System - You are now at the Down-Load Site for Tol-O - Tolomatic

3600-4640_00

SystemUser Manual

TOL-O-MATIC, INCExcellence in Motion®

ELECTRIC LINEAR MOTION PRODUCTS

© Copyright 2004 Tol-O-Matic, Incorporated. All rights reserved. Axidyne and Tol-O-Matic are registered trademarks of Tol-O-Matic Incorporated. All other products or brand names are trademarks of their respective holders.

3/04

1: Health and Safety Regulations .................................................1-11.1 General .....................................................................................................1-11.2 Warning for hot surfaces .........................................................................1-11.3 Modifications to equipment...................................................................1-11.4 Requirements regarding personnel .......................................................1-21.5 Packing, transport and unpacking.........................................................1-21.6 Risk area and personnel..........................................................................1-21.7 Repair and maintenance ........................................................................1-2

2: General .............................................................................2-12.1 Intended use ............................................................................................2-1

2.1.1 Weld Axis component system.........................................................2-12.1.2 Weld Axis panel system ..................................................................2-2

2.2 Identification ...........................................................................................2-42.2.1 Actuator identification ..................................................................2-42.2.2 Weld Axis component system.........................................................2-52.2.3 Weld Axis panel system ..................................................................2-5

2.3 Manufacturer ...........................................................................................2-6

3: Function Description .............................................................3-13.1 Weld Axis controls ...................................................................................3-13.2 Hand-held teach pendant ......................................................................3-23.3 Single board computer............................................................................3-23.4 Axiom Plus (PV) .......................................................................................3-2

4: Installation ........................................................................4-14.1 Installing the weld actuator ....................................................................4-14.2 Installing the weld component system..................................................4-14.3 Installing the Weld Axis panel system....................................................4-14.4 Power required for Weld Axis ..................................................................4-14.5 Interface to master controller.................................................................4-24.6 Setup.........................................................................................................4-2

4.6.1 General............................................................................................4-24.6.2 Inspection of mechanical travel limits..........................................4-24.6.3 Axiom Plus controller setup...........................................................4-34.6.4 Axiom Plus PLC program...............................................................4-44.6.5 Axiom Plus sequential program....................................................4-64.6.6 Weld Axis teach pendant / single-board computer.......................4-6

4.6.6.1 Menu Structure .....................................................................4-64.6.6.2 Setup weld data ....................................................................4-8

5: Repair and Maintenance ........................................................5-15.1 Weld actuator ...........................................................................................5-15.2 Weld Axis control panel...........................................................................5-1

5.2.1 Testing of the actuator weld force..................................................5-15.2.2 Changing the caps..........................................................................5-1

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Contents

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6: Appendix ...........................................................................6-16.1 Motor specifications................................................................................6-1

6.1.1 HT12 ...............................................................................................6-16.1.2 HT23 ...............................................................................................6-1

6.2 Connector pinout ....................................................................................6-26.2.1 Motor armature..............................................................................6-26.2.2 Motor encoder ................................................................................6-26.2.3 Teach pendant................................................................................6-3

6.3 Weld Axis base system wiring diagram ..................................................6-46.4 Weld Axis panel system wiring diagram ................................................6-56.5 Axiom Plus standard PLC program ........................................................6-96.6 Axiom Plus standard sequential program ...........................................6-19

LIST OF FIGURES

Figure Description2.1 Weld Axis component system ............................................................2-22.2 Weld Axis panel system.......................................................................2-32.3 HT series weld actuator.......................................................................2.42.4 Actuator identification label...............................................................2-42.5 Control panel label..............................................................................2-53.1 Example Weld Axis control panel.......................................................3-13.2 Hand-held teach pendant ..................................................................3-24.1 Manual operation of HT series actuator ...........................................4-24.2 Axiom Plus setup and configuration screen .....................................4-34.3 Axiom Plus register precision configuration screen.........................4-44.4 I/O table ...............................................................................................4-54.5 Teach pendant menu structure..........................................................4-76.1 Pinout of motor armature connection ..............................................6-26.2 Pinout of motor encoder connection ................................................6-26.3 Pinout of teach pendant connection.................................................6-36.4 Base system wiring..............................................................................6-46.5 Weld Axis HT12 3-phase wiring diagram (1 of 4) ..............................6-56.6 Weld Axis HT12 3-phase wiring diagram (2 of 4) ..............................6-66.7 Weld Axis HT12 3-phase wiring diagram (3 of 4) ..............................6-76.8 Weld Axis HT12 3-phase wiring diagram (4 of 4) ..............................6-8

C O N T E N T S

1.1 General

Read completely through the applicable sections of the manualbefore the equipment/unit is unpacked, installed or operated. Paycareful attention to all of the dangers, warnings, cautions and notesstated in this manual.

Serious injury to persons or damage to the equipment may result ifthe information contained in this manual is not followed.

Items that are specifically marked DANGER!, WARNING!,CAUTION!, OR NOTE!, are arranged in a hierarchical system andhave the following meaning:

DANGER! Indicates a very hazardous situation which, if notavoided, could result in death or serious injury. This signalword is limited to the most extreme situations.

WARNING! Indicates a potentially hazardous situation which,if not avoided, could result in death or serious injury.

CAUTION! Indicates a potentially hazardous situation which, ifnot avoided, this situation may result in property damage orminor or moderate injury.

NOTE! This Information requires special attention.

1.2 Warning for Hot Surfaces

WARNING! Normal operating temperature of weld actuatorcan reach 175 Degrees F.

1.3 Modifi cations to the equipment

WARNING! The manufacturer takes no responsibilitywhatsoever if the equipment is modified or if the equipment isused in any way not intended at the time of delivery.Unauthorized modifications or changes to the equipment arestrictly forbidden.

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Health and Safety Regulations 1

1.4 Requirements regarding Personnel

NOTE! All personnel must be completely informed regardingall safety regulations and the function of the equipment.

1.5 Packing, T ransport and Unpacking

NOTE! Anchor and secure actuator in such a way as to preventdamage during transport. Also make sure the actuator is cleanand dry and protected from moisture.

1.6 Risk Area and Personnel

WARNING! When Weld Axis components are installed in a weldgun, pinch points are generated that exert dangerous forcescapable of severe bodily injury. The risk area surrounding theweld actuator must either be enclosed or clearly markedincluding display signage in accordance with all applicablenational and international legal requirements for weldingactuators. The risk area must be protected by a safety systemthat stops the equipment if anyone enters the risk area.Personnel who enter the risk area must be authorized, trainedand qualified for the different tasks inside the risk area.

1.7 Repair and Maintenance

All supply media must be shut OFF (electricity) before any work isbegun on any equipment that is associated with the welding gunapplication.

1 : H E A L T H A N D S A F E T Y R E G U L A T I O N S

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2.1 Intended Use

The Weld Axis System is intended to be used as a servo retrofit to anexisting pneumatic actuator on a spot welding gun where inputsfrom a primary controller such as a robot, weld controller, or PLCpoint to a weld schedule(s) and triggers the servo actuator to close.The Weld Axis System is also intended to be a cost-effectivealternative to the 7th axis of robots, as well as in fixture applicationswhere no other motion control exists.

The Weld Axis functions as a motion controller, a motor driver, and aconvenient setup and calibration tool for servo welding. Setup andcalibration is performed using a hand-held teach pendant. Setupinformation is retained within a removable flash card on thecomputer and not in the teach pendant, allowing a single teachpendant to be used with multiple systems.

