SRL-250 . USER`S MANUAL - Die Cast Machinery, LLC
Contents
1. VW IH 26 1 EE 0117 024 Page 41 SRL 250 Mounting Vertical Unit to Base Assembly FIGURE 6 8 Advance Products Corporation SAL 250 USER S MANUAL 0 S Des B N KEE x WETE WV JA AN 5 2 s0 Aa ENE gt 26 SDH 4 0 SS So 5 Es 5 amp 9 0 3 gt o OI 6 0 S N E q n u N d i a e gt 0 wa A ws gt EES Ja DN AJ P x Va G DM SE mme ADL 22 x d i N 10173 XX Advance Products Corporation Page 42 SRL 250 USER S MANUAL SRL 250 Valve Plate Assembly FIGURE 6 10A Page 43 Advance Products Corporation SRL 250 USER S MANUAL SRL 250 Valve Plate Assembly FIGURE 6 10B Page 44 Advance Products Corporation TECHNICAL DOCUMENTATION MODEL 5 0 SPRAY HEAD After years of research and development Advance the industry leader in spraying tech nology has developed the ultimate spray head for die spraying It is the Advance Model SH 3000 spray head The Model SH 3000 has fewer parts and an improved design over previous Advance models Adjustablility is greatly improved with a full three turn range compared to 1 1 2 on the Model 2000 There is also improved at om2. B B O Figure 3 1 APC Sprayer software diagram Advance Products Corporation Page 9 SRL 250 USER S MANUAL To change any program or machine parameter of the sprayer system use the operator panel and its different sections on the keypad A gen eral procedure of how the operator interacts with the sprayer system via the operator panel will be explained below and before entering the soft ware menus explanation To select a menu it is necessary to use function keys Once selected a menu for the correspond ing screen will be displayed The function keys available on the sprayer system can be seen in Figures 3 2 and 3 3 Note that only 2 lines are displayed on the op erator panel To see any more information as sociated with the screen displayed it is neces sary to push the down arrow button Y 0 wv gt S s 7 8 9 5 6 2 3 Figure 3 2 E150 Operator Panel MAIN EDIT VO JOG LOAD HOME wwe Figure 3 Function keys on the E150 Operator Panel Ww Page 10 INITIAL AND NORMAL RUNNING MENUS Once the sprayer system is powered pull the red power button The display will show the startup screen shown in Figure 3 4 E150 V6 03 FX SERIES CPU Power up Screen Figure 3 2 After the power up screen is displayed the Main Menu screen is displayed Advance Products Corporation 27 25250 USER S MANUAL MAIN MENU This is the first screen as shown in Figure
3. Ph 269 849 1000 Fax 269 849 2200 System Information screen Figure 3 34 Advance Products Corporation Press MAIN PREV again and the following screen will be displayed _ gt gt LOGIN REQUIRED lt lt PRESS NEXT 6 ENTER PASSWORD Login Required screen Figure 3 35 Before changing parameters an authorization code must be entered and recognized by the system Press HOME NEXT function key F6 for entry of the password as shown in Figure 3 36 Password Password Entry screen Figure 3 36 Touch the 3 key the key andthe 3 key Touch the enter key in the lower right hand corner The system will display the following screen momentarily to indicate that the system is now unlocked and Machine Setting modifications are possible System Unlocked screen Figure 3 37 Figure 3 38 is then displayed _ gt gt LOGIN REQUIRED lt lt PRESS NEXT F6 TO ENTER PASSWORD Login Required screen Figure 3 38 Press MAIN PREV and the machine parameter Page 17 81 3622 PLC Parameter Description Fast Jog Speed Slow Jog Speed Home Speed Acc Dec Retract speed Cycle Complete Time Maximum Stroke in Inches Sprayer Type SJONPOlY aou ANON Unlock 0005 Cycle Power After Setting 54 Motor Direction MACHINE PARAMETER DEFINITIONS Parmeter Definition Default Values The speed the arm move
4. ADVANCE AUTOMATION EQUIPMENT 2 e 0 P Digital Servo Reciprocating Sprayers Digital Servo Die Casting Extractor Ladlers gt Mini Max Die Lube Reclaimer Tool Temp Temperature Control Unit Kawasaki Robots Central Lube Systems Your Window to the World of Die Casting Automation and Consumable Products Phone 269 849 1000 2527 HWY M 63 Benton Harbor MI 49022 Fax 269 849 2200
5. MIANUAL S N SRL250C 320105 2 2 057 q Servo Recipro cating Linear I Die Spray System FEATURES The Advance SRL 250 die sprayer is designed to be used with both zinc and aluminum die cast machines ranging in size from 150 ton to 400 ton machines The unit is controlled by an industry proven Mitsubishi FX1s series programmable logic controller Programming is done through a menu driven two line back lit liquid crystal display using push buttons for data entry There is program storage for up to 8 different programs Programs can have up to 20 different spraying positions At each position the unit can spray lube blow off the dies or perform both actions a once The SRL 250 has two axis of movement vertical and horizontal The vertical axis movement is servo driven The servomotor is coupled directly to a gear box which is then connected to a belt driven linear actuator The top speed of the vertical axis is 72 in sec The vertical axis is programmed through the HMI on the main control panel The horizontal axis is manually adjusted The horizontal axis can be adjusted 8 1 2 to accommodate various die thickness In addition to help with die change outs both the vertical and horizontal axis can be rotated about the base to provide the needed clearance to remove the dies As a standard the SRL 250 comes with a 4 spray head 10 long bar manifold A 6 head 15 long manifo
6. p A eng I MULTIPLE POSITION SWITCHES X SHOWS CLOSED STATE 0 SHOWS OPEN STATE YEL GENERAL NOTE E D DR 3 2 2 NOT CONNECTED IN MAN OX lt THIS LINE CONNECTED TO E IN MAN NOT CONNECTED IN AUTO BLUE WIRE FOR LOW VOLTAGE LESS THAN 50 VOC UNSUPPRESSED INDUCTIVE LOAD YELLOW WIRE IS USED WHEN A CONTACT MAY BE USED IN AN EXTERNALL LINE NUMBER SHEET NUMBER Y POWERED CIRCUIT POWER MUST DISCONNECTED AT ITS SOURCE AS WELL AS THE DRIVE POWER ONLY NOTES INDICATED ON THE ELECTRICAL OR INTERCONNECTION DIAGRAMS APPLY ANY ADDITION OR DELETION TO THIS ENGINEERED CONTROL SYSTEM WITHOUT WRITTEN AGREEMENT BY MITSUBISHI IS THE RESPONSIBILITY OF THE INSTALLING PERSONNEL MOUNTED ON CABINET P MOUNTED ON CONTROL PANEL MOUNTED ON DOOR J JUMPER ON TERMINAL STRIP MOUNTED ON DRIVE THIS EQUIPMENT MAY BE AT LINE WARNING VOLTAGE EVEN WHEN NOT IN OPERATION TO AVOID ELECTRIC SHOCK DISCONNECT NEVER REMOVE OR INSERT ANY MODULE WARNING OR CARD WHILE THE POWER 5 ON CONNECT INPUT TO Li L2 AND L3 AS SHOWN IF THE PHASE SEQUENCE INDICATOR DOES NOT LIGHT INTERCHANGE L1 AND L3 CONNECTIONS REMOVE JUMPER IF ADDITIONAL INTERLOCK S ADDED 5 SEPARATELY MOUNTED NOT SUPPLIED BY MITSUBISHI 6 SEPARATELY MOUNTED SUPPLIED BY MITSUBISHI 7 SEPARATELY MOUNTED 8 USE TWISTED TWO CONDUCTOR CABLE THIS CABLE MUST BE IN A SEPARATE SIGNAL CONDUIT IT CAN
7. parameters No 3 4 5 Encoder faulty Change the servo motor 1 Short occurred in servo amplifier Correct the wiring output phases U V and W 2 Transistor IPM of the servo Change the servo amplifier Current that flew is higher than the permissible current of the servo amplifier faulty amplifier Checking method Alarm AL32 occurs if power is switched on after U V and W 3 Ground fault occurred in servo amplifier output phases U V and W 4 External noise caused the overcurrent detection circuit to misoperate Take noise suppression measures SRL 250 USER S MANUAL AL33 Overvoltage Converter bus 1 Lead of built in regenerative brake 1 Change lead voltage exceeded resistor or regenerative brake 2 Connect correctly 400V option is open or disconnected 2 Regenerative transistor faulty Change servo amplifier 3 Wire breakage of built in 1 For wire breakage of built in regenerative brake resistor or regenerative brake resistor change regenerative brake option servo amplifier 2 For wire breakage of regenerative brake option change regenerative brake option Add regenerative brake option or increase capacity 1 Pulse frequency of the command Change the command pulse frequency to a pulse is too high proper value 2 Noise entered command pulses Take action against noise 4 Capacity of built
