CNV Converter Manual - Signature Technologies
Contents
1. One wire of each of the pairs is Black The color in parenthesis is the other color in the pair Wire Color Current TEC Signal Name OLD TEC All 0 repre PA PET PERELE TE SHD urala Shield Ground 0 0 c 1 WIGS 2 22 ccc ceupeves Sacartacdexsesnaviontiads S32 EEA ITEE SING ORREL PEA A TET ENE 2 ETE ROEE EE E a ETE AEE I NIG N E A E Gre eNaiticciste rn ated adic S E EA 001 3 a alii 4 AN LE EAE E E SB ooo ceeeeeeeeeetteteeeeee N C ce eeeststeeeeeeeeeesss SCC GND Below POO ET laisaetdeie eerie EEE ETET Reference 6 ENRETE PE ET ETET E E TAAT E i OA T EEE Black White cccccceseeeeee 5 ie E ET ON 5 VllS enrocar aae 8 Black Blue amp Black Red GN Diii fa ccstetieet AC Ground 5 Black Green a TEP ET 5 VONS anaiei 9 h Make sure the SA2000 is powered up but DON T plug the 9 pin D shell OUTPUT connector into the CNV converter yet Make Sure your SA2000 is configured for SLAVE operation 11 It is ABSOLUTELY necessary that the SA2000 position module that is used with the Resolver converter is a RES Resolver input card with BOTH reference jumpers as shown below REMOVED In cases where the Resolver Converter and SA2000 module are shipped together as a system the SA2000 will be configured correctly when received i 1 nolaa eee me eeieiemsitoiie tetsiie tails ite i Slonaterefte th j JIII H g E n gt la LEICC CETRA 010 DUO O o 02. 0 adel 8 Slololololaloalalatale Reference Jumpers Figure 8 Reference jumpers on RES board Be careful when replacing SA2000 units individually to insure that they are equipped with RES Resolver input adapters and that the jumpers as shown are REMOVED Improperly configured SA2000 units will not operate properly and may cause adverse reaction in the existing resolver system Set up your Host Computer system a Install the Host Computer apparatus wherever you like and remove its cover b Install the Network Card and the SA2000 modules into 3 empty ISA slots in the Host Computer The Network Card is already set up properly before it is shipped c Run the short RG 62U 93 Ohm coaxial cable from the SA2000 module to the network cards in the Host Computer d Bring up the power to the system elements and turn on the Host Computer e The third green light from the far end of the SA2000 module should shortly begin to flash at about 1 cycle per second This is the Heartbeat indicator and shows that the firmware in the SA2000 is executing properly If the light is either OFF or ON continuously or if there is another pattern of lights shut the computer off and call ST at 972 488 9777 f If the Computer has started into Windows 95 Select Start from the Windows menu bar and then select Shut down When the Shut down Windows box appears select Restart the computer in MS DOS Mode When the DOS Prompt C
3. name and location of the existing system we will research the installation for you 2 The Existing Resolver mechanical drive system must meet the criteria outlined in the S T I publication Resolver installation considerations In general the resolver MUST be driven in a manner that insures a true crankshaft position reference Programmable limit switches can and do operate acceptably with 1 2 degrees of slop or position ambiguity Signature Analysis is not so forgiving The result of a sloppy resolver drive will be horizontally unstable signatures CNV Converter Mounting The CNV Converter requires no mounting in order to operate properly There are mounting holes provided to enable the user to fasten the unit to a panel but the unit can simply be placed into existing panel channel when the setup procedure was finished or attached with Velcro to any flat surface The Converter should be mounted within 3 feet of the existing system and wired directly to the point where the existing resolver is connected using the supplied input cable You can also install the CNV Converter in junction boxes on the machine frame in places where the resolver cable passes through This is possible in large machines particularly if the cable brought through several sets of terminals on its way back to the machine control enclosure In cases where the Resolver is feeding a Tonnage monitor such as the Data Instruments or Helm Instruments units there
