TC3200 User Manual Updated August 2005 in - Techna
Contents
1. 1213145656 24 V DC Earth Rs485 Shield A RS485 Note Earth connected to housing inside TC3200 Appendix C Interface to Vibration Transducer VM 100 Measurement Transducer T 1 2345671781 9101112 Vibration Sensor Di 20 2 x gna Shielded cable earth S4 u connected at one end S3 3e a S1 Shielded cable eartfi connected at one end Digital In Common Cut Select 6 Cut Select Cut Select 4 Cut Select 3 4 Cut Select 2 Cut Select 1 Reset Learn Start Jr Blunt Output lt Break Output 1 2 3 4 5 6 7 8 910 111213 1415 16 HH G N co TC 3200 Station 1 2 3 4 123456 24 V DC Earth Rs485 Shield A RS485 Note Earth is not used connected inside VM100 Earth is connected to housing inside TC3200 Appendix E Dip Switch Usage Dip Switch Function Default Factory Test Only a OC Le cV rra s T C e rr rr O e News 0n O rnFvn EE Lo on on or Lor messer of on on or om mm Range on or on of or 27 Outside Range I II IORIIIAIIII4II XI IIIIIIWw Lo on or or or 29 usidenango on on or or or2. 1 Password dee de e e e 3 TC3200 Lock Off The password menu is activated by first pressing Fn1 followed by F6 In order to enter a password 1 Enter password 2 Confirm password 3 TC3200 Lock ON When locked the unit must be unlocked before the parameter functions are accessible Unlock ing is done by entering the password followed by the enter key The password dialog appears when one of the F keys is pressed When the unit is unlocked it may be locked again from the password menu PWM350 Wiring 6 Wiring of the PWM350 Module For proper operation of the system it is important that the PWM350 be set up properly see Ap pendix A Incorrect settings of Current Measurement Range may severely reduce the functional ity of the system 6 1 Current Measurement Range The current measurement range is set by applying 24 VDC input signals to pins 4 and 5 according to the logic diagram shown on page 20 The appropriate measuring range is selected by determin ing the Full Load Current FLA of the motor which should be marked on the motor housing Then the percentage of the rating of the PWM350 should be calculated For example when using a mo tor with an FLA rating of 5 Amps with a PWM350 rated at 25 A the percentage of the PWM350 rating would be 20 In this case the 20 range on the PWM350 would be used In cases where the percentage does not exactly correspond to one of the curre
3. 3 5 2 Missing Tool Learn Work Mode Figure 4 shows how the missing tool detection Learn Work mode is set up relative to a typical machining cycle In the Learn Work mode the Missing Tool Limit is a user defined relative per centage of the work calculated during the Learn cycle If the work calculated during a cycle does not exceed this percentage of the learned work then a Missing alarm is generated In the event of a missing tool fault a red 1 will appear in the missing window and the particular station number will flash red Missing Tool supervision remains active for the duration of Tw if Tw is enabled If Tw is turned off Missing Tool supervision remains active the entire time the start signal is present fol lowing the Start Delay and the idle power measurement Figure 4 Tool Missing Learn Work Mode P f t Tw 0 0 Off 999 9 Sec gt Consumption Learned Work 100 lt Start Delay Po gt i 0 Off 250 Samples t s Start Supervision Active Setting these parameters too aggressively can result in more frequent nuisance trips A good com promise and starting point for adjustment seems to be to set the Missing Limit fairly low around 30 50 since if the tool is missing there will be NO rise above idle Tool Break 3 6 Tool Break Supervision 3 6 1 Break Mode Selection When a tool breaks while it is machining a part it is typical to notice a sh
4. Parameter 1 Break Mode Abs Peak Learn Peak Abs Peak Curve 2 Break Limitl Break Limit 1 0 100 0 Off 3 Break Limit2 Break Limit 2 0 100 0 Off Active only in Abs Peak Curve mode 4 Break Limit3 Break Limit 3 0 100 0 Off Active only in Abs Peak Curve mode 5 Break Point 1 s Break Point 1 0 0 999 9 seconds Active only in Abs Peak Curve mode 6 Break Point 2 s Break Point 2 0 0 999 9 seconds Active only in Abs Peak Curve mode 7 Break Delay s Break Delay 0 0 25 0 seconds Break Reaction Time Keep as low as possible F2 Blunt Parameters 5 7 F2 Blunt Parameters T iz S 013 3 2 prp G N 4 750 6 i CS IP Gei Eat Jel Drill Smm 708m CR mea 1 0 s Tat 5A amp Blunt 0 a aum PPartilo4569 Fn1 Fn2 Fn3 Stacioni 1 Drill hani v 1 4 A Blunt Mode Blunt Limit Blunt Delay s Blunt Count Blunt Duration s 7 Blunt Part Limit 4 A parameter is selected by the arrow up and down keys The enter key may be pushed to acti vate the parameter When activated the arrow up and down key may be used to alter the vari able When the enter key is activated again the modification is made permanent The numerical keys may also be used to alter a variable The enter key or the arrow up down keys are used to make the change permanent Parameter 1 Blunt Mode Abs Peak Learn Peak Learn Work 2 Blunt Limit Blunt
5. stu argo On or or or EE or or or or or s2 Qusige Range Appendix D TC3200 Back Side Print 8T LT 9T ST PT ET ZT TT OT 6 8 Vit UONEIS dwy xe HOA 0 81 Ave DUD AbZ V V G amp gy s co ph S ED NZD NL9 N ee s sgpSH 8 h S8bSH V ll 8T LI 9T ST VI ET ZI TT OT 6 8 L 9 S y Z T L WHOL JSISEN CH uonels V V Sg sg s smi s ED NZD NL9 N isn py 188002 GO1 e ST LT 9T ST VT ET CT LL OT 6 8 LY GS P EZ T Jase W09 00 BUY99 MMM CH uoles SH ooze T3qOMW W3 LSAS ONIHOLINOW TOOL MO3HO VNHO3L V V S s sg smi s ED NZD NLO N OUT OO euUYII 81 LT 9T ST OT ET ZT TT OT 6 8 L 9 S P C T L4 uonels yesoy sa e ssouppy 9IA49S NC S S L V V gpg s ED NED NLD N Appendix G Cut Select Chart INPUT 1 a 5 a z INPUT 5 INPUT 4 INPUT 3 INPUT 6 Appendix F Networking and Communicating Networking and Communicating TC3200 Up to 24 TC3200 units may be connected in a network and interfaced to a PC running the TOOLMON application TOOLMON will be able to modify all parameter and to show the tooling operation graphically TOOLMON maintain a tool peak and work statistic as well The network address is programmable via dipswitches on the back of the unit Ifthe RS232 port on the side is used then the unit is disconnected
6. 36 6 1 Current Measurement Hange ener nnne ens 36 6 2 PWM350 Technical Specifications sse 37 6 3 PWM125 Technical Specifications aaa 38 6 4 VM100 Technical Specifications 40 Appendix A Interface to 3 Phase Transducer PWM350 41 Appendix B Interface to Single Phase Transducer PWM125 42 Appendix C Interface to Vibration Transducer VM100 43 Appendix D TC3200 Back Side Print 44 Appendix E Dip Switch Usage a 45 Appendix F Networking and Communication aa 46 Appendix G Cut Select Chart 47 Appendix G Panel Cut Out Profile sse 48 The Concept 1 The Concept LTE 1 Drill 8mm S 1 Drill 6mm 100 75 501 M S S aes 1 Miller 75 50 25 s The TECHNA CHECK TC3200 is a modular Tool Monitoring system s The TC3200 is hardware configurable and is able to monitor 1 2 3 or 4 tooling spindles stations The stations are electrically isolated and can be used with 4 machines in a cell The TECHNA CHECK TC3200 has been exclusively developed for the supervision of cutting tools on single spindle automatic machine tools It is capable of detecting missing blunt and broken or damaged tooling The TC3200 measures from external measurement transducer s the electrical power consumption of the spindle motor A blunt or worn tool
