Cs1000 Instructions
From Galco
Notice
Improvements and modifications will be made to the CS 1000 Control. The operation of the control as described in this manual may be changed without notice. The contents of this manual are for reference or guidance only. This manual reflects software version 1.6 . A label with your current version is affixed to the outside ot your computer.
Saftey Warning
High Voltages
This equipment is connected to a hazardous
line voltage and outputs hazardous voltages. All standard precautions
against electrical shock must be taken when working on or around this
equipment. Always disconnect electrical power before working on the
unit. Standard OSHA lockout procedures must be followed.
High Electrical Energy
This equipment controls large
currents. Precautions must be taken against possible arc flashes
resulting from accidental connections or component failures.
High Mechanical Energy
This equipment is used in conjunction with high-risk mechanical
equipment such as presses and blanking machines. Machine guards must be
in place for equipment operation. All safety interlocks must be checked
and verified for proper operation. Standard OSHA lockout procedures
must be followed.
Acknowledgments
This product is a result of contributions and suggestions from the following individuals.
Mark Shollenberger - Galco Industrial Electronics
Bob Rugenski - Galco Industrial Electronics
Deepak Chandrashekar -Galco Industrial Electronics
Salvatore Orlando - Galco Industrial Electronics
Mike Parker - RTS-Tech
Dave Berry - Ford Motor Company
Fred Hernacki - Ford Motor Company
Mark Woudenberg - SquareD
GENERAL DESCRIPTION
The CS1000 Eddy Current Drive Control is designed to be a drop-in hardware replacement for the Dynamatic Digital CES press drive. It is capable of delivering 678 volts DC at 100 amps to both the clutch and the brake coils of a Dynamatic eddy current clutch/brake assembly.
The control maximizes reliability by using software for its functionality and by keeping the parts count low. This improves troubleshooting and reduces downtime.
Key components are oversized. The computer and its power supply are passively cooled with no fans or disk drives, thereby improving hardware reliability.
A Human Machine Interface (HMI) displays the status of the control and allows adjustments to its operation. The most common adjustments will be to the speed profile settings. These are similar to, but not identical with, the Dynamatic control. The user should read the Press Speed Setup sections of this manual.
Specifications
Input 480 V AC 100 amps 60 hz / 50hz selectable
Output 678 V DC 100 amps
Major Components
Computer Control Module
The computer control module is the heart of the CS1000 and performs all supervisory and control activities including:
Communication with MODICON I/O module via Ethernet. Excitation of the press-mounted resolver and measurement of slide angle. Ability to derive speed feedback from the resolver on units with no tachometer. Direct digital firing of clutch and brake rectifier bridges. Phase loss detection of incoming power. Tachometer frequency measurement for speed feedback. Electronic overload protection for clutch and brake. Fault detection. Fault log in English of the last 16 faults and time of fault since power-up. Speed regulation and programming of the press cycle. Serial interface to press control (RS-422 Dynamatic protocol) for the press HMI. Graphical HMI for monitoring and control of drive control operation. Remote HMI services via Ethernet (optional)
Field Interface Board Assembly
Provides gate pulse amplification for brake and clutch SCR bridges as well as providing AC sync and tachometer signals to the computer control module.
Modicon TSX Ethernet Input-Output Module
IP address set to 192.168.0.3. This unit gets its output power from the press control. The fast-blinking green LAN indicator on the module indicates normal communication with the computer control module.
Clutch Contactor
Connected on the AC side of the bridge. There is no DC contactor.
Clutch Rectifier Bridge and Brake Rectifier Bridges
SCRs rated at 2600 volts, 1200 amps. Protected by JJS-125 125 amp fuses.
12 Volt Computer Power Supply
Passively cooled 30 watt. Easy-to-measure output voltage.
24 Volt Field Interface Board Assembly Power Supply
Passively cooled 30 watt. Easy to measure output voltage.
OPERATION
Overview
Monitoring, operation, and adjustment of the CS1000 is through a
Human Machine Interface (HMI), which consists of a series of screens on
the monitor and a keypad.
The Monitor Screen is the opening and main screen for operation. Selecting Press Setup will take you to the Setup Screen.
The Setup Screen allows the operator to set adjust the press
speed profile. Selecting Maint Screen will take you to a screen for
maintenance personnel to make further adjustments.
The Maintenance screen allows setting the machine parameters,
such as maximum speed. It also has several subscreens for setting
specific components, such as callibrating the resolver position.
Subscreens for resolver settings, overload settings, SCR gate pulse settings, and factory settings
Using the Keypad
The CS1000 uses a standard numeric keypad, available separately or as part of most keyboards, to manipulate the screens of the HMI to make adjustments to the it's operation. See the appendix for other keyboard options.
