Dynamatic EC 2000-CES Manuel utilisateur
EC 2000 – CES
Stamping Press Position Controller
Instruction Manual
Sturtevant, Wisconsin, USA 53177
Telephone: 262-554-7977
Fax: 262-554-7041
Toll Free: 800-548-2169
www.dynamatic.com
EC-2000-CES MANUAL
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Table of Contents
SECTION 1 - THEORY OF OPERATION ............................................................................................................... 6
SECTION 2 – MODELS AND PART NUMBERS .................................................................................................... 9
SECTION 3– SPECIFICATIONS ......................................................................................................................... 10
3.1 Features ..................................................................................................................................... 10
3.2 Power and Load Ratings ............................................................................................................. 10
3.3 Electrical Protection ................................................................................................................... 10
3.4 Environmental Ratings ............................................................................................................... 11
3.5 Electrical Noise ........................................................................................................................... 11
3.6 Enclosures .................................................................................................................................. 11
3.7 Weight ........................................................................................................................................ 11
3.8 Dimensions (see Figure 3&4) ..................................................................................................... 11
3.9 Reliability .................................................................................................................................... 11
3.10 Codes and Standards.................................................................................................................. 11
SECTION 4 – CONTROL OPERATION MODES.................................................................................................. 13
4.1 Control Modes ........................................................................................................................... 13
4.2 Mode of Operation ................................................................................................................... 13
SECTION 5 – Inputs/Outputs .......................................................................................................................... 14
5.1 Analog Inputs ............................................................................................................................. 14
5.2 Digital Inputs .............................................................................................................................. 14
5.3 Analog Outputs .......................................................................................................................... 14
5.4 Digital Outputs ........................................................................................................................... 14
SECTION 6 – INSTALLATION ........................................................................................................................... 15
6.1 Panel & Keypad Layouts ............................................................................................................. 15
6.2 Mounting Hardware ................................................................................................................... 18
6.3 Wiring ......................................................................................................................................... 18
6.4 Hardware Jumper & Potentiometer Setup ................................................................................ 19
SECTION 7 – KEYPAD ...................................................................................................................................... 22
SECTION 8 – PROGRAMMING ........................................................................................................................ 23
8.1 Menu A: Control Setup .............................................................................................................. 23
8.2 Menu B: CLCH PERFORMANCE .................................................................................................. 26
8.4 Menu C: ACCEL/DECEL SETUP ......................................................................................................... 27
8.4 Menu D: BRAKE PERFORMANCE ...................................................................................................... 27
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8.5 Menu F: PROCESS ....................................................................................................................... 29
8.6 Menu G: FAULT .......................................................................................................................... 30
8.7 Menu H: FAULT TIMER SETUP .......................................................................................................... 31
8.8 Menu I POSITION ERROR SETUP .................................................................................................... 34
8.9 Menu J: METER SETUP ..................................................................................................................... 35
8.10 Menu K: SERIAL OPTIONS .............................................................................................................. 35
SECTION 9 – PRESS CONTROL OPERATION -- WIRED INTERFACE .................................................................. 36
9.1 CONTROL INPUT SIGNALS ................................................................................................................ 36
9.2 CONTROL - OUTPUT SIGNALS .......................................................................................................... 37
9.3 PRESS CONTROL INTERFACE - SERIAL PORT ..................................................................................... 38
9.4 SIGNALS FOR CUSTOMER’S RECORDER ........................................................................................... 39
9.5 BRAKE CONTACTOR.......................................................................................................................... 39
9.6 CONTROL OPERATING MODES ......................................................................................................... 39
SECTION 10 – STARTUP & ADJUSTMENT ....................................................................................................... 43
10.1 POWER CONVERSION .................................................................................................................... 43
10.2 PRESS SPEED CONTROL .................................................................................................................. 43
10.3 BRAKE CONTROL BOARD ................................................................................................................ 43