7. Two opto coupler isolated inputs allow the selection of 4 measurement ranges 100 50 20 and 5 The transducer outputs a current of 0 20mA propor tional to power which is galvanically isolated from the measurement system The three motor wires must pass through the wholes in the transducer in the same direction to the motor either fromTop Bottom or from Buttom Up Note The PWM350 is designed for use with inductive loads only motors TECHNA CHECK is a registrered trade mark by Techna Tool Inc Hartland Wisconsin USA Voltage connection 6 3 PWM125 Technical Specifications PWM 125 Technical Specifications Tiy TECHNA CHECK PWM125 Load Transducer Power Transducer for Symmetrical Loads A fast measurement transducer specifically developed for Ma chine Tool Monitoring applications PWM125 measures motor power kW RMS voltage RMS current and Power Factor Analog Output 0 20 mA reflecting power Programmable Averaging Programmable Zoom function True Digital Design no pots no dials no screw drivers 144 samples per cycle at 50 Hz 120 samples per cycle at 60 Hz 4 quadrant digital multiplication Ultra Compact DIN rail mount only 1 of rail space Current wire feeds through hole in unit An Intelligent CT Monitor any size motor external CT gt 25Amp peaks up to 75 Amp measured High precision resolution measurement works when amp meters don t Measures and displays kW kW
8. 18 3 7 5 Blunt Tool Blunt On Part Gout 19 3 7 6 Blunt Tool Resetting the Part Counter 19 3 8 Idle Limit Gupernvislon enne 20 3 9 Touch Point Limit Function eseeeneneneneenen mene 21 4 Installation NOtGS redirect ti co etai ite eaves kta BK qasqa qayay ete s 22 4 1 Mechanical Mounting seen nennen nnnm enn 22 4 2 Electrical Connection enne nennen 22 e 22 Seed dee Inptez n m e im ete s o e hii e nd 22 4 2 3 Control Outputs 31 12 eat the eee sienne Bhai ata 22 4 3 Wiring of the PWM350 Module 22 4 3 1 Current Measurement Range sse 22 Table of Contents Table Of Contents 5 Operating the nit iue ei hana Pe a code al i cee te edd 23 5 MONO cu E 23 GEET EE EE 23 5 3 Auto Man and Stop mode seet 23 5 4 Spindle and Roll Mode a 25 5 5 Spindle expand MOC ssa au ecd im aii takiyuspa a Sakiyu taqata Qa 25 5 6 F1 Break Parameters wits reri ttt e e eee res atisqa kuyka nd 26 5 7 F2 Blunt Parameters e ete oe eta ter e AE GAEE RETE 27 5 8 F3 Missinig Paramet rs n ette tee eee e lr eroe 28 5 9 F4 Idle Parameters sick eine tert ether e nr ee eor n en ene 29 5 10 F5 Measurement Parameters AAA 30 5 11 F6 Miscellaneous Parameterg AAA 31 5 12 Stop Mode nei ee aee ette Ui rd e eite kids 32 Hal Si Leam GOMMANG BEE 33 EE ell ue WEE 34 5 15 Password ProtectiQn uui br a uqa e riter teen erro 35 6 Wiring of the PWM350 Module
9. active open condition until a reset is received Analog Zoom Function 3 4 Analog Zoom Function Prior to setting the monitoring parameters it is desirable to set up the Analog Zoom Function parameters The Analog Zoom Function enables the TECHNA CHECK Model 3200 to monitor even very small tools by focusing the unit s full analog to digital conversion resolution into a nar row band of power consumption To set the parameters it is most helpful to use the TMSMON support software see below Note that the Analog Zoom Function should be set up prior to set ting monitoring parameters as the monitoring parameters will be re scaled if changes are made to the Analog Zoom The current measurement range must first be set The current measurement range is set by hard wiring pins 4 and 5 on the PWM350 module see Appendix A for wiring diagram Once the current measurement range has been set then any large idle powers may be subtracted from the display by adjusting P1Min so that the idle is only 5 to 10 of the full load P1 Max may then be adjusted so that the cutting torque is a rise of 10 to 20 above idle Figure 2 shows a hypothetical application to highlight the power of the Analog Zoom Function In this application a 380 VAC three phase motor is being monitored If the Current Range is set to 10 A then 100 power is equivalent to 6 58 kW If a small tool with a high spindle speed is being used it is entirely possible that the idle po
10. are accessed by holding wiring inistake is eliminated SE own the mode and the arrow up key simultane SS Ext 200 1 159 ously for app 5 seconds The display returns to If however neg is selected then all negative meas Eason 199 normal mode by pressing the reset key or by no key ured power is set to zero Power becomes negative py soy 239 activation in app 20 seconds when a motor suddenly behaves as a generator Ext 400 1 319 Keyboard lock feature This is possible for instance when hoists or cranes Extsoo i 398 The display will be flashing between showing Loc lowers a large load Normally it makes no Sense U em T P and On Off Lock mode may be changed by the monitor the generator situation and a negative n arrow keys If the keyboard is locked it will be possi Measurement is set to zero in this mode In tool Ext 125 5 995 ble to view but not alter variables monitor applications this feature may be used to mc Power measurement option ignore spindle reversals A new Ts will be activated ext 2005 159 The display will be flashing between P and Abs When the motor start to run normally again The eee neg Absolute mode indicates the unit measures ina of an Wes ESCH via oF ee ipn match m Cm mp the numeric power value ie negative power is con IIS aro Satie Side Tape ln aie mode ot operator Ext 500 5 398 VM 100 Technical Specifications Ty TECHNA CHECK VM100 Vibration Interface Vibration Sensor Interface A measurement tran
11. measure the idle power before the tool begins cutting the part The idle power consumption Po is the portion of work done by the machine not going into the cut Idle power consumption will vary normally during the course of the day due to such factors as friction temperature oil and grease viscosity etc The idle power is calculated as an average of a number of power measurements taken over a user defined number of half electrical cycles in North America there are 60 electrical cycles per second The number of samples half electrical cycles used to calculate the idle power is user set as the value of Po Averaging Minimum and maximum values of Idle Power PoMin and PoMax may be set After the idle power measurement the tool monitoring becomes active The duration of monitoring may be limited through the use of the monitoring timers Ta and Tw in order to avoid monitoring undesired events such as motor speed changes In many cases these timers may be turned off allowing monitoring for as long as the start signal is present The TECHNA CHECK Model 3200 includes a user programmable Power Averaging feature which sets the number of individual power measurements which are averaged into one calculated value again the number of power measurements are related to the frequency of the supply power This averaging can be used to smooth very noisy electrical signals but it should be set as low as possible in order not to filter out very short
12. needs more en ergy to complete a machining cycle and when a tool breaks a short energy peak or spike is cre ated If no tool is present the power consumption drops back to the idle power of the spindle The TC3200 is designed to monitor motor power in the primary or secondary of a variable fre quency motor drive see the specification of the external measurement transducer PWM 325 It is also capable of storing 64 complete sets of monitoring parameters These features make it ideal for monitoring flexible transfer machines utilizing single spindle CNC heads The unit may be interfaced and operated from a PC through its RS232 or RS485 interface The TOOLMON application adds statistic features to the tool monitoring The function of the TOOL MON application is covered by a separate manual A vibration sensor VM100 makes it possible to monitor spindles for excessive vibrations also Key Benefits 2 Key Benefits Improved part quality The detection of missing or broken tools helps insure that the proper machining is being per formed Detection of tool wear and damage can help improve surface finish and tolerances Maximized tool life By detecting for tool wear and damage expensive tooling can be changed before the damage gets too severe This detection also reduces dependence on hit or miss part counting schemes Protection of spindle and feed mechanism By detecting catastrophic tool failures the TECHNA CHECK Model 3200 can preve