The Weld Axis System can be supplied as a component system forconvenient integration into existing panels or as a complete systemin its own enclosure

2.1.1 WELD AXIS COMPONENT SYSTEM

The Weld Axis Component System includes the following:• Servo weld actuator • Controller/drive (Axiom Plus PV20 or PV30)• Single board computer• Hand-held teach pendant (one may be used for multiple systems)• 24 VDC Power supply• Cables and Connectors• Schematics/wiring diagrams

Components are integrated into the users panel as shown in Figure 2.1

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General Information 2

Figure 2.1 – Weld Axis Component System

2.1.2 WELD AXIS PANEL SYSTEM

The Weld Axis Panel System shown in figure 2.2 includes the itemsfrom the base system plus a control reliable E-stop system allmounted into a NEMA 12 rated enclosure

HH

AA GG

BB

CCDD

EE

FF

SingleBoard Computer

24 Vdc50 WattPowerSupply

MotorArmature

MotorEncoder

SupplyPower

TeachPendant

Connector

COM/SHLDMOT TEMP

ENCODEROUT

ENCODERFOLLOWER

R

S

T

TB3

TB2

TB1

COMM

BRAKE

BRAKE

REGEN COM

EXT REGEN

INT REGEN

COM 13-15INPUT 7INPUT 8INPUT 9

ENC +5VA+A-B+B+I+I-

J7

J6

Out 1+Out 1-Out 2+Out 2-Out 3+Out 3-

+24Vdc24 Vdc RTNOut 4+Out 4-Out 5+Out 5-

Out 6+Out 6-Out 7+Out 7-Out 8+Out 8-

+24Vdc24 Vdc RTN

COM 1-6INPUT 1INPUT 2INPUT 3INPUT 4INPUT 5INPUT 6

+24Vdc24 Vdc RTN


INPUT 10INPUT 11INPUT 12

J1

J3

J2

J5

J4

Red

White

Black

Green/Yellow

L3

L2

L1

GND

BrownOrange

YellowVioletGrayBlack

WhiteBlue/Grn/Shield

Red

Pin 3Pin 5

Pin 2L3

L2

L1

RXD1

TXD1

TXD2

RXD2 IN0

RA

WG

ND

L1 L2 GND

O VdcGNDNL + 24 Vdc

2 : G E N E R A L I N F O R M A T I O N

2 - 2

Figure 2.2 – Weld Axis Panel System

The following options are available:• Devicenet interface.• Thirty meter motor and encoder cables• Drive isolation transform

WARNING! Before installation and commissioning of theequipment, this manual and all accompanying manufacturerdocuments and manuals MUST be completely read by theconcerned personnel. All warning texts must be given specialattention.

GNDGNDGNDGND

END CVREND CVREND CVREND CVR

GNDGND

CB 2AMP 1PCB 2AMP 1P CB 25AMP 1PCB 25AMP 1P

SSTERMSSTERMSSTERMSSTERMSSTERMSSTERMSSTERMSSTERMSSTERMSSTERMSSTERMSSTERM SSTERMSSTERMSSTERMSSTERMSSTERMSSTERMSSTERMSSTERMSSTERMSSTERMSSTERMSSTERMSSTERMSSTERMSSTERMSSTERMSSTERMSSTERMSSTERMSSTERM SSTERMSSTERMSSTERMSSTERMSSTERMSSTERMSSTERMSSTERM

END CVREND CVRSSTERMSSTERM SSTERMSSTERM SSTERMSSTERM SSTERMSSTERM SSTERMSSTERM

END CVREND CVR

SSTERMSSTERM SSTERMSSTERM SSTERMSSTERM SSTERMSSTERM SSTERMSSTERM SSTERMSSTERMEND CVREND CVR END CVREND CVR

END CVREND CVR

CB 2AMP 1PCB 2AMP 1P CB 25AMP 1PCB 25AMP 1P CB 25AMP 1PCB 25AMP 1P

SSTERMSSTERM SSTERMSSTERM

OUT 6 +OUT 6 -OUT 7 +OUT 7 -OUT 8 +OUT 8 -

+24 Vdc24 Vdc RTNOUT 4 +OUT 4 -OUT 5 +OUT 5 -

+24 Vdc24 Vdc RTN


+24 Vdc24 Vdc RTN



ENC +5VA +A –B +B –I +I –

COM/SHLDMOT TEMP

ENCODEROUT

ENCODERFOLLOWER

BRAKE

BRAKE

REGEN COM

EXT REGEN

INT REGEN

R

S

T

L3

L2

L1


COMM

WARNING: VOLTAGE EXISTS UP TO 2 MIN.AFTER POWER IS REMOVED

TOL-O-MATICHAMEL, USA

J1

J2

J3

J4

J6

P1

P2

TB2

TB1

TB3

HandheldTeachPendant

HT12Actuator

DS106?

DISCONNECTSWITCH

PS24V50W305

POWERSUPPLY

SAFERELAY314

SAFETYRELAY

SAFETYCONTACTOR

SAFETYCONTACTOR

DEVICENETI/O BOX

POWERDIST

BLOCK

SBCOMPUTER328?

SINGLE BOARDCOMPUTER

2 - 3

G E N E R A L I N F O R M A T I O N : 2

2.2 Identification

2.2.1 ACTUATOR IDENTIFICATION

Figure 2.3 shows an example of a standard Tol-O-Matic, Inc. HTseries actuator.

Figure 2.3 – HT series weld actuator

Figure 2.4 shows a sample label that is affixed to the actuator. Donot remove the actuator identification label and do not make itunreadable!

Figure 2.4 – Actuator identification label


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2.2.2 WELD AXIS COMPONENT SYSTEM

The Weld Axis Component system consists of the following parts:

DESCRIPTION QUANTITY

PWR SUP,24VDC,50W 1

Weld Axis SBC WITH 1

ASSY,CABLE W/CONN,SBC 1

CABLE,RS232 1

CABLE,AXIOM PLUS/SBC 1

AXIOM PLUS,PV20,W/SFT 1

CABLE ASSY,15M,POWER 1

CABLE ASSY,15M,ENCODER 1

The following table shows the proper Axiom Plus(PV) to be use withthe various size weld actuators:

Actuator Model # Axiom Plus Model #

HT7 PV10

HT12 PV20

HT23 PV30

SWxx PV30

2.2.3 WELD AXIS PANEL SYSTEM

In the Weld Axis panel system manufactured by Tol-O-Matic, Inc.there will be a label affixed to the inside of the control panel door(see figure 2.5).

Figure 2.5 – Control Panel Label

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G E N E R A L I N F O R M A T I O N : 2

2.3 Manufacturer

Tol-O-Matic, Inc.3800 County Road 116Hamel, MN 55340USA763-478-8000

Perform repairs, maintenance and inspections before storing theactuator to ensure that the gun is in good working order.Make sure the actuator is placed in a suitable storage position toprevent damage to the connectors and electronics. Store the controlcabinet in a clean dry place with humidity between 5% and 95%, non-condensing. Make sure the temperature is between -4° to 158° F (-20°to 70° C).


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3.1 Weld Axis Controls

The Weld Axis controls are used to control the position and force ofthe weld actuator based on the inputs from a master controller. TheI/O structure is designed to mimic a pneumatic system allowing foreasy retrofitting into an existing application. Figure 3-1 shows anexample Weld Axis panel system.

Figure 3.1 – Example Weld Axis control panel

WARNING! High voltage may be present on the terminals ofthe unit. Remove power and disconnect the power cablebefore making or removing any connection.

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System Functionality 3

3.2 Hand-held T each Pendant

The hand-held teach pendant is used as the operator interface. Theoperator enters the setup and welding parameters and the values aretransferred to the Single Board Computer/removable flash card. Thesame hand-held teach pendant can be used with multiple systems.If an installation has multiple Weld Axis systems only one hand-heldteach pendant would be needed.

Figure 3.2 – Hand-held teach pendant

3.3 Single Board Computer

The single board computer gets user data from the hand held teachpendant and converts the user data into the register values that theAxiom Plus requires. The single board computer can backup thedata entered by the user and the Axiom Plus program to a removableflash memory card.

3.4 AxiomPlus (PV)

The Axiom Plus controller/drive provides the power to run themotor and the logic to respond to the interface signals. The AxiomPlus runs PLC and Sequential programs to produce the desiredmotion and weld forces. For more information on the Axiom Plussee the Axiom Plus Users Manual (3600-4628).

3 : S Y S T E M F U N C T I O N A L I T Y

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4.1 Installing the Weld Actuator

Please refer to your weld gun documentation for mechanicalinstallation

4.2 Installing the Weld Axis Component System

The Weld Axis Component System includes the necessary parts tointegrate a Weld Axis system into an existing enclosure or customerdesigned control panel. A wiring diagram is included in appendix6.3. The heat dissipation of the Axiom Plus for cabinet sizing is:

Actuator Model Axiom Plus Model Heat dissipation

HT7 PV10 28 Watts

HT12 PV20 47 Watts

HT23 PV30 65 Watts

SWxx PV30 65 Watts

4.3 Installing the Weld Axis Control System

Weld Axis enclosures supplied by Tol-O-Matic, Inc. are NEMA 12rated and should be mounted in a location were the environmentdoes not exceed the specifications of the NEMA 12 rating.

4.4 Power required for the Weld Axis

Tol-O-Matic recommends the Weld Axis system be used with threephase 208-230 VAC power. The table below lists the requiredamperage. If a step down transformer is required, it isrecommended a drive isolation type transformer with a deltaprimary and a wye secondary winding be used.