4. Standard Converter OUTPUT cable assy System Grounding Caution NOTE The COMMON connection for the CNV Converter is connected to EARTH Ground in the SmartSAM SignatureACE system It may be that the existing system you are connecting to has a fully floating Common connection which would make hooking the CNV converter COMMON to this point inadvisable In general it s SAFER to connect the CNV common wire to the machine frame rather than to connect it to the existing system common or even the system Shield connection which also sometimes floats NOTE You MUST determine whether the existing System COMMON is acceptably related to EARTH GROUND This can be done as follows 1 Connect with the system power turned ON a VOLTMETER between the Common connection and the panel sheet metal 2 Set the voltmeter to AC Volts If the voltage you measure is a fraction of a volt up to 1 or 2 volts go to the next step If there is significant gt 5 voltage present call Signature Technologies 972 488 9777 for further information 3 Set the Voltmeter to DC Volts If the voltage you measure is a fraction of a volt up to 1 or 2 volts you can connect the CNV Common to the Chassis common If there is significant gt 5 voltage present call Signature Technologies 972 488 9777 for further information In Current production are the SB 027 8004 INPUT and SB 027 8006 OUTPUT cables Make special note that there are THREE BLACK wi
5. WINDOWSs appears enter CD lt cr gt The prompt will become C gt and you are ready to proceed NOTE In order to run SAMview software The host computer MUST BE operating in DOS mode NOT a DOS Window from the Windows 3 x or Windows 95 system You must drop COMPLETELY out of Windows to run ST software To cause a Windows 95 machine to automatically come on in DOS mode do the following 1 RESTART the computer Control Alt Del twice or hit the reset button 2 When you see the Starting Windows 95 message press the F8 key 3 On the menu that appears choose the Safe Mode Prompt Only item 4 Type attrib s h r msdos sys lt cr gt edit msdos sys lt cr gt 5 Change the line in MSDOS SYS that reads BootGUl 1 to BootGUI 0 6 Save the MSDOS SYS file and close the editor 7 Type attrib s h r msdos sys 8 Restart the computer again Now when the computer starts up it will go into the DOS mode automatically To run Windows 95 type win lt cr gt At the prompt And windows 95 will start Put the SAMview disk in the computer Type A INSTALL lt cr gt And follow the onscreen instructions Repeat steps f thru h for any other ST option software disks you may have SPCView FeatureView etc When the computer has finished copying the software type C lt cr gt Take the SAMview disk out of the drive and store it in a safe place You won t need it again unle
6. network module If you see another light but NO text that you recognize underneath then the address of the SA2000 may be different than you programmed The Light will come on in the address location that the SA2000 is set for It causes all sorts of problems to re program the address in Press Information screen so CHANGE THE SETTING of the ADDRESS Switch on the SA2000 module to match the address you gave it during setup If the Switch on the SA2000 module is turned to a different address position RESET Button see Fig 10 must be pushed to allow the new address to be recognized by SAMnet 3 If everything looks O K but the system still doesn t function do a Grand Power Cycle turn off the host computer Wait 20 seconds then turn the computer on again 4 If you still can t get on line give us a call at 972 488 9777 Make sure your Resolver is hooked up properly When you have the system on line you can Click on the BYPASS box and have the yellow light flicker but stay on check the rotation of the resolver Note the Angular Position of the press as shown in the box at the upper right side of the signature screen Bump the press several degrees forward See if the Angle reading increases or decreases If it decreases swap the SINE S1 S3 wires on the INPUT cable from the existing system and go back to step b If it Position Increases numerically the connection is O K If it doesn t move there is a p
7. of the Adjustment potentiometers and indicator lights Make sure they are visible and that you can get to the adjustments The unit can be left loose on the panel until after the setup is done Installing the INPUT Cable c With the machine stationary take note of the angular reading on the existing system and write it down somewhere handy d Power the system down and connect the CNV Converter Input cable SB 027 8004 to the existing system Don t plug the input cable into the CNV converter yet or worry about the direction of rotation at this time e Power the system up again Look again at the displayed angle on the existing system and then plug the INPUT cable into the CNV converter Make sure the angle displayed on the existing system doesn t change significantly A degree or so isn t important although you may have to reset the offset slightly in the existing system to compensate for the CNV Converter loading If the reading displayed on the existing system changes by 5 10 degrees the converter may not be usable with the existing system Call ST for further details f Run the Converter OUTPUT cable SB 027 8006 from the CNV Converter back to the Signature Technologies TEC enclosure g When the OUTPUT cable is in place between the Converter and the TEC enclosure connect the wiring to the 10 pin terminal strip at the end of the enclosure as follows Installing the OUTPUT Cable The SB 027 8006 Cable Color Code is
