IndraMotion for Metal Forming Rollfeed Extended 02VRS

Transcription

1 Electric Drives Linear Motion and and Controls Hydraulics Assembly Technologies Pneumatics Service IndraMotion for Metal Forming Rollfeed Extended 02VRS R Edition 01 Functional Description

2 About this Documentation Rollfeed Extended 02VRS Title Type of Documentation IndraMotion for Metal Forming Rollfeed Extended 02VRS Functional Description Document Typecode Internal File Reference B305-01/EN Purpose of Documentation This documentation serves for the description of the system solution "IndraMotion for Metal Forming Rollfeed Extended 02VRS". Record of Revisions Description Release Date Notes 11/07 First edition Copyright 2007 Bosch Rexroth AG Copying this document, giving it to others and the use or communication of the contents thereof without express authority, are forbidden. Offenders are liable for the payment of damages. All rights are reserved in the event of the grant of a patent or the registration of a utility model or design (DIN 34-1). Validity The specified data is for product description purposes only and may not be deemed to be guaranteed unless expressly confirmed in the contract. All rights are reserved with respect to the content of this documentation and the availability of the product. Published by Bosch Rexroth AG Bgm.-Dr.-Nebel-Str. 2 D Lohr a. Main Telephone +49 (0)93 52/40-0 Tx Fax +49 (0)93 52/ Dept. BRC/EAM Note This document has been printed on chlorine-free bleached paper.

3 Rollfeed Extended 02VRS Content I Content 1 System Presentation Brief Description Configurations Rollfeed Extended Further Documentation Important Directions for Use Appropriate Use Introduction Areas of Use and Application Inappropriate Use Safety Instructions for Electric Drives and Controls Introduction Explanations Hazards by Inappropriate Use General Information Protection Against Contact with Electrical Parts Protection by Protective Low Voltage (PELV) Against Electrical Shock Protection Against Dangerous Movements Protection Against Magnetic and Electromagnetic Fields During Operations and Mounting Protection Against Contact with Hot Parts Protection During Handling and Installation Battery Safety Protection Against Pressurized Systems Functional Description Range of Application Operation Modes Parameter Mode Manual Mode Automatic Mode Setup Mode Automatic Feed Adjustment Quantity Count Program Run Diagnostics Messages Product Data Use of Feed Angle

4 II Content Rollfeed Extended 02VRS Average Path Velocity Strokes per Minute Measuring Wheel Programmable Limit Switch Tool Wear Override Micro-Adjust Presses Monitoring Roll Lift Product Data Management Safety Queries (SIC) Integrated Safety Engineering In- / Outputs Overview In- / Output Assignment PLC-Inputs PLC-Outputs In- / Output Assignment on the Basic Circuit Board Meaning of the Other Signals at Connector X In- / Output Assignment of the Digital I/O-Extension on the Option Module MD In- / Output Assignment of the Control Interface Parallel Interface HMI General VCP08 Key Description Display Menu Keys Operation Keys Edit Keys Navigation Keys Special Keys Brief Description Overview Main Menu Submenus Status Line Start Screen Main Display Display "Product" (F1) Display "Product Edit Product" (F1) Display "Product Edit Part Lengths" (F2) Display "Product Preset Actual Quantity" (F3) Display "Product Edit Product Load Default Product Data" (F2) Display "Feed Data" (F2) Display "Feed Preset Total Length / Total Quantity" (F1) Display "Feed Feed Parameter" (F3)

5 Rollfeed Extended 02VRS Content III Display "Feed Feed Configuration" (F4) Display "Feed Feed Optimization" (F5) Display "Diagnosis" (F3) Display "Diagnosis - Inputs" (F1) Display "Diagnosis Outputs" (F2) Display "Diagnosis Tools" (F2) Display "Diagnosis Tools Tool Control" (F2) Display "Diagnosis Tools Tool Acknowledgment" (F3) Display "Diagnosis Tools Time Acknowledgment" (F4) Display "Diagnosis Cam Switch" (F3) Display "Diagnosis Safety Switch" (F4) Display "Diagnosis Extras" (F5) Display "Diagnosis - Extras - Positions" (F2) Display "Diagnosis Extras Versions" (F4) Display "Diagnosis Extras Feed Optimization" (F4) Display Diagnosis Extras Feed Diagnosis (F5) Display "Setup" (F4) Display "Machine Parameter" (F5) Display "Machine Tools" (F1) Display "Machine Tools Tool Control" (F2) Display "Machine Tools Time Acknowledgment" (F3) Display "Machine Tools Preset Tool Counter" (F4) Display "Machine Cam Switch" (F2) Display "Machine Safety Switch" (F3) Display "Machine Parameter" (F4) Display "Machine Parameter System Parameter" (F1) Display "Machine Parameter Load Base Parameter" (F2) Display "Machine Parameter Extras" (F3) Pass-Through Mode Functional Description General Command Format Status Requests...2 Representation of Numerals in a Telegram...3 List of System Status Requests Input (Write) Requests Parameter Request Parameter Input (Write) Command Drive Parameter Read Request Error Messages Check Sum Generation Parameters System Parameters P , Product Data and Machine Parameters P , Manual Velocity

6 IV Content Rollfeed Extended 02VRS P , Setup Velocity P , Velocity Limit Bipolar P , Rollfeed Configuration parameter P , - reserved P , Monitoring Cycle Time P , Rollfeed Configuration Parameter P , Average Path Velocity P , - reserved P , Micro-Adjust Value P , Delay Time Close Rolls P , Number of Presses Strokes P , Rollfeed Diagnostics Messages and Error Numbers P , Preset Status Parameter P , Press: Time Monitoring P , Internal Presses Velocity P , Rollfeed System Diagnostics P , Rollfeed Status Parameter Commmissioning General Checklist Rollfeed Extended Download of the VCP-Application on the VCP General Notes Operation Instructions to the VCP-Application Download Ordering Information Ethernet Cables Service Case Control Unit Replace with Fixed Stuck MMC-Card Diagnostics Error Diagnostics Product Data Errors Command Parameter Errors System Errors Diagnostics Messages Connecting Diagrams In- / Output Assignment on the Basic Circuit Card In- / Output Assignment of the Digital I/O-Extension on the Option Module MD In- / Output Assignment on the Parallel Interface Encoder Connection Measuring Wheel Encoder Connection ENS Encoder Connection EN SSI-Encoder Evaluation on MD

7 Rollfeed Extended 02VRS Content V 12 Service & Support Helpdesk Service-Hotline Internet Vor der Kontaktaufnahme... - Before contacting us Kundenbetreuungsstellen - Sales & Service Facilities Index 13-1

8 VI Content Rollfeed Extended 02VRS

9 Rollfeed Extended 02VRS System Presentation System Presentation 1.1 Brief Description Fig. 1-1: Rollfeed The Bosch Rexroth rollfeed solution "IndraMotion for Metal Forming - Rollfeed Extended" is an uniaxial feed that can be customized for a variety of needs by using specific hardware and software components. Rollfeed Extended has been optimized for applications with controlled feeding of metals, foils or similar materials that are processed using a shear, a press, a plastic covering machine, a thermoformer or related machine types. Adding features such as a PLS, safety queries or tool control enables more complex machine applications. From the machine manufacturer or the end user no further programmings are required. Parameterization as well as wiring of predefined inputs and outputs for feed-specific data are quickly executed and provide the basis for far-reaching diagnostics possibilities. The machine manufacturer or operator combines the Rollfeed Extended System by input of a few parameters via an user interface. The configuration of the system is simplified again by deposited standard parameters and user data. Via the Bosch Rexroth compact HMI VCP 08 the operator gets only the essential information and input fields to the use of the system. By pushing a button it is possible to change the operation mode (Manual, Parameter, Setup, Automatic) or to select a certain product from the product administration. Besides, in every mask meaningful status information is available. The use of the compact HMI VCP 08 for the system solution is optional. Generally there also exists the possibility to create own user interfaces for the different operation terminals. The relevant system information for the display menus etc. are provided by the system parameters (cp. chapter 8). The system solution Rollfeed Extended also supports an ASCII-Pass- Through mode (cp. chapter 7) that allows a serial communication link from a PC (press controller) through a VCP HMI device to a Rollfeed control. Via this connection, the PC can retrieve process information from the Rollfeed control or send action commands to the Rollfeed control. The system has been developed for high integrity and security. An extensive diagnostics system shows conditions of the inputs and outputs

10 1-2 System Presentation Rollfeed Extended 02VRS 1.2 Configurations just as operation mode typical messages. The clear language of the diagnostics messages provides all-around support to the machine operator.this helps to quickly return to the production process after an error occurs. Rollfeed Extended Fig. 1-2: Rollfeed Extended Hardware Components Following hardware components are required: Drive control section IndraDrive Advanved with following options: Encoder interface on option slot 1 (X4) for motor encoder Control interface Parallel-Interface (X15, HCC01) Digital I/O-Extension and SSI-Encoder evaluation MD2 (X10) MMC (X7, MultiMediaCard) Following hardware components are optional: Encoder interface on option 2 (X8) for measuring wheel encoder on the drive control section IndraDrive Advanced Safety Engineering S1 (X41) Starting lock L1 (X41) VCP 08 Serial interface cable RS232 (RKB0004) between VCP 08 (X3-SER1, 25-pins) and IndraDrive (X2, MiniDIN, 8-pins) Serial interface cable RS232 (IKB0053) for communication between commissioning PC and VCP 08 Ethernet cross link cable or Ethernet standard cable (RKB0007 or RKB0008) between PC and VCP for downloading the VCP application user interface

11 Rollfeed Extended 02VRS System Presentation 1-3 Software Components Following software components are required: Drive firmware "MPH" with functional package Synchronization and IndraMotion MLD-S on MultiMediaCard (FWA-INDRV*-MPH-04VRS- D5-1-NNN-ML) Technology Function Block on MultiMediaCard (FWS-MLDTFA-RFE-02VRS-D0) Engineering-Framework IndraWorks (SWA-IWORKS-D**-03VRS-D0-CD650) Following software components are optional: Application user interface on the VCP08 RFE_02VRS_VCP0x0x.cb The finished user interface for the operation terminal VCP 08 is available on CD or via the Internet (Rexroth portal). The access to the Rexroth portal is only possible if a registration is present. IndraMotion for Metal Forming - CD (SWA-IM*MLD-MF*-02VRS-D0-CD650-COPY) IndraMotion for Metal Forming - Internet en/software_en/download_automationssysteme_en Note: The following files and documentation are additionally available in folder "\User" on the delivered MMC: VCP-HMI application (VCP 08) Description to the download of the VCP-HMI application Functional description - Rollfeed Extended 02VRS Release notes Further Documentation Firmware-Documentation: Parameter Description DOK-INDRV*-GEN-**VRS**-PA**-EN-P Notes to the failure description (diagnostics description) DOK-INDRV*-GEN-**VRS**-WA**-EN-P Functional Description DOK-INDRV*-MP-**VRS**-FK**-EN-P Integrated Safety Engineering DOK-INDRV*-SI*-**VRS**-FK**-EN-P Hardware-Documentation (Project Planning): Power Section IndraDrive C DOK-INDRV*-HCSxx.1****-PR**-EN-P Power Section IndraDrive M DOK-INDRV*-HMS+HMD****-PR**-EN-P Control Section DOK-INDRV*-CSH********-PR**-EN-P Supply Device IndraDrive M DOK-INDRV*-HMV-*******-PR**-EN-P

12 1-4 System Presentation Rollfeed Extended 02VRS

13 Rollfeed Extended 02VRS Important Directions for Use Important Directions for Use 2.1 Appropriate Use Introduction Bosch Rexroth products represent state-of-the-art developments and manufacturing. They are tested prior to delivery to ensure operating safety and reliability. The products may only be used in the manner that is defined as appropriate. If they are used in an inappropriate manner, then situations can develop that may lead to property damage or injury to personnel. Note: Bosch Rexroth as manufacturer is not liable for any damages resulting from inappropriate use. In such cases, the guarantee and the right to payment of damages resulting from inappropriate use are forfeited. The user alone carries all responsibility of the risks. Before using Bosch Rexroth products, make sure that all the prerequisites for an appropriate use of the products are satisfied: Personnel that in any way, shape or form uses our products must first read and understand the relevant safety instructions and be familiar with appropriate use. If the products take the form of hardware, then they must remain in their original state, in other words, no structural changes are permitted. It is not permitted to decompile software products or alter source codes. Do not mount damaged or faulty products or use them in operation. Make sure that the products have been installed in the manner described in the relevant documentation.

14 2-2 Important Directions for Use Rollfeed Extended 02VRS Areas of Use and Application Drive controllers made by Bosch Rexroth are designed to control electrical motors and monitor their operation. Control and monitoring of the motors may require additional sensors and actors. Note: The drive controllers may only be used with the accessories and parts specified in this document. If a component has not been specifically named, then it may not be either mounted or connected. The same applies to cables and lines. Operation is only permitted in the specified configurations and combinations of components using the software and firmware as specified in the relevant Functional Descriptions. 2.2 Inappropriate Use Every drive controller has to be programmed before commissioning, making it possible for the motor to execute the specific functions of an application. The drive controllers have been developed for use in single- and multiaxis drive and control tasks. To ensure an application-specific use, the drive controllers are available with different drive power and different interfaces. Typical applications of the drive controllers include: handling and mounting systems, packaging and food machines, printing and paper processing machines and machine tools. The drive controllers may only be operated under the assembly and installation conditions described in this documentation, in the specified position of normal use and under the ambient conditions as described (temperature, degree of protection, humidity, EMC, etc.). Using the drive controllers outside of the operating conditions described in this documentation and outside of the indicated technical data and specifications is defined as "inappropriate use". Drive controllers must not be used, if... they are subject to operating conditions that do not meet the specified ambient conditions. This includes, for example, operation under water, under extreme temperature fluctuations or extremely high maximum temperatures. Furthermore, the drive controllers must not be used in applications which have not been expressly authorized by Bosch Rexroth. Please carefully follow the specifications outlined in the general Safety Instructions!

15 Rollfeed Extended 02VRS Safety Instructions for Electric Drives and Controls Safety Instructions for Electric Drives and Controls 3.1 Introduction Read these instructions before the equipment is used and eliminate the risk of personal injury or property damage. Follow these safety instructions at all times. Do not attempt to install, use or service this equipment without first reading all documentation provided with the product. Read and understand these safety instructions and all user documentation of the equipment prior to working with the equipment at any time. If you do not have the user documentation for your equipment contact your local Bosch Rexroth representative to send this documentation immediately to the person or persons responsible for the safe operation of this equipment. If the product is resold, rented or transferred or passed on to others, then these safety instructions must be delivered with the product. WARNING Inappropriate use of this equipment, failure to follow the safety instructions in this document or tampering with the product, including disabling of safety devices, may result in product damage, personal injury, severe electrical shock or death! 3.2 Explanations The safety warnings in this documentation describe individual degrees of hazard seriousness in compliance with ANSI Z 535: Warning symbol with signal word Degree of hazard seriousness The degree of hazard seriousness describes the consequences resulting from non-compliance with the safety guidelines. Death or severe bodily harm will occur. DANGER Death or severe bodily harm may occur. WARNING Bodily harm or product damage may occur. CAUTION Fig. 3-1: Classes of danger with ANSI Z 535

16 3-2 Safety Instructions for Electric Drives and Controls Rollfeed Extended 02VRS 3.3 Hazards by Inappropriate Use DANGER High voltage and high discharge current! Danger to life, risk of severe electrical shock and risk of injury! DANGER Dangerous movements! Danger to life and risk of injury or equipment damage by unintentional motor movements! WARNING High electrical voltage due to wrong connections! Danger to life, severe electrical shock and severe bodily injury! WARNING Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Surface of machine housing could be extremely hot! Danger of injury! Danger of burns! CAUTION CAUTION Risk of injury due to inappropriate handling! Bodily injury caused by crushing, shearing, cutting and mechanical shock or improper handling of pressurized systems! Risk of injury due to inappropriate handling of batteries! CAUTION

17 Rollfeed Extended 02VRS Safety Instructions for Electric Drives and Controls General Information The Bosch Rexroth AG is not liable for damages resulting from failure to observe the warnings given in these documentation. Order operating, maintenance and safety instructions in your language before starting up the machine. If you find that due to a translation error you can not completely understand the documentation for your product, please ask your supplier to clarify. Proper and correct transport, storage, assembly and installation as well as care in operation and maintenance are prerequisites for optimal and safe operation of this equipment. Trained and qualified personnel in electrical equipment: Only trained and qualified personnel may work on this equipment or within its proximity. Personnel are qualified if they have sufficient knowledge of the assembly, installation and operation of the product as well as an understanding of all warnings and precautionary measures noted in these instructions. Furthermore, they should be trained, instructed and qualified to switch electrical circuits and equipment on and off, to ground them and to mark them according to the requirements of safe work practices and common sense. They must have adequate safety equipment and be trained in first aid. Only use spare parts and accessories approved by the manufacturer. Follow all safety regulations and requirements for the specific application as practiced in the country of use. The equipment is designed for installation on commercial machinery. European countries: see directive 89/392/EEC (machine guideline). The ambient conditions given in the product documentation must be observed. Use only safety features that are clearly and explicitly approved in the Project Planning manual. For example, the following areas of use are not allowed: Construction cranes, Elevators used for people or freight, Devices and vehicles to transport people, Medical applications, Refinery plants, the transport of hazardous goods, Radioactive or nuclear applications, Applications sensitive to high frequency, mining, food processing, Control of protection equipment (also in a machine). Start-up is only permitted once it is sure that the machine, in which the product is installed, complies with the requirements of national safety regulations and safety specifications of the application. Operation is only permitted if the national EMC regulations for the application are met. The instructions for installation in accordance with EMC requirements can be found in the Bosch Rexroth document "EMC in Drive and Control Systems. The machine builder is responsible for compliance with the limiting values as prescribed in the national regulations and specific EMC regulations for the application. European countries: see Directive 89/336/EEC (EMC Guideline). U.S.A.: See National Electrical Codes (NEC), National Electrical Manufacturers Association (NEMA), and local building codes. The user of this equipment must consult the above noted items at all times. Technical data, connections and operational conditions are specified in the product documentation and must be followed at all times.

18 3-4 Safety Instructions for Electric Drives and Controls Rollfeed Extended 02VRS 3.5 Protection Against Contact with Electrical Parts Note: This section refers to equipment with voltages above 50 Volts. Making contact with parts conducting voltages above 50 Volts could be dangerous to personnel and cause an electrical shock. When operating electrical equipment, it is unavoidable that some parts of the unit conduct dangerous voltages. DANGER High electrical voltage! Danger to life, severe electrical shock and severe bodily injury! Only those trained and qualified to work with or on electrical equipment are permitted to operate, maintain or repair this equipment. Follow general construction and safety regulations when working on electrical installations. Before switching on power the ground wire must be permanently connected to all electrical units according to the connection diagram. Do not operate electrical equipment at any time if the ground wire is not permanently connected, even for brief measurements or tests. Before working with electrical parts with voltage potentials higher than 50 V, the equipment must be disconnected from the mains voltage or power supply. The following should be observed with electrical drives, power supplies, and filter components: Wait five (5) minutes after switching off power to allow capacitors to discharge before beginning work. Measure the voltage on the capacitors before beginning work to make sure that the equipment is safe to touch. Never touch the electrical connection points of a component while power is turned on. Install the covers and guards provided with the equipment properly before switching the equipment on. Prevent contact with live parts at any time. A residual-current-operated protective device (r.c.d.) must not be used on an electric drive! Indirect contact must be prevented by other means, for example, by an overcurrent protective device. Equipment that is built into machines must be secured against direct contact. Use appropriate housings, for example a control cabinet. European countries: according to EN 50178/1998, section U.S.A: See National Electrical Codes (NEC), National Electrical Manufacturers Association (NEMA) and local building codes. The user of this equipment must observe the above noted instructions at all times.

19 Rollfeed Extended 02VRS Safety Instructions for Electric Drives and Controls 3-5 To be observed with electrical drives, power supplies, and filter components: DANGER High electrical voltage! High leakage current! Danger to life, danger of injury and bodily harm from electrical shock! Before switching on power for electrical units, all housings and motors must be permanently grounded according to the connection diagram. This applies even for brief tests. Leakage current exceeds 3.5 ma. Therefore the electrical equipment and units must always be firmly connected to the supply network. Use a copper conductor with at least 10 mm² cross section over its entire course for this protective connection! Prior to startups, even for brief tests, always connect the protective conductor or connect with ground wire. High voltage levels can occur on the housing that could lead to severe electrical shock and personal injury. European countries: EN 50178/1998, section USA: See National Electrical Codes (NEC), National Electrical Manufacturers Association (NEMA), and local building codes. The user of this equipment must maintain the above noted instructions at all times.

20 3-6 Safety Instructions for Electric Drives and Controls Rollfeed Extended 02VRS 3.6 Protection by Protective Low Voltage (PELV) Against Electrical Shock All connections and terminals with voltages between 5 and 50 Volts on Bosch Rexroth products are protective low voltages designed in accordance with the following standards on contact safety: International: IEC EU countries: see EN 50178/1998, section WARNING High electrical voltage due to wrong connections! Danger to life, severe electrical shock and severe bodily injury! Only equipment, electrical components and cables of the protective low voltage type (PELV = Protective Extra Low Voltage) may be connected to all terminals and clamps with 0 to 50 Volts. Only safely isolated voltages and electrical circuits may be connected. Safe isolation is achieved, for example, with an isolating transformer, an optoelectronic coupler or when battery-operated. 3.7 Protection Against Dangerous Movements Dangerous movements can be caused by faulty control or the connected motors. These causes are be various such as: unclean or wrong wiring of cable connections inappropriate or wrong operation of equipment malfunction of sensors, encoders and monitoring circuits defective components software errors Dangerous movements can occur immediately after equipment is switched on or even after an unspecified time of trouble-free operation. The monitors in the drive components make faulty operation almost impossible. Regarding personnel safety, especially the danger of bodily harm and property damage, this alone should not be relied upon to ensure complete safety. Until the built-in monitors become active and effective, it must be assumed in any case that some faulty drive movements will occur. The extent of these faulty drive movements depends upon the type of control and the state of operation.

21 Rollfeed Extended 02VRS Safety Instructions for Electric Drives and Controls 3-7 DANGER Dangerous movements! Danger to life and risk of injury or equipment damage! Personnel protection must be secured for the above listed reason by means of superordinate monitors or measures. These are instituted in accordance with the specific situation of the facility and a danger and fault analysis conducted by the manufacturer of the facility. All the safety regulations that apply to this facility are included therein. By switching off, circumventing or if safety devices have simply not been activated, then random machine movements or other types of faults can occur. Avoiding accidents, injury or property damage: Keep free and clear of the machine s range of motion and moving parts. Prevent people from accidentally entering the machine s range of movement: - use protective fences - use protective railings - install protective coverings - install light curtains or light barriers Fences must be strong enough to withstand maximum possible momentum. Mount the emergency stop switch (E-stop) in the immediate reach of the operator. Verify that the emergency stop works before startup. Don t operate the machine if the emergency stop is not working. Isolate the drive power connection by means of an emergency stop circuit or use a start-inhibit system to prevent unintentional start-up. Make sure that the drives are brought to standstill before accessing or entering the danger zone. Secure vertical axes against falling or slipping after switching off the motor power by, for example: - Mechanically securing the vertical axes - Adding an external brake / clamping mechanism - Balancing and thus compensating for the vertical axes mass and the gravitational force The standard equipment motor brake or an external brake controlled directly by the servo drive are not sufficient to guarantee the safety of personnel!