HT23 &HT7 (PV10) HT12 (PV20) SWxx (PV30)

Maximum Input Current Single Phase 12.5 A (rms) 25 A (rms) 37.5 A (rms)

Maximum Input Current Three Phase 7.5 A (rms) 15 A (rms) 22.5 A (rms)

Input Voltage (Single or Three Phase) 190VAC – 250VAC 190VAC – 250VAC 190VAC – 250VAC

Peak Inrush Current 65 A 160 A 160 A

Input Frequency 47 Hz – 63 Hz 47 Hz – 63 Hz 47 Hz – 63 Hz

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Installation 4

4.5 Interface to master controller

The Weld Axis is designed to operate as a slave to a master controller.The interface can be customized to work with an existing mastercontroller.

4.6 Setup4.6.1 GENERAL

Before commissioning the weld actuator, there are certaininspections and settings that must be carried out. Also aftermaintenance activities, the gun must be inspected before it isreturned to service.

4.6.2 INSPECTION OF MECHANICAL TRAVEL LIMITS.

The mechanical travel limits of the actuator must be verified toensure the actuator will not reach an internal hard limit duringnormal operation. Turn the controller power off. With the actuatorinstalled on a weld gun, manually rotate the servo gun gear or pullthe gun arms apart, extending the tube until the weld gun tips areclosed and record the distance the rod is extended (d1). Remove onearm and manually rotate the servo gun gear or push the gun armstogether, until the actuator reaches its end of travel and record thedistance the rod is extended (d2). The difference between the twomeasurements, minus the gun deflection (d3) should be greaterthan 5 mm (d2 - d1 - d3 ≥ 5mm).

Figure 4.1 – Manual operation of HT series actuator

4 : I N S T A L L A T I O N

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4.6.3 AXIOM PLUS CONTROLLER SETUP

The setup of the Axiom Plus only needs to be verified during initialinstallation. All settings are backed up on the Single BoardComputer (SBC) flash memory card. Using the Axiom Plusprogramming software running on a PC the following selections areverified:

1. Select the correct indexer model being used.2. Select the motor winding being used. This information is

indicated on the actuator label3. Select the register precision. See figure 4.3 for settings.

After the settings have been made, they should be downloaded tothe Axiom Plus using the “Download Parm’s to indexer” button.

Figure 4.2 – Axiom Plus Setup and Configuration Screen

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I N S T A L L A T I O N : 4

Figure 4.3 – Axiom Plus Register Precision Configuration Screen

4.6.4 AXIOM PLUS PLC PROGRAM

The Axiom Plus PLC program needs to be set up to match the I/Orequirements and assignment of the supervisory controller. A listingof the Axiom Plus standard PLC program is included in the appendix6.5. The first 12 rungs of the PLC program are used to assignphysical inputs to local flags and the next 3 rungs assign internalflags to physical outputs. Although physical inputs can bereassigned to any of the internal flags, it is recommended that thedefault assignment be used. The PLC program contains the logic todetermine what routine that the sequential program will run basedon the inputs from the master controller. The following table is a listof the I/O in the standard Weld Axis PLC program.


4 - 4

Physical Input Internal Flag DescriptionIN001 LF001 "Binary 1" - Binary 1-8 input sequence is used to select the weld

schedule 1-15. The binary sequence has to be set before the

close gun command is received for the master controller.

IN002 LF002 "Binary 2"



IN005 LF006 "Backup 1" - Backup 1-4 input sequence is used to select the

open positions 0-7 based on the

IN006 LF007 "Backup 2"

IN007 LF008 "Backup 4"

IN008 Spare

IN009 LF005 "Close" - When input is on the actuator will close at the position

and pressure set with binary 1,2,3,4 and remain closed until the

input is removed.

IN010 LF019 "ClearErr" - Clears the position error output.

IN011 LF012 "CheckCap" - Used to check the wear of the caps. When this

input is on and the close signal is received the actuator will close

at a slow speed until the tips touch. If the caps are worn past the

value entered in the TP then the "CapWore" output will be

activated.

IN012 LF017 "ManNewCP" - Used to indicate that new caps have been

installed. When this input is on and the close signal is received

the actuator will close at a slow speed until the tips touch. This

position will become the new cap value.

IN013 spare

IN014 spare

IN015 LF010 "No Estop" - When input is on drive stage will be enabled

OUT1 STP021 "Sig Weld" - Ready to weld signal

OUT2 IS002 "Fault" – The drive is faulted.

OUT3 STP018 "Opened" – Actuator is at an open position.

OUT 4 LF018 "PosError" - When using either the "close position" or the

"dynamic" position checks, this output will turn on if the actuator

stops during a weld move in an invalid position.

OUT 5 STP012 "CapWore" - Indicated that the caps are worn beyond the service

limit entered in the TP. The output will stay on until another cap

check is done and the caps are with the wear limit.

OUT 6 spare

OUT 7 spare

OUT 8 spare

Figure 4.4 – I/O Table

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4.6.5 AXIOM PLUS SEQUENTIAL PROGRAM

The sequential program consists of a main loop that calls thesubroutines associated with each weld schedule and open position.The PLC program sets internal flags that are read by the sequentialprogram. In most applications the Axiom Plus sequential programwill not need to be modified. A listing of the sequential is includedin appendix 6.6.

4.6.6 WELD AXIS TEACH PENDANT/SINGLE BOARD COMPUTERRRRRRRRRRRRRRRRRRRRRRRRRRR

4.6.6.1 Menu StructureThe Weld Axis teach pendant and single board computer areused to provide the user with a simple way to interact with theAxiom Plus controller. All the setup and troubleshooting of thesystem is done from the teach pendant.

Figure 4-5 shows the teach pendant menu structure with adescription of each item.


4 - 6

SETUP Force units Select between imperial and metric units Length units Select between imperial and metric units Gun Ratio Enter the ratio of actuator travel to tip travelForce Capacity of Gun Enter the maximum force the weld gun can produce.Define Limits The Define Limits is used to define the travel limits of the actuator. To determine the limits remove

the tips from the weld gun and choose this command then give the gun close signal from the external controller. The gun will close at a low speed until the end of travel is reached. When the end of travel is reached the position will be recorded and that this position minus 0.05 inches will become the forward position limit. If the forward position limit is reached during normal operation a FL1 will be displayed on the Axiom Plus front panel LED.

Position Checks None No position checks are done at the weld positionClose Position When Close Position is selected a valid weld position window is created. Before the ready to weld

signal is given the tips must be between the deceleration point and the tips closed position plus the cap wear value. If the current position is outside the valid window the "poserror" output is turned on and the ready to weld signal will not be given.

Dynamic When Dynamic is selected a valid weld position window is created. Before the ready to weld signal is given the tips must be between the deceleration point and the last valid weld position plus the cap missing value entered as part of the dynamic position check setup. If the current position is outside the valid window, the "poserror" output is turned on and the ready to weld signal will not be given.

Start Calibration Start calibration is used to set the starting value of motor torque used during the calibration process. The default value is 5% of motor torque. If the actuator will not move at 5% during calibration, raise the value in Start Calibration until the first calibration move is successful.

Decel Point Offset Decel Point Offset is the distance before the tips touch the part, where the actuator starts to decelerate to the soft touch speed. The default value is 0.125". A larger value may be required if the tips are not at soft touch speed before impacting the workpiece.

CALIBRATION Calibration is the process of defining the relationship between the drive output current and the weld force. When the calibration option is chosen from the menu, the teach pendant will ask the operator to close the tips on a force gage and enter the resulting force at ten different levels of drive current. When a force is entered in the weld schedule, the value of drive current is interpolated from the values entered during calibration. During the calibration process the positions are recorded at the different force levels to create a force vs. deflection curve. This curve is used when doing position checks and cap wear monitoring.

DEFINE CLOSE Used to define the tips closed position of the weld gun. The Define Close is a two stage process. The first move is done at minimum torque and is used to determine the soft touch decel point. The second stage is done at the maximum gun force and is used to calculate values for positioning checking and cup wear.The fifteen weld schedules are used to enter the weld force and the thickness of the material being

WELD 1-8 welded. The thickness is used along with the gun closed location to calculate the decel point for the soft SCHEDULE touch feature. A text field is included to allow for a comment to be entered for each weld schedule. The

9-15 weld schedule number corresponds to the binary sequence set by four. The second page of the weld schedules is accessed by pressing the ? key.

OPEN 0-7 The eight open positions are used to define the distance between the tips when the weld gun is in the POSITION open position.

Current Drive Status Shows the drive status code and description along with the current position of the actuator.Drive History Shows the last 13 drive status changes including the status code and the time/date.Reset Drive Used to reset a non-fatal fault from the teach pendantReset Parameters Resets all the setup parameters entered from the teach pendant.Change Date/Time Set the current date and time for use in the drive history.

