RC4000 Manual.qxd - Gordon Engineering Corp.
Contents
1. B Gsi dsn nttp Www gordoneng com revision date 05 17 01 Series Reel Control Systems Installation Operation and Applications aa call toll free in the US 1 800 315 9233 RC4000 Series Warranty Five Year Warranty This product will be repaired or replaced for five years from the date of purchase if it fails to perform to published specifications The product must be used in accordance with the specified manufacturer s ratings and must not be physically abused All questions related to this warranty should be directed to the Sales Dept of Gordon Engineering Corp See the contact information below for address phone fax and email Contact Information Product Information Distributor Sales Support Your Distributor s Phone Your Distributor s Fax Your Distributor s email Factory Sales Support Phone 1 203 775 4501 Fax 1 203 775 1162 email sales gordoneng com Factory Mailing Address Gordon Engineering Corp 67 Del Mar Drive Brookfield CT 06804 USA RC4000 Series Reel Control Part Number Serial Number Date of Purchase Notes 1 800 315 9233 www gordoneng com Five Year Warranty Contents i Contact Information ii Contents 1 Overview 1 Features Benefits 2 3 Specifications RC4000 Reel Control page 2 RC4000M Reel Control page 3 4 6 Antenna Selection 7 Speed Reduction 8 9 RC4000 Installati2. w on sal omi peia RELAY cem iaun ihii De TET PTALI 03A155 SHOCK MOUNT KIT CAUTION DO NOT OVERTIGHTEN Nut Lockwasher 3 4 Washer oa ___ Box Mounting Flange Shock Mount _ a T ns Mounting Bracket Lockwasher Nut www gordoneng com 03A 155 Shock Mount Kit Our 03A155 shock mount kits contain Lord Corporation s SMB006 0100 7 shock mounts We recommend that you use these or their equivalents whenever the control unit is mounted in a high vibration environment 1 800 315 9233 13 Keypad Controls SELECT in setup mode push to select reel or dereel mode antenna position and high and low limit relay activation ENTER in setup mode push to lock in SELECT settings TUNE in setup mode push to tune system JOG in setup mode push and release to nudge motor push and hold to run motor Manual Speed Mode push and hold simultaneously press Enter use Adjust Up Down to adjust speed any other key terminates this mode AUTO SETUP push to toggle between setup and auto modes ADJUST Up Down in auto mode allow motor on realtime loop height adjustment Control Interface This is an illustration of the RC4000 Series control interface Indicators and Keypad Functions are defined above Indicators Bargraph displays loop height relative to antenna Limit lights lit when loop height exceeds control range Run light on when motor
3. 30 5mm 18 45 7mm 12 30 5mm 18 45 7mm 12 30 5mm 18 45 7mm 12 30 5mm 18 45 7mm 12 30 5mm 18 45 7mm RC4000 Series Antenna Selection and Specifications Flat 0 0mm 0 0mm 0 0mm 0 0mm 2 5 1mm 2 5 1mm 4 10 2mm 4 10 2mm 6 15 2mm 6 15 2mm 12 30 5mm Mounting Plate dimensions for 04A073 04A092 04A074 04A067 04A091 04A068 Mounting Plate 4 50 04A023 114 3 A 18 hole 1695 4 31 All dimensions expressed in inches and millimeters 5 25 133 35 6 0 152 40 3 70 93 98 y Width 2 5 1mm 2 5 1mm 1 2 54mm 1 2 54mm 1 2 54mm 1 2 54mm 1 2 54mm 1 2 54mm 1 2 54mm 1 2 54mm 2 5 1mm Use to Control fine wire 5 wire or strip fine wire 5 wire or strip 125 1 wire or strip 125 1 wire or strip 3 strip 3 strip strip strip strip 7 strip 6 or wider strip Mounting Plate dimensions for 04A069 04A071 4 10 104 14 Mounting Plate CPi 1 i Mounting Plate F ax 25 oy www gordoneng com a Coupler Cable N Flat Antenna Width Part Number 04A073 04A074 04A091 04A092 04A067 04A068 04A069 04A071 04A070 04A072 04A088 Mounting Plate dimensions for 04A070 04A072 04A088 5 10 129 54 A Mounting Plate 4 50 04B013 3 70 114 3 A 18 hole 169
4. function is active AUTO or JOG Auto light on when unit is in the Auto mode reel motor is controlled by antenna information flashes to indicate auto interlock is engaged flashes with standby light to indicate shutoff interlock is engaged Setup light on when unit is in the Setup mode reel motor is controlled by Jog function or Manual Speed mode flashes with standby light to indicate shutoff interlock is engaged REEL CONTROL www gordoneng com Indicators Tune light flashes when tuning is required on while unit is tuning flashes with fault light on to indicate antenna fault Fault light indicates a loss of antenna signal or internal fault Selection indicators for reel dereel antenna position and high and low limit relay activation the indicators flash to show they are available for selection Use the SELECT key to step through the choices Use the ENTER key to set each choice Indicators stay lit to show how the unit is configured 1 800 315 9233 SYSTEM CONFIGURATION The Reel Control always powers up in SETUP mode and this is expressed by the SETUP indicator being lit The system configuration is expressed by the yellow indicators in the blue area of the panel These can be set as follows Press the SELECT key The indicators which represent the selected configuration will blink Each subsequent entry of the SELECT key will toggle to the next configuration choice and its corresponding in
