Communication Press

This indicates whether the Controller is the MASTER Press for (PC) communication and I/O (PLC) communication or is a SLAVE Press.

D-No.008 Press Cycle Count (×1 million) D-No.009 Press Cycle Count (×1)

These indicate the count at which the controller performed the pressing operation. * When the count is less than 1 million times, [------] is indicated for D-No. 008.

D-No. 010 Controller maximum current

This indicates the maximum current value of the controller.

D-No. 011 IP Address (upper 6 digits) D-No. 012 IP Address (lower 6 digits)

The IP address is set here. Setting range: 0 ~ 255

D-No. 013 Subnet Mask (upper 6 digits) D-No. 014 Subnet Mask (lower 6 digits)

The subnet mask is set here. Setting range: 0 ~ 255

D-No. 015 Default Gateway (upper 6 digits)

D-No. 016 Default Gateway (lower 6 digits)

The default gateway is set here. Setting range: 0 ~ 255

･ After being changed, the settings of D-Nos. 011~016 are made available by reactivation

of the control power.

･ Please execute the reactivation of the control power after confirming that the “BYPASS”

indication on the upper stage of the indicator changes from being lit up to being unlit after changing the setting.

･ If the control power is turned OFF while “BYPASS” lights up, the parameters may

become initialized.


Page 7-7

D-No. 017 MAC Address (upper 6 digits) D-No. 018 MAC Address (lower 6 digits)

The MAC address is indicated.

D-No. 019 RTC: Year/Month/Day Setting range: 13 ~ 99 (year), 1 ~ 12 (month), 1 ~31 (day)

D-No. 020 RTC: Time Setting range: 0 ~ 23 (hours), 0 ~ 59 (minutes), 0 ~ 59 (seconds)

The date and time of the RTC are indicated. The range for the year is 2013 ~ 2099. * This is not indicated at a SLAVE Axis of the Multi System.

D-No. 021 Erase Pressing Record/Format CF Card

Erasure of the pressing results record is executed. Also, if the Expansion Unit 2 (Model: MFC-CF*-S) is installed, formatting of the CF card can be

executed.

D-No. 022 Parameter Copy

Copying of parameters is performed.

D-No.026 Controller Front Panel SW1 Setting State

D-No.027 Controller Bottom Panel SW2 Setting State

The setting states of the SW1 switch on the controller front panel and the SW2 switch on the controller bottom panel are indicated.

The ON/OFF states of SW No. 1 to No. 8 are indicated in 8-bit hexadecimal code in the part in which “00H” is indicated in the drawing above.

SW setting examples Indication examples

All OFF 00H

Only No. 1 ON 01H

Only No. 2 ON 02H

Only No. 3 ON 04H

Only No. 4 ON 08H

Only No. 5 ON 10H

Only No. 6 ON 20H

Only No. 7 ON 40H

Only No. 8 ON 80H

All ON FFH


Page 7-8

7-2-2. System Parameters

D-No.050 Offset Load [kN] [Setting at shipment] 0

Setting range: -( Tool Maximum Load X 0.1) ~ Tool Maximum Load <example> Tool DPS-301R4H-**F -3.00 ~ 30.00kN

This is set when load that cannot be detected by the servo press is already applied to a work, in such a case when a work retaining jig, etc., is attached. When this is set to 10, it judges as 10kN in the status of the load value 0 for control.

D-No.051 Distance Compensation [mm] [Setting at shipment] 0

Setting range: 0~9.999 This setting is used to compensate for the target distance value shifting due to part/fixture deflection or compressing when a load is applied. The value to be entered reflects the maximum deflection/compression measured when the rated load of the press is applied to the part/fixture. When set, the target distance will be adjusted proportionate to the load being applied. This is effective when you want to accurately control the distance in applications where the fixture may deflect or part may compress when a load is applied.

D-No.052 No Load Current Limit [Setting at shipment] 250~500

Setting range: 0~1023 The current of the servo for operation without load is set. By not raising the electric current more than necessary, impact given by collision at high speed, etc., is eased. Raise the set value in such a case that the speed cannot be raised for heavy material attached on the press ram.

D-No.053 Current Load Conversion Ratio [%] [Setting at shipment] 100

Setting range: 0~999 The corresponding value in the case to control the current without load is set.

D-No.054 Home Position Offset [mm] [Setting at shipment] 0

Setting range: 0~99.99 This setting is for adjusting the Home Position after the “Home Position Search” has been performed. (Example: If 10 is set; after the Home Position Search has been performed and the zero point set, the Home Position will be reset to 10mm from that zero point.) Due to the fact that the Home Position is calculated from a proximity switch position, the distance between Home and distance related data can also very between presses. So if different presses are running the same operation or if a press needs to be changed out, this setting is used to adjust for the difference between press units. In this case, parameter settings can stay consistent for the part/operation.

D-No.055 Resolver Position [Setting at shipment] 0

Setting range: 0~4095 (Example: If the resolver position is 2816 and a value of 200 is input, then the controller will see the resolver at position 2616) *This only changes how the controller interprets the resolver position but does not change the actual position of the resolver.

D-No.056 Home Position Search Time Out [sec] [Setting at shipment] 120.0

Setting range: 0~999.9 The time limit of the home position search operation is set.

* If the home position search operation is not completed within this set time, it becomes an abnormality, and Abnormal “A.03-05”.

D-No.057 Home Position Search Speed [mm/sec] [Setting at shipment] 10.00

Setting range: 0.01~10.00 The speed in the home position search operation is set.


Page 7-9

D-No.058 Home Return Speed [mm/sec] [Setting at shipment] 10.00

Setting range: 0.01~10.00 The speed in the home return operation is set.

D-No.059 Jog High Speed [mm/sec] [Setting at shipment] 10.00

Setting range: 0.01~10.00 The speed in the high speed jog operation is set.

D-No.060 Jog Medium Speed [mm/sec] [Setting at shipment] 5.00

Setting range: 0.01~10.00 The speed in the medium speed jog operation is set.

D-No.061 Jog Low Speed [mm/sec] [Setting at shipment] 1.00

Setting range: 0.01~10.00 The speed in the low speed jog operation is set.

D-No.062 Stroke Distance Limit [mm] [Setting at shipment] 0

Setting range: 0~500 When this is set to 200, the distance and position can only be set up to 200mm.

* Checked when inputting. Already set data is not changed.

D-No.063 Approach Distance Limit [mm] [Setting at shipment] 0

Setting range: 0~500 When this is set to 200, the approach distance can only be set up to 200mm.

* Checked when inputting. Already set data is not changed.

D-No.064 Home Returned Signal Output Range [mm] [Setting at shipment] 0

Setting range: 0~500 When it stops within + 1mm of the set value, the home position signal is outputted. (Ex: If 10 is set, the Home Returned signal will be output if the press stops between 0 and 11mm)

D-No.065 Advance Load High Limit [kN]

It is effective when [D-No.070 Option 1 Advance Load High Limit Variable] is set to "1". Setting range: 0 to tool maximum load The load upper limit value when using forward jog motion can be arbitrarily set.

D-No.066 Return Load High Limit [kN]

It is effective when [D-No.070 Option 1Return Load High Limit Variable] is set to "1". Setting range: 0 to tool maximum load

The load upper limit value for Home Position search, home return, jog return, and parameter return operation can be arbitrarily set.

D-No.067 Load Sampling Interval [Setting at shipment] 0

Setting range: 0~3 0: 0.1mm, 1: 0.05mm, 2: 0.01mm, 3: 0.005mm


Page 7-10

D-No.070 Option 1

□ □ □ □ □ □

⑥ ⑤ ④ ③ ② ①

① Load Cell 0: Yes ② Advance Load High Limit Variable [Setting at shipment] 0: No

1: Yes (The load high limit value measured during a Jog advance operation is made variable.) ③ Return Load High Limit Variable [Setting at shipment] 0: No

1: Yes (The load high limit value measured during a Home position search, Home return, Jog

return, or Parameter return operation is made variable.) ④ Distance High Limit Stop [Setting at shipment] 0: Yes

* Stroke limit is judged as operation high limit. This does not function when the stroke limit is 0. ⑤ Deadman Function Home Search / Home Return [Setting at shipment] 0: No

1: Yes (when the start signal is OFF, the Home Position search/return operation is stopped.) ⑥ Deadman Function Parameter Return [Setting at shipment] 0: No

1: Yes (when the start signal is OFF, the parameter return operation is stopped.) * During pressing operations the Deadman Function is always activated.

D-No.071 Option 2

□ □ □ □ □ □

⑥ ⑤ ④ ③ ② ①

① Disable Home Search CCW Limit Sensor Position Abnormal [Setting at shipment] 0: No

1: Yes (CCW limit sensor position abnormalities are not detected during Home Position search.)

② Compatible with DSP1500 [Setting at shipment] 0: No

1: Yes (Single System: Signal output compatible with the DSP1500 with standard I / O.) (Single System: Data Results compatible with the DSP1500 can be output via standard

RS232C port.)

③ [Distance Control] Auto Deceleration [Setting at shipment] 0: Yes

1: No (No automatic deceleration prior to Target Distance.) ④ Standard RS232C Result Output [Setting at shipment] 0: Yes

1: No (No Data Results for the press operation is output from the standard RS232C) ⑤ Stored Data Save [Setting at shipment] 0: Yes

1: No (No Data Result is saved) ⑥ Dynamic Hold [Setting at shipment] 0: No

1: Yes (Servo OFF when Manual or Press operation ends)


Page 7-11

7-2-3. Connected Tool Settings

D-No. 100 Connected Tool No.

The tool No. corresponding to the tool model is indicated.

D-No. 101 Connected Tool Information

The Instantaneous maximum load and motor capacity of D-No. 100 [Connected Tool No.] are indicated.

D-No. 102 Tool CAL Load Decimal Point

The decimal point of the D-No. 103 [Tool CAL Load] is indicated.

D-No. 103 Tool CAL Load [kN]

The CAL load of the tool is indicated.

D-No. 104 Tool CAL Voltage [V]

The CAL voltage of the tool is indicated.

D-No. 105 Tool ZERO Voltage [V]

The ZERO voltage of the tool is indicated.

D-No. 106 Tool Internal Gear Ratio (×100)

The value obtained by multiplying the gear ratio of the tool by 100 is indicated.

D-No. 107 Tool Serial No. (upper 3 digits) D-No. 108 Tool Serial No. (lower 4 digits)

The serial No. of the tool is indicated.

D-No. 109 Tool Rotation Direction

The rotation direction of the tool is indicated. (CW: 0, CCW: 1)

D-No. 110 Tool Order No. (upper 2 digits) D-No. 111 Tool Order No. (lower 5 digits)

The order No. of the tool is indicated.

D-No. 112 Tool Cycle Count (×1 million)

D-No. 113 Tool Cycle Count (×1)

These indicate the count at which the connected tool performed the fastening operation. * When the count is less than 1 million cycles, [------] is indicated for D-No. 112.


Page 7-12

7-2-4. Press Controller Information 2

D-No. 200 Controller Setting Tool No. Setting range: Tool No. registered for the model

The tool No. of the connected tool model is indicated.

D-No. 201 Controller Setting Tool Information

The Instantaneous maximum load and motor capacity of the tool of D-No. 200 [Controller Setting Tool No.] are indicated.

D-No. 202 Parameter Configuration File Version

The version of the parameter file set in the controller is indicated.

D-No. 203 Sequence Configuration File Version

The version of the sequence file set in the controller is indicated.

D-No. 204 PLC Output Layout Configuration File Version

The version of the PLC output layout file set in the controller is indicated.