8. Installation Guide for the ICNV Resolver Converter As used with the signatureACE System Revised 4 26 99 Bicie ie UA Pa d E E L aF SIGNATURE TECHNOLOGIES 13375 N Stemmons Frwy 320 Dallas TX 75234 Phone 972 488 9777 Fax 972 488 2924 email www signaturetechnologies com Table of Contents Figure 12 Obsolete Converter OUTPUT SB 027 8007 cable aSSy ccceecceece eee tee tee tet eenttenetenttes 19 SAMview SPCview FeatureView InSitu MPMview and HiRes are trademarks and Signature Technologies ST Statistical Process Controller are registered trademarks of Signature Technologies Inc Dallas TX 75234 SmartPac is a registered trademark of Wintress a Div of Honeywell Various technologies herein are either patented or patent pending in the US and Foreign Countries 1995 1999 Copyrighted All Rights Reserved Introduction This publication is a step by step look at the installation of a Signature Technologies Signature Analysis system using for position reference an existing Resolver system This resolver system may be a programmable limit switch system or an integrated subsystem of the press control The CNV Resolver converter unit can be used to provide position input from the existing resolver system It is used when the cable run from the existing system would be long over 15 feet or when the existing system is sensitive to external connections The CNV Con
9. a return while the Reference wires are driven in Push Pull mode Resolver Converter INPUT Cable Ground _ BLUE Panel Grourid Figure 6 Mixed mode connection Full Floating Hookup A Fully Floating connection is shown below like Helm uses One version of this is where transformers to couple the resolver windings into the electronic system Connect the Ground wire to the chassis of the external system This type of hookup must be watched for loading effects The position displayed on the existing system may change significantly when the CNV Converter is connected See the procedure in the installation steps below INPUT R1 BLACK Cable Ground BLUE i S2 BLACK E Resolver H Converter m E E y Panel Ground Figure 7 Full Floating connection Resolver Converter typical installation steps The installation will consist of several major steps Installing the CNV Converter a Inspect the wiring diagram for the resolver system already installed on the machine Compare with the typical schematics in this publication If nothing seems to match we suggest that a copy of the existing system technical details be Faxed 972 488 2924 or mailed to us so that we can render assistance b When the requirements of the installation are understood and the CNV Unit is used decide on a location for the CNV Converter unit and mount it to the machine or electrical panel 10 NOTE Take notice of the location
10. box Yellow light just to the LEFT of the box should blink out momentarily and then come back on If it does the Host Computer is Talking to the SmartSAM unit normally proceed to the next section BUT If it just goes OUT and stays OUT You re Off line There is no communication over the Coaxial cable between the Host and the SmartSAM In this case 1 Check to see that the address of the SA2000 as shown on the ADDRESS rotary switch as shown below matches the address for the press that you have made If they re different change the switch position to match HEARTBEAT Indicator TEST Buffer Full Connector Indicator RESET Button Address swich lesi Switch W TEST Button Slaving Connector Censor isi a Sensor Gain Gage Excitation Jumpers Jumpers Figure 10 Switches on SA2000 Module set 2 Select from the menu bar CONFIGURE Then select Configure SAMnet You will be shown a screen with 32 locations on it The location 16 green light should be ON and the text below the light should say This Node This indicates that the Network module is in place and operating properly You should also see another light generally at location 1 and the text below this light should be the name you gave your press when you set it up If there is NO other light then the SA2000 is NOT communicating with the network module Make sure your short coaxial cable is installed between the SA2000 and the