5. indicators for reel dereel antenna position and high and low limit relay activation the indicators flash to show they are available for selection Use the SELECT key to step through the choices Use the ENTER key to set each choice Indicators stay lit to show how the unit is configured HIGH LWIT RELAY 1 800 315 9233 SYSTEM CONFIGURATION The Reel Control always powers up in SETUP mode and this is expressed by the SETUP indicator being lit The system configuration is expressed by the yellow indicators in the blue area of the panel These can be set as follows Press the SELECT key The indicators which represent the selected configuration will blink Each subsequent entry of the SELECT key will toggle to the next configuration choice and its corresponding indicators will blink When the desired system configuration is displayed press ENTER and the new settings will be stored in memory Next the High Limit Relay indicators will blink Press the SELECT key repeatedly until the desired configuration is indicated Choose a dimly blinking indicator if you wish to disable the relay function or a brightly blinking one to enable the relay function Press ENTER to save settings Repeat for the Low Limit Relay These settings will remain in effect until this process is repeated TUNE Each combination of antenna and material requires tuning of the system for proper operation First ensure your antenna is positioned and ins
6. or antenna Grounded metal or a person touching the antenna Flashing FAULT Indicator Indicates loss of System Synchronization Unit must be powered down and restarted If problem persists try filtering power input lines If problem still persists call factory for assistance 1 800 315 9233 11 RC4000M Installation Control Unit If you have a standard 04A049 coupler cable your control unit must be mounted within eight feet of your antenna however if a remote location for your control is required you can order cables with special cable lengths of fifteen or twenty five feet 04A049 15 and 04A049 25 respectively For convenience during setup the control unit should be as close to the machine and motor controls as possible but a minimum distance of three feet from the antenna should be maintained This should be a sufficient distance to prevent tuning errors that can be caused by the presence of the operator in the sensing field You shouldn t mount the control unit directly onto a machine that has an excessive amount of vibration as this can cause mechanical failure of some components If you have no alter native and the control must be mounted on a machine that vibrates soft shock mounts must be used Please ask for our 03A155 Shock Mount Kit see page 13 Antenna Coupler Assembly For most reeling applications you can mount your antenna in a looking up configuration with the Reel mode selected For s
7. safety This will ensure against tight loop or excessive payoff conditions if a control or process problem should occur e g material breaks or runs out or something moves or damages the antenna These relays fulfill the same function as stand alone limit switches provided they are properly wired to your control system FAULTS Any detectable condition that will prevent proper operation will be indicated by the FAULT Indicator being lit When this occurs AUTO operation will be locked out Fault conditions are as follows Fault Flashing TUNE Indicator Indicates inability to tune properly Cable and or antenna not connected Short or open circuit in cable or antenna Grounded metal or a person touching the antenna Flashing FAULT Indicator Indicates loss of System Synchronization Unit must be powered down and restarted If problem persists try filtering power input lines If problem still persists call factory for assistance 1 800 315 9233 15 Call the Pioneers of Capacitive Presence Sensing Technology for Your Reeling and Guarding Solutions Call Gordon Engineering There s always a knowledgeable person at Gordon Engineering to answer your questions When you need to guard perimeters or complex machines such as four slides or automatic presses call us When you need a Brake Monitor for your mechanical power press our engineers will gladly assist you in solving your application problem
8. 1 05mm fo 100 21 259 33mm A Knockout amp B Hole 860 dia 21 84mm O C Coupler 50 dia 12 7mm 2 475 62 9mm e 1 94 4 13 49 3mm 104 9mm 39 5mm z 4 03 Side View 1024mm 1 800 315 9233 Input Voltage Power Consumption Motors Interlocks Enclosure Mounting Shipping Weight Environment 115 230 VAC 50 60 Hz 1200VA directly drives DC shunt wound or permanent magnet motors up to 1 2 HP 90 volt armature or 1 HP 180 volt armature auto allows on off control of the reel motor by processing equipment JOG active shutoff allows on off control of the reel motor by processing equipment JOG inactive NEMA 12 industrial plastic 10 2 L x 7 8 W x 4 0 D 259mm x 199mm x 102 mm vertical or horizontal to any bulkhead chassis or panel 6 0 Ibs 2 7 Kg unaffected by dirt grease vibration etc O F 130 F 0 95 R H temperature humidity Keypad Controls SELECT in setup mode push to select reel or dereel mode antenna position and high and low limit relay activation ENTER in setup mode push to lock in SELECT settings TUNE in setup mode push to tune system JOG in setup mode push and release to nudge motor push and hold to run motor AUTO SETUP push to toggle between setup and auto modes ADJUST Up Down in auto mode allow motor on realtime loop height adjustment 7 30 185 42mm Fuse
