Service 488
Service 488
Service 488
1 ANTRIEBSEINHEIT ALPHA 488 BASIS MASCHINE SERVO AXIS ALPHA 488 BASE MACHINE .. 2
D AC 0 8 D AC 0 5 / X D AC 0 8 D A C 0 5 /X D AC 0 5 / X
K o m a x N r. 0 24846 K o m a x N r. 0 245 16 K o m a x N r. 0 245 17 K om a x N r. 0 245 1 6 K o m a x N r. 0 245 16
R S 422
Service_488.doc
zu P C C
d elta d rive d elta d rive d elta d rive d eltad rive d elta d rive
K a b elencoder
R S 48 5
ink l . F errit
L= 0 . 145 m
Stations -Adres s e N r. 0 2484 9
1 2 N r. 0 2485 1 N r. 0 248 5 2 3 4 N r. 0 248 5 3 N r. 0 248 5 4 5
N r. 0 2485 0
D C -B u s D C -B u s
3 x 220 V 3 x 220 V 3 x 22 0 V
SA C 9 0 L2 0 /3/T B /E Y -2 0 48 SA C 9 0 S2 5 /3/T B /F T /E Y -2 0 48 SAC 9 0 L2 0 /3/T B /E Y -20 48 SAC 9 0 S25 /3/T B /F T /E Y -20 48 SAC 9 0 S25 /3/T B /F T /E Y -2 0 48
K o m ax N r. 0 24844 K o m ax N r. 0 24845 K o m ax N r. 0 24844 K o m a x N r. 0 2484 5 K om a x N r. 0 2484 5
Motor m it K ab el k o m p let: Motor m it K ab el k om p let: Motor m it K ab el k o m p let: Moto r m it K a b el k om p let: Motor m it K a b el k om p let:
K o m ax N r. 0 249 0 1 K om a x N r. 0 24 9 0 2 K o m ax N r. 0 249 0 3 K o m ax N r. 0 24 9 0 4 K om a x N r. 0 249 0 5
N r. 1 N r. 2 N r. 3 N r. 4 N r. 6
D AC 0 8 D AC 0 5 /X D AC 0 8 D AC 0 5 /X D AC 0 8/F B K 10 0
K o m ax N r. 0 245 17 K o m ax N r. 0 245 16 K o m a x N r. 0 245 17 K om a x N r. 0 245 16 K om a x N r. 0 2484 6
Service_488.doc
R S 422
zu P C C
d eltad rive d eltad rive d eltad rive d eltad rive d eltad rive
K a b elencoder
R S 485
R S 485
ink l. F errit
ink l. F errit
L = 0 . 145 m
Station s -Adres s e L= 0 . 23m N r. 0 2485 5
1 N r. 0 24849 2 N r. 0 248 5 1 N r. 0 248 5 2 3 N r. 0 248 5 3 4 6
N r. 0 248 5 0 N r. 0 2 5 5 0 4
D C -B u s D C -B u s
E ncoderk ab el
L nge = 4. 5 m L = 9 . 0 m N r. 0 25 6 9 2 L nge = 4. 2 m s h ort N r. 0 2 5 6 9 4 L nge = 4 . 2m
N r. 0 25 6 9 1 L = 12. 5 m N r. 0 2 6 0 6 5 N r. 0 246 9 3 long N r. 0 2 5 6 9 8 N r. 0 25 6 9 6
L = 16 . 0 m N r. 0 2 5 6 9 7
Service-Unterlagen Motorregler deltadrive
Motork a b el
25 70 2
el
0 25 85 1
0 25 6 9 9
Motork a b el L nge = 4 . 3 m Motork ab el
L nge = 4. 5 m N r. 0 2 5 7 0 3 L nge = 4. 3m
N r. 0 25 70 6
Motork ab el
N r. 0 25 70 1
Motork ab
long N r. 0 25 70 0
s h ort N r. 0 25 70 4
L = 9 . 0 m N r. 0
L = 12. 5 m N r.
L = 1 6 . 0 m N r.