11. degrees should be absolute Bottom Dead Center for the Main Ram or Inner Slide this has safety implications since if somebody s stuck in the press near B D C you NEED TO KNOW whether to reverse the drive to free him without doing further damage In general where there is bending or coining performed by the tooling in the press there will be a well defined rounded Hump in the signature with its peak exactly at 180 degrees If this Hump AT LOW SPEED lt 100 S P M doesn t line up with the 180 degrees the position offset is a little off and can be corrected most easily by editing the Position Offset value in the Configure Press utility See the User s Manual for details When you have passed the above tests you should be able to Roll the press and see the force signatures It will take a couple of revolutions before anything will show up If your Cable color code doesn t match There are some other cable types still in circulation that are wired identically but have different color codes associated with them The alternates are listed below Connector 9 Pin T Female with shell amp Jock screws Cable 4 Twisted pair shellded 20 Manhattan Miagi 5 be Connect to the chagsis of the system being coupled ta Figure 11 Obsolete Converter INPUT SB 027 8002 cable assy Converter End Cable Soe Connector 9 Pin D4 Pr Indiv Shid 20 EC Enclosure Male with shell amp jack Manhattan Mi46
12. he machine turns turn the SIN adjustment potentiometer CCW until they both stay OUT If both lights are always out go to step 3 THEN 3 Turn the SIN adjustment CW until the Green light just flashes ON 4 Continue turning the SIN Adjustment CW until the Red light just flashes ON 5 Turn the SIN Adjustment screw CCW until the Red light doesn t flash on 6 At this point the Green light should flash ON and OFF and the Red light should stay OUT 7 Repeat steps 2 thru 6 for the Cosine signal looking at the COS lights and adjustment If there is a problem getting the lights to behave properly or if the SIN and COS lights tend to come and go off together instead of 90 Deg apart the Resolver Converter connection to the existing system may be non standard For example C amp A programmable cam units use S1 S2 as the SINE and S3 S4 as the COSINE windings instead of the more standard S1 S3 and S2 S4 In this case reverse the GREEN and BLACK White wires and try re adjusting the levels If you have continued problems check the wiring of the OUTPUT Cable to make sure it s just as the instructions require If nothing is found there note down how the lights are acting as the press turns and give ST acall at 972 488 9777 15 Make sure you re on line a The Yellow light just to the LEFT of the BYPASS box at the lower right side of the SIGNATURE screen should be on If it isn t You re Off line b Click on the BYPASS
13. is normally room inside the instrument enclosure for the CNV Converter In general the idea is to minimize the length of the cable at the SOURCE end This is why the Converter INPUT cable is 30 long This cable should NOT be lengthened without consultation with ST Engineering at 972 488 9777 The CNV Converter contains line drivers so that the cable length between the Converter and the Signature Technologies system is not important The Standard Converter OUTPUT cable is 30 Feet long but can be much longer if necessary CNV Converter Wiring The CNV Converter is supplied with two cables which are used to perform ALL the interconnection Input Cable The Converter INPUT cable is 30 long and should not be extended to avoid loading of the existing system with excessive cable capacity This cable CAN be shortened if the installation warrants Just make sure that the SHIELD is insulated at the termination end to prevent accidental contact with metal components This cable should NOT be lengthened without consultation with ST Engineering at 972 488 9777 The INPUT cable connection to the existing system is where the confusion in installation may occur There are several configurations of resolver hookups all the way from single ended SIN COS and REF signals to transformer coupled systems with NO common reference at all SB 027 8004 INPUT cable Connector 9 Pin D Cable fhe e 4 Pair Shielded 24go BELDEN 9504 External S
14. o4 Terminals Screws OLD Current Style Style Sine Mite teas 2 5 455 Black j 5 l Tir af 5 Cosine areen ite ere Whiter p gt TP T whi Thi g p Ret amp Ri AGND Shield he 1 SHO Green fX 5 GND Figure 12 Obsolete Converter OUTPUT SB 027 8007 cable assy Refer to the SAMview System User s Manual to find out about Channel Calibration procedures Virtual Channel setup Viewing window setups General System Use 19