DIAGNOSTICS Backup Axiom Plus This option will backup both the Axiom Plus program and configurations to the removable flash memory card. This operation will take about 5 minutes to complete

Restore Axiom Plus This option will restore the Axiom Plus program and configurations that was backup on the removable flash card. This operation will take about 5 minutes to complete.

Data Storage Manually backup weld data This option will backup all the data entered into the teach pendant.Restore manual weld data This option will restore the teach pendant settings backed up using the "Manually backup weld data

option"Restore autosaved weld data This option will restore the teach pendant settings that are automatically saved every time the teach

pendant goes to the main menu.I/O Status Shows the status of the Axiom Plus inputs, outputs and the current position.

Figure 4.5 – Teach pendant menu structure

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4.6.6.2 Setup Weld DataWhen setting up a new Weld Axis system, the following steps shouldbe completed in order.

1) Enter the system of units for the force.

2) Enter the system of units for distance.

3) Enter the gun ratio. The ratio is the actuator travel divided bythe tip travel.

4) Enter the mechanical force limit for the weld gun.

5) Define the position limits. The actuator limit is the forwardtravel limit of the actuator. The limit is found by removing thetips from the weld gun and choosing the define limits optionfrom the setup menu and then giving the gun close signal fromthe external controller. The gun will close at a low speed untilthe end of travel is reached. The end of travel position is thenloaded into the Axiom Plus as the forward position limit.

6) Calibrate the actuator. Calibration is needed to create arelationship between the motor armature current and the forceoutput of the actuator. The user will use a force gage to measurethe force between the tips at ten motor current levels. On theteach pendant select the calibration option. The screen willindicate the percentage torque being used and will wait for theuser to enter the force value measured. To measure the forceplace the gage between the tips and turn on the close guncommand from the master controller. The gun will close at aslow speed until the tips contact the force gage. Once the forcehas been entered it will progress to the next current level untilthe calibration is complete. If the actuator fails to move at thelower levels of motor torque, enter zero for the force. When thecalibration is complete, change the “Start Calibration Value” inthe setup menu to the first value where the actuator closedcorrectly.

7) Define the tips closed position. This position is needed tocalculate the deceleration point for the soft touch feature. Usethe define close position option on the teach pendant, thesystem will wait until the close gun command is turned on from


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the master controller. The gun will then close at a slow speed atminimum motor torque until the tips are closed. The actuatorwill open slightly and close again at gun capacity.

8) Setup the desired weld schedule. The weld schedule is whatspecifies the force for the weld and the stackup of the materialbeing welded. The stackup and the tips closed position are usedto determine the position were the system goes to soft touchspeed. There are 15 possible weld schedules possible. The weldschedule is displayed in two pages, the second page is displayedby pressing the down arrow button. To modify the value for aweld schedule enter the number of the weld schedule, anotherpage is displayed allowing the user to enter a description, theweld force and the max stackup.

9) Determine the desired open position. The open position isdefined as the distance between the weld gun tips. There areeight possible open positions. To modify an open positionnumber to be modified and the choose the comment or theopen distance.

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NOTES:


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5.1 Weld Actuator

NOTE! Before starting any maintenance activities, make surethat the supply voltage is shut OFF.

No lubrication is required during the service life of the weldactuator.

Disassembly of the weld actuator is not recommended. WeldActuators should be returned to Tol-O-Matic for evaluation andrepair. Contact the weldgun manufacturer for instructions on howto return the weld actuator for evaluation.

5.2 Weld Axis Control Panel

5.2.1 TESTING OF THE ACTUATOR WELD FORCE

When the Weld Axis starts to close the gun, it does not limit themotor torque until it transitions to the soft touch speed. Whenchecking weld force, be sure to select a weld schedule that has astackup larger than the force gage being used. If the force measuredis not within specifications for the force set in the weld schedule, thesystem should be re-calibrated.

5.2.2 CHANGING THE CAPS

When changing the caps, the tips closed position will need to beredefined if the new caps are a different style or if the close positionhas been redefined with used caps. If these conditions do not apply,the new caps can be installed without accessing the teach pendant.

5 - 1

Repair and Maintenance5

5.2.3 FAULT CODES

Troubleshooting Guide

Tol-O-Matic Axiom series drives are designed for ease of installationand years of trouble-free operation. If difficulties are encountered inthe setup or in operation, this guide should prove useful indiagnosing and correcting the problem. If problems persist, pleasecontact your Tol-O-Matic distributor for further assistance.

Symptom/F ault Code: Status display not lit.Possib le Causes: No ac power; internal malfunction.

Possib le Solutions: Verify ac power and connections; call your Tol-O-Matic distributor.

Symptom/F ault Code: Digital I/O not working correctly.Possib le Causes: No 5-25Vdc power.

Possib le Solutions: Verify correct connection.

Symptom/F ault Code: F01 - Power selection switch fault.Possib le Causes: Line-power selection switch set incorrectly.

Possib le Solutions: Set to “115 V” for 115 Vac operation or “230 V” for 208 Vac or 230 Vacoperation.

Symptom/F ault Code: F02 - Bridge hardware fault.Possib le Causes: Motor lead short circuit; bus over-voltage; drive’s output bridge

damaged.Possib le Solutions: Check motor cables and motor for shorts; connect internal or external

regen resistor; call your Tol-O-Matic distributor.

Symptom/F ault Code: F03 - Current feedback fault.Possib le Causes: Possible open winding; current feedback circuitry not functioning

correctly.Possib le Solutions: Check motor cable wiring and motor windings; call your Tol-O-Matic

distributor.

Symptom/F ault Code: F04 - Current regulation fault.Possib le Causes: Drive current regulation out of tolerance; current feedback in

“saturation” for 1 second.Possib le Solutions: Check motor cables and motor windings; verify that torque/speed

requirement not greater than motor/drive capability.

5 : R E P A I R A N D M A I N T E N A N C E

5 - 2

Symptom/F ault Code: F05 - Drive over-temperature fault.Possib le Causes: Drive heat sink over 90° C.

Possib le Solutions: Ambient temp above 50° C.; need external regen pack.

Symptom/F ault Code: F06 - Motor over-temperature fault.Possib le Causes: Motor thermostat tripped.

Possib le Solutions: Inadequate motor cooling; motor rating exceeded.

Symptom/F ault Code: F51 - Phasing fault.Possib le Causes: Initial phase estimation routine not executed successfully.

Possib le Solutions: Check encoder and motor wiring; increase phasing torque.

Symptom/F ault Code: F52 - Drive over-current fault.Possib le Causes: Inverse time trip calculated based on the drive’s peak and

continuous rating exceeded.Possib le Solutions: Verify sizing requirements; check tuning; check for mechanical

problems in system.

Symptom/F ault Code: F53 - Motor over-current fault.Possib le Causes: I^2*time protection based on the motor’s peak and continuous

rating exceeded.Possib le Solutions: Verify sizing requirements; check for mechanical problems in system.

Symptom/F ault Code: F54 - Bus under-voltage fault.Possib le Causes: Bus voltage falls below low-limit.

Possib le Solutions: Check line voltage under load (must be at least 90 Vac).

Symptom/F ault Code: F55 - Maximum following-error fault.Possib le Causes: Maximum position following error reached.

Possib le Solutions: Verify correct maximum following error setting; check tuning; checkfor mechanical problems in system.

Symptom/F ault Code: F56 - Velocity regulation fault.Possib le Causes: Velocity regulation out of tolerance.

Possib le Solutions: Check tuning; check for mechanical problems in system.

Symptom/F ault Code: F57 - Serial communication fault.Possib le Causes: Communication cable not connected.

Possib le Solutions: Check communication cable connections.

5 - 3

5 - 4

66.1 Motor Specifications

6.1.1 HT12

Continuous Stall Torque: 3.4 N-mPeak Stall Torque: 16.9 N-mThermal Resistance: 0.58 celsius/wattStall Current: 6.13 A RMSPeak Current: 30.7 A RMSNumber of Poles: 4Kt: 0.58 N-m/Amp per phase RMSKe: 0.332 V/rad/s L-L RMSResistance @ 25 C: 2.0 ohms L-LStator Inductance: 6.1 mH L-LMaximum Bus Voltage: 325 VdcRated Speed @ Maximum Voltage: 4500 RPMDemagnetization Current: 39 AmpsThermal sensor will shut down the motor at 311 degrees F. Howeverthe motor should not perform a duty cycle that repeatedly generatemotor temperatures above 175 degrees F, or premature bearingfailure will result.

