Ternary Integrated Actuator
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Description
Ternary Integrated Actuator Maintenance and Troubleshooting Training
Tim Brennan
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Outline
1. 2. 3. 4. 5.
System Components Wiring – Power and Command Programming – ProTern Commissioning Software Command Data – Homing, moving, jogging Troubleshooting – Error Reading, Handling, and other basics
Tim Brennan
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Ternary System Configuration Consists of: 1. Actuator (TLSA, TRSA, TSSA) 2. Power Cable (TCC 001-001)
3. Command cable (TCC 002-008) 4. Chaining terminal (TBG 002-003) 5. Programming Cable (TCC 002-001) 6. Bus Converter (TBG 001-001) 7. ProTern Software (TET 002-002)
8. PLC 9. 24 VDC Power Supply 10. Power Switching Circuitry
Tim Brennan
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Ternary Actuator Components – Motor/Electronics Motor with motor mounting plate Brushless motor for long lifetime protected by seal Feedback system TTL Encoder for position feedback to close position loop. Optional Brake Electro-magnetic motor holding brake for vertical loads or holding position in loss of power Logic PCB with integrated memory Storage of 16 (STP) or 64 (BLM) points (w/ pos, accel,vel and torque) and electronic commutation Amplifier with heat sink High Power Pulse signal generator for stepping motor or PWM for Servo motor. Housing with cabling IP65 protection for complete integrated system Optional Fieldbus cabling Devicenet, Profibus, or CAN Open Tim Brennan
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Ternary Actuator Components – Cylinder
Ballscrew with recirculating Ballnut – Maintenance Free 3, 6 or 12 mm Pitch (Distance per 1 rotation) Up to 300 mm length Stainless Steel Rod Double-D Cut Rod and Bushing (for Anti-Rotation) Flange or T-Slot Mounting Dual Input bearings for added thrust support
Tim Brennan
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Power Connection
Tim Brennan
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Command Cable Command Cable connects Ternary to PLC through the Chaining Terminal Command Cable Contains both RS485 Communication as well as Discrete IO
Tim Brennan
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Breakout Board CN1 – Serial Connection to Computer CN3 – Serial Daisy Chain to other Actuator CN2 – Connection to Ternary
PIO Terminal – Discrete IO to PLC
Tim Brennan
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ProTern Commissioning Software 1. 2. 3. 4. 5. 6.
Installation of ProTern Startup and connecting to a device Program basics Loading Prestored parameter files Editing Parameters Saving to EEPROM
Tim Brennan
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Installation of ProTern 1. Install ProTern.msi
2. Installed to: C:\Program Files\alpha gear drives\ProTern 3. ProTern.exe to start program 4. ProTern Folder contains Subfolders for: 1.“Doc” – contains ProTern manual
2.“Help” – Contains Help File 3.“Projects” – For stored files 4.“Traces” – For Stored Traces
Tim Brennan
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© WITTENSTEIN
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Startup and Connecting to Device 1. When Program Starts, choose Network Connection and Baud (115.2 Default)
2. Choose Device you are looking for 1. Scan for first found device 2. Specify Device Address 3. Search for All
Tim Brennan
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Startup and Connecting to Device 1. After the devices are found, the data is uploaded
2. You are given the choice to make a new project. Select yes to view or edit current parameters on the device.
Tim Brennan
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Program Basics 1. Program Tree – Shows any actuators in project as well as each point. Uses Name Label.
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2. Status Area – Shows status of Inputs and Outputs. 3. Real-time Data – Shows Position, velocity and temperature data. 4. Project Area – Shows actuator parameters and allows for actuator commands to be issued.
Tim Brennan
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Programming Basics – Units of measure 1. View allows you to change the units of measure between inch, metric and native units.
Tim Brennan
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Program Basics - Project Window 1. Actuator Parameters – Includes Homing, Software Limits, I/O Mode, and Communication Parameters.
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2. Point Parameters – Change Positions, speeds, acceleration rates. 3. Command Page – Allows generation of movement (homing, move to point, jog and teach, scope function).
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Loading from a file 1. To Open File choose 1.File/Open or 2.Open File Icon
2. Choose the Program file you want to open.
Tim Brennan
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Saving Existing Parameters to a file 1. To Save an existing parameter set from the actuator into a file that can be loaded to a device select: 1.File/Save As or 2.Click on Disk Icon to Save
2. Name the actuator and hit save for future use.
Tim Brennan
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Factory Default Parameters In case there is an error in parameter values that can not determined, you can also load factory default parameters. 1. Choose “Tools/Reload from EEPROM File” 2. Save to EEPROM.
Tim Brennan
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Editing Parameter Data 1. Click on the field you would like to edit. 2. #2 Notes the min and max values in the current measuring units.
3. #3 Notes the min and max values in the native units
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4. #4 Notes the current value in native units. 5. Only data in software will be changed, not on Permanent Memory (EEPROM). 2
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Saving to EEPROM 1. When the correct parameter values are in the ProTern Project, they must be saved to the EEPROM for permanent memory storage in the actuator.