9. 5 egal Al imensi e PE 9 45 240 03 10 2 259 08 Antenna Dimensions The dimensions for all RC4000 Series antennas are listed in the chart at the top of the page All dimensions are in inches with metric equivalents in parentheses For mounting instructions and specifics on setup please see the Installation section of the RC4000 User s Manual 1 800 315 9233 5 RC4000 Series Antenna Installation The length of your coupler cable will determine how far from the control unit you can position the antenna assembly but a minimum distance of three feet 3 or 1 meter is strongly sug gested This helps to ensure that the operator s body is not close enough to the antenna to affect the tuning The standard cable length is eight feet 8 or 2 4 meters and optional lengths of fifteen feet 15 or 4 6 meters and twenty five feet 25 or 7 62 meters are readily available Mount your antenna so the material runs through the middle of the V and the lowest point of the loop is either directly above or below the coupler depending on whether you are looking up or down respectively The antenna should be securely mounted with either four 4 or six 6 8 machine screws flat and lock washers as required The illustrations below depict both direct and indirect methods of sensing the material loop Antenna Installation Direct Control of Conductive Once you ve selected the proper antenna for yo
10. J 7 F 1 75 44 45mm 82 198 63mm 6 07 154 18mm 4 75 120 65mm 8 71 221 23mm 9 49 241 05mm 10 21 259 33mm A Knockout amp B Hole 860 dia 21 84mm Front View base onl 4 Mounting Holes clearance holes for 250 6mm bolt RC4000M Specifications Indicators Bargraph displays loop height relative to antenna Limit lights lit when loop height exceeds control range Run light on when motor function is active AUTO or JOG Tune light flashes when tuning is required on while unit is tuning flashes with fault light on to indicate antenna fault Fault light indicates a loss of antenna or internal fault Selection indicators for reel dereel antenna position and high and low limit relay activation the indicators flash to show they are available for selection Use the SELECT key to step through the choices Use the ENTER key to set each choice Indicators stay lit to show how the unit is configured RC4000M Dimensions 1 94 49 3mm 4 13 104 9mm 175 44 45mm jj 1 555 39 5mm C Coupler 50 dia 12 7mm 2 475 62 9mm af Side View 4 03 102 4mm www gordoneng com This is a dimensional drawing of the RC4000M enclosure All dimensions are in inches with metric equivalents in parentheses For mounting instructions and specifics on shock mounts please
11. We also make a full range of inductive ring sensors For price and delivery call our sales department or the regional distributor listed below Don t forget our Five Year Guarantee it comes with every RC4000 Series Reel Control we sell and we offer a 30 day Free Trial on all standard products toll free 1 800 315 9233 call 1 203 775 4501 fax 1 203 775 1162 email sales gordoneng com website www gordoneng com distributed by OrowrdtZzoqoqg r mmJ Gordon Engineering Corp 67 Del Mar Drive Brookfield CT 06804 2494 USA www gordoneng com G rd n
12. cables with special cable lengths of fifteen or twenty five feet 04A049 15 and 04A049 25 respectively For convenience during setup the control unit should be as close to the machine and motor controls as possible but a minimum distance of three feet from the antenna should be maintained This should be a sufficient distance to prevent tuning errors that can be caused by the presence of the operator in the sensing field You shouldn t mount the control unit directly onto a machine that has an excessive amount of vibration as this can cause mechanical failure of some components If you have no alter native and the control must be mounted on a machine that vibrates soft shock mounts must be used Please ask for our 03A155 Shock Mount Kit see page 9 Antenna Coupler Assembly For most reeling applications you can mount your antenna in a looking up configuration with the Reel mode selected For specifics on mounting the antenna coupler assembly refer to page 6 In dereel applications if the material breaks it may be pulled from the sensing field by the machine processing the material This will cause the dereel motor to pay off material onto the floor If you wish to ensure against this you should activate the High and Low Limit Relays Coupler Cable The cable has locking connectors on both ends to make replacement of the antenna or the control fast and easy Plug one end into the antenna and other into the control scr