22 3-8 Safety Instructions for Electric Drives and Controls Rollfeed Extended 02VRS Disconnect electrical power to the equipment using a master switch and secure the switch against reconnection for: - maintenance and repair work - cleaning of equipment - long periods of discontinued equipment use Avoid operating high-frequency, remote control and radio equipment near electronics circuits and supply leads. If use of such equipment cannot be avoided, verify the system and the plant for possible malfunctions at all possible positions of normal use before the first start-up. If necessary, perform a special electromagnetic compatibility (EMC) test on the plant. 3.8 Protection Against Magnetic and Electromagnetic Fields During Operations and Mounting Magnetic and electromagnetic fields generated by current-carrying conductors and permanent magnets in motors represent a serious health hazard to persons with heart pacemakers, metal implants and hearing aids. WARNING Health hazard for persons with heart pacemakers, metal implants and hearing aids in proximity to electrical equipment! Persons with pacemakers, metal implants and hearing aids are not permitted to enter following areas: - Areas in which electrical equipment and parts are mounted, being operated or started up. - Areas in which parts of motors with permanent magnets are being stored, operated, repaired or mounted. If it is necessary for a person with a pacemaker to enter such an area, then a physician must be consulted prior to doing so. Pacemaker, that are already implanted or will be implanted in the future, have a considerable deviation in their resistance to interference. Due to the unpredictable behavior there are no rules with general validity. Persons with hearing aids, metal implants or metal pieces must consult a doctor before they enter the areas described above. Otherwise health hazards will occur.

23 Rollfeed Extended 02VRS Safety Instructions for Electric Drives and Controls Protection Against Contact with Hot Parts CAUTION Housing surfaces could be extremely hot! Danger of injury! Danger of burns! Do not touch surfaces near the source of heat! Danger of burns! Wait ten (10) minutes before you access any hot unit. Allow the unit to cool down. Do not touch hot parts of the equipment, such as housings, heatsinks or resistors. Danger of burns! 3.10 Protection During Handling and Installation Under certain conditions unappropriate handling and installation of parts and components may cause injuries. CAUTION Risk of injury through incorrect handling! Bodily harm caused by crushing, shearing, cutting and mechanical shock! Observe general instructions and safety regulations during handling installation. Use only appropriate lifting or moving equipment. Take precautions to avoid pinching and crushing. Use only appropriate tools. If specified by the product documentation, special tools must be used. Use lifting devices and tools correctly and safely. Wear appropriate protective clothing, e.g. safety glasses, safety shoes and safety gloves. Never stay under suspended loads. Clean up liquids from the floor immediately to prevent personnel from slipping.

24 3-10 Safety Instructions for Electric Drives and Controls Rollfeed Extended 02VRS 3.11 Battery Safety Batteries contain reactive chemicals in a solid housing. Inappropriate handling may result in injuries or equipment damage. CAUTION Risk of injury through incorrect handling! Do not attempt to reactivate discharged batteries by heating or other methods (danger of explosion and corrosion). Never charge batteries (danger from leakage and explosion). Never throw batteries into a fire. Do not dismantle batteries. Handle with care. Incorrect extraction or installation of a battery can damage equipment. Note: Environmental protection and disposal! The batteries contained in the product should be considered as hazardous material for land, air and sea transport in the sense of the legal requirements (danger of explosion). Dispose batteries separately from other refuse. Observe the legal requirements given in the country of installation Protection Against Pressurized Systems Certain Motors (ADS, ADM, 1MB etc.) and drives, corresponding to the information in the Project Planning manual, must be provided with and remain under a forced load such as compressed air, hydraulic oil, cooling fluid or coolant. In these cases, improper handling of the supply of the pressurized systems or connections of the fluid or air under pressure can lead to injuries or accidents. CAUTION Danger of injury when pressurized systems are handled by untrained personnel! Do not attempt to disassemble, to open or to cut a pressurized system. Observe the operation restrictions of the respective manufacturer. Before the disassembly of pressurized systems, lower pressure and drain off the fluid or gas. Use suitable protective clothing (for example protective eyewear, safety shoes and gloves) Remove any fluid that has leaked out onto the floor immediately. Note: Environmental protection and disposal! The fluids used in the operation of the pressurized system equipment is not environmentally compatible. Fluid that is damaging to the environment must be disposed of separate from normal waste. Observe the national specifications of the country of installation.

25 Rollfeed Extended 02VRS Functional Description Functional Description 4.1 Range of Application The system solution "IndraMotion for Metal Forming - Rollfeed Extended" was especially developed for feed to length machines. It is used to control the feed of materials like metal, foil or paper and the processing of the material by a shear, punch or press. Up to 99 products can be produced in each case existing from up to 6 different part lengths. The processing of the products can be linked so that different product variants are possible. Each of this 594 (99 x 6) part lengths can be assigned an own velocity, acceleration, commanded quantity and up to 8 tool positions, before and after carried out feed progression. Every tool control can be acknowledged via inputs. To every product up to 8 outputs can be assigned which are switched as a function of an absolute presses encoder (programmable limit switch). Fig. 4-1: Product definition

26 4-2 Functional Description Rollfeed Extended 02VRS The press (shear) can be synchronized via 4 different application types in Automatic mode. The motor or measuring wheel feedback can be used as the positioning feedback. All feeds can be altered by a programmed Micro-Adjust (adding length method). The synchronization between rollfeed and press or shear is controlled by the input signal "Feed angle" or by an external presses encoder (PLS-Switch 1, evaluation of the presses position via option card MD2). The feed progression is only possible when the feed angle is available. The system is designed for functional capability and reliability. The signal exchange takes place via 24V-Signals at defined in- and outputs. A diagnostics system monitors the I/O- and operation states and stops the system if an error is reported. Extensive diagnostics messages are available from the HMI to assist a user to operate and troubleshoot the system. Fig. 4-2: Feed angle By the use of interrupt and Override a sag regulation can take place. Fig. 4-3: Rollfeed 4.2 Operation Modes 4 different operation modes are supported: Parameter mode Manual mode Automatic mode Setup mode

27 Rollfeed Extended 02VRS Functional Description 4-3 Parameter Mode In Parameter mode all machine-specific data like feed constant, maximum velocity, encoder information, PLS-Outputs etc. are entered. In this operation mode the power section is switched off. The parameter mode is activated if at input "Parameter" (X31/5, P ) the signal level "H" is detected. In parameter mode the drive changes to phase 2. Now drive parameters can be changed. Parameter mode is normally used only at initial startup of the drive control unit for the input of machine data. The parameter input can take place via the compact HMI VCP 08 or by means of the Engineering-Framework IndraWorks. Nearly all parameters are changeable by the user. The function of the individual parameters can be seen in the parameter description DOK-INDRV*-GEN-**VRS**-PA02-EN-P. Additionally the following listed parameters are used as system parameters (see chapter 8, Parameters). Parameter Function P Product data and machine parameters P Manual velocity P Setup velocity P Velocity limit bipolar P Rollfeed Configuration parameter 1 P reserved P Monitoring cycle time P Rollfeed Configuration parameter 2 P Average path velocity P Selection part number P Micro-Adjust value P Deceleration time Close rolls P Number of presses strokes P Rollfeed Diagnostics messages- and error number P Preset status parameter P Standstill time press P Internal presses velocity P Rollfeed System diagnostics messages P Rollfeed Status parameter Fig. 4-4: System parameters With the comfortable user interface of the Engineering-Framework IndraWorks the parameters can be stored on a PC. Note: At any time it can be switched to Parameter mode. On this account it should be secured by a key-operated switch or by other methods.

28 4-4 Functional Description Rollfeed Extended 02VRS Manual Mode In Manual mode, progressions can be made via the inputs "Jog Forward" (Jog+) and "Jog Backward" (Jog-) using the pre-defined velocity in Parameter P , Manual velocity. It is a percentage value related to the maximum machine velocity from parameter P , Velocity limit value bipolar. A possibly configured velocity override is considered. In this operation mode no tools or press are activated by the system solution. The feed progression is not possible if input "Feed angle" is "0". This condition is cancelled by either applying "Start" input or pressing the "START" key on the VCP. Following functions can be activated: Roll lift Manual mode Override Jogging is not possible when: Feed interrupt Stop No feed angle or no start Note: For easing with the first commissioning, input "Stop neg " (P ) and input "Feed interrupt neg " (P ) has no function if bit 4 in parameter P , Rollfeed Configuration parameter 1 is set. Automatic Mode Automatic mode is activated by applying 24 Vdc to input "Automatic". The output "Automatic" is set to indicate the system is in Automatic mode. This mode is started by a rising edge at input "Start". Via output "Run" a running Automatic mode is signaled. In Automatic mode the products are processed with the input data of length, velocity etc. A possibly configured velocity override is considered. Before and after each feed, up to 8 outputs for tool control can be used. An acknowledgment query of the used tools is also possible. Tools can be accepted by input signal, time acknowledgment or by a combination of both variants. The switching operations of these outputs are counted so that information about tool wear is available. If the given commanded quantity of the production is reached, or if either the "Cycle Stop" or "Product Stop" signal is present, the press is stopped, all outputs for tool control are turned off (not the PLS outputs) and Automatic mode is interrupted. By presetting 0 as the commanded quantity for the batch counter, a continuous-operation mode can be activated. The Automatic mode can be continued with the start signal. The Automatic mode can only be left if the complete product has been processed or if "Immediate Stop" is actived. Should the Automatic mode be left before, so this can be achieved with a rising edge at input "Clear Errors" and not set input "Automatic". A re-entry with residual lengths processing is not possible in this case. If an external absolute encoder is connected that signals the presses position, four inputs can be compared with four presses positions (PLS outputs) for monitoring. The comparison can be based on "0," "1," rising edge or falling edge.

29 Rollfeed Extended 02VRS Functional Description 4-5 Note: If the evaluation of the presses signals TDC in parameter P , Rollfeed Configuration parameter 2 (Bit 4) is activated, the automatic program can only be started, if the feed angle is pre-set (press in TDC). If the press is not in TDC, it must be externally moved to TDC in Manual mode. The feed movement by the system solution Rollfeed Extended is configureable and allows the following moving profiles: Feed via the drive-internal operation mode "Drive-positioning" (trapezoid or triangle profile) Feed via the drive-internal operation mode "Electronic motion profile" coupled to the internal virtual master axis (VMA) Feed via the drive-internal operation mode "Electronic motion profile" coupled to an external presses encoder (real master axis, RMA) With the operation mode "Electronic motion profile with real / virtual master axis" exists a fixed connection between master axis position and feed axis. In this case the feed movement is represented by the standardized profile "Polynomial 5th order" or via a "Cam table". The wished moving profile is set via parameter P , Rollfeed - Configuration parameter 1 (bit 11, 12). The wished profile type (e.g., polynomial 5th order) must be selected via the parameter P , Product data and machine parameters (element 3643). With master axis coupling the feed area (switch-on/off angle for cam switches) must be defined via the elements 3601 and 3609 of parameter P , Product data and machine parameters. The feed movement can be shortened, in addition, by a parameterizable tolerance window, concerning the end of the feed area (switch-off angle), (cp. parameter P , Product data and machine parameters (element 3642)). With use of an external presses encoder the current position is output in parameter P , Rollfeed Status parameter (element 12). For avoidance of a reverse turning feed axis with master axis coupling with external presses encoder, a negative velocity limit value must be parameterized for the external presses encoder in parameter P , Product data and machine parameters (element 3644). If the press moves backwards and exceeds the velocity of this limit value, the error "Negative presses velocity" is generated. If,0' is given for the limit value, so the monitoring is deactivated. Application Types in Automatic Mode In Automatic mode it is differentiated between the application types "Press before feed" or "Feed before press" and "Press intermittent" or "Press continuous". "Press continuous" can be turned on at any time via an input signal or via the VCP 08. "Press before feed" or "Feed before press" can also selected via input signal. Also via parameter can be selected whether the press is turned off with falling edge of the feed angle or first with rising edge of the feed angle and whether a shared output or two separate outputs are used for the presses control modes "Press intermittent" and "Press continuous". These functions are activated via parameter P , Rollfeed Configuration parameter 2. Master Axis Coupling with Real Master Axis With feed movements via master axis coupling to the external presses encoder (RMA) the operation mode "Press in continous mode" is always set inside. With this moving profile is to be paid attention that in application type "Feed before press" the first feed movement is realized via the positioning of the virtual master axis. In this case the positioning

30 4-6 Functional Description Rollfeed Extended 02VRS velocity is defined via parameter P , Number of presses strokes. In application type "Press before feed" the last feed movement is realized via the positioning of the virtual master axis. In this case the positioning velocity is determined via the current velocity of the external presses encoder during the last presses stroke. Note: A switching from "Press before feed" to "Feed before press" and reversed is internally only accepted by a not active Automatic mode (see output "Run"). Press Before Feed in Intermittent Mode Fig. 4-5: Press before feed In intermittent mode In this application type the cycle begins with the setting of maximum 8 outputs. A tool acknowledgement (input query) can then be executed. After taken place acknowledgement the output for presses control is switched on. After carried out presses stroke the 8 outputs for tool control are accessed again. Also here an acknowledgement query can take place. If all desired tool acknowledgements are present, the feed progression and quantity count are executed. Subsequently, if neither the quantity counter has been reached and no "Stop" command is present, the cycle re-starts.

31 Rollfeed Extended 02VRS Functional Description 4-7 Press Before Feed in Continuous Mode Fig. 4-6: Press before feed in continuous mode In this application type, the exact same order is used as for "Press before feed intermittent" operation. The difference only consists in the fact that the press is not switched off after taken place presses stroke. In this case the press is only switched off if the commanded quantity was reached or if a stop signal was given.

32 4-8 Functional Description Rollfeed Extended 02VRS Feed Before Press in Intermittent Mode Fig. 4-7: Feed before press in intermittent mode In this application type, at first 8 outputs for tool control are addressed with the corresponding input query. Then the feed is executed. After the feed is completed, these outputs are accessed again with the corresponding acknowledgement. After carried out acknowledgment the output to the presses control is set and is deleted again after carried out presses stroke.

33 Rollfeed Extended 02VRS Functional Description 4-9 Feed Before Press in Continuous Mode Fig. 4-8: Feed before press in continuous mode The time flow in this operation mode corresponds to that of the "Feed before press intermittent" and "Press before feed intermittent". The difference is that the output for presses control is not cleared after the presses stroke is carried out. This output is only cleared if a counter is reached or if a stop signal is present. Setup Mode The Setup mode in principle has the same function like operation mode "Automatic". However, the Setup mode enables to move a complete product in Automatic mode with a separate velocity via the "Jog"-Inputs "Jog forward" (Jog+) and "Jog backward" (Jog-). The velocity is entered in parameter P , Setup velocity. It is a percentage value of the maximum machine velocity of parameter P , Velocity limit bipolar. A possibly activated velocity override is effective. Once the feed length is reached, the outputs "Feed length reached" and "Press permit" are set. The presses control doesn't take place automatically but must be released external. Quantities are counted. The operation modes "Press before feed" or "Feed before press" are considered. The presses stroke and feed angle are monitored. The Setup mode can only be left if a complete cycle ("Feed before press" or "Press before feed") is finished. If this mode is to be exited earlier, this is possible only via setting the "Clear errors" input and not active input "Setup". A re-entry with residual lengths processing is not possible in this case. In Setup mode always the drive-internal operation mode "Drive-controlled positioning" (trapezoid or triangle profile) is normally active (exception see "Automatic moving of the feed length").

34 4-10 Functional Description Rollfeed Extended 02VRS Note: When the feed length was moved up to the end position, a backward movement in presses operation mode "Feed before press" is only possible if, in addition, the release in configuration bit 11 of parameter P , Rollfeed Configuration parameter 2 is set. Clearing Remaining Distance of the Feed Length In Setup mode there is the possibility to delete the current remaining length of the feed distance. The remaining length is deleted by a positive edge at input "Error" if no jog movement is active. In operation mode "Feed before press" afterwards a complete feed length can be moved again without execution of a presses stroke. This procedure is often repeatable arbitrarily. In operation mode "Press before feed" the current cycle is finished on deleting the remaining length immediately, i.e. another feed movement is possible only after a taken place presses stroke. Automatic Moving of the Feed Length Besides jogging the feed length there is the possibility to activate the automatic moving of the current remaining length of the feed length by presetting a positive edge at the "Start" input. In this case the input "Jog forward" must not be activated any more to reach the end position of the feed length. If no feed movement via the Jog inputs has still taken place (start position existing), the feed movement with the parameterized movement profile, coupled to the internal virtual master axis (VMA), takes place by activation of the automatic movement of the feed length. Besides, the virtual master axis is positioned inside. This is only the case if the master axis coupling (VMA or RMA) is configured as the moving profile. Note: In Setup mode the presses operation mode Single stroke is always activated inside. 4.3 Automatic Feed Adjustment To avoid unnecessarily high acceleration and deceleration ramps, a feed angle adaptation (adjustment) can be performed in Automatic mode in presses operation mode "Continuous". If the press has reached the desired velocity, this function can be activated via input "Feed optimization". However, precondition is a not working to full capacity feed angle. In this case, depending on the feed angle utilization, acceleration and deceleration is increased or decreased. To adjust the optimal feed angle utilization for the machine, a lower and an upper limit value can be given for the optimized feed angle utilization. The minimum acceleration and deceleration values are internal limited automatically to 15% of parameter S , Acceleration bipolar. If the feed angle utilization is more than 90 percent, the output "Utilization < 90%" is cleared. The feed optimization can be activated via input "Feed optimization" (P , Bit 8). This is generally only posible if the feed movements take place via the trapezoid- or triangle profile. The following figures show the feed profile with and without automatic feed adjustment, with the same feed angle and feed length, and a selected feed angle utilization of percent of the feed angle.

35 Rollfeed Extended 02VRS Functional Description 4-11 Note: If the feed optimization is activated during the run-up of the press (acceleration phase), so it is possible that the feed may not be completed within the feed angle. The error message "Feed monitoring" appears if the feed monitoring is activated (comp. P ). Fig. 4-9: Without automatic feed optimization Signal 1 feed angle Signal 2 feed progression Fig. 4-10: With automatic feed optimization Signal 1 feed angle Signal 2 feed progression 4.4 Quantity Count The system solution "Rollfeed Extended" provides 4 actual quantity counter. The quantity count is active in operation mode "Automatic" and "Setup". The listed actual quantities refer to the product data management explained in chapter Following actual quantity counter are available: Actual quantity counter of the batch passes Actual quantity counter active product Actual quantity counter active part length Total actual quantity counter of the part lengths

36 4-12 Functional Description Rollfeed Extended 02VRS Actual Quantity of the Batch Passes After reaching this counter the machine and the press are stopped, the system diagnostics message "Commanded quantity reached" is generated and output "Commanded quantity reached" is set. Actual Quantity Active Product This counter indicates the number of already manufactured products of the active product. Actual Quantity Active Part Length This counter indicates the number of already moved part length of the active part length of the active product. Total Actual Quantity of the Batch Passes This counter indicates the total number of all already manufactered batches. The current actual quantities are displayed in parameter P , Rollfeed Status parameter and may be changed arbitrary (see chapter 8.1). With the operation via the VCP 08 the actual quantities can be preset and adjusted in menu display "Product - Preset actual quantity" and "Feed - Preset total length / Total quantity". 4.5 Program Run Diagnostics Messages The actual state of the system solution "Rollfeed Extended" is basically displayed on the VCP 08. In addition the actual diagnostic messages texts are available in parameter P , System diagnostics messages. The display can take place in the languages German, English, French, Spanish or Italian. With the VCP 08 the selection of the language takes place via menu display "Machine Parameter - Extras". If no VCP 08 is present, the language can be selected via drive parameter S , Language selection. Note: A change in parameter S , Language selection is detected first after a phase switching from parameterization- to operation mode.

37 Rollfeed Extended 02VRS Functional Description 4-13 The following table gives an overview about the possible system-specific diagnostics message texts: No. Fig. 4-11: Diagnostic message text 1 A Quantity reached 2 S Roll is open 3 S Stop is present 4 S Product stop active 5 S Cycle stop active 6 S Waiting for tool acknowledgment 7 S Feed angle missing 8 S Press permit 9 S Interrupt active 10 S Both Jog-Inputs active 11 S Jog forward 12 S Jog backward not possible 13 S Jog backward 14 S E Jog enabled 15 S Feed incomplete 16 S Jog enabled 17 A Product stop active 18 A Tool counter exceeded 19 A Roll open 20 A Stop present 21 A Cycle stop active 22 Cycle start only with feed angle 23 A No cycle start 24 A Interrupt active 25 A Feeding 26 A Waiting for tool acknowledgment 27 A Waiting for feed angle 28 A Waiting for press 29 M Roll is open 30 M Stop is present 31 M Interrupt active 32 M Feed angle missing 33 M Both Jog-Inputs active 34 M Jog forward 35 M Jog backward 36 M Jog inactive Diagnostics message texts

38 4-14 Functional Description Rollfeed Extended 02VRS The used tokens in the diagnostics message text have the following meaning: "A_" : Automatic mode is active "S_" : Setup mode is active "S_E_" : Setup mode is preselected but not yet active. Via input "Setup" the Setup mode can be deactivated again. "M_" : Manual mode is active The exact description to the individual diagnostics messages can be seen in chapter Product Data Use of Feed Angle The "Use of feed angle" is the rate of the time which is required for a feed to the available time for the feed. A value less than 90% (output X15/32, P ) signals to the machine user that the maximum feed velocity has not yet been reached and the press velocity can be increased. If a value of 100% is exceeded, this leads to a feed angle loss that immediately stops the system. The error is then displayed in the status line of the VCP08. If the feed angle is not working to full capacity, the press velocity can be increased. The current feed angle utilization is displayed in P , Rollfeed Status parameter. Fig. 4-12: Use of feed angle L: T1=Feed time T2=Feed angle time Fig. 4-13: Feed angle use calculation 100 *T1 Load = T2 Average Path Velocity The average path velocity can be output as a reference value via an analog output (X32/1 and X32/3) to activate the unwinder. This function which is activated in parameter P , Rollfeed Configuration parameter 1 considers the material velocity, the number of presses strokes and the processing time. With maximum velocity (Parameter P , Velocity limit bipolar) 5 Volt are output via analog output 1 of

39 Rollfeed Extended 02VRS Functional Description 4-15 connector X32. In Manual mode no output of the avarage path velocity takes place. For diagnostics messages displays and analyses the actual average path velocity is additionally always available via parameter P , Average path velocity. Technical data of the analog output: Datum Unit min. typ. max. Output voltage V 0 +5 Output load kohm 5 Output current ma 0 +1 Converter width digitalanalog-converter incl. sign Bit 8 Resolution mv/inc 19,5 Accuracy with R = 5 kohm % 5 of MRF 1) Accuracy with R = 10 kohm % 2,5 of MRF 1) Converting time (incl. settling time) µs 10 Cyclical convertion µs depends on the firmware Short-circuit protection Overload protection 1) MRF: Measurement range final value Fig. 4-14: Analog output included included Strokes per Minute With each rising edge of signal "Feed angle", the elapsed duration to the previous rising edge is calculated. This time was available to the last feed (stroke). This time is annualized and displayed (in strokes per minute) as the actual number of strokes of the machine. 4.7 Measuring Wheel To compensate a possible slip between feed rolls and material, the measurement of the length can be switched from motor encoder to an external measuring wheel encoder. The measuring wheel may only be activated if there is contact between measuring wheel and material surface. If such a contact is not possible, the measuring of the length must be switched back to the motor encoder. In Manual mode generally the motor encoder is used. The measuring wheel can be activated via input "Measuring wheel", if it is activated in parameter P , Rollfeed Configuration parameter 1. For reduction of jerky slip appearance the added up actual position difference can be damped by a filter. The time constant is adjustable in parameter P , Actual position smoothing time constant for hybrid position control. When using the measuring wheel operation the slip that may appear between material and drive motor is compensated by the actual position control. The current slip actual value is displayed in parameter P , Current actual slip value in %. It is related to one measuring wheel rotation.