D-No. 205 Fieldbus Configuration File Version

The version of the fieldbus file set in the controller is indicated.

D-No. 206 Fieldbus Message Configuration File Version

The version of the fieldbus message file set in the controller is indicated.

D-No. 207 RS232C Input/Output Configuration File Version

The version of the RS232C input/output set in the controller is indicated.

D-No. 208 Standard RS232C Communication Speed [bps]

Setting range: 9600, 19200, 38400 The communication speed of the RS232C interface on the controller front panel is set.

D-No. 209 Standard RS232C Parity

Setting range: Odd, Even, None The parity of the RS232C interface on the controller front panel is set.

D-No. 210 Standard RS232C Stop Bit [bit]

Setting range: 1 or 2 The Stop Bit of the RS232C interface on the Unit front panel is set.

D-No. 211 Standard RS232C Data Bit [bit]

Setting range: 7 or 8 The Data Bit of the RS232C interface on the Unit front panel is set.


Page 7-13

7-2-5. Expansion Unit 1 Information

D-No. 300 Connected Fieldbus Information

The type of fieldbus installed on the Expansion Unit 1 is indicated.

D-No. 301 ANYBUS-CC Version (besides standard IO and expansion IO)

The ANYBUS-CC version of the Expansion Unit 1 is indicated.

D-No. 302 Controller Setting Fieldbus Information

The type of fieldbus set in the controller is indicated.

Fieldbus not set

Expansion Unit 1 Uninstalled (Standard IO)

MFC-DT-S Installed (Expansion IO)

MFC-CC-S Installed

(CC-Link)

MFC-DN-S Installed (DeviceNet)

MFC-PB-S Installed (PROFIBUS DP-V1)

MFC-PN-S Installed (PROFINET IO)

MFC-EN-S Installed (EtherNet/IP)

CC-Link V1 CC-Link V2


Page 7-14

○：The used parameter

D-No.300 Expansion IO CC-Link DeviceNet PROFIBUS

DP-V1 PROFINET IO EtherNet/IP

D-No.303 - ○ ○ ○ - -

D-No.304 - ○ ○ - - -

D-No.305 - ○ - - - -

D-No.306 - ○ - - - -

D-No.307 - ○ ○ ○ ○ ○

D-No.308 - ○ ○ ○ ○ ○

D-No.309 - ○ ○ ○ ○ ○

D-No.310 - ○ ○ ○ ○ ○

D-No.311 - ○ ○ ○ ○ ○

D-No.312 - - - - ○ ○

D-No.313 - - - - ○ ○

D-No.314 - - - - ○ ○

D-No.315 - - - - ○ ○

D-No.316 - - - - ○ ○

D-No.317 - - - - ○ ○

D-No. 303 Station No. (Node Address) (CC-Link, Device Net, PROFIBUSDP-V1)

The station No. (Node address) of the fieldbus set in the controller is indicated.

Fieldbus Type

CC-Link Device Net PROFIBUSDP-V1

1~64 0~63 0~125

D-No. 304 Communication Speed Setting range: 0 ~ 4 (CC-Link, Device Net)

The communication speed of the fieldbus set in the controller is indicated.

Fieldbus Type System Parameter D-No.304

0 1 2 3 4

CC-Link 156kbps 625kbps 2.5Mbps 5Mbps 10Mbps

Device Net 125kbps 250kbps 500kbps - -

D-No. 305 Occupied Stations Setting range: 1~ 4 (CC-Link)

The number of occupied stations of the fieldbus set in the controller is indicated.

D-No. 306 Extended Cyclic Setting Setting range: 1, 2, 4, 8 (CC-Link)

The extended cyclic setting of the fieldbus set in the controller is indicated.

D-No. 307 I/O Setting Byte Length “PLC → PRESS” [byte]

(besides standard IO and expansion IO) The I/O setting byte length for “PLC → PRESS” of the fieldbus set in the controller is indicated.

D-No. 308 I/O Setting Byte Length “PRESS → PLC” [byte]

(besides standard IO and expansion IO) The I/O setting byte length for “PRESS → PLC” of the fieldbus set in the controller is indicated.

D-No. 309 Message Block Byte Length [byte] (besides standard IO and expansion IO)

The message block byte length of the fieldbus set in the controller is indicated.

Fieldbus type

CC-Link Device Net PROFIBUSDP-V1 PROFINET IO EtherNet/IP

144byte 250 byte 64 byte 250 byte 250 byte


Page 7-15

D-No. 310 Message Setting Byte Length “PLC → PRESS” [byte]

(besides standard IO and expansion IO) The message setting byte length for “PLC → PRESS” of the fieldbus set in the controller is indicated.

D-No. 311 Message Setting Byte Length “PRESS → PLC” [byte]

(besides standard IO and expansion IO) The message setting byte length for “PRESS → PLC” of the fieldbus set in the controller is indicated.


Setting range: 0 ~ 255 (PROFINET IO, EtherNet/IP) The IP address of the fieldbus set in the controller is indicated.

D-No. 314 Subnet Mask (upper 6 digits) D-No. 315 Subnet Mask (lower 6 digits)

Setting range: 0 ~ 255 (PROFINET IO, EtherNet/IP) The subnet mask of the fieldbus set in the controller is indicated.

D-No. 316 Gateway (upper 6 digits) D-No. 317 Gateway (lower 6 digits)

Setting range: 0 ~ 255 (PROFINET IO, EtherNet/IP) The gateway of the fieldbus set in the controller is indicated.

7-2-6. Expansion Unit 2 Information

D-No. 400 CF Card Storage Capacity [%]

The storable capacity of the CF card installed in the Expansion Unit 2 is indicated.

D-No. 401 Expansion RS232C-2 Communication Speed [bps]

The Communication Speed of the RS232C-2 interface of the Expansion Unit 2 is indicated.

D-No. 402 Expansion RS232C-2 Parity

The Parity of the RS232C-2 interface of the Expansion Unit 2 is indicated.

D-No. 403 Expansion RS232C-2 Stop Bit [bit]

The Stop Bit of the RS232C-2 interface of the Expansion Unit 2 is indicated.

D-No. 404 Expansion RS232C-2 Data Bit [bit]

The Data Bit of the RS232C-2 interface of the Expansion Unit 2 is indicated.

D-No. 405 Expansion RS232C-3 Communication Speed [bps]

The Communication Speed of the RS232C-3 interface of the Expansion Unit 2 is indicated.

D-No. 406 Expansion RS232C-3 Parity

The Parity of the RS232C-3 interface of the Expansion Unit 2 is indicated.

D-No. 407 Expansion RS232C-3 Stop Bit [bit]

The Stop Bit of the RS232C-3 interface of the Expansion Unit 2 is indicated.

D-No. 408 Expansion RS232C-3 Data Bit [bit]

The Data Bit of the RS232C-3 interface of the Expansion Unit 2 is indicated.

D-No. 409 Upload CF Card Backup File

The Configuration files in the CF card installed in the Expansion Unit 2 can be updated by the Controller Indicator. Refer to “DSP3000 Expansion Unit Manual”.


Page 7-16

7-2-7. Touch Panel


Setting range: 0 ~ 255 The IP address of the touch panel connected in the Unit is indicated.

D-No.502 Touch Panel Function / Language Setup standard setting : 0 Setting range : 0～4

Disabling/enabling of the touch panel function and the language setting are changed.

● If the touch panel is not used

Set ”0.”

● If the touch panel is used

Set any of “1” ～ “4” in accordance with the language to be used.

D-No.502 0 1 2～4

Setting Details Touch Panel Function Disable Language/

Japanese

Language/

English

･ After being changed, the settings of D-Nos. 500~502 are made available by reactivation

of the control power.

･ Please execute the reactivation of the control power after confirming that the “BYPASS”

indication on the upper stage of the indicator changes from being lit up to being unlit after changing the setting.

･ If the control power is turned OFF while “BYPASS” lights up, the parameters may

become initialized.


Page 7-17

7-3. Press Parameters

Par No. Indication: P.01~128 Item D-No. Contents

Press Mode

000 Press Method 001 Press Option 1 002 Press Option 2 003 Judgment Operation 1 004 Judgment Operation 2 005 Judgment Operation 3 006 Judgment Operation 4 007 Return Operation

Load

[kN]

100 Calibration Load 101 Final Load Low Limit 102 Final Load High Limit 103 Load Low Limit 104 Load High Limit 105 Target Load 106 Interference Check Load 107 Load Inhibit Limit 108 Press Speed 1 Start Load 109 Press Speed 2 Start Load 110 Distance Measurement Start Load 111 Load Rate Change / Load Change 112 Time Start Load 113 Return Load 114 Part Check 1 Load 115 Part Check 2 Load Low Limit 116 Part Check 2 Load High Limit 117 Part Check 3 Load Low Limit 118 Part Check 3 Load High Limit

Distance

[mm]

200 Final Distance Low Limit 201 Final Distance High Limit 202 Distance Low Limit 203 Distance High Limit 204 Target Distance 205 Judgment Load Detection Point 206 Approach Distance 207 Interference Check Distance 208 Load Inhibit Distance 209 Press Speed 1 Start Distance 210 Press Speed 2 Start Distance 211 Detection Start Distance 212 Detection End Distance 213 Decompression Position 214 Job Start Position 215 Part Check 1 Distance Low Limit 216 Part Check 1 Distance High Limit 217 Part Check 2 Start Distance 218 Part Check 2 Start Distance 219 Part Check 3 Start Distance 220 Part Check 3 Start Distance

Position

[mm]

250 Advance ON Position 251 Advance OFF Position 252 Return ON Position 253 Return ON Position


Page 7-18

Item D-No. Contents

Time

[sec]

300 Slow Start Time 301 Target Hold Time 302 Press Time 303 Press Time Low Limit 304 Press Time High Limit 310 Acceleration Time 311 Deceleration Time 312 Press 1 Deceleration Time 313 Press 2 Deceleration Time

Speed

[mm/sec]

400 Slow Start Speed 401 Approach Speed 402 Part Search Speed 403 Press Speed 1 404 Press Speed 2 405 Load Hold Speed 406 Decompression Speed 407 Return Speed

7-3-1. Press Mode

D-No.000 Press Method

Pressurizes to the load value set in [D-No.105 Target Load]. After increasing the pressure to the Target Load, the distance between the peak load value and the press limit end is judged. When [D-No.104 Load High Limit] and [D-No.203 Distance High Limit] are exceeded, the press operation is stopped.

Pressurizes to the load value set in [D-No.204 Target Distance] After increasing the pressure to the Target Distance, the distance between the peak load value reached and the press limit end is judged. When [D-No.104 Load High Limit] and [D-No.203 Distance High Limit] are exceeded, the press operation is stopped.

Basically it is the same control as the [Load Control]. Judgment is performed by detecting the load value at the position set in [D -No.205 Judgment Load Detection Point]. If [Judgment Load Detection Point] is set as a negative value, the load value is detected by the calculation of [press limit end – (minus) detection position of the judged load value]. Pressurizes to the load value set in [D-No.105 Target Load]. When [D-No.102 Final Load High Limit] and [D-No.203 Distance High Limit] are exceeded, the press operation is stopped.

When [Judgment Load Detection Point] is not reached, Judgment Load will

become 0 kN.

