P40 Controller is a commonly used control system for hydraulic press brakes, and some hydraulic press brakes produced by KRRASS use the P40 Controller system.
Description
This manual contains important information regarding the handling of the device.
For your own safety and operational safety, please observe all safety warnings and instructions.
Precondition for safe operation is the compliance with the specified safety and handling instructions.
Moreover, the existing local accident prevention regulations and the general safety rules at the site of operation have to be observed.
Please read the operating manual carefully before starting to work with the device!
It is part of the product and should be kept close to the device and accessible for the staff at any time. The illustrations in the manual are for better demonstration of the facts. They are not necessarily to scale and can slightly differ from the actual design.
Product Features
The positioning controller of P40 series is applicable to easy positioning tasks. An important feature is the easy structured function menu. It allows a quick and comfortable setting of the target value, if necessary a specific quantity of desired pieces.
Target and actual value of the axes plus quantity will be displayed on the front panel. The keyboard is simple and user-friendly. With the keyboard the target and the actual value can be forced and the positioning can be started.
The P40 series has an internal program memory for up to 1000 lines. For the positioning two different kinds of output signals are available: Switch mode positioning and PID-analogue output.
The P40 series can alternatively be supplied with 24VDC.
Overview of essential features:
- Single or Two Axis-Controller
- Analogue or digital outputs for 1 – 3 speed operation
- 16 free programmable digital in-/outputs (optional 8 digital in-/outputs)
- Program memory for up to 1000 sets
Design and Function
NOTE!
Display elements can vary depending on control mode and configura tion.
Installation and First Start-Up
Mounting / Installing
For the installation of the device an opening according to the disruption degree (see Chapter “Technical Data”), must be cut in machine chassis.
The device is tensed up by two studs and two swiveling flaps, screwed on in the case, with the machine chassis (included in delivery). Only a screwdriver is necessary for this.
Activation of the device
The device starts automatically after operation voltage application.
Menu Structure, Sections and Parameters
Menu Axis
Distances
Relevant distances for the axes can be set in this menu.
- Axis distances
Access to parameters concerning distances e.g. speeds etc.
- Axis times
Access to parameters concerning times e.g. position reached, zero speed monitoring, rotary encoder etc.
- Axis analogue
Access to parameters concerning the analogue output.
- Axis settings
Access to general parameters concerning the axes.
Slow forward
Creep forward
Correction stop forward
Slow backward
Creep backward
Correction stop backward
Tolerance window
Manipulation
Spindle compensation Forced loop
Reference value
Retract length
End position Min
End position Max
Factor
Displacement
Tool correction
Fix position
Slow forward/slow backward = middle speed
This parameter serves the input of the distance, at which the controller switches from high speed to slow speed before reaching the target position.
Creep forward/creep backward = slow speed
This parameter serves the input of the distance, at which the controller switches from slow speed to creep speed before reaching the target position.
Correction stop forward/correction stop backward
Here a constant overrun can be compensated.
Example:
The target position is overrun by 0.2 mm constantly. The data entry has to be 0.2mm.
The stop command is then moved forward by 0.2 mm.
When starting the operation the stop offset is set first to “0” in order to be able to calibrate the overrun accurately. For an exact positioning the stop offset should be as small as possible (0.0 to 0.2 mm) i.e. the mechanical friction should be steady over the entire run distance and the slow speed and/or creep speed must be adjusted accordingly small.
Example: Positioning with two speeds
For the adjustment of the parameters generally applies:
Slow speed: 10,0mm
Creep speed: 10,0mm
Correction stop: 1,0mm
Example: Positioning with three speeds
Here for the adjustment of the parameters generally applies: Slow speed > Creep speed > Correction stop
Slow speed: 20,0mm
Creep speed: 10,0mm
Correction stop: 1,0mm
Tolerance window
If the current actual position of the target position corresponds + / – to the value of “tolerance window”,
the corresponding output “tolerance zone” (see the main configuration) is set.
Manipulation
It is possible to adjust the indicator of the actual value of the corresponding axis to the target value within the entered tolerance window. The entered range of tolerance is always active in the + and – range around the demand value. The real actual value is saved in the processor, i.e. no positioning errors add up.
Example:
Entered Value = 0,2mm (i.e. Tolerance Window +/- 0.2mm)
Internal actual value 99.8 mm
Displayed actual value 100.0 mm
Target Value 100.0 mm
Spindle compensation
In order to adjust spindle or sprocket tolerances the target position must always be approached from the same direction, i.e. in one direction the target position will be overrun by the entered value. After expiration of the time that was entered in menu/times/backlash dwell the entered target position will be reached again.
