P1P20FH20 - 001 : Installation Manual

Document Release	Description	Date

Document	MDI_P1P20FH20-001
Description	Installation Manual
Drawn up by	Michele Sandri
Approved by	Gabriele Bazzi
Link	http://www.qem.eu/doku/doku.php/en/strumenti/qmoveplus/j1p20/p1p20fh20-001/mdi_p1p20fh20-001
Link	http://www.qem.eu/doku/doku.php/strumenti/qmoveplus/j1p20/mimj1p20fx
Language	English

01	New manual	07/07/2014

All rights reserved on this manual. No part of this document can be copied or reproduced in any form without prior written authorisation. QEM does not insure or guarantee its contents and explicitly declines all liability related to the guarantee of its suitability for any purpose. The information in this document can be changed without notice. QEM shall not be held liable for any error or omission in this document. QEM® is a registered trademark.Microsoft® and MS-DOS® are registered trademarks and Windows® is a trademark of Microsoft Corporation.

1.Description
2. Hardware J1-P20-FH20
2.1. Standard Symbols & Buttons
2.2. MAIN SCREEN
3. Startup
4. Setup
4.1. HMI Setup
4.2. General Parameters - GP
4.3. Machine Parameters - MP
4.4. Belt and Head Calibrations
4.5. Calibration
4.5.1. Belt resolution
Axis Resolution
4.5.2. Maximum Belt Speed calibration
4.5.3. Head Calibration
4.5.4. Slab IN limit switch offset
4.5.5. Dynamic head Up/Down correction
5. Diagnostic
5.1. Digital Input diagnostic
5.2. Digital Output diagnostic
5.3. Operating Diagrams
5.4. Belt encoder count
5.5. Analog Inputs and Outputs
5.6. System Info
6. Warnings
7. Alarms
7.1. Alarm list
7.2. Alarm history
8. Typical wiring diagram

1. Description

Il software P1P20FH20 - 001, installato nell'hardware Qmove J1-P20-FH20, realizza l'automazione di macchine levigatrici/levigabordi .

Caratteristiche principali

lo strumento comanda 19 teste di lavoro
controlla l'avviamento sequenziale dei motori (per limitare l'eccessivo richiesta di corrente )
gestisce l'eventuale spostamento del ponte
per ogni testa di lavorazione è possibile impostare gli anticipi e i ritardi di lavorazione, sia all'inizio, sia alla fine del pezzo
I comandi di salita/discesa delle teste di levigatura, vengono calcolati automaticamente al variare della velocità del nastro trasportatore.
lo strumento conta i metri lavorati ed è in grado di lavorare fino a 30 pezzi presenti contemporaneamente in macchina.

Altre Caratteristiche

HMI con touchscreen
Tasti funzione
Programmi di lavoro
Messaggi di allarme
Messaggi di warning
Reset dei pezzi difettosi
Reset di tutti i pezzi in lavorazione
Compensazione dell'offset del finecorsa di presenza pezzo
Modo di lavorazione delle teste
1. Levigatura
2. Fresatura
3. Molatura
4. Spazzolatura
5. Getto d'acqua

Opzioni e caratteristiche di possibile futura implementazione

Con l'installazione dei moduli RMC1XX sarà possibile automatizzare 2 o 4 calibratori
Con l'installazione dei moduli RMC1YY sarà possibile leggere la corrente di ogni testa
E' possibile dotare lo strumento del software necessario per realizzare delle lavorazioni di bocciardatura
E' possibile dotare lo strumento di funzionalità software di abilitazione/disabilitazione di ogni singola testa
E' possibile dotare lo strumento di porta Etnernet, che consente di trasmettere i dati della macchina agli uffici di programmazione della produzione .
Risparmio energetico : accensione dei motori solo durante la lavorazione
Nota : in questo caso si dovrà utilizzare un modulo di espansione degli I/O

Note Se il cliente è interessato a queste opzioni e caratteristiche, oppure altre di Sua scelta, contattare l'Ufficio Commerciale della QEM ( info@qem.it )

2. Hardware J1-P20-FH20

		MAIN MENU
		RESERVED SETUP (enter password)
		WORK PROGRAMS
		RESET ALL SLABS
		RESET SELECTED SLABS
		ALARMS
		ESC TO PREVIOUS SCREEN