The legend on the lower right of the screen is a map of a typical keypad and indicates each keys function. Pressing the Focus Next (*) key will move the focus forward to controls that accept focus, while pressing the Focus Prev (/) key will move the focus in reverse to controls that accept focus.
You should practice using the Focus Next (*) and Focus Prev (/) keys to move the focus around the screen.
Every subscreen has a Previous Screen button which will take you back up to the previous screen if the Previous Screen button has the focus when the Enter key is pressed. Make sure you move the focus to this control before pressing Enter.
The keypad operation is the same for installation and setup as for operation, except that three additional data entry functions are available for setting up certain controls. These are:
Analog Adjusters
An analog adjuster looks like a
horizontal meter. The set point is indicated by the red marker. When
the adjuster has the focus (boxed by a white outline) and you are
logged in (screen background is blue, not black), pressing the 6 key
(Right Arrow) on the keypad will increase the setting one major
division. Pressing the +(plus) key will increase the value one-tenth of
a major division. Pressing the 4 key (Left Arrow) will decrease the set
value one major division, and the - (minus) key will decrease the
setting one-tenth of a major division.
Digital Adjusters
A digital adjuster looks like a
digital readout. When a digital adjusteer gets focus, the selected
digit will be blue. You can change the selected digit to the right with
the 6 key (Right Arrow) or change the selected digit to the left with
the 4 key (Left Arrow). Once a digit is selected, it can be increased
with the 8 key (Up Arrow) and decreased with the 2 key (Down Arrow).
Push Buttons
Push Buttons can be momentary or latch.
A momentary button is on as long as the enter key on the keypad is kept
depressed. A latch button alternates between on and off with each
successive press of the enter key.
Main Operations Screen
After the CS1000 has powered up, the screen shown above appears, showing the status of important signals.
The main screen provides a view of the overall operation of the CS1000. On the left are the inputs from the press control. At the top center are the fault indicators. At the top right are the outputs to the press control. In addition, the main screen includes the fault log, slide angle, clutch and brake excitation, temperature, and speed profile monitors.
There are no adjustments and no controls on this screen (except for allowing a fault reset). Setting the focus to the press setup box will take you to the press speed setup screen.
Inputs
On the top left of the screen are indicators for all the inputs from the main press control, including the safety circuits (enable) and the mode selections. These are green when on. The terminal block number is given next to the function name as an aid to troubleshooting.
Enable 1, Enable 2, Clutch On
The clutch contactor will close and the press will operate if these three inputs are on at the same time.
Inch
Shows green when Inch mode is selected by the press control.
Micro Inch
Shows green when Micro-inch mode is selected by the press control.
If Inch and Micro-inch are not present, the press will cycle as determined on the press setup screen.
Continuous
Shows green when “single stroke” is not selected. The press will cycle continuously once enabled, until a stop is requested.
Reverse
Reverse is an input from the press control
that will prevent the CS1000 from issuing a direction fault when
detecting reverse motion of the press. Shows green when reverse is
active. Reverse will come on, for example, when the press control is
set to run the motor backwards in order to get the press off the
bottom.
Faults
On the top center of the screen are ten fault indicators, plus the Modicon fault indicator on the right. These indicators monitor internal faults and turn red when a fault condition exists.
Enable Present FaultThis fault occurs when either Enable or the Clutch On signal is not removed within one second after the press has executed a Stop Normal.
Enable Sequence Fault This fault occurs if Enable 1, Enable 2, and Clutch On do not come on and off together within a window of one second.
Clutch Contactor FaultThis fault occurs when the auxiliary contact on the clutch contactor does not open within one second after the contactor has been de-energized. The purpose is to detect whether the contacts have welded shut.
Tachometer Fault
This fault occurs when a speed
command is present and no speed feedback is detected, or when there is
no command but a speed reference is detected.
Inch Micro Inch Fault
This fault occurs if the CS1000 has simultaneous inputs for Inch and Micro-Inch.
Direction Fault
This fault occurs if the control
detects the press running in the reverse direction and the direction
override is not present. This fault also occurs if the press is running
in the forward direction with the direction override present.
Clutch Overload
This fault occurs when the estimated
temperature in the clutch exceeds a set point. The control estimates
the temperature rise in the clutch in the same way that a starter
overload estimates it for a motor, by monitoring the power supplied to
the motor. In this case the drive monitors the clutch voltage and
effectively models the temperature rise in the clutch coil over ambient
temperature. The trip value is set at 2 seconds at 200% rated voltage
and is indicated on the temperature rise meter as 100. You will not be
able to reset the fault until the clutch temperature rise drops below
50. (See Clutch Temp Meter.)
Brake Overload
The drive monitors the brake voltage and acts exactly like the clutch overload.