Forced loop
If the actual value is within the range target value +/- value of forced loop window during an absolute positioning a forced loop is moved.
Reference value
A reference value and a reference position can be forced in this parameter.
Retract length
When activating the external retract input, the axis moves depending on the retract mode (see Chapter „ Menu Axis – Settings -> Retract Mode”) around this value or on this value.
Software-end position minimum/maximum
These two values can be used if no mechanical switch end-positions are present or additionally for already existing mechanical switch end-positions.
End position min.: This value should be between the smallest length/position that has to be proceeded and zero (respectively shortly before the mechanical switch end-position).
End position max.: This value should be between the largest length/position that has to be proceeded and the maximum length (respectively shortly before the mechanical switch end-position).
The factor for analysis of the pulses is set here.
Displacement (no PIN necessary)
Here positive or negative dimensions are programmed, which are added to the actual value by activating an allocated input.
Tool correction (Saw blade) (no PIN necessary)
In the incremental measurement mode this correction value is automatically added, i.e. the positioning process continues working off to this value
Fix Position
Length values to control the length limit stop axes can be set here. If the set values are reached / passed the corresponding output is .
Times
The times relevant for the respective axis can be entered here.
Axis distances
Access to parameters concerning distances e.g. speeds etc.
Axis times
Access to parameters concerning times e.g. position reached, zero speed monitoring, rotary encoder etc.
Axis analogue
Access to parameters concerning the analogue output.
Axis settings
Access to general parameters concerning the axes.
Position reached
Spindle compensation
Manual change
Monitoring
Delay Control enable
Start delay
Shutdown control
Retract time
Delay retract
Reference time
Quantity reached
Position reached
The output signal is based on a variable time during input of a time value or statically/maintained (axis in position) if the value is set to 0.
It is set if the according axis has reached the target position.
Spindle compensation
In the peak of the loop drive, the drive signals decline. The controller returns to the target value when the parameterized time has expired (adjustment range 0.0 sec. … 99.9 sec.). If the value is zero, there is no waiting period at the peak.
Manual change
Here the time in manual mode can be entered to set the speed from the low speed to the next higher speed.
Monitoring
Here a time (adjustment range 0.0 sec. … 99.9 sec.) is set to monitor the measurement system. If there are no signals from the measuring system during the programmed period of time, the drive signals are switched off to stop the engine. If the value is zero the monitoring is deactivated.
Delay control enable
After the start command the output “control enable” is activated. After reaching the target position and only after the expiration of the programmed time (adjustment range 0.0 sec. … 99.9 sec.) in the parameter “fall delay time control enable” the output is set back. If the parameter “delay control enable”is at the value of zero, the output for the control enable is adjusted statically and remains set until a change of operation modes respectively until activating the stop key.
Start delay
At a starting command the start of the positioning is delayed for the entered time.
Shutdown control
Here the time for shutdown after the position is reached is entered (adjustment range 0.0 sec. … 99.9 sec.).
Retract time
The dwell-time at the peak is entered here (adjustment range 0.0 sec. …99.9 sec.). After this time the position control is set back from the retract peak to the target value. In addition this value is also used for a retraction on time.
Delay retract
The retract is delayed for the entered time.
Reference time
In the peak of the reference run, the drive signals decline. The controller will continue positioning when this time has expired (adjustment range 0.1 sec. … 99.9 sec.).
Quantity reached
Here the time is entered in 0.1 sec. for the signal “quantity reached”. If the value = 0, the output “quantity reached” is statically set.
Analog
The axis relevant analogue parameters can be set in this menu.
Axis distances
Access to parameters concerning distances e.g. speeds etc.
Axis times
Access to parameters concerning times e.g. position reached, zero speed monitoring, rotary encoder etc.
Axis analog
Access to parameters concerning the analogue output.
Axis settings
Access to general parameters concerning the axes.
Velocity
Acceleration P-Portion I-Portion D-Position I-Limit
Impulses encoder
Start mode
Stop mode
Stop mode manual
Manual fast
Manual slow
v Reference mode 1
v Reference mode 2
U fast forward
U slow forward
U creep forward
U fast backward
U slow backward
U creep backward
Velocity
The maximum speed is set in this parameter, in rpm. Should there be gearing between the motor and the measuring system, this has to be considered in the calculations (e.g. gear or spindle)
Example!
Demanded (below the maximum possible !) motor speed rpm = 3000
Gearing ratio i = 10
V = rpm/i = 3000 rpm/10 = 300 rpm
Acceleration
The acceleration during positioning is set in this parameter in revolutions per square second ( ] [ ] [ 2 sU ).