6.1.2 HT23

Continuous Stall Torque: 5.0 NmPeak Stall Torque: 24.9 NmThermal Resistance: 0.56 celsius/wattStall Current: 7.55 A RMSPeak Current: 37.8 A RMSNumber of Poles: 4Kt: 0.69 Nm/amp per phase RMSKe: 0.396 V/rad/s L-L RMSResistance @ 25 C: 1.4 ohms L-LStator Inductance: 5.1 mH L-LMaximum Bus Voltage: 325 VdcRated Speed @ Maximum Voltage: 4500 RPMDemagnetization Current: 45 AmpsThermal sensor will shut down the motor at 311 degrees F. Howeverthe motor should not perform a duty cycle that repeatedly generatemotor temperatures above 175 degrees F, or premature bearingfailure will result.

6 - 1

Appendix

6.2 Connector Pinout

6.2.1 MOTOR ARMATURE

Figure 6.1 – Pinout of motor armature connection

6.2.2 MOTOR ENCODER

Figure 6.2: Pinout of motor encoder connection

6 : A P P E N D I X

6 - 2

6.2.3 TEACH PENDANT

HAND-HELD CONNECTOR PINOUTPIN FunctionA Transmit TXD2B +24 VdcC 0 VdcD Receive RXD2E Input #1 on SBCFF O VdcGH

Figure 6.3 – Pinout of teach pendant connection

6 - 3

A P P E N D I X : 6

6.3 Weld Axis Base System wiring diagram

Figure 6.4 – Base System Wiring

PP

RXD1

TXD1

TXD2RXD2

IN0

RAW

GND

Sing

leBo

ard

Com

pute

r

24 Vdc

50 Wat

tPo

wer

Supp

ly

Hand

held

Teac

hPe

ndan

t

HT12

Actu

ator

L1L2

GND

OVdc

GND

NL

+ 24 V

dcx

Out 1

+Ou

t 1-

Out 2

+Ou

t 2-

Out 3

+Ou

t 3-

+24V

dc24

Vdc

RTN

Out 4

+Ou

t 4-

Out 5

+Ou

t 5-

Out 6

+Ou

t 6-

Out 7

+Ou

t 7-

Out 8

+Ou

t 8-

+24V

dc24

Vdc

RTN

COM

1-6

INPU

T 1IN

PUT 2

INPU

T 3IN

PUT 4

INPU

T 5IN

PUT 6

+24V

dc24

Vdc

RTN

COM

7-12

INPU

T 7IN

PUT 8

INPU

T 9IN

PUT 1

0IN

PUT 1

1IN

PUT 1

2

TT BB 33TT BB 22 T B 3T B 2T B 1

J 1 J 3J 2

JJ 77J 7J 6J 5J 4

ENCO

DER

OUT

ENCO

DER

FOLL

OWER C O M M

Pin

3P

in 5

Pin

2

BRAK

E

BRAK

E

REGE

N CO

M

EXT R

EGEN

INT R

EGEN

COM

13-1

5IN

PUT 7

INPU

T 8IN

PUT 9

ENC

+5V A+ A- B+ B+ I+ I-

COM/

SHLD

MOT T

EMP

R S T L3 L2 L1

RE

D

WH

ITE

BL

AC

K

GR

EE

N/Y

EL

LO

W

L3

L2

L1

GN

D

HA

G

B

CD

E

F

BR

OW

NO

RA

NG

EY

EL

LO

WV

IOL

ET

GR

AY

BL

AC

KW

HIT

EB

LU

E/G

RN

/SH

IEL

DR

ED

6 : A P P E N D I X

6 - 4

6.4 Weld Axis Panel System wiring diagram

Figure 6.5 – Weld Axis HT12 3-phase wiring diagram (1 of 4)

141140139138137136135134133132131130129128127126125124123122121120119118117116115114113112111110109108107106105104103102101

107

108

109X1

X2

X3

47

X0

9

58

6

11 KVA DRIVE ISOLATION TRANSFORMER

101102103

104105

106

DS106

T3

T2

T1

L3L3

L2L2

L1L1

AMP30DISCONNECT

30AMP FUSE (1MDC)

CB127

111112

L/233L/234L/235

110

T3

T2

T1

L3

L2

L1

L2

L1

T2

T1

113114

L/303L/304

CB133

25 AMP

TOL-O-MATIC, INC. : WELD-AXIS HT12 3-PHASE DWG#3620-7104, REV 00, PAGE 1

6 - 5

A P P E N D I X : 6


241240239238237236235234233232231230229228227226225224223222221220219218217216215214213212211210209208207206205204203202201

GNDL1L2L3

GNDTSR

INTREGENEXTREGENREGENCOMBRAKEBRAKE

OUT8-OUT8+OUT7-OUT7+OUT6-OUT6+

OUT5-OUT5+OUT4-OUT4+24VDCRTN+24VDC

OUT3-OUT3+OUT2-OUT2+OUT1-OUT1+

532

MOTTEMPCOM/SHIELD

I-I+B-

B+A-

A+ENCODER+5V

INPUT13

INPUT15INPUT14

COM13-15

INPUT12

INPUT8

INPUT11INPUT10

INPUT9

INPUT7COM7-12

24VDCRTN+24VDC

INPUT6INPUT5INPUT4INPUT3INPUT2INPUT1COM1-6

24VDCRTN+24VDCAXIOMPLUS201

228229

230

110

GND237

L/127L/128L/129

111112

223

332333

300

231232233

234235

236

MRV342223

RELAYSET241.1

L/321

L/332L/333

L/331

P

1

32

GROUND

ABHED

NGFK

INTERGAL MOTOR(MRV342)

BROWNORANGEYELLOWVIOLETGREYBLACKWHITE

REDBLUE/GREEN/SHIELD

RELAYSET241

P2

TB3

J7TB2

J6

TB1

J5

J2

J2

J4

AXIOM PLUSJ1

203 L/321

TOL-O-MATIC, INC: WELD-AXIS HT12 3-PHASE DWG# 3620-7104, PAGE 2

6 : A P P E N D I X

6 - 6


TOL-O-MATIC, INC.: WELD-AXIS HT12 3-PHASE DWG# 3620-7104, PAGE 3

341340339338337336335334333332331330329328327326325324323322321320319318317316315314313312311310309308307306305304303302301

PS24V50W305

SAFERELAY314

HHTERMINAL337

GND303

E-STOP318EXTRESET319RELAY319

K1COIL323

K2COIL327

SBCOMPUTER327

PLUG338

PLUG339

PLUG340PLUG341

PLUG342PLUG343

TB

L/133L/134

L/203 L/223

L/236L/237

L/238

113114

324

324

324324

324

324

301 302

305203

304 303

223

307

308

334335

G

+ -

NL

48382414

S41S33S22

B2

3747

2313

S21S11S10

B1

GREEN

BLUEYELLOW

WHITE

3TXD24RXD21TXD12RXD1

7IN0

11GND12+RAW

1

EXTERNALE-STOP

EXTERNALRESET

K1 K2

K1 COIL

K2 COIL

24VDC 50 WATTPOWER SUPPLY

(1PS)

ALLEN BRADLEYMSR20D SAFETY RELAY

(1MRS)

HAND HELDTERMINAL

(1HT)

SINGLE BOARDCOMPUTER

(1PC)

J11 PLUG, P/N 3620-9501

B

A

D

C

E

F

B

A

D

C

E

FP/N 3620-9601

333

300

300

300

300

300300

300

332

331

306

6 - 7

A P P E N D I X : 6

Figure 6.8 – Weld Axis HT12 3-phase panel layout (4 of 4)

324

324

324

324

300

324

300

300

300

300

332

333

331

334

335

301

302

303

304

305

306

TOL-O-MATIC, INC. : WELD-AXIS HT12 3-PHASE DWG# 3620-7204, REV 00

DS106?

DISCONNECTSWITCH

CB 2A

MP 1P

CB 25

AMP 1

P

POWERDIST

BLOCK

END

CVR

CB 2A

MP 1P

CB 25

AMP 1

P

CB 25

AMP 1

P

PS24V50W305

POWERSUPPLY

SAFERELAY314

SAFETYRELAY

SAFETYCONTACTOR

SAFETYCONTACTOR

END

CVR

END

CVR

GND

END

CVR

END

CVR

END

CVR

SBCOMPUTER328?