8. 01 13 32 13 gt Main Menu Figure 3 24 _ lt lt SELECT MODE gt gt JOG AUTO Jog Selection Screen Figure 3 25 Press the JOG function key lt F2 gt to display a Page 14 Advance Products Corporation SRL 250 USER S MANUAL Jog Screen similar to the one shown in Figure 3 26 SPEED FAST SPRAY BLAST LUBE AIR 00 00 Position Jog Screen Figure 3 26 Pressing the SPEED function key F2 toggles the speed between SLOW and FAST Pressing the SPRAY LUBE function key F4 causes lube to be sprayed while the F4 function key is de pressed Pressing the BLAST AIR function key F5 causes air to be blown while the F5 function key is depressed Press the down arrow W key to display the cur rent position Press the HOME NEXT function key F6 to dis play a screen similar to the one shown in Figure 3 27 STOP STEP 01 MOVE MOVE INC DEC Y Jog Screen Figure 3 27 Pressing the STOP MOVE function key F2 stops any move currently in progress Pressing the INC function key F3 causes the step num ber to be incremented by one up to step num ber 20 Pressing the DEC function key F4 causes the step number to be decremented down one but not below step number one Pressing the MOVE TO function key F5 causes the sprayer to move to the position speci fied in the currently displayed step number Press the HOME NEXT function key F6 to dis play a screen similar to the one shown in
9. ZA X00 257 312 00 355 CYCLE START DIE OPEN PART SENSOR RELAY 315 RELAY 316 RELAY 321 3CSRI 3DORI 3PSR 16 YEL 320 321 322 323 324 325 5 3 015 7 FOR END USER FOR END USER FOR END USER CONNECTION CONNECTION CONNECTION SRL 250 PLC INPUTS 400 W SERVO SYSTEM FIGURE 7 6 Advance Products Corporation 7032 141 FXIN 24MT DEVICE SRL 250 USER S MANUAL ABS BIT O ABS BIT SEND DATA READY SPARE CYCLE START DIE OPEN HOME SWITCH AUTO SERVO ALARM RELAY SPARE ON PART SENSOR JOG UP JOG DOWN SPARE Page 51 1 24VDC FROM SHT 2 SRL 250 USER S MANUAL 7032 140 257 110 408 256 DEVICE 18 BLU 18 ul 24 256 256 257 SERVO PULSE TRAIN 257 TO SERVO INPUTS SHT 5 40 NP CN1A 2 1820 TERM 0 SERVO DIRECTION 422 BRAKE RELAY 2 424 422 5 2 55 LUBE RELAY 2 221 7 2 3 PART DET RELAY r AT AIR BLAST RELAY 225 257 2MCRI 492 422 208 CYCLE COMPLETE DIE SAFE 425 T 408 ABSM CN1B 8 1820 TERM 3 TO SERVO INPUTS ERI 409 ABSR CN1B 9 TB20 TERM 14 SHT 5 AFANI 256 FAN SARI Ai 88 25 529 41 ACCRI APDRI T d 16 YEL 257 414 SEXO 1 een CYCLE T 7 2 PART DETECTED COMPLETE BRAKE RELAY CONTACT GN CONTACT TO MOTOR SHT 5 SRL 250 PLC OUTPUTS 400 W SERVO SYSTEM FIGURE 7 7 Page 52 16 YEL W 16 YEL 24 0 COM 415 416 Advance Products Corporation SRL 250
10. gt to display an Auto Screen similar to the one shown in Fig ure 3 44 POSITION 13 03 CYCLE TIME 006 9 PARTS P H 521 TOTAL PARTS 00000000 PRESS LOAD F5 TO RESET PART COUNTER _LUBE OFF AIR OFF Auto Cycle screen Figure 3 44 To edit lines in the currently running program press the EDIT PROG function key lt F2 gt Press the LOAD SAVE function key lt F5 gt to set the counters back to zero Press the MAIN PREV function key lt F 1 gt to re turn to the Main Menu Page 20 Advance Products Corporation TROUBLESHOOTING 4 This part ofthe Manual willhelp you locate and correct difficulties that might occur in your Reciprocating Die Spray System The following chart lists specific problems and one or more conditions that could cause each difficulty Also referto the Technical Documentation section 6 of this Manual for additional information concerning pinout jumper configurations schematics etc for each board or module discussed in this section lf you need to order parts refer to the Replacement Parts list on page 7 1 to obtain descriptions for each part In an extreme case where you are unable to resolve a difficulty please contact Advance Products and we will do all we can to help you resolve the problem Our address and telephone number are located at the bottom of the front page in this Manual or by pressing the Help keypad on the Operator s Panel IMPORTA
11. in the Auto mode and relay 30581 is energized This input is anti repeat so it must be released before the sprayer will cycle again The cycle start signal can be found on wires 320 and 321 Description Part Sensor 3PSR1 Optional input for part detection that can be added by the customer on wires 324 and 325 If this input is activated during an auto cycle and it is enabled during the current step of the program the sprayer will stop any active move and return to the home position and abort the cycle A part detect error is generated on the display OUTPUT DEFINITIONS Description Die Safe 4DSR1 This output will be enabled by the home proximity switch input Contacts from terminal 4DSR1 are Supplied on wire numbers 412 and 413 These must be interlocked with the customers die close circuitry Cycle Complete 4CCR1 This output is enabled at the end of a Spray Cycle The contact is on wire numbers 410 and 411 and is a momentary contact closure This may be used to start the Die Close Cycle Advance Products Corporation 24 06 FROM SHT 2 SHT 257 256 289 256 DO CN18 4 1820 TERM 1 0 FROM SERVO ZSP CN18 19 TB20 TERM 19 301 SHT 5 118 BLU TLC CNIB 6 820 TERM 2 302 gis 257 SCSRI 304 SWITCH 326 257 SOORT 305 3 WIRE PROX 325 306 MAN AUTO 257 a 49 307 257 og 257 SARI 3552 308 529 257 JPR 310 JOG UP JOG DOWN 328 lt 5 0 311
12. the left arrow and right arrow ls keys as shown in Figure 3 18 to move between the fields on the screen Arrow Keys on the E150 Keypad Figure 3 18 The edit screen is displayed with the cursor on the position field ready for keypad entry Press the desired numbers with or without a decimal point Press the lt ENTER gt key for the number to be placed in the current program in memory Enter Key on the E150 Keypad Figure 3 19 Page 13 SAL 250 USER S MANUAL If the number entered is too large or too small screens similar to the ones shown in Figure 3 JOG Functions 20 are displayed and the cursor is returned to the offending field Val gt Max 35 Val lt MIN 0 Position Entry Error Screens Figure 3 20 ND The speed and dwell values can be entered in a similar fashion AN T J A J 1 Lu To toggle the Lube Air and Part Detect press the ENTER key as shown in Figure 3 21 be 2 Enter Key on the E150 Keypad Figure 3 21 A A Front Console Figure 3 23 To enter JOG mode make sure that the mode switch is pointed to MAN as shown in Figure 3 23 which enables the JOG up and down switch also shown in Figure 3 23 To view the Jog Selection Screen Figure 3 25 press the JOG AUTO function key F4 on the Main Menu as depicted below MAIN MENU PROGRAM AAAAAAAA PRESS MAIN F1 FOR _ SYSTEM INFORMATION 03 08