13. remains active for the duration of Tw if Tw is enabled If Tw is turned off Missing Tool supervision remains active the entire time the start signal is present following the Start Delay and the idle power measurement Figure 3 Tool Missing Absolute Mode P f t Tw 0 0 Off 999 9 Sec Leben Trm 0 1 25 0 Sec Consumption d Tool Missing limit ds an absolute U percentage gt Po lt Ts P wo Start Delay gt Po 0 Off 250 Samples t s Start Supervision Active In determining appropriate values for the Missing Limit and Missing Delay more aggressive moni toring can be achieved with higher Missing Limits and longer Missing Delays in other words for a good cycle the power must stay higher longer However setting these parameters too aggres sively can result in more freguent nuisance trips A good compromise and starting point for adjust ment seems to be to set the Missing Limit fairly low around 3 5 since if the tool is missing there will be NO rise above idle and to set a Missing Delay of about 3 4 of the total machining time Better results seem to be achieved by leaving the Missing Limit low and tuning out nuisance trips by adjusting the Missing Delay The Time Over Missing is displayed on the screen when no Missing Alarm is present This makes it easier to fine tune the setting of the Missing Delay Tool Missing
14. CHNA CHECK Model 3200 is designed to look for this rise in torque and to stop the machine when a tool has reached a point where it would be desirable to change it There are three Blunt Modes If Absolute Peak Mode is selected the detection of blunt tools is based on the value of the instantaneous torque measurement above idle In Work Mode the de tection of blunt tools is based on the area under the torque curve for the duration of the cutting cycle which is proportional to the work or energy used to cut the part Peak Mode is recom mended for most simple machining operations Work Mode may be used when there are multiple or changing load levels observed during the cycle such as when a step tool or complicated boring tool is used Additionally there are two Blunt Modes representing Learn versions of the two modes already described They allow the system to automatically adjust to changes in grind from one tool to the next In any blunt mode the use of the Show Statistics option from the TOOLMON software package is helpful in setting appropriate values for the Blunt Limit When a computer running TOOLMON is connected to the TECHNA CHECK Model 3200 it is continually keeping track of the peak torque or work used in each cycle This data may be viewed in the Show Statistics display This display will give you an idea over time of how the tool has worn and where an appropriate Blunt Limit may be set Also in any blunt mode the Blunt Count
15. G 24 Electrical Voltage Input 3 x 0 500 VAC VDC max Current Input 3 x 100 Amp 0 Hz 35kHz Power Range 0 86 5 kW AC 0 50 kW DC Supply 18 36 V DC max 2 0 Watt Analogue output 0 20mA 200 ohm isolated TC compatible Digital Inputs 10 30 VDC CE marked to TBD Range Select The measurement range is selected from 3 digitally iso lated inputs The inputs may be hardwired or controlled from a PLC S3 S2 S1 Range 0 0 0 1 0 0 24V 2 5 0 24V O 5 0 24V 24V 10 24V O 0 15 24V 0 24V 25 24V 24V 0 50 24V 24V 24V 100 0 is zero volt or open circuit no connection Features The PWM3100A is designed primarily for measuring AC or DC power or current delivered to motors by variable frequency inver ters AC power is measured from the formula P 43 x U x I x Cose DC power is measured from the formula P Uxl The PWM3100A Power or Current Transducer is specifically developed to function as a load transducer for the TECHNA CHECK Range of Machine Tool Monitors Three opto coupler isolated inputs allow the selection of 8 mea surement ranges 1 Amp 2 5 Amp 5 Amp 10 Amp 15 Amp 25 Amp 50 Amp and 100 Amp The transducer outputs a current of 0 20mA 200 ohm compatible to Techna Check TC3200 and Techna Check TC101 The three motor wires must pass through the external hall sen sors in the same direction to the motor either fromTop Bottom or from Bottom Up TECHNA CHECK is a registrer
16. Limit 0 100 0 Off Blunt Limit 101 999 Learn Work Mode 3 Blunt Delay s Blunt Delay 0 0 25 0 seconds Active only in Abs Peak and Learn Peak mode Blunt Count Blunt Count 1 15 cont Blunt Count 1 15 cont cycles 1 5 Blunt Duration s Blunt Duration EEN 0 999 9 seconds Off Blunt On Partt Enable Disable Blunt Parti Limit 100 1000000 1000000 F3 Missing Parameters 5 8 F3 Missing Parameters m 22 3 HHRHH St Da pI3 CUIB 112 43 74 bh 4 5 6 0 41 Drill 8mm ERR UNO Ge 3 7 8 9 2 E mu 0 op A a 9 Fn1 Fn2 Fn3 Station 1 Drill 8mm v 1 4 E A 1 Missing Mode 3 Missing Delay s gt 4 Missing Count v 5 Missing Tw s A parameter is selected by the arrow up and down keys The enter key may be pushed to acti vate the parameter When activated the arrow up and down key may be used to alter the vari able When the enter key is activated again the modification is made permanent The numerical keys may also be used to alter a variable The enter key or the arrow up down keys are used to make the change permanent Parameter 1 Missing Mode Absolute Learn Work 2 Missing Limit Missing Limit 0 99 0 Off 3 Missing Delay s Missing Delay 0 1 25 0 seconds Active only in Absolute mode 4 Missing Count Missing Count 1 15 cont cycles 5 Missing Tw s 0 0 999 9 seconds 0 0 Off F4 ldle Paramet
17. MODEL 3200 J Jj echna Tool Inc TOOL MONITORING SYSTEM MODEL 3200 La I ed ed ed B Vid s 106 1 Drill 8mm 75 50 25 S a ai Tool Monitoring System Technical Documentation Released August 2005 Contents Copyright 2003 2005 Techna Tool Inc Hartland Wisconsin USA The information in this document is subject to change without notice TECHNA CHECK is a registered trademark of Techna Tool Inc Table of Contents Table Of Contents 1 The ConGcept sii te das ta se AE eem eue Ree eae dee eee 5 E NEE EEN 6 GO e Diere EE 7 SEET ET H KREE 8 3 2 1 Learn Cycle Initiation Machine Controlled 8 3 2 2 Learn Cycle Initiation Face Plate sse 8 3 2 3 Learn Cycle Initiation OO MONN 8 3 3 Fault Signals and Resetting of Faute 8 3 4 Analog ZOOM FUNCION EE 9 3 5 Missing Tool Gupervielon u u aaa 10 3 5 1 Missing Tool Absolute Mode A 10 3 5 2 Missing Tool Learn Work Mode A 11 3 6 Tool Break SuperviSlON u uuu anu au kaq ayunarqa Qua ERAN br EEN 12 3 6 1 Break Mode S lection iet d eer tei td ee er RR etg 12 3 6 2 Tool Break Absolute Peak Mode 12 3 6 3 Tool Break Learn Peak Mode AA 13 3 6 4 Tool Break Absolute Peak Curve dan 14 3 7 Blunt Tool Supervision I enne 15 3 7 1 Blunt Mode Selection dan 15 3 7 2 Blunt Tool Absolute Peak Mode A 16 3 7 3 Blunt Tool Learn Peak Mode 17 3 7 4 Blunt Tool Learn Peak Mode
18. RMS Voltage RMS Current and PF Power Factor Peak Min capture for all variables Reset by key Power displayed in true kW Voltage Current and Power Factor dis played also Typical Installation In lt 25 Amp Note The wire that feeds through the UniGuard device must be the wire which connects to L3 L1 L2 L3 In 25A TECHNA CHECK PWM125 W Ave eU V e P1Max el A eP1Min ePF CT A KI i Techna Tool Inc The PWM125 measures true power for symmetrical 3 phase loads from the formula P Y3xUxlx Coso The PWM125 Power Transducer is specifically devel oped to function as a load transducer for the TECHNA CHECK Range of Machine Tool Monitors The Tool Monitoring application require very fast meas urement in order to be able to detect the breakage of a tool Averaging is programmable from 0 01 0 1 seconds but normally kept fixed at 0 01 seconds fastest measure ment TECHNA CHECK is a registrered trade mark by Techna Tool Inc Hartland Wisconsin USA Functional Ranges Mode Function Range kW kW Display measured U V Voltage Display measured A Current Display measured PF Power Factor Display measured Ave Averaging 0 01 0 1 Sec PiMax P1Max kW Limit P1Min Range 10 Range 100 PiMin P1Min kW Limit 0 0 PiMax Range 10 CT A Current Range See table on page 2 When a display mode other than kW is selec