40 4-16 Functional Description Rollfeed Extended 02VRS If the calculated slip exceeds the value in parameter P , Monitoring window of slip in % (value unequal 0), the slip monitoring responds with the error message F2036, Excessive position feedback difference and the drive reacts with the preset error reaction. For determination of the monitoring window the maximum appearing slip, e.g. during a processing cycle, is kept in parameter P , Maximum occurred actual slip value in %. Note: The slip monitoring is deactivated by a value of "0" in P The value in parameter S , Monitoring window encoder 2 must be set to 0. Otherwise the error "F2036 Excessive position feedback difference" is generated. For parameterization of the function the following parameters are used: P , Rollfeed Configuration parameter 1 P , Actual position smoothing time constant for hybrid position control P , Current actual slip value in % P , Maximum occurred actual slip value in % P , Monitoring window of slip in % For parameterization of the measuring wheel encoder the following parameters are used: S , Position feedback 2 type S , Feedback 2 resolution P , Feed constant 2 (optional encoder) P , Gear 2 load-side (optional encoder) P , Gear 2 encoder-side (optional encoder) P , Control word of encoder 2 (optional encoder) To ensure a satisfactory correction behavior of the feed axis in the measuring wheel operation, the position resolution of the applied measuring wheel encoder must be high enough sufficiently. Typically TTL encoder types are not suitable for this. Therefore, it is recommended to use a sine encoder (1Vss). Note: The measuring wheel encoder is an optional (external) encoder and is connected according to the connecting diagram (see chapter 11.4). 4.8 Programmable Limit Switch If an external absolute encoder is attached to the press, the feed angle can be derived by switch 1 from it. A maximum of 8 PLS positions that are output via 8 PLS outputs can be programmed. The outputs can be controlled within the entire PLS range. Each output possesses a fixed defined switching hysteresis in order to prevent the flickering of the PLS output when reaching the on- resp. off threshold. To balance switching times for controlled peripherals, a rate time for turning on/off each PLS

41 Rollfeed Extended 02VRS Functional Description 4-17 output can be set. These outputs are then controlled for correct positioning, depending on the presses velocity. As physical outputs "Switch 1-8" are available. The on- and off thresholds of the switches must be proper entered in parameter P , Product data and machine parameters. The rate times can be preset in parameter P , Phase limit switch - rate times. Note: If in parameter P , Rollfeed Configuration parameter 2 the option "Usage external presses encoder" (Bit 10) is set, the required configuration for usage of the external presses encoder for the programmable limit switch takes place automatically. If the option is not activated, so with usage of the programmable limit switch the external presses encoder must be manually parameterized in the Engineering- Framework IndraWorks in dialog "Measuring encoder". 4.9 Tool Wear The number of switching operations of the 8 outputs "Tool 1-8" for tool control are counted. The counter values can be read in parameter P , Rollfeed Status parameter. In parameter P , Product data and machine parameters the number of the wished switching operations can be entered. If the programmed number of switching operations is reached, a corresponding bit in the status word for the tool wear (cp. P ) is set. At the same time the system diagnostics message "A Tool counter exceeded" is set with active Automatic mode. By input "Clear errors" or pressing the "Clear"-Key of the VCP 08 the system diagnostics messages can be cleared. The system diagnostics message is indicated only again if the Automatic mode is activated a new. The counter values are displayed on the VCP 08 or can be called up by a higher-ranking control. Note: The system diagnostics message "A Tool counter exceeded" is only generated if at least one of the commanded quantities of the tools 1-8 are unequal 0 and this is smaller than the actual quantity. If the commanded quantities of the tools 1-8 are set to 0, no system diagnostics messages will be generated Override All programmed velocities can be adjusted with an analog override. If this function is activated in parameter P , Rollfeed Configuration parameter 1, the programmed velocity is moved if at input X32/4 and X32/5 an analog input voltage of +10V is applied. If this voltage is reduced, the movement velocity decreases in the same relation. The movement velocity Vo arises by multiplication of the programmed movement velocity Vp with the override factor F (F = 0-1 corresponds 0V- 10V). Application: Loop regulation Velocity alteration

42 4-18 Functional Description Rollfeed Extended 02VRS Vo = Vp F L: Vo = active movement velocity Vp = programmed movement velocity F = Override-Factor Fig. 4-15: Velocity calculation with analog override The programmed movement velocity (Vp) corresponds in "Manual mode" to parameter P , Manual velocity "Setup mode" to parameter P , Setup velocity "Automatic mode" to the preset velocity in parameter P , Product data and machine parameters Note: This function is available only by the drive control section IndraDrive Advanced if at the same time the feed movement via the drive-internal operation mode "Drive-controlled positioning" (trapezoid or triangle profile) was selected Micro-Adjust With the Micro-Adjust the preselected feed length is adjusted. The Micro- Adjust can be preset via parameter P , Micro-Adjust value. With operation via the VCP 08 the correction value can be changed by the Micro-Adjust increment in display "Machine" (F1) Presses Monitoring If no presses stroke (signal change of the feed angle) occurs after a programmed time after a control signal was sent to the press, an error message is issued. The time is preset via parameter P , Monitoring cycle time Roll Lift If roll lift function is enabled in parameter P , Rollfeed Configuration parameter 1 and the press or pilot pin engages the material, the drive is switch to the torque free state and rolls are set apart. For lifting the feed rolls output "Lift rolls" (X32/8, P ) is set. This output activates an external device (hydraulics systems or something similar) that opens the feed rolls. The signal for lifting the rolls is given external via input X15/7 (P ) or X15/25 (P ) to the control. As long as the signal for roll lifting is present, all measuring wheel movements are ignored and the output for lifting the rolls is switched on. Movements of the motor encoder do not lead to errors and at switching off the function these movements are not canceled. A feed is delayed as long as the signal "Rolls closed" is present.

43 Rollfeed Extended 02VRS Functional Description 4-19 In order to lift the feed rolls there are several possibilities. 1. Roll lifting in Manual mode If "electrical / mechanical lifting" in parameter P , Rollfeed Configuration parameter 1 is enabled, output "Lift rolls active" is set to lift the feed rolls if in Manual mode at input "Lift rolls manual" 24 Volt are applied. As long as the input is set the output also is set. When switching to Automatic mode the output is automatically canceled. 2. Roll lifting in Automatic mode If "electrical / mechanical lifting" in Parameter P , Rollfeed Configuration parameter 1 is enabled and 24 Volt are applied at input "Roll lifting enable", output "Lift rolls active" is set synchronous to input "Lift rolls automatic". Via input "Roll lifting enable" the function "Lift rolls" can be disabled in Automatic mode. Via parameter P , Delay time Close rolls can be selected whether the rolls close automatically after a preset time in [ms] or the rolls are only closed if input "Rolls closed" (X31/7, P ) is activated. If a time unequal 0 ms is entered in the parameter, so input "Rolls closed" (X31/7, P ) is not effective. It is expected that the rolls are closed after the expiration of the waiting time. With a preset of 0 ms the closing of the rolls must be received via input "Rolls closed" (X31/7, P ). Signal diagram of lift rolls with Close rolls via input "Rolls closed" (X31/7, P ): Fig. 4-16: Lift rolls Automatic mode via input "Rolls closed"

44 4-20 Functional Description Rollfeed Extended 02VRS Signal diagram of lift rolls with Close rolls via "Time delay": Fig. 4-17: Lift rolls Automatic mode via time delay 4.14 Product Data Management If the application requires making different parts, a product data management (batching) is available. Batching allows the automatic production of multiple different products. Batching also allows multiple feed lengths for each product. It allows program branching to automatically execute different parts. Rollfeed Extended can store up to 99 different parts, each with a maximum of 6 part lengths (feeds). So the system solution can administrate up to 594 (99 x 6) feeds. You can select to sequentially execute single or different parts (product data management program). The processing of a cycle of the product data management program is denoted always as a "batch" in the further run. Each batch possesses the following parameters: Start product Commanded quantity (number it is repeated each batch) Each single product (1-99) possesses the following parameters: Next product Commanded quantity (number it is repeated each product) Each single part length (1-6) possesses the following parameters: Feed length Feed velocity Feed acceleration Commanded quantity (number it is repeated each feed) Tool block number (for controlling the tools) Via the VCP 08 an own name can be assigned to each product (1-99). All information of the product data management are displayed on the VCP 08 in every operation mode. The product data can be changed even if the

45 Rollfeed Extended 02VRS Functional Description 4-21 press is running. If the product data are changed during an feed progresson, however, these are taken over only in the following feed cycle. Note: In addition, a jerk for the feed progressions can be parameterized via parameter S , Jerk limit value bipolar. However, this jerk is independent on the product and applies equally to all feeds. Trapezoid or Triangle Profile With the motion profile via the drive-internal operation mode "Drivecontrolled positioning" (trapezoid or triangle profile) the feed velocity and acceleration are valid according to the given product data. Master Axis Coupling with Virtual Master Axis With a feed via the drive-internal operation mode "Electronic motion profile" coupled to the internal virtual master axis (VMA) the acceleration during the feed movement is derived via the chosen profile type (polynomial 5th order or cam table). The internal positioning velocity of the virtual master axis must be preset via parameter P , Number of presses strokes. For compliance the movement limit values of the feed axis (cp. parameter P , Velocity limit value bipolar and S , Acceleration bipolar) this preset value may not exceed the admissible maximum number of presses strokes. The maximum number of presses strokes is provided in parameter P , Rollfeed Status parameter (element 22). Master Axis Coupling with Real Master Axis With a feed via the drive-internal operation mode "Electronic motion profile" coupled to a real master axis (RMA, external presses encoder) the velocity and acceleration during the feed movement is derived via the chosen profile type (polynomial 5th order or cam table) and depends directly on the current number of strokes of the press. For the compliance of the movement limit values of the feed axis (cp. parameter P , Velocity limit value bipolar and S , Acceleration bipolar) the number of strokes of the press may not exceed the admissible maximum. This value is provided in parameter P , Rollfeed Status parameter (Element 22). Note: If during an feed movement with master axis coupling a feed break appears, e.g., by the "Stop" input, so the remaining distance of the feed is always moved via the trapezoid or triangle profile with the parameterized velocity- and acceleration values.

46 4-22 Functional Description Rollfeed Extended 02VRS Fig. 4-18: Product data management The feed data are preset via parameter P , Product data and machine parameters (see chapter 8). Note: All product data are saved in the retain data memory of the system solution via parameter P , Product data and machine parameters. Saving takes place cyclical every 500 ms.

47 Rollfeed Extended 02VRS Functional Description 4-23 Presetting Product Data Before the Automatic operation is started, a start product of the batch must be forced. A batch (product data management program) may start with each of the 99 products. This enables the saving of several product data management programs that contain in each case an own start product and a series of products to the automatic manufacturing. Via parameter "Next product number" is given the product that should be produced after reaching the commanded quantity of the start product or the previous product. A jump to each of the 99 products is possible, i.e. every product can jump to another, after it is processed. This allows the automatic manufacturing of several different products. Different batches of products can be programmed for common processing. By presetting of,0' or by presetting the,start product' in parameter "Next product" of the last to be manufactured product, the end of a batch is defined. Then the start product is called again if the commanded quantity of the batch is not yet reached. If the commanded quantity is reached, the Automatic mode is finished and output "Commanded quantity reached" is set. If,0' is preset for the commanded quantity of the batch, then a continuous-operation is activated. The batch is repeated continuously until input "Cycle stop neg " or "Product stop neg " is set. The number of the part lengths to be executed for a product may lie between 1 and 6. If the commanded quantity 0' is preset for the part length, so this and all following part lengths are not called. The following figure shows as an example a processing of a batch pass with 5 products at which every product possesses an own commanded quantity. Fig. 4-19: Example of a batch Note: The commanded quantity of the first part length of a product to be manufactured may not be,0'. Product Linking Normally the product data management provides up to six part lengths (feeds) per product. If more than six part lengths are required for a product which must be just as often repeated like the part lengths of the following product, then up to 99 products can be "linked" to produce a product with up to 594 feeds. The programmed part lengths in the current product are executed followed from those of the product which is specified in parameter "Next product". A product is "linked" with the next product by presetting 0 as the commanded quantity. The commanded quantity of the "linked" products is defined in the last product by parameter "Commanded quantity" (unequal,0', the latter link in the chain).

48 4-24 Functional Description Rollfeed Extended 02VRS Example: In the following example the products 1 and 2 are linked with each other. After the six feeds of product 1 are executed, the six feeds of product 2 are executed. By input of a commanded quantity unequal 0 (100), product 2 is defined as the link end. The linked product 1 and 2 with 12 feeds is executed 100 times, then the program execution is continued with the next product 3. Start product == 1 Product 1: "next product" == 2 "commanded quantity" == 0 (linked) Product 2: "next product" == 3 "commanded quantity" == 100 (link end) Product 3: "next product" == 0 "commanded quantity" == 100 Product Data Management in Automatic Mode This section describes the operation of Rollfeed Extended in Automatic mode. Cycle start After the end of the Automatic mode by reaching the commanded quantity (cp. output "Commanded quantity reached"), the execution of the Automatic mode always begins with the start product. If the cycle was stopped during production (by a Cycle stop, Product stop or Stop), the batch processing is continued with the current part length (feed) of the current product and the current counter reading, since the product is reached which was programmed in order to finish the current batch. After switching off/on the system solution the batch processing starts in Automatic mode always with the start product again. Note: An already active production run can be started at any time again anew so that the first called product is the start product again. The actual quantities for the product counter as well as the part lengths of the start product are cleared. For that purpose the inputs "Automatic" and "Product stop neg " must be reset and a rising edge at input "Clear errors" must be set. Resetting the production run takes place in principle also, if: the Parameterization mode was activated an error occurred or a Jog movement has taken place in Manual Mode Product manufacturing sequence The actual counter are incremented after cycle end. The to be manufactured part length number (feed) is incremented if the commanded quantity of the current part length is reached. The system solution checks whether the current part length is the last of the current product. If this is the case, the current product counter is set and the first part length of the current or next product is called. The next product is called if the commanded quantity of the current product is reached. If it is about a linked product with more than six part lengths (feeds), it is always

49 Rollfeed Extended 02VRS Functional Description 4-25 continued with the part lengths of the next product. The processing of the products is repeated as often as the commanded quantity of the batch was specified. Cycle stop and Product stop The system solution Rollfeed Extended supports a second cycle stop input for product data management. The cycle stop input stops the Automatic mode immediately after the current cycle stop completes. The added "Product stop neg " input stops the cycle at the end of a batch processing, i.e. after all part lengths (feeds) of the programmed products were finished. If Product stop is used, the cycle won't be stopped in the middle of a product. The status message "A: Cycle stop active" is displayed if the "Cycle stop neg" input was activated. This message indicates that the product may be incomplete. The status message "A: Product stop active" is displayed if input "Product stop neg " was activated. This message indicates that the product (batch) is complete Safety Queries (SIC) SIC stands for Security Input Control and means "safety-relevant montoring inputs". Besides, it is about four input signals which can be compared with four presses positions (PLS-Switch outputs). Fig. 4-20: SIC - Grafics If this function is activated via the appropriate parameters, the inputs "SIC - Signal 1-4" are checked for signal changes within the test area. An inadmissible signal change is reported via output "SIC-Error". This output remains set until acknowledgment via input "Clear errors" or a parameterswitching or a voltage switch-off takes place. In addition to setting output "SIC Error", via a configuration bit in parameter P , Rollfeed Configuration parameter 2, also the system error "Control-Signal Bit x wrong" can be generated in case of an inadmissible signal change at one of these inputs. In this case the Automatic mode is finished. There is a common release via input "SIC Enable". Via parameter P , Product data and machine parameters for each "SIC Signal 1-4" input the function can be released individually and the check mode can be determined. The chosen input signals can be checked on condition "0", "1", rising edge or falling edge. This task is determined in parameter P , Product data and machine parameters.

50 4-26 Functional Description Rollfeed Extended 02VRS Fig. 4-21: SIC-Inputs and possible tasks

51 Rollfeed Extended 02VRS Functional Description Integrated Safety Engineering Rollfeed Extended can utilize integrated safety solution in the IndraDrive system. In conjunction with the integrated safety engineering the system solution supports the following functions: Coherent continuation of a feed movement after interruption by a safety engineering operation mode (ASP, SH, SBH) Automatic limitation of the commanded velocities after activation of a safe movement (SBB1-4) When the machine is in Automatic or Setup mode, an active feed movement is interrupted by activating the SI operation modes "Drive Lock (ASP)" or "Special operation mode Standstill (Safe Halt (SH) / Safe Operation Halt (SBH))". Previously made feedings are not cleared by the system and will be continued after the SI relating mode is cleared and the system resumes its normal operation. Thus an already moved part length of the feed length is always considered. If the system solution detects the active safety engineering operation mode "Safe movement 1,2,3 or 4" (SBB1-4), an automatic limitation of the preset commanded velocity to the adjusted value in parameter P , Product data and machine parameters (List element 401) takes place in Manual- resp. Automatic mode. The presetting acts in percentage in reference to the parameterized value of the particular velocity threshold (P , P , P resp. P ). Note: If the value in P (List element 3640) is set to 0, no automatic limitation of the commanded velocities on part of the system solution takes place. In this case the higher-ranking control itself is responsible for the presetting of reduced commanded velocities in Manual- resp. Automatic mode (P , P , P ).

52 4-28 Functional Description Rollfeed Extended 02VRS

53 Rollfeed Extended 02VRS In- / Outputs In- / Outputs 5.1 Overview In- / Output Assignment The following two tables give an overview of all available in- and outputs with their internal linkage to the used PLC-Input- and output words and its respective provided function. PLC-Inputs Parameter Bit no. I/O Function Comment P I Parameterization mode P I Feed angle P I Rolls closed P I Jog forward P I Jog backward P I Lift rolls Automatic P I Manual neg / Automatic P I Setup P I Start This signal is OR linked: - to the appropriate operation key of the VCP 08, if the system control VCP 08 in parameter P , Rollfeed Configuration parameter 2 is activated - to the appropriate input via P , Bit 14 This signal is OR linked: - to the appropriate operation key of the VCP 08 if the system control VCP 08 in parameter P , Rollfeed Configuration parameter 2 is activated - to the appropriate input via P , Bit 15 This signal is OR linked to the appropriate operation key of the VCP 08 if the system control VCP 08 in parameter P , Rollfeed Configuration parameter 2 is activated. This signal is OR linked to the appropriate operation key of the VCP 08 if the system control VCP 08 in parameter P , Rollfeed Configuration parameter 2 is activated. This signal is OR linked to the appropriate operation key of the VCP 08 if the system control VCP 08 in parameter P , Rollfeed Configuration parameter 2 is activated. P I Stop neg 1373, Rollfeed Configuration parameter 1 This signal is only evaluated if in parameter P-0- the input is activated. P I Cycle stop neg "STOP" of the VCP 08 if the system control VCP 08 in parameter P , Rollfeed This signal is AND linked to the operation key Configuration parameter 2 is activated. P I Clear errors Clears errors or forces Automatic- or Setup abort. P I Press BDC P I Press intermittent neg / This signal is only evaluated if in parameter P , Rollfeed Configuration parameter 2 the function Press BDC is activated.

54 5-2 In- / Outputs Rollfeed Extended 02VRS continuous P I Feed Interrupt neg 1373, Rollfeed Configuration parameter 1 This signal is only evaluated if in parameter P-0- the input is activated. P I Press before feed P I Lift rolls Manual P I Product stop neg P I Lift rolls enabled P I Measuring Wheel P I Jog forward P I Jog backward P I Feed Interrupt neg This signal is only available with use of the control interface "Profibus". Then the signal is OR linked: - to the appropriate operation key of the VCP 08 if the system control VCP 08 in parameter P , Rollfeed Configuration parameter 2 is activated - to the appropriate input via P , Bit 3. This signal is only available with use of the control interface "Profibus". Then the signal is OR linked: - to the appropriate operation key of the VCP 08 if the system control VCP 08 in parameter P , Rollfeed Configuration parameter 2 is activated - to the appropriate input via P , Bit 4. This signal is only effective after activation in parameter P , Rollfeed Configuration parameter 2. After activation this signal is AND linked to the appropriate input via P , Bit 8. P I P I P I Preset actual quantity batch counter Preset actual quantity product counter Preset actual quantity part lengths counter P I Preset total quantity batch P I Preset total length P I P I P I P I P I P I P I Preset switching operation Tool 1 Preset switching operation Tool 2 Preset switching operation Tool 3 Preset switching operation Tool 4 Preset switching operation Tool 5 Preset switching operation Tool 6 Preset switching operation Tool 7 P I Preset switching operation

55 Rollfeed Extended 02VRS In- / Outputs 5-3 Tool 8 P I Tool 1 acknowledgment P I Tool 2 acknowledgment P I Tool 3 acknowledgment P I Tool 4 acknowledgment P I Tool 5 acknowledgment P I Tool 6 acknowledgment P I Tool 7 acknowledgment P I Tool 8 acknowledgment P I Feed optimization P I SIC enable P I SIC signal 1 P I SIC signal 2 P I SIC signal 3 P I SIC signal 4 Fig. 5-1: PLC-Inputs Meaning of the PLC-Inputs Parameterization Mode Via this input the control is switched to operation mode "Parameterization mode". The Parameterization mode is normally only required with the first commissioning for input the machine data. In this operation mode the power section is switched off. Feed Angle If no presses encoder is connected, the feed angle can be advised to the control via this input. The feed is synchronized with the press by the feed angle. A feed progression is only possible with set input. Should this input be defined as the feed angle, this also must also be entered in parameter P , Rollfeed Configuration parameter 1. If a presses encoder is available, this signal can also be generated by PLS-Switch 1. The switch-on/off angle must be specified in parameter P , Product data and machine parameters (elements 3601 and 3609). Rolls Closed Via this input it can be checked whether the rolls are closed. The feed is delayed till the input is "1". Jog forward If no signal is present at the inputs "Parameter" or "Automatic", then the Manual mode becomes active. In this operation mode the drive can now be moved forward with a defined velocity. The drive moves while the signal is applied. With the automatic operation mode "Setup" via this input all part lengths can be moved with a defined velocity in forward direction. The jog movement is started after a rising edge at the input. In Manual mode the feed moves with the preset velocity in parameter P , Manual velocity. The acceleration resp. deceleration corresponds to the preset value in parameter S , Acceleration bipolar. In Setup mode the feed moves with the velocity preset in parameter P , Setup velocity. The acceleration resp. deceleration corresponds to the value assigned for the acceleration in parameter P , Product data and machine parameters.