13. dicators will blink When the desired system configuration is displayed press ENTER and the new settings will be stored in memory Next the High Limit Relay indicators will blink Press the SELECT key repeatedly until the desired configuration is indicated Choose a dimly blinking indicator if you wish to disable the relay function or a brightly blinking one to enable the relay function Press ENTER to save settings Repeat for the Low Limit Relay These settings will remain in effect until this process is repeated TUNE Each combination of antenna and material requires tuning of the system for proper operation First ensure your antenna is positioned and installed according to the instructions on page 6 then remove the material from the field and press TUNE The TUNE indicator will remain on during the tuning process and will go off when the unit is successfully tuned If for any reason proper tuning cannot be achieved the FAULT indicator will light Auto operation will be locked out and TUNE indicator will blink Refer to the section on FAULTS Any subsequent operation of the TUNE key turns off the FAULT indicator and initiates another tuning procedure Position the material in the sensing field so that one of the green bargraph lights is lit you may move the material through the sensing field either manually or with the JOG key JOG The JOG function is enabled only when the unit is in SETUP mode Pressing the JOG key cau
14. entheses Use 4 20 bolts and flat washers to mount the control unit If there is moderate to heavy vibration use an 03A155 Shock Mount Kit Front View base only 12 __________ _ 10 21 259 33mm A Knockout amp B Hole 860 dia 21 84mm www gordoneng com C Coupler 50 dia 12 7mm 2 475 62 9mm 1 39 5mm S 7 82 Top View 198 63mm 6 07 154 18mm 4 75 120 65mm o o p N A 8 71 221 23mm ________5 1 94 4 13 lt 1 75 49 3mm 104 9mm 44 45mm 9 49 241 05mm Side View 3 00 76 2mm 4 03 102 4mm 1 800 315 9233 Power Input Wiring All power wires must be brought into the box through the 860 21 8mm hole on the left side using a suitable 1 2 13mm electrical fitting Wire size must conform to local electrical code requirements for 8 amperes normally 14 AWG will meet these requirements Set the 115 230 volt selector switch to the proper position Connect three wire 115 or 230 VAC single phase power to terminals 1 2 and 3 Terminal 1 must be well grounded to a common electrical ground The AC line power must be sup plied from a disconnect box that is either fused or equipped with circuit breakers Output Wiring If you use a permanent magnet motor in your application connect the motor armature wires to terminals 4 and 5 please note the polarity of the terminals and
15. es a loss of antenna signal or internal fault Selection indicators for reel dereel antenna position and high and low limit relay activation the indicators flash to show they are available for selection Use the SELECT key to step through the choices Use the ENTER key to set each choice Indicators stay lit to show how the unit is configured Input Voltage Power Consumption Motor Drive DC Output Range Isolation Enclosure Mounting Shipping Weight Environment 115 230 VAC 50 60 Hz 3W provides an isolated analog input drive to AC or DC motor controllers or hysteresis clutch controllers 0 to 10 VDC maximum 0 to 5 VDC minimum isolated 1000 volts RMS NEMA 12 industrial plastic 10 2 L x 6 1 W x 4 0 D 259mm x 154mm x 102 mm vertical or horizontal to any bulkhead chassis or panel 5 5 lbs 2 5 Kg unaffected by dirt grease vibration etc O F 130 F 0 95 R H temperature humidity This is a dimensional drawing of the RC4000 enclosure All dimensions are in inches with metric equivalents in parentheses For mounting instructions and specifics on shock mounts please see the Installation section of the RC4000 User s Manual Top View Front View base onl 2 www gordoneng com 8 71 221 23mm 4 Mounting Holes clearance holes for 250 6mm bolt 4 75 6 07 120 65mm 154 18mm Y 9 49 24
16. ew down the locking collars and you re ready to go If you elect to enclose your coupler cable in a conduit it should not share a conduit with high voltage lines as this could create a situation where interference from the high voltage lines affects the coupler voltage and degrades the performance of the system Gear Box Ratio The gearbox ratio for speed reduction between motor and reel must be calculated according to the formula on Page 7 If your step down ratio is too low for the application the system will be overly sensitive and tend to exhibit jerkiness instead of a smooth control of the material RC4000 Dimensions This is a dimensional drawing of the RC4000 enclosure All dimensions are in inches with metric equivalents in parentheses Use 4 20 bolts and flat washers to mount the control unit If there is moderate to heavy vibration use an 03A155 Shock Mount Kit Front View base onl 8 www gordoneng com le 10 21 259 33mm A Knockout amp B Hole 860 dia 21 84mm 4 Mounting Holes clearance holes for Top View 250 6mm bolt 4 75 6 07 120 65mm 154 18mm Y 8 71 221 23mm 1 94 4 13 49 3mm 104 9mm 9 49 241 05mm C Coupler 50 dia 12 7mm G 2 475 62 9mm me Side View 4 03 102 4mm 1 800 315 9233 Power Input Wiring All power wires must be brought into the box through the 860 21 8m