2.1 Standard Symbols & Buttons

Button	Description	———————–	Top Bar Symbol	Description
	Confirm Popup entry			Manual
	Popup Select			Alarm
..	Previous screen & Next screen			Automatic
..	Scroll list			Function mode
	Reserved Area			Not initialized
	Quit without saving			Setup Locked/Unlocked
	Confirm setting			Calibration
	Green settings can be changed
- - - - - - - - - - - - -	- - - - - - - - - - - - - - - - - - - -	- - - - - - - - - - - - - - - - - -	- - - - - - - - - - - - -	- - - - - - - - - - - - - - - - - - - -

2.2 MAIN SCREEN

		Right IN
Top Bar (grey) - Machine State - Page name - Page number - Time Bottom Bars - Alarms (red) - Warnings (light blue)		Left IN

3. Startup

Important

	hardware, wiring, general info, system info: Hardware manual

★Per una corretta messa in funzione della macchina, si raccomanda di seguire l'ordine delle attività di seguito descritte e illustrate

Control the application software code in the Start screen
Controllare la funzionalità del Touch in HMI Setup
Load the Default Parameters
Control the General Parameters - GP and Machine Parameters - MP
Check the wiring in Diagnostic (see Typical Wiring Diagram)
Check the Beam direction forward/backward in the Manual screen
Go to Calibration
1. Check the count direction and calibrate the Belt resolution in Belt Resolution
2. Calibrate the Maximum Belt Speed Calibration
3. Calibrate the Slab IN limit switch offset
4. Calibrate the Head Calibration
  1. Work diameter
  2. Set the head distances from the slab IN limit switches
  3. Set the Dynamic head Up/Down correction to the Belt speed
Carry out the Backup Procedure
Carry out the Archiving Procedure

4. Setup



	PASSWORD:462

4.1 HMI Setup


PASSWORD:462

Parameter	Default	Range	Description
LOGO	ON	OFF ~ ON	OFF: No logo ON: logo
LANGUAGE	en_GB	-	en_GB : English it_IT : Italiano
BUZZER	ON	OFF ~ ON	OFF: no buzzer ON: buzzer
DATE	-	-	Set the date
TIME	-	-	Set the time
GMT TIME	OFF	OFF ~ ON	OFF: no legal time ON: legal time

Touch Screen calibration

Keep + pressed until bar is full

4.2 General Parameters - GP

Parameter	U.M.	Default	Range	Description
GP-01	-	4000	P ( Pulse )	Encoder pulse reading x 4, corresponding to length in Measure .
GP-02	-	400.0	M ( Measure )	Length corresponding to encoder pulses (Pulse) - P/M is the resolution. It must be 0.000935 ~ 1.000000. - Pulse ane Measure are set by the procedure Axis Resolution.
GP-03	-	1	0 ~ 3	Decimal point for Belt speed 0=xxxx, 1=xxx.x, 2=xx.xx, 3=x.xxx
GP-04	-	0	0 ~ 1	Decimal point for Belt misura 0: xxxx, 1: xxx.x
GP-05	-	1	0 ~ 1	Heads Position at belt speed below the minimum (GP-06 ) 0 = heads remain DOWN . 1 = heads go to UP .
GP-06	-	0.1	0 ~ 999999	Minimum Belt speed
GP-07	-	0.5	0 ~ 999999	Speed Delta, when above the filter is applied ( GP-08 ).
GP-08	msec	50	0 ~ 9999	Filter on Belt speed
GP-09	-	0	0 ~ 5	Sampling Time of the frequency meter (used to determine the belt speed) 0 = 240 ms, 1 = 480 ms, 2 = 24 ms, 3 = 120 ms, 4 = 960 ms, 5 = 1920 ms.
GP-10	-	0	0 ~ 1	0 = Save slabs when machine OFF 1 = Do not save slabs when machine OFF
GP-11	-	0	0 ~ 1	Slab IN (input I09) below minimum speed . 0 = YES 1 = NO
GP-12	mm	10.0	0 ~ 9999	Distance, if below two adjacent slabs are worked in continuous The slab counter still counts 2 slabs
GP-13	msec	1000	0 ~ 9999	t1 time for motor start output
GP-14	msec	1000	0 ~ 9999	t2 time between one motor start and another
GP-15	msec	1000	0 ~ 9999	t3 time between the last motor start and O24 output for end of motor start sequence
GP-16	-	0	0 ~ 1	Abrasive Change Position 0 = on backward LS 1 = on forward LS
GP-17	-	0	0 ~ 1	Enclosures contact logic 0 = NC 1 = NO