56 5-4 In- / Outputs Rollfeed Extended 02VRS Note: If the parameterized or resulting feed length is negative, so the movement direction by "Jog Forward" is backwards, i.e. in direction to the end position. Jog Backward In operation mode Manual the drive can be moved in backward direction via this input. If the Setup mode is active, via this input (Jog-) a backward motion up to the starting point of the movement can be executed. The jog movement is started after a rising edge at the input. The movement parameters are analogous to input "Jog forward". Note: If the parameterized or resulting feed length is negative, so the movement direction by "Jog Backward" is forward, i.e. in direction to the starting position. Manual neg / Automatic This input activates the automatic operation. In Automatic mode the programmed parts are processed with the input part data. Note: The switch-off of this input at active Automatic mode (output "Run" is set) leads to the termination of the Automatic mode in the cycle (see input "Cycle stop neg "). Setup This input activates the Setup mode. The feed is moved by the "Jog Forward" (Jog+) and "Jog Backward" (Jog-) inputs. Start In Automatic mode, the rising edge of Start input will initiate automatic feed cycle. When the system is stopped due to "Stop", "Cycle Stop" or programmed quantity has been reached, then automatic cycle must be restarted via this input. In Setup mode the automatic moving of the current remaining length is activated via this input. Note: The automatic program can only be started if the Automatic mode is active, i.e. output "Automatic" (P , Bit 1) is set. Stop neg To allow motion, the signal "Stop neg " must always be present in all operating modes. If this signal drops off, the automatic program and any progressions in process are interrupted. After the "Stop neg " signal is returned to high and then a new "Start" pulse is issued, the program continues where it left off. Without the "Stop neg " signal, no Jog movements in Manual mode are possible. If the input should not be used so it must be wired up permanently to 24V dc. When a feed is interrupted due to the loss of "Stop neg " input, the previously made feed is always considered upon resumption of feed. Thus an already moved part length of the feed distance is always considered. An active feed progression is decelerated to standstill with the value assigned for the acceleration in parameter P , Product data and machine parameters. Note: For easing the first commissioning this input has no function if in parameter P , Rollfeed Configuration parameter 1 bit 4 is set.

57 Rollfeed Extended 02VRS In- / Outputs 5-5 Cycle Stop neg If the signal drops out at this input, the automatic program is stopped after a finished cycle. Via input "Start" the automatic program can be continued. The cycle is considered as finished if the feed and the presses stroke was executed. If the input should not be used, it must be wired up permanently to 24Vdc. Note: A falling edge at the input within a cycle always leads to a cycle stop also if the input is set again in this cycle. Product Stop neg Via this input the feed axis can be stopped if the complete product is finished. If this input drops out is first stopped when all part lengths of the products of a batch are processed. If the batch consists only of one product with one part length, this input has the same effect like Cycle stop. If this function is not used, the input must be wired up permanently to 24V dc. Clear Errors With a rising edge at input "Clear errors" all present errors are cleared. In Setup mode the current remaining length of the feed is deleted via this input. Note: With a rising edge at input "Clear errors" and not set input "Automatic" or "Setup", an active Automatic- or Setup mode can be canceled anytime. Thus an existing remaining length of a feed distance is canceled. Press BDC Via this input the press reports when its "bottom dead center" is reached. But the signal Press BDC is only evaluated if the evaluation of the signal is activated in parameter P Rollfeed Configuration parameter 2. Press Intermittent neg / Continuous The press can be run in "Continuous"- or "Intermittent" mode. Via this input it is selected whether the press is stopped after every stroke or whether the press is stopped only after reaching the quantity, by a stop or by a fault. Note: With feed movements via a master axis coupling to the external presses encoder (RMA), the operation mode "Press Continuous" is always set inside. Feed Interrupt neg This input serves for interrupt of a feed progression. If the signal drops out at this input, a current feed is canceled and the remaining distance is stored. After this signal is applied again, the automatic program is continued without renewed starting signal at the point where the signal drops out. A possibly remaining feed is started. The material length does not get lost by loss of this signal. If the signal "Press continuous" applies, it is switched to "Press intermittent" during the interrupt. This input can be used, for example, to inform the feed that no more material is available in the loop cavity. If the input should not be used, it must be wired up permanently to 24Vdc. An active feed progression is decelerated to standstill with the value assigned for the acceleration in parameter P , Product data and machine parameters.

58 5-6 In- / Outputs Rollfeed Extended 02VRS Note: The input "Feed Interrupt neg " is only active in presses operation mode Single stroke. Press Before Feed The cycle of a feed consists of a presses stroke and the movement of a feed length. Via this input it is selected whether the cycle begins with a presses stroke and ends with the feed or whether the cycle begins with the feed and ends with the presses stroke. Note: A switching from "Press before feed" to "Feed before press" and reversed is internally only accepted by a not active Automatic mode (see output "Run"). Lift Rolls Manual Via this input the roll lift in operation mode "Manual" is activated. If this input is set, the output for lifting the rolls is switched on. When the roll is open it can be moved via inputs "Jog forward" (Jog+) and "Jog backward" (Jog-). The activation of this function takes place in parameter P Rollfeed Configuration parameter 1. Lift Rolls Automatic If "Lift rolls enabled" is activated, the output "Lift rolls active" is set synchronously to input "Lift rolls Automatic". The drive is switched torquefree. The torque at the drive is first activated again with the signal "Rolls closed" or after expiration of a programmed time (see P , Delay time Close rolls). Roll Lifting Enabled Via this input and via parameter P Rollfeed Configuration parameter 1 the "Lift rolls in Automatic" is activated. If input "Lift rolls in Automatic" is set, output "Lift rolls active" for lifting the feed rolls is switched on and the drive is switched torque-free. As long as the roll lifting is active, measuring wheel movements are ignored. Movements activated by the cycle processing are not executed. A monitoring takes place only by the feed angle with function "Press continuous". Measuring Wheel With this input the position control can be switched over from motor encoder to measuring wheel encoder in Automatic operation mode and with the Automatic function "Setup" to compensate slip between material and feed rolls. The activation of this function takes place in parameter P Rollfeed Configuration parameter 1. Preset Actual Quantity Batch Counter With this input a presetting for the issued actual quantity of the active batch counter can be made in parameter P , Rollfeed Status parameter (list element 4). The value of the actual quantity is set to the preset value in parameter P , Preset status messages parameter. Preset Actual Quantity Product Counter With this input a presetting for the issued quantity of the actual product counter can be made in parameter P , Rollfeed Status parameter (list element 5). The value of the actual quantity is set to the preset value in parameter P , Preset status messages parameter. Preset Actual Quantity Part Lengths With this input a presetting for the issued actual quantity of the actual part lengths counter can be made in parameter P , Rollfeed Status parameter (list element 6). The value of the actual quantity is set to the preset value in P , Preset status messages parameter.

59 Rollfeed Extended 02VRS In- / Outputs 5-7 Preset Total Quantity Batch With this input a presetting for the issued total quantity of the batch can be made in parameter P , Rollfeed Status parameter (list element 7). The value of the total quantity is set to the preset value in P , Preset status messages parameter. Preset Total Length With this input a presetting for the issued total length can be made in parameter P , Rollfeed Status parameter (list element 8). The value of the total length is set to the preset value in parameter P , Preset status messages parameter. Preset Switching Operations Tool 1-8 With this input a presetting for the issued number of switching operations of the tools 1-8 can be made in parameter P , Rollfeed Status parameter (list element 14-21). The respective value of the switching operations is set to the preset value in P , Preset status messages parameter. Acknowledgment Tool 1-8 The 8 inputs can be used for the acknowledgment query of set tools before and after every presses stroke. These inputs can be checked on signal level low and high. The check of the signal level is optional and can be also disabled. Feed Optimization If the press has reached the desired velocity, an automatic feed adjustment can be executed via this input. The available feed angle is detected and the acceleration and deceleration is automatically adjusted to ensure a maximum utilization of the feed angle. The desired utilization of the feed angle is also programmable. SIC Enable This inputs activates the function Safety Query. The programmed signal monitoring (Switch / SIC signal) is executed with the next rising edge of the test range. SIC Signal 1-4 A presses position (switch output) can be assigned to these inputs in each case. The input is checked on its programmed state in the assigned test range. PLC-Outputs Parameter Bit no. I/O Function Comment P O Lift rolls active P O Manual P O Automatic P O Setup P O Fault neg P O Run P O Press permit P O Press on P O Feed angle utilization < 90% P O Drive Ready P O Presses stroke

60 5-8 In- / Outputs Rollfeed Extended 02VRS P O Feed length reached P O Commanded quantity reached P O Warning P O Cycle time exceeded P O SIC error P O Tool 1 P O Tool 2 P O Tool 3 P O Tool 4 P O Tool 5 P O Tool 6 P O Tool 7 P O Tool 8 P O Switch 1 (feed angle) P O Switch 2 P O Switch 3 P O Switch 4 P O Switch 5 P O Switch 6 P O Switch 7 P O Switch 8 Fig. 5-2: PLC-Outputs Meaning of the PLC-Outputs Lift Rolls Active This output signals when "Roll lifting" is active. With the help of this signal the roll can be opened clock-cyclical. Manual The output Manual signals that the operation mode "Manual" is active. Only Jog mode via inputs "Jog forward" ("Jog+) and "Jog backward" (Jog- ) or via the corresponding keys on the VCP is possible. Automatic The output Automatic signals that the operation mode "Automatic" is active. The automatic program can be started. The automatic mode will only be left when the selection is removed and one of the following events are active: Quantity reached Cycle stop Fault Setup This output signals when the automatic mode "Setup" is active. The feed length can now be moved via inputs "Jog forward" (Jog+) and "Jog backward" (Jog-). Fault neg This output is active if no fault is present. In case of a fault the output is cleared.

61 Rollfeed Extended 02VRS In- / Outputs 5-9 Run The "Run" output is active, if Automatic or Setup mode is preselected and the automatic program was started or Setup mode is active. If the quantity is reached or "Stop" or "Cycle stop" was given, the output is cleared. An activation of the Automatic mode can only take place by an edge at the "Start" input. Press Permit This output is only relevant in the Setup mode. It indicates when press is enabled in Setup mode. Press On With "Press intermittent" this output is set cyclical in the process. With "Press continuous" the output remains active until the programmed quantity is reached or the automatic processing is aborted by an error or "Stop" input. With the interface for the press permit it is about a safety feature that creates a signal to couple/uncouple a presses coupler. A high level causes coupling and the press runs (if at the press all other logic safety circuits are functioning accordingly). A low level causes uncoupling and the press stops. Warning The machine manufacturer should include this signal in the other logical safety circuits of the press. Don't use this signal to start the press without the other safety conditions like Opened safety interlock, Emergency Stop machine etc. The time control of signal Press depends on the setting of the interface to the press and the operation mode. The specific time control of this signal can be seen in the flow-charts in chapter "Functional Description". Feed Angle Utilization < 90% If this output is not set, the feed angle is working to a full capacity more than 90%. If the number of strokes of the press is still more increased or the feed length is programmed more largely, this can lead to the fact that the feed cannot be finished anymore in the available feed angle. In this case the message " Feed monitoring" would be issued. Drive Ready This output signals that the drive is in operating mode and is torqueafflicted. Press Intermittent If to the presses control for the operation modes "Press intermittent" and "Press continuous" two separated inputs are desired, the press is activated via this output in intermittent mode. The release takes place in parameter P , Rollfeed Configuration parameter 2. Feed Length Reached This output is set as soon as the programmed feed length is reached. By a rising edge at input "Feed angle" the output is cleared. Commanded Quantity Reached If the commanded quantity of the current product is reached, this output is set and the message "Quantity reached" is issued. After a restart this output is also cleared. Warning Depending on the operation mode and the parameter settings a lot of monitorings are executed. If a condition is recognized which still admits the normal operation, but in further run leads to an error, the output warning is set to 1.

62 5-10 In- / Outputs Rollfeed Extended 02VRS Cycle Time Timeout This output serves for monitoring the machine. If the preset cycle time is exceeded, the machine stops without an error (see parameter P , Monitoring cycle time). SICError If the function safety query SIC (input query to presses position) in parameter P , Product data and machine parameters was activated, this output signals that an error has appeared. One of the four inputs did not have the programmed condition in the test range. After error acknowledgment, switching to parameterization mode or switch-on again, this output is cleared. Tool 1-8 The 8 outputs can be used for activating tools. These outputs are parallel activated before and after each presses stroke. Via the parameter P , Product data and machine parameters, in addition, resetting the tool outputs can be adjusted with falling or rising edge of the feed angle. Independent on the chosen presses mode can be guaranteed by this option that tools are reset only after executed feed progression. PLS-Switch 1-8 If an absolute presses encoder is connected, the presses position can be issued via this outputs. Then via these outputs different functions can be activated. With use of an absolute presses encoder the feed angle is provided by switch 1. The switches 1-4 are used for the safety query SIC. 5.2 In- / Output Assignment on the Basic Circuit Board The following two tables show the default assignment of the I/O-Signals at the connectors X31 and X32 of the basic circuit board. The default assignment of the I/O-Signals is available at the delivery state and can be restored anytime after made changes (see P , Rollfeed Configuration parameter 1, Bit 9). Pin I/O Function Parameter Bit no. 1 O bb Relay Rel(a) P O bb Relay Rel(b) P I Not used S I E-Stop neg P I Parameter P I Feed angle P I Rolls closed P PWR U ext PWR GND ext Fig. 5-3: Connector X31

63 Rollfeed Extended 02VRS In- / Outputs 5-11 Pin I/O Function Parameter Bitno. 1 - Analog output Analog output Analog_GND Analog input 1 U+ S Analog input 1 U- S I Jog forward 1) 2) P I Jog backward 1) 2) P O Lift rolls active P I Lift rolls Automatic P Fig. 5-4: Connector X32 1) This signal is OR linked to the appropriate operation key of the VCP 08 if the system control VCP 08 in parameter P , Rollfeed Configuration parameter 2 is activated. 2) This signal is OR linked to the appropriate input via P Bit 14 resp. Bit 15. Note: If in parameter P , Rollfeed Configuration parameter 1, Bit 9 is set, then the assignment of the connectors X31 and X32 can be changed arbitrary. Changes also remain after a switch-off or phase-switching. Meaning of the Other Signals at Connector X31 Bb Relay The ready contact accepts the attendance of the drive control section for applying the supply voltage. The Bb-Contact is opened with not applied control voltage for the drive control section not applied 24 V at input E-Stop neg E-Stop neg At this input +24Vdc must be applied in the operating state. If this input drops out then the ready contact (bb) opens and the drive is set to standstill (see "Best possible standstill").

64 5-12 In- / Outputs Rollfeed Extended 02VRS 5.3 In- / Output Assignment of the Digital I/O-Extension on the Option Module MD2 The following table shows the default assignment of the I/O-Signals of the digital I/O-Extension on the option module MD2 (connector X10). The default assignment of the I/O-Signals is available at the delivery state and can be restored anytime after made changes (see P , Rollfeed Configuration parameter 1, Bit 9). Pin I/O Function Par. Bit Pin I/O Function Par. Bit 7 I Tool 1 acknowledgment P I Feed optimization P I Tool 2 acknowledgment P I SIC enable P I Tool 3 acknowledgment P I SIC signal 1 P I Tool 4 acknowledgment P I SIC signal 2 P I Tool 5 acknowledgment P I SIC signal 3 P I Tool 6 acknowledgment P I SIC signal 4 P I Tool 7 acknowledgment P I Not used I Tool 8 acknowledgment P I Not used PWR GND ext PWR GND ext PWR U ext PWR U ext O Tool 1 P O Tool 5 P O Tool 2 P O Tool 6 P O Tool 3 P O Tool 7 P O Tool 4 P O Tool 8 P PWR GND ext PWR GND ext PWR U ext PWR U ext O Switch 1 (feed angle) P O Switch 5 P O Switch 2 P O Switch 6 P O Switch 3 P O Switch 7 P O Switch 4 P O Switch 8 P PWR GND ext PWR GND ext PWR U ext PWR U ext Fig. 5-5: Connector X10, MD2

65 Rollfeed Extended 02VRS In- / Outputs In- / Output Assignment of the Control Interface Parallel Interface The following table shows the default assignment of the I/O-Signals on the Parallel Interface (connector X15). The default assignment of the I/O- Signals is available at the delivery state and can be restored anytime after changes took place. (see P , Rollfeed Configuration parameter 1, Bit 9). Pin I/O Function Par. Bit Pin I/O Function Par. Bit 1 I Manual neg / Automatic 1) P I Feed interrupt neg 3) P I Setup 1) P I Press before feed P I Start 1) P I Lift rolls Manual P I Stop neg 3) P I Product stop neg P I Cycle stop neg 2) P I Lift roll enabled P I Clear errors P I Measuring wheel P I Press BDC 4) P I Not used 5) I Press intermittent neg / continuous P I Not used 5) PWR GND ext PWR U ext O Manual P O Drive ready P O Automatic P O Presses stroke P O Setup P O 11 O Fault neg P O Feed length reached Commanded quantity reached P P PWR U ext PWR U ext O Run P O Warning P O Press permit P O Cycle time timeout P O Press on P O SIC error P O Feed angle utilization < 90% 19 PWR U ext P O Not used Fig. 5-6: Connector X15, HCC01 1) This signal is OR linked to the appropriate operation key of the VCP 08 if the system control VCP 08 in parameter P , Rollfeed Configuration parameter 2 is activated. 2) This signal is AND linked to the operation key "STOP" of the VCP 08 if the system control VCP 08 in parameter P , Rollfeed Configuration parameter 2 is activated. 3) This signal is only evaluated if in parameter P , Rollfeed Configuration parameter 1 the input is activated.

66 5-14 In- / Outputs Rollfeed Extended 02VRS 4) This signal is only evaluated if in parameter P , Rollfeed Configuration parameter 2 the function Press BDC is activated. 5) These signals are freely available and may be used among other things for the safety engineering. Note: If in parameter P , Rollfeed Configuration parameter 1, Bit 9 is set, then the assignment of the Parallel Interface (connector X15) can be changed arbitrary. Changes also remain after a switch-off or phase-switching.

67 Rollfeed Extended 02VRS HMI HMI 6.1 General The compact HMI VCP 08 is a machine operation terminal which can be used as input- and operation -unit for the system solution "IndraMotion for Metal Forming - Rollfeed Extended". Fig. 6-1: Compact HMI VCP VCP08 Key Description The keyboard contains all required keys for data input and for controlling the system. The LED of the various keys signal the machine operator the actual state of the system. The key elements are placed under a coined environmental influences-restistant polyester foil. The caption of the upper 2 operation key rows below the display as well as the operation key row right hand of the display can be changed. This takes place by two insertion stripes which can be inserted from the right and upper side.

68 6-2 HMI Rollfeed Extended 02VRS For this system the following two insertion stripes are enclosed at delivery. Fig. 6-2: Lateral insertion stripe Fig. 6-3: Lower insertion stripe Display Menu Keys to Control of the display screens F1... F7 are functional keys and are used in order to select menus or functions. If it is possible to display a further display or to activate a deposited function, the appropriate LED flashes permanent. Returns back to the first display level. The Cursor home-key changes back to the previous display. Note: If an edit field is available in the actual display menu and the edit mode is active (LED "Data entry enable" flashes), so the edit mode must be deactivated first by pressing the Data entry enable-key before it can be changed back to the previous display menu.

69 Rollfeed Extended 02VRS HMI 6-3 Operation Keys Parameter P Rollfeed Configuration parameter 2 bit0 or bit1 activates the VCP08 keys. This permits controlling of axis in the Manual mode or mode switching. Thereby the keys are monitored on cable break. Note: Should the connection be interrupted between the IndraDrive control part and the VCP 08, for example, by drawing off the cable, so this is recognized. When exceeding the monitoring time (approx. 1.5 seconds) a VCP-Communication error is generated and indicated. Moving axes are stopped immediately after detecting a connection error. However, the connection monitoring is only active if the operation keys of the VCP 08 have been activated in parameter P , Rollfeed Configuration parameter 2 (see description bit 0 and bit 1). Jogging in negative direction (strip pull-in direction) in Manual mode. The movement takes place by pressing the key JOG- and stops when the key is released. In Automatic mode with activated Setup-Function the feed progression takes place only by means of the Jog-Keys within the programmed feed length. Jogging in positive direction (production direction) in Manual mode. The movement takes place by pressing the key JOG+ and stops when the key is released. During Setup mode, feed movement for the programmed feed length is only possible with utilizing JOG-Keys. In Automatic mode with activated Setup-Function the feed progression takes place only by means of the Jog-Keys within the programmed feed length. Activation of the "Automatic" mode. Pressing this key activates Automatic mode. The LED flashes. Pressing the key again cancels Automatic mode and the system switches to Manual mode. Then the LED expires. A change from operation mode "Automatic" is only possible with correct completion of a product or must be extra acknowledged with the CLEAR-Key. If the LED blinks, the Automatic mode is still active internal, however, the input is not active any more. When the system is in "Automatic" mode, pressing this key starts the program. The LED flashes as long as the input "Start" is present. Activates a Cycle stop of the machine. If the key is pressed, then the LED flashes. If the LED flashes, the Automatic mode is not active or input "Cycle stop neg " is not set via the control interface. Note: The STOP-Key is zero-active.