Overspeed
If the press should exceed the overspeed limit, the drive will issue a Stop Now to the press control.
AC Power Fault
The control detects a loss of a phase to the power section of the rectifier bridges.
Modicon Fault
The control detects loss of communication with the modicon IO module.
Fault Reset
If a fault occurs even momentarily, the fault indicator will latch on in order to stop the press and allow the fault to be identified. To clear the fault, use the Fault Reset button on the main press control. To clear the fault from the HMI: Move the focus to the Fault Reset indicator. Enter 12345678 on the keypad. Press the Enter key.
Outputs
On the top right of the screen are indicators of signals sent back to the press control. These may also indicate faults.
Stop Motor Fault
This signal is present for legacy compatibility reasons and will always signal OK to the press control. All faults in the CS1000 issue a STOP_NOW signal to the press control.
Stop On Top
This signal is present for legacy compatibility reasons and will always signal OK to the press control. All faults in the CS1000 issue a STOP_NOW signal to the press control.
Stop NormalThis signal will OPEN (turn off) when the press has stopped after completing a cycle in run mode or when it has stopped after inching.
Stop Now This signal will OPEN (off) if any of the fault conditions are present.
Watch Dog This fault indicates a problem in the CS1000 computer, either software or hardware.
CR1 Relay This output pulls in the 1CR pilot relay that brings in the clutch contactor.
Other Monitors
Fault Log
Displays the last 16 faults that have occurred, along with the time and date of each.
This display is cleared when the computer is powered down.
Clutch Excitation
Firing angle of the clutch rectifier
bridge. Because of the nature of an inductive load, 20 degrees would
indicate a very small amount of power. 120 degrees would be maximum
power.
Clutch Temp
Theoretical temperature rise of the
clutch coils. See OVERLOAD fault signal above.
The scale is not degrees, but percentage of allowable temperature rise.
Readings range from 0, when there has been no operation for a long
period, to 100, when the Overload fault is triggered.
Brake Excitation
Firing angle of the brake rectifier bridge. See discussion of Clutch Excitation above.
Brake Temp
Theoretical temperature rise of the brake coils. See description of Clutch Temp above.
Press Speed
This graph display shows the commanded
speed (green) and the actual speed (red) of the press as it cycles.
Speed is expressed in Strokes per Minute (SPM) as if the press were
running continuously at the indicated speed.
Press Speed Setup
To get to the Press Setup screen from the Operations screen, press the Focus Forward (*) key on the keypad one or more times. A white box will outline the Press Setup box on the screen. Then press the Enter key
Changing Settings
Logging In
When the screen comes up, the background will
be black. This indicates that you are not "LOGGED IN" and you cannot
change any settings. To change any settings you must LOG IN. You do
this by entering 12345678 on the keypad. If the LOG IN is successful,
the background on the screen will change from Black to Blue. You may
use the Focus Next (*) key and the Focus Prev (/) key to move to the
Analog Adjuster you want to set.
Logging Out
When you are finished changing settings, press the Log Out (del) key.
The screen background will change from blue to black, and it will not
be possible to change settings on the control without logging in again.
The Press Speed Setup screen is used to set the parameters that control the press cycle speeds. The blue background objects are controls that allow settings, and the blue-gray background objects are monitors. See the keypad description above for how to adjust the values of the analog adjusters. Below is a description of what each control does. All speeds are expressed in strokes per minute (SPM) if the press were to run continuously at that speed.
Creep Angle
Adjusts the slide angle at which the creep speed will become active.
Stop Angle
Adjusts the slide angle at which the press will apply the brake
Micro-Inch Speed
Adjusts the micro-inch speed of the press.
Inch Speed
Adjusts the inch speed of the press.
Creep Speed
Adjusts the creep speed of the press. When
the press is in single-stroke mode or commanded to stop at the end of
the cycle, creep speed will be the speed at which the press will
approach top-stop.
Programming the Press Cycle Speed Profile
The CS1000 allows for using different speeds for up to eight different sections of the press stroke. Two of these sections--creep and stop--are used at the end of the stroke to assure a smooth and accurate stop at the top. The remaining six speeds may be used in the remainder of the press stroke.
The speed profile programming on the CS 1000 is slightly different from the programming of the Dynamatic control. The most important difference is that speed settings do not continue across the top of the press cycle (from 259 degrees to 1 degree) during continuous operation. 0 degrees always begins Angle 1 and therefore at 0 degrees the press will accelerate or decelerate to Speed 1. For continuous mode operations, the speed of the last angle used will probably be the same as Speed-1.
The Angle settings indicate the start of that angular section and continue until the next angular section begins.
The Angle-1 setting should always be 0.