Also here you have to consider possible gearing ratio.
P-Portion
Proportional amplification: setting range 1 … 99999
General:
The P-controller exclusively consists of a proportional portion and has thereby its reinforcing characteristic. The P-term multiplies the input value with a constant coefficient.
P40:
At offset the difference between the target and actual value is multiplied with the entered value and shown as power-sharing. The bigger the proportional amplification the more sensitive the control loop will be (possibly even unstable).
I-portion / I-Limit
Integral step: setting range 1 … 99999
General:
An I-controller (integrating controller) determines the control value through timed integration of the offset taking the reset time into account. A continuing offset leads to further increase of the analogue output. The reset time determines how big the temporal influence is. The maximum reset time is limited through I-limit. The step response of the I-portion is a linear increase. That means for a constant offset the integral will be increased and thus reinforces the I-portion.
P40:
At offset the analogue control voltage will continue to increase step by step until there is zero difference between the target and actual position and the entered I-limit in this parameter is reached respectively.
The greater the I-portion, the slower is the response.
D-portion
Differential voltage: setting 1…1000
General:
The D-controller (differential controller) determines the control value from the derivative with respect to time of the offset.
P40:
At offset a short voltage pulse proportional to the rate of change will be put out to compensate quickly without sacrificing the stability of the control loop permanently. The value of the voltage pulse is entered. (max + / – 10 V).
Impulses encoder (rotary encoder resolution)
The number of pulses per revolution of the engine is entered in this parameter. This enables amongst others the calculation of speed to be effected (max. 9999 pulses per revolution).
Start mode
Stop mode / Stop mode manual
- Manual fast
Here the speed “fast” for moving the axis in manual mode can be defined.
- Manual slow
Here the speed „slow“ for moving the axis in manual mode can be defined.
v Reference mode 1
Here the reference run speed of the stopping point until reaching the initiator is defined.
v Reference mode 2
Here the reference run speed of stopping point until reaching the index pulse is defined.
U fast / slow / creep speed forward
Voltage during fast / slow / creep speed forward.
U fast / slow / creep speed backward
Voltage during fast / slow / creep speed backward.
Settings
System relevant general parameters can be entered in this parameter.
Axis distances
Access to parameters concerning distances e.g. speeds etc.
Axis times
Access to parameters concerning times e.g. position reached, zero speed monitoring, rotary encoder etc.
Axis analogue
Access to parameters concerning the analogue output.
Axis settings
Access to general parameters concerning the axes.
Axis type
Button manual mode
Drive signal configuration Reference mode
Spindle compensation mode
Software end-position
Hardware end-position Retract mode
Error compensation
Piece counter
Incremental positioning
Decimal point
Display option manual
Unit
Axis type
The type of axis is defined.
- Digital + CPU (use with positioning through digital drive signals)
- Digital + PID (use with PID version)
Button manual mode
The function of the keys in manual mode is defined in this parameter.
- off (The buttons F1, F3 on the control are deactivated for the according axis.
This axis can only be moved via the correspondingly assigned inputs.) - normal
- inverted
Drive signal configuration
With configuration of the drive signals different starting combinations for the corresponding speeds can be adjusted.
- Drive signals = Mode 1
3 speeds
Speed = output signals 1-3 ascending
Output 4 sets direction reverse
- Drive signals = Mode 2
2 speeds ((ELGO Standard)
Independent outputs for forwards and reverse
Independent outputs for fast and slow
- Drive signals = Mode 3
2 speeds
speed = output signals 2 + 3
output 4 set direction reverse
- Drive signals = Mode 4
2 speeds
Independent outputs for direction and speed
- Drive signals = Mode 5
3 speeds
Speed forward = output signals 1-3 ascending
Speed backward = always fast
output 4 sets direction reverse
- Drive signals = Mode 6
3 speeds
Binary coded
output 1 = forward
output 4 = backward
outputs 2+3 = speed
- Drive signals = Mode 7
3 speed
Forward/backward separately
Reference mode
(see Chapter “Operation and Operation Modes”)
- Mode 1 Reference via parameter with “F2”- button *
- Mode 2 Reference via parameter & external input *
- Mode 3 Reference via Target value & “F2” button
- Mode 4 Reference via Target value & external input **
- Mode 5 Reference drive pos. via parameter with “F2” button **
- Mode 6 Reference drive pos. via external input. **
- Mode 7 Reference drive neg. via “F2” button **
- Mode 8 Reference drive neg. via external input **
* see axis parameters · axis · distances · reference value
** see axis parameters · axis · time · reversion Ref. drive
1223133123132
Extra on PID – positioning:
Menu Axis
Axis
Analogue
v. Ref. drive part 1
v. Ref. drive part 2
Above the “F2”-button the reference symbol of the corresponding axis is displayed
External input has to be allocated.