17. ic mismatches exist in the application you will want to choose an 18 antenna This provides more control range and enhances the ability of the RC4000 to com pensate for any mismatches in the application In applications where wide strips 6 or more in width are to be reeled it is possible to use a flat plate antenna These types of antennas should be positioned directly above or below the lowest point of the material loop with the long dimension of the antenna perpendicular to the direction of travel 04A049 Cable 8 2 44m Standard length other lengths quoted on request sold separately Coupler Dimensions 2 20 55 9mm For RC4000 Series Reel Controls only gt 1 25 31 8mm j 1 10 i 27 9mm This is a dimensional drawing of Ogor UO emam u Po 54mm T the 04A035 Coupler f poo l eed i ate Mounting Holes T All dimensions are in inches with 3 20 ET T cape i 81 3mm 190 4 83mm dia j 04A 03 i 1 25 metric equivalents in parentheses 3 10 Antenna Coupler 8175mm 18 7mm These couplers come mounted to a Lot Holle eset p ANTENNA SIDE EE aT an antenna but are available for sale separately Cables are sold 1 separately 8 2 44m is standard Separe Caie La with other lengths available on w Locking Connector Front View Side View request 4 www gordoneng com End View 1 800 315 9233 Length of V 12
18. interfaces with various third party motor drives RC4000M has an integrated motor drive www gordoneng com RC4000 Series Overview Once the system is properly installed and configured for your application the operator simply presses the TUNE button The tuning process takes only a few seconds Then the operator positions the payoff or take up loop within the V either manually or with the use of the JOG button so that one of the green Loop Height indicators is lit Once these conditions are met he she presses the AUTO STANDBY button and the sys tem is functional After your operation is running you may find that you want to adjust the loop height relative to the antenna This is as easy as pressing the ADJUST Up or Down buttons located next to the bargraph indicators This is done dynamically with the motor running A pair of selectable relays for HIGH and LOW LIMIT are included in the control unit These act in a similar manner to stand alone models of limit switches with the exception that there is no contact with the material required by our limit relays The result is non contact protection against tight or slack loop conditions when the relay contacts and the unit interlocks are properly wired to your control system Please direct any questions you have to our Sales Department toll free in US 1 800 315 9233 or sales gordoneng com Benefits E Control fine wire delicate stamped parts and plated metals w
19. ithout marring or damage E Quick and easy setup and material changes minimize downtime and maximize profits E The intuitive operator interface requires very little training which saves you time and money E No need to stop the motor for adjustments to the loop height therefore no lost production E Prevents costly damage to machines materials and dies Eliminates the need for external limit switches E RC4000 access to sophisticated motor drive options through use of third party motor controllers RC4000M delivers economical basic motor control in a single enclosure 1 800 315 9233 RC4000 Specifications Keypad Controls SELECT in setup mode push to select reel or dereel mode antenna position and high and low limit relay activation ENTER in setup mode push to lock in SELECT settings TUNE in setup mode push to tune system JOG in setup mode push and release to nudge motor push and hold to run motor AUTO SETUP push to toggle between setup and auto modes ADJUST Up Down in auto mode allow motor on realtime loop height adjustment RC4000 Dimensions Indicators Bargraph displays loop height relative to antenna Limit lights lit when loop height exceeds control range Run light on when motor function is active AUTO or JOG Tune light flashes when tuning is required on while unit is tuning flashes with fault light on to indicate antenna fault Fault light indicat
20. m hole on the left side using a suitable 1 2 13mm electrical fitting Wire size must conform to local electrical code requirements for 1 ampere normally 14 AWG will meet these requirements Set the 115 230 volt selector switch to the proper position Connect three wire 115 or 230 VAC single phase power to terminals 1 2 and 3 Terminal 1 must be well grounded to a common electrical ground The AC line power must be sup plied from a disconnect box that is either fused or equipped with circuit breakers Output Wiring The RC4000 requires a separate external motor control to drive the reel motor The control voltage is taken from the Isolated DC Output Terminals Select the 5 or 10 volt range as required by your controller In general all wire should be heavy enough to accept crimped push on style terminals and to withstand the rigors of your production environment We recommend shielded twisted pair with the shield grounded at the control unit end only These wires should not be run through conduit with high voltage lines Wiring Terminals RC4000 Installation Auto Interlock This feature allows external on off control of the reel motor in AUTO mode only To use this function connect the AUTO and COM terminals to a relay contact that closes when reel motor stop is required The Auto LED blinks to indicate the interlock is asserted and since the unit is temporarily in SETUP mode the JOG feature can be used Whe