19. able freguency inverter Ultra Compact DIN rail mount Less than 2 of rail space Current wires feeds through 3 holes in unit 3 internal 50 Amp current sensors Technical Specification Mechanical Housing Polycarbonate Mounting 35 mm DIN rail Protection Class IP40 Temp Range 15to 50 C Weight App 500g 1 Ib Dimensions D 118 x B 45 x H 137 5 mm Connections Max 2 5 mm AVG 24 Electrical Voltage Input Current Input 3 x 50 Amp 5Hz 5kHz or 3 x 25 Amp 5Hz 5kHz or 3 x 12 5 Amp 5Hz 5kHz see side label for actual range Power Range 0 48 3 kW Supply 18 36 V DC max 2 5 Watt Analogue output 0 20mA 0 400 ohm isolated Digital Inputs 10 30 VDC CE marked to EN50081 1 EN50082 2 EN61010 1 Measurement Ranges The measurement range is selected by hardwiring or PLC control of the two inputs S1 and S2 Range 3x50 Amp 3 x 25 Amp 3 x 12 5 Amp 100 43 3 kW 21 7 kW 10 8 kW 50 21 7 kW 10 8 kW 5 42 kW 20 8 66 kW 4 33 kW 2 17 kW 5 2 17 kW 1 08 kW 0 54 kw 3 x 0 500 V PWM 0 600V max The PWM350 is designed primarily for measuring the power delivered to motors by variable frequency invert ers Power is measured from the formula P 3x U xIx Coso The PWM350 Power Transducer is specifically devel oped to function as a load transducer for the TECHNA CHECK Range of Machine Tool Monitors The PWM350 is available as a 3 x 50 Amp 3 x 25 Amp or a 3 x 12 5 Amp transducer
20. and PWM350 are as shown in Ap pendix A The current measurement input on the unit is rated for motors with full load ratings up to the rating of the PWM350 module 4 2 2 Control Inputs All control inputs to the module are 24 VDC PLC inputs In cases where relay logic is used it may be necessary to set a Debounce Delay which will allow the system to ignore any bouncing of me chanical relay contacts at the inputs 4 2 3 Control Outputs Fault conditions are signaled to the machine by two sets of relay contacts In typical applications the Break Missing relay is wired to cause an immediate retraction of the machine head and the Blunt relay is wired to allow the machine to complete its current cycle before stopping the machine Because the outputs are relays they will wire into almost any machine control system whether it uses relay logic or a PLC It should be noted that the output relays will be open when the unit is not powered 4 3 Wiring of the PWM350 Module For proper operation of the system it is important that the PWM350 be set up properly Incorrect settings of Current Measurement Range may severely reduce the functionality of the system 4 3 1 Current Measurement Range The current measurement range is set by applying 24 VDC input signals to pins 4 and 5 according to the logical diagram shown in Appendix A The appropriate measuring range is selected by de termining the Full Load Amps FLA of the motor which should be marked o
21. arp short duration spike of torque in the motor This torque spike is the extra energy being used by the machine to actually break the tool The TECHNA CHECK Model 3200 can detect this spike and indicate a broken tool It should be noted that not all tools break the same way every time and that a torque spike may not necessarily be generated in the process of breaking the tool In this case a missing tool condition should be noticed on the following cycle There are three Break Modes available Absolute Peak Mode Absolute Peak Curve Mode and Learn Peak Mode which are described below 3 6 2 Tool Break Absolute Peak Mode Figure 5 shows a typical tool break situation including the setting of the tool Break Limit The Break Limit is a user defined percentage increase above the Idle Power If the Break Limit is ex ceeded for a cumulative time greater than the user defined Break Delay Trb then a tool break fault will be generated In the event of a broken tool fault a red 1 will appear in the broken window and the particular station number will flash red Tool Break supervision remains active for the dura tion of Tw if Tw is enabled If Tw is turned off Tool Break supervision remains active the entire time the start signal is present following the Start Delay and the idle power measurement Figure 5 Absolute Peak Break Mode P f t Ta 0 0 Off 999 9 Se I Trb 0 0 25 0 sec gt Po S lt a Br
22. cal keys may also be used to alter a variable The enter key or the arrow up down keys are used to make the change permanent Parameter Range 1 PlMax PlMax P1Min 10 100 Measurement zoom function 2 P1Min P1Min 0 P1Max 10 Measurement zoom function 3 Averaging 1 10 samples Keep as low as possible 4 Po Avging Samples 0 250 samples 0 Off no Po measurement Backlight On Period 15 Minutes 30 Minutes 1 Hour 2 Hour 0 100 0 Off Touch Point Not Enabled F6 Miscellanous Parameters 5 11 F6 Miscellaneous Parameters zu ES ES STT EL H Ha 4 5 6 EX CI Ge 7 8 9 mim Nu ECH 03 773 EG Fni Fn2 Fn3 Station 1 Drill 8mm v 1 4 A Drill 8mm lt gt Start Signal Mode Level Signal Start Signal Length Start Delay s Duration Ta s Relay Arm Disarm A parameter is selected by the arrow up and down keys The enter key may be pushed to acti vate the parameter When activated the arrow up and down key may be used to alter the vari able When the enter key is activated again the modification is made permanent The numerical keys may also be used to alter a variable The enter key or the arrow up down keys are used to make the change permanent Parameter Range 1 Language English English or German available DEE 3 Start Signal Mode Level Signal Strobe Signal Pulse Start Signal length 0 0 999 9 seconds O
23. duration power surges caused by tooling problems The TECHNA CHECK Model 3200 includes a unique Analog Zoom Function which greatly improves the monitoring of small tools Refer to the section on Analog Zoom Function for details Function The TECHNA CHECK Model 3200 is capable of monitoring 64 completely different cutting opera tions This feature is useful when making multiple machining passes with the same machine head or when making several different parts on the same machine Prior to the Start Signal being re ceived the machine signals the unit with six input signals Cut Select which cause the appropri ate parameters to be used in monitoring the subsequent machine operation 3 2 Learn Signal For each type of monitoring Missing Break and Blunt there are one or more Learn modes available The Learn modes allow the monitoring to change to take into account variations in tool grind from one tool to the next In most applications when using Learn modes a Learn cycle should be initiated whenever the tool is changed A Learn cycle may be initiated in three ways as described below It should be noted that during a Learn cycle only Idle Power monitoring is taking place 3 2 1 Learn Cycle Initiation Machine Controlled A Learn cycle may be initiated by the machine controller If the Start signal is made active while the Reset signal is being held active the cycle will be a Learn cycle If an Idle Power fault would occur du
24. eak limit SA EAK eege m apas s 1 100 be o Les o O lt Ts _ Start Delay 1 P P lt OOF 250 Samples t s Start Supervision Active Break alarm Reset I1 In setting the Break Limit and Break Delay more aggressive monitoring is achieved by setting a lower limit and shorter delay However setting these parameters too aggressively will result in in creased nuisance trips In typical applications the Break Limit is set fairly high between 20 and 30 but with a very short Break Delay often the minimum 0 01 second When a tool break oc Curs the rise in torque is often quite dramatic so a high limit and short delay are best to eliminate nuisance faults Tool Break 3 6 3 Tool Break Learn Peak Mode Figure 6 shows a typical tool break situation including the setting of the tool Break Limit in Learn Mode The Break Limit in Learn Mode is a user defined percentile increase of the power consump tion above the Idle Power PLUS the Learned peak power If the Break Limit is exceeded for a cu mulative time greater than the user defined Break Delay Trb then a tool break fault will be gener ated In the event of a missing tool fault a red 1 will appear in the missing window and the particu lar station number will flash red Tool Break supervision remains active for the duration of Ta if Ta is enabled If Ta is turned off Tool Break supervision remains ac