0 : Load Control

1 : Distance Control

2 : Specified Point Load Judgment


Page 7-19

Basically it is the same control as the [Load Control]. The change amount of load in each 0.1 mm after exceeding [D-No.211 Detection Start Distance] is used for judgment, with the inflection point of 0.1 mm before the point exceeding the 1/10 load of [D-No.111 Load Rate Change] to the advancing direction. If the load inflection point is not judged as 0 kN, then the process is run to judge the distance to the 0 mm point. Pressurizes to the load value set in [D-No.105 Target Load]. When [D-No.102 Final Load High Limit] and [D-No.201 Final Distance High Limit] are exceeded, the press operation is stopped.

Basically it is the same control as [Load Control]. Judgment is performed by detecting the peak load value reached between [D-No.211 Detection Start Distance] and [D-No.212 Detection End Distance]. When [Detection Start Distance] and [Detection End Distance] are negative values, the peak load

value reached between [Press limit end－Detection start distance] to [Press limit end－Detection

end distance] is detected. Pressurizes to the load value set in [D-No.105 Target Load]. When [D-No.102 Final Load High Limit] and [D-No.203 Distance High Limit] are exceeded, the press operation is stopped.

Basically it is the same control as [Load Control]. Over the time set in [D-No.302 Press Time], pressurizes in multi-stage (minimum unit of the tool resolution) from [D-No.112 Time Start Load] to [D-No.105 Target Load].

Basically it is the same control as [Load Control]. The falling load is detected (decline from the peak value) previously set in [D-No.111 Change Load] between [D-No.211 Detection Start Distance] from [D-No.105 Target Load]. A previously recorded peak load is used as the basis for detection. Pressurizes to the load value set in [D-No.105 Target Load]. When [D-No.102 Final Load High Limit] and [D-No.201 Final Distance High Limit] are exceeded, the press operation is stopped.

Because the amount of change in the load is monitored in each 0.1 mm, accurate detection may be disabled if the distance between the inflection point and the press end limit is 0.2 mm or more. If the inflection point is not detected, the load is

judged as 0 kN.

Press tool (Type F) can be used for this function, but take care not to subject the

press to abnormal loading.

(Example) [D-No.112 Time Start Load]: 1 kN, [D-No.105 Target Load]: 10 kN

When setting [D-No.302 Press Time] to 10 seconds, it will be pressurized in

stages up to 10kN over 10 seconds from 1kN.

If the detection end distance is not reached, the judged load will become 0 kN.

If the yield point cannot be detected, the load is judged as 0 kN.

3 : Load Rise Detection

4 : Specified Range Peak Load Judgment

5 : Time Controlled Press

6 : Load Drop Detection


Page 7-20

Basically it is the same control as [Load Drop Detection]. What differs is, at the end of the operation the falling edge of the load value is detected (the decline from the peak value). If it cannot be detected, pressing will be set at the load value set in [D-No.105 Target Load]. When [D-No.102 Final Load High Limit] and [D-No.201 Final Distance High Limit] are exceeded, the press operation is stopped.

The load set in [D-No.105 Target Load] or less is retained, and the tool stops when reaching the distance set in [D-No.204 Target Distance]. This function is useful for the height control for such Part that is easily getting damaged if pressed under a specific load value.

With the load inflection point as a start point, pressurizes to the distance set in [D-No.204 Target Distance]. The change amount of load in each 0.1 mm after exceeding [D-No.211 Detection Start Distance] is used for judgment, with the inflection point of 0.1 mm before the point exceeding the 1/10 load of [D-No.111 Load Rate Change] to the advancing direction. If the load inflection point is not judged as 0kN, then the process is run to judge the distance to the 0 mm point. When [D-No.102 Final Load High Limit] and [D-No.201 Final Distance High Limit] are exceeded, the pressing operation is stopped.

D-No.001 Press Option 1

□ □ □ □ □ □

④ ③ ② ①

① Disable Self-check

1: Self-check of the load cell is not performed at the start of the parameter operation. Used for the next operation startup after operation end with Keep Load.

② Disable Curve Data Output

1: Curve data is not output. Used when the curve data is unnecessary in the distance method.

③ Disable Stored Curve Data Save

1: Curve history (RAM) is not saved at the operation end. NG curve history (Flash-Rom) is saved.

④ Advance / Return Position Signal Output

1: PLC signal is output at Press Advance/Return operation.

If the yield point cannot be detected, the load is judged to be 0 kN.

Because the amount of change in the load is monitored in each 0.1 mm, accurate detection may be disabled if the distance between the inflection point and the press end limit is 0.2 mm or more. If the inflection point is not detected, the load is judged as 0 kN.

7 : Load Drop Detection Point Stop

8 : Distance Control With Load Limit

9 : Distance Control With Load Rise Detection


Page 7-21

D-No.002 Press Option 2

□ □ □ □ □ □

①

① Two-stage Load Hold

1: Only "Load Control" is valid. Retains the load values for [D-No.105 Target Load] and [D-No.112 Time Start Load].

D-No.003 Judgement Operation 1

□ □ □ □ □ □

③ ② ①

① Interference Check

1: Enables to detect Part abnormality and/or pinching of foreign matters.

② Load Inhibit Check

1: Used to ignore the load bounce immediately after the operation start.

③ Disable Final Load Low Limit Judgment

1: Used typically for [Distance Control], such as when the final load falls, and the low limit judgment is unwanted.

D-No.004 Judgment Operation 2

□ □ □ □ □ □

⑥ ⑤ ④ ③ ② ①

① Part Check 1

1: Performs Part Check 1.

② Part Check 2


③ Part Check 3


④ Disable Part Check 1 Reject Stop

1: Pressurizes to the target even when Part Check 1 resulted in Reject.

⑤ Disable Part Check 2 Reject Stop


⑥ Disable Part Check 3 Reject Stop


[105 Target Load] (Target Load 1)

[403 Press Speed 1] Decompression or Press operation

Load

[112 Time Start Load] (Target Load 2)

Judgment Distance

2nd Load Hold

[302 Press Time] (Hold Time 2) [405 Load Hold Speed]

Final Distance

Final Load

Judgment Load


Page 7-22

D-No.005 Judgment Operation 3

□ □ □ □ □ □

② ①

① Band Check

1: Performs Band Check. Page 7-29

② Disable Band Check Reject Stop

1: Pressurizes to the target even when Band Check resulted in Reject.

D-No.006 Judgment Operation 4 Not used

D-No.007 Return Operation

At both Accept/Reject judgments, after pressurizing, tool returns to [D-No.214 Job Start Position]. If the start signal is turned OFF in the middle of the operation, the tool returns to the Return Position to complete the operation. After removing the load in [D-No.406 Decompression Speed], returns to the Job Start Position.

At Accept judgment, the load is removed in [D-No.406 Decompression Speed], and the tool returns to [D-No.214 Job Start Position]. When Reject is judged, the load is removed and the tool stops at that position. When the start signal is turned OFF in the middle of the operation, and if within the OK range, the tool returns to the Job Start Position to complete the operation.

At Accept is judged, the load is removed and the tool stops at that position. When Reject is judged, the tool returns to [D-No.214 Job Start Position]. When the start signal is turned OFF in the middle of the operation, and if within the OK range, the tool returns to the Return Position to complete the operation.

1: [ACCEPT] Return [REJECT] No Return

When the current position at the press operation end is smaller than the return position, the tool moves to the home position (0 mm), instead of the Job Start Position. When starting the return operation from the load generated state, first the load removal is performed. When reaching the Approach Distance, the load removal

is stopped, and the tool returns to the Job Start Position in the return speed.

0 : Return

2: [ACCEPT] No Return [REJECT] Return


Page 7-23

At both Accept/Reject judgments, the load is removed and the tool stops at that position.

Stops the operation by turning the Start Signal OFF, and starts the operation from the stop position by turning the Start Signal ON. Not like Return, Jog Return stops the operation when the Start Signal is turned to OFF even during the return operation, and starts from the return operation as the Start Signal is turned to ON. When the Start Signal is turned OFF with the load generated, the operation stops after removing the load.

At Accept judgment, the tool stops at that position without removing load. At Load High Reject or Distance High Reject, the tool stops with the load removed to a certain level. For other Reject results, the tool stops at that position without removing the load. In using this function for [Time Controlled Press], it is possible to perform a smooth curve for loading the pressing operation of the multi-stage by setting [D-No.1 12 Time Start Load] as same as the target load value of the previous operation. Since it is not operating at the end of load holding function, start the next operation as quickly as possible. This can gradually remove the load.

At both Accept/Reject judgments, the tool returns to [D-No.214 Job Start Position] without removing the load. When a spring is included in the jig, the load removal is normally performed until the spring compression is relaxed; setting to Load Ignore Return can quickly complete the return operation.

At both Accept/Reject judgments, the operation stops after the load removal is performed up to [D-No.113 Return Load]

Returns the tool to [D-No.213 Decompression Position] with [D-No.406 Decompression Speed], and returns the tool to [D-No.214Job Start Position] with [D-No.407 Return Speed].

When the depressurized position is smaller than the return position, the tool stops at the return position to end the operation. When the depressurized position is smaller than [D-No.206 Approach Distance], returns the tool to the approaching distance with the depressurized speed, and returns the tool to the return position with the return speed. When the current position at the press operation end is smaller than the return position, the tool stops at that position.

8 :Two Speed Return

Load removal operation is performed.

No Return only means the tool does not return to the Return Position. When any load is detected, load is removed until it approaches close to 0. To end the operation by stopping the tool to the target distance by ”Distance

Control”, select “Keep Load”.

The following parameter operations requires [D-No.001 Press Option 1] “Disable Self-check” to be active. If "Disable Self-check" is not set, the operation will be performed with the current load value compensated to 0 (this may damage the machine). Press tool (Type F) can be used for this function, but take care not to subject the press to abnormal loading.

3 : No Return

4 : Jog Return

5 : Keep Load

6 : Load Ignore Return

7 : Load Return


Page 7-24

7-3-2. Load, Distance, Position, Time, Speed

D-No.100 Calibration Load [kN]

Setting range: Tool Maximum Load × 0.8 ~ Tool Maximum Load × 1.2 Setting the tool number automatically sets the tool maximum load. When the tooltip is mounted with a plate applying a load, or when the peak display value differs from the result of load testing devices due to the Part properties, the result of the testing devices can be compensated by adjusting the setting value of Calibration Load.

Calibration Load to adjust ＝ Actual Peak Load (obtained by testing device)／ Peak Load × Current

Calibration Load

(Example) Tool: DPT-501R4H-**F Actual Peak Load : 38.00 kN Peak Load : 39.00 kN Current Calibration Load : 49.03 kN

38.00 kN / 39.00 kN × 49.03 kN = 47.77 kN ⇒ Calibration Load

D-No.101 Final Load Low Limit [kN]

D-No.102 Final Load High Limit [kN]

D-No.103 Load Low Limit [kN]

D-No.104 Load High Limit [kN]

[Final Load Low Limit] [Load Low Limit] Setting range: 0 ~ Tool Maximum Load [Final Load High Limit] [Load High Limit] Setting range: 0 ~ Tool Maximum Load × 1.2 Sets the upper/lower limit values for operation judgement load. When the upper limit value is reached, the press operation is stopped. When the press method follows the following, [Final Load Low Limit] and [[Final Load High Limit] will be activated: ”Specified Point Load Judgment”, “Load Rise Detection”, “Specified Range Peak Load Judgment”, “Load Drop Detection”, “Load Drop Detection Point Stop”, and “Distance Control With Load Rise Detection”. Here, [Load High Limit] is used only for judgment, and the press operation does not stop even when it is exceeded.

D-No.105 Target Load [kN]

Setting range: 0 ~ Tool Maximum Load Set the load value of operation target. Setting to 10.00 allows the operation until the load value reaches 10.00 kN.