Speed-1 should always be set. The press will begin its stroke at this speed and continue until the press reaches the start of Angle-2. The press will now run at the setting in Speed 2 until the press reaches the start of Angle-3. And so on. If Angle-6 is used, the press will continue at Speed-6 until it reaches 360 degrees (in continuous mode).
To avoid any problems, always set the Angles in increasing order. Set any unneeded Angles to 360 and any unused Speeds to be equal to the last used speed.
If the press is in single-stroke mode or commanded to top-stop at the end of the stroke, when the press reaches the Creep Angle, the control will override any profile settings and reduce the speed to the Creep Speed. At the Stop Angle, the control will remove all clutch power and apply the eddy current brake.
Note: It is important to make sure that there are angle
settings that cover the full 360 degrees of the press cycle. Remember
that the Creep Angle and Stop Angle cover the last portion of the cycle
only in single-stroke mode or when a top-stop is commanded.
Blanker Example A blanker usually requires only a single speed (plus creep when it prepares to stop). The settings might be Angle-1 0 deg Speed-1 25 SPM Angle-2 360 deg (Unused Angles set to 360 deg. Unused Speeds set to 25 SPM.)
Press Example (see diagram) The materials may require a low speed at the bottom of the press stroke, but cycle time will be improved by a fast down-stroke and up-stroke. The following might be the settings:
| Adjustment | Degrees | Speed |
| Angle 1 | 0 | 20 |
| Angle 2 | 120 | 5 |
| Angle 3 | 180 | 20 |
(Unused Angles set to 360 degrees. Unused Speeds set to 20 SPM.)
While the settings will take effect immediately, if you want to save the new settings so they are retained after power-down, you must move the focus to the Save Settings option on this screen and press Enter.
In addition to the analog adjusters, the Press Speed Setup screen contains monitor displays you can use while making adjustments. These are the same as on the Operator Monitor screen described earlier.
You can return to the main Operator Monitor screen by moving the focus to the box marked Previous Screen and pressing the Enter key.
Maintenance Screen
The maintenance screen is password-protected. To enter the maintenance screen, set the focus to the screen selector button.. In sequence, press 87654321 and Enter on the keypad.
The Maintenance screen is used to set control parameters. These can affect safety as well as operational smoothness. It is important that only trained personnel make adjustments on this screen and its subscreens. The blue background objects are controls that allow settings, and the blue-gray background objects are monitors. See the keypad description above for how to adjust the values of the analog adjusters. Below is a description of what each control does. All speeds are expressed in strokes per minute (SPM) if the press were to run continuously at that speed.
Setting changes will take effect immediately, but the old
ones will be restored after power-down. If you want to save the new
settings so they are retained after power-down, you must select the
Save Settings option on the main Maintenance screen.
The following adjustments are made on the Maintenance screen:
The speed regulator (gain settings) needs to be adjusted for proper speed control. The eddy current clutch/ brake is not designed for tight regulation. Setting the gains too high for tight speed regulation will result in wasting of energy and overheating of the rotating equipment. This wasteful and damaging condition will be seen if there is oscillating clutch and brake current during a steady-speed operation. Proper speed regulator adjustment will show about a 10% steady-state error between reference and feedback
Accel Rate
Factory setting. Strokes per minute per second.
Decel Rate
Factory setting. Strokes per minute per second.
Max Speed
Controls the maximum reference to the speed
regulator. This will be determined by press specifications and the
rated capabilities of the motor and clutch/brake assembly. If set too
high, trying to regulate speed above the rated speed will result in
overheating of the clutch.
PID: Proportional, Integral, Differential Gain
Factory setting. Speed regulator adjustments. These controls work in
concert with each other and are adjusted to optimize the trade-off
between the transient response and the steady-state speed error of the
drive. These adjustments are set at startup and should not need to be
adjusted thereafter.
Clutch Gain
Factory setting. This value when
multiplied with a positive output of the speed regulator determines the
gate pulse angle advance of the clutch bridge in degrees.
Brake Gain
Factory setting. This value when
multiplied with a negative output of the speed regulator determines the
gate pulse angle advance of the brake bridge in degrees.
Resolver Speed Dampening
Factory setting. This adjustment provides low pass filtering of the derived speed signal from the resolver.
Tachometer Scaling Factor
This control is used to
scale the tachometer feedback signal, if it is used, from the frequency
of the tach feedback signal to strokes per minute used by the speed
regulator. In other words, the control is set to a number that when
multiplied with the tach frequency will result in the correct strokes
per minutes of the press. Run the press in continuous mode for several
minutes to fine-tune and confirm this setting.
Overspeed Trip
This sets the speed at which an overspeed fault will occur. Normally this will be set 20% higher than the Max Speed.