70 6-4 HMI Rollfeed Extended 02VRS Activation of the "Setup" mode. This key enables Setup mode when the system is in Automatic mode. Flashing LED indicates that the Setup mode has been selected but is not yet active. The setup mode becomes active when "Start" command is issued. The LED will continuously flash as long as Setup mode is active internally. The CLEAR-Key clears all existing error messages. Note: With a rising edge at key "CLEAR" and not set input "Automatic" an active Automatic mode can be canceled anytime. Edit Keys To activate or deactivate the Edit mode, the special key "Data entry enable" must be pressed. Only if the status LED "Data entry enable" flashes, an input by the edit keys is possible. The alphanumeric keypad (keys 0..9) serve for input the product data. to The Decimal point-key is used for data modification in the editor. The Plus-Key is used for data modification in the editor. If during the parameter input the cursor stands on the parameter number in menu "System parameters", the current parameter number is increased by one if the Plus-Key is pressed. In menu "Extras" the contrast of the display can be adjusted with this key. The Minus-Key is used for data modification in the editor. If during the parameter input the cursor stands on the parameter number in menu "System parameters", the current parameter number is decreased by one if the Minus-Key is pressed. In menu "Extras" the contrast of the display can be adjusted with this key.

71 Rollfeed Extended 02VRS HMI 6-5 Navigation Keys In Edit mode the Cursor left-key positions the cursor one position to the left in the edit field. In Edit mode the Cursor right-key positions the cursor one position to the right in the edit field. In Edit mode the Cursor up-key positions the cursor one position up in the edit field. In Edit mode the Cursor down-key positions the cursor one position down in the edit field. Special Keys As long as the Help-Key is pressed, several informations are displayed. Not used. The Data entry-key serves for completion of the data input. Data inputs are only accepted and stored permanently by pressing this key. Changing the menus does not lead to a storage of the data. The Data entry enable-key changes to the Edit mode. The status LED "Data entry enable" flashes. A repeated pressing of the key leads to the quitting of the Edit mode. Then the LED expires.

72 6-6 HMI Rollfeed Extended 02VRS The Delete-Key deletes the character under the cursor in the editor. The Browse-Key allows changing the screens within display menus.

73 Rollfeed Extended 02VRS HMI Brief Description The display has a resolution of 320x240 pixel. It informs the operator about the actual state of the system and displays diagnostics messages in plain text. The keyboard contains all required keys for data input (parameters, feed length, product counter etc.) and for controlling (operation mode changes, Start, Stop etc.) the system. The LED of the several keys signal the operator the actual state or the selected operation mode of the "Rollfeed Extended" system. Note: On the VCP the languages German and English are supported in the current Release version of the system solution. The languages French, Spanish and Italian are in preparation and will be provided in a later Release version. 6.4 Overview The listed boxes show the screen displays. The menu navigation takes place via the function keys F1... F5 and MAIN. The function key MAIN is realized as a global variable and thus permits the direct return to the main screen in each submenu. Main Menu Fig. 6-4: Main menu Overview

74 6-8 HMI Rollfeed Extended 02VRS Submenus Fig. 6-5: Submenu Product Fig. 6-6: Submenu Feed

75 Rollfeed Extended 02VRS HMI 6-9 Fig. 6-7: Submenu Diagnostics Fig. 6-8: Submenu Machine

76 6-10 HMI Rollfeed Extended 02VRS Status Line The top line of the VCP always displays the status message. In the status line the actual state of the system is cyclically displayed as plain text. In addition, the actual time and date is displayed. The system status may appear in two different formats. 1. A plain text message to the actual state, like "A0050 Parameterization level 1 active". 2. X: STATUS MESSAGE, whereas X is the indicator of the actual operation mode and the STATUS MESSAGE supplies the information about the system. Explanation: A: AUTOMATIC mode S: SETUP mode S E: SETUP mode is preselected but not yet active. Via input "Setup" the Setup mode can be deactivated again. M: MANUAL mode Example: A Feeding the system is in Automatic mode. A feed progression is just active. Fig. 6-9: Status line 6.5 Start Screen The start screen appears for approx. 5 seconds after switching on the operation terminal. This time is fix and cannot be changed. If the "Data entry"-key is pressed while the start screen is displayed, the display changes to the setup menu. In this menu the desired language can be selected via the +/- - Keys. After pressing the "Data entry"- or "Data entry enable"- Key the VCP reboots. Fig. 6-10: Start display

77 Rollfeed Extended 02VRS HMI 6-11 Fig. 6-11: Setup display 6.6 Main Display Fig. 6-12: Main display The displayed information in the main display are Number of the active product and active part length (product / part length Length of the activ part length in mm or Inch Velocity of the active part lenght in percent Actual number of strokes of the machine in strokes per minute Actual utilization of the feed angle in percent Actual machine velocity in m/min or Inch/min On this page no values can be edited. If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-13: Help display in main menu

78 6-12 HMI Rollfeed Extended 02VRS 6.7 Display "Product" (F1) Fig. 6-14: Display "Product 1" Fig. 6-15: Display "Product 2" In this menu the following product processing information are displayed to the operator Current product number and the appropriate product name Next to be processed product number and the appropriate product name Commanded- and actual quantity of the current product and batch processing Active part length of the active product with following information Length in mm or Inch Velocity in % Actual quantity Commanded quantity Acceleration or deceleration in % Tool block number Start product number for batch pass Start product number with parameterized linking End product number with parameterized linking On this pages cannot be edited.

79 Rollfeed Extended 02VRS HMI 6-13 In this display can be changed with the "Browse"-Key between "Product 1" and "Product 2". Key F1 selects the menu for entering the batch processing. Pressing the F2-Key calls the menu for editing the part lengths. By pressing F3 a confirmation menu for deleting/correcting the actual quantity of the batch pass, the current product and the current part length is displayed. If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-16: Help display in menu "Product 1-2" Note: All product data are saved in the retain memory (option module MD2) of the system solution. Display "Product Edit Product" (F1) Fig. 6-17: Dispay "Edit Product" This display menu enables the operator to preset the following product data Selection of the to be edited product by number Next to be processed product number and the appropriate product name related to the edited product Commanded quantity of the product Start product number with the appropriate product name for the batch pass Commanded quantity of the batch passes Product data that are changed during an active processing cycle are first taken over in the next following feed cycle.

80 6-14 HMI Rollfeed Extended 02VRS If a value greater 0 is entered for the commanded quantity of the batch passes, the batch pass is repeated until the quantity is greater or equal the specified quantity. Then the cycle is stopped and output "Commanded quantity reached" (P ) is set. With input of quantity 0 a continuous-operation is specified. In this case the cycle continues and the actual quantity counter continues counting. If a value greater 0 is entered for the commanded quantity of the product, the product is repeated until the quantity is greater or equal the specified quantity. Subsequently the next product is processed. With input 0 for the quantity the product is linked with the next product, i.e. the product is first repeated if the last product of the "linked" products was executed. Besides, the repetition takes place as often like for the last product of the "linked" products (commanded quantity unequal 0 ) was entered. With input 0 for the next product the end of the batch pass is marked. After processing this product, the start product number of the batch pass is called again if the commanded quantity of the batch passes are not yet reached. The operator may change the commanded quantities any time during a cycle. If the cursor stands on the commanded quantity, pressing the + - Key increments and pressing the - -Key decrements the quantity. By pressing the F3-Key a confirmation menu for setting the default values of the product data is displayed. If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-18: Help display in menu "Edit Product" Note: All product data are saved in the retain memory of the system solution.

81 Rollfeed Extended 02VRS HMI 6-15 Display "Product Edit Part Lengths" (F2) Fig. 6-19: Display "Edit Part Lengths 1" Fig. 6-20: Display "Edit Part Lengths 2" In this display menu the operator can select the to be edited product via product number or product name and set the following part data for the to be processed part lengths. Length in mm or Inch Velocity in % related to the maximum velocity (P ) Acceleration or deceleration in % related to the maximum acceleration (S ) Commanded quantity Tool block number Data of the part lengths changed during an active processing cycle are taken over only in the next following feed cycle. The operator may change the commanded quantities any time during a cycle. If the cursor stands on the commanded quantity, pressing the + - Key increments and pressing the - -Key decrements the quantity. Via the F3-Key a part length can be added to a product. Via the F4 Key a part length in the product can be deleted. For each product maximum 6 part lengths are available. In this display can be changed with the "Browse"-Key between "Part lengths 1" and "Part lengths 2".

82 6-16 HMI Rollfeed Extended 02VRS If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-21: Help display in menu "Part lengths 1" Fig. 6-22: Help display in menu "Part lengths 2" Note: All product data are saved in the retain memory of the system solution. Display "Product Preset Actual Quantity" (F3) Fig. 6-23: Display "Preset Actual Quantity" Via the keys F2, F3 and F4 the actual quantity of the batch passes, the actual quantity of the current product and the actual quantity of the current part length can be set to the preset value. The preset value itself can be specified arbitrarily.

83 Rollfeed Extended 02VRS HMI 6-17 If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-24: Help display in menu "Preset Actual Quantity" Display "Product Edit Product Load Default Product Data" (F2) Fig. 6-25: Display "Load Default Product Data" In this display menu the parameterized product data can be reset to their default values by pressing the F3-Key. For the part lengths 1-6 of the products 1-99 the default values for the length, acceleration, commanded quantity and the tool number are set. The commanded quantity of the products as well as the next product of products 1-99 are set to 1. The start product number for the batch pass and the commanded quantity for the batch passes are also set to 1. In the displayed status the actual status as well as a confirmation message after activation are displayed. Note: By loading the default values of the product data the current settings of the product data get lost. A display change during an active load procedure is not possible. During loading a display menu with status line and progress indication appears.

84 6-18 HMI Rollfeed Extended 02VRS If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-26: Help display in menu "Default Parts..." 6.8 Display "Feed Data" (F2) Fig. 6-27: Display "Feed Data" The display "Feed Data" gives the operator information about the feeded forward total length and the total actual quantity of the manufactured products. These data get not lost by switching off/on. At the end of a cycle the counters are updated. Partly moved feeds are not counted. Furthermore are displayed the current presses mode ("Press before feed" or "Feed before press") as well as the chosen operation mode. With the operation mode it can be about "Press continuous" or "Press intermittent". The F2-Key can be used to change between these operation modes. If the operation mode "Press continuous" is selected, the press is not switched off after an executed presses stroke. In this case the press is only switched off if a counter was reached or if an error occured or a stop signal was given. With operation mode "Press intermittent" the press is switched off/on in time at the end or short before the end of each feed cycle. In addition, the actual positions of the motor encoder and measuring wheel encoder are displayed in this screen. In order to delete the total length and the total quantity it can be changed via the F1-Key to the display menu "Preset total length / total quantity". Via the keys F3, F4 and F5 the menus for displaying and configuring the feed parameters, feed configuration and feed optimization are reached.

85 Rollfeed Extended 02VRS HMI 6-19 If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-28: Help display in menu "Feed Data" Display "Feed Preset Total Length / Total Quantity" (F1) Fig. 6-29: Display "Preset Total Length / Total Qantity" Via the F2- or F3-Key the total length or total quantity of the manufactured products can be preset to the respective specified preset value. The preset value itself can be specified arbitrarily. If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-30: Help display in menu "Preset Length/Quantity"

86 6-20 HMI Rollfeed Extended 02VRS Display "Feed Feed Parameter" (F3) In the screens "Feed Parameter 1"... "Feed Parameter 3" the actual values of the system-specific parameters are displayed. With active edit mode the parameters can be edited. With the Data entry-key the parameters are stored directly. The meaning and effect of the several parameters is described in chapter 8. Via the Browse-Key it can be changed between the displays of "Feed Parameter 1"... "Feed Parameter 3". Fig. 6-31: Display "Feed Parameter 1" Fig. 6-32: Display "Feed Parameter 2" Fig. 6-33: Display "Feed Parameter 3"

87 Rollfeed Extended 02VRS HMI 6-21 Following parameters are displayed in the menus: P , Manual velocity P , Setup velocity P , Velocity limit value bipolar P , Micro-Adjust value Micro-Adjust increment P , Cycle time monitoring P , Delay time close rolls P , Number of presses strokes P (element 405), tolerance window for feed range end with master axis coupling with external presses encoder P (element 407), negative velocity limit value for external presses encoder P (element 406), profile type with master axis coupling with external presses encoder If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-34: Help display in menu "Feed Parameter" Display "Feed Feed Configuration" (F4) In the displays "Feed Configuration 1"... "Feed Configuration 5" the actual values of the system-specific configuration are displayed. With active edit mode it can be edited via the keys + and -. With the Data entry-key the settings are stored directly. Note: The meaning and effect of the several configuration settings is described in chapter 8 (cp. parameter P and P ). Via the Browse-Key it can be changed between the displays of "Feed Configuration 1-5".

88 6-22 HMI Rollfeed Extended 02VRS Fig. 6-35: Display "Feed Configuration 1" Fig. 6-36: Display "Feed Configuration 2" Fig. 6-37: Display "Feed Configuration 3" Fig. 6-38: Display "Feed Configuration 4"

89 Rollfeed Extended 02VRS HMI 6-23 Fig. 6-39: Display "Feed Configuration 5" Following configurations are displayed in the menus: Selection press / punch (P , Bit 0) Override (P , Bit 1) Measuring wheel operation (P , Bit 2) Electrical / mechanical lifting (P , Bit 3) Input "Stop neg " / "Feed interrupt neg " active (P , Bit 4) Unit for translatory scaling (P , Bit 5) Feed monitoring (P , Bit 6) Cycle time monitoring (P , Bit 7) Analog output average path velocity (P , Bit 8) Usage of an external presses encoder (P , Bit 10) System control VCP08 with input "Automatic" via VCP-Key (P , Bit 0) System control VCP08 with input "Automatic" via control interface (P , Bit 1) Evaluation presses signal BDC (P , Bit 4) Evaluation presses signal TDC (P , Bit 5) Feed interrupt PLC (P , Bit 6) Usage of output Press intermittent (P , Bit 8) Reset of the tool outputs with positive/negative edge of the feed angle (P , Bit 9) Generating a system error at existing SIC-Error (P , Bit 10) Pass-Through mode (P , Bit 2) Feed angle via external presses encoder (P , Bit 10) Moving profile trapezoid or master axis coupling with RMA or VMA, (P , Bit 11 and Bit 12) Note: Changes of the settings to the moving profile become only effective if the Automatic or Setup mode is not active or a Cycle stop is active.

90 6-24 HMI Rollfeed Extended 02VRS If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-40: Help display in menu "Feed Configuration" Display "Feed Feed Optimization" (F5) To avoid unnecessarily high acceleration and deceleration ramps, a feed angle optimization (adjustment) can be performed in Automatic mode. When the press has reached the desired velocity, this function can be activated. However, precondition is a not working to full capacity feed angle. In this case, depending on the feed angle utilization, acceleration and deceleration is increased or decreased. To adjust the optimal feed angle utilization for the machine, a lower and an upper limit value can be given. The minimum acceleration and deceleration values are internal limited automatically to 15% of parameter S , Acceleration bipolar. If the feed angle utilization is more than 90 percent, the output "Feed angle utilization < 90%" is cleared. The feed optimization can be activated via input "Feed optimization" (P , Bit 8). This is generally only posible if the feed movements take place via the trapezoid- or triangle profile. Fig. 6-41: Display "Feed Optimization"

91 Rollfeed Extended 02VRS HMI 6-25 If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-42: Help display in menu "Feed Optimization" 6.9 Display "Diagnosis" (F3) Fig. 6-43: Display in menu "Diagnosis" The display "Diagnosis" shows the system-specific status and the drive status as plain text. Via the F1-Key the menu for displaying the in- and outputs is reached. Via the F2-Key the displays of the tool administration can be reached. Via the F3-Key the display of the PLS is called. The F4-Key calls the display of the safety queries (SIC). Via the F5-Key a submenu for selecting further diagnostics displays with regard to encoder positions, versions and feed optimization can be displayed. If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-44: Help display in menu "Diagnosis"

92 6-26 HMI Rollfeed Extended 02VRS Display "Diagnosis - Inputs" (F1) In the displays "Inputs 1"... "Inputs 4" the actual values of the system inputs are displayed. The meaning and effect of the several inputs is described in chapter 5. Via the Browse-Key it can be changed between the displays of "Inputs 1-4". Fig. 6-45: Display in menu "Inputs 1" Fig. 6-46: Display in menu "Inputs 2" Fig. 6-47: Display in menu "Inputs 3"

93 Rollfeed Extended 02VRS HMI 6-27 Fig. 6-48: Display in menu "Inputs 4" If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-49: Help display in menu "Inputs 1-4" Display "Diagnosis Outputs" (F2) In the displays "Outputs 1"... "Outputs 3" the actual values of the system outputs are displayed. The meaning and effect of the several outputs is described in chapter 5. Via the Browse-Key it can be changed between the displays of "Outputs 1-3". Fig. 6-50: Display in menu "Outputs 1"

94 6-28 HMI Rollfeed Extended 02VRS Fig. 6-51: Display in menu "Outputs 2" Fig. 6-52: Display in menu "Outputs 3" If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-53: Help display in menu "Outputs 1-3" Display "Diagnosis Tools" (F2) In the displays "Tool Wear 1" and "Tool Wear 2" the preset switching operations with the actually executed tool controls and its status are displayed. The operator gets an information about the current status of the tool counter and therefore he can monitor the tool wear. Besides, an x in column status indicates the exceeding of the maximum switching operations. In this case a tool change is advisable. Via the Browse-Key it can be changed between the displays of "Tool Wear 1-2".

95 Rollfeed Extended 02VRS HMI 6-29 Fig. 6-54: Display in menu "Tool Wear 1" (Tool 1-4) Fig. 6-55: Display in menu "Tool Wear 2" (Tool 5-8) If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-56: Help display in menu "Tool Wear 1-2" Display "Diagnosis Tools Tool Control" (F2) In display "Tool Control" the configuration of the tool blocks are displayed. The number of the to be displayed tool block is editable. The allocation of the tool block for setting and acknowledging the tools 1-8, in each case before activation of the presses stroke and after executed presses stroke, is displayed. Syntax: Besides, the syntax of the input is to be understood as follows: 0 = Output is set to zero 1 = Output is set to 1 2 = Output remains unchanged

96 6-30 HMI Rollfeed Extended 02VRS Tools can be acknowledged per input signal, time acknowledgment or by a combination of both variants. Fig. 6-57: Display in menu "Tool Control" If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-58: Help display in menu "Tool Control" Display "Diagnosis Tools Tool Acknowledgment" (F3) In the displays "Tool Acknowledgment 1" and "Tool Acknowledgment 2" the name of the tools, the status of the tool outputs and the status of the tool inputs are displayed. Via the Browse-Key it can be changed between the displays of "Tool Acknowledgment 1-2". Fig. 6-59: Display in menu "Tool Acknowledgment 1" (Tool 1-4)

97 Rollfeed Extended 02VRS HMI 6-31 Fig. 6-60: Display in menu "Tool Acknowledgment 2" (Tool 5-8) If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-61: Help display in menu "Tool Acknowledgment 1-2" Display "Diagnosis Tools Time Acknowledgment" (F4) In display "Tool Time Acknowledgment" the parameterization of the time values for the acknowledgment of tools 1-8 in the respective tool block are displayed. The to be displayed number of the tool block is editable. For the acknowledgment of the tool outputs it is waited for the duration of the current value indicated here before or after the presses stroke. Only one time for all 8 outputs can be specified. Not later than at the end of the current time value all tools are considered as acknowledged. If no time acknowledgment should take place, the value 0.00 sec must be entered. Fig. 6-62: Display in menu "Tool Time Acknowledgment"

98 6-32 HMI Rollfeed Extended 02VRS If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-63: Help display in menu "Tool Time Acknowledgment" Display "Diagnosis Cam Switch" (F3) In the displays "Cam Switch 1" and "Cam Switch 2" the name, the switchon- and switch-off angle, the rate time and the status of Cam switch 1-8 are displayed. Besides, the actual position of the external presses encoder is displayed. Via the Browse-Key it can be changed between the displays of "Cam Switch 1-2". Fig. 6-64: Display in menu "Cam Switch 1" (Cam Switch 1-4) Fig. 6-65: Display in menu "Cam Switch 2" (Cam Switch 5-8)

99 Rollfeed Extended 02VRS HMI 6-33 If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-66: Help display in menu "Cam Switch 1-2" Display "Diagnosis Safety Switch" (F4) The safety switches (SIC = Security Input Control) serve for monitoring of "safety-relevant" inputs. Besides, it is about 4 inputs (SIC 1-4) which are controlled as a function of the switch position. The SIC monitoring is active in every operation mode. However, the four SIC-Inputs can be completely locked via input "SIC enable" (P ). Besides, the allocation of SIC-Inputs to the switches is determined as follows: SIC-1 to switch 1 SIC-2 to switch 2 SIC-3 to switch 3 SIC-4 to switch 4 To satisfy the most different signal sources, an individual signal level can be assigned to every SIC-Input. Besides, the meaning of the signal choice is as follows: OFF = No test takes place. 0 = Check signal level on "0", thereby outside the enable it is checked for edge changing. The input must be "0" during the whole test range. 1 = Check signal level on "1", thereby outside the enable it is checked for edge changing. The input must be "1" during the whole test range. 0>1 = Check signal level on rising edge. 1>0 = Check signal level on falling edge. ~0 = Check signal level on "0" when leaving the test range. ~1 = Check signal level on "1" when leaving the test range. 0~1 = Check on rising edge during test range. 1~0 = Check on falling edge during test range. In the screen "Safety inputs" the following information are displayed: General release of the SIC-Signals via input "SIC-Enable" Status of output SIC-Error Switch-on- and switch-off angle of the assigned switches 1-4

100 6-34 HMI Rollfeed Extended 02VRS Name of the SIC-Signals 1-4 Assigned signal level to the SIC-Signals 1-4 Status of the SIC-Signals 1-4 Fig. 6-67: Display in menu "Safety inputs" If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-68: Help display in menu "Safety inputs" Display "Diagnosis Extras" (F5) After call of menu "Extras" the operator can change via the F2-, F3- and F4-Keys to screens displaying the encoder positions, versions or feed optimization. Fig. 6-69: Display in menu "Diagnosis Extras"

101 Rollfeed Extended 02VRS HMI 6-35 If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-70: Help display in menu "Diagnosis Extras" Display "Diagnosis - Extras - Positions" (F2) In this menu the positions of the measuring wheel, the motor encoder and the external presses encoder are displayed. In addition, the resulting slippage and the current lag are displayed. Fig. 6-71: Display in menu "Encoder Positions" If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-72: Help display in menu "Encoder Positions"

102 6-36 HMI Rollfeed Extended 02VRS Display "Diagnosis Extras Versions" (F4) Fig. 6-73: Display in menu "Versions" In screen "Versions" the following firmware versions / hardware identifications are displayed. - Rollfeed Extended: Version of the firmware option Version of the visualization user interface - Drive: Manufacturer version Control part type - Motor: Motor type - VCP: Firmware version If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-74: Help display in menu "Versions"

103 Rollfeed Extended 02VRS HMI 6-37 Display "Diagnosis Extras Feed Optimization" (F4) In this screen the adjusted lower and upper limit value of the wished feed angle utilization for the feed optimization is displayed. Fig. 6-75: Display "Feed Optimization" If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-76: Help display in menu "Feed Optimization" Display Diagnosis Extras Feed Diagnosis (F5) Fig. 6-77: Display in menu "Feed Diagnosis" In display "Feed Diagnostics" the following information are displayed: current position of the external presses encoder calculated maximum number of presses strokes, relevant with feed via master axis coupling

104 6-38 HMI Rollfeed Extended 02VRS current moving profile (trapezoid, master axis coupling with VMA/RMA) If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-78: Help display in menu "Feed Diagnosis" 6.10 Display "Setup" (F4) Fig. 6-79: Display "Setup" The display "Setup" shows the actual status and the settings for the Setup mode. In the status a plaintext message is displayed that informs the operator whether the part length was moved or not. Via the commanded length the current to be moved commanded distance is displayed. Via the actual length the already moved distance is displayed. In addition, the actual parameterized Setup velocity and the current position actual value of the drive are displayed. With active Edit mode the Setup velocity can be changed. A changed Setup velocity is directly stored.