D-No.106 Interference Check Load [kN]

Setting range: 0 ~ Tool Maximum Load × 1.2

D-No.207 Interference Check Distance [mm]

Setting range: 0 ~ Stroke Distance Limit Operates when [D-No.003 Judgment Operation 1: Interference Check] is activated. Work abnormality and pinching of foreign matters are detectable. Detecting [Interference Check Load] up to [Interference Check Distance] causes Reject, and the press operation is stopped.

D-No.107 Load Inhibit Limit [kN]


D-No.208 Load Inhibit Distance [mm]

Setting range: 0 ~ Stroke Distance Limit Operates when [D-No.003 Judgment Operation 1: Load Inhibit Check] is activated. Performs load inhibit from the operation start to [Load Inhibit Distance]. When the load exceeds [Load Inhibit Limit] during the load inhibit, it is judged as Reject, and the pressing operation is stopped.

D-No.108 Press Speed 1 Start Load [kN]

Setting range: 0 ~ Tool Maximum Load Sets the load value switching from [Part Search Speed] to [Press Speed 1].

D-No.109 Press Speed 2 Start Load [kN]

Setting range: 0 ~ Tool Maximum Load Sets the load value switching from [Press Speed 1] to [Press Speed 2].


Page 7-25

D-No.110 Distance Measurement Start Load [kN]

Setting range: 0 ~ Tool Maximum Load Judgment is performed by starting the distance calculation from the position exceeding [Distance Measurement Start Load]. Setting 0 processes the absolute distance from the mechanical zero point. Setting other than 0 processes the relative distance from the position detecting [Distance Measurement Start Load]. Settings affected by [Distance Measurement Start Load are: [Final Distance Low Limit] [Final Distance High Limit]

[Distance Low Limit] [Distance High Limit]

[Target Distance] [Judgment Load Detection Point]

[Press Speed 1 Start Distance] [Press Speed 2 Start Distance]

[Part Check 2 Start Distance] [Part Check 2 End Distance]

[Part Check 3 Start Distance] [Part Check 3 End Distance]

D-No.111 Load Rate Change [kN]

Setting range: 0 ~ Tool Maximum Load

Activated when the press method is“Load Rise Detection” / “Distance Control with Load Rise

Detection”. Each advance in 0.1mm enables comparison of the load value before 0.1mm and the current load value. When the load increase of 1/10 or more of [Load Rate Change] is detected, the operation is processed with the point before 0.1 mm of the current position regarded as an inflection point.

D-No.111 Load Change [kN]

Setting range: 0 ~ Tool Maximum Load Activated when the press method is ”Load Drop Detection”, and “Load Drop Detection Point Stop”. Each advance in 0.1mm enables comparison of the peak load value after the detection start and the current load value. When the load fall in [Load Change] is detected, the peak load value reached is used for judgment.

D-No.112 Time Start Load [kN]


D-No.302 Press Time [sec]

Setting range: 0 ~ 999.9 Activated when the press method is “Time Controlled Press”. Press load increases over the period of [Press Time] until [Target Load] from [Time Start Load].

D-No.113 Return Load [kN]

Setting range: 0 ~ Tool Maximum Load Activated when Return Operation is “Load Return”. At both Accept/Reject judgment, the tool stops with the load removal operation until [Return Load] is reached.

D-No.200 Final Distance Low Limit [mm]

D-No.201 Final Distance High Limit [mm]

D-No.202 Distance Low Limit [mm]

D-No.200 Distance High Limit [mm]

Setting range: 0 ~ Stroke Distance Limit Sets the upper/lower limit values for operation judgement load. When the upper limit value is reached, the press operation is stopped. When the press method follows the following, [Final Distance Low Limit] and [Final Distance High Limit] will be activated: Load Rise Detection”, “Load Drop Detection”, “Load Drop Detection Point Stop”, “Distance Control With Load Rise Detection”. Here, [Distance High Limit] is used only for judgment, and the press operation does not stop even when it is exceeded.

When the load is too much removed, slow down [D-No.406 Decompression Speed]. When the load value at the press operation end is smaller than [D-No.113 Return

Load], the tool will stop with the load of the end of press operation retained.


Page 7-26

D-No.204 Target Distance [mm]

Setting range: 0 ~ Stroke Distance Limit When the press method is “Distance Control”, “Distance Control With Load Limit”, and “Distance Control With Load Rise Detection”, the distance value of the operation target is set. For “Distance Control” and “Distance Control With Load Limit”, the operation is performed from the distance detecting [Distance Measurement Start Load] to [Target Distance]. For “Distance Control With Load Rise Detection”, the operation is performed from the distance detecting Load Rise Point to [Target Distance]

D-No.205 Judgment Load Detection Point [mm]

Setting range: -99.999 ~ Stroke Distance Limit When the press method is ”Specified Point Load Judgment”, the load value of [Judgment Load Detection Point] is detected, and the judgment is given after the press operation ends. When [Judgment Load Detection Point] is a negative value, detect the load value by "Press end limit

－(minus) [Judgment Load Detection Point] ".

D-No.206 Approach Distance [mm]

Setting range: 0 ~ Approach Distance Limit Sets the distance to start [Part Search Speed]. Decelerates from [Approach Speed] so that [Part Search Speed] is obtained at [Approach Distance].

D-No.209 Press Speed 1 Start Distance [mm]

Setting range: 0 ~ Stroke Distance Limit Sets the distance value to switch from [Part Search Speed] to [Press Speed 1].

D-No.210 Press Speed 2 Start Distance [mm]

Setting range: 0 ~ Stroke Distance Limit Sets the distance value to switch from [Press Speed 1] to [Press Speed 2].

D-No.211 Detection Start Distance [mm]

Press method: “Load Rise Detection”, “Load Drop Detection”, “Load Drop Detection Point Stop”, “Distance Control With Load Rise Detection” Setting range: 0 ~ Stroke Distance Limit

Press method: “Specified Range Peak Load Judgment” Setting range: -99.999 ~ Stroke Distance Limit

Starts the load value detection from the position exceeding [Detection Start Distance]. When [Detection Start Distance] is a negative value in “Specified Range Peak Load Judgment”,

"Press limit end －(minus) [Detection Start Distance]" becomes the starting value.

D-No.212 Detection End Distance [mm]

Setting range: -99.999 ~ Stroke Distance Limit When the press method is “Specified Range Peak Load Judgment”, the peak load value up to

[Detection End Distance] is detected.

When [Detection End Distance] is a negative value, "Press limit end －(minus) [Detection End

Distance]" becomes the end position.

D-No.213 Decompression Position [mm]

Setting range: 0 ~ Stroke Distance Limit Activated when Return Operation is “Two Speed”. The tool returns to [Decompression Position] with [Decompression Speed].

D-No.214 Job Start Position [mm]

Setting range: 0 ~ Stroke Distance Limit Activated when Return Operations are “Return”, “[ACCEPT] Return [REJECT] No Return”, “[ACCEPT] No Return [REJECT] No Return”, “Jog Return”, and “Load Ignore Return”. The tool returns to [Job Start Position] and ends the operation. Load is removed and the operation stops when “[ACCEPT] Return [REJECT] No Return” is judged as Reject and “[ACCEPT] No Return [REJECT] No Return” is judged as Accept.


Page 7-27

D-No.114 Part Check 1 Load [kN]


D-No.215 Part Check 1 Distance Low Limit [mm]

D-No.216 Part Check 1 Distance High Limit [mm]

Setting range: 0 ~ Stroke Distance Limit Operates when [D-No.004 Judgment Operation 2: Part Check 1] is activated. This is the load value judged to be contacted with Part. If [Part Check 1 Load] is not detected between [Part Check 1 Distance Low Limit] and [Part Check 1 Distance High Limit], it is judged as Reject, and the press operation is stopped. When Interference Check is performed, the operation is not activated unless [Interference Check Distance] is exceeded. When [Part Check 1 Load] is detected in the distance larger than [Interference Check Distance] and smaller than [Part Check 1 Distance Low Limit], it is also judged as Reject, and the press operation is stopped. When [D-No.004 Judgment Operation 2: Disable Part Check 1 Reject Stop] is activated, the press operation is continued up to the target value.

D-No.115 Part Check 2 Load Low Limit [kN]


D-No.116 Part Check 2 Load High Limit [kN]


D-No.217 Part Check 2 Start Distance [mm]

D-No.218 Part Check 2 End Distance [mm]

Setting range: 0 ~ Stroke Distance Limit Operates when [D-No.004 Judgment Operation 2: Part Check 2] is activated. Enables check for the intermediate load. When a load out of the range from [Part Check 2 Load Low Limit] to [Part Check 2 Load High Limit] is detected between [Part Check 2 Start Distance] and [Part Check 2 End Distance], it is judged as Reject, and the press operation is stopped. When [D-No.004 Judgment Operation 2: Disable Part Check 2 Reject Stop] is activated, the press operation is continued up to the target value.

D-No.117 Part Check 3 Load Low Limit [kN]


D-No.118 Part Check 3 Load High Limit [kN]


D-No.219 Part Check 3 Start Distance [mm]

D-No.220 Part Check 3 End Distance [mm]

Setting range: 0 ~ Stroke Distance Limit Operates when [D-No.004 Judgment Operation 2: Part Check 3] is activated. Enables check for the intermediate load. When a load out of the range from [Part Check 3 Load Low Limit] to [Part Check 3 Load High Limit] is detected between [Part Check 3 Start Distance] and [Part Check 3 End Distance], it is judged as Reject, and the press operation is stopped. When [D-No.004 Judgment Operation 2: Disable Part Check 3 Reject Stop] is activated, the press operation is continued up to the target value.

D-No.250 Advance ON Position [mm]

D-No.251 Advance OFF Position [mm]

Setting range: 0 ~ Stroke Distance Limit Operates when [D-No.001 Press Option 1: Advance/Return Position Signal Output] is activated. Sets the position to output ON/OFF the [Advance Position] Signal during Advance operation. To move to the Return direction by “Distance Control”, the operation to the target is judged as Advance.

D-No.252 Return ON Position [mm]

D-No.253 Return OFF Position [mm]

Setting range: 0 ~ Stroke Distance Limit Activated when [D-No.001 Press Option 1: Advance/Return Position Signal Output] is activated. Sets the position to output ON/OFF the [Return Position] Signal during Return operation. To move to the Return direction by “Distance Control”, the operation after the target is reached is judged as Return.


Page 7-28

D-No.300 Slow Start Time [sec]

Setting range: 0 ~ 999.9

D-No.400 Slow Start Speed [mm/sec]

Setting range: 0.01 ~ Tool Maximum Speed Used to mitigate the impact after the operation start. During [Slow Start Time], enables operation in [Slow Start Speed]. Setting 0 to [Slow Start Time] enables operation from [Approach Speed].

D-No.301 Target Hold Time [sec]

Setting range: 0 ~ 999.9 Sets the time to hold the press operation at the position where [Target Load] or [Target Distance] is reached. When the load is the target, the operation is controlled to retain the Target Load.

When the distance is the target, the operation is controlled to retain the Target Distance. During the operation with the load retained, output is activated (“ON”) to the [Advanced] signal. Turning OFF the start signal during the load retained operation, the operations ends without completing the sequence.

For Press-fitting (F Type) Tool Setting range: 1 sec. or lower (varies depending on the operation cycle interval)

For Press (P Type) Tool Setting 999.9 makes [Target Hold Time] limitless.

D-No.303 Press Time Low Limit [sec]

D-No.304 Press Time High Limit [sec]

Setting range: 0 ~ 999.9 Activated when the press method is “Distance Control With Load Limit”. Starts the time monitoring when [Distance Measurement Start Load] is detected, and judges the time until which [Target Distance] is reached. When set to 0, no judgment operation is performed.