SA C 9 0 L20 /3/T B /E Y -20 48 SAC 9 0 S5 0 /3/T B /F T /E Y -20 48 SAC 9 0 S2 5 /3/T B /E Y -20 48 SAC 9 0 S2 5 /3/T B /F T /E Y -20 48 SAC 9 0 L20 /3/T B /E Y -2 0 48
K om ax N r. 0 24844 K om ax N r. 0 24810 K om ax N r. 0 24845 K o m ax N r. 0 2484 5 K o m a x N r. 0 24844
Motor m it K ab el k om p let: Motor m it K ab el k o m p let: Motor m it K ab el k o m p let: Motor m it K ab el k o m p let: Motor m it K ab el k om p let:
K om a x N r. 0 2 5 6 81 0 2 5 6 82 in k l . 0 25 70 2 K om a x N r. 0 2 5 6 83 K om ax N r. 0 2 5 6 86
0 2 6 0 6 4 ink l . 0 25 85 1
0 26 10 2 ink l. 0 25 6 9 9
ALPHA488 Service-Unterlagen Motorregler deltadrive 4/17
Stations A d r e s s e nE r k e n n u n g :
Ein Widerstand, vergossen in einem Gehuse, wird beim ersten Einschalten des Controllers vom
A/DWandler eingelesen und ausgewertet.
Station-Addre s -R e cognizing :
T h e s t a t i o n n u m b e r i s d e f i n e d b y a resistor value. The value will be read on the first Power Up.
U e b e r l a s t k o n t r o l l e d e r S e r v o a c h s e n m i t t e l s I 2t U e b e r w a c h u n g i m C o n t r o l l e r .
K e i n T h e r m o-K o n t a k t i m M o t o r .
= > B e i F e h l e r m e l d u n g " U e b e r t e m p e r a t u r M o t o r " , m u s s d er Motor nic h t gewec h s e lt werden, weil der
C o ntroller den Motor s c h tzt . ( A u s s e r b e i m e c h a n i s c h e m D e f e k t )
Overload control with the I2t supervisor in the axis controller.
There is no thermo contact in the motor.
=> If error message "temperature overload ..." appears, motor doesn't have to change, because the
controller protects the motor against overheating. (except for mechanical defect)
ON
OF
mssen alle in der Stellung OFF stehen.
All DIP - switches on the controller must be in the OFF - Position.
D i e E n c o d e r k a b e l s i n d b e i d s e i t i g m i t ei n e m H D -9 p o l D -SUB S t e c k e r v e r s e h e n . D i e
Befestigungsschrauben mssen immer gut angezogen sein, um eine gute Masseverbindung sicher
zu stellen.
The encoder cables are on both sides equipped with HD-9 pol SUB-D connectors. The connectors
must always be screwed well to ensure correct grounding.
D i e M o t o r r e g l e r m s s e n m i t d e r C -S c h i e n e ( M a s s e s c h i e n e ) g u t v e r s c h r a u b t s e i n . D i e S c h r a u b e
b e f i n d e t s i c h u n t e r d e r C -S c h i e n e , z w i s c h e n d e n S c h n e l l v e r l e g e r k l a m m e r n .
The axis controllers must always be fixed well with the corresponding screw to the groundrail below
the controllers.
Schlechte, oder gar fehlende Masseverbindungen der Kabelschirme knnen zu Fehlern in den
Motorreglern f h r en .
Bad or even missing ground connections may cause errors on axis controllers.