4.3 Machine Parameters - MP

Parameter	U.M.	Default	Range	Description
MP-01	-	1	1 ~ 19	Number of heads
MP-02	mm	0	0 ~ 999999	Machine length Distance between the slab IN limit switch and end of the machine
MP-03	-	0	0 ~ 4	Belt Command/Control 0 - External Command/Control - speed reading 1 - Command - speed reading - analog out 2 - Command - speed reading - analog out (set by potentiometer). 3: - Command & Control by encoder feedback - speed reading - analog out - Start/Stop from controller 4: - Command & Control by encoder feedback - speed reading - analog out (set by potentiometer) - Start/Stop from controller
MP-04	-	0	0 ~ 1	*Beam Command* 0 = External Control. 1 = Beam Control with min & max limit switches and slowdown (Il movimento avviene con almeno un pezzo in macchina).
MP-05	-	0	0 ~ 1	*Motor Start Sequence* . 0 = NO 1 = yes
MP-06	-	-	-	-
MP-07	-	-	-	-
MP-08	m/min	5.0	0 ~ 5.0	Maximum Belt speed ( AO1 = 10 Volt ) (MP-03 > 0)
MP-09	m/min	3.0	0 ~ 5.0	Max Belt Speed in automatic (MP-03 > 0 )
MP-10	m/min	1.0	0 ~ 5.0	Belt Jog speed ( MP-03 > 0)
MP-11	-	0	0 ~ 1	Beam start mode in automatic ( MP-04 = 1). 0 = Start with belt 1 = Start when slab IN
MP-12	s	1.000	0 ~ 999.0	Tempo di ritardo tra la Belt start and Beam start (MP-05 = 1)
MP-13	%	5.0	0 ~ 100.0	% maximum speed of Beam in automatic
MP-14	%	5.0	0 ~ 100.0	Slow speed of Beam in automatic (MP-04 = 1)
MP-15	%	50.0	0 ~ 100.0	Jog speed of Beam (MP-04 = 1)
MP-16	s	2.000	0 ~ 999.0	Beam stop time at max & min limit switches ( MP-04 = 1)
MP-17	-	0	0 ~ 1	Slab IN Direction 0 = right 1 = left

4.4 Calibration


PASSWORD:462

4.4.1 Belt resolution

→

Procedure

Press and check the ENCODER box increases(Analog out +1 Volt)
Press and check the ENCODER box decreases (Analog out -1 Volt)
A - A' = The maximum space
Take note of the start position (A)
Zero-set the ENCODER:
Move the axis from A to A'
Take note of the reading in ENCODER box and write it in the PULSE box
Measure the distance from A to A' = space delta
Enter the A - A' space delta in the MEASURE box

Important:

PULSE must alway be greater than MEASURE (the best is “MEASURE x 10 = PULSE”)
Enter MEASURE in the selected unit measure. E.G. if a unit measure of 1/10mm is selected and the space delta is 133.5mm, enter 1335 in the MEASURE box

4.4.2 Maximum Belt Speed calibration

Set the same speed in MP-08 and MP-10

start the belt

Take note of the speed

Set the speed in MP-08

Set MP-09 and MP-10 as required

4.4.3 Head Calibration

	OR
	MP-16 = Slab infeed direction
head group box
- -

Parameter	U.M.	Default	Range	Description
Type	-	-	0 ~ 5	Head function modes 0: OFF 1: Polishing 2: Milling 3: molatrice 4: Brush 5: Air/water jet
Interaxis	mm	-	0 ~ 99999.0	Distance from slab IN limit switch to the head center
Diameter	mm	-	0 ~ 99999.0	Work diameter

4.4.4 Slab IN limit switch offset

Measure the length of a slab and enter in Real length
Start the belt so the controller reads the slab length by the slab In limit switch
Measur. length gives the length reading
to set the limit switch offset
The offset can also be changed manually
Correc. Length shows the new corrected length

4.4.5 Dynamic head Up/Down correction

	set all motors to OFF

	OR
	MP-16 = Slab infeed direction
head group
- -

Parameter	U.M.	Default	Range	Description
SPEED CORR.	m/min	3.0	0 ~ 5.0	Reference speed for Dynamic calibration
Down lag	mm	-	-999.0 ~ 999.0	( + ) Delay distance for head DOWN on slab front .
Rise adv	mm	-	-999.0 ~ 999.0	( + ) Advance distance for head UP before slab end .
	Copy settings to all heads