D-No.310 Acceleration Time [sec] Default: 0.20

Setting range: 0.10 ~ 5.00 Sets the acceleration time from the press operation start until [Slow Start Speed], [Approach Speed],

is reached, and from the target until [Decompression Speed] and [Return Speed] are reached.

D-No.311 Deceleration Time [sec] Default: 0.10

Setting range: 0.10 ~ 5.00 Sets the deceleration time from [Approach Speed] until [Part Search Speed] is reached, and from

[Return Speed] until the stop state (speed: 0) is reached.

D-No.312 Press 1 Deceleration Time [sec] Default: 0.00

Setting range: 0.00 ~ 5.00 Sets the deceleration time from [Part Search Speed] until [Press Speed 1] is reached.

D-No.313 Press 2 Deceleration Time [sec] Default: 0.00

Setting range: 0.00 ~ 5.00 Sets the deceleration time from [Press Speed 1] until [Press Speed 2] is reached.

D-No.401 Approach Speed [mm/sec]

Setting range: 0.01 ~ Tool Maximum Speed Sets the speed of the movement at no load, at high speed.

“Overload” abnormal may occur. Consult FEC if it should occur.

For target load, adjusts the load to perform Advance/Return by using [D-No.405 Load Hold Speed]. Some work condition may not be able to hold the load. In such cases,

slow down [D-No.405 Load Hold Speed].


Page 7-29

D-No.402 Part Search Speed [mm/sec]

Recommendation setting: 0.01 ~ 50.00, or Less than 1/4 of Tool Maximum Speed Sets the speed after the end of operation under Approach Speed until the start of the press operation. When [Press Speed 1 Start Load] or [Press Speed 1 Start Distance] is reached during Approach Operation, switches to [Press Speed 1]. In the operation of [Press Speed 2], the operation also switches to [Press Speed 2] if [Press Speed 2 Start Load] or [Press Speed 2 Start Distance] is reached during the Approach Operation.

D-No.403 Press Speed 1 [mm/sec]

Recommendation setting: 0.01 ~ 20.00, or Less than 1/4 of Tool Maximum Speed Sets the speed during the press operation.

D-No.404 Press Speed 2 [mm/sec]

Recommendation setting: 0.01 ~ 20.00, or Less than 1/4 of Tool Maximum Speed When a precision is required, set 3.00 mm/sec. or less. Sets the speed for the final stage of press operation.

D-No.405 Load Hold Speed [mm/sec]

Recommendation setting: 0.01 ~ 20.00, or Less than 1/4 of Tool Maximum Speed When the target is the load, sets the speed during the load retained operation.

D-No.406 Decompression Speed [mm/sec]

Setting range: 0.01 ~ Tool Maximum Speed Activated when Return Operation is “Return”, “[ACCEPT] Return [REJECT] No Return”, “[ACCEPT] No Return [REJECT] No Return”, “Jog Return”, and “No Return”. Operates at this speed until the current load value reaches approximately 0 kN. “Load Return” is also operated at this speed.

D-No.407 Return Speed [mm/sec]

Setting range: 0.01 ~ Tool Maximum Speed Sets the speed to return from the target operation end position to [Job Start Position].

The lower the speed is set, the higher the stopping accuracy can be achieved.


Page 7-30

Par No. Indication: P.01~128 Item D-No. Contents

Band Check Load Low Limit

[kN]

500 Band Check L1 Load










Band Check Distance Low Limit

[mm]

510 Band Check L1 Distance










Band Check Load High Limit

[kN]

520 Band Check H1 Load










Band Check Distance High Limit

[mm]

530 Band Check H1 Distance










When [D-No.005 Judgment Operation 3: Band Check] is “1” (checked), Band Check is operated.

D-No.500～509 Band Check L1 ~ L10 Load [kN]


D-No.510～519 Band Check L1 ~ L10 Distance [mm] * Band Check operation other than 0

Setting range: 0 ~ Stroke Distance Limit L1 < L2 < L3 <・・・< L10 (*More than 0.1 mm of interval) When the load is less than Low Limit check line of the interval between consecutive L-No., it is judged

as Reject, and the pressing operation is stopped.

D-No.520～529 Band Check H1 ~ H10 Load [kN]

Setting range: 0 ~ Tool Maximum Load x 1.2

D-No.530～539 Band Check H1 ~ H10 Distance [mm] * Band Check operation other than 0

Setting range: 0 ~ Stroke Distance Limit H1 < H2 < H3 <・・・< H10 (*More than 0.1 mm of interval) When the load is exceed High Limit check line of the interval between consecutive H-No., it is judged

as Reject, and the pressing operation is stopped.


Page 7-31

7-3-3. Example of setting procedures of parameters

First operate the press in the “Load Control” or “Distance Control”, and change the press method when it must be operated in another controlling method. Here the setting procedures of the “Load Control” and “Distance Control” are described. It is described assuming that the tool to use is the 2tF type (DPT-201R3-25FS).

* It is described that the home position search in the manual operation is already carried out in the conditions.

The set values are determined in the order specified in the flow chart below.

Setting of Interference Check

Actually set the jig and parts, etc., to create the same conditions of automatic operation to be carried out. Check the distance just before contacting the work using the advance jog of manual operation. The current distance value can be checked in the moving distance display of the real time display. When the checked distance is 200mm, set the [207 Interference Check Distance] to 200mm, and the [106 Interference Check Load] to 1 kN (0.1 kN for some tools).

* Adjust the numerical value of the [106 Interference Check Load] as necessary.

Setting of approach

For safety, set the [206 Approach Distance] to 190mm. Operate it slowly at first to check the series of motions, so set the [401 Approach Speed] to 20 mm/s.

* After checking the operation, adjust the [401 Approach Speed] as necessary.

Start

Target Load ? NO

YES

Load Control setting Distance Control setting

Setting of interference check Setting of approach

Setting of Time / Speed, etc.

Press Method: Load Control Return Operation: Return

Press Method: Distance Control Return Operation: Return


Page 7-32

Setting of Load Control

Assuming that the target load value is 15 kN: high limit 16 kN, low limit 14 kN, and that the pressing in high limit of the work is 6 mm, and low limit is 4 mm.

It is set in the press mode to be “Load Control”, and “”Return”. In this case, [103 Load Low Limit] is 14 kN, [104 Load High Limit] is 16 kN, [105 Target Load] is 15 kN. [108 Press Speed 1 Start Load] is to be the press speed 1 after contacting the work, so set it to 1 kN that is the same value as [106 Interference Check Load]. [109 Press Speed 2 Start Load] is to be at low speed near the final point, so set it to 10 kN that is slightly lower than [103 Load Low Limit]. [202 Distance Low Limit] is to be 204mm that is the previously measured distance to the part 200mm + 4mm, and the [203 Distance High Limit] is 206mm that is 200mm + 6mm, however set it to 210mm allowing some extra.

* Extra distance for distortion of the equipment due to the load is necessary, so set a value with a little extra at first.

Set 0mm for the meantime to [209 Press Speed 1 Start Distance] and [210 Press Speed 2 Start Distance], since the actually press fit distance is not known correctly. Set the distance to decelerate as necessary. Set [114 Part Check 1 Load] to 1 kN that is the same as [Interference Check Load]. Set [215 Part Check 1 Distance Low Limit] to 200mm that is the previously measured distance to the part, and set the [216 Part Check 1 Distance High Limit] to 210mm that is the same as [Distance High Limit].

Setting of Distance Control

Assuming that the part is pressed in for 5mm, the distance high limit 6mm, distance low limit 4mm, the high limit of the generated load is 16kN, the low limit is 14 kN.

It is set in the press mode to be “Distance Control”, and “”Return”. In this case, [103 Load Low Limit] is 14 kN, [104 Load High Limit] is 16 kN. [108 Press Speed 1 Start Load] is to be the press speed after contacting the part, so set it to 1 kN that is the same value as [Interference Check Load]. [109 Press Speed 2 Start Load] is to be at low speed near the final point, so set it to 10 kN that is slightly lower than [Load Low Limit]. [110 Distance Measurement Start Load] is treated with absolute distance, so 0 kN is set. [202 Distance Low Limit] is to be 204mm that is the previously measured distance to the part 200mm + 4mm, and the [203 Distance High Limit] is 206mm that is 200mm + 6mm, however set it to 210mm allowing some extra.

* Extra distance for distortion of the equipment due to the load is necessary, so set a value with a little extra at first. Set [204 Target Distance] to 205mm that is 200mm + 5mm. Set 0mm for the meantime to [209 Press Speed 1 Start Distance] and [210 Press Speed 2 Start Distance], since the actual press fit distance is not known precisely. Set the distance to decelerate as necessary. Set [114 Part Check 1 Load] to 1 kN that is the same as [Interference Check Load]. Set [215 Part Check 1 Distance Low Limit] to 200mm that is the previously measured distance to the part, and set [215 Part Check 1 Distance High Limit] to 210mm that is the same as [Distance High Limit].


Page 7-33

Setting of Time and Speed

Set [300 Slow Start Time] to 0.1 second and [301 Target Hold Time] to 0.1 second. Set [400 Slow Start Speed] to 10mm/s, [402 Part Search Speed] to 10mm/s, [403 Press Speed 1] to 1mm/s, [404 Press Speed 2] to 1mm/s, [406 Decompression Speed] to 1mm/s, [407 Return Speed to 50mm/s. Set [214 Job Return Position] to 0mm.

The above settings are listed.

D-No. DATA Load Control Distance Control

000 Press Method 0 1

003 Judgment Operation 1 Interference Check Interference Check

004 Judgment Operation 2 Part Check 1 Part Check 1

007 Return Operation Return Return

100 Calibration Load 19.61 19.61

103 Load Low Limit 14.00 14.00

104 Load High Limit 16.00 16.00

105 Target Load 15.00 －

106 Interference Check Load 1.00 1.00

108 Press Speed 1 Start Load 1.00 1.00

109 Press Speed 2 Start Load 10.00 10.00

110 Distance Measurement Start Load － 0.00

114 Part Check 1 Load 1.00 1.00

202 Distance Low Limit 204.000 204.000

203 Distance High Limit 210.000 210.000

204 Target Distance － 205.000

206 Approach Distance 190.000 190.000

207 Interference Check Distance 200.000 200.000

209 Press Speed 1 Start Distance 0.000 0.000

210 Press Speed 2 Start Distance 0.000 0.000

214 Job Start Position 0.000 0.000

215 Part Check 1 Distance Low Limit 200.000 200.000

216 Part Check 1 Distance High Limit 210.000 210.000

300 Slow Start Time 0.1 0.1

301 Target Hold Time 0.1 0.1

400 Slow Start Speed 10.00 10.00

401 Approach Speed 20.00 20.00

402 Part Search Speed 10.00 10.00

403 Press Speed 1 1.00 1.00

404 Press Speed 2 1.00 1.00

406 Decompression Speed 1.00 1.00

407 Return Speed 50.00 50.00

This is an example of setting to check operation. Reexamine each set value as necessary.


Page 7-34

7-3-4. Example of setting for Home Return by Distance Control

In the case of Home Return by Distance Control, set as shown below.