2. This can be done by selecting Tools/Recall or using the Red Diamond Icon.
Tim Brennan
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Saving to EEPROM 1. Click checkbox to designate what you would like to save to. All boxes underneath will automatically be checked. 2. Choosing Project writes to all parameters in every actuator in the project. 3. Choosing A0 writes to all parameter in Actuator 0. 4. You can also download selectively to specific points or to actuator level only.
Tim Brennan
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Command Page Command Page allows motion. The following areas are found in the screen capture on the right:
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1. Shows data for each point 2. Change view between what is in software (proTern) vs what is stored in EEPROM. 3. Allows Servo to be turned on and off 2
4. Issue commands 5. Generate Moves 6. Configuring Trace Data to be captured (view by clicking graph icon)
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7. Jog and teach function Tim Brennan
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Command Page - Moves 1
1. Moves are not allowed until axis has been homed (area 4) 2. Moves can be generated by double clicking Black boxes in area 1 or clicking one of the Move commands in area 5. 3. The GoTo Px in area 5 and Teach Px are changed to different point number by single clicking in area 1. 4. Jog In or out in area 7 to move actuator to correct position. Teach stores the data in the Program point only. It must still be saved to EEPROM.
Tim Brennan
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Troubleshooting 1. 2. 3. 4.
Troubleshooting Steps How to find Error Code Error Code Definition Typical modes of failure
Tim Brennan
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Troubleshooting Steps 1. If actuator isn’t moving, check: 1. Is the LED on back of actuator green, red, or off 1. Green = No Error detected, Go to step 2 2. Red = Check Alarm Code (see page 26) 3. Off = Check if power source and power cable are OK, replace if necessary. 2. If Green and not moving, remove load and try moving again. 1. If moves without load, 1. check for mechanical misalignment of load 2. Check Protern to determine if input signals are reaching actuator; if not check for break in command cable or loose wire on chaining terminal 3. If signals are reaching actuator, actuator moves, but PLC doesn’t recognize position complete, home or alarm 1. Check Command cable or breakout board if OK return to Wittenstein for replacement of Output Optocouplers Tim Brennan
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Troubleshooting Steps (continued) 2. If doesn’t move w/o load when commanded, remove power and try to move by hand. 1. If it moves by hand, return to Wittenstein to have motor evaluated. 2. If doesn’t move by hand, return to Wittenstein to have cylinder evaluated. 3. Not possible to swap motor or cylinder in the field. 2. If Actuator is moving but slowly: 1. Check for mechanical misalignment 2. Verify load weight is not “too much” 3. If not too heavy or misaligned, remove load to determine if actuator still moves slowly. 1. If yes, return Ternary to Wittenstein for cylinder Evaluation 2. If moves slowly in one direction only, probable crash, return to Wittenstein for encoder re-alignment. 3. If moves OK without Load, check again for mis-alignment or load weight. Tim Brennan
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Checking Error Codes •Real-time Statistics must be on
In case the LED is Red, check alarm code. 1. Realtime Statistics must be on 2. Alarm code can be read out of real time data 3. Consult Error code data on next page
Tim Brennan
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Error Codes Alarm
Items
Check and repair
B0
Data error in Bank30 ( Bank0)
Download default data from PC from file.
B1
Data error in Bank31 (Bank1)
Download default data from PC from file.
B8-B9
The relation with encoder and motor is wrong ( connection, circuits ...)
Check the internal friction without power. Check the motor cable. This can be caused if motor rotor or cylinder is locked (internally or due to external jam). Return for Repair
BB-BE
Error at origin return (Homing)
Check the movement and load condition at homing. Increase homing current if necessary. If error continues, Return for repair.
C0
Over velocity
C1
Motor abnormal movement
D0
Over voltage input
This can be caused by power supply. If the actual power level is OK, return for repair.
D1
Internal over voltage by regenerative power
Check the movement with default data. If this doesn't fix error, return for repair
D8
Positional deviation counter overflow
Due to continuously movement in 1 direction (for rotary only). Set shortest travel bit to allow for rollover. If error remains, return for repair.
E0
Over heat (85degC)
Change the load condition. If it is not caused by load condition or excessive ambient temperature, return for repair.
E8-EC
Encoder error
Return for Repair.
F8
Check sum error in EEPROM
Re-write default data. If "F8" error still happens, Return for repair.
Tim Brennan
Can be caused by vertical falling axis (drive runaway). If can't remove condition that causes this, return for repair
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Other Modes of failure 1. Damaged or pinched cables. Do not bend cables past maximum bend radius (see chart at the right)
2. Rotated cylinder. Do not apply rotational force to output rod. Always apply counterforce to prevent internal bushing from being damaged.
Tim Brennan
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Other Modes of failure 3. If positioning repeatability goes down, check for rotational play in output rod. This can be a sign of wear on the output bushing.
4. If Cylinder makes loud or grinding noise, typically due to damaged input bearings, normally caused by crash. Return for repair.
Tim Brennan
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Thank you for your attention
Tim Brennan
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