25. ed trade mark by Techna Tool Inc Hartland Wisconsin USA Using the PWM3100A The operating mode is selected from a dip switch located at the top of the unit A small screw driver must be used to access the individual dip switches Offset Zeroing Offset zeroing is a function that calibrates the Hall Sensors to the unit Offset zeroing must be done once after the Hall Sensors are connected and the spindle motor is NOT running The offset button must be activated for 5 seconds and the green on led flashes for 5 seconds during the offset adjustment Calibration values are maintained after power off saved in EEPROM Dip Switch No 1 2 Off Off Default Operating Mode This is the default AC measurement mode The PWM3100A measures the current frequency and uses this a time base for the measurement The measurement speed and reaction speed of the unit increases as the spindle speed increases This mode cannot be used in DC measurement mode Dip Switch No 1 2 On Off Fixed measuring interval 10 ms millisecond May be used in both AC and DC mode Dip Switch No 1 2 Off On Fixed measuring interval 25 ms millisecond May be used in both AC and DC mode Dip Switch No 1 2 On On Fixed measuring interval 100 ms millisecond May be used in both AC and DC mode Dip Switch No 3 Off 3 Phase Measurement Default On 1 Phase Measurement 1 Phase measurement is usually used with DC measurement Only phase L1 U must be con
26. en On Off LED will be flashing 5 2 Station Select Station 1 2 Select 13 4 The 4 station select keys are used to select the station which will be displayed If a channel is not hardware activated not present it cannot be selected There also is a button for selecting a dis play of all channels simultaneously Some of the actions that are carried out from the keyboard require a single station to be displayed The Reset command can only be issued while a single station is selected while the reset will only apply to the currently displayed channel The same is true for the Learn command and the Parameter Modify command 5 3 Auto Man and Stop mode select In Auto mode the display follows the current operation cycle of the machine tool When the ma chine selects a new tool cut the display Automatically displays this cut In manual mode the user is allowed to select display and alter other cuts rather than the currently active cut When Manual mode is selected the bottom half of the display is used to select the cut Manual mode LER ER ER EC e oo oe eo F2 Sag 13 Blunt 50 25 Cut 08 Cut 16 Cut 09 Cut 17 Cut 10 Cut 18 F5 Cut 11 Cut 19 Cut 12 Cut 20 Cut 13 Cut 21 Cut 14 Cut 22 Cut 15 Cut 23 lt In Manual mode the arrow keys are used to select a cut As soon as a cut is selected its last pro file is displayed in the spindle window in the upper half of t
27. er feature is available In order to reduce the number of undesired nuisance trips the Blunt Counter may be set to require a number of consecutive blunt tool faults to be detected before the machine is signaled to stop For example a hard part or tem porary chip build up may cause a blunt fault to occur in one cycle but the condition may not be present again in the next cycle In this case a Blunt Counter setting of for example three would require this condition to occur three cycles in a row before a blunt trip stops the machine In typical applications a Blunt Counter setting from 2 to 5 is generally used depending on material consis tency and chip build up but higher settings may be used Tool Blunt 3 7 2 Blunt Tool Absolute Peak Mode Figure 8 shows a typical blunt tool situation using Absolute Peak Mode monitoring including the setting of the tool Blunt Limit The Blunt Limit is a user defined percentage increase above the Idle Power If the Blunt Limit is exceeded for a cumulative time greater than the user defined Blunt Delay Trs then a tool blunt fault will be generated In the event of a blunt tool fault a red number will appear in the blunt window and the particular station number will flash red Blunt Tool supervi sion remains active for the duration of Tba if Tba is enabled If Tba is turned off Blunt Tool super vision remains active the entire time the start signal is present following the Start Delay and the idle powe
28. ercentage increase over the Learned Work note that the Blunt Delay becomes inactive in Work Mode In the event of a blunt tool fault a red number will appear in the blunt window and the particular station number will flash red Blunt Tool supervision remains active for the duration of Tba if Tba is enabled If Tba is turned off Blunt Tool supervision remains active the entire time the start signal is present following the Start Delay and the idle power measurement Because Work Mode monitoring calcu lates total energy used in the entire cycle any faults will always be signaled at the end of the cy cle Figure 10 Learn Work Blunt Mode P f t Ta 0 0 Off 999 9 Sec s Tba 0 0 Off 999 9 Sec o S E D S Blunt limit 8 101 999 gt Learn Work lt Ts _ gt Start Delay EG P lt gei 250 Samples t s Start Supervision Active Blunt alarm Reset I1 Setting the Blunt Limit in Learn Work Mode is much the same as setting the limit in regular Work Mode The Learn feature gives the system the ability to adjust monitoring for differences in tool grind from one tool to the next Tool Blunt 3 7 5 Blunt Tool Blunt On Part Count Each cut is counted by the TC3200 This part count may even be used to generate a Blunt Alarm The number of parts to generate a Blunt Alarm is programmable form the fr
29. ers 5 9 F4 Idle Parameters I ER mE 9 lt 15 1 EL 3200 oa gan em 2 3 AER Ws m SR 6 ENS LN Gas 7 8 9 Hm emm a Parti o4 69 Fni Fn2 Fn Station 1 Drill 8mm v 1 4 A 1 Idle Max Limit A parameter is selected by the arrow up and down keys The enter key may be pushed to acti vate the parameter When activated the arrow up and down key may be used to alter the vari able When the enter key is activated again the modification is made permanent The numerical keys may also be used to alter a variable The enter key or the arrow up down keys are used to make the change permanent Parameter Range 1 Idle Max Limit Idle Max Limit 0 100 0 Off 2 Idle Min Limit Idle Min Limit 0 100 0 Off F5 Measurement Parameters 5 10 F5 Measurement Parameters D PE ES TTT H uto GR 4536 ES ID Gs 7 8 9 EB uu 838 02 Em Fni Fn2 Fn3 Station 1 i Drill 8mm v 1 4 1 PlMax 2 P1Min 0 lt gt i3 Averaging Samples 1 4 Po Avging Samples 10 v 5 Show Reference Curve On 6 Backlight On Period 15 Minutes 7 Touch Point Limit 0 lt A parameter is selected by the arrow up and down keys The enter key may be pushed to acti vate the parameter When activated the arrow up and down key may be used to alter the vari able When the enter key is activated again the modification is made permanent The numeri
30. f a step limit is set to zero it is not monitored at all Figure 7 Absolute Peak Curve Mode P f t Ta 0 0 Off 999 9 Seg Trb 0 0 25 0 se gt FO s 7 7 Break limit 3 step curve E 0 Off 100 2 0 c O O 4 S gt Start Delay F E OOt 250 Samples t s Start Supervision Active Break alarm Reset I1 In setting the Break Limit and Break Delay more aggressive monitoring is achieved by setting a lower limit and shorter delay However setting these parameters too aggressively will result in in creased nuisance trips In typical applications the Break Limit is set fairly high between 25 and 50 but with a very short Break Delay often the minimum 0 01 second When a tool break oc curs the rise in torque is often quite dramatic so a high limit and short delay would be best to eliminate nuisance faults Note This mode may well be used to monitor threading operations The first step is used to moni tor the forward threading and the middle step is set to zero while the direction of the tool changes and the last step is then used to supervise the reverse threading pulling the threading tool out of the part Tool Blunt 3 7 Blunt Tool Supervision 3 7 1 Blunt Mode Selection As a tool wears it is normal for its cutting surfaces to become less efficient and thus it requires more torque to cut the part The TE