10.4 CLUTCH CONTROL BOARD ............................................................................................................. 44
10.5 PRE-START-UP PROCEDURE ........................................................................................................... 44
10.6 START-UP PROCEDURE................................................................................................................... 46
SECTION 11 – FAULT LISTING & DESCRIPTIONS ............................................................................................. 48
11.00 FAULT LIST .................................................................................................................................... 48
11.01 LEVEL 100 FAULTS ........................................................................................................................ 48
11.02 LEVEL 200 FAULTS ........................................................................................................................ 48
11.03 LEVEL 300 FAULTS ........................................................................................................................ 50
SECTION 12 PRESS CONTROL INTERFACE - SERIAL PORT ............................................................................. 52
12.0 SERIAL PORT PRESS CONTROL INSTRUCTIONS .............................................................................. 52
12.1 SERIAL PORT PARAMETER DATA PACKET INSTRUCTIONS ............................................................. 53
12.2 SERIAL PORT PARAMETER DATA PACKET INSTRUCTIONS (ALTERNATE METHOD)........................ 54
12.3 SERIAL PORT EXECUTE PARAMETER INSTRUCTION ....................................................................... 54
12.4 SERIAL PORT FAULT REPORT INSTRUCTION ................................................................................... 54
12.5 SERIAL PORT FAULT REPORT DATA PACKET CONTENT .................................................................. 55
12.6 SERIAL PORT MONITOR DATA INSTRUCTION ................................................................................ 55
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12.7 SERIAL PORT MONITOR DATA PACKET CONTENT .......................................................................... 55
12.8 SERIAL PORT CONNECTIONS .......................................................................................................... 56
SECTION 13 – TROUBLESHOOTING ................................................................................................................ 57
13.1 TROUBLE SHOOTNG 100 LEVEL STOP MOTOR FAULTS ................................................................. 58
13.2 TROUBLE SHOOTNG 200 LEVEL STOP NOW FAULTS ..................................................................... 58
13.3 TROUBLE SHOOTNG 300 LEVEL STOP ON TOP FAULTS ................................................................. 62
13.4 TROUBLE SHOOTING. NO FAULT DISPLAYED: ................................................................................ 64
13.41 Blank Display: ............................................................................................................................... 64
13.42 Keypad Does Not Respond. Display works: ................................................................................. 65
13.43 Control does not engage. No faults: ............................................................................................ 65
13.44 Unit runs at top speed only - No control: .................................................................................... 65
13.45 The speed range is limited—doesn’t reach maximum speed: ..................................................... 65
13.46 High Voltages Fuses blow on power up: ...................................................................................... 66
13.47 High Voltages Fuses blow while running: .................................................................................... 66
13.48 Low Voltages Fuses on clutch control board blow: ..................................................................... 66
13.49 Low Voltages Fuses on brake control board blow: ...................................................................... 66
13.50 Unstable Speed Running: ............................................................................................................. 66
13.51 Unstable Speed Slowing or Braking: ............................................................................................ 67
Table of Figures
Figure 1: Eddy Current Drive Block Diagram ................................................................................ 7
Figure 2: EC 2000-CES Keypad Display...................................................................................... 8
Figure 3: Standard Panel Dimensions (Not to scale) ..................................................................... 15
Figure 4: Keypad Cutout Template (to Scale, Inches) .................................................................... 16
Figure 5: Keypad Dimensions (to Scale) .................................................................................... 17
Figure 6: Clutch Control Board Layout ....................................................................................... 20
Figure 7: Brake Control Board Layout ........................................................................................ 21
Figure 8: Keypad Layout ......................................................................................................... 22
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Listing of Tables
Table 1: Models and Part Numbers ............................................................................................. 9
Table 2: Clutch Control Board Programmable Jumpers Default Settings in Green ................. 19
Table 3: Follower Set Point Jumper Settings .............................................................................. 19
Table 4: Brake Control Board Programmable Jumpers .................................................................. 21
Table 5: Keypad Button Descriptions ......................................................................................... 22
Table 6: Mechanical Unit Tach Pulses/REV Setting ...................................................................... 24
Table 7: Parameter Locations .................................................................................................. 40
Table 8: Press Run Data Format .............................................................................................. 53
Table 9: Control Fault Data Format ........................................................................................... 55
Table 10: Control Monitor Data Format ...................................................................................... 56
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SECTION 1 - THEORY OF OPERATION
The Dynamatic® Eddy Current CES press drive system consists of a prime mover (AC induction motor), an
AC motor starter (optional and not provided), the Eddy Current coupling, Eddy Current Brake a speed
feedback device (tachometer generator), a resolver (position measurement) and a controller with an
operator interface.