105 Rollfeed Extended 02VRS HMI 6-39 If the operator presses the HELP-Key, the following screen is displayed: Fig Help display in menu "Setup" 6.11 Display "Machine Parameter" (F5) Fig. 6-81: Display in menu "Machine Parameter" Here it is about a pure screen of information. No changes or inputs can be carried out. Strokes per Minute Shows the current number of strokes of the machine in strokes per minute. Feed Angle Utilization Shows the utilization of the feed angle in percent which is calculated by the control. A value less 90% signals to the operator that the maximum feed velocity is not yet reached and the presses velocity can be increased. If the value of 100% is exceeded, this leads to a feed angle loss which shuts down the machine immediately if the feed angle monitoring is activated. Then the error is indicated in the status line of the VCP 08. If the feed angle does not work to full capacity, an automatic feed optimization is possible. Machine Velocity Shows the current machine velocity in m/min or Inch/min. In this connection always the current actual velocity of the machine is used for calculation. Maximum Machine Speed Shows the maximum machine velocity in m/min or Inch/min.

106 6-40 HMI Rollfeed Extended 02VRS If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-82: Help display in menu "Machine Parameter" Display "Machine Tools" (F1) In the displays "Tool Wear 1" and "Tool Wear 2" are indicated the given switch cycles with the actually executed tool controls and the status in addition. The operator gets information about the current state of the tool counter and therefore he can monitor the tools wear. Besides, an x in column "Stat" indicates the exceeding of the maximum switching operations. In this case a tool change is advisable. In these menus a tool name can be given for each of the tools 1-8 and the commanded quantity for the number of the switching operations can be forced. Via Browse-Key it can be changed between the displays of "Tool Wear 1-2". Fig. 6-83: Display in menu "Tool Wear 1" (Tool 1-4) Fig. 6-84: Display in menu "Tool Wear 2" (Tool 5-8)

107 Rollfeed Extended 02VRS HMI 6-41 If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-85: Help display in menu "Tool Wear 1-2" Display "Machine Tools Tool Control" (F2) In screen "Tool Control" the configuration of the tool blocks are displayed. The number of the to be displayed tool block is editable. The allocation of the tool block for setting and acknowledging the tools 1-8, in each case before activation of the presses stroke and after executed presses stroke, is displayed. Syntax: Besides, the syntax of the input is to be understood as follows: 0 = Output is set to zero 1 = Output is set to 1 2 = Output remains unchanged Tools can be acknowledged per input signal, time acknowledgment or by a combination of both variants. Fig. 6-86: Display in menu "Tool Control"

108 6-42 HMI Rollfeed Extended 02VRS If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-87: Help display in menu "Tool Control" Display "Machine Tools Time Acknowledgment" (F3) In display "Tool Time Acknowledgment" the parameterization of the time values for the acknowledgment of tools 1-8 in the respective tool block are specified. The number of the tool block for which the time values should be changed is editable. For the acknowledgment of the tool outputs it is waited for the duration of the time value registered here before or after the presses stroke. Only one time for all 8 outputs can be specified. Not later than at the end of the time value all tools are considered as acknowledged. If no time acknowledgment should take place, the value 0.00 sec must be entered. Fig. 6-88: Display in menu "Tool Time Acknowledgment" If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-89: Help display in menu "Tool Time Acknowledgment"

109 Rollfeed Extended 02VRS HMI 6-43 Display "Machine Tools Preset Tool Counter" (F4) In display "Preset Tool Counter" the operator can correct or preset the actual number of the executed tool operations. Via the edit field to the tool number every arbitrary tool 1-8 for which a correction should be executed is selectable. For easier allocation the tool name of the chosen tool is also indicated. The preset value itself can be given arbitrarily. Fig. 6-90: Display in menu "Preset Tool Counter" If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-91: Help display in menu "Preset Tool Counter" Display "Machine Cam Switch" (F2) In the displays "Cam Switch 1" and "Cam Switch 2" the name, the switchon- and switch-off angle and the rate time of the individual switches can be edited. The switch-on and switch-off angle must lie between 0 and 360 degrees. In addition, the status of the switches 1-8 and the current position of the external presses encoder is displayed. Via the Browse-Key it can be changed between the displays of "Cam Switch 1-2".

110 6-44 HMI Rollfeed Extended 02VRS Fig. 6-92: Display in menu "Cam Switch 1" (Cam Switch 1-4) Fig. 6-93: Display in menu "Cam Switch 2" (Cam Switch 5-8) If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-94: Help display in menu "Cam Switch 1-2" Display "Machine Safety Switch" (F3) The safety switches (SIC = Security Input Control) serve for monitoring of "safety-relevant" inputs. Besides, it is about 4 input (SIC 1-4) which are controlled as a function of the switch position. Besides, the allocation of SIC-Inputs to the switches is determined as follows: SIC-1 to switch 1 SIC-2 to switch 2 SIC-3 to switch 3 SIC-4 to switch 4

111 Rollfeed Extended 02VRS HMI 6-45 To satisfy the most different signal sources, an individual signal level can be assigned to every SIC-Input. Besides, the meaning of the signal choice is as follows: OFF = No test takes place. 0 = Check signal level on "0", thereby outside the enable it is checked for edge changing. The input must be "0" during the whole test range. 1 = Check signal level on "1", thereby outside the enable it is checked for edge changing. The input must be "1" during the whole test range. 0>1 = Check signal level on rising edge. 1>0 = Check signal level on falling edge. ~0 = Check signal level on "0" when leaving the test range. ~1 = Check signal level on "1" when leaving the test range. 0~1 = Check on rising edge during test range. 1~0 = Check on falling edge during test range. In the screen "Safety inputs" the following information are displayed: General release of the SIC-Signals via input "SIC-Enable" Status of output SIC-Error Switch-on- and switch-off angle of the assigned switches 1-4 Name of the SIC-Signals 1-4 Assigned signal level of SIC-Signals 1-4 Status of the SIC-Signals 1-4 In this display an individual text can be assigned to the SIC-Inputs. The SIC monitoring is active in every operation mode. However, the four SIC- Inputs can be completely locked via input "SIC enable" (P ). If a SIC-Input is not needed, it can be switched off. In order to switch off, the signal selection must be set to off. Thus no monitoring of this input takes place. Fig. 6-95: Display in menu "Safety Inputs"

112 6-46 HMI Rollfeed Extended 02VRS If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-96: Help display in menu "Safety Inputs" Display "Machine Parameter" (F4) Fig. 6-97: Display "Parameter" In display menu "Parameter" the parameters of the IndraDrive-Control part can be displayed and edited. With active edit mode the operator can read an arbitrary drive parameter by input of the number. After a successful read access the datum of the parameter can be edited. For that purpose the edit focus must be moved to the value in the edit field. By pressing the Data entry-key the current edited value is written into the parameter of the control part. For input of alphanumerical characters the F6-Key must be pressed. Note: The actual value of the parameter is displayed cyclic, if the edit focus does not stand on the input field of the value.

113 Rollfeed Extended 02VRS HMI 6-47 If the operator presses the HELP-Key, the following screen is displayed: Fig. 6-98: Help display in menu "Parameter" Display "Machine Parameter System Parameter" (F1) Fig. 6-99: Display "System Parameter" In display menu "System Parameter" the operator can display and edit the system parameters. The selection of the system parameter takes place with active edit mode via input in field "No.". After a successful read access the datum of the system parameter can be edited. For that purpose the edit focus must be moved to the value in the edit field. By pressing the Data entry-key the current edited value is written into the system parameter. For input of alphanumerical characters the F6-Key must be pressed. The assignment in input field "No." can be taken from the parameter list of the system parameters in chapter 8. Note: The actual value of the system parameter is displayed cyclic, if the edit focus does not stand on the input field of the value.

114 6-48 HMI Rollfeed Extended 02VRS If the operator presses the HELP-Key, the following screen is displayed: Fig : Help display in menu "System Paramameter" Display "Machine Parameter Load Base Parameter" (F2) Fig : Display "Load Base Parameter" In display menu "Load Base Parameter" the following basic settings can be restored in the drive depending on the selected option Load "Default closed loop parameters" or Load "Default drive parameters" With active edit mode the option setting can be selected via the + or - Key. Note: By this command all executed parameterizations of the drive will be overwritten. However, the communication settings of the serial interface as well as the system-specific parameters of the Rollfeed Extended system solution are kept.

115 Rollfeed Extended 02VRS HMI 6-49 If the operator presses the HELP-Key, the following screen is displayed: Fig : Help display in menu "Load Base Parameter" Display "Machine Parameter Extras" (F3) Fig : Display "Extras" In this menu the language, date, time and contrast of the display can be adjusted. For the input of the language, date and time the edit mode must be activated. The date, time and the contrast can be changed via direct input or via the + or - -Keys. The language selection must take place via the + or - -Key. Note: After confirmation of a new selected language by the Data entry-key the display changes automatically to the main screen. If the operator presses the HELP-Key, the following screen is displayed: Fig Help display in menu "Extras"

116 6-50 HMI Rollfeed Extended 02VRS

117 Rollfeed Extended 02VRS Pass-Through Mode 1 7 Pass-Through Mode 7.1 Functional Description The RollFeed Extended supports a Pass-Through mode that allows a serial communication link from a presses controller (further referred to as a PC) through a VCP HMI device to a RollFeed control. Via this connection, the PC can retrieve process information from the RollFeed control or send action commands to the RollFeed control. The communication protocol used between the PC and the RollFeed control is based on the Rexroth OptiFeed system. The Pass-Through mode allows ASCII communication between a PC and a RollFeed control to be relayed through a VCP HMI device. Any ASCII communication between the PC and the RollFeed control is recognized by the VCP HMI device and simply relayed without affecting the communication. Refer to Fig. 7-1 for a basic principle of the connection between a PC and a RollFeed control. Fig. 7-1: Pass-Trough communication The PC is connected to the VCP (VCP05 or VCP08) via a serial RS 232 cable. Serial messages sent by the PC are analyzed by the RollFeed HMI application. If this message is recognized as a Pass-Through protocol, it is forwarded to the RollFeed control. The RollFeed control then sends a telegram with the requested information back to the PC or performs the requested command. Note: The Pass Through mode must be activated in parameter P , Rollfeed Configuration parameter 2 (Bit 2).

118 2 Pass-Through Mode Rollfeed Extended 02VRS 7.2 General Command Format Three different command types are supported. Each type is determined by a corresponding start character or message identifier in the command telegram. Message identifier ASCII code (hex) Meaning? 0x3F Request, read operation (status requests, parameter requests) # 0x23 Write operation (parameter write command)! 0x21 Action command (system macro commands) Fig. 7-2: Telegram start characters / message identifier All telegram messages are terminated by a carriage return and a linefeed character (<cr><lf>). Write commands also include a two-digit checksum with is separated from the other characters in the message by a $ character. 7.3 Status Requests Command Format Status requests are commands that retrieve the current status of the RollFeed system. Every status request starts with the message identifier? followed by a space character, a status request identifier (capital X) that is followed by two spaces and then a two-digit request number. The telegram is terminated by <cr><lf> (carriage return and line feed). Any additional information between the request number and the <cr> is ignored.?_x nn_<cr><lf> ( _ = space: 0x20) _ Line feed ASCII character (0x0A) _ Carriage return character (0x0D) _ Two characters for the request number _ Status request identifier: Capital X followed by two spaces (0x58)(0x20)(0x20) _ Request identifier:? and space (0x3F)(0x20) Response Format The response to a status request issued by the RollFeed system has the following format: X_nn ####$hh<cr><lf> _ Line feed character (0x0A) _ Carriage return character (0x0D) _ $ (0x24) and check sum, 2 char _ The response value or message, max 40 char _ The number of the original request and two spaces(0x20) _ Capital X and a space (0x58)(0x20)

119 Rollfeed Extended 02VRS Pass-Through Mode 3 Representation of Numerals in a Telegram Every individual decimal and hex digit is represented by its ASCII character. Negative numbers begin with a - sign (ASCII: 0x2D). A + sign (ASCII: 0x2B) for positive is optional. A number that does not start with a sign is assumed positive. The decimal sign is the period sign (ASCII: 0x2E). No spaces or other characters are allowed in-between the individual digits, the sign, and the decimal point of a numeral. Leading or trailing zeros are not required but will be processed accordingly. The maximum (string) length of a float representation is 13 characters. Floating Point Numbers Integers Binary Values Strings In the description of the telegrams, the following expressions are used to describe the representation of different numeral types: [Float1] = a floating point number accurate to 1 decimal place [Float3] = a floating point number accurate to 3 decimal places and so forth [Int2] = a two-digit integer, [Int4] = a four-digit integer with leading zeros, and so forth. [Hex8] = an eight-digit hexadecimal number (4 bytes). [Char40] = a string with maximum of 40 characters List of System Status Requests Note: Space characters in the following text are represented with an underscore "_". Status request 00 Position error Request?_X 00_<cr><lf> Action Response Fig. 7-3: Read the current position lag in the pre-selected unit. X_00 [Float3]$hh<cr><lf> Position error Status request 01 Current RollFeed diagnostic text Request?_X 01_<cr><lf> Action Response Fig. 7-4: Read the current RollFeed diagnostic message X_01 [max 32chr]$hh<cr><lf> Example: X_01 Motor has Overheated!$4B<cr><lf> Current RollFeed Diagnostic Text

120 4 Pass-Through Mode Rollfeed Extended 02VRS Status request 02 RollFeed system information Request?_X 02_<cr><lf> Action Provide the current system status Response X_02_mx$hh<cr><lf> with m = current mode: 0 = manual mode 1 = automatic mode 3 = setup mode 2= Parameter mode, not existent x = add. information: Auto. mode: 0 = in-feed not complete 1 = system is in-cycle and cycle start is on Manual mode: 0 = jogging inactive 1 = jogging active Fig. 7-5: RollFeed System Information Status request 03 Travel distance Request?_X 03_<cr><lf> Action Response Fig. 7-6: Provide the actual distance in the pre-selected unit that the material has traveled in the current (not yet finalized) feed process. X_03_[float]$hh<cr><lf> Example: X $A0<cr><lf Travel Distance Status request 04 Measuring wheel data Request?_X 04_<cr><lf> Action Response Read the current position values of the measuring wheel and the motor encoder in the pre-selected units. X_04_xys_[Float3]_[Float3]$hh<cr><lr> _ Motor encoder position _ measuring wheel position x = Drive address, always 1 (only 1 axis) y = always 0 s = Status: 0 = measuring wheel deactivated 1 = measuring wheel activated Example: X $68<cr><lf> Fig. 7-7: Measuring wheel data

121 Rollfeed Extended 02VRS Pass-Through Mode 5 Status request 05 Current feed length and velocity Request?_X 05_<cr><lf> Action Response Fig. 7-8: Read the current feed length in the pre-selected unit and the current velocity in % of the programmed velocity. X_05_[Float3]_[Float1]$hh<cr><lf> Example: X $E0<cr><lf> Current feed length and velocity System parameters Status request 09 Stroke rate and feed angle utilization Request?_X 09_<cr><lf> Action Response Fig. 7-9: Read the current stroke rate in the pre-selected unit and the feed angle utilization in %. X_09_[Int4]_[Int2]$hh<cr><lf> Example: X $AE<cr><lf> Stoke rate and feed angle utilization Status request 10 Inputs (hex) Request?_X 10_<cr><lf> Action Response Fig. 7-10: Read the current digit input signals to the RollFeed control. X_10_[Hex8]$hh<cr><lf> Example: X B64$63<cr><lf> Inputs (hex) Status request 11 Outputs (hex) Request?_X 11_<cr><lf> Action Response Fig. 7-11: Read the current digit output signals of the RollFeed control. X_11_[Hex8]$hh<cr><lf> Example: X $74<cr><lf> Outputs (hex) Status request 12 Total amount of pieces / total length Request?_X 12_<cr><lf> Action Response Fig. 7-12: Read the current total amount of pieces and the total length of pieces in the pre-selected unit. X_12_[Int8]_[Float3]hh<cr><lf> _ total length _ Piece count Example: X $4C<cr><lf> Total amount of pieces and total length

122 6 Pass-Through Mode Rollfeed Extended 02VRS Status request 14 Current RollFeed diagnostic text Request?_X 14_<cr><lf> Action Response Fig. 7-13: Provide the current RollFeed system diagnostics. X_14_[Char40]$hh<cr><lf> Example: X 14 Motor has overheated!$26<cr><lf> Current RollFeed diagnostic text Status request 19 RollFeed version number Request?_X 19_<cr><lf> Action Response Fig. 7-14: Provide the version number of the RollFeed system. X_19 [Char40]$hh<cr><lf> Example: X 19 RollFeed Extended 2 01V03$0C<cr><lf> System parameters Status request 21 System flag Request?_X 21_<cr><lf> Action Response Fig. 7-15: System flag Provide the flag for Single Stroke / Continuous Stroke. X_21_ $hh<cr><lf> 0= Single stroke 1= Continuous stroke Status request 22 Average material velocity Request?_X 22_<cr><lf> Action Response Fig. 7-16: Read the average velocity of the fed-in material in the preselected unit per minute. This information is equal to the current material throughput. X_22_[Int7]$hh<cr><lf> Example: X $A8<cr><lf> Average material velocity Status request 25 Current diagnostic text Request?_X 25_<cr><lf> Action Provide the current diagnostic text. Identical to request #14. Response X_25_[Char40]$hh<cr><lf> Example: X 25 Motor has overheated!$24<cr><lf> Fig. 7-17: System parameters

123 Rollfeed Extended 02VRS Pass-Through Mode 7 Status request 28 Drive status Request?_X 28_<cr><lf> Action Response Fig. 7-18: Drive status Provide the current diagnostic message of the drive. X_28_[Char40]$hh<cr><lf> Status request 29 Drive firmware version Request?_X 29_<cr><lf> Action Response Fig. 7-19: Read the firmware version of the drive. X_28_[Char40]$hh<cr><lf> Drive firmware version

124 8 Pass-Through Mode Rollfeed Extended 02VRS 7.4 Input (Write) Requests Input Requests are used to download values to the control or to reset counters and accumulators. Input request 00 Set feed length and feed rate Request #_X 00_[Float]_[Float]$hh<cr><lf> _ Feed rate _ Feed length Example: # X $32<cr><lf> Derivatives: # X 00 M+$2C<cr><lf> # X 00 M-$2A<cr><lf> Action Set or change the active feed length (in the pre-selected unit) and feed rate [1/min]. Derivatives: - M+: Add Micro-Adjust value to the current feed length Response Fig. 7-20: - M-: Subtract Micro-Adjust value from current feed length Acknowledgement: Y_<cr><lf> Modify Feed length and feed rate command Input request 03 Reset total piece count Request #_X 03$hh<cr><lf> Actual command: # X 03$C1<cr><lf> Action Response Fig. 7-21: Reset the total piece counter. Acknowledgement: Y_<cr><lf> Reset Total Piece count command Input request 04 Reset total length Request #_X 04$hh<cr><lf> Actual command: # X 04$C0<cr><lf> Action Response Fig. 7-22: Clear the total material length accumulator. Acknowledgement: Y_<cr><lf> Reset Total Length command

125 Rollfeed Extended 02VRS Pass-Through Mode Parameter Request A parameter request has the general format:?_k_[parameter number]<cr><lf> If a parameter number is detected to be invalid, the control will send back an error message (E_K_nnnn_INVALID). Parameter request B101 Read dimensional unit Request?_K_B101<cr><lf> Action Response Fig. 7-23: Read the pre-selected dimensional unit. This unit is used for all calculations on the control. Remark: This information was stored in parameter B101 on the CLM control. K_B101_[Char12]$hh<cr><lf> _ Units: mm or in. Example: K B101 mm$c5<cr><lf> Read Dimensional Unit Parameter request B107 Read micro-adjust Increment Request?_K_B107<cr><lf> Action Response Fig. 7-24: Read the current setting of the feed length Micro-Adjust increment. Remark: The Micro-Adjust value was stored in parameter B107 on the CLM control. K_B107_[Float3]$hh<cr><lf> Example: K B $A1<cr><lf> Read Micro-Adjust Increment

126 10 Pass-Through Mode Rollfeed Extended 02VRS 7.6 Parameter Input (Write) Command A parameter input / write command has the following format: #_K_[Param.]_[value]_[add. optional chars]$hh<cr><lf> The numeral value in the command must match the type of the corresponding parameter to be interpreted correctly. Parameter input B107 Set micro-adjust Increment Command #_K_B107_[Float]$hh<cr><lf> Example: # K B107_1.234$1F<cr><lf> Action Response Fig. 7-25: Set the value for the feed length Micro-Adjust increment in the pre-selected unit. Remark: The Micro-Adjust value was stored in parameter B107 on the CLM control. Acknowledgement: Y_<cr><lf> Set Micro-Adjust Increment

127 Rollfeed Extended 02VRS Pass-Through Mode Drive Parameter Read Request In addition to the adaptation of the CLM OptiFeed commands, Pass- Through Mode also provides a direct read access to all drive parameters, except for list parameters. Read request S-Parameter from Drive Request?_K_S[Int4]<cr><lf> Example:? K S0051<cr><lf> or in short form? K S51<cr><lf> Action Response Fig. 7-26: Read the requested S parameter from the drive. The response depends on the data type of the requested parameter: Binary param.: K_S[Int4]_[Hex8]$hh<cr><lf> Real param.: K_S[Int4]_[Float3]$hh<cr><lf> String param.: K_S[Int4]_[Char40]$hh<cr><lf> Example: K S $FD<cr><lf> S-Parameter Read request Read request P-Parameter from Drive Request?_K_P[Int4]<cr><lf> Example:? K P0052<cr><lf> or in short form? K P52<cr><lf> Action Response Fig. 7-27: Read the requested P parameter from the drive. The response depends on the data type of the requested parameter: Binary param.: K_P[Int4]_[Hex8]$hh<cr><lf> Real param.: K_P[Int4]_[Float3]$hh<cr><lf> String param.: K_P[Int4]_[Char40]$hh<cr><lf> Example: K P $FC<cr><lf> P-Parameter Read request

128 12 Pass-Through Mode Rollfeed Extended 02VRS 7.8 Error Messages Every request or command is acknowledged by the control. In case of an error, one of the following error strings are returned: Format Error E_00_Format_Error $hh<cr><lf> This error message is sent when the received message format is not valid. It is also a generic error response that is issued when a message is not being received properly due to improper handshaking or carriage return and /or linefeed characters. Invalid Identifier E_01_Identifier_Error$hh<Cr><Lf> This error is issued when an identifier character is invalid, e.g. instead of K, S or P for a parameter request another character is received. E_02_#_Out_Of_Bounds_$hh<Cr><Lf> This error is sent when the number in the identifier is greater than the maximum number. Checksum Error E_03_Checksum_Error $hh<cr><lf> This error occurs when the checksum computed by the control does not match with the one received or if a checksum is missing. In the case of a general communication error, a checksum error also functions as a request to repeat the last command. String Invalid E_04_String_Invalid $hh<cr><lf> This message is sent when the received data is invalid, e.g. if the feed length data does not contain a decimal value. Wrong Parameter Value E_06_K_xxx_Invalid_$hh<Cr><Lf > This message is sent when a downloaded parameter exceeds its limits. Not implemented E_11_Not_Implemented_$hh<Cr><Lf > This error is issued when the requested function or information is not available. It accommodates for the fact that due to general differences between the RollFeed and the OptiFeed system not all commands of the previous system are available anymore. General Internal Error E_99_Internal Error $hh<cr><lf > This error is returned when an internal problem has occurred.