13. too far adjustment Defective Home Prox switch Sprayer completes Cycle Start signal did not Verify Cycle Start signal and cycle but won t re release interface relay Cycle Start start is amomentary signal Advance Products Corporation Page 23 SRL 250 USER S MANUAL Servo Drive Errors AL10 Undervoltage AL24 Motor output ground fault AL12 Memory error 1 AL25 Absolute position erase AL13 Clock Error AL30 Regenerative error AL15 Memory error 2 AL31 Overspeed AL16 Encoder error 1 AL32 Overcurrent AL17 Board error 2 AL33 Overvoltage AL19 Memory error 3 AL35 Command pulse frequency error AL1A Motor combination error AL37 Parameter error AL20 Encoder error 2 AL45 Main circuit device overheat servo Drive Warnings ALEO Excessive regenerative warning ALE1 Overload warninc ALES3 Absolute position counter warning ALE5 ABS time out warning ALE6 Servo emergency stop ALES Main circuit off warning ALEA ABS servo on warning When any of the following alarms has occurred always remove its cause and allow about 30 minutes for cooling before resuming operation If operation is resumed by switching control circuit power off then on to reset the alarm the servo amplifier and servo motor may become faulty e Regenerative error AL30 e Overload 1 AL50 e Overload 2 AL51 The alarm can be deactivated by switching power off then on or by turning on the reset signal RES When an ala
14. will not shift Spray head air pressure too low Tank is out of lube Control not programmed to spray Foreign material under poppet assembly Spring broken Poppet assembly worn Lube valve will not turn off e Turn selector switch to MANUAL Check mechanical linkages for binding Check Servo Amp indicators for faults Replace Servo Amp if unable to clear faults Hestore air pressure Restore lube pressure Adjust lube pressure Remove obstruction Clean spray head with a solvent Check output replace lube valve Check output replace air valve Adjust air pressure Restore supply Check program Disassemble and clean Replace spring Replace poppet assembly Replace lube valve Advance Products Corporation SRL 250 USER S MANUAL Chart continued PROBLEM POSSIBLE CAUSE SOLUTIONS Inconsistent spray Spray head clogged Clean spray head with a mist under poppet assembly solvent Spray head nozzle Rinse Lube strainer on the clogged incoming line to sprayer Lube strainer plugged on Increase air supply the incoming line to Add lube to tank sprayer Adjust spray head needle Inadequate air supply Check for minimum pressure Tank is out of lube fluctuation in air amp lube Spray head needle is set for too fine a spray Inadequate air supply or lube supply pressure Sprayer retracts up Home Limit switch out of Lower prox switch bracket
15. 3 4 From this screen all other screens may be reached MAIN MENU PROGRAM AAAAAAAA _ PRESS MAIN F1 FOR SYSTEM INFORMATI 03 08 01 13 32 13 lt Main Menu Figure 3 4 This screen shows the actual sprayer program that is loaded into memory The sprayer program is identified by the Program on the display followed by the program name In the example the program name used is AAAAAAAA Push the down arrow button to see the lines shown in reverse video in Figure 3 4 The date is displayed in European Date Format in the bottom left hand corner with the year listed first followed by the month and then the day In this case the year is 2003 the month is August and the day is the 1st The time is displayed next to the date in the bot tom line To change the date type the new en try over the old Note See the table in Figure 3 5 for the dash and colon entries To display later push entries you must push the key again in quick succes sion For example Push the zero key once to get 0 Push the zero key twice quickly to get the R symbol Push the zero key three times quickly to get the symbol Push the zero key four times quickly to get the symbol Push the zero key five times quickly to get the symbol To change the time the date must first be re entered then enter the time Please note that the time is 24 hour time No AM or PM Push the enter key to complete your entry of the date and time Adva
16. 6 hhcs MOUNTING THE CONTROL CABINET CAUTION Do not mount the control cabinet on the die cast machine where vibrations could cause damage to its components 1 If you wish to mount the control cabinet to a fixed location use the 4 mounting holes in the control cabinet Page 7 SRL 250 USER S MANUAL CONNECTING THE AIR AND LUBE LINES The standard SRL 250 sprayer is designed to rotate 90 degrees during a die change out Make your air and lube connections to allow for this rotation 1 Use a 1 2 I D hose or pipe to supply lube to the sprayer valve package Plumb the provided lube filter into the lube line The lube connection at the sprayer is 3 8 NPT Be sure to flush the lube lines before connecting them to the sprayer to keep contaminants from entering the sprayer 2 Use 8 3 4 I D hose or pipe to supply filtered air to the sprayer valve package Filter is not supplied 3 After mounting the valve plate at the desired location make up 1 spray air hose 1 blast air hose and 1 lube hose Both the blast air hose and the spray air hose need to have 34 FJIC fitting on both ends The lube hose needs to have 3 8 FJIC fitting on both ends 4 Connect the lube hose between the lube valve and the sprayer mechanism 5 Connect the spray air hose between the spray air valve the valve with the pressure regulator and the sprayer mechanism See Figure 5 1 for the correct connection point 6 Connect the
17. Connect properly warning after servo amplifier had entered absolute position data transfer mode Advance Products Corporation Page 29 SRL 250 USER S MANUAL SPRAY AIR CONNECTION BLAST AIR CONNECTION 3 4 MJIC LUBE CONNECTION 3 8 MJIC ANTI ROTATION PIN REMOVE HITCH PIN TO ROTATE SPRAYER SRL 250 Position Adjustments FIGURE 5 1 Page 30 Advance Products Corporation MAINTENANCE AND ADJUSTMENTS SPRAYER POSITION ADJUSTMENTS The sprayer mechanism is not designed to be removed from the base The sprayer can be rotated in the base to provide clearance during a die change out To rotate the sprayer follow the below procedure 1 Loosen the 2 13 SHCS in the front of the base 2 Remove the 3 8 hitch pin from the base 3 Rotate the sprayer mechanism in the base Repeat this procedure in reverse order to reposition the sprayer in the correct position after the new die has been installed The horizontal distance between the spray manifold and the base can also be adjusted 1 Loosen the 2 13 shcs on the horizontal tube of the sprayer There is an anti rotation pin that will prevent the unit from rotation when these SHCS are loosened 2 Manually push the sprayer to the desired position Caution DO NOT push against the manifold or against the chromed tubes when trying to reposition the sprayer This may damage the sprayer 3 Tighten the 2 13 shcs to prevent the sprayer
18. EDIT MODE by pressing the EDIT F2 key from the main menu Press the LOAD SAVE F5 key Select NEW by and press the SAVE function key You now have the option to CLEAR the program Select the CLEAR F2 to start with a clean program select NO F5 to retain the origi nal values and make changes CAUTION Start ing in the EDIT MODE this option will not clear the original program that was saved in memory but if you started from the MAIN MENU this op tion will clear the original program Type the LOAD SAVE F5 key Type the name of the new program Type OK Type the MAIN PREV key F1 The new program will now be loaded and changes can be made at any time Type EDIT PROGRAM F2 key Enter new values in program To delete a program from the Main Menu press the LOAD SAVE function key PROGRAM OPTIONS _ NEW DEL SAVE LOAD Program Selection Screen Figure 3 11 Push the DEL function key F3 and a screen similar to the one below is displayed Advance Products Corporation gt ALL FILES SELEC EXIT DEL Program Selection Screen Figure 3 12 Pressing the SELEC function key lt F2 gt deletes the program displayed above the SELEC key In this case ALL programs will be deleted Push the down arrow W to see the complete list of stored program files that can be deleted Press the EXIT function key lt F5 gt to return to the Program Selection Screen as shown in Fig ure 3 13 gt PROGRAM OPTIONS NEW DEL SAVE LOAD Program Se