Reference Select
This selects where the speed
reference is derived. Move the focus to this button and press Enter to
toggle the selection. The options are "programmed" or "pot." When
"programmed" is selected, the speed of the press operates as described
above in the setup screen section. When set to "pot," Speed 1 is
determined by an externally connected potentiometer, which can adjust
the speed between creep speed and max speed as set on the HMI. In order
for the pot to control the speed over the entire cycle, Angle 1 must be
set to zero and Angle 2 must be set to 360 degrees. Otherwise the speed
will refert to Speed 2 once Angle 2 is reached.
Speed Feedback Selection
This control either selects
a separate tachometer or uses the resolver for speed feedback. A
separate tachometer provides for slightly smoother speed regulation.
Using the resolver signal for speed feedback will be acceptable for
almost all applications. Move the focus to this button and press Enter
to toggle the selection.
Stop Angle, Creep Angle, Speed 1
For convenience some analog adjusters from the Setup Screen are duplicated here.
The Maintneance Screen has four subscreens: Resolver, Gate
Pulse, Overload, and Factory Settings. You can get to these by placing
the focus on the appropriate selector box and pressing ENTER.
Resolver Setup Screen
Check that the resolver used for position feedback is dedicated to the CS1000 and is capable of operating at 10 kHz.
The external resolver coupled to the press provides position and, optionally, speed feedback to the CS1000. The CS1000 supplies a 90° phase-shifted 10 kHz excitation current to the two stator windings of the resolver. The slide angle is derived from the phase angle of the voltage from the rotor winding relative to one of the stator windings. The resolver must be used only by the CS1000. No other equipment should be connected to it.
Setting Direction The press direction of rotation must agree with the CS1000 measured direction. This can be checked by inching the press to see if the direction indicated on the screen by the CS1000 agrees with the actual direction of the press.
If they do not agree, the stator windings on the resolver need to be interchanged on the terminal board of the CS1000. While swapping the leads to one winding will also work, it is recommended that you swap the sine and cosine windings by swapping the wires from the encoder on terminals 327 and 329 and swapping the wires on terminals 326 and 328. Some resolvers have built-in switches or two plugs for switching directions.
Setting Resolver Signal Amplitude
Uncouple the resolver from the press and slowly rotate it through 360°.
Monitor the output signal of the resolver rotor terminals 330 and 331
with an oscilloscope. This should appear as a clean sine wave.
If there is jitter or noise in the wave, check the shield grounding. Note that the shield is jumped to one side of the signal input. The signals should not saturate as the resolver rotates through 360°. The amplitude of the signal should be at least 0.8 V peak-to-peak. If saturation--seen as a flattening of the peaks of the wave--is observed, reduce the amplitude of the signals supplied to the stator windings until no saturation is observed anywhere in the rotation.
Monitor the exciter outputs to the stator windings of the resolver. The sine winding is across terminals 326 and 327. The cosine winding is across terminals 328 and 329. These should appear as clean sine waves. The amplitudes will normally vary up to 20% as the resolver moves from changes in transformer loading.
The maximum amplitudes of each stator channel should be adjusted so that they are equal. The amplitude for each channel is adjusted by varying the value in the digital setting on the Resolver Setting screen (see above).
Setting Resolver Offset
The resolver offset adjustment needs to be made on the analog adjuster
so that the actual slide angle agrees with the indicated slide angle of
the CS1000. Put the press in a known slide position such as Top Dead
Center (0°). Change the setting of the Resolver Offset adjuster so that
the digital angle display shows the actual angle of the press. If the
press is at Top Dead Center the display should now read 0°.
Inch the press around, checking for the accuracy of the position indicated on the screen at key points 0° and 180°. Modify the setting of the Resolver Offset adjuster so that the position monitor provides accurate readings.
Overload Setup Screen
Please note that any adjustments made on this screen will NOT
take effect immediately. After you have changed settings you must
select the Save Settings option on the main Maintenance screen AND then
REBOOT the control by removing and restoring power to the CS1000.
The CS1000 features internal electronic overload protection against overheating of the clutch and brake coils by integrating the voltage squared over time for both the clutch and the brake.
The overloads are set to trip in 2 seconds at 200 percent rated coil voltage. The trip point is at 100 on the Clutch Temp or Brake Temp indicators. If a trip occurs, you cannot reset until the temperature rise returns to below 50.
One benefit of voltage overload protection is that it is
independent of how many parallel coils are being used in the clutch and
the brake. No readjustment has to be done if a coil is removed. Another
benefit is that current is limited only by the maximum voltage that can
be applied to the coil. This gives you the maximum torque available on
the clutch, which should minimize getting stuck on bottom.