15. ome on Don t worry yet if they don t Adjust the REFERENCE signal level on the CNV Converter To do this take a look at the REF lights on the CNV converter ee REF LOS Sz amp 2 2 Figure 9 Indicators Adjustments on the Resolver Converter 1 If Green only or both Red amp Green lights are on turn the REF adjustment potentiometer CCW until they both are OUT If both lights are out go to step 2 THEN 2 Turn the REF adjustment CW until the Green light just comes ON NOTE If you can t get the REF light to come on make sure you have power to the SAM Module and that the wiring connection are O K c 3 Continue turning the REF Adjustment CW until the Red light just comes ON 4 Turn the REF Adjustment screw CCW until the Red light goes out 5 At this point the Green light should be ON and the Red light should be OUT Next adjust the SIN and COS signal levels on the CNV Converter The machine should be running in continuous mode if possible although repeated single strokes will work also The SIN and COS signals will vary their amplitude as the machine turns and we must set the maximum levels that are fed to the SA2000 module Both the SIN and COS signals will reach peak amplitude twice each revolution but 90 degrees away from each other In order to adjust the levels do the following 1 Adjust the SIN signal looking at the SIN lights 2 If Green only or both Red amp Green lights flash on as t
16. res in the Input cable and FOUR Black wires in the OUTPUT Cable one in each pair Make sure you have the right one as shown in the pairing in the diagrams below Hookup Type Variations for the CNV Resolver Converter There are quite a few different system configurations just about all of which can be serviced equally well by the ST Resolver converter can t be all inclusive but the following section gives typical types of resolver connection for popular Existing systems The terminal names on the Existing system may be different from what is shown on the drawing or assistance contact ST at 972 488 9777 Single Ended Hookup A Single Ended Hookup as shown below As used in the Data Instruments SmartPac is where one side of the Sine Cosine and Reference windings on the resolver are each hooked to system common Resolver Converter INPUT Cable Parel Ground Figure 4 Single ended Hookup SmartPac by Data Instruments hookup This is a Single Ended Hookup as shown above but with specific terminal numbers given for the connection to the WPC board in the Data Instruments SmartPac Data Instruments WPS Board Term s S2_ BLACK 408 412 Resolver Coriverter 407 INPUT jas Cable 411 Panel Ground Figure 5 SmartPac Hookup Mixed Hookup A Mixed connection is shown below As used by AMCI amp Autotech where the Sine and Cosine windings are connected to system common for
17. roblem with the wiring to the resolver or with the resolver drive If the existing system angle display behaves normally and the lights on the CNV unit are normal the Output Cable connection or the SA2000 Module is suspect Make sure the Resolver Resolution is set Properly a Continue to bump the press around Make sure that the angle display increases each time you move the press and that you see the angle reading rise to 360 degrees in one press revolution before re setting to 0 degrees and climbing again 1 If the angle doesn t make it to smoothly to 360 in one full revolution the Jumper settings of the SA2000 module is in disagreement with the Resolution value you entered for your press in the Configure PRESS utility SA2000 Modules are normally configured for 4096 increments per revolution This is valid for machines running up to 200 S P M and in some cases for machines running even faster with reduced channel usage If you are running a faster application say 500 600 S P M the SA2000 will have been configured for high speed operation requiring a 1024 increment setting 17 2 If the angle rises from zero to 360 in only 90 degrees of press rotation the SA2000 is configured for 4096 but the SAMview system is programmed for 1024 3 If the angle rises from zero to 90 degrees with 360 degrees of press rotation the SA2000 is configured for 1024 while the SAMview system is programmed for 4096 4 Changing the en
18. ss the SAMview program is erased or becomes corrupted Type MD MOUSE lt cr gt Then type CD MOUSE lt cr gt At the C MOUSE gt prompt insert the Mouse driver disc and type Copy A lt cr gt When the copy is complete remove the Mouse disk and type CD SAMview lt cr gt Add the lines 13 CD MOUSE FMOUSE CD SAMVIEW SAMview QQ CD To the end of your AUTOEXEC BAT file in the C directory Restart your computer again The computer will automatically start ST s SAMview program whenever it is turned on Refer now to the system user s manual for instructions on getting into and setting up the SAMview program Enter the required press and tool information at this time since you won t be able to go any farther in the resolver setup without it This step will take a while If there are questions contact ST at 972 488 9777 When you have entered your press and tool information and configured the Overview screen bring up the SIGNATURE screen in the SAMview program Refer to the SAMview System User s Manual for details Adjusting the Resolver Signal levels a Again looking at the position display on the existing system plug the Output cable into the CNV converter and make sure the angle display on the existing system doesn t change significantly When the output cable is connected to the terminals in the TEC unit and the system is powered some combination of lights on the converter will probably c