31. from the network When Us ing the RS232 port on the side to program the unit it requires a straight through RS232 cable to communicate We recommend not using a USB to RS232 adapter If your computer does not have a com port on it we suggest using a Siig Single Serial PC card part JJ PCM012 WE have found that most of the USB to RS232 adapters will not work with the Techna Check Appendix H Panel Cut Out Profile 298 mm 285 mm 153mm 233 mm 220 mm
32. he screen If a Parameter key is acti vated the parameter for the cut selected may be viewed or modified In manual mode it is possible to display the LAST ALARM cut also Spindle and Roll mode 5 4 Spindle and Roll mode LH EQ ad El 2 kri E 41 Drill 8mm 75 50 25 oe The R key is used to select this display mode The bottom of the screen shows all measurement in a Rolling fashion This display may be used when analyzing if the start signal appears at the right point The rolling may be stopped and started again by two keys on the panel 5 5 Spindle expand mode 2 prp 1 Drill 8mm The S key is used to select this display mode The whole screen displays the current cycle zoom mode F1 Break Parameters 5 6 F1 Break Parameters 1 2 3 m A St fStfSt St HI EUIS Ga CB a Ad 2 eo GA 41 Drill 8mm ES GS GI 100 7 en 8 US Gs OF 38 so A Fni Fn2 Fn3 1 Break Mode Break Limit lt gt Break Limit Break Point Break Point Break Delay lt A parameter is selected by the arrow up and down keys The enter key may be pushed to acti vate the parameter When activated the arrow up and down key may be used to alter the vari able When the enter key is activated again the modification is made permanent The numerical keys may also be used to alter a variable The enter key or the arrow up down keys are used to make the change permanent
33. ital inputs S1 S2 S3 8 S4 Appendix A Interface to 3 Phase Transducer PWM350 Frequency Inverter example 1 1 phase fed Frequency Inverter example 2 3 phase fed Measurement Transducer Current measuring range E r 1 2 3 14516 78 910 E 24V t Gnd Sgnd S2 S1 Shielded cable earth connected at one end Digital In Common Cut Select 6 Cut Select 5 Cut Select 4 ut Select 3 Cut Select 2 Cut Select 1 Reset Learn Start H Break Output 1 2 3 4 5 6 7 8 9 to 1t 12341516 OH H N TC 3200 Station 1 2 3 4 1 2 3 4 5 6 24 V DC 24 Earth Rs485 Shield A RS485 Note Earth connected to housing inside TC3200 Appendix B Interface to Single Phase Transducer PWM 125 Note The wire that feeds through the UniGuard device mustbe the wire which connects to L3 PWM125 PWM125 L1 L1 3 L2 L3 L2 L3 In lt 25A In gt 25A Digital In Common Cut Select 6 Reset Learn Start Shielded cable earth Break V M Output ut L at one end 1 2 3 4 5 6 7 8 9 tO t1 12 13 14 15 16 17 18 GH H TC 3200 Station 1 2 3 4
34. may be activated from the dip switches no 1 and 2 on the front When the filter is activated higher frequency vibrations are suppressed The dip switch no 3 and 4 are reserved for future use Sw1 Sw2 Function Off Off No low pass filter On Off 100 Hz low pass filter Off On 500 Hz low pass filter On On 1000 Hz low pass filter The VM100 interfaces a propriety acceleration sensor to the existing TECHNA CHECK range of Machine Tool Monitors The purpose of the vibration monitoring is to catch for instance the damage of a tool like for instance a miller which has damaged one of its inserts When one insert is broken the next insert is forced to cut twice the amount of material which will generate machine vibrations to be picked up by the VM100 The VM100 has 4 measurement ranges which can be selected from two opto coupler isolated inputs A green LED on the front will show which range is selected The green LED will be flashing at a low frequency to signal the internal microprocessor is alive and operating The VM100 has 4 RMS Averaging periods which can be selected from two opto coupler isolated inputs The transducer outputs a current of 0 20mA pro portional to vibration which is galvanically isolated from the measurement system TECHNA CHECK is a registrered trade mark by Techna Tool Inc Hartland Wisconsin USA Connection 1 2 3 4 5 6 7 8 9101112 Acc Acc Earth 1 S2 S3 S4 Sgnd Gnd 24V lout lout Dig
35. n the motor housing Then the percentage of the rating of the PWM350 should be calculated For example when using a motor with an FLA rating of 5 Amps with a PWM350 rated at 25 A the percentage of the PWM350 rating would be 20 In this case the 20 range on the PWM350 would be used In cases where the percentage does not exactly correspond to one of the current ranges on the unit the next larger range should be used It should also be noted that it is permissible to use external current transformers CT s in cases where the motor current is above the rating of the PWM350 As an example if it were desired to monitor a motor having an FLA of 100 Amps a 20 1 current transformer might be employed Since the CT has a ratio of 20 1 the maximum current on its secondary would be 5 Amps Applying the example above the current measurement range would be set to 2096 Operating the unit 5 Operating the unit 5 1 On Off key e On Off The On Off key may be used to switch the display On Off only if the machine is not running If the display is turned off it will be switched on again as soon as one of the stations is activated start signal active A parameter Backlight On Period is used to program how long the display will stay on after the start signal has been removed or a key has been activated Switching off the display when the machine is not running increases the lifetime of the display When the display is switched off black the gre
36. nected Dip Switch No 4 Off Power Measurement Default On Current Measurement When power is measured after a variable frequency inverter a certain amount of noise is introduced The noise comes from the high frequency voltage switching PWM Voltage In some applications the noise can be eliminated by measuring current only Measuring current after a frequency converter often has similar sensitivity as power measurement but the noise is sig nificantly reduced The current measurement may be used for monitoring smaller dimension tools When current is measured the voltage connection terminals 1 2 and 3 are not used and may be left open 3 Phase AC Connection with Frequency Inverter Red Wire White Wire Shield Red Vite Chiedi Fed 1 MAE i V s Shielded cable earth connected at one end O S1 S2 S3 Sgnd ILM Analog Out 24V 24V Gnd PWM 350 Technical Specifications 6 2 PWM350 Technical Specifications ig TECHNA CHECK PWM350 Load Transducer Power Transducer for 3 phase Inductive Loads A fast measurement transducer specifically developed for Machine Tool Monitoring applications PWM350 measures motor power kW Analog Output 0 20 mA reflecting power 4Programmable Measurement Ranges Analogue Design 4 guadrant analogue multiplication Measures power after vari
37. nly used in strobe signal mode Start 5 Start Delay s 5 Start Delay s 0 0 25 0 seconds 0 25 0 seconds ferent ct ens saras D S Relay Arm Disarm Armed Disarmed The Cut name has a maximum of 14 characters Letters are entered by first pressing a Fn1 Fn2 or Fn3 key followed by a numerical key Arrow right is the space character and arrow left is the delete key Stop Mode 5 12 Stop Mode te i 2 el ea cs EH Eg Cute 0 AAA vvv Fn1 Fn2 Fn3 When stop mode is selected the current cut is latched in the window and only updated at the end of the cut cycle When stop mode is selected the limits may be changed by the arrow keys in the upper right corner If step curve is selected the stepto modify is selected by the three function keys Fn1 Fn2 and Fn3 Learn Command 5 13 Learn Command Tt st St fSt St l2 ai gt 5 2 Eee CT 108 15 50 Station 1 Drill 8mm 1 Drill 8mm Use Arrow Keys to Change Mode The learn command is used to cause the station selected to learn a cut It is possible to learn the current cut or to learn all cuts Reset Command 5 14 Reset Command ri StISt8IStISt PP mz 5 gt 2 Eck T 1 Drill 8mm 75 50 25 Reset Station 1 An alarm is signaled by a flashing station number The reset command resets the alarm on the selected station Password Protection 5 15 Password Protection LL ga Auto 1 Drill 8mm