D-No. DATA Set value

000 Press Method 1: Distance Control

003 Judgment Operation 1 Interference Check

004 Judgment Operation 2 Part Check 1

007 Return Operation Return

100 Calibration Load Maximum load value

103 Load Low Limit 0

104 Load High Limit Tool maximum load value

106 Interference Check Load 1 or tool maximum load value

108 Press Speed 1 Start Load 1

109 Press Speed 2 Start Load 1

110 Distance Measurement Start Load 0

114 Part Check 1 Load 1 (Do not set 0.)

202 Distance Low Limit 0

203 Distance High Limit 2

204 Target Distance 1

206 Approach Distance 10 (If over run occurs, make this value larger)

207 Interference Check Distance 4

209 Press Speed 1 Start Distance 3

210 Press Speed 2 Start Distance 2

214 Job Start Position 0

215 Part Check 1 Distance Low Limit 0

216 Part Check 1 Distance High Limit Larger value than the current position

300 Slow Start Time 0

301 Target Hold Time 0

400 Slow Start Speed 1

401 Approach Speed 100

402 Part Search Speed 5

403 Press Speed 1 3

404 Press Speed 2 1

406 Decompression Speed 5

407 Return Speed 100


8


Page 8-2

8-1. Items to be Checked

Please perform periodic inspections based on the following inspection items. Although the approximate period of periodic inspection differs according to the installation environment and usage circumstances of the controller, it is recommended that periodic inspection be performed at least once a year. Also, please perform the periodic load accuracy inspection and calibration inspection once a year for accurate load management. And, please be prepared to shut down the power securely when an error occurs.

8-1-1. Tools (Motor Part)

Mechanical degradation and malfunction are predicted for the tools because a powerful load is applied each time pressing is performed.

･ Ensure that the surrounding environment conforms to the environmental conditions specified in

“Safety Precautions.”

･ Ensure that the duty cycle during pressing conforms to the specified range.

(Check for excessive duty cycle and heating of the motor due to the load.) ･ Ensure that there is no abnormal noise or vibration when the tool rotates.

･ Ensure that there is no adhesion of dust or foreign matter on the tool.

･ Ensure that the tool is fixed firmly. Check the mounting screws for play and loosening.

･ Ensure that nothing comes into contact with the tool and that no excessive force in directions

besides the pressing direction is applied to the tool.

8-1-2. Cables

This refers to the cables joining the controllers and the tools. Check carefully in the case where a cable has any movable parts.

･ Ensure that the cable does not come into contact with any operating parts.

Also ensure no excessive strength is applied to the cable.

･ Ensure that the cable has no flaws that may cause disconnection.

･ Ensure there is no adhesion of dust, foreign matter, or oil on the cable.

･ Ensure that the cable is not generating heat and that the cable sheath is free of deformation due to

heating.

･ In the process of mounting, ensure that the cables are fixed properly.

･ Check for any loose attaching screws.

･ Ensure that cable connectors between the tools are inserted firmly.

8-1-3. Controller

The Controllers of the DSP3000 System are made up of semiconductor devices and are ensured with high reliability. However, depending on the surrounding environment and usage conditions, the semiconductor devices may deteriorate. It is therefore required that periodic inspections be performed.

･ Ensure that the ABNORMAL is not indicated by the controller indicator.

･ Ensure that the power source voltage conforms to the specification (including during the

pressing operation).

･ Ensure there is no instantaneous power failure or rapid voltage change.

･ Ensure that the surrounding environment (or environment inside the housing) conforms to

the environmental conditions specified in “Safety Precautions.”

･ Ensure that there is no adhesion of dust, foreign matter, or oil on the controller.

･ Ensure that controller is fixed firmly. Check the mounting screws for play and loosening.

･ Ensure that there is no abnormal heat generation by the controller.

･ Ensure that the controller display is mounted securely.

Please perform periodic inspections to use the DSP3000 in the best condition.


Page 8-3

8-2. Servo Press Maintenance

Be sure to inspect the press tool once every month, and apply grease as needed.

Check press frequently if it is used under severe environment.

8-2-1. DPT Tool

Check Press tool periodically, and replace worn or damaged parts.

0.2t ~ 7.0t

10t ~ 20t


Page 8-4

(1) Procedure to check gears and applying grease

(1-1) Procedure to check gears ① Turn the power OFF and verify that the servo press will not move. ② Fix press ram (Output Shaft) so that it will not fall. ③ Remove hex bolts on gear case cover. ④ Remove the gear case cover. Take special caution on collars and bearings inside not to fall. ⑤ Mark on a gear direct on ball screw to see the original direction.

Mark the gear and gear case.

⑥ Check if there is any crack on gears or gear shaft, and any gap between gears. Take special caution on removing intermediate gear because output shaft would be loose.

Any crack or damage? Any gap or step? ⑦ Contact DDK agent if there is any of them.

※Assemblying takes reverse procedure of disassemblying.

(1-2) Apply grease to gears

① Apply Grease to gear, use a grease gun if there is a grease nipple. (This does not apply to all

gears) If there is a screw plug, remove it and then use brushes, spatulas or grease gun to apply grease directly on gears.

② There is no problem to apply gears during inspection of (1-1).

③ Apply 10-20ml of grease.

④ Recommended Grease: Lithium General Grease CGR-160（TRUSCO）

Be sure to turn the power off to controllers to check or apply grease.

Fix press ram (Output Shaft) so that it will not fall.


Page 8-5

(2) Procedure to check ball screw, apply grease

(2-1) Procedure to check ball screw ① Turn the power OFF after advancing Ram roughly 100mm. ② Remove a plug of ball screw (Phillips Bolt) or screw plug. ③ Check ball screw through a screw hole with a light and see if there is any damage or is worn. ④ Contact FEC if there is any.

※ Take reverse procedure for assemblying.

(2-2) How to apply grease to Ball Screw ① Turn the power OFF to controllers. ② Remove plug on ball screw (Phillips Bolt) or screw plug. ③ Use a grease gun if there is a grease nippple. If not, Put the plug or screw plug back in, turn the

power ON to the controllers, advance Ram approximately 100mm, turn the power OFF to the controllers, and repeat procedure from ②.

④ Check the ball screw with light through a plug hole and apply grease with brushes or spatulas. ⑤ Apply approximately 10 to 20ml. ⑥ Recommended grease: High and Heavy Load Grease by YS2(Lube)

(3) How to check Ram and apply grease

(3-1) Procedure to check Ram ① Turn the power OFF to controllers after advancing Ram 100mm approximately. ② Check the Ram visually and see if there is any damage or is worn. ③ Contact FEC if there is any.

(3-2) How to apply grease on the Ram ① Turn the power OFF to controllers. ② Use a grease gun to apply grease on a grease nipple of Ram. ③ Apply grease approximately 10 to 20 ml.

④ Recommended Grease: Lithium Universal Grease CGR-160（TRUSCO）

※10t to 20t models are grease free type.

(4) How to check Brake Unit

① Turn the Power OFF to controllers. ② Remove cover (Phillips Bolts). There are two kinds, one covers only a brake unit, the other one

covers the entire brake unit and motor. With the one with covering brake unit and motor, remove connecting connector first before removing the cover.

③ Check if there is any damange or is worn. ④ Contact FEC if there is any.

Turn the power OFF to controllers to check or apply grease.




Page 8-6

(5) Check Home position of DPT Servo Press Operate Home Position Search and see if value of CCW limit Sensor shows between 1000 and 3000. If the value of CCW Limit Sensor does not show between 1000 to 3000, use the following procedure to adjust the sensor and check other items.

(6) How to adjust CCW Limit Sensor

① Removing Limit Sensor Cover CCW Limit Sensor Cover is attached on side of tool unit. There are two kinds, one covers only Limit Sensor and the other one covers tool and motor also. With one covering tool and motor, remove connecting connector first, and then remove the cover.

② Marking on Limit Sensor Mark the present position of Limit Sensor Bracket. Sensor Bracket appears as below

Mark here.

Mark here also.

③ How to adjust Limit Sensor position

If the value shows 0 through 1000, move the sensor to direction shown in A, if the value shows 3000 through 4095, move the sensor opposite direction shown in A. The direction means on top view (Pressing vertically to floor).

Tool Model A Direction

Adjust by 1000

Tool Model A Direction

Adjust by 1000

DPT-021R1-**F Downward 0.75mm DPT-201R3-**F Upward 0.25mm

DPT-021R3-**P Downward 0.31mm DPT-201R4H-**P Upward 0.25mm

DPT-051R2A-**F Upward 0.42mm DPT-301R4H-**F Downward 1.00mm

DPT-051R3-**P Upward 0.14mm DPT-301R4H-**P Upward 0.20mm

DPT-101R3-**F Upward 0.42mm DPT-501R4H-**F Downward 0.63mm

DPT-101R4H-**P Upward 0.42mm DPT-501R5B-**P Upward 0.25mm

DPT-151R3-**F Upward 0.42mm DPT-701R4H-**F Downward 0.42mm

DPT-151R4H-**P Upward 0.36mm DPT-701R5-**P Upward 0.18mm

In spite of adjusting the CCW Limit Sensor position, if the value moves more than 500, check gears and ball screw visually.

For models greater than 10ton, contact FEC on how to adjust.

If the value exceeded the adjustable range of sensor, contact FEC.


Page 8-7

8-2-2. DPM Tool

(1) How to check ball screw and apply grease

(1-1) Procedure to check ball screw ① Turn the power OFF to controllers after advacing RAM 20mm. ② Remove side plate to access ball screw (Hexagonal Flat Bolt). ③ Check the ball screw visually through hole with light to see if there is damage or is worn. ④ Contact FEC if there is any.

※Take reverse procedure for assembling the unit.

(1-2) How to apply grease on ball screw ① Turn the power OFF to controllers after advancing RAM 100mm (20mm min.). ② Remove side plate to access ball screw (Hexagonal Flat Bolt). ③ Apply Grease to ball screw with brush or spatula directly. ④ Apply grease approximately 10 to 20 ml.

⑤ Recommended Grease: Lithium Universal Grease CGR-160（TRUSCO）

(2) How to check RAM

① Turn the power OFF to controllers after advancing RAM 100mm. ② Check the RAM visually, see if there is any damage or is worn. ③ Contact FEC if there is any.

Turn the power OFF to controllers to check.



Page 8-8

(3) How to check belt and how to adjust tension

(3-1) Procedure to check belt ① Turn the power OFF to controllers. ② Remove a safety cover (Hexagonal Flat Bolt). ③ Check the belt visually if there is any damages or is worn. ④ Contact FEC if there is any.

※ Take a reverse procedure for assemblying.

(3-2) How to adjust belt tension.

① Turn the power OFF to controllers. ② Remove the safety cover (Hexagonal Flat Head Bolt). ③ Loose two bolts on motor slide plate. (Do not loosen too much otherwise the pulley may become

tilted.) ④ Turn the tension bolt on side of unit to adjust the tension. Moving the pulley toward motor

loses tension, and backward creates tension ⑤ On gaining proper tension, tighten the bolts to fix. And then, measure the tension again.

⑥ Repeat the procedure from ③～⑤ until gaining proper tension.

(*) Proper Belt Tension

(*1) Supersonic Tension Meter “U-507” (by Gates Unitta Asia) recommended (*2) Belt Manufacturer: Gates Unitta Asia

Tool Model Belt Model Tension [N]

DPM-050H1※ 198-3GT-9 44 （40～48）

DPM-011H1※ 198-3GT-9 44 （40～48）

Turn the power OFF to controllers before starting.

A Tension Checker is required for this operation.

Do not proceed without it.

Do not use if out of range, otherwise it may result in damage or failure.


Page 8-9

8-2-3. DPS Tool

(1) How to check ball screw and how to apply grease

(1-1) Procedure to check ball screw ① Turn the power OFF to controllers after advacing RAM 100mm. ② Remove plug for ball screw (Hexagonal Flat Bolt). ③ Check the ball screw visually through plug hole with light if there is damage or is worn. ④ Contact FEC if there is any. ⑤ Take a reverse procedure for assemblying.