4 4 4 4 4 4
G ateway
N othalt
5 N othalt
5 5 5 5 5
6 6 6 6 6 6
7 7 7 7 7 7
N ota u s 8 8 8 8 8 8
Emergency Stop R eady R eady-Signal B IO
R elais K 5 9 9 9 9 9 9 Inp u t 5
R eady
10 10 10 10 10 10
+24V D C 11 11 11 11 11 11
B IO
0 V D C 12 12 12 12 12 12 Ou tp u t 24
Start-P u l s
1 1 1 1 1 1
2 2 2 2 2 2 R E AD Y = +24V
3 3 3 3 3 3
E m ergency Stop = 0 V
4 4 4 4 4 4
5 5 5 5 5 5
6 6 6 6 6 6
7 7 7 7 7 7
8 8 8 8 8 8
9 9 9 9 9 9
10 10 10 10 10 10
1 1 1 1 1 1
2 2 2 2 2 2
3 3 3 3 3 3
4 4 4 4 4 4
The following diagram shows the wiring of the setup loop. The HW-signal "Automatic / Setup" will be sent
from CH 0 and CH 1 from MRS-board. This signals will be analyzed in Swivel 1 and Wire Pull.
Au to/Setu p Ou tp u t
MR S C H 0 Au to/Setu p Inp u t
Base cabinet
Swivel1 Pu llOff1 Swivel2 Pu llOff2 K nife
Au to m atik = +24V
RJ45
(E na b le, B etrie b ) 4 4 4 4 4
G ateway
E nable
5 5 5 5 5
Setu p = 0 V 6 6 6 6 6
7 7 7 7 7
Betrieb
8 8 8 8 8
9 9 9 9 9
10 10 10 10 10
+24V D C
11 11 11 11 11
0 V D C
12 12 12 12 12
Au to/Setu p In p u t
Au to/Setu p Ou tp u t MR S C H 1
Twister cabinet
T wis ting T wis ting T wis ter
Length Head B ridge Wire Pu ll
RJ45 SW - C o m m and
4 4 4 4
G ateway
E nable
5 5 5 5
Betrieb
6 6 6 6 Au to m atik = +24V
7 (E na b le, B etrie b )
7 7 7
Betrieb
8 8 8 8
Setu p = 0 V
9 9 9 9
10 10 10 10
+24V D C
11 11 11 11
0 V D C
12 12 12 12
By the two communication lines (CH 0, CH 1), the controllers get the message "Automatic / Setup". This
comands are shared to the two gateways as follow:
S W IVE L U N IT 1 P U L L OF F U N IT 1 S W IVE L U N IT 2 P U L L OF F U N IT 2 KN IF E U N IT
Nr.1 Nr.2 Nr.3 Nr.4 Nr.5
D A C 0 8 D A C 0 5 / X D A C 0 8 D A C 0 5 / X D A C 0 5 / X
K om a x N r. 0 2484 6 K o m a x N r. 0 24 5 1 6 K om a x N r. 0 24 5 17 K o m a x N r. 0 24 5 1 6 K o m ax N r. 0 245 1 6
RS 422
z u P C C
Ch 0
d eltad rive d eltad rive d eltad rive d eltad rive d eltad rive
1 2 3 4 5
TW I S TI N G L E N G TH TW IS TIN G H E A D TR A N S F E R B R I D G E W IR E P U L L
N r. 1 N r. 2 N r. 3 N r. 6
D AC 0 8 D A C 0 5 /X D AC 0 8 D AC 0 8/F B K 1 0 0
K om ax N r. 0 245 17 K om ax N r. 0 245 16 K om ax N r. 0 245 17 K o m ax N r. 0 2484 6
R S 422
zu P C C
d eltad rive d eltad rive d eltad rive d eltad rive
1 2 3 6
When changing the state of the HW-channel ASB, this change will also be sent to all controllers by
communication-lines. As soon as the level of the HW-channel ASB rises to 24V and all controllers get the
message "Automatic", they switch to the state "Automatic". As soon as the level of the HW-channel ASB
falls down to 0V or any controller get the message "Setup", all controllers switch to the state "Setup".
The Parameter IP109 on the controller which contains the gateway shows us the presence of the 24V of
the ASB-Signal.
IP109 = 0x4F00 bei 24V.
IP109 = 0x4700 bei 0V.
If the green LED (ASB) on the RCS_board lights, the value of IP109 must show 0x4F00. Otherwise, the
RS422 wire, coming from the MRS-board is broken.