19. try in the RESOLUTION or PULSES window in the SAMview Configure PRESS utility to the appropriate value will remedy the problem Make sure that the press is programmed for RESOLVER input while you re in the Configure PRESS Utility Making the displayed Angle unit agree with the actual machine angle a Go to the PEAK display b Look at the angular position display on the existing system c Select Configure Calibration from the Configure item on the menu bar d Answer NO to the Enable Static calibration Pop Up e Click on the SET box to the left of the Angle display f Enter the press angle g The displayed angle will change probably rounding off what you enter somewhat h Select Exit Configure from the Configure item on the menu bar i Answer Yes to any saving questions that appear Make sure that the SAMview angle display TRACKS with the existing system display j Bump the machine around a complete rotation in short moves and compare the position on the existing system with the position displayed on SAMview There should be no significant difference at any machine angle The systems should agree to about 1 degree at all positions NOTE Don t be surprised if the Existing System displayed angle is different than the Machine actual angle In many cases the existing system wasn t set up properly to begin with so you may have to adjust the ST angle differently 180
20. verter is remotely mounted on the machine close within 30 of the resolver system wiring The purpose of the Resolver Converters is to enable the Signature Technologies SA2000 module to use the Reference and Sine Cosine signals from another resolver based electronic system without loading or interfering with the existing system Connector HiRes Resolver Converter 3 20 OUTPUT Connector Figure 1 Resolver Converter dimensions There are TWO basic requirements For the Resolver Converter 1 Mounting holes Indicators amp Adjustments The system to which the Resolver Converter is attached MUST supply a reference signal to the ROTOR R1 R2 points of the resolver The Sine and Cosine signals S1 S3 amp S2 S4 points are then received as a return from the resolver If the existing system does not operate this way the Resolver Converter can t be used and another Resolver must be fitted For example if the Sine and Cosine windings are driven with reference signals and the resultant return signal is from the rotor The Resolver Converter wouldn t give us anything we could use in our system If there is doubt about the way the existing system operates contact the manufacturer of the system and ask Does your system supply a reference to the resolver ROTOR and accept back Sine and Cosine signals Alternatively if you will supply Signature Technologies with the Make Model and manufacturer s
21. ystem Connection 4 te n S4 2 2 3 53 Si 51 R2 R2 Connect to CHASSIS in at system being coupled to k 4 9 h 36 00 eens Figure 2 Standard Converter INPUT cable assy Output Cable The Converter OUTPUT cable will be supplied in a 30 foot length unless different lengths are specified If different lengths are required the cable can be ordered by adding the length in feet to the Cable part number Example If an output cable 80 feet long is needed Order a SB 027 8006 80 The Output cable is supplied with the Converter end connector in place and should be pulled into conduit STARTING AT THE Converter end When the cable is pulled in the pre terminated wire ends can be inserted into the terminal strip according to the wire list below The cable is brought into the TEC enclosure by punching appropriate holes for conduit or glands If the TEC enclosure is mounted using Vibration mounts make sure to terminate any conduit to the enclosure using a link of FLEX conduit This will prevent the rigid conduit from destroying the effect of the vibration mounts SB 027 8006 OUTPUT cable Canverter End Cable Connector 9 Pin D 4 Pair Shielded 24ga TEC Enclosure Male with shell amp jack BELDEN 9504 Terminals SCTEWS OLD Current Style Style Sine 9 5 5 Cosine 5V Ref AGND Shield Male end DGND je Cable length XX suffix in feet gt Figure 3
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