38. nt ranges on the unit the next lar ger range should be used It should also be noted that it is permissible to use external current transformers CT s in cases where the motor current is above the rating of the PWM350 As an example if it was desired to monitor a motor having an FLA of 100 Amps a 20 1 current transformer might be employed Since the CT has a ratio of 20 1 the maximum current on its secondary would be 5 Amps Applying the example above the current measurement range would be set to 20 Big recuna cueck PWM3100A Load Transducer Load Transducer for 1 or 3 phase AC amp DC Loads An ultra fast measurement transducer specifically developed for Machine Tool Monitoring applications PWM3100A measures motor power kW or motor current A Analog Output 0 20 mA reflecting power or current 8 Programmable Measurement Ranges 1 2 5 5 10 15 25 50 or 100 Amp Digital Design 4 quaarant digital multiplication Measures power or current before or after variable frequency inverter Ultra Compact DIN rail mount Less than 2 of rail space External Hall Sensor s for Current Measure ment 1 or 3 external 100 Amp custom designed current sensors Hall Effect Sensors Technical Specification Mechanical Housing Polycarbonate Mounting 35 mm DIN rail Protection Class IP40 Temp Range 15 to 50 C Weight App 250g Dimensions D 118 x B 45 x H 137 5 mm Connections Max 2 5 mm AV
39. nt serious damage to your head and feed mechanisms not just at the station being monitored but at down stream stations where chain reaction effects can occur Improved up time By creating the process improvements listed above TECHNA CHECK Model 3200 keeps your machine running longer Easy installation No mechanical modification of the machinery is necessary The entire system mounts easily in your electrical cabinet Function 3 Function 3 1 General Figure 1 shows typical power consumption on a machine spindle during a machining cycle The first power peak which is caused by a change in motor speed or a motor start is not monitored at all Only the portion of the cut where the spindle speed is constant and the tool is actually in cut is monitored by the unit When the machine head begins to move towards the part a Start Signal is generated by the machine which tells the TECHNA CHECK Model 3200 that a new cycle is beginning When the unit receives the start signal the green Start LED is illuminated and the user defined Start Delay Ts is activated Figure 1 Function Ta 0 0 Off 999 9 Seg Break limit Consumption Missing limit Measurement Idle consumption i i Po i 0 Off 250 samples Start Supervision Active 4 Ts Start Delay t s When the start delay ends the unit initiates the idle power measurement It is very important to
40. ont see Blunt Menu or from the TOOLMON application The Blunt On Part function must be enabled as well 3 7 6 Blunt Tool Resetting the Part Counter The part counter is reset to zero when a new learn is done The part counter may also be set to zero from the TC3200 front When no Alarm is present the Reset Button is used to reset the part counter Same function in TOOLMON If no alarm is present the Reset Alarm is used to reset the part counter Idle Monitoring 3 8 Idle Limit Supervision In some applications it may be necessary to check that the machine idle power is within certain boundaries For example a very low idle power may indicate that a belt is broken or that there is no power to the motor A very high idle power may also indicate belt problems or problems with lubrication or bearings In these cases a high and low limit IdleMax and IdleMin for the idle power may be set After the idle power is measured and Po is calculated the value is compared with Idle Max and IdleMin If it is not within the limits then a Tool Break fault occurs immediately Each of the Idle Power Monitoring limits may be disabled by turning them all the way down to zero Figure 11 Idle Limits EC Idle Limit i 1 100 Absolute Consumption J Idle Min Limit al SUE E 1 100 Absolute Ts Start Delay L ve Po gt 0 08 250 Samples t s Start Supervision Active Break rela
41. r measurement Figure 8 Absolute Peak Blunt Mode Ta 0 0 Off 999 9 Se Tba 0 0 Off 999 9 Sec Trb 0 0 25 0 sec lt 4 Blunt limit 1 100 gt Po Consumption enone lt To Start Delay P lt 0 Off 250 Samples t s Start Supervision Active Blunt alarm Reset I1 In setting the Blunt Limit and Blunt Delay more aggressive monitoring is achieved by setting a lower limit and shorter delay However setting these parameters too aggressively will result in in creased nuisance trips As a tool wears the load will gradually increase and will eventually stay at a higher level for the entire duration of the cut In typical applications the Blunt Limit is set fairly low between 10 and 25 but with a fairly long Break Delay often around 75 of the total dura tion of the cut Adjustments are then made based on data from the Show Statistics display usu ally leaving the Blunt Delay alone but changing the Blunt Limit Tool Blunt 3 7 3 Blunt Tool Learn Peak Mode Figure 9 shows a typical blunt tool situation using Learn Peak Mode monitoring including the set ting of the tool Blunt Limit The Blunt Limit is a user defined percentile increase above the Idle Power PLUS the Learned Peak If the Blunt Limit is exceeded for a cumulative time greater than the user defined Blunt Delay Trs then a tool blunt fault will be generated In
42. ring the Learn cycle the reset signal must be taken low then brought back high again to reset the fault 3 2 2 Learn Cycle Initiation Face Plate A Learn cycle may be initiated from the keyboard on the face plate of the unit With the system not password protected the learn key is pressed once The display shows press enter to learn cur rent cut To initiate the Learn cycle the enter key is pressed The next cycle will be a Learn cycle 3 2 3 Learn Cycle Initiation TOOLMON A Learn cycle may be initiated from the TOOLMON software package by pressing the appropriate function key 3 3 Fault Signals and Resetting of Faults All faults generated by the TECHNA CHECK Model 3200 are signaled to the machine controller by normally closed dry contact relays refer to the section on Electrical Connection The Tool Break and Tool Missing faults share a common relay It is typical that the machine will be pro grammed to stop its present cycle immediately and retract the machine head on detection of a Tool Missing or Tool Break condition The Blunt Tool fault is signaled by a second relay It is typi cal that the machine will be programmed to finish the current cycle before stopping the machine on a Blunt Tool fault All faults may be reset by using the RESET button located on the front panel of the unit or through the use of the external Reset input refer to the section on Electrical Connection The fault relays will remain in their
43. sducer which provides Vibration Monitoring for the TECHNA CHECK units TC3200 TC6400 and TC101 VM100 measures vibration acceleration Analog Output 0 20 mA reflecting vibration 4 Programmable Measurement Ranges 4 Programmable RMS averaging periods Programmable low pass filter Technical Specification Mechanical Housing Polycarbonate Mounting 35 mm DIN rail Protection Class IP40 Temp Range 15 to 50 C Weight App 300g 1 Ib Dimensions D118 x B 45 x H 137 5 mm Connections Max 2 5 mm AVG 24 Electrical Sensor Input Vibration Range Proprietory sensor with unit 0 5G 0 1000 Hz Supply 18 24 V DC max 2 5 Waitt Analogue output 0 20mA 0 400 ohm isolated Digital Inputs 10 30 VDC Measurement Ranges The measurement range are selected by hardwiring or PLC control of the two inputs S1 and S2 Small tools usually generates small vibrations and one of the low ranges must be used Range 100 50 20 5 MaxG 0 5G_ 0 25G 0 1G 0 01G 1 Open 2 Open Open RMS Averaging Period The RMS averaging period is selected by hardwiring or PLC control of the two inputs S3 and S4 25 ms millisecond averaging will do well for most cases If the vibrations are of very low frequency 100 ms may be selected and for higher frequencies a value less than 25 ms may be selected Time 100ms 25ms 10ms 1ms S3 Open Open S4 Open Open Low Pass Filter A low pass filter