MRS:CH0
RSA ASB
Base cabinet
IP109
Gateway
RJ45
24 V 24 V 24 V 24 V 24 V
SW SW SW SW SW
5 5 5 5 5
HW 8 HW 8 HW 8 HW 8 HW 8
MRS:CH1
RSA ASB
Twister cabinet IP109
Gateway
RJ45
24 V 24 V 24 V 24 V 24 V
SW SW SW SW SW
5 5 5 5 5
HW 8 HW 8 HW 8 HW 8 HW 8
SW: Auf den beiden seriellen Schnittstellen (CH0, CH1) wird jedem Regler "Automatik" oder
"Setup" gemeldet.
By the two communication-lines (CH 0, CH 1), the controllers get their messages
"Automatic" or "Setup".
RSA: Wenn b e ide K a n l e b e i allen Motorreglern vor h a nden s i nd, i s t der Set u p -K r e i s g e s c h l o s s e n .
Die Regler sind in der Betriebsart "Automatik". Das Signal RSB bringt 24V zurck zur MRS
u n d s o m i t a u f d e n R C S-Print . D i e g r n e L E D R S A le u c h t e t .
If both channels have the meaning "Automatic" ,the HW-loop on the controllers will be
closed.(24V on all connectors X5/pin 5 and X5/pin 8). The controllers are in Automatic-
mode. The signal RSA is on 24V, so the RCS-board gets this 24V as well, which is indicated
by the green LED RSA.
D e r Z u s t a n d d e r H W - S e t u p -L e i t u n g ( I n p u t a u f R J 4 5 ) w i r d i m P a r a m e t e r I P 1 0 9 a u f B i t 1 1 a b g e b i l d e t .
Der IP 109 kann auf dem TopWin unter "Werkzeuge / Achsen Debuggen / Schwenker 1" bzw.
" W e r k z e u g e / A c h s e n D e b u g g en / T w i s t er Wire P u l l" a b g efragt werden .
The state of the HW-channel can be seen on the parameter IP109 bit 11 in the axis controller.
The parameter IP109 can be shown on the TopWin under "Tools / Axisdebug / Swivel 1" resp. "Tools /
Axisdebug / Twister wirepull".
D e r I P 2 4 9 W A T C H L A T C H zeigt die HW - u n d SW - Z u s t n d e i m R e g l e r a n .
The parameter IP249 WATCHLATCH shows the HW - and SW - states in the axis controllers.
MSB LSB
HW HW SW SW
SETUP NOTAUS SETUP NOTAUS
1=Auto 1=Notaus 1=Auto 1=Notaus
Die folgende Tabelle zeigt die typischen Werte bei den verschiedenen Maschinenzustnden.
Typical values of diffrent maschine modes.
6 G e samtbersicht
Cover Cover approval Cover Cover Mouse /
machine wire drive 1 button machine wire drive 1 return
Channel B Channel A
24 VDC
Output 32-35
5 5 5 5 5
8 8 8 8 8
Pre
Twisting Twisting Transfer Twisting
Length Head Bridge Wire Puller
Head
5 5 5 5 5
8 8 8 8 8
7 Fe h l e r s uc h e / Trouble shooting
7.1 L E D - D i s p l a y
d e l t a d r i v e verfgt b e r ein Sel b s t diagno s e - u n d b e r w a c h u n g s s y s t e m , d a s a u f e i n e V i e l z a h l
vo n F e h l e r n r e a g i e r t , d i e i m B e t r i e b a u f t r e t e n k n n e n . D i e m e i s t e n F e h l e r w e r d e n d u r c h d i e
L E D s a n d e r F r o n t d e s d e l t a d r i v e angezeigt.
deltadrive has a self-diagnosis and supervising-system, which reacts on most errors and faults. Most of
the errors are displayed by the LED, mounted on the front panel of the axis controller.
All controllers are connected parallel on the controller network. Any defective controller is able to disturb the
whole network communication. The axis controllers in the Alpha 488 are shared into two networks. After power
on, the machine controller checks the communication to each axis controller in the order of their mounted place.