Spindle compensation mode
No spindle compensation
Negative spindle compensation –
Positive spindle compensation +
With forced loop –
With forced loop +
Software end-position
all end positions active
end position min deactivated
end position max deactivated
all end positions deactivated
Hardware end-position
all end positions active
end position min (defined input) deactivated
end position max (defined input) deactivated
all end positions deactivated
Retract mode
Mode 1 Descent/retract to actual value + adjusted value*
Mode 2 Descent/retract to adjusted value*
Mode 3 Descent/retract positive to actual value for the adjusted time period**
Mode 4 Descent/retract to actual value + adjusted value* without return
Mode 5 Descent/retract to adjusted value* without return
Mode 6 Descent/retract positive to actual value for the adjusted time period** without return
Mode 7 Descent/retract to actual value – adjusted value*
Mode 8 Descent/retract negative to actual value for the adjusted time period**
Mode 9 Descent/retract to actual value – adjusted value* without return
Mode10 Descent/retract negative to actual value for the adjusted time period** without return
* see Menu Axis Axis Distances descent/retract distance
** see Menu Axis Axis Times descent
Error compensation
Here the activity of the error compensation is defined for incremental measurement positioning.
off
on
Piece Counter
With this parameter the counter mode will be set into the “single mode”.
without counter
auto decrement *
auto decrement + Stop *
auto increment *
auto decrement/ increment *
decrement **
decrement + Stop **
increment **
decrement/ increment **
– With the function “Counter increment”, it is counting up from the current actual value.
– With the function “Counter decrement”, it is counting towards zero.
– With the function “counter decrement/increment”, it is decrementing if a certain number of items have been assigned. If it reaches zero, the number of units corresponding to the time stored in the parameter “times-axes-quantity reached” is set for a time and not static. Then the counter is incrementing.
* reaching the position the counter will be activated ** with the input quantity the counter will be activated.
Incremental positioning
Here the option “absolute / incremental Positioning” is activated.
off no selection possible, always absolute positioning
on selection via keypad possible
extern selection via external inputs possible
If this function is activated, one of the following Symbols (see Fehler! Verweisquelle konnte nicht gefunden werden. Display Elements) is displayed.
There is always an absolute measurement, if there is none of the signs on the display and if the function is deactivated.
Decimal point
Here the decimal point is defined.
Display option manual
Here the image of the manual button will be defined.
Unit
The displayed unit can be specified here: mm, inch or degree.
Menu System
12.3.3.1 Linking of Inputs with Functions
In the Chapter “Table of I/O Configurations” you will find an overview of all functions which can be assigned to
the inputs. After dialling a function by using the navigation buttons you can select an input for this function by
pressing the Enter key. If a previously used input needs to be reset, you can use “delete key” to dial in the “not
used” state. It is also possible to press the Enter key repeatedly until “not-used” is displayed. A multiple use of
inputs is not possible here. If an input is already used only the next free input can be chosen automatically.
12.3.3.2 Assigning the Logic to input
If you have allocated the inputs of the controller with functions, then you can use this menu to define whether the
corresponding input function shall be triggered at a logical “High”-level or at a logical “Low”-level. Assigning the
logic takes place by selecting the corresponding function and pressing the enter key.
12.3.3.3 Linking of Outputs with functions
In the Chapter “Table of I/O Configurations” you will find an overview of all functions of the outputs which can be assigned. After dialling a function by using the navigation buttons you can select an output for this function by pressing the Enter key. If a previously used output needs to be reset, you can use the “delete key” to dial it in the “not used” state. A multiple use of outputs is not possible here. If an output is assigned with a function, only the next free input can be chosen automatically.
12.3.3.4 Assigning the Logic to Outputs
For the outputs it is also possible to assign logic depending on the selected output function. The setting follows
the same procedure as in Chapter “Assigning the Logic to Inputs “.
Menu Password
The password is input in the menu password.
NOTE!
The service mode / parameter level is saved by password
PIN CODE: 250565 After login all parameters can set.
Menu Diagnosis / Error Messages
Error Message
Table 3 Error Messages
Menu Contrast
In this menu the contrast of the display can be configured.
Use therefor the following buttons:
Parameter Table
Table 4 Axis Parameters – Distances
* = dependent on decimal point setting (particulars with 1/10)
Table 5 Axis Parameters – Times
Table 6 Axis Parameters – Analog
Tabelle 1Calibration of analog Inputs
Table 8 System – Settings
Table 9 System – Times
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