21. motor and the reel You can use the following formula to calculate gear ratios r S8144 F Where R step down ratio between motor and reel F maximum machine feed rate units of measure min d reel hub diameter units of measure S motor speed RPM In order to allow some margin for feed rate increase a motor speed S less than maximum should be used for example for a motor rated at 1725 RPM calculate the ratio for 1500 RPM Sample Calculation 1500 3 14 6 _ 1000 7 28 2 Where S 1500 RPM F 1000 units of measure min d 6 units of measure Speed Reduction Checklist EE Note the Speed S at which your motor is rated to operate here RPM and in the top line of the formula below EE Note your Reel Hub Diameter d here units of measure and in the top line of the formula below EE Note the Feed Rate F of your machine here units of measure min and in the bottom line of the formula below 3 14 EE Note the Step Down Ratio R of your machine below round your answer to the nearest whole number R 1 Checklist www gordoneng com Speed Reduction is Required for Most Applications 1 800 315 9233 7 RC4000 Installation Control Unit If you have a standard 04A049 coupler cable your control unit must be mounted within eight feet of your antenna however if a remote location for your control is required you can order
22. n the AUTO interlock is released the control returns to AUTO mode without operator intervention Shut off Interlock This feature allows external shut off control of the reel motor in both Auto and Manual modes To use this feature connect the SHUT OFF and COM terminals to a relay contact that closes when reel motor stop is required The AUTO and SETUP LEDs both blink as long as the contacts are closed When the contacts open the unit stays in SETUP mode until the AUTO key is pushed by the operator Relay Outputs The Operation section describes the procedure for enabling the High and Low Limit Relays Connections must be made to output terminals 8 9 and 10 to utilize this feature Connect to the COM and either the NO or the NC terminal depending on the control function to be performed for RC4000 i auae a a a 4a E T Li Li w g and RC4000M PI a eee tc sa CAUTION DO NOT lt OVERTIGHTEN Nut Lockwash r Our 03A155 shock mount kits Oa Washer contain Lord Corporation s ____ Box SMB006 0100 7 shock mounts Mounting Flange Shock Mount We recommend that you use these or their equivalents whenever the ye Se control unit is mounted in a high ins Mounnng bracket vibration environment N tet Nut www gordoneng com 1 800 315 9233 9 RC4000 Operation Keypad Controls SELECT in setup mode push to select reel or dereel mode antenna position and high and low limit relay acti
23. on Input Output Wiring page 9 Interlocks page 9 Shock Mounts page 9 10 11 RC4000 Operation Tuning and Setup pages 10 11 12 13 RC4000M Installation 14 15 RC4000M Operation Tuning and Setup pages 14 15 1 800 315 9233 i www gordoneng com Shown with 04A049 Cable and 04D067 Antenna Operational Overview The system is comprised of a control unit connecting cable and an antenna assembly The RC4000 is designed to interface with third party motor controllers while the RC4000M has a self contained motor controller The control unit determines the load and status of the antenna assembly and establishes a tuned RF sensing field around the antenna elements yellow inner pieces This field is shaped through the use of grounded shield elements black outer pieces and is essentially contained within the V Features E RF Sensing Technology Non contact stress free control of conductive materials E Full Line of Modular Antennas Match your material to our list it tells you the proper antenna to choose for your application E Two Button Tune and Run Connect your antenna press TUNE Position your loop so that one green bargraph light is lit Press the AUTO SETUP keypad You re running E Motor On Realtime Loop Height Adjustment Allows on the fly adjustment of loop height E Integrated High Low Limit Relays Ensure against tight or slack loop conditions E Variety of Motor Drive Capabilities RC4000
24. pecifics on mounting the antenna coupler assembly refer to page 6 In dereel applications if the material breaks it may be pulled from the sensing field by the machine processing the material This will cause the dereel motor to pay off material onto the floor If you wish to ensure against this you should activate the High and Low Limit Relays Coupler Cable The cable has locking connectors on both ends to make replacement of the antenna or the control fast and easy Plug one end into the antenna and other into the control screw down the locking collars and you re ready to go If you elect to enclose your coupler cable in a conduit it should not share a conduit with high voltage lines as this could create a situation where interference from the high voltage lines affects the coupler voltage and degrades the performance of the system Gear Box Ratio The gearbox ratio for speed reduction between motor and reel must be calculated according to the formula on Page 7 If your step down ratio is too low for the application the system will be overly sensitive and tend to exhibit jerkiness instead of a smooth control of the material RC4000M Dimensions 4 Mounting Holes clearance holes for 250 6mm bolt Fus 2 gt Holder 7 30 185 42mm t i 185 42mm 1 75 e 44 45mm This is a dimensional drawing of the RC4000M enclosure All dimensions are in inches with metric equivalents in par