If the press is laboring over multiple cycles, the electronic overload
will keep track of the cumulative coil heating. The Clutch Temp monitor
on the Operator Screen indicates how close you are to the trip point
(100). Normal operation should be around 20 on the scale. The initial
settings for the Overload Screen are set at the factory. They may be
adjusted slightly to reflect real-world conditions.
Clutch/Brake Maximum Input Volts
Factory setting. This setting is based on the rating of the clutch/brake assembly and should not be increased.
Clutch/Brake Heat Capacity
Factory setting. This factor represents the mass of the clutch/brake
assembly and its ability to dissipate heat to the surrounding
environment. You can increase the time before a trip occurs by
increasing the heat capacity setting.
Clutch/Brake Continuous Voltage
Factory setting. You can increase the steady-state operating point by increasing the continuous voltage rating.
Programmable Gate Pulse Generator Screen
Setting changes will take effect immediately, but the old ones will be restored after power-down. If you want to save the new settings so they are retained after power-down, you must select the Save Settings option on the main Maintenance screen.
The programmable gate pulse generator screen allows
adjustment of the programmable gate pulse generator and consists of the
following controls:
Max Firing Angle
Factory setting. This control sets
the maximum degrees of the gate pulse advance. If set too high the eddy
current device saturates, resulting in instability.
Min Firing Angle
Factory setting. This adjustment sets the minimum firing angle for the
bridge when calling for excitation. A highly inductive load does not
draw appreciable current on a three-phase bridge until the firing angle
reaches 30°. If this adjustment is set between 15° and 30°, the speed
regulator does not require as much gain to overcome the dead band of
firing amps vs. firing angle that an inductive load presents. This
improves the stability of the speed regulator.
Plugging Time
Factory setting. When the speed
regulator changes from calling for clutch to calling for brake, the
gate pulse generator retards the firing angle of the clutch coil to
minus 45 degrees for the plugging time This allows the clutch bridge to
forcefully remove the stored energy in the clutch coil before applying
the brake. This prevents overlap of brake and clutch current when
switching modes. After the plugging time has elapsed, power is removed
from the gate pulse amplifier that was active.
Dead Band Time
Factory setting. This is the period of time when both the clutch and
the brake gate pulse amplifier power are off. This is used to allow
time for the previously active bridge to power down.
Pulse Width in Degrees
Factory setting. The SCR
firing pulse is a 25 kHz pulse train coupled through a gate pulse
transformer, providing isolation between the Rectifier and the Gate
Pulse Amplifier. This control sets the width of that pulse train.
Tachometer Timeout
Factory setting. This control is used at very low speeds when the
frequency of the tachometer is lower than the PID calculation rate. PID
calculations are scheduled 100 times per second. If the tachometer
frequency is less than 100 Hz, the drive uses the last detected speed
for the number of times specified by the tachometer timeout parameter.
After the Tachometer Timeout has expired, the speed regulator will be
told that the drive has stopped.
Factory Setting Screen
This screen combines some monitors and analog adjusters from other screens as well as some special adjustments for factory use and testing only. The screen can be accessed only with a special password and should be used by trained Factory Employees.
TROUBLESHOOTING
If you are confident that there are no problems external to the CS1000, your first step in the troubleshooting process is to power down by opening the circuit breaker and making the following readings:
Disconnect the tachometer leads from the drive and check for grounds. Disconnect the resolver leads and check for grounds. Disconnect the brake leads and check for grounds--preferably with a Megger. Disconnect the clutch leads and check for grounds--preferably with a Megger. Check for blown fuses. Check for shorted SCRs by removing the control power fuses 4FU through 9FU and measuring the resistance between each AC leg of rectifier bridges and each DC output.
The HMI screen is black
Check that the monitor has not been switched off or lost power. If there are signs of power, disconnect the video cable. The screen should display a "Video Input Missing" message, indicating that the problem is in the video cable or the control computer. If the screen is still black, the monitor may be defective.
The computer does not boot normally
If the computer control module does not execute a successful POST (Power-on self-test), replace the computer control module; there are no serviceable parts inside.
If the computer completes the POST but fails to complete booting, note where it stops and any error messages and call GALCO.
Hard-wire inputs not seen on HMI but are present on the terminal strip
Hard-wire outputs are present on HMI but not seen on the terminal strip
Check that the Modicon I/O module is communicating with the computer control module. This is indicated by a fast flashing light on the Modicon I/O module and on the Ethernet card in the computer control module. Check the Ethernet cable. This cable is wired for crossover not requiring a hub. If this does not solve the problem, replace the Modicon I/O module or the computer control module.
Slide angle readout erratic
The resolver can be monitored on the Resolver Setup screen. On this screen the output of the resolver is displayed in thousandths of a degree. When the press is stopped, this display should remain stable, with variation only in the last digit.