The AC motor is started under no load and runs at full speed before the controller is energized The
output of the control is determined by reference setting (based on press position) and feedback
magnitude with drive speed and torque being based on the operational mode and load requirements.
Speed control mode with tachometer or resolver feedback will regulate within 0.5% of set speed. Preset
speeds, and external reference inputs are available as standard parameter selections with the EC 2000-CES
control.
The EC 2000-CES uses digital technology to provide a flexible, low noise control for today’s high tech
industrial environment. It provides setup and programming via a keypad with a user friendly
alphanumeric display; drive parameters may be programmed and displayed by the customer to activate
the many built-in features. Below is a schematic of a typical press drive.
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Figure 1: Eddy Current Drive Block Diagram
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Figure 2: EC 2000-CES Keypad Display
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SECTION 2 – MODELS AND PART NUMBERS
Table 1: Models and Part Numbers
Dynamatic Part
Number
Output
Voltage
Maximum
Current
Required
Input Voltage (50/60
Hz)
Notes
015-000248-2002 300VDC * 135A 600V 1ph ** SCRs in F.W. bridge rectification
015-000248-2003 300VDC * 80A 600V 1ph ** SCRs in F.W. bridge rectification
015-000248-2004 300VDC * 32A 600V 1ph ** SCRs in F.W. bridge rectification
* (Field Forcing to 600V -- Transformer sold separately)
** (Input Voltage with step up Isolation Transformer)
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SECTION 3– SPECIFICATIONS
3.1 Features
Direct Drop in Replacement for Dynamatic Digital CES Controls, Galco or Control
Techniques
Voltage ranges available from 45 – 300VDC
Up to 135 amps output (see Table 1 for model list)
Control Modes (3) Speed (AC tachometer generator or pulse pickup), torque (clutch
current) feedback. Position Control with Resolver Feedback. Tach-less Speed control
when Resolver is used.
Six selectable angles and speeds. Programmable Creep Angle, Creep Speed and Stop
Angle
Adjustable brake & clutch current output
Controllable via potentiometer, follower signal (0-10V, 4-20mA), or Programmed angles
and speeds
Digital, noise free operation
Fuse and MOV protected
Back-lit LCD with keypad user interface
Recorded and displayed faults
RS422 / 485 Com port. Remotely programmable speeds and angles.
Ethernet IP add-on to be available
3.2 Power and Load Ratings
Input voltage: 200, 230, 460, 575V AC
Output Currents:24 to 135 Amp (See Table #1)
Output: Voltage 300VDC Field Forcing to 750 VDC with Inversion
Solid State Relay Outputs (5) Normal Stop Stop on Top, Stop Now, Stop Motor, &
Control Fault
Load Regulation: -0.25% load change from 25% to full load
Line Regulation: +/- 1% of rated speed for +/-10% change in line voltage
Thermal Drift: +/- 0.05% of rated speed per °C
Linearity: +/- 2% of maximum rated speed
Minimum Regulated Speed: 25 RPM
Linear Acceleration/Deceleration Range: 1% - 199% of top speed/sec or Instantaneous.
3.3 Electrical Protection
Fuses: Class T, 600V, 125 A
Circuit Breaker 125 Amp 2P
Metal Oxide Varistor on Clutch & Brake Output
1800V/m 10kA
Metal Oxide Varistor on power board line input
o 240V, 6.5kA
Ce manuel convient aux modèles suivants
3
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