44. ted the display returns to kW mode after no key has been activated for app 8 seconds PWM 125 Technical Specifications Technical Specifications Electrical Voltage Range s Typical Installation In gt 25 Amp See unit side label for actual range 3 x 220 x 380 x 440 x 460 x 575V Internal max 25 A External N 1 or N 5 converter Note The wire that feeds through the UniGuard device mustbe the wire which connects to L3 Current Range EI Cos p Range 1to 1 i2 7 p Frequency Range 50 60 Hz L3 Consumption Supply voltage measurement voltage 1 VA Analogue Output 0 20 mA 0 400 Ohm Mechanical Housing Polyamide 6 6 FR Light Gray RAL 7035 Mounting Snap on for 35mm DIN rail mounting Protection Class IP40 DIN VDE 0470 UL94 V 0 house P20 connector Terminals Green RAL 6018 6 5 mm wire stripping length 7 5 AWG 2 5 mm wires max Int CT Wire Hole Op Temp Range 21 AWG 7 mm wire max 5 to 122 F 15 to 50 C Weight 1 2 Ib 0 25 kg Dimensions D 2 95 x B 1 02 x H 4 37 In gt 25A PES D 75 x B 26 x H 111 mm Int 3 2 39 CE mark to EN50081 1 EN50082 2 EN61010 1 wm Generally Int 6 4 78 The power measurement principle is based on digital sampling 4 quadrant multiplication and integration m SE summing of the power in every half period 10 ms at 50 Hz or 8 33 ms at 60 Hz The sampling freq
45. the event of a blunt tool fault a red number will appear in the blunt window and the particular station number will flash red Blunt Tool supervision remains active for the duration of Tba if Tba is enabled If Tba is turned off Blunt Tool supervision remains active the entire time the start signal is present follow ing the Start Delay and the idle power measurement Figure 9 Learn Peak Blunt Mode Ta 0 0 Off 999 9 Sec Toa 0 0 Off 999 9 Sec Trb 0 0 25 0 seg Blunt limit 1 11007 A gt Po Learn Peak v Consumption 4 Is Start Delay 1 gt P 1 i gt lt 0 Off 250 Samples t s Start Supervision Active Blunt alarm Reset I1 Setting the Blunt Limit and Blunt Delay in Learn Peak Mode is much the same as setting them in regular Peak Mode The addition of the Learn function means that the monitoring limit will auto matically adjust for variations in grind from tool to tool Tool Blunt 3 7 4 Blunt Tool Learn Work Mode Figure 10 shows a typical blunt tool situation using Learn Work Mode monitoring including the setting of the tool Blunt Limit The work or energy consumed during the cutting cycle is propor tional to the black area in the Figure The Blunt Limit is a user defined percentage increase above the Learned Work A fault is generated if the measured work exceeds the p
46. tive the entire time the start signal is present following the Start Delay and the idle power measurement Figure 6 Learn Peak Break Mode P f t Ta 0 0 Off 999 9 Sec Trb 2 0 0 25 0 sec X Break limit Se 131 00 gt Po Learn Peak Y Consumption 4 Ts gt Start Delay pr lt Po O Off 250 Samples t s Start Supervision Active Break alarm i x Reset I1 Setting the Break Limit and Break Delay in Learn Mode is much the same as in the Absolute Peak Mode except that the Break Limit in Learn Mode will move with respect to the learned cut This adaptation allows the unit to adjust to changes in grind from one tool to the next when the profile is re learned Tool Break 3 6 4 Tool Break Absolute Peak Curve Mode The Absolute Peak Curve mode works just like Absolute Peak Mode sec 3 6 2 but the limit changes in a step fashion as a function of time This mode may well be used to supervise step tools If the Break Limit is exceeded for a cumulative time greater than the user defined Break De lay Trb then a tool break fault will be generated Tool Break supervision remains active for the entire time following the Start Delay and idle power measurement that the Start Signal is present on the unit if monitoring timer Ta is turned off or for the duration of Ta if it is enabled Three steps are available and i
47. uency qs 7 17 at 7 2 kHz is well higher than many professional power measurement devices This guaranties true power _Int 10 7 97 measurement also for not sine shaped loads such as the loads generated by variable frequency inverters int 11 8 76 and soft starters The PWM125 must always be mounted before variable frequency drives and soft starters int 12 9 56 input side Int 13 10 4 Programming Int 14 12 The PWM125 is programmed by the use of only three keys located on the front panel The Mode key is H ke eg used to select display values or one of 4 programmable parameters When a parameter is chosen the mme BE value may be altered by the use of the arrow keys Se qua Measurement Ranges Int 19 151 The PWM125 has a built in converter that works up to 25 Amp One of 25 internal current ranges may be nt 20 15 9 selected or one of 20 external converters Current up to 75 Amp is measured in order to ensure correct ns Aer measurement of non sine shaped loads The table on the right side of this page show the power range in n kW for all possible CT A ranges The kW range is displayed when both arrow keys are activated and the SC display shows kW or kW The power range is calculated from the formula Int 25 199 Pmax Unom x CT A x V3 Ext 50 1 39 8 Ext 75 1 59 8 Advanced Options verted to positive In this mode the direction of the Ext 1001 797 wire through the unit CT has no impact thus a Ext 125 1 99 6 a advanced options
48. wer may be as high as 50 of the scale while the cut ting torque may only rise 2 or 3 In order to maximize the ability to monitor this application P1Min is Zoomed to 50 while P1Max is Zoomed to 60 The entire resolution of the unit is now concentrated in a 10 band The unit is now only monitoring between 3 29 kW and 3 95 kW The cutting torque will appear to be 10 times bigger Figure 2 Analog Zoom Function P1Max 100 6 58 kW P1Max 60 3 95 kW 60 7 50 P1Min 0 0 kW Bus P1Min 50 3 29 kW Before Zoom After Zoom Tool Missing 3 5 Missing Tool Supervision 3 5 1 Missing Tool Absolute Mode Figure 3 shows how the missing tool detection absolute mode is set up relative to a typical ma chining cycle The Missing Mode parameter 5 defines the type of Missing Tool Limit which will be set In the Absolute mode the Missing Tool Limit is a user defined absolute torque rise above idle The power consumption during the machining cycle must remain above the limit for a cumula tive time longer than the Missing Delay Trm Note that the cumulative nature of this measure ment means that brief power dips below the Missing Limit will not cause a fault as long as the TO TAL amount of time spent above the Missing Limit is greater than the Missing Delay In the event of a missing tool fault a red 1 will appear in the missing window and the particular station number will flash red Missing Tool supervision
49. y Touch Point Limit 3 9 Touch Point Limit Function Relay 3 output may be used as a touch point indication If a Touch Point Limit greater than zero has been programmed the relay no 3 contacts are closed when the power consumption reaches a threshold equal to Po Touch Point Limit The relay 3 contacts are released again when the start signal is removed This function may be used in some systems to tell the tool feed mechanism that a tooling opera tion has begun and the feed rate needs to be decreased The tooling cycle may be shortened if a different faster feed rate can be used until the tool touches the target Figure 12 Touch Point Limit P f t i__Ta 0 0 Off 999 9 Sec Consumption Touch Point Limit 1 100 gt Po NA 77 hana gt Po gt O Off Ts Start Delay 250 Samples t s Supervision Active Start Touch relay Installation Notes 4 Installation Notes 4 1 Mechanical Mounting The TECHNA CHECK Model 3200 mounts simply through the electrical cabinet or an optional enclosure can be supplied The PWM350 module mounts inside the electrical cabinet using stan dard 35mm DIN rail It is typical to mount this unit directly beneath the motor drive or starter since the motor cables are routed through the holes in the unit 4 2 Electrical Connection 4 2 1 Power Electrical connections to the TECHNA CHECK Model 3200
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