129 Rollfeed Extended 02VRS Pass-Through Mode Check Sum Generation To ensure that the correct data is being sent and received, a checksum is calculated and checked by the PLC. To compute the checksum, add up the hexadecimal ASCII values of all of the characters before the '$'. Then add the most significant digits of the checksum to the two least significant digits. Then, negate this value to form the two's complement. Take the last 2 digits of this number. The result is a 2-digit checksum to be transmitted to the requesting device. Example: #_B_A03$B6<cr><lf> Checksum on #_B_A03: 23 hex ASCII ( # ) 20 space 42 B 20 space 41 A A Checksum = -(4A) = B6 = Not(4A) +1 [two s complement]

130 14 Pass-Through Mode Rollfeed Extended 02VRS

131 Rollfeed Extended 02VRS Parameters Parameters 8.1 System Parameters This chapter describes the system-specific parameters. They serve for the definition and for the adaptation of the machine components and for the activation of specified functional flows. For parameterization of the machine the engineering Framework IndraWorks, as well as the compact HMI VCP 08 is available. No. Designation ID-No. 1 Control word encoder 2 (optional encoder) P Allocation optional encoder -> option position P Feed constant S Load gear input revolutions S Load gear output revolutions S Safe reduced velocity P (element 3640) 7 Velocity limit value bipolar P Manual velocity P Setup velocity P Acceleration bipolar S Drive Halt acceleration bipolar S Jerk limit value bipolar S Position command smoothing time constant P Positioning window S Monitoring window S Monitoring window slip in % P Rollfeed Configuration parameter 1 P Rollfeed Configuration parameter 2 P Number of presses strokes P Standstill time press P Monitoring cycle time P Micro-Adjust value P Delay time Close rolls P Preset diagnostics parameters P Position polarities parameter Polarity S Encoder type 2 (optional encoder) P Type of position encoder 2 (external encoder) Encoder S Rotary encoder 2, resolution (external encoder) Encoder S Feed constant 2 (optional encoder) P Current loop proportional gain 1 S Current loop integral action time 1 S P-component of speed controller Controller S Integral-action component of speed controller S

132 8-2 Parameters Rollfeed Extended 02VRS Controller 34 Velocity loop smoothing time constant P Loop gain factor of position controller Controller S Acceleration feedforward gain S Acceleration feedforward smoothing time constant P Velocity control loop: acceleration feedforward P Actual pos. smoothing time constant for hybrid pos. control P Torque/force peak limit P Motor peak current Limit value S Motor zero-speed current Amplifier S Maximum motor speed (nmax) Limit value S Fig. 8-1: Parameter list In the following the function of the system parameters are described which cannot be taken from the parameter description DOK-INDRV*- GEN-** VRS **-PA02-EN-P. P , Product Data and Machine Parameters Via this parameter the relevant product data as well as the machine parameters are preset and backed up. Following functions are configured via this parameter: Product processing Tool administration Programmable limit switch Safety queries (SIC) Feed optimization Integrated safety engineering Product Data Up to 99 products with 6 part lengths in each case can be administrated. If product data are changed during a feeding, they are first accepted in the following feed cycle. For the batch pass the following batch data are available: Product start number for the batch pass (List element 0) Commanded quantity of the batch passes (List element 100) Note: If 0 is given for the commanded quantity of the batch pass, so a continuous-operation of the batch processing without quantity limitation is activated. For the products 1-99 following product data are available: Next product number (List elements 1-99) Commanded quantity products (List elements )

133 Rollfeed Extended 02VRS Parameters 8-3 Note: If,0 is given for the commanded quantity of the product, so it is linked with the next product. The end of a batch pass is characterized by a 0 for the next product number (see chapter 4.10). For the part lenghts 1-6 of the products 1-99 the following feed data are available: Feed length in [mm] or [Inch] (List elements ) Velocity in percentile of the maximum velocity (P ) (List elements ) Commanded quantity part length (List elements ) Acceleration in percentile of the maximum acceleration (S ) (List elements ) Tool block number (List elements ) With active Automatic mode changed part data are always first accepted after a falling edge at the feed angle. Note: The feed length must be greater 0. The presettings for the velocity and acceleration must be greater than 0 % and less equal 100%. If 0 is given for the commanded quantity, so this part length and all following in the respective product are not active. The commanded quantity of the first part length must always be unequal 0. Tool Administration For the respective part lengths 1-6 of the products 1-99 can be given a tool block number in which the wished tool control is determined. Via the tool block number the setting and accepting of tools before and after the press are parameterized. A total of 99 tool blocks are available. Setting the tool outputs 1-8 for the tool blocks 0-99 (List elements ) Accepting the tool inputs 1-8 for the tool blocks 0-99 (List elements ) Time acknowledgment of the tool inputs 1-8 before press for the tool blocks 0-99 (List elements ) Time acknowledgment of the tool inputs 1-8 after press for the tool blocks 0-99 (List elements ) Commanded quantity of the switching operations of tools 1-8 (List elements ) Tools can be acknowledged by input signal, time acknowledgment or by a combination of both variants. Should no time acknowledgment take place, the value,0 ms' must be insert. The configuration of the parameter assignment of the several list elements for setting/accepting of tools is explained in the following tables.

134 8-4 Parameters Rollfeed Extended 02VRS Assignment of the list elements for setting the tools Tools after press Tools before press Byte 3 Byte 2 Byte 1 Byte 0 Task mask tool 1-8 Changing mask tool 1-8 Task mask tool 1-8 Changing mask tool 1-8 Bit 24 = Tool 1 Bit 25 = Tool 2 Bit 26 = Tool 3 Bit 27 = Tool 4 Bit 28 = Tool 5 Bit 29 = Tool 6 Bit 30 = Tool 7 Bit 31 = Tool 8 Bit 16 = Tool 1 Bit 17 = Tool 2 Bit 18 = Tool 3 Bit 19 = Tool 4 Bit 20 = Tool 5 Bit 21 = Tool 6 Bit 22 = Tool 7 Bit 23 = Tool 8 Bit 8 = Tool 1 Bit 9 = Tool 2 Bit 10 = Tool 3 Bit 11 = Tool 4 Bit 12 = Tool 5 Bit 13 = Tool 6 Bit 14 = Tool 7 Bit 15 = Tool 8 Bit 0 = Tool 1 Bit 1 = Tool 2 Bit 2 = Tool 3 Bit 3 = Tool 4 Bit 4 = Tool 5 Bit 5 = Tool 6 Bit 6 = Tool 7 Bit 7 = Tool 8 Meaning: Meaning: Meaning: Meaning: 0 = Reset tool 1 = Set tool 0 = No check 1 = Check according to task mask 0 = Reset tool 1 = Set tool Fig. 8-2: Parameterization for setting tools 0 = No check 1 = Check according to task mask Assignment of the list elements for accepting the tools Tools after press Tools before press Byte 3 Byte 2 Byte 1 Byte 0 Task mask tool 1-8 Changing mask tool 1-8 Task mask tool 1-8 Changing mask tool 1-8 Bit 24 = Tool 1 Bit 25 = Tool 2 Bit 26 = Tool 3 Bit 27 = Tool 4 Bit 28 = Tool 5 Bit 29 = Tool 6 Bit 30 = Tool 7 Bit 31 = Tool 8 Bit 16 = Tool 1 Bit 17 = Tool 2 Bit 18 = Tool 3 Bit 19 = Tool 4 Bit 20 = Tool 5 Bit 21 = Tool 6 Bit 22 = Tool 7 Bit 23 = Tool 8 Bit 8 = Tool 1 Bit 9 = Tool 2 Bit 10 = Tool 3 Bit 11 = Tool 4 Bit 12 = Tool 5 Bit 13 = Tool 6 Bit 14 = Tool 7 Bit 15 = Tool 8 Bit 0 = Tool 1 Bit 1 = Tool 2 Bit 2 = Tool 3 Bit 3 = Tool 4 Bit 4 = Tool 5 Bit 5 = Tool 6 Bit 6 = Tool 7 Bit 7 = Tool 8 Meaning: Meaning: Meaning: Meaning: 0 = Acknowledgment of the tool must be deleted 1 = Acknowledgment of the tool must be set 0 = No check 1 = Check according to task mask 0 = Acknowledgment of the tool must be deleted 1 = Acknowledgment of the tool must be set Fig. 8-3: Parameterization for setting tools 0 = No check 1 = Check according to task mask Programmable Limit Switch For the use of the switches 1-8 the switch-on/off angles are preset via this parameter. Switch-on angle, switch 1-8 (List elements ) Switch-off angle, switch 1-8 (List elements ) Note: Via cam switch 1 also the begin and end of the feed range with master axis coupling with external presses encoder is specified in [ ].

135 Rollfeed Extended 02VRS Parameters 8-5 Safety Queries (SIC) To satisfy the most different signal sources, an individual signal level or task (list elements ) can be assigned to every SIC input 1-4. Besides, the parameterization of the task is defined as follows: Task value Fig. 8-4: Function 0 No check takes place. 1 2 Check signal level on "0", thereby outside the enable it is checked for edge changing. The input must be "0" during the complete test range. Check signal level on "1", thereby outside the enable it is checked for edge changing. The input must be "1" during the complete test range. 3 Check signal level on rising edge. 4 Check signal level on falling edge. 5 Check signal level on "0" when leaving test range. 6 Check signal level on "1" when leaving test range. 7 Check on rising edge during test range. 8 Check on falling edge during test range. SIC - Task Feed Optimization For the function feed optimization the minimum (list element 3633) and maximum (list element 3634) limit value (in [%]) to the wished full utilization of the feed angle are set via this parameter. Integrated Safety Engineering The following machine parameters are preset via this parameter: Safe reduced velocity in [%] (List element 3640) With active safety operation mode state "Safe movement 1,2,3 or 4" the internal preset commanded velocity in Manual- or Automatic mode is automatically limited to the preset value by the system solution. The presetting works proportionally concerning the parameterized value of the respective velocity threshold (P , P , P or P ). If the value is set to,0', no automatic limitation of the commanded velocities takes place on the part of the system solution. In this case the higher level control itself is responsible for the presetting of reduced commanded velocities in the Manual- or Automatic mode (P , P , P ). Parameters to the Moving Profile Following settings to the moving profile are forced via this parameter: Tolerance window with master axis coupling with external presses encoder in [ ] (List element 3642) The feed movement can be shortened with master axis coupling with external presses encoder by this value, concerning the end of the feed range (switch-off angle). Presetting the moving profile with master axis coupling (List element 3643)

136 8-6 Parameters Rollfeed Extended 02VRS There applies the following meaning: 0 = Polynomial 5 th order 1 = Cam table 1 (P ) 2 = Cam table 1 (P ) 3 = Cam table 1 (P ) 4 = Cam table 1 (P ) 5 = Cam table 1 (P ) 6 = Cam table 1 (P ) 7 = Cam table 1 (P ) 8 = Cam table 1 (P ) Negative velocity limit value for the master axis coupling with external presses encoder in [r.p.m.] (List element 3644) For avoidance of a reverse turning feed axis with a master axis coupling with external presses encoder, a negative velocity limit value can be parameterized for the external presses encoder in this parameter. If the press moves backwards and exceeds the velocity of this limit value, the error "Negative presses velocity" is generated. If,0' is given for the limit value, so the monitoring is deactivated. Note: Changes of the settings to the moving profile become only effective if the Automatic or Setup mode is not active or a Cycle stop is active. System Parameters Following system parameters are available: Factor for the calcualtion of the monitoring time of the internal PLC- Task cycle (List element 3641) With appearance of the error "Exceeding time limit PLC-Task" (F2012 SPS - error No 2) the internal monitoring time can be increased. The monitoring time is increased by the parameterized factor multiplied by the minimal possible resolution time. A change of the parameter is recognized only after a change-over from Parameter- to Operation mode. An overview of the usage of the product data and machine parameters in parameter P gives the following table: List element Usage Scaling / Unit Start product number for batch pass Product 1: next product number Product 2: next product number 10^0 10^0 10^0 99 Product 99: next product number 10^0

137 Rollfeed Extended 02VRS Parameters Commanded quantity of the batch passes 10^0 101 Commanded quantity product 1 10^0 102 Commanded quantity product 2 10^0 199 Commanded quantity product Reserved Product 1 Part length 1: Feed length Part length 2: Feed length Part length 3: Feed length Part length 4: Feed length Part length 5: Feed length Part length 6: Feed length Part length 1: Feed length Part length 2: Feed length 10^0 10^-4 mm or 10^-6 Inch 10^-4 mm or 10^-6 Inch 10^-4 mm or 10^-6 Inch 10^-4 mm or 10^-6 Inch 10^-4 mm or 10^-6 Inch 10^-4 mm or 10^-6 Inch 10^-4 mm or 10^-6 Inch 10^-4 mm or 10^-6 Inch 209 Product Product Product 99 Part length 5: Feed length Part length 6: Feed length Part length 1: Feed length Part length 2: Feed length Part length 3: Feed length Part length 4: Feed length Part length 5: Feed length Part length 6: Feed length 10^-4 mm or 10^-6 Inch 10^-4 mm or 10^-6 Inch 10^-4 mm or 10^-6 Inch 10^-4 mm or 10^-6 Inch 10^-4 mm or 10^-6 Inch 10^-4 mm or 10^-6 Inch 10^-4 mm or 10^-6 Inch 10^-4 mm or 10^-6 Inch

138 8-8 Parameters Rollfeed Extended 02VRS Reserved Product 1 Part length 1: Velocity Part length 2: Velocity Part length 3: Velocity Part length 4: Velocity Part length 5: Velocity Part length 6: Velocity Part length 1: Velocity Part length 2: Velocity 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 809 Product Product Product Reserved Product 1 Part length 5: Velocity Part length 6: Velocity Part length 1: Velocity Part length 2: Velocity Part length 3: Velocity Part length 4: Velocity Part length 5: Velocity Part length 6: Velocity Part length 1: Commanded quantity Part length 2: Commanded quantity 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^0 10^0

139 Rollfeed Extended 02VRS Parameters Part length 3: Commanded quantity Part length 4: Commanded quantity Part length 5: Commanded quantity Part length 6: Commanded quantity Part length 1: Commanded quantity 10^0 10^0 10^0 10^0 10^ Part length 2: Commanded 10^0 Product 2 quantity Product 98 Part length 5: 1987 Commanded quantity 10^ Product Reserved Part length 6: Commanded quantity Part length 1: Commanded quantity Part length 2: Commanded quantity Part length 3: Commanded quantity Part length 4: Commanded quantity Part length 5: Commanded quantity Part length 6: Commanded quantity 10^0 10^0 10^0 10^0 10^0 10^0 10^0

140 8-10 Parameters Rollfeed Extended 02VRS Product 1 Part length 1: Acceleration Part length 2: Acceleration Part length 3: Acceleration Part length 4: Acceleration Part length 5: Acceleration Part length 6: Acceleration Part length 1: Acceleration Part length 2: Acceleration 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 2009 Product Product Product Reserved Product 1 Part length 5: Acceleration Part length 6: Acceleration Part length 1: Acceleration Part length 2: Acceleration Part length 3: Acceleration Part length 4: Acceleration Part length 5: Acceleration Part length 6: Acceleration Part length 1: Tool block Part length 2: Tool block Part length 3: Tool block Part length 4: Tool block 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^-4 % or 10^-6 % 10^0 10^0 10^0 10^0

141 Rollfeed Extended 02VRS Parameters Part length 5: Tool block Part length 6: Tool block Part length 1: Tool block Part length 2: Tool block 10^0 10^0 10^0 10^ Product Product Product Reserved Tool block 0: Setting tools Tool block 1: Setting tools Part length 5: Tool block Part length 6: Tool block Part length 1: Tool block Part length 2: Tool block Part length 3: Tool block Part length 4: Tool block Part length 5: Tool block Part length 6: Tool block 10^0 10^0 10^0 10^0 10^0 10^0 10^0 10^0 10^0 10^ Tool block 99: Setting tools 3300 Reserved Tool block 0: Accepting tools Tool block 1: Accepting tools 10^0 10^0 10^ Tool block 99: Accepting tools 10^0

142 8-12 Parameters Rollfeed Extended 02VRS 3400 Reserved Tool block 0: Time acknowledgment tools before press Tool block 1: Time acknowledgment tools before press 10^0 ms 10^0 ms 3499 Tool block 99: Time acknowledgment tools before press 10^0 ms 3500 Reserved Tool block 0: Time acknowledgment tools after press Tool block 1: Time acknowledgment tools after press 10^0 ms 10^0 ms 3599 Tool block 99: Time acknowledgment tools after press 10^0 ms 3600 Reserved 3601 Switch-on angle switch 1 10^0 degrees 3602 Switch-on angle switch 2 10^0 degrees 3608 Switch-on angle switch 8 10^0 degrees 3609 Switch-off angle switch 1 10^0 degrees 3610 Switch-off angle switch 2 10^0 degrees 3616 Switch-off angle switch 8 10^0 degrees Commanded quantity of the switching operations of tool 1 Commanded quantity of the switching operations of tool 2 10^0 10^ Commanded quantity of the switching operations of tool Reserved 10^ Task SIC signal 1 10^ Task SIC signal 2 10^ Task SIC signal 3 10^ Task SIC signal 4 10^ minimum limit value of the utilization with feed optimization maximum limit value of the utilization with feed optimization Reserved 10^0 % 10^0 %

143 Rollfeed Extended 02VRS Parameters Safe reduced velocity 10^-4 % or 10^-6 % Fig. 8-5: Factor for calculation the monitoring time of the internal PLC-Task cycle Tolerance window with master axis coupling with external presses encoder Presetting the moving profile with master axis coupling Negative velocity limit value for the master axis coupling with external presses encoder Product data and machine parameters 10^0 10^0 degrees 10^0 10^-4 r.p.m. or 10^-6 r.p.m. Note: With the presetting of the product data and machine parameters via the corresponding menu on the VCP 08, these are automatically set in P Note: The backup of the product data and machine parameters in parameter P into the retain memory of the system solution takes place every 500 ms. Parameter attributes: Data length: 4 Byte variable length Display format: Signed decimal number Scaling / Unit: see table Minimum input value: -- Maximum input value: -- Default value: -- Access: No write protection P , Manual Velocity In operation mode "Manual" the drive is moved with the input manual velocity by pressing "Jog forward" ("Jog+) or "Jog backward" (Jog-). The manual velocity is entered in % of P , Velocity limit bipolar. Parameter attributes: Data length: 4 Byte Display format: Unsigned decimal number Scaling / Unit: 10^-2 % Minimum input value: 0 % Maximum input value: 100 % Default value: 20 % Access: No write protection

144 8-14 Parameters Rollfeed Extended 02VRS P , Setup Velocity With the "Setup-Function" in operation mode "Automatic" the drive is moved with the input setup velocity by pressing "Jog forward" (Jog+) or "Jog backward" (Jog-). The setup velocity is input in % of P , Velocity limit bipolar. Parameter attributes: Data length: 4 Byte Display format: Unsigned decimal number Scaling / Unit: 10^-2 % Minimum input value: 0 % Maximum input value: 100 % Default value: 20 % Access: No write protection P , Velocity Limit Bipolar P Velocity Limit Bipolar sets the maximum allowed velocity limit value for both acceleration and deceleration in either mm/min or inch/min. The system automatically sets the S Velocity limit bipolar to about 20% higher value than P User should not modify S since it will be overwritten by the system. Parameter attributes: Data length: 4 Byte Display format: Unsigned decimal number Scaling / Unit: 10^-3 mm/min or 10^-5 inch/min Minimum input value: -- Maximum input value: -- Default value: 1000 mm/min Access: No write protection Note: If the absolute difference between parameter S and P is less than 1 [m/min] or 10 [Inch/min], the parameter S is automatically set to an increased value by 1 [m/min] or 10 [Inch/min] related to parameter P P , Rollfeed Configuration parameter 1 Construction of the parameter: Bit Designation / Function Comment 0 Press / Punch 0: Press active 1: Punch active 1 Override 0: Override not active 1: Override active 2 Measuring wheel 0: Measuring wheel inactive 1: Measuring wheel active See functional description See functional description

145 Rollfeed Extended 02VRS Parameters Electrical / mechanical lifting 0: electrical / mechanical lifting inactive 1: electrical / mechanical lifting active 4 Activation input Stop neg/feed interrupt neg 0: Input Stop neg and Feed interrupt neg is active 1: Input Stop neg and Feed interrupt neg is inactive 5 Measuring unit for translatory scaling 0: Millimeter [mm] 1: Inch [in] See functional description Serves for commissioning A change is effective only after a phase switching from Parameter- to Operation mode 6 Feed monitoring 0: Feed monitoring active 1: Feed monitoring inactive 7 Cycle time monitoring 0: Cycle time monitoring inactive 1: Cycle time monitoring active 8 Analog output average path velocity 0: Analog output average path velocity via analog output 1 inactive 1: Analog output average path velocity via analog output 1 active See parameter P See functional description 9 Free configuration of the I/O-Signals 0: free configuration of the I/O-Assignment inactive 1: free configuration of the I/O-Assignment active 10 Feed angle via external presses encoder 0: feed angle via binary input signal 1: feed angle via position of the external presses encoder (cam switch) 11 Moving profile via master axis coupling 0: no master axis coupling active, trapezoid or triangle profile active 1: master axis coupling active, selection RMA/VMA via bit Selection of the master axis 0: master axis coupling with real master axis (external presses encoder) 1: master axis coupling with virtual master axis reserved Fig. 8-6: P , Rollfeed Configuration parameter 1 Press / Punch If the function "Punch" is activated, output "Press" (X15/13, P ) is switched off with the falling edge of signal "Feed angle". If the function "Punch" is activated, output "Press" (X15/13, P ) is first switched off with the rising edge of signal "Feed angle". Activation Input Stop neg and Feed Interrupt neg For easing with the first commissioning, input "Stop neg " (X15/21, P ) has no function and the function "Feed interrupt" is switched off if the bit is set to "1".