Check for correct connections between the resolver and the input to the CS1000. Check for damaged cable and loose connections, particularly on ground connections. Check the connections on 1RSV. Replace Computer Control Module 1CPU.
Tachometer fault
This fault detects a discrepancy between the command to the clutch/brake and the feedback. Thus the fault can appear in either of two very different circumstances
The control has commanded a motion but is getting no speed feedback.
If the press is indeed running, check the resolver, the tach (if used), their couplings, and the wiring in these circuits. If the press is not moving, check that the main motor is on, and check that power is reaching the clutch.
The control detects that the press is moving but the control has not commanded a motion.
If the press is not moving, check for noise or miswiring in the resolver and tach circuits.
Error messages seen on HMI screen
These error messages are text that overwrites portions of the screen. These are generated by the software. The content may give you some idea as to the problem. For example, if the keyboard connection is loose, a message will indicate something about the keyboard. Similarly, if the Ethernet connection to the Modicon module is loose, you may see a message about "ETH0." These messages may be cleared by changing to a different screen and changing back. If the messages repeat or you cannot identify the cause, call GALCO.
Settings cannot be made from press control
If settings can be made from the CS1000 HMI and normal operation is possible, check the RS422 cable, the 1TX Serial Link Interface module, and the RS232 connection to the control computer
Rough or unstable operation
Check the resolver and tach (if used) for noise. See "Slide Angle Readout Erratic." If using the tach, try switching to the resolver for Speed Feedback Selection (see Regulator Setup).
Check that the settings for the regulator have not been changed.
Look for intermittent shorts and grounds in cables as the press cycles.
Double-check the initial checks at the beginning of this section.
Try to determine whether the instability is in firing the clutch, the brake, or both.
Try to determine whether the instability happens at all speeds.
Check the press counterweights (pressure).
Check for mechanical problems.
If the firing board has been replaced, make sure that the 480 volts on the terminal strip on the firing board are A, B, C from the top.
Monitor the wave forms of the clutch and the bridge with an oscilloscope to be sure that all SCRs are firing evenly. There should be one pulse every 2.8 ms.
Caution: High Voltages are present. DO NOT USE a standard single-trace oscilloscope with a grounded input. Shock hazards as well as damage to equipment will be the result. You can use a standard dual-input oscilloscope in differential mode with 100X probes. You can also use equipment like the Fluke ScopeMeter, which uses a non-grounded input and a high-voltage probe
INSTALLATION
This section describes the procedure for initial installation and setup of the CS1000.
Check to see that the wiring from the press control to the CS1000 is correct. Make sure that all electrical connections are tight.
Double-check for shorts and grounds in the 480 V AC circuits.
Apply power to the CS1000.
CS1000 configuration
The CS1000 must be configured for its operating environment. This process should only be necessary upon initial installation or when installing a new computer module for the first time.
The configuration menu is entered during system start-up by pressing the 1 key momentarily when the screen clears and the message "press an option key" appears on the screen. The "1" key must be pressed within three seconds of the message appearing or the CS1000 will continue to start up with the factory default settings.
The configuration menu provides you with the following choices. Each option is selected by typing the corresponding number and ENTER on the keyboard. When you are finished with settings changes, you may go directly to the main Operations screen by selecting 1. Start.
Note that once you exit this menu, you must reboot and press the "1" key to return to this maintenance menu.
Below is an explanation of the menu items.
Start
Proceed with normal startup. This option is selected when all configuration options are complete. After the HMI comes up, navigate to the resolver screen (selected from maintenance screen) and set the resolver offset so that the indicated slide angle agrees with the actual slide angle. If after inching the press, you get a direction fault and the graph indicates reverse direction, swap one of the stator leads of the resolver at the terminal board.
Set Time
The log used in troubleshooting uses the system time. This selection takes you to a sub-menu where the time is entered in format MMDDHHmmYYYY. If you wanted to set the time to 11:05 AM March 12, 2006, you would enter 031211052006 ENTER
Set Time Zone
This option takes you to a sub-menu where you can select the time zone
Speed Range
This option takes you to a sub-menu where you can select the high-speed or low-speed HMI. The high-speed HMI allows setting of speeds up to 60 strokes per minute. The low-speed hmi HMI allows setting speeds up to 25 strokes per minute
Line Frequency
This option allows you to select either 50Hz or 60Hz operation.
Factory
This option is for factory use only and requires a password. If you select it by mistake, you must remove power from the system and restart.
REPLACING COMPUTER
The computer is supplied by Galco complete with the CS-1000 computer program as part of the firmware. It should provide reliable operation since it uses no moving parts (hard drives and fans). There are no user-serviceable parts in the computer except for the replaceable CMOS battery. In the event that trouble-shooting indicates computer problems, normal computer techniques should be tried before replacing the unit. These include making sure that all connectors, cards and components are firmly seated and removing any moisture or dirt on the components.