SINGLEBOARD

COMPUTER

END

CVR

21.0

0

21.00

GND

GND

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

END

CVR

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

SSTE

RMSS

TERM

TB 1+24 -24 SP SBC E-STOPSS

TERM

SSTE

RM

K1COIL323 K2COIL327


+24 Vdc24 Vdc RTNOUT 4 +OUT 4 -OUT 5 +OUT 5 -

+24 Vdc24 Vdc RTN


+24 Vdc24 Vdc RTN



ENC +5VA +A –B +B –I +I –

COM/SHLDMOT TEMP

ENCODEROUT

ENCODERFOLLOWER

BRAKE

BRAKE

REGEN COM

EXT REGEN

INT REGEN

R

S

T

L3

L2

L1


COMM

WARNING: VOLTAGE EXISTS UP TO 2 MIN.AFTER POWER IS REMOVED

TOL-O-MATICHAMEL, USA

J1

J2

J3

J4

J6

P1

P2

TB2

TB1

TB3

6 : A P P E N D I X

6 - 8

6.5 Axiom Plus Standard PLC Program

RUNG 001 User Rung Comment

| Binary 1 Binary 1 ||----| |----+-----------+-----------+-----------+-----------+----( )----|| IN 001 LF 001 |








| Close Close ||----| |----+-----------+-----------+-----------+-----------+----( )----|| IN 009 LF 005 |


| Backup 1 Backup 1 ||----| |----+-----------+-----------+-----------+-----------+----( )----|| IN 005 LF 006 |



6 - 9

A P P E N D I X : 6




| NO Estop No Estop ||----| |----+-----------+-----------+-----------+-----------+----( )----|| IN 015 LF 010 |


| ClearErr ClearErr ||----| |----+-----------+-----------+-----------+-----------+----( )----|| IN 010 LF 019 |


| CheckCap CapCheck ||----| |----+-----------+-----------+-----------+-----------+----( )----|| IN 011 LF 012 |


| ManNewCp New Cap ||----| |----+-----------+-----------+-----------+-----------+----( )----|| IN 012 LF 017 |


| SigWeld Sig Weld ||----| |----+-----------+-----------+-----------+-----------+----( )----|| STP 021 OUT 001 |


| PosError PosError ||----| |----+-----------+-----------+-----------+-----------+----( )----|| LF 018 OUT 002 |

6 : A P P E N D I X

6 - 10

6 - 11

A P P E N D I X : 6


| CapWore CapWore ||----| |----+-----------+-----------+-----------+-----------+----( )----|| STP 012 OUT 003 |


| opened PosError fault Opened ||----| |----+----|/|----+----|/|----+-----------+-----------+----( )----|| STP 018 LF 018 IS 002 OUT 004 |


| PowerOK ||-----------+-----------+-----------+-----------+-----------+----( )----|| OUT 005 |


| fault Fault ||----| |----+-----------+-----------+-----------+-----------+----( )----|| IS 002 OUT 006 |


| PosError PosError ||----| |----+-----------+-----------+-----------+-----------+----(L)----|| STP 013 LF 018 |


| ClearErr PosError ||----| |----+-----------+-----------+-----------+-----------+----(U)----|| LF 019 LF 018 |


| Close Close ||----| |----+-----------+-----------+-----------+-----------+----( )----|| LF 005 PTS 020 |

6 - 12


| No Estop Estopdly ||----| |----+-----------+-----------+-----------+-----------+--|TMR01|--|| LF 010 ONDL | || P=1.00 |


| Estopdly SftReset Enable ||----| |----+----|/|----+-----------+-----------+-----------+----( )----|| TMR 001 FF 007 ICC 001 |


| No Estop Enabled Phase Dn QuitMove Cyc Strt ||----| |----+----| |----+----| |----+----|/|----+-----------+----( )----|| LF 010 ICS 001 IS 001 FF 005 ICC 002 |


| Homed Home ||----|/|----+-----------+-----------+-----------+-----------+----( )----|| IS 004 PTS 002 |


| IP flag Close IP In Pos ||----|/|----+----| |----+-----------+-----------+-----------+----( )----|| IS 006 | STP 001 | PTS 001 || | | | | | | | Home IP | | +----| |----+ | STP 002


| Delay delay ||----| |----+-----------+-----------+-----------+-----------+--|TMR02|--|| STP 011 ONDL | || P=0.10 |

6 : A P P E N D I X

6 - 13


| delay delay ||----| |----+-----------+-----------+-----------+-----------+----( )----|| TMR 002 PTS 003 |


| Close Manual New Cap CapCheck ManualOR ||----| |----+----|/|----+----|/|----+----|/|----+-----------+----( )----|| LF 005 FF 002 LF 017 LF 012 LF 011 |


| Binary 1 Binary 2 Binary 4 Binary 8 ManualOR Press1 ||----| |----+----|/|----+----|/|----+----|/|----+----| |----+----( )----|| LF 001 LF 002 LF 003 LF 004 LF 011 PTS 005 |


| Binary 1 Binary 2 Binary 4 Binary 8 ManualOR Press2 ||----|/|----+----| |----+----|/|----+----|/|----+----| |----+----( )----|| LF 001 LF 002 LF 003 LF 004 LF 011 PTS 006 |


| Binary 1 Binary 2 Binary 4 Binary 8 ManualOR Press3 ||----| |----+----| |----+----|/|----+----|/|----+----| |----+----( )----|| LF 001 LF 002 LF 003 LF 004 LF 011 PTS 007 |


| Binary 1 Binary 2 Binary 4 Binary 8 ManualOR Press4 ||----|/|----+----|/|----+----| |----+----|/|----+----| |----+----( )----|| LF 001 LF 002 LF 003 LF 004 LF 011 PTS 008 |


| Binary 1 Binary 2 Binary 4 Binary 8 ManualOR Press5 ||----| |----+----|/|----+----| |----+----|/|----+----| |----+----( )----|| LF 001 LF 002 LF 003 LF 004 LF 011 PTS 009 |

A P P E N D I X : 6

6 - 14


| Binary 1 Binary 2 Binary 4 Binary 8 ManualOR Press6 ||----|/|----+----| |----+----| |----+----|/|----+----| |----+----( )----|| LF 001 LF 002 LF 003 LF 004 LF 011 PTS 010 |


| Binary 1 Binary 2 Binary 4 Binary 8 ManualOR Press7 ||----| |----+----| |----+----| |----+----|/|----+----| |----+----( )----|| LF 001 LF 002 LF 003 LF 004 LF 011 PTS 011 |


| Binary 1 Binary 2 Binary 4 Binary 8 ManualOR Press8 ||----|/|----+----|/|----+----|/|----+----| |----+----| |----+----( )----|| LF 001 LF 002 LF 003 LF 004 LF 011 PTS 012 |


| Binary 1 Binary 2 Binary 4 Binary 8 ManualOR Press9 ||----| |----+----|/|----+----|/|----+----| |----+----| |----+----( )----|| LF 001 LF 002 LF 003 LF 004 LF 011 PTS 013 |


| Binary 1 Binary 2 Binary 4 Binary 8 ManualOR Press10 ||----|/|----+----| |----+----|/|----+----| |----+----| |----+----( )----|| LF 001 LF 002 LF 003 LF 004 LF 011 PTS 014 |


| Binary 1 Binary 2 Binary 4 Binary 8 ManualOR Press11 ||----| |----+----| |----+----|/|----+----| |----+----| |----+----( )----|| LF 001 LF 002 LF 003 LF 004 LF 011 PTS 015 |


| Binary 1 Binary 2 Binary 4 Binary 8 ManualOR Press12 ||----|/|----+----|/|----+----| |----+----| |----+----| |----+----( )----|| LF 001 LF 002 LF 003 LF 004 LF 011 PTS 016 |

6 : A P P E N D I X

6 - 15


| Binary 1 Binary 2 Binary 4 Binary 8 ManualOR Press13 ||----| |----+----|/|----+----| |----+----| |----+----| |----+----( )----|| LF 001 LF 002 LF 003 LF 004 LF 011 PTS 017 |


| Binary 1 Binary 2 Binary 4 Binary 8 ManualOR Press14 ||----|/|----+----| |----+----| |----+----| |----+----| |----+----( )----|| LF 001 LF 002 LF 003 LF 004 LF 011 PTS 018 |


| Binary 1 Binary 2 Binary 4 Binary 8 ManualOR Press15 ||----| |----+----| |----+----| |----+----| |----+----| |----+----( )----|| LF 001 LF 002 LF 003 LF 004 LF 011 PTS 019 |


| Close Opened0 Backup 1 Backup 2 Backup 4 Open 0 ||----|/|----+----|/|----+----|/|----+----|/|----+----|/|----+----( )----|| LF 005 STP 003 LF 006 LF 007 LF 008 PTS 021 |


| Close Opened1 Backup 1 Backup 2 Backup 4 Open 1 ||----|/|----+----|/|----+----| |----+----|/|----+----|/|----+----( )----|| LF 005 STP 004 LF 006 LF 007 LF 008 PTS 022 |


| Close opened2 Backup 1 Backup 2 Backup 4 Open 2 ||----|/|----+----|/|----+----|/|----+----| |----+----|/|----+----( )----|| LF 005 STP 005 LF 006 LF 007 LF 008 PTS 023 |


| Close opened3 Backup 1 Backup 2 Backup 4 Open 3 ||----|/|----+----|/|----+----| |----+----| |----+----|/|----+----( )----|| LF 005 STP 006 LF 006 LF 007 LF 008 PTS 024 |