Starting in the base cabinet with the one which is nearest to the gateway 0, (controller no 1 up to controller no 5),
it is possible to find the defective controller, by plugging one by one onto the network. In the twister cabinet, the
machine controller starts the communication on CH 1 to gateway 1, which is mounted in the controller no 6. Then,
the communication to no 3, 2, and 1 is established.
As long as the error message "Baudrate not found for init gateway" or "No communication to gateway" appears, a
defective axis controller is connected to the network.
Otherwise, the errormessage "No communication to axis no x" appears. x is the controller, which is not connected
to the network or defektive.
Attention: Before connecting and disconnecting network cables, first unplug the fuse F105! (24V for the
Controllers).
This prevents from damages on network drivers and the error messages will occur in the right
way.
After putting in the fuse, the pcc-card always has to be reset.
d elta d riv e d elta d rive d elta d r ive d elta d rive d elta d rive
d elta d rive d elta d rive d elta d rive d elta d rive d eltad rive
1 2 3 4 5 3 6
1 2 4
The load cell is mounted behind the holding gripper. The charge amlifier converts the measured force into
a voltage between 0V and +10V. This voltage can be measured, while twisting, at pin 1 and 2 on X5 on
the Twisting Length controller. The voltage must be positiv if the voltmeter is connected as shown below.
Otherwise, the wires to AD+ and AD- must be changed.
Voltmeter
+
V 1 AD+
Kraft - - 2 AD -
Mess - Ladungs -
D o s e Verstrker
load cell Charge amp.
Motor
Regler
axis
controller
Mgliche Fehlerflle:
1. G r e i f e r m i t K ra f t m e s s d o s e s t r e i f t a n i r g e n d w e l c h e n A b d e c k u n g e n , o d e r k a n n s i c h s o n s t w i e
nic h t frei b e wegen .
2. Kraftmessdose defekt.
3. Ladungsverstrker defekt.
4. Verkabelung defekt oder falsch.
5 . Motorregler defe k t .
1. E i n g e s p a n n t e L e it u n g e n t s p r i c h t n i c h t d e r j e n i g e n v o m T o p W i n g e l a d e n e n L e i t u n g . ( F a l s c h e r -
Durchmesser).
2. Kraftmessung funktioniert nicht.
3. Kraftmessdose oder Ladungsverstrker defekt.
4. Verkabelung defekt oder falsch.
1. Eingespannte Leitung entspricht nicht derjenigen vom TopWin geladenen Leitung. (Falscher
Durchmesser).
Possible errors:
Wire will not be tightened
1. Holding gripper with load cell touches some mechanical surface
2. Load cell defect
3. Charge amplifier defect
4. Wiring defect or wrong
5. Axis controller defect
Service_488.doc komax AG /Peter Flury 18. Oktober 2005
ALPHA488 Service-Unterlagen Motorregler deltadrive 16 /17
Twisting Length runs too fast forward. Wires will be untighten while twisting.
1. Actual wire is not equal the loaded one from TopWin (wrong diameter)
The correct function of the two wire encoders can be checked by reading the parameter IP 240
(XENC_ANGLE). While turning the measure weel, the value on IP240 must change.
The wire encoder of wire line A is conected to the axis controller Swivel 1 in the base cabinet.
The wire encoder of wire line B is connected to the axis controller Wire Pull in the twister cabinet.
As described in chapter Fehler! Verweisquelle konnte nicht gefun d e n wer d e n. all parameters can be
shown under "Tools / axes debug". Here are the most important parameters:
HW Hardware hardware
SW Software software
MRS Verteiler Karte (Multi RS485) distribution board
R C S R e d u n d a n t e s S t e u e r u n g s -Sy s t e m redundant control system
ASA Auslsen Schalter A activate switch A
RSA R c k m e l d u ng Sc h a lter A response switch A
ASB Auslsen Schalter B activate switch B
RSB Rckmeldung Schalter B response switch B
WD1 Wire Drive 1 (Kabelantrieb) wire drive 1
CPU Zentrale Recheneinheit central processing unit
IP Interner Para m e ter internal parameter