25. see the Installation section of the RC4000 User s Manual 1 800 315 9233 3 RC4000 Series Antenna Selection and Specifications Antenna Selection Providing the proper antenna for your application is a crucial part of making the RC4000 Reel Control system perform to its best abilities Fortunately this process has been made easy due in large part to the introduction of our line of modular antennas These modular antennas come with an integrated coupler and are designed to be quickly and easily swapped by unplugging the locking cable connector This allows for rapid replacement if an antenna is physically damaged and for quick and easy setups in applications where a variety of material sizes are processed by the same equipment Process down time is kept to a minimum allowing you to maximize productivity Once you ve determined the size of the material you wish to control just look at the chart on the next page to select the proper antenna for your application Under the heading Use to Control find the size range of the material you need to control There are two sizes of V antennas for each material size one 12 in length and one 18 in length For applications where the process speed is slow or where the motor and gear ratio are well matched to the process a 12 antenna will provide all the control you need with the added bonus of being very compact Where the process runs at fast speeds or where dynam
26. ses the motor to run at an increasing speed until the key is released and the motor stops For Manual Speed Control press JOG until the desired speed is reached then press ENTER The ADJUST Up and Down keys allow the speed to be fine tuned Pressing any other key than ADJUST Up or Down disables this function www gordoneng com RC4000M Operation AUTO Ensure that your line is operational and that all personnel are clear of any hazardous areas Then press the AUTO SETUP key to put the system into Auto mode The AUTO and RUN indicators will light The reel speed should automatically follow the feed rate of the material In the REEL mode with the antenna below or DEREEL mode with antenna above ensure the motor stops when the material reaches the farthest distance away from the antenna Use the ADJUST keys to bring the loop back towards the antenna until it always stops when the associated Limit indicator lights Note The ADJUST keys only function when the motor is running and are limited to the green range of the bargraph In the DEREEL mode with antenna below or REEL mode with antenna above operation is reversed and the motor should stop when the material is close to but not touching the antenna Use the ADJUST keys to place the loop farther away from the antenna until it always stops when the associated Limit indicator lights We strongly suggest that you employ the selectable High and Low Limit Relays as an added level of
27. talled according to the instructions on page 6 then remove the material from the field and press TUNE The TUNE indicator will remain on during the tuning process and will go off when the unit is successfully tuned If for any reason proper tuning cannot be achieved the FAULT indicator will light Auto operation will be locked out and TUNE indicator will blink Refer to the section on FAULTS Any subsequent operation of the TUNE key turns off the FAULT indicator and initiates another tuning procedure Position the material in the sensing field so that one of the green bargraph lights is lit you may move the material through the sensing field either manually or with the JOG key JOG The JOG function is enabled only when the unit is in SETUP mode Pressing the JOG key causes the motor to run at an increasing speed until the key is released and the motor stops For Manual Speed Control press JOG until the desired speed is reached then press ENTER The ADJUST Up and Down keys allow the speed to be fine tuned Pressing any other key than ADJUST Up or Down disables this function www gordoneng com RC4000 Operation AUTO Ensure that your line is operational and that all personnel are clear of any hazardous areas Then press the AUTO SETUP key to put the system into Auto mode The AUTO and RUN indicators will light The reel speed should automatically follow the feed rate of the material In the REEL mode with the antenna belo