A P P E N D I X : 6

6 - 16


| Close opened4 Backup 1 Backup 2 Backup 4 Open 4 ||----|/|----+----|/|----+----|/|----+----|/|----+----| |----+----( )----|| LF 005 STP 007 LF 006 LF 007 LF 008 PTS 025 |


| Close opened5 Backup 1 Backup 2 Backup 4 open 5 ||----|/|----+----|/|----+----| |----+----|/|----+----| |----+----( )----|| LF 005 STP 008 LF 006 LF 007 LF 008 PTS 026 |


| Close opened6 Backup 1 Backup 2 Backup 4 open 6 ||----|/|----+----|/|----+----|/|----+----| |----+----| |----+----( )----|| LF 005 STP 009 LF 006 LF 007 LF 008 PTS 027 |


| Close opened7 Backup 1 Backup 2 Backup 4 open 7 ||----|/|----+----|/|----+----| |----+----| |----+----| |----+----( )----|| LF 005 STP 010 LF 006 LF 007 LF 008 PTS 028 |


| DoCalib Close Manual dontrun DoCalibr ||----| |----+----| |----+----| |----+----|/|----+-----------+----( )----|| FF 001 LF 005 FF 002 LF 016 PTS 030 |


| Manual Close CloseSet SetClose ||----| |----+----| |----+----| |----+-----------+-----------+----( )----|| FF 002 LF 005 FF 003 | PTS 031 || | || | || New Cap Close | ||----| |----+----| |----+-----------+ || LF 017 LF 005

6 : A P P E N D I X

6 - 17


| CapDone ReadExt ||----| |----+-----------+-----------+-----------+-----------+----( )----|| STP 015 LF 013 |


| CloseLim Manual Close CloseLim ||----| |----+----| |----+----| |----+-----------+-----------+----( )----|| FF 004 FF 002 LF 005 PTS 032 |


| CapCheck Close CapCheck ||----| |----+----| |----+-----------+-----------+-----------+----( )----|| LF 012 LF 005 PTS 029 |


| DoCheck ||-----------+-----------+-----------+-----------+-----------+----( )----|| PTS 033 |


| BegWTim Welding ||----| |----+-----------+-----------+-----------+-----------+--|TMR03|--|| STP 016 PLS | || P=2.75 |


| Welding Close TimeClos ||----| |----+----| |----+-----------+-----------+-----------+----( )----|| TMR 003 LF 005 PTS 035 |


| Welding BegWTim waitcool ||----|/|----+----| |----+-----------+-----------+-----------+--|TMR04|--|| TMR 003 STP 016 |PLS | || P=1.50 |

A P P E N D I X : 6

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| waitcool dontrun ||----| |----+-----------+-----------+-----------+-----------+----( )----|| TMR 004 LF 016 |


| GotTor GotTor ||----| |----+-----------+-----------+-----------+-----------+----( )----|| IS 012 PTS 004 |


| CWLimit Homed lim IP CW lim ||---|PVAR|--+----| |----+----|/|----+-----------+-----------+----( )----|| |CMPR| IS 004 STP 014 ICC 011 ||P > PNV 027


| neg lim Homed CCW lim ||----| |----+----| |----+-----------+-----------+-----------+----( )----|| IS 011 IS 004 ICC 012 |

RUNG 066

| Homed Homed ||----| |----+-----------+-----------+-----------+-----------+----( )----|| IS 004 PTS 036 |

6 : A P P E N D I X

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6.6 Axiom Plus Standard Sequential Program

Line#001label: comment: user comment for line #0001Assign Register - VEL 001 = 3.00

Line#002label: comment: user comment for line #0002Position Compare - Branch Label: DONE Comparison: Command Position < PNV 027 CWLimit

Line#003label: comment: user comment for line #0003Conditional Branch to Label: DONE Conditional Operand: PLC-to-SEQ PRG FLAG #036 : PTS 036Branch on Logic 1 (normally-open)

Line#004label: comment: user comment for line #0004Assign Register - PNV 027 CWLimit = 999.990

Line#005label: DONE comment: user comment for line #0005Time Delay: 1 seconds

Line#006label: comment: Set the In-Position Band Set In-Position Band = 1500 Encoder Counts,or 0.075 inch

Line#007label: comment: user comment for line #0007Set/Clear Flag Bit -- CLEAR STP 003CLEAR SEQ PRG-to-PLC FLAG #003 : STP 003


Line#009label: LOOP1comment: user comment for line #0009Conditional Subroutine Call: HOME Conditional Operand: PLC-to-SEQ PRG FLAG #002 : PTS 002Call Subroutine on Logic 1 (normally-open)

Line#010label: comment: Flag ext computer, move done Set/Clear Flag Bit -- CLEAR STP 015CLEAR SEQ PRG-to-PLC FLAG #015 : STP 015


Line#012label: comment: user comment for line #0012Conditional Subroutine Call: CLOSEPOSConditional Operand: PLC-to-SEQ PRG FLAG #031 : PTS 031Call Subroutine on Logic 1 (normally-open)

Line#013label: comment: user comment for line #0013Conditional Subroutine Call: CLOSELIMConditional Operand: PLC-to-SEQ PRG FLAG #032 : PTS 032Call Subroutine on Logic 1 (normally-open)

A P P E N D I X : 6

Line#014label: comment: user comment for line #0014Conditional Subroutine Call: CALIBConditional Operand: PLC-to-SEQ PRG FLAG #030 : PTS 030Call Subroutine on Logic 1 (normally-open)

Line#015label: comment: user comment for line #0015Conditional Subroutine Call: CAPCHECKConditional Operand: PLC-to-SEQ PRG FLAG #029 : PTS 029Call Subroutine on Logic 1 (normally-open)

Line#016label: comment: user comment for line #0016Conditional Subroutine Call: PRESS1 Conditional Operand: PLC-to-SEQ PRG FLAG #005 : PTS 005Call Subroutine on Logic 1 (normally-open)










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Line#031label: comment: user comment for line #0031Conditional Subroutine Call: OPEN0Conditional Operand: PLC-to-SEQ PRG FLAG #021 : PTS 021Call Subroutine on Logic 1 (normally-open)







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A P P E N D I X : 6


Line#039label: comment: user comment for line #0039Branch to Label: LOOP1

Line#040label: OPEN0comment: user comment for line #0040Call Subroutine with Start Label: OPENSTRT

Line#041label: comment: Move to open position Abs Position Move -- Position = PNV 001-Vel = 1.00 Acc = 799.999 Dec = 799.999Trigger #1: PLC-to-PRG Flag #003 Logic OneAction #1 (Trig #1): New Speed = VEL 001 Action #2 (Trig #1): New Torque Limit = 100.0%Trigger #2: No Trigger Event


Line#043label: comment: user comment for line #0043Set/Clear Flag Bit -- SET STP 003SET SEQ PRG-to-PLC FLAG #003 : STP 003


Line#045label: comment: user comment for line #0045Return from Subroutine





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A P P E N D I X : 6














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Line#088label: HOME comment: Low torque for home Set Maximum Torque Limit -- 30.0 %

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A P P E N D I X : 6


Line#090label: comment: user comment for line #0090Velocity Move -- Velocity = -0.50 inch / secAcc = 20.0 Dec = 100.0Trigger #1: PLC-to-PRG Flag #001 Logic OneAction #1 (Trig #1): Terminate Motion InstructionAction #2 (Trig #1): No ActionTrigger #2: No Trigger Event


Line#092label: comment: user comment for line #0092Set Command Position = Actual -- Zero Following Error

Line#093label: comment: user comment for line #0093Inc Position Move -- Distance = 0.125 inchVel = 1.00 Acc = 4.998 Dec = 4.998Trigger #1: No Trigger EventTrigger #2: No Trigger Event