19. Figure 3 28 PRESS SAVE F5 TO STORE IN STEP 01 CURRENT POS 00 00 Jog Screen Figure 3 28 Press the down arrow W key to display the cur Advance Products Corporation rent position Pressing the SAVE function key F5 stores the current position in the current program step num ber Page 15 SRL 250 USER S MANUAL VO STATUS INPUTS These menus can be displayed by choosing the STEP OUTPUT OFF YO O Status function key F3 on the Main DIRECTION 1 Menu shown in Figure 3 29 MOTOR BRAKE 0 2 SPRAY LUBE 43 MAIN MENU PROGRAM AAAAAAAA PART FAULT 441 ATR BLAST _PRESS MAIN F1 FOR _ SYSTEM INFORMATION CYCLE COMPLT OFF Y6 DIE SAFE OFF Y7 SERVO ABSIT 0 SERVO ABS2 OFF YLI 03 08 01 13 32 13 Main Menu Figure 3 29 l OUTPUTS Screen Figure 3 31 The first screen shown is the INPUTS screen 9 as shown in Figure 3 30 This screen shows the status of the digital inputs to the sprayer sys tem for example limit switches push buttons Touch the HOME NEXT key to display the SYS and some incoming signals from the customer TEM STATUS BITS screen shown in Figure 3 32 INPUTS SERVO ABSO OFF XO _SYSTEM STATUS BITS_ SERVO ABSI OFF X1 STOP BIT MI DEE SERVO 852 7 JOG DOWN M61 0FF SPARE OFF JOG UP M62 CYCLE START OFF START MOVE M8 OFF DIE OREN O STOP MOVE M102 0FF HOME SWITCH OFF IN CYCLE M110 OFF AUTO MODE OFF SERVO READY OFF SYTE
20. GURE 1 1 Page 4 Advance Products Corporation TECHNICAL SPECIFICATIONS 1 Motor AC brushless servo motor with high resolution encoded and electromagnetic spring action safety brake Manufacturer Mitsubishi Servomotor Model HC MFS43B Rated Output 400 W Rated Torque 1 3 N m Rated Speed 3000 rpm Unit Size See Figure 1 Weight 240 Lbs Control Box Size 8 1 2 deep x 15 3 4 wide x 19 3 4 tall Power Requirements Single phase 110 VAC 15 amps Weight 45 Lbs Valve Package Size 8 3 4 deep x 10 wide x 15 1 2 tall Weight 40 Lbs Air Requirements Air Flow 50 cubic feet per minute Air Pressure 50 to 90 psi Air connection 3 4 NPT Lube Requirements Lube Pressure 40 410 80 psi Lube connection 3 8 NPT Advance Products Corporation Page 5 SHL 250 USER S MANUAL SHCS 3 8 16 x 1 1 2 3 8 COIL TYPE LOCK WASHER SPRAYER PLATEN O RING 1 8 THICK x 1 1 2 O D SPRAY MANIFOLD SRL 250 Manifold Attachment FIGURE 1 2 Page 6 Advance Products Corporation UNPACKING AND SETUP 2 UNPACKING The SRL 250 contains the following 1 Sprayer mechanism 1 valve package 1 main control cabinet 1 Lube filter 1 spray manifold Perform the following steps to unpack the unit 1 Unfasten the sprayer from the shipping container 2 Move X axis member to the full retracted position 3 Remove the main control cabinet from the shipping container and set aside 4 Remove the va
21. Lubricate the drive unit rails by the below process 1 At about half the stroke press and manually move the belt in order to see one of the two rails inside the unit 2 Using a grease syringe or brush apply a conspicuous quantity of grease on the raceways Use a lithium based grease of medium consistency 3 Repeat this procedure for the other rail Replace the sprayer cover power the unit up move the sprayer to the home position Cycle the unit up and down 5 10 times for the full stroke of the unit at slow speed to distribute the grease on the full length of the rails 6 months Remove and replace the lube filter with new This interval may change depending on your die lube Dirty lube can cause your spray head to malfunction Small contaminants in the lube can prevent the poppet inside of the spray head from sealing properly This will cause the spray head to leak As these small contaminates build up in the spray head the spray head may become plugged and no lube will pass through the spray head Page 32 Advance Products Corporation REPLACEMENT PARTS 21 i This section lists all of the User replaceable components in the SRL 250 Servo Reciprocating Linear Die Spray system Use the Part Number when you place your order to help speed delivery You can call or write Advance Products and we will ship the part to you as soon as possible Our address and phone number are listed at the bottom of the
22. M STATUS BITS Screen Figure 3 32 SPARE JORE PART DETECT OFF JOG UP HOFFE JOG DOWN s SPARE OEE INPUTS Screen Figure 3 30 Touch the HOME NEXT key to display the OUT PUTS screen shown in Figure 3 31 Page 16 Advance Products Corporation SRL 250 USER S MANUAL MACHINE SETTINGS Caution In this section there are several menus contain ing the main machine parameters By changing these parameters you can change the complete behavior of the sprayer system Great care must be taken in changing any of these parameters These parameters should only be modified by qualified technical personnel This section allows the user to change any of the parameters on the sprayer system IMPORTANT These parameters are set at the factory and are critical for proper ma chine operation Modifying these parameters may cause machine damage and or injury to personnel operating the sprayer Do not make any changes to these settings without a thorough understanding of each parameter refer to the Main Default Parameters dis cussed on Page 18 To begin press MAIN PREV on the Main Menu as depicted in Figure 3 33 below lt MAIN MENU gt PROGRAM AAAAAAAA _PRESS MAIN F1 FOR _SYSTEM INFORMATION 03 08 01 13 32 13 gt Main Menu Figure 3 33 The System Information screen is then dis played as shown in Figure 3 34 E Term Rev 101 FX PLC Rev 101 Cycles 37631678 For Assistance Call Advance Products
23. NCODER MOTOR BRAKE WIRES 3 4 HOLE FOR SEALTIGHT FITTING FOR MOTOR LEADS 1 HOLE FOR SEALTIGHT FITTING FOR ENCODER LEADS 7 8 HOLES FOR 1 2 NPT SEALTIGHT FITTING Advance Products Corporation SRL 250 USER S MANUAL ELECTRICAL CABINET REPLACEMENT PARTS TY DEC PSSR B24 P S OMRON 0860YK SOCKET OMRON G2R SN 24 06 RELAY ABB TRA CB ABB 10 5271 10A CB ABB CBK C3SK 3005 SW ABB CBK KLF8R RED P L ABB CBK C2AMK 2005 SW ABB CBK PMP3R MSHD PB ABB CBK CB10 NO CONTACT GRAINGER 4WT37 FAN MITSUBISHI FX1N 24MT PLC ITSUBISHI JCCBLS5M H CABLE NJ MITSUBISHI CAB19 3M CABLE 2 ALTECH 1056 2 GRD BLOCK Advance Products Corporation DESCRIPTION RITTAL AE1045 CABINET PART DESIGNATION OMRON GR2 SN 120VAC RELAY aw ABB S271 K1 1A CB ABB CBK CBO1 NC CONTACT FINDER 58 51 7 024 0050 TB RELAY LU 4CCR1 1 8314 MITSUBISHI MR J2S 40A1 SERVO AMP MITSUBISHI HC MFS4SBK MOTOR INDICATES LEN M INDICATES LENGTH MITSUBISHI MR J2TBLOSM CABL MITSUBISHI MR TB20 SERVO TB M ITSUBISHI E150 OIT MITSUBISHI 5911861204 RELAY 34 ALTECH CTS4U N6 25A 600 TB LTECH CA802 END STOP APC PART 10559 10560 3PSR1 8019 7404 7405 umm 10569 TBST Page 55 SRL 250 USER S MANUAL Page 56 Advance Products Corporation
24. NOT BE RUN WITH OTHER CONDUCTORS OR CABLES REFER TO TABLE BELOW FOR WIRE SPECIFICATION DATA 9 SIGNAL WIRE CABLES WITH THIS NOTE NUMBER CAN BE IN THE d SAME SEPARATE SIGNAL CONDUIT THEY CANNOT BE RUN WITH NON SIGNAL WIRES FOR TWISTED TWO CONDUCTOR CABLES USE BELDEN PART NUMBER 9497 OR EQUIVALENT FOR TWISTED THREE CONDUCTOR CABLES REFER TO TABLE 1 BELOW FOR WIRE SPECIFICATION DATA REFER TO NOTE 9 THE NUMBER FOLLOWING THE NOTE 9 IDENTIFIES THE CABLES THAT MAY BE GROUPED TOGETHER IN THE SAME SIGNAL CONDUIT FOR EXAMPLE CABLES REFERENCED WITH NOTE 10 CANNOT BE RUN IN THE SAME SIGNAL CONDUIT WITH NOTE 9 2 CABLES TWISTS PART NO NUMBER OF PER FOOT NOMINAL wem OR LAY 0 COLOR SPEC NO MOT BLK 7 ORG TWISTED 1 n 9498 THREE BLK TWISTED 1 7 ORG WITH BLK TRACER BOTH HAVE THE FOLLOWING VOLTAGE RATING wa AWG SIZE 16 STRANDING INSULATION PVC TEMPERATURE unt TO 105 C TABLE 1 BELDEN Page 48 ALL NOTES ABOVE HAVE BEEN PRE NUMBERED SIGNAL WIRE WILL BE NON SHIELDED TWISTED CONDUCTOR WILL NOT BE RUN WITH NON SIGNAL WIRE WILL ALWAYS BE RUN IN STEEL CONDUIT WILL BE TWISTED TWO OR THREE CONDUCTOR CABLE 2 12 13 6 1 DO NOT OPEN DISCONNECT SWITCH WHILE THE MOTOR 15 ENERGIZED WARNING REFER TO TRANSFORMER NAMEPLATE FOR CONNECTIONS OF PRIMARY LEADS WARNING TRA