Replacement of the computer will allow immediate operation with default press settings. Before operation, you must use the HMI to enter the correct settings for all parameters for the specific application. Keep an up-to-date hard copy of all settings as you change them (see appendix).
Restoring BIOS settings
In normal operation, the CMOS battery on the computer motherboard should last at least five years. We recommend that you replace the battery every five years. If a spare computer is stored for a several years the battery may fail to support the CMOS memory in the computer. Open the computer and replace the CMOS battery.
When the battery is replaced the BIOS settings will need to be reset in order for the computer to work properly. This procedure may be done when the computer is mounted in the control. Or the procedure can be done on a replacement computer in a "white room" with a standard computer keyboard and monitor. Connect a standard keyboard and monitor to the computer and plug in the 12V supply.
In normal operation the computer should boot up and display the GALCO logo, go through its boot-up routine and the HMI main operations screen will appear. If the computer is not connected in the control, the operations screen will indicate a Modicon Fault, an AC Power Fault, and there will be hash showing on the Press Speed graph.
If the battery has been replaced or fails to start properly, reset the BIOS.
- Open the computer so that the motherboard is accessible
- Connect a standard keyboard and monitor and plug in the 12 volt power supply
- Momentarily jumper pins 6 (PW_BN+) and 8 (PW_BN-) on the
16-pin motherboard front panel header to start the computer. Refer to
case connectors F_PANEL on page 2-12 of the MotherBoard Instruction Manual.
- Hold down the DEL key as the computer is booting up to enter the BIOS setup screen.
- Select "Optimized Defaults."
- Navigate to: Standard CMOS Features.
- Set "Drive A" and Drive B" to NONE.
- Press ESC to navigate to the main menu.
- Navigate to "Advanced BIOS Features."
- Set First Boot Device to USB-HDD.
- Set Second Boot Device to HDD-0.
- Set Third Boot Device to LAN.
- Press ESC to navigate back to main menu.
- Navigate to "Integrated peripherals"
- Set USB Keyboard Support to ENABLED.
- Set Onboard Lan Boot to ENABLED.
- Set Onboard Lan Boot Rom to ENABLED.
- Press ESC twice to navigate to main menu.
- Navigate to "Power management setup."
- Set "AC Loss Auto Restart" to ON.
- Press F10 and select "Y."
- Press enter to save CMOS and exit.
- Follow the Installation Procedure in this manual to properly configure the control.
- Check all press settings.
KEYBOARD OPTIONS
For keyboards with no numeric keypad, the following keys may be used:
| Tab | Focus Next |
| Shift Tab | Focus Previous |
| Right Arrow | Increase one Major Division |
| Left Arrow | Decrease one Major Division |
| Equals Key | Increase 1/10 of a Major Division |
| Minus Key | Decrease 1/10 of a Major Division |
| Period | Log out so changes adjustments cannot be made |
| Space Bar | Clear and Refresh Screen |
| Right Arrow | Move one place to the right on digital adjusters |
| Left Arrow | Move one place to the left on digital adjusters |
| Up Arrow | Increase one digit on digital adjusters |
| Down Arrow | Decrease one digit on digital adjusters |
APPENDIX
Maintenance Screen Settings
| Accel Rate | 15 SPM/Second |
| Dcel Rate | 40 SPM/Second |
| Max Speed | 20 SPM |
| PID Proportional Gain | 15 |
| PID Integral Gain | 1 |
| PID Differential Gain | 72 |
| Clutch Gain | 1 |
| Brake Gain | .8 |
| Resolver Speed Dampening | .3 |
| Tach Scaling Factor | .08 |
| Speed Reference Select | Programmed |
| Speed Feedback Select | Resolver |
Gate Pulse Settings
| Min Firing Angle | 20 Degrees |
| Max Firing Angle | 80 Degrees |
| Pulse Width | 3 Degrees |
| Plugging Time | .12 seconds |
| Deadband Time | .02 seconds |
| Tach Timeout | .2 |
Resolver Settings
| Resolver Offset | Set to match digital readout of slide angle with actual |
| Cosine Amplitude | 6000 |
| Sine Amplitude | 6000 |
Overload Settings
| Clutch RMS input voltage | 480 volts | AC input to rectifier bridge |
| Clutch Heat Capacity | 30 | Related to the mass of the copper coils |
| Clutch Continuous Voltage Rating | 175 Volts | DC voltage across the clutch |
| Brake RMS input voltage | 480 volts | AC input to rectifier bridge |
| Brake Heat Capacity | 30 | Related to the mass of the copper coils |
| Brake Continuous Voltage Rating | 175 Volts | DC voltage across the brake |
rev. #2 (12/6/05)