28. ur application Materials you will need to decide whether you want to look up or look down at the material loop The RC4000 Selection Mode allows you to configure the control for either scenario whether you are in Reel or Dereel mode We strongly suggest that you employ the selectable High and Low Limit Relays as an added level of safety This will ensure against tight loop or excessive payoff conditions if a control or process problem should occur e g material breaks or runs out or something moves or damages the antenna These relays fulfill the same function as stand alone limit switches when properly wired to your control system Sensing Field Indirect Control V Antenna w 12A844 Coupler This illustration depicts one way that a nonconductive material could be controlled using an RC4000 Series Reel Control An idler pulley that rides on the material is used to transfer the loop height information to a grounded metal target which travels up and down within the V of the antenna Idler Pulley Many variations of this approach are possible and they can be as simple as a grounded metal weight or target suspended from the material loop within the V of the antenna www gordoneng com Guide Rails Grounded Metal Target 1 800 315 9233 Since the feed rate in most applications requires much less than standard 1725 RPM DC motor speed you must connect a speed reducer between the
29. vation ENTER in setup mode push to lock in SELECT settings TUNE in setup mode push to tune system JOG in setup mode push and release to nudge motor push and hold to run motor Manual Speed Mode push and hold simultaneously press Enter use Adjust Up Down to adjust speed any other key terminates this mode AUTO SETUP push to toggle between setup and auto modes ADJUST Up Down in auto mode allow motor on realtime loop height adjustment Control Interface This is an illustration of the RC4000 Series control interface Indicators and Keypad Functions are defined above Indicators Bargraph displays loop height relative to antenna Limit lights lit when loop height exceeds control range Run light on when motor function is active AUTO or JOG Auto light on when unit is in the Auto mode reel motor is controlled by antenna information flashes to indicate auto interlock is engaged flashes with standby light to indicate shutoff interlock is engaged Setup light on when unit is in the Setup mode reel motor is controlled by Jog function or Manual Speed mode flashes with standby light to indicate shutoff interlock is engaged REEL CONTROL www gordoneng com Indicators Tune light flashes when tuning is required on while unit is tuning flashes with fault light on to indicate antenna fault Fault light indicates a loss of antenna signal or internal fault Selection
30. w or DEREEL mode with antenna above ensure the motor stops when the material reaches the farthest distance away from the antenna Use the ADJUST keys to bring the loop back towards the antenna until it always stops when the associated Limit indicator lights Note The ADJUST keys only function when the motor is running and are limited to the green range of the bargraph In the DEREEL mode with antenna below or REEL mode with antenna above operation is reversed and the motor should stop when the material is close to but not touching the antenna Use the ADJUST keys to place the loop farther away from the antenna until it always stops when the associated Limit indicator lights We strongly suggest that you employ the selectable High and Low Limit Relays as an added level of safety This will ensure against tight loop or excessive payoff conditions if a control or process problem should occur e g material breaks or runs out or something moves or damages the antenna These relays fulfill the same function as stand alone limit switches provided they are properly wired to your control system FAULTS Any detectable condition that will prevent proper operation will be indicated by the FAULT Indicator being lit When this occurs AUTO operation will be locked out Fault conditions are as follows Fault Flashing TUNE Indicator Indicates inability to tune properly Cable and or antenna not connected Short or open circuit in cable
31. your armature wires if you reverse the polarity your motor will run in the opposite direction Terminals 6 and 7 are not used with permanent magnet motors If you use a shunt wound motor for your application connect the motor armature wires to terminals 4 and 5 please note the polarity of the terminals and your armature wires if you reverse the polarity your motor will run in the opposite direc tion Then connect the motor field wires to terminals 6 and 7 Wiring Terminals for RC4000 and RC4000M a a ih MENE LAE a a T APLES Le RC4000M Installation once again be sure to observe the polarity of the terminals and your field wires Modification 04A060 must be installed on any RC4000M Reel Control that is intended for use with Form Factor 1 0 motors Bodine Electric has a line of these as follows 04A060 1 04A060 2 04A060 3 for1 50 1 20 amp 1 12 HP for 1 8 HP for 1 4 HP In general all wire should be heavy enough to accept crimped push on style terminals and to withstand the rigors of your production environment Auto Interlock This feature allows external on off control of the reel motor in AUTO mode only See page 9 for details Shut off Interlock This feature allows external shut off control of the reel motor in both Auto and Manual modes See page 9 for details Relay Outputs The Operation section describes the procedure for enabling the High and Low Limit Relays See page 9 for details
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