25. NSFORMER 5 CONNECTED TO LINE VOLTAGE EVEN WHEN THE A C DISCONNECT 5 OPEN MOUNTED ON CONTROL PANEL MOUNTED ON REMOTE CONTROL STATIONS MOUNTED ON OPERATOR CONSOLE 17 MOUNTED amp WIRED SUPPLIED BY CUSTOMER gl GROUND DEVICE TO PANEL GROUND STUD BUS BAR U SIGNAL CONDUIT 1 SE EITHER A RIGID STEEL OR B FLEXIBLE ARMORED STEEL CABLE WILL CROSS NON SIGNAL CONDUIT AT AN ANGLE OF BETWEEN 45 DEGREES AND 90 DEGREES WILL NOT BE ROUTED THROUGH JUNCTION OR TERMINAL BOXES THAT CONTAIN NON SIGNAL WIRING REFER TO THE ELECTRICAL DIAGRAM WHEN SELECTING CONDUIT DO NOT ASSUME ALL SIGNAL WIRE WILL BE IN THE SAME CONDUIT FUN PREFERRED SPECIFIC INSTRUCTIONS FOR EACH SIGNAL CABLE ARE FOUND ON THE ELECTRICAL DIAGRAMS IF SHIELDED WIRE IS USED FOR SIGNAL WIRE THE GROUND SHIELD IS TO BE GROUNDED ON ONE END ONLY TO AVOID SIGNAL GROUND LOOPS AND ERRATIC OPERATION SRL 250 INSTALLATION Note Sheet FIGURE 7 4 Advance Products Corporation SRL 250 USER S MANUAL 115V 1PH 30 14 RED 201 201 2MCRI 288 FROM 3 ee USER S 10 A 208 AMP PROTECTED L2 289 14 WHT 289 AC SUPPLY S APPROXIMATE INPUT CURRENT 15A ui 1 16 RED 16 WHT EMERGENCY STOP 2281 CONTACTOR 21 204 211 320 7 MAINTAINED 211 203 X amp 289 D 212 213 O A 5049 04 4 P 200 2087 204 2MCRI 205 2 POWE
26. NT If it becomes necessary to ship any part of your Reciprocating Die Spray System to Advance for repair please make sure that you include a thorough description of the problem s you are having on your Return Materials Authorization form received from ADVANCE CHART PROBLEM Sprayer will not power up E Stop jumper missing or customer interface is not connected Sprayer powers up but won t run in Auto performed Auto Manual switch not in Auto No position entered in MMI program POSSIBLE CAUSE Disconnect switch not on Missing 120 VAC power Check 120 VAC line fuses Home sequence not SOLUTIONS e Turn disconnect switch on Install jumper see Elect Schematic Line 1 Home sequence must be performed after initial power selector Up Turn selector switch to AUTO Enter a position other than zero No cycle start received Advance Products Corporation Page 21 571 250 USER S MANUAL Chart continued PROBLEM POSSIBLE CAUSE SOLUTIONS Sprayer won t do a home sequence Sprayer goes to spray positions but does not spray Spray head con stantly drizzles Page 22 Auto Manual selector switch not in manual or is defective Mechanical bound up Defective Servo Amp Defective motor linkage No air pressure No lube pressure Low lube pressure Air or lube line is plugged Spray head is clogged Lube valve will not shift Air valve
27. R SUPPLY B5 264VAC N o 7 208 B5 PS5R B24 y V 18 BLU 256 24VDC TO SHT 3 4 5 257 PLC POWER 2 100 240 N INPUT SHOWN ON SHT 3 200 2 3 208 208 AR ES 5 413 AIR 5 208 SABRI 207 289 NR BLAST 5 416 SRL 250 1PH POWER DISTRIBUTION FIGURE 7 5 Advance Products Corporation Page 49 SAL 250 USER S MANUAL MAKING THE INTERFACE CONNECTIONS You will need to provide some of the following inputs These inputs can be as a dry contact closure ora 120 VAC 24 VDC available upon request signalfromaPLC output The following isolation relays supplied by Advance Products provide normally open contacts that are prewired to the proper inputs The following section provides you with information you will need to make the interface connections NOTE Due to noise on the control lines we require that all interfacing for the inputs be switched through isolation relays These relays are supplied by Advance Products and provide normally open contacts that are prewired to the proper inputs to the PLC INPUT DEFINITIONS Description Die Open 3DOR1 A user input signal on wires 322 and 323 that enables the sprayer to move down in the die opening If this signal is missing during automatic operation an emergency retract condition will occur The spray arm will retract to the home position Cycle Start 3CSR1 This input will start the sprayer cycle if it is
28. USER S MANUAL 81 5SRVO1 DE 4 52 N SHT 4 415 LI MR J2S 40A1 U 288 SERVO 2 294 115VAC 6 V 515 13 FR V 0 32 NEC APPROX 9 7A 289 ges Z1 T Lj igi 8 Spe Sa 25 9 T E ENCODER FROM PLC 0 er zs OUTPUTS lt YO 400 0 SHT 4 11 ow P 5 o 12 FROM P S SHT 2 SO 256 257 E Sic 257 E st CN1A CN1B 256 255 NN IN POSITION j TO PERSONAL COMPUTER NOT USED O z 2 La GRN PLUG WITH TERMINALS FOR L11 L21 P C D SERVO ALARM RELAY 319 18 BLU SRL 250 400 W SERVO AMPLIFIER FIGURE 7 8 Advance Products Corporation Page 53 SHL 250 USER S MANUAL TO ENO OF SCREEN NOT CUTOUT 115VAC INPUT FROM PROTECTED SOURCE EXT E STOP CIRCUIT 5 288 LYBE sN WG L1 200 L2 288 GRD 202 203 289 206 5X 289 AIR BLAST 207 256 HOME PROX CYCLE START RELAY COIL INPUT DIE OPEN RELAY COIL INPUT PART SENSOR RELAY COIL INPUT CYCLE COMPLETE RELAY OUTPUT DIE SAFE RELAY OUTPUT PART DETECT RELAY OUTPUT Page 54 320 321 322 323 324 325 410 411 412 413 41 416 19 74 LELLLLT 8 IT pzm CR atin ma e w ie KE T lt EP sp mmc LA MARA YT Aa test SRL 250 SERVO PANEL FIGURE 7 9 J E
29. ange the servo motor 3 Encoder cable faulty Repair or change cable Wire breakage or shorted error occurred between encoder and servo amplifier 4 Wrong combination of servo Use correct combination amplifier and servo motor CPU parts fault Faulty parts in the servo amplifier Change the servo amplifier Checking method Alarm AL17 or AL19 occurs if power is switched on after all ROM memory fault Wrong combination Wrong combination of servo Use correct combination of servo amplifier amplifier and servo motor connected and servo motor 1 Encoder connector disconnected 2 Encoder cable faulty Repair or change the cable Wire breakage or shorted 1 Power input wires and servo motor Connect correctly output wires are in contact at main circuit terminal block TE1 2 Servo motor power cable Change the cable insulation deteriorated 1 Reduced voltage of super capacitor After alarm has occurred hold power on in encoder for a few minutes and switch it off once then on again Make home position return again 2 Battery voltage low Change battery 3 Battery cable or batter is faulty Make home position return again Ground Fault occurred at the servo motor outputs U V and W phases of the servo amplifier Absolute position Advance Products Corporation Page 25 SRL 250 USER S MANUAL Regenerative Permissible alarm regenerative power 2 Built in regenerative bra
30. ation to execute auto tuning Load ratio 200 2 Change auto tuning response setting 3 Set auto tuning to OFF and make gain adjustment manually 3 Machine struck something 1 Review operation pattern 2 Install limit switches 4 Wrong connection of servo motor Connect correctly Servo amplifiers output terminals U V W do not match servo motors input terminals U V W 5 Encoder faulty Checking method When the servo motor shaft is rotated slowly with the servo off the cumulative feedback pulses should vary in proportion to the rotary angle If the indication skips or returns midway the encoder is faulty 100s or more Change the servo motor Advance Products Corporation Page 27 SHL 250 USER S MANUAL AL51 Overload 2 Machine colision or 1 Machine struck something 1 Review operation pattern the like caused max 2 Install limit switches output current to 2 Wrong connection of servo motor Connect correctly flow successively for Servo Amplifiers output terminals several seconds U V W do not match servo Servo motor locked motors input terminals U V W 8E 15 or more 3 Servo system is unstable and hunting 1 Repeat acceleration deceleration to communication execute auto tuning time out 8 8 8 8 8 Watchdog 2 Change auto tuning response setting 3 Set auto tuning to OFF and make gain adjustment manually Change the servo