A Typical example

To Polish ALL the slab at V1 = 3 m/min, set Downlag = 10, Rise adv = - 30
The lags and advances for other speeds are calculated automatically

5. Diagnostic

5.1 Digital Input diagnostic

INPUT	NAME	LOGIC	DESCRIPTION
I01	Emergency	NC - O	Stop	with Alarm message
I02	Not used	-	-
I03	Start motors	NO - C	Start motor sequence	con MP-05 = 1
I04	Power system enabled	NO - C	Machine ready	-
I05	NE	NC - O	In automatic, stop beam and belt /Reset the “motor rotation startup error” message	-
I06	Overload cutouts	NC - O	Chain of overload cutouts	with Alarm message
I07	Enclosures	NC - O	Chain of enclosures
I08	Air pressure switch	NC - O	No air
I09	Slab IN	NO / C	Limit switch for slab length acquisition
I10	Not Used	-	-
I11	Not Used	-	-
I12	Inverter fault	NC - O	Inverter alarm	with Alarm message
I13	Beam Forward LS	NC - O	Beam forward limit switch with fast speed	con MP-04 = 1
I14	Beam Backward LS	NC - O	Beam backward limit switch with fast speed
I15	Beam Forward Slow LS	NO - CC	Beam forward limit switch with slow speed
I16	Beam Backward Slow LS	NO - CC	Beam backward limit switch with slow speed

Note
★ NC - O = Normally Closed contact, action when the contact Opens
★ NO - C = Normally Open contact, action when the contact Closes
★ NO - CC = Normally Open contact, action when the contact Closed in Continuous

5.2 Digital Output diagnostic

N°	DESCRIPTION
O1~O19	Head UP/DOWN and motor start commands
O20	Belt direction - OFF forward - ON backward
O21	Beam direction - OFF forward - ON backward
O22	Water valve output
O23	Trips when slabs < 30 in machine (upline machine consensus)
O24	Machine OK output

5.3 Operating Diagrams

t1 one motor start time
t2 time between one motor start and another
t3 at end of motor starts(O19 = OFF), wait t3 time for O23 = ON
O23 = ON end of motor starts and OK to start loading slabs upline
A - B start head motors time
C time before machine is ready for work

5.4 Belt encoder count

N°	NAME	DESCRIPTION
PHA1/PHB1	Belt encoder signals	- to measure the slab lengths and establish their position on the belt - measure the feed speed of the slabs and calculate the head Up/Down advances - delays

Note:
• Z_INP led signals the Z pulse input state (not used in this application).
• Pulse : Encoder pulses x 4

5.5 Analog Inputs and Outputs

N°	NAME	DESCRIPTION
AI1	Analog input, belt speed variation (analog out AO1).	Potentiometer input. Reading in bit and percentage
AO1	Out 0~10 Volt	Inverter command	Belt
AO2	Out 0~10 Volt	Inverter command	Beam

5.6 System Info

Fw name	firmware and checksum names
Aux fw	I/O module firmware (not used in this application
Task time	CPU cycle time: Minimum, Medium, Maximum
CPU time	CPU run time (hh:mm)
Touch screen	Test touch

6. Alarms

6.1 Alarm list

To cancel alarms
- eliminate the cause
- press for 3 seconds

Message	Cause	Input
Emergency pressed	Check the emergency button and line	I01
Inverter fault	Control the inverter	I12
Belt encoder fault	Control the belt encoder (Acive only with MP-03 > 2).
Overload cutouts	Check the overload cutouts	I06
Enclosures	Check the enclosures	I07
No air	Check the air pressure switch	I08
	the Belt encoder fault alarm trips automatically if the belt moves less 2 u.m. in 5 seconds (less than 60 mm/min)

6.2 Alarm history

		To cancel alarms - eliminate the cause - press for 3 seconds
	Maximum 60 alarms

7. Warnings

Message	Description
Too many slabs in the machine	There are more than 30 slabs in the machine
Waiting for power system…	Waiting for the power system to startup (MP-08 enabled)(I04 = ON )
Going to change abrasive position…	The beam has been commanded to move to change abrasive
Power system disabled	Power system disabled (I04 = OFF).
Caution Motors off	Belt start attempted with motors off

Indice