146 8-16 Parameters Rollfeed Extended 02VRS Feed Monitoring If the "Feed monitoring" is activated, the feed progression is monitored. A feed progression is only possible if at input "Feed angle" (X31/6, P ) a signal is applied. If this signal drops out during a feed, the error "Feed angle loss" is issued. If the "Feed monitoring" is deactivated, a movement in Manual is also possible if input "Feed angle" is not active. This serves for easing the commissioning. Free Configuration of the I/O-Signals With a not active configuration, all I/O-Assignments regarding the connectors X31/X32, as well as the configuration of the cyclical channels of the control interface are set to their default assignment. Made changes are set again to the default values with a new switching on or after a phase switching. The default assignment is described in chapter "In- / Outputs". With activated free configuration the I/O-Assignments of connectors X31/X32 and the configuration of the cyclical channels of the control interface can be parameterized arbitrary. After a new switch on or phase switching this assignment is changed no longer. Feed Angle via External Presses Encoder If the usage of the external presses encoder is activated, the synchronization between rollfeed and press or shear does not take place via the input signal "Feed angle" but via the absolute position of the external presses encoder. In this case the synchronization is made via switch 1 of the programmable limit switch. The parameterization of the switch range is possible via parameter P , Product data and machine parameters. Note: With master axis coupling with external presses encoder (RMA) the synchronization of rollfeed and press always takes place via the parameterized cam switch. Moving Profile Master Axis Coupling with RMA/VMA Changes of the settings to the moving profile become only effective if the Automatic or Setup mode is not active or a Cycle stop is active. Parameter attributes: Data length: 4 Byte Display format: Binary digit Scaling / Unit: -- Minimum input value: -- Maximum input value: -- Default value: 0 Access: No write protection P , - reserved - This parameter is not used by the system solution.

147 Rollfeed Extended 02VRS Parameters 8-17 P , Monitoring Cycle Time P bit 7 activates the cycle time monitoring function. P defines the time values for this function in milliseconds. The motion of press monitoring is based on the falling edge of feed angle (X31/6, P bit 1) signal. In Automatic mode, the falling edge of feed angle signal is monitored and error will be issued if transition does not occur within the programmed time. Via the function "Clear Errors" the diagnostics and the output bit are cleared. Thereafter, time monitoring restarts. Parameter attributes: Data length: Display format: Scaling / Unit: Minimum input value: Maximum input value: Default value: Access: 4 Byte Unsigned decimal number 1 ms 0 ms ms ms No write protection P , Rollfeed Configuration Parameter 2 Construction of the parameter: Bit Designation / Function Comment 0 Activation system control VCP 08 0: System control VCP 08 inactive 1: System control VCP 08 active, AUTO only via VCP08 1 Activation system control VCP 08 0: System control VCP 08 inactive 1: System control VCP 08 active, AUTO only via X15/1 (P ) 2 ASCII-Pass-Through mode 0: not active 1: active 3 reserved 4 Evaluation presses signal Top Dead Center (TDC) 0: Presses signal TDC is not evaluated 1: Presses signal TDC is evaluated 5 Evaluation presses signal Bottom Dead Center (BDC) 0: Presses signal BDC is not evaluated 1: Presses signal BDC is evaluated 6 Activation "Feed interrupt" via parameter "PLC-Input %IW 2" (P , Bit 11) 0: Input is not evaluated 1: Input is evaluated 7 Activation internal programmable limit switch 0: internal programmable limit switch inactive 1: internal programmable limit switch active See chapter 7 See chapter 5 Only for commissioning purposes, velocity via P

148 8-18 Parameters Rollfeed Extended 02VRS 8 Usage of output Press intermittent 0: Output is not used 1: Output is used 9 Evaluation feed angle with punch 0: Feed angle is evaluated 1: Feed angle is not evaluated 10 Evaluation SIC-Error 0: Generate no system error 1: Generate system error 11 "Jog backward" allowed in Setup mode after reaching end position 0: Jog backward not allowed 1: Jog backward allowed reserved Fig. 8-7: P , Rollfeed Configuration Parameter 2 System Control VCP 08 Bit 0 All VCP 08 operation keys except for the keys "Auto" and "Stop" are ORlinked with the signals at connector X15. The key "Stop" is AND-linked with signal "Cycle stop" at connector X15. Automatic mode can only be activated/deactivated via the "Auto"-Key of the VCP 08. System Control VCP 08 Bit 1 All VCP 08 operation keys except for the keys "Auto" and "Stop" are ORlinked with the signals at connector X15. The key "Stop" is AND-linked with signal "Cycle stop" at connector X15. Automatic mode can only be activated/deactivated via input "Automatic" X15/1 (P ). Note: If bit 0 and bit 1 are parameterized simultaneously to "1", so bit 1 has the higher priority, i.e. Automatic mode can only be activated/deactivated via X15/1 (P ). Evaluation Presses Signal Top Dead Center (TDC) If the evaluation of the presses signal TDC is activated, the Automatic mode can only be started if the feed angle is given (press in TDC). If the press is not in TDC, it must be externally moved to TDC in Manual mode. Evaluation Presses Signal Bottom Dead Center (BDC) If the evaluation of the presses signal BDC is activated, further feed progressions only take place if signal press BDC was present. Activation "Feed Interrupt" via Parameter If the evaluation of the input "Feed interruptionneg" via parameter P , PLC-Input %IW2 (Bit 0) is activated, a feed interruption can be activated via this input. Beside the appropriate input via the control interface, this input can be used e.g., for the loop control. Internal Programmable Limit Switch It is possible to activate an internal programmable limit switch for test purposes. Thereby a feed angle of 270 degree degree is output. The presses velocity can be preset via parameter P , Internal presses velocity. Note: In presses operation mode "Press intermittent" it must be noticed that the reachable number of strokes is determined by

149 Rollfeed Extended 02VRS Parameters 8-19 the required time of the drive for feed progression. After commissioning, the internal programmable limit switch must be switched off again. Usage of Output Press Intermittent Via this configuration bit a second output can be set if the press is in intermittent operation. So two separate outputs for the presses control are available in the operation modes "Press intermittent" and "Press continuous". Then the control of the press intermittent takes place via output "Press intermittent" (P ). If this parameter is not activated, output "Press on" (P ) is used for Press continuous and Press intermittent. Evaluation Feed Angle with Punch If the system function "Punch" (cp. P , bit 0) is activated, the synchronization between rollfeed and punch can take place via the tool acknowledgments without evaluation of the feed signal. Reset the Tool Outputs 8 outputs "Tool 1-8" (P ) can be used for controlling tools. These outputs are parallel activated before and after each presses stroke. Via the parameter P , Product data and machine parameters, in addition, resetting the tool outputs can be adjusted with falling or rising edge of the feed angle. Independent on the chosen presses mode can be guaranteed by this option that tools are reset only after executed feed progression. Evaluation SIC Error If this configuration bit is set, so with an inadmissible signal change at one of the inputs "SIC Signal 1-4" (P ) the output "SIC Error" (P ) is set, the automatic program is interrupted and the system error "Control-Signal Bit x wrong" is generated. With not set configuration bit only output "SIC Error" (P ) is set, but the Automatic mode is not aborted. "Jog backward" in Setup Mode after Reaching the End Position If in Setup mode the feed length was moved up to the end position, the control of the tool signals becomes immediately active when reaching the end position. Avoiding backward movements with set tool outputs this bit must be parameterized to 0. If a backward movement of the feed axis with set tool outputs is possible and should be allowed, this bit can be parameterized to 1. In this case a backward movement of the material must be possible with set tools. Parameter attributes: Data length: 4 Byte Display format: Binary digit Scaling / Unit: -- Minimum input value: -- Maximum input value: -- Default value: 0 Access: No write protection

150 8-20 Parameters Rollfeed Extended 02VRS P , Average Path Velocity Via this parameter the average path velocity in [mm/min] or [Inch/min] of the feed can be readout. Parameter attributes: Data length: 4 Byte Display format: Signed decimal number Scaling / Unit: 10^-3 mm/min or inch/min Minimum input value: -- Maximum input value: -- Default value: -- Access: Write protected P , - reserved - This parameter is not used by the system solution. P , Micro-Adjust Value Via this parameter the desired value for the Micro-Adjust can be preset. If the Micro-Adjust value is changed during a feed progression so it is accepted first in the following feed cycle. Note: With the presetting of the Micro-Adjust value via the corresponding menu on the VCP 08, the Micro-Adjust value is automatically set in P Parameter attributes: Data length: 4 Byte Display format: Signed decimal number Scaling / Unit: 10^-4 mm or 10^-6 Inch Minimum input value: -- Maximum input value: -- Default value: mm Access: No write protection P , Delay Time Close Rolls Via this parameter a time in [ms] can be preset after that is assumed the opened rolls are closed again. If a time unequal 0 ms is entered, input "Rolls closed" (X31/7, P ) is not effective. With a preset of 0 ms the closing of the rolls must be receipted via input "Rolls closed" (X31/7, P ). Parameter attributes: Data length: 4 Byte Display format: Unsigned decimal number Scaling / Unit: 1 ms Minimum input value: -- Maximum input value: -- Default value: 0 ms Access: No write protection

151 Rollfeed Extended 02VRS Parameters 8-21 P , Number of Presses Strokes Via this parameter the number of strokes of the press for the cycle start can be preset. With this value the parameters P , Average path velocity and P , Rollfeed Status- parameter (List element 9 Strokes per minute) are initialized during the first presses cycle. As from the second presses cycle the parameters are calculated and set accordingly via the internal calculated cycle values. Master Axis Coupling with External Presses Encoder (Real Master Axis) With this movement profile is to be paid attention that in application type "Feed before Press" the first feed movement is realized via the positioning of the virtual master axis. In this case the positioning velocity is calculated via the value of this parameter. Master Axis Coupling with Virtual Master Axis With this moving profile the positioning velocity for the internal master axis must be specified via this parameter. The value must be lower than the maximum admissible number of strokes (cp. P , Rollfeed Status parameter (list element 10). Parameter attributes: Data length: 4 Byte Display format: Unsigned decimal number Scaling / Unit: 10^-2 Strokes/min Minimum input value: -- Maximum input value: -- Default value: Strokes/min Access: No write protection P , Rollfeed Diagnostics Messages and Error Numbers In this parameter the actual diagnostics messages- and error numbers of the system solution are entered. If an error is detected by the system solution "Rollfeed Extended", an assigned error number is set in the parameter. In the error-free state the existing state diagnostics is always provided (see chapter 10). If the value is less than 100, a state diagnostics message is displayed. If the value is greater equal 100, a drive error or warning is present. For a more exact diagnostics the plaintext diagnostics messages are stored in parameter P , Rollfeed System diagnostics messages. If a system-independent drive error or warning is present, the value of parameter P , Rollfeed Diagnostics messages and error number is equal 100.

152 8-22 Parameters Rollfeed Extended 02VRS The following table shows the possible diagnostics messages and error numbers and its description. P S Meaning Description (P ) reserved 1 A4002 State diagnostics A Quantity complete 2 C1300 State diagnostics S Roll open A4002 or E2047 A0010 bzw. A4002 A0010 bzw. A4002 A4002 or E2047 State diagnostics State diagnostics State diagnostics State diagnostics S Stop is present S Product stop active S Cycle stop active S Waiting for tool acknowledgment 7 A4002 State diagnostics S Feed angle missing 8 A4002 State diagnostics S Pressing permitted 9 E2047 State diagnostics S Interrupt active 10 E2047 State diagnostics S Both jog inputs active 11 A4002 State diagnostics S Jog forward 12 A4002 State diagnostics S Jog backward not possible 13 A4002 State diagnostics S Jog backward 14 A0010 or A4002 State diagnostics S E Jog enabled 15 E2047 State diagnostics S Feed incomplete 16 E2047 State diagnostics S Jog enabled 17 A4002 State diagnostics A Product stop active 18 A4002 State diagnostics A Tool counter exceeded 19 C1300 State diagnostics A Roll open A4002 or E2047 A0010 or A4002 A0010 or A4002 A0010 or A4002 State diagnostics State diagnostics State diagnostics State diagnostics A Stop is present A Cycle stop active Cycle start only with feed angle A No cycle start 24 E2047 State diagnostics A Interrupt active 25 A4002 State diagnostics A Feeding 26 A4002 State diagnostics A Waiting for tool acknowledment 27 A4002 State diagnostics A Waiting for feed angle 28 A4002 State diagnostics A Waiting for press 29 A0010 or A4002 State diagnostics M Roll open 30 A0010 State diagnostics M Stop is present

153 Rollfeed Extended 02VRS Parameters A0010 State diagnostics M Interrupt active 32 A0010 State diagnostics M Feed angle missing 33 A0010 State diagnostics M Both jog inputs active 34 A4002 State diagnostics M Jog forward 35 A4002 State diagnostics M Jog backward 36 A0010 State diagnostics M Jog inactive 37 arbitrary State diagnostics No system-specific diagnostics available. There is considered the drive diagnostics reserved 100 arbitrary Drive error No system-specific drive error or warning available. It is necessary the drive diagnostics. 101 F2012 System error Timeout PLC-Task 102 F2011 System error VCP Communication error 103 F2011 System error Not supported drive firmware 104 F2011 System error Feed angle loss 105 F2011 System error Cycle time exceeded 106 F2011 System error Movement error 107 F2011 System error Rolls lift during feed 108 F2011 System error Control-Signal Bit x wrong 110 F2011 Parameter error 111 F2011 Parameter error 112 F2011 Parameter error 113 F2011 Parameter error 114 F2011 Parameter error 115 F2011 Parameter error 116 F2011 Parameter error 117 F2011 Parameter error Manual velocity (P ) too small Manual velocity (P ) out of range Setup velocity (P ) too small Setup velocity (P ) out of range Velocity limit value (P ) too small Velocity limit value (P ) out of range Monitoring cycle time (P ) too small Monitoring cycle time (P ) out of range 130 F F F F F F2011 Product data error Product data error Product data error Product data error Product data error Product data error Product- or part lengths number (P ) too small Product- or part lengths number (P ) out of range Length (P ) too small Length (P ) out of range Velocity (P ) too small Velocity (P ) out of range 136 F2011 Product data Acceleration (P ) too

154 8-24 Parameters Rollfeed Extended 02VRS Fig. 8-8: error 137 F2011 Product data error 138 F2011 Product data error 139 F2011 Product data error 140 F2011 Product data error 141 F2011 Product data error 142 F2011 Product data error 143 F2011 Product data error small Acceleration (P ) out of range Commanded quantity (P ) too small Commanded quantity (P ) out of range Tool block (P ) too small Tool block (P ) out of range Number of strokes (P ) too small Number of strokes (P ) out of range 150 F2011 System error Negative presses velocity Rollfeed Diagnostic messages and error numbers Parameter attributes: Data length: 4 Byte Display format: Unsigned decimal number Scaling / Unit: -- Minimum input value: -- Maximum input value: -- Default value: 0 Access: Write protected P , Preset Status Parameter With parameter P a presetting for the following diagnostics messages values in parameter P , Rollfeed Status parameter can be adjusted. Status value List element P Actual quantity of the batch runs 4 Actual quantity active product 5 Actual quantity active part length 6 Total actual quantity of the products 7 Moved total lengths 8 Actual quantity switching operations tool Fig. 8-9: Preset Status values The preset value is taken over with the following inputs (see chapter 5) in the corresponding list element of P , Rollfeed Status parameter.

155 Rollfeed Extended 02VRS Parameters 8-25 Status value Input Parameter Actual quantity of the batch runs Actual quantity active product Actual quantity active part length Total quantity of the products Preset actual quantity batch counter Preset actual quantity product counter Preset actual quantity part lengths counter Preset total quantity of the products P P P P Moved total length Preset total length P Actual quantity switching operations tool 1-8 Fig. 8-10: Preset inputs Preset switching operations tool 1-8 P Note: With the presetting of the preset value for the total length the scaling of the moved total length (P , list element 8) must be considered. Note: With use of the VCP 08 a presetting of the status values is also possible via the corresponding dialogs. Parameter attributes: Data length: 4 Byte Display format: Unsigned decimal number Scaling / Unit: -- Minimum input value: -- Maximum input value: -- Default value: 0 Access: No write protection P , Press: Time Monitoring Via this parameter a time to detect a presses stop in Automatic mode can be preset. If the press is stopped longer than the parameterized time, so after a restart of the press the parameters P , Average path velocity and P , Rollfeed Status parameter (List element 9 - Strokes per minute) are initialized during the first presses cycle by means of the value in parameter P , Number of presses strokes. As from the second presses cycle the parameters are calculated and set accordingly via the internal calculated cycle values. If the press is stopped no longer than the parameterized time, the actual calculated values are entered in parameter P , Average path velocity and P , Rollfeed Status parameter (List element 9 - Strokes per minute). Parameter attributes: Data length: 4 Byte Display format: Unsigned decimal number Scaling / Unit: 10^0 Seconds Minimum input value: --

156 8-26 Parameters Rollfeed Extended 02VRS Maximum input value: -- Default value: 0 Seconds Access: No write protection P , Internal Presses Velocity The parameter defines the internal velocity for the PLS. Parameter attributes: Data length: 4 Byte Display format: Unsigned decimal number Scaling / Unit: 10^-3 r.p.m. Minimum input value: -- Maximum input value: -- Default value: 20 r.p.m. Access: No write protection P , Rollfeed System Diagnostics The plain text diagnostics message is available from through this parameter (see also chapter 10, "Diagnostics"). Parameter attributes: Data length: 1 Byte variable length Display format: ASCII - Text Scaling / Unit: -- Minimum input value: -- Maximum input value: -- Default value: -- Access: Write protected P , Rollfeed Status Parameter Via this list parameter the diagnostics messages values listed in the following table are displayed cyclical. List no. Description Access Scaling / Unit 0 Active product number Write protected 10^0 1 Active part lengths number Write protected 10^0 2 Active part length Write protected 3 Active part velocity Write protected 4 Actual quantity of the batch passes Write protected 10^-4 mm or 10^-6 Inch 10^-4 % or 10^- 6 % 10^0 5 Actual quantity active product Write protected 10^0

157 Rollfeed Extended 02VRS Parameters Actual quantity active part length Total actual quantity of the batch passes Write protected Write protected 8 Moved total lengths Write protected 9 Strokes per minute Write protected 10^0 10^0 10^-4 mm or 10^-6 Inch 10^0 Strokes/min 10 Utilization feed angle Write protected 10^0 % 11 Moved length in current feed cycle Write protected 10^-4 mm or 10^-6 Inch 12 Position of the external presses encoder Write protected 10^-4 mm or 10^-6 Inch 13 Status of the tool wear of tools 1-8 Write protected 10^0 14 Actual quantity switching operations tool 1 Write protected 10^0 15 Actual quantity switching operations tool 2 Write protected 10^0 16 Actual quantity switching operations tool 3 Write protected 10^0 17 Actual quantity switching operations tool 4 Write protected 10^0 18 Actual quantity switching operations tool 5 Write protected 10^0 19 Actual quantity switching operations tool 6 Write protected 10^0 20 Actual quantity switching operations tool 7 Write protected 10^0 21 Actual quantity switching operations tool 8 Write protected 10^0 22 Maximum number of presses strokes Write protected 10^-2 Strokes/min Strokes/min. 23 Active moving profile Write protected 10^0 24 Active switch-on angle cam switch or beginning of the feed range with master axis coupling Write protected 10^0 25 Active switch-off angle cam switch or end of the feed range with master axis coupling Write protected 10^0 26 Active tolerance window with master axis coupling Write protected 10^0 27 Active analytic motion profile with master axis coupling Write protected 10^ Reserved Fig. 8-11: Status parameter

158 8-28 Parameters Rollfeed Extended 02VRS Status of the Tool Wear of Tool 1-8 The status of the tool wear of tool 1-8 (list number 13) is according the following bit bar. Bit 0: 0 = Under-run number of switching procedures tool 1 1 = Number of switching procedures tool 1 reached Bit 1: 0 = Under-run number of switching procedures tool 2 1 = Number of switching procedures tool 2 reached Bit 2: 0 = Under-run number of switching procedures tool 3 1 = Number of switching procedures tool 3 reached Bit 3: 0 = Under-run number of switching procedures tool 4 1 = Number of switching procedures tool 4 reached Bit 4: 0 = Under-run number of switching procedures tool 5 1 = Number of switching procedures tool 5 reached Bit 5: 0 = Under-run number of switching procedures tool 6 1 = Number of switching procedures tool 6 reached Bit 6: 0 = Under-run number of switching procedures tool 7 1 = Number of switching procedures tool 7 reached Bit 7: 0 = Under-run number of switching procedures tool 8 1 = Number of switching procedures tool 8 reached Fig. 8-12: Status tool wear Master Axis Coupling with Virtual Master Axis Maximum Number of Presses Strokes For the compliance of the movement limit values of the feed axis (cp. parameter P , Velocity limit value bipolar and S , Acceleration bipolar) the positioning velocity of the virtual master axis is limited inside to this maximum. Note: As a basis for the calculation of the maximum presses stroke number the standardized profile "Polynomial 5th order" is applied. Master Axis Coupling with External Presses Encoder For the compliance of the movement limit values of the feed axis (cp. parameter P , Velocity limit value bipolar and S , Acceleration bipolar) the number of presses strokes may not exceed this maximum. Current Moving Profile The value of this parameter element indicates the active moving profile and has the following meaning: 0 == Movement via trapezoid or triangle profile 1 == Master axis coupling with external presses encoder (RMA) 2 == Master axis coupling with virtual master axis (VMA) Parameter attributes: Data length: 4 Byte variable length Display format: Signed decimal number Scaling / Unit: see table Minimum input value: -- Maximum input value: -- Default value: 0 Access: see table

159 Rollfeed Extended 02VRS Commmissioning Commmissioning 9.1 General After taken place first commissioning the application-specific determined parameter values, which also contain the production data, must be saved. The reproducibility of the drive behavior required in the respective machine axis is made possible by the saved parameter values. By renewed loading the saved parameter values of the axis drive, the original state can be recovered again after the first commissioning! Saving the parameters can take place via the commissioning tool "Indra- Works D". 9.2 Checklist For a smoothly commissioning the use of the correct hard- and software components is assumed. In the following you find a list of all parts and tools required for the first commissioning. Note: In the delivery status of the system solution Rollfeed Extended the drive firmware (FWA) as well as the firmware option (FWS) are already contained on the provided MMC. Rollfeed Extended (ADVANCED): FWA-INDRV*-MPH-04VRS-D5-1-NNN-ML FWS-MLDTFA-RFE-02VRS-D0 Rollfeed Extended Hardware Components Following hardware components are required: Drive control section IndraDrive Advanced with following options: Encoder interface on option slot 1 (X4) for motor encoder Control interface via