31. blast air hose between the blast air valve and the sprayer mechanism See Figure 5 1 for the correct connection point Page 8 CONNECTING THE CABLES 1 The motor control and encoder cables have plug connectors at the motor Connect these two cable The proximity switch cable needs to be wired in to the junction box near the sprayer motor The valves need to be wired to the control box Holes are already provided in the bottom of the control box and on the junction box on the valve plate CONNECTING THE AC POWER 1 The sprayer is designed to run on 120 VAC single phase 15 amp service Connect power to through the provided hole in the bottom of the control cabinet Advance Products Corporation PROGRAMMING amp SOFTWARE 3 The software used by the Mitsubishi operator terminal in the sprayer system is the appli cation program that is used as a Human Machine interface HMI By using this operator inter face the operator can change several variables or parameters involved in the sprayer system to modify its behavior as desired The software system uses different menus as options to change the variables or param eters of the sprayer These menus are shown in Figure 3 1 below Main Menu Modify Modify Date Time Manage Hel Edit Input Mode Home Programs H Program Status Select Sprayer Verify Current Output Auto New Position Status Cycle Machine Misc Parameters Bits Regs Mode Jog
32. crew S 8947 S 8983 Bod gt f A O ring 8949 Retainer Needle SH 3000 Spray Head Spray Head Assembly FIGURE 7 2 Page 46 Advance Products Corporation SRL 250 USER S MANUAL SH 3000 Extensions Accessories FIGURE 7 3 AVAILABLE HEADS AND TUBES SERIES TUBE SYLE LENGTH SH 3000 Dual Outlet None SH TUBE 000 Opposed Side 1 4 copper 2 SH TUBE 001 SH 3000DC Dual Outlet 1 4 copper 4 SH TUBE 002 Cover Side 1 4 copper 6 SH TUBE 003 SH 3000DE Dual Outlet 1 2 alum straight 2 SH TUBE 004 Ejector Side 1 2 alum straight 4 SH TUBE 005 1 2 alum straight 6 SH TUBE 006 1 2 alum 90 2 SH TUBE 007 1 2 alum 90 4 SH TUBE 008 1 2 alum 90 6 SH TUBE 009 Advance Products Corporation Page 47 571 250 USER S MANUAL DRAWING STANDARDS RELAY NAMING CONVENTION WITH CONTACT SYMBOLS LOCATIONS MNEUMONIC RELAY NAME NOTE REFERENCE SEE THIS SHEET AG AC TWISTED PAIR c E dt I RA LY ONL DC Sue DC TWISTED PAIR END ONLY 5619 6612 S S INDICATES RELAY SUPPRESSION 5 T CAN BE WITH TAN WIRE NC CONTACT ARROW INDICATES FUNCTION ik e dr INSIDE CONTROL ENCLOSURE o TERMINAL BOARD CONNECTION WITH COIL LOCATION 6 RR SHEET NUMBER AUTO MAN 6623 6624 e GR TWISTED TRIPLE N X0 TO A IN AUTO 4001
33. epair or change the cable communication device 3 Communication device 8 9 personal Change the communication device e g e g personal computer faulted personal computer computer CPU parts faulty Serial communication Fault of parts in servo amplifier Change servo amplifier Checking method Alarm 8 8 8 8 8 occurs if power is switched on after all connectors are disconnected Page 28 Advance Products Corporation SRL 250 USER S MANUAL Warnings If ALE1 overload warning occurs operation may be continued but an alarm may take place or proper operation may not be performed If another warning ALE6 or ALE9 occurs the servo smplifier will go into a servo off status Eliminate the cause of the warning according to this section Use the optional Servo Configuration software to refer to the cause of warning AL92 Open battery Absolute position 1 Battery cable is open Repair cable or replace cable warning detection system 2 Battery voltage dropped to 2 8V or less battery voltage is low 1 Inincremental 1 Droop pulses remaining are greater than system Zeroing the in position range setting occurance 2 Command pulse entered after the Clearing of droop pulses could not be made 1 In absolute position detection system Zero setting could not be Regenerative power increased to 85 or 1 Reduce frequency of positioning more of per
34. from moving see Figure 3 Advance Products Corporation MAINTENANCE 30 days Fully extend the spray manifold into the die area Turn the sprayer off to prevent accidental movement of the sprayer Remove the front cover of the sprayer mechanism There are 3 14 20 bolts on the top and bottom of the cover that hold the cover in place Wipe the 2 chromed inner telescoping tubes clean with a clean cloth Wipe the 3 chromed outer telescoping tubes clean with a clean cloth Check that all air and lube fittings are tight These fittings are located on the mechanism and the valve plate located remote from the sprayer mechanism Tighten any lose fitting Inspect the lube hose for wear or damage Replace if it is damaged Check that the fittings that hold the outer telescoping tube to the platen and the mechanism are tight Tighten any lose fitting Check that the 6 mounting blocks that hold the linear actuator to the base are tight Tighten any lose blocks Wipe the motor and gearbox clean with a clean cloth Replace the sprayer cover power the unit up move the sprayer to the home position Page 31 SRL 250 USER S MANUAL 90 days or 100 000 cycles Fully extend the spray manifold into the die area Turn the sprayer off to prevent accidental movement of the sprayer Remove the front cover of the sprayer mechanism There are 3 14 20 bolts on the top and bottom of the cover that hold the cover in place
35. front page of this manual Advance Products Corporation Page 33 SRL 250 USER S MANUAL 10309 1 FIGURE 6 1 Advance Products Corporation SRL 250 Top Block Assembly Page 34 SRL 250 USER S MANUAL 10171 10172 10160 10159 1 SRL 250 Slide Block Assembly FIGURE 6 2 Advance Products Corporation Page 35 SRL 250 USER S MANUAL Figure 5 Noises 2 10158 2 10192 XX SRL 250 Vertical Unit Assembly FIGURE 6 3 Page 36 Advance Products Corporation SRL 250 USER S MANUAL 0 3 2i EE g SRL 250 Vertical Unit Assembly 2 FIGURE 6 4 Page 37 Advance Products Corporation SRL 250 USER S MANUAL VIE S hD Figure 6 4 712 e St Wi SS Y H JH SRL 250 Gearbox Attachment Assembly FIGURE 6 5 Advance Products Corporation Page 38 SRL 250 USER S MANUAL 8 2 af 0 711115 n EE na 10185 SRL 250 Prox Switch Bracket Assembly FIGURE 6 6 Page 39 Advance Products Corporation SRL 250 USER S MANUAL 0121 032 1029 10188 x ke Advance Products Corporation TD qu e 10179 SRL 250 Base Assembly FIGURE 6 7 10187 Page 40 SRL 250 USER S MANUAL ch je VY VS AM
36. in regenerative brake resistor or regenerative brake option is insufficient Command Input pulse pulse frequency frequency of the command pulse is too high 3 Command device failure Change the command device Parameter setting is wrong error Parameter error Main circuit device overheat parameter setting to be rewritten 2 Regenerative brake option not used with servo amplifier was selected in parameter No 0 Main circuit device overheat 1 Servo amplifier faulty Change the servo amplifier 2 The power supply was turned on Review the drive method and off continuously by overloaded Status Servo motor Servo motor 1 Ambient temperature of servo motor Review environment so that ambient overheat temperature rise is over 40 C temperature is 0 to 40 C actuated the 2 Servo motor is overloaded 1 Reduce load thermal protector 2 Review operation pattem 3 Use servo motor that provides larger output 3 Thermal protector in encoder is faulty Change servo motor Overload 1 Load exceeded 1 Servo amplifier is used in excess 1 Reduce load overload protection of its continuous output current 2 Review operation pattern characteristic of 3 Use servo motor that provides larger servo amplifier output Load ratio 300 2 Servo system is unstable and 1 Repeat acceleration 2 55 or more hunting deceler