(1-2) How to apply grease on ball screw

① Remove a plug of ball screw (Hexagonal Flat Head Bolt).

② Apply grease to grease nipple by grease gun.

③ Apply grease 10-20ml.

④ Recommended grease: High and Heavy Load Grease by YS2(Lube)

(2) Procedure to check RAM

① Turn the power OFF to controllers after advancing RAM 100mm. ② Check the RAM visually and see if there is any damage or is worn. ③ Contact FEC if there is any.

Turn the power OFF to controllers before starting.

Turn the power OFF to the controller to check.


Page 8-10

(3) Procedure to check Guide Key

① Turn the power OFF to controllers and check that servo press does not move. ② Hold RAM by a device other than servo press brake so that it would not fall. ③ Remove Guide Key (Hexagonal Flat Head Bolt) ④ Check faces indicated on this drawing visually and see if any damage or worn-out. (Remove

grease using cloth) ⑤ Contact FEC if there is any damage or excessive wear.

※Use reverse procedure for assembling.

・Apply new grease after wiping out grease.

・Apply grease approximately 10 to 20ml

・Recommended Grease: Lithium Universal Grease CGR-160（TRUSCO）

(4) Procedure to check Belt and Adjust Belt tention

(4-1) Procedure to check blet ① Turn the power OFF to controllers. ② Remove a safety cover (Hexagonal Flat Bolt). ③ Check the belt visually to see if there is any damages or excessive wear ④ Contact FEC if there is any.

※ Use reverse procedure for assembling.

(4-2) How to adjust Belt Tension

① Turn the power OFF to units. ② Remove safety cover (Hexagonal Flat Head Bolt). ③ Loosen the two bolts on motor slide plate. (Do not loosen too much otherwise pulley may become

tilted.) ④ Turn tension bolt on side of unit to adjust the tension. Moving the pulley toward to motor loosens

tension, and backward creates tension. ⑤ On gaining proper tension, tighten the bolts to fix. And then, measure the tension again.

⑥ Repeat the procedure from ③～⑤ until gaining proper tension.

※Proper Belt Tension

(a) A Supersonic Tension Meter “U-507” is recommended (by Gate Unitta Asia) (b) Belt Manufacturer by Gates Unitta Asia

Tool Model Belt Model Tension [N]

DPS-101R3※ 305-EV5GT-25 232 （209～255）

DPS-301R4※ 432-EV8YU-25 350 （315～385）

DPS-501R※ 560-EV8YU-40 500 （450～550）

DPS-102R※ 680-EV8YU-50 710 （660～760）

Turn the power OFF to controllers before starting the check.

Hold RAM not to fall by other than a servo press brake.

Turn the power OFF to controllers to adjust belt tension.

A Tension Meter is required for this operation. Do not try this without it.

Do not use if out of range, otherwise it may result in damage or failure.

Worn-out?


Page 8-11

(5) Check Home Position of DPS Servo Press Run Home Position Search and check if CCW Limit Sensor OFF falls in between 1000 and 3000. If the value of CCW Limit Sensor does not show 1000 to 3000, use the following procedure to adjust the sensor and check other items.

(6) How to adjust CCW Limit Sensor

① Removing Limit Sensor Cover CCW Limit Sensor Cover is attached on side of tool unit. There are two kinds, one covers only Limit Sensor and the other one covers tool and motor also. With one covering tool and motor, remove connecting connector first, and then remove the cover.

② Marking on Limit Sensor Mark the present position of Limit Sensor Bracket.

③ Sensor Bracket appears as below If the value shows 0 through 1000, move the sensor to direction shown in A, if the value shows 3000 through 4095, move the sensor opposite direction shown in A. The direction means on top view (Pressing vertically to floor).

Tool Model A Adjustment

By 1000

DPS-101R3-**F Downward 0.33mm

DPS-301R4H-**F Downward 0.63mm

DPS-501R4H-**F Downward 0.50mm



CCW Limit Sensor OFF position moves greater than 500, even after adjustment, check belt and ball screw visually.

For model greater than 10ton, contact FEC on how to adjust.

Contact FEC if it goes beyond CCW Limit Sensor adjustable range.

<<<<< Mark Here

<<<<< Mark Here


Page 8-12

8-2-4. Calibrate Load Cell

Press a master load cell by servo press and calibrate based on values from the master load cell. Since F-Type Tool cannot hold at rated load a long time, calibrate with value at peak load. P-Type can hold at rated load long enough to calibrate. Use data # 10: Full Scale Load to adjust the calibration. Contact FEC if a large scale calibration is required. Also, please consult FEC service department for calibration or periodical check.


9


Page 9-2

9-1. Abnormal Operation Indications

When an abnormal condition is detected in the Tool/Press Controller, the red STATUS LED of the

Press Controller turns on, and the display details the abnormality as: Abnormality No. in “PAR No.”

and Abnormality Sub No. in “D-No.”

Abnormality No.

PARNo. Indication Abnormality Type

A.01 Load Cell Error

A.03 Pre-amplifier Error

A.04 System Memory Error

A.05 Servo Reply Error

A.06 Servo Type Error

A.08 Servo Amplifier Error

A.09 Setting Data Error

A.10 Main System Error (multi-controller system error)

Abnormality Sub No.

Abnormality No.

STATUS LED lights in red


Page 9-3

9-2. Details of Abnormality / Cause and Countermeasures

When Abnormality Flag cannot be reset even after performing the specified recovery method or when mechanical breakage or failure is suspected, contact FEC.

9-2-1. A.01: Load Cell Error

Indication Description / Cause Recovery Method

A.01-01

Zero Master Error Abnormality detected by Zero Voltage

Check performed by Load Cell, when

control power supply is turned on.

1. Perform inspection of the Tool cable.

2. Confirm that the Tool has been securely installed.

3. Verify ZERO/CAL Voltage of the Load Cell.

4. Verify the drive load of the Servo Press.

5. Confirm that no stress is added to the Ram of the Tool.

6. Turn off the control power and wait at least 5 minutes

before turning on the power again.

7. Replace the Tool cable or the Tool itself with known good

spares.

*When jamming has occurred at the vertical ends of the

shaft, release it via Jog Advance / Return Operation, by

setting 1023 to the system parameter [SYS-052] No Load

Current Limit.

Contact us if the jammed parts cannot be released by

using the above method.

A.01-02

CAL Master Error Abnormality detected by CAL Voltage

Check performed by Load Cell, when

control power supply is turned on.

A.01-03

Zero Check Error Abnormal detected by Zero Voltage Check

performed by Load Cell at the start of

operation.

A.01-04

CAL Check Error Abnormal detected by CAL Voltage Check


operation, with the self check function

enabled.

A.01-05

CAL Judgment Error Abnormal detected by CAL Voltage Check


operation, without the self check function

enabled.

A.01-06

Started with ZERO Error Operation is started while Abnormal is

detected by Zero Voltage Check performed

by Load Cell at control power supply

turning on.

A.01-07

Started with CAL Error Operation is started while Abnormal is

detected by CAL Voltage Check performed

by Load Cell at control power supply

turning on.

・When any abnormal condition occurs, ensure safety measures are conducted

before restarting the operation.

・When a fatal error should occur in the Press Controller, the CONTROL POWER

LED lights in red without displaying the usual Abnormality code No.: When this

happens, contact FEC.


Page 9-4

9-2-2. A.03: Pre-amplifier Error


A.03-01 Pre-amplifier ID Data Error Abnormal error ID data within Pre-amplifier.

1. Inspect the Tool cable.

2. Tool cable or the Tool itself may have been malfunctioned

or damaged.

A.03-02 Tool Type Error D-No.100 [Connect Tool No.] and D-No.200

[Setting Tool No.] do not match.

1. Set the same value for the Tool No. “D-No.100 and “D-

No.200” in the system parameter (PRR No. SYS).


or damaged.

A.03-03 Tool Not Connected

The Tool is not connected.



damaged.

A.03-04 CCW Limit Sensor Position Abnormal error occurred in CCW Limit

Sensor position

1. Confirm that the CCW sensor turns ON and OFF by

raising and lowering operation in the Manual mode.

2. Refer to the Repair and Maintenance section for Home

Position check and readjustment, and perform

readjustment of CCW limit sensor position.

* For the DPM Tool, contact FEC.

A.03-05 Home Search Time Out Home Search operations not completed

within the set period.

Verify settings for the system parameter: [SYS-056: Home

Search Time Out] and [SYS-057: Home Search Speed].

Check if Home Search operation completes within the set

period.

9-2-3. A.04: System Memory Error


A.04-01 Flash ROM Write Error Error occurred during writing process of the

Flash ROM for the Press Controller.

1. Turn off the control power and wait at least 5 minutes


2. The Press Controller may have been malfunctioned or

been damaged.

A.04-02 Flash ROM Read Error Error occurred during reading process of

the Flash ROM for the Press Controller.

A.04-03 Amplifier Flash ROM Error Error occurred during reading or writing

process of Amplifier Flash ROM.

A.04-04 Stored Data Write Error Error occurred during writing process for the

SDRAM saving.

A.04-05 Stored Data Read Error Error occurred during reading process for

the SDRAM saving.

A.04-06 RTC Write Error Error occurred in writing settings to RTC

A.04-07 RTC Read Error Error occurred in reading settings from RTC


Page 9-5

9-2-4. A.05: Servo Reply Error


A.05-01

Servo Reply Error Position Pulse from the Resolver indicating

the Tool operation is not changing. Or, the

speed command of the amplifier is not

responding.

1. Inspect the Tool cable or the Tool itself.

2. Replace with a spare cable if any.

3. Replace the Tool.

4. Tool cable or the Tool itself may have malfunctioned or

been damaged.

5. Verify [SYS-052 No Load Current Control Value] (250 to

500) in the system parameters.

If any heavy jig is mounted on the end of the output shaft,

raise its setting value.

6. Verify the Drive Load of the Servo Press.

7. Check that the brake release operates.

9-2-5. A.06: Servo Type Error


A.06-01 Servo Type Mismatch Motor Type and Press Controller Type

do not match.

1. Exchange Press Controller.

[Press Controller Type] [Motor Type]

MFC-S024S RM1, RM2, RH1

MFC-S060S RM3

MFC-S120S RM4H, RM5

2. The Tool or the Press Controller has malfunctioned or

been damaged.

9-2-6. A.08: Servo Amplifier Error


A.08-01 Driver Overheat Error

The Press Controller has overheated

and its servo drive circuit failed.

1. Check if the ambient temperature is within 0 to 45

degrees centigrade.

2. Verify that the duty cycle is within the specified range.

3. Turn off the control power and wait at least for 5 minutes


A.08-02 Watchdog Timer Error The watchdog timer of the Press Controller

has malfunctioned.

The Press Controller has malfunctioned or been damaged.

A.08-03

Drive Power Error The driving power supply has been

disconnected. Or, the driving power supply

has been turned off during press operation.

1. Inspect the driving power cable.

2. Confirm that the power supply voltage of the driving

power supply is between 200VAC and 230VAC.

3. There may have been a momentary power failure: Check

the power source capacity.

A.08-04 Overcurrent Error

The Press Controller has overheated.

1. Check the speed setting value.


3. The Tool cable or the Press Controller has malfunctioned

or been damaged.

A.08-05 Overvoltage Error

The Press Controller has overheated.