Line#094label: comment: define pos as "Home"Define Present Absolute PositionDefine Absolute COMMAND Position as 0.000 inch


Line#096label: PRESS1 comment: user comment for line #0096Call Subroutine with Start Label: CLOSESET

Line#097label: comment: user comment for line #0097Abs Position Move -- Position = PNV 010-Vel = VEL 001- Acc = 500.0 Dec = 500.0Trigger #1: No Trigger EventTrigger #2: No Trigger Event

Line#098label: comment: user comment for line #0098Wait for Input / Flag -- IN 014 -- Logic 1Conditional Operand: PHYSICAL INPUT #014 : IN 014Continue on Logic 1 (normally-open)Do NOT Enable PLC Commanded JOG Motion while Waiting

Line#099label: comment: user comment for line #0099Set Maximum Torque Limit -- TNV 001 %

Line#100label: comment: user comment for line #0100Velocity Move -- Velocity = 1.00 inch / secAcc = 250.0 Dec = 250.0Trigger #1: Incremental Distance = 0.250 inchAction #1 (Trig #1): Set PRG-to-PLC Flag #001Action #2 (Trig #1): No ActionTrigger #2: PLC-to-PRG Flag #001, Logic OneAction #1 (Trig #2): Terminate Motion InstructionAction #2 (Trig #2): No Action

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6 : A P P E N D I X

Line#101label: comment: user comment for line #0101Conditional Branch to Label: PR1GOConditional Operand: PLC-to-SEQ PRG FLAG #033 : PTS 033Branch on Logic 0 (normally-closed)

Line#102label: comment: user comment for line #0102Position Compare - Branch Label: PR1STOP Comparison: Actual Position < PNV 010

Line#103label: comment: user comment for line #0103Position Compare - Branch Label: PR1GOComparison: Actual Position < POS 001

Line#104label: PR1STOP comment: user comment for line #0104Call Subroutine with Start Label: NOTPOS

Line#105label: PR1GOcomment: Move to weld position Call Subroutine with Start Label: CLOSEDN

Line#106label: comment: user comment for line #0106Conditional Branch to Label: EXIT1Conditional Operand: SEQ PRG-to-PLC FLAG #020 : STP 020Branch on Logic 1 (normally-open)

Line#107label: comment: user comment for line #0107Store Position to Register: POS 016-Store Absolute ACTUAL Position

Line#108label: EXIT1comment: user comment for line #0108Return from Subroutine






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A P P E N D I X : 6














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A P P E N D I X : 6














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6 : A P P E N D I X














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A P P E N D I X : 6













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6 : A P P E N D I X













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A P P E N D I X : 6













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6 : A P P E N D I X








Line#209label: comment: user comment for line #0209Conditional Branch to Label: PR10GO Conditional Operand: PLC-to-SEQ PRG FLAG #033 : PTS 033Branch on Logic 0 (normally-closed)

Line#210label: comment: user comment for line #0210Position Compare - Branch Label: PR10STOPComparison: Actual Position < PNV 019

Line#211label: comment: user comment for line #0211Position Compare - Branch Label: PR10GO Comparison: Actual Position < POS 010

Line#212label: PR10STOPcomment: user comment for line #0212Call Subroutine with Start Label: NOTPOS

Line#213label: PR10GO comment: Move to weld position Call Subroutine with Start Label: CLOSEDN

6 - 35

A P P E N D I X : 6

Line#214label: comment: user comment for line #0214Conditional Branch to Label: EXIT10 Conditional Operand: SEQ PRG-to-PLC FLAG #020 : STP 020Branch on Logic 1 (normally-open)


Line#216label: EXIT10 comment: user comment for line #0216Return from Subroutine










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A P P E N D I X : 6













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A P P E N D I X : 6













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Line#277label: CLEARcomment: user comment for line #0277Set/Clear Flag Bit -- CLEAR STP 003CLEAR SEQ PRG-to-PLC FLAG #003 : STP 003











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A P P E N D I X : 6


Line#289label: CLOSESETcomment: user comment for line #0289Set Maximum Torque Limit -- 100.0 %

Line#290label: comment: user comment for line #0290Call Subroutine with Start Label: CLEAR


Line#292label: CLOSEDN comment: user comment for line #0292Conditional Subroutine Call: NOTPOS Conditional Operand: PLC-to-SEQ PRG FLAG #004 : PTS 004Call Subroutine on Logic 0 (normally-closed)

Line#293label: comment: user comment for line #0293Conditional Branch to Label: SKIP Conditional Operand: SEQ PRG-to-PLC FLAG #020 : STP 020Branch on Logic 1 (normally-open)


Line#295label: SKIP comment: user comment for line #0295Set/Clear Flag Bit -- CLEAR STP 001CLEAR SEQ PRG-to-PLC FLAG #001 : STP 001

Line#296label: comment: user comment for line #0296Wait for Input / Flag -- PTS 020 -- Logic 0Conditional Operand: PLC-to-SEQ PRG FLAG #020 : PTS 020Continue on Logic 0 (normally-closed)Do NOT Enable PLC Commanded JOG Motion while Waiting


Line#298label: NOTORQUEcomment: user comment for line #0298Return from Subroutine

Line#299label: OPENSTRTcomment: Open Position Binary 0 Set/Clear Flag Bit -- CLEAR STP 021CLEAR SEQ PRG-to-PLC FLAG #021 : STP 021

Line#300label: comment: user comment for line #0300Call Subroutine with Start Label: CLEAR


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6 : A P P E N D I X


Line#303label: CALIBcomment: user comment for line #0303Call Subroutine with Start Label: CLOSESET




Line#307label: comment: user comment for line #0307Time Delay: 1 seconds





Line#312label: comment: user comment for line #0312Store Position to Register: PNV 025-CalibPosStore Absolute ACTUAL Position

Line#313label: comment: user comment for line #0313Inc Position Move -- Distance = -0.250 inchVel = 1.00 Acc = 400.0 Dec = 400.0Trigger #1: No Trigger EventTrigger #2: No Trigger Event

6 - 43

A P P E N D I X : 6


Line#315label: NOTORQU2comment: user comment for line #0315Return from Subroutine

Line#316label: CLOSEPOScomment: user comment for line #0316Call Subroutine with Start Label: CLOSESET

Line#317label: comment: Move to weld position Set Maximum Torque Limit -- TNV 017 %


Line#319label: comment: user comment for line #0319Velocity Move -- Velocity = 0.75 inch / secAcc = 250.0 Dec = 250.0Trigger #1: PLC-to-PRG Flag #001 Logic OneAction #1 (Trig #1): Terminate Motion InstructionAction #2 (Trig #1): No ActionTrigger #2: No Trigger Event

Line#320label: comment: user comment for line #0320Store Position to Register: PNV 025-CalibPosStore Absolute ACTUAL Position

Line#321label: comment: user comment for line #0321Time Delay: 0.5 seconds

Line#322label: comment: user comment for line #0322Inc Position Move -- Distance = -0.500 inchVel = 1.00 Acc = 25.0 Dec = 25.0Trigger #1: No Trigger EventTrigger #2: No Trigger Event


Line#324label: comment: Move to weld position Set Maximum Torque Limit -- TNV 018 %


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Line#326label: comment: user comment for line #0326Store Position to Register: PNV 026-Store Absolute ACTUAL Position






Line#332label: CLOSELIMcomment: user comment for line #0332Call Subroutine with Start Label: CLOSESET

Line#333label: comment: Move to weld position Set Maximum Torque Limit -- 30.0 %






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A P P E N D I X : 6


Line#340label: comment: user comment for line #0340Store Position to Register: PNV 027-CWLimitStore Absolute ACTUAL Position




Line#344label: CAPCHECKcomment: user comment for line #0344Call Subroutine with Start Label: CLOSESET


Line#346label: comment: Move to weld position Set Maximum Torque Limit -- 30.0 %




Line#350label: comment: user comment for line #0350Position Compare - Branch Label: GOODTOGOComparison: Actual Position < PNV 029


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6 : A P P E N D I X

Line#352label: GOODTOGOcomment: user comment for line #0352Set/Clear Flag Bit -- SET STP 015SET SEQ PRG-to-PLC FLAG #015 : STP 015




Line#356label: NOTPOS comment: user comment for line #0356Set/Clear Flag Bit -- SET STP 013SET SEQ PRG-to-PLC FLAG #013 : STP 013





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A P P E N D I X : 6

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6 : A P P E N D I X

NOTES

TOL-O-MATIC, INC.3800 County Road 116Hamel, MN 55340763.478.8000 Telephone763.478.8080 Faxhttp://www.tolomatic.com

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