37. ization consistency over a larger variation of air to lube pressure The Model SH 3000 offers a wide range of spray patterns with 9 interchangeable nozzles from ultra fine mist to maximum out put Special nozzles are available that offer consistent flow lube rates at a given pressure regardless of air pressure All internal parts are warranted for 1 000 000 cycles The spray head body has a 10 year warranty Advance Products Corporation Advance Model SH 3000 Spray Head FIGURE 7 1 FEATURES e Wide range of spray volumes from ultra fine mist to heavy dosing e Not dependent on the same air and lube pressures In fact the independent air and lube pressures can vary from 40 psi to 110 psi without affecting each other 5 GPM per each nozzle outlet No leak construction GUARANTEED Advance s new positive shutoff doesn t permit leaking Either internal or external mix nozzle outlets can be used on the same head An APC exclusive All internal parts are warranted for1 000 000 cycles against leakage Body warranted for 10 years Page 45 SRL 250 USER S MANUAL 8960 Socket Head Cap Screw 0692 Ball Fan Cone Be 8948 Fine Fan 8968 Wide Fan vo 8969 90 Cone 8975 Oval 2 Es NA Poppet NEE Be 8977 0 Cone CD 3963 p 8980 O ring 90 Fan e 2 CH AW R 2 8962 A 2 8953 O ring 3 Nozzl Nozzle s 5 6 G 0692 Comes 8959 Standard g s 5 E x Set S
38. ke Connect correctly of the built in resister or regenerative brake regenerative brake option is not connected resistor or 3 High duty operation or continuous 1 Reduce the frequency of positioning regenerative brake regenerative operation caused the 2 Use the regenerative brake option of option is exceeded permissible regenerative power of larger capacity the regenerative brake option to 3 Reduce the load be exceeded Checking method the status display and check x the regenerative load ratio 260V or more Regenerative 5 Regenerative transistor faulty Change the servo amplifier transistor fault Checking method 1 The regenerative brake option has overheated abnormally 2 The alarm occurs even after removal of the built in regenerative brake resistor or AL31 Overspeed 1 Input command pulse frequency exceeded the permissible Instantaneous speed frequency 2 Smallacoeleration deceleration Increase acceleration deceleration time time constant caused overshoot to constant be large 3 Servo system is unstable causing 1 Re set servo gain to proper value Page 26 Advance Products Corporation Speed has exceeded the instantaneous permissible speed overshoot 2 lf servo gain cannot be set to proper value 1 Reduce load inertia moment ratio or 2 Reexamine acceleration deceleration time constant 4 Electronic gear ratio is large Set correctly
39. ld is also available Air blast is provided with both manifolds The SRL 250 uses a remote valve package that can be mounted for customer convenience The valve package is mounted to a 1 2 x 10 x 15 1 2 plate for ease of installation The valve package Advance Products Corporation consists of a 3 8 lube valve a 3 4 spray air valve with pressure regulator and a 3 4 air blast valve The main control cabinet for the SRL 250 is a wall mount Nema 12 rated cabinet The overall size of the cabinet is 8 1 2 deep x 15 3 4 wide x 19 3 4 tall Twelve foot cables come standard with the control cabinet The control cabinet needs 120 VAC to run Page 3 SRL 250 USER S MANUAL mismas 2 DIT 1 ll NOTE Unit is shown in the full up and full back position 8 1 2 REF E HORIZONTAL TRAVEL EN 6 5 8 REF E 2 58REF lt ae 9 e d 12 STROKE A 39 3 16 A TEH 24 STROKE 52 a 1 36 STROKE A 63 3 16 1 nn VIEW A A 1 0 PIVOT CENTERLINE BEES Es 1 J 3 3 16 REF bd ten E d He 10 REF m PLATEN WIDTH Jo MANIFOLD R CENTERLINE 493 8 1 4 REF COVER DIE STATIONARY PLATEN SRL 250 Dimensions FI
40. lection Screen Figure 3 13 Push the LOAD function key lt F5 gt and the screen shown in Figure 3 14 is displayed gt ZZ11Y221 SELEC EXIT LOAD Screen Figure 3 14 Press the up arrow and down arrow W keys to cycle through the program names available Press the SELEC function key lt F2 gt to load the program into memory Press the EXIT function key lt F5 gt to return to the program selection screen PROGRAM OPTIONS NEW DEL SAVE LOAD Program Selection Screen Figure 3 15 Touch the MAIN PREV function key lt F1 gt to re turn to the Main Menu shown in Figure 3 10 is displayed PROGRAM AAAAAAAA _PRESS MAIN F1 FOR SYSTEM 03 08 01 13 32 13 lt Main Menu Figure 3 16 Advance Products Corporation SRL 250 USER S MANUAL PROGRAM EDIT Program editing may be initiated by pressing the EDIT PROG function key on the Main Menu as shown in Figure 3 8 Then the program edit screen similar to the one in Figure 3 17 is dis played 1 P 00 00 S 00 00 D 00 0L OffA Off y 2 P 00 00 S 00 00 D 00 0L O0ffA 0ff P N 20 P 00 00 S 00 00 D 00 0L 0fFA OfFF P N Edit Program Screen Figure 3 17 Each screen shows 2 lines of program informa tion at a time Each program may contain up to 20 program steps After entering values for Step 10 you must press the EDIT PROG key to reach step 11 20 Press the up arrow and down arrow W keys as shown in Figure 3 18 to cycle through the program steps Press
41. lve package from the shipping container and set aside Caution the unit is top heavy do not leave free standing until the unit is bolted down MOUNTING THE SPRAY MANIFOLD If the spray manifold is already mounted to the sprayer mechanism proceed to the next section PREPARATIONS FOR MOUNTING THE SPRAYER 1 Install O rings in the spray manifold O ring sizes are O D 1 1 2 width 1 8 material Viton Dash No 218 2 Align the ports in the sprayer platen to the holes in the spray manifold 3 Boltthe spray manifold to the platen using 4 3 8 coil type lock washers and 4 3 8 16 x 1 1 2 shcs See Figure 1 2 Advance Products Corporation PREPARATIONS FOR MOUNTING THE SPRAYER 1 The sprayer is designed so the base is mounted on the stationary platen so the front of the base is mounted flush with the front of the stationary platen See Figure 1 1 Four 13 shcs along with lock washers are to be used to fasten the sprayer to the platen 2 Drill and tap the 4 13 holes so there are at least 1 of useable threads 3 Lift the sprayer into position on the platen and fasten in place 4 f required the linear actuator can be moved vertically up or down relative to the base because of clearance issues To do this hold the linear actuator from falling Loosen the 6 hhcs that hold the mounting blocks APC P N 10207 to the base Raise or lower the linear actuator as required Retighten the