1. Check the speed setting value.



3. The Press Controller has malfunctioned or been damaged.


Page 9-6

A.08: Servo Amplifier Error


A.08-06

Source Voltage Error 1. The internal power supply circuit of the

Press Controller has malfunctioned.

2. The power supply voltage is outside the

specified range 200 ~ 230VAC.

1. Check the wiring of the control power supply.

2. There may have been a momentary power failure:

Check the power source capacity.

A.08-07

Control Power Voltage Drop Error

Power supply voltage of the driving power

supply has dropped and is between 18V

and 17V.

1. Check the wiring of the control power supply.

2. There may have been a momentary power failure:

Check the power source capacity.

A.08-08 Over-speed Error The Press Controller is unable to control the

motor rotation.


2. The Tool cable or the Tool itself has malfunctioned or

been damaged.

A.08-09 CPU Error Abnormal error occurred in the CPU of the

Press Controller. The Press Controller has malfunctioned or been damaged.

A.08-10 Overload Error

The motor protection circuit has

malfunctioned.

1. Check the Work piece.

2. Confirm that the duty cycle (the ratio of the operating time

to the downtime) is within the specified range.

3. Shorten the operating time by increasing the Part Search

Speed and the Press Speed 1, 2.

4. Increase the Press Speed 1, 2 Start Load.

5. Allow a longer interval time to the next operation.

6. Shorten the Target Hold Time.


8. If a brake is used, check the release actuation of the

brake.

A.08-11 Resolver Error The Press Controller cannot recognize the

resolver. The function has been disabled.


2. The Tool cable or the Tool itself has malfunctioned or

been damaged.

A.08-12 System Error Abnormal error occurred in the Press Controller.

The Press Controller has malfunctioned or been damaged.

A.08-13 Current Sensor Error Abnormal error occurred in the current sensor of the Press Controller.

A.08-14 Motor Parameter Error Abnormal error occurred in an internal

parameter of the Press Controller.

A.08-15 Drive Board Error Abnormal error occurred on the drive board.


Page 9-7

9-2-7. A.09: Setting Data Error


A.09-02 Load Setup Error Load setting value has not been setup.

Setup the correct value if “0” or any value outside the range

is set for the following:

・D-No.102 [Final Load High Limit] *1

・D-No.103 [Load High Limit]

・D-No.104 [Target Load] *2

・D-No.116 [Part Check 2 Load High Limit] *3

・D-No.118 [Part Check 3 Load High Limit] *4

*1: In case the Press Method is other than 0, 1, 5, and 8. *2: In case the Press Method is other than 1 and 9 *3: In case the Part Check 2 in Judgment Operation 2 is set

to “ON”. *4: In case the Part Check 3 in Judgment Operation 2 is set

to “ON”.

A.09-03 Distance Setup Error Distance setting value has not been setup.

Setup the correct value if “0” or any other value outside the

expected range is set for the following:

・D-No.211 [Detection Start Distance] *1

・D-No.212 [Detection End Distance] *2

・D-No.216 [Part Check 1 Distance High Limit] *3

*1, 2: In case the Press Method is 4 and if any of the following applies, an abnormal error occurs.

・*1 is 0 or greater, and *2 is less than 0.

・*1 is less than 0, and *2 is 0 or greater.

・*1 is greater than *2.

*3: In case the Part Check 1 in Judgment Operation 2 is set to “ON”.

A.09-04 Speed Setup Error Speed setting value has not been setup.

Setup the correct value if “0” or any value outside the range

is set for the following:

・D-No.400 [Slow Start Speed]

・D-No.401 [Approach Speed]

・D-No.402 [Part Search Speed]

・D-No.403 [Press Speed 1]

・D-No.404 [[Press Speed 2]

・D-No.405 [Load Hold Speed]

・D-No.406 [Decompression Speed]

・D-No.407 [Return Speed]

・D-No.SYS-057 [Home Position Search Speed]

・D-No.SYS-058 [Home Return Speed]

・D-No.SYS-059 [Jog High Speed]

・D-No.SYS-060 [Jog Medium Speed]

・D-No.SYS-061 [Jog Low Speed]

A.09-08 Parameter Number Select Error

Abnormal error occurred in the selected

parameter No.

Check the parameter No. selected.

A.09-09

Press Number Set Value Error 1. Press No. for the Press Controller is set to

a number other than 1 to 32.

2. SW: 8 for the 2nd Controller and after are

set to “ON”.

1. Check the rotary switch for the AXIS ADDRESS (Press

No.) after turning off the Press Controller and removing

the display on the front panel.

2. Confirm setting set for SW1:8 on the front after turning

off the Press Controller and removing the display on the

front panel.


Page 9-8

A.09: Setting Data Error


A.09-10 Overload : Jog Return / Auto Return Load exceeding 1/6 rated value has been

detected.


2. Confirm that no additional stress is being added to

the output shaft of the Tool.

3. Perform an operation after having released the

brake

and the load while the Servo Press is in “OFF”

state.

4. The Tool or the Press Controller has malfunctioned

or may have been damaged.

5. In case the next operation is to be started while the

load is being applied, set the “Disable Self-check” in

the parameter [D-No.001 Press Option 1], and input

the start signal.

*Reduce the weight of jigs or take other

countermeasures in the case of punching operations

A.09-11 Overload : Jog Advance Load exceeding 1/6 rated value has been

detected during a Jog Advance.

A.09-12 Overload : Home Search Load exceeding 1/6 rated value has been

detected during a Home Search.

A.09-13 Overload : Home Return Load exceeding 1/6 rated value has been

detected during a Home Return.

●Check Method for the Drive Load

In case the output shaft is mounted to a bearing or rail guide, and a driving force becomes necessary to move this guide, the Servo Press will look as if load is being generated. In order to verify to what extent the drive load is being generated, monitor the load value displayed in real time display mode. This can be performed by setting the display to the load value monitoring state and then performing jog advancing operation in manual mode. This will activate the load value display in real-time. Check the current load value (Drive Load).

Be sure to confirm the following when performing the check. (1) Emergency stop signal is cleared. (2) If a brake is applied, check that the release actuation of the brake during Servo Press operation is

operating normally. (3) The system parameter [SYS-059: Jog High Speed] is approximately 10mm/sec. (4) There is no mechanical interference during operation.


Page 9-9

9-2-8. A.10: Multi System Error

*Available in the Multi System only.


A.10-01

Sequence Selection Error Abnormal error occurred to the sequence No.

selected at the start of the sequence

operation.

1. Check the sequence selection in the PLC.

2. RS232C input format: Check the sequence selection

setting.

A.10-02

Press Not Found 1. Sequence operation has started with the

Press Communication Cable connector

disconnected.

2. The Press Controller of which the Use

Press No. has been enabled in the

sequence setting the start of the sequence

operation is not responding.

1. Check the Press Communication Cable and its

connector.

2. The Press Controller has malfunctioned or may be

damaged.

A.10-03

Sequence Pressing Error The Press Controller is not responding

during the pressing operation in the

sequence.

Contact FEC if abnormal error occurs frequently.

A.10-04 Missing Press Select in Sequence The sequence operation has started with no

Use Press No. selected in the sequence. Check the sequence selection in the PLC and the

sequence setting.

A.10-05 Sequence is not Set The operation has started by selecting

sequence with no setting.

A.10-06

Sequence Setting Error Abnormal error occurred in the sequence setting at the start of the sequence operation or during operation.

Confirm the sequence setting.

A.10-07 Press Not Homed At operation sequence start the press motion axis home position has not been determined

Perform the Home Search operation.

A.10-08

Drive Power OFF Press Detected The driving power supply of the Press

Controller of which the Use Press No. was

set at the start of the manual operation or

sequence operation, has been turned OFF.

1. Perform inspection of the driving power cable.



3. There is the possibility that momentary power failure has

occurred: Check the power source capacity.

A.10-09

Communication Error 1. A Press Controller with” Single System”

setting has been detected from the SLAVE

Controllers.

2. Abnormal error has been detected from

transmitted data from a SLAVE Controller.

1. Change settings in the “Multi System” in D-No.003

[System Select] of the system parameter (PAR No.SYS)

2. Contact FEC if this abnormal error occurs frequently.

A.10-10 Expanded I/O unpopulated Expansion I/O is disconnected.

Connect the expansion I/O such as the Field Bus.

A.10-11 Press Number Select Error The press No. for Jogging operation has not

been selected.

Confirm the Press Controller selection in the PLC.


Page 9-10

9-3. Press Controller Judgment: Confirmation of REJECT status

During pressing judgment operations by the Controller, if values are determined during normal press

operations to be outside the previously set upper and lower limits of the press parameters, rejects will

occur, and the JUDGE LED of the Press Controller lights up in red.

The first encountered reason detected for operation stop can be confirmed on the display.

●Confirmation of the pressing operation

Step 1．After completion of the pressing operation, as shown above, “r.**” will be displayed in the

PAR No. display of the indicator of the Press Controller. The two digits shown in “**” represent the last operated parameter Nos.

Step 2．*Available only in the multi-controller system.

By pressing the [▲] and [▼] switch below the display, the sequence Nos. of the operations that have

been completed can be confirmed. If “13” is selected in the D-No. display, the two digits that will appear in the “**” part of the ”S**” shown in the upper row of the display represent the sequence No. of the last completed operation. *Sequence No. is available in the display of the Master Controller only.

Step 3．By pressing the [▲] and [▼] switch below the display, the parameter Nos. that have

completed the operation can be confirmed. If “14” is selected in the D-No. display, two digits that will appear in the “**” part of the ”P**” shown in the upper row of the display will represent the parameter No. that has completed its operation.

●Confirmation of the cause of operation stop

Step 1．Press the [▲] and [▼] switch below the display, and select “11” in the D-No. display. The

cause of operation stop will be displayed in the upper row of the display.

Step 2．In case a REJECT has occurred as a result of a pressing judgment, the D-No. “12” displayed

in the D-No. display represents the first stopped parameter setting value. (104 in this case represents the upper limit of the load). As to items where REJECT status has been determined as a result of a pressing judgment, “H/L” will be shown in the top digit of the number displayed in the upper row of the display.


Page 9-11

9-4. RTC

A real time clock (RTC) is installed in the Press Controller for retention of date and time data.

・Model type: ANG－RTC

・Backup power source: Electric double layer condenser

Available period for backup creation in the power-off state: Approx. 1000 hours

Required period of power-on required for fully charging the clock unit: 1 hour

Note that internal time setting of the Press Controller will be cleared in the case where it is powered down for more than two months (including backup units).

●Change date/time setting for the Press Controller (Indicator)

(1) By pressing the ▲, ▼ switch below the display, select from the PAR No. display: SYS, and in

the D-No. display: 019, and confirm that 020:RTC: Year/Month/Date/(Time) is displayed.

(2) Switching the RUN/BYPASS switch to BYPASS enables switching to Setting Value Edit mode:

Press the [◎(SET)] switch.

(3) By pressing the ▲, ▼ switch, change any given values

(▲or ▼ switch increases or decreases the value, and or switch moves the cursor)

(4) Switch from [NO] [YES] using the ▲,▼ switch within 2 seconds from pressing the [◎(SET)]

switch. Then press the [◎(SET)] switch once again.

(5) The setting will be completed by switching to the RUN mode using the RUN/BYPASS switch of the Press Controller.

*Date and time can be synchronized over the network (PC) by selecting the [Date/Time] on the User

Console.

Date and time settings change

◎(SET) [▲]

[▼]

The clock will accumulate an error of about 10 minutes per month: Check and

adjust the time setting regularly.


Page 9-12

Memo

Documents

DSP3000 Expansion Unit Manual - FEC-USA