42. missible regenerative power of 2 Change regenerative brake option for the built in regenerative brake resistor or one with larger capacity regenerative brake option 3 Reduce load made Checking method Invoke the status display and check the regenerative load ratio There is a possibility that regenerative powe warning Load increased to 85 or more of overload alarm 1 or 2 occurance level may exceed permissible ALE1 Overload warining K Cause checking method SH ALE3 Absolute Absolute position 1 Noise entered the encoder position counter encoder pulses faulty 2 Encoder faulty Change servo motor warning regenerative power of ALE5 ABS time out 6 1 PC ladler program wrong Contact APC for program correction AL96 Zero setting error ALEO Excessive regenerative Refer to 41 50 AL51 built in regenerative i 2 ST2 TLC signal mis wiring Connect properly brake resistor or warning regenerative brake option ALE6 Servo EMG SG are open External emergency stop was made valid Ensure safety and deactivate emergency ALES Main circuit off Servo was switched on Switch on main circuit power power off There is a possibility ALEA 85 Servo on signal SON 1 PC ladder program wrong Contact APC for program correction that overload alarm 1 or 2 may occur 1 servo on turned on more than 1s 2 SON signal mis wiring 2
43. motor 4 Encoder faulty Checking method When the servo motor shaft is rotated slowly with the servo off the cumulative feedback pulses should vary in proportion to the rotary angle If the indication skips or returns midway the encoder is fau constant is too small time constant Increase torque limit value is too small Droop pulse value of the deviation counter exceeded 80k pulses 3 Motor cannot be started due to torque 1 Review the power supply capacity shortage caused by power supply 2 Use servo motor which provides larger drop output 4 Position control gain 1 parameter No 6 Increase set value and adjust to ensure value is small proper operation 1 When torque is limited increase the limit value 2 Reduce load 3 Use servo motor that provides larger output 6 Machine struck something 1 Review operation pattern 2 Install limit switches 5 Servo motor shaft was rotated by external force 7 Encoder faulty Change the servo motor Connect correctly input terminals U V W 8 Wrong connection of servo motor Servo amplifiers output terminals U V W do not match servo motors RS 232 or RS 422 communication stopped forlonger thanthetime set in parameter No 56 Serial communication error occurred parameter No 56 setting disconnected between servo 2 Communication cable fault R
44. n Any entry may be changed by position ing the cursor over the desired field enter a new value and press the ENTER key to accept it If the selected value is out of range when en tered the parameter value will not be changed Of interest on this screen is the sprayer type For the MMI to run the correct program the Front Console Figure 3 40 sprayer type must be accurate While in Auto Cycle a screen similar to the one To select a different sprayer type justtouch the bDelow is displayed appropriate sprayer model number POSITION 13 03 CYCLE TIME 006 9 HANIS Irvin 2 BE TOTAL PARIS 00000000 PRESS LOAD F5 TO RESET PART COUNTER LUBE OFF ATR OFF Arrow Keys on the E150 Keypad Figure 3 40 Auto Cycle screen Figure 3 41 The Auto Cycle screen shows the cycle time Parts per hour and total parts As the sprayer arm moves the current arm posi tion of the sprayer is updated in the Position field The Auto Cycle screen also shows the current Advance Products Corporation Page 19 SRL 250 USER S MANUAL status of the lube valves and air valves To view the Auto Screen Figure 3 25 press the JOG AUTO function key lt F4 gt on the Main Menu as depicted below PROGRAM AAAAAAAA _ PRESS MAIN F 1 FOR SYSTEM INFORMATION 03 08 01 13 32 13 Main Menu Figure 3 42 _ lt lt SELECT MODE gt gt JOG AUTO Auto Selection Screen Figure 3 43 Press the AUTO function key lt F5
45. nce Products Corporation 8 30 3 88868 RAAD EE AlphaNumeric Entry Table Figure 3 5 Page 11 SRL 250 USER S MANUAL HOME Performing a Home Sequence is required after power is applied This allows setting a zero ref erence position relative to a programmed move in a user program The HOME NEXT key is used to perform a sprayer home sequence After touching the HOME NEXT key the following screen appears Home Sprayer PRESS HOME F6 To Start Home Screen Figure 3 6 Once the Start Home Sequence key is touched the sprayer arm will begin moving back to the home position During that time the current position is displayed next to Position in a screen similar to Figure 3 7 below Home in Progress Position 7 12 Home in Progress Screen Figure 3 7 The Stop Move key should be pressed if it is necessary to abort the move Press the MAIN key when you are ready to re turn to the Main Menu The NEXT key is inactive at this time Page 12 PROGRAM SELECTION PROGRAM AAAAAAAA PRESS MAIN F1 FOR SYSTEM INFORMATION 03 08 01 13 32 13 Main Menu Figure 3 8 Program selection can be initiated by pressing the LOAD SAVE function key on the Main Menu as shown in Figure 3 8 Then the program se lection screen similar to the one in Figure 3 9 is displayed _ PROGRAM OPTIONS NEW DEL SAVE LOAD Program Selection Screen Figure 3 9 Note To create a new program you must be in
46. rm occurs the trouble signal ALM switches off and the dynamic brake is operated to stop the servomotor At this time the display indicates the alarm number The servo motor comes to a stop Remove the cause of the alarm in accordance with this section The optional Servo Configuration Software may be used to refer to the cause Page 24 Advance Products Corporation SRL 250 USER S MANUAL Display AL10 15 EEE m AL19 1A BS DS ES Undervoltage emory error i ock error Memory error EEP ROM fault Alarm any of AL12 13 and 15 Encoder error 1 Communication Board error 2 Memory Error Motor combination ncoder error 2 Communication m o 1 Motor output ground fault Absolute positionerase data in error Power supply Inspect the power supply 2 Power failed instantaneously for 15 ms or longer 3 Shortage of power supply capacity caused the power supply voltage to drop at start etc it had switched off voltage dropped MR J2S uA 160V or less 5 Faulty parts in the servo amplifier Change the servo amplifier Checking method Alarm AL10 occurs if power is switched on after all connectors Change the servo amplifier RAM memory fault Faulty parts in the servo amplifier Printed board fault Checking method occurs if power is switched on after all connectors are disconnected 1 CN2 connector disconnected 2 Encoder fault Ch
47. s when being jogged manually in fast mode 10 0 The speed the arm moves when being jogged manually in slow mode 5 0 The speed at which the arm moves during a home sequence after power up 3 0 The acceleration value in milliseconds used when the arm moves to ramp up 300 and down to the program speed e Ns Acc 66 03 K Kin ms The speed of the arm during a an emergency retract operation or end of 100 cycle The time in seconds the cycle output will stay on 3 0 The maximum distance from home to the furthest spray position 35 0 The sprayer type is set in the Sprayer Type Setting screen For the MMI to 1 run the correct program the ladler type must be accurate Default Values 0105 TVANVW 5 500 5 SRL 250 USER S MANUAL AUTO CYCLE screen similar to the one below is shown The following screen depicts the default Machine Pa rameter values To enter Auto Cycle make sure the mode switch is pointed to AUTO as shown below in Figure 3 40 Acustomer supplied input is required to run an AUTO CYCLE SLOW JOG SPD C HOME SPEED ACC DEC RETRACT SPD Cortes OMIM MAX POSITION S35 SPRAYER TYPE 01 Machine Parameters screen Figure 3 39 To show different lines of Machine Parameters press the up arrow and down arrow W keys as shown in Figure 3 40 Press the left arrow lt a and right arrow m keys as shown in Fig ure 3 40 to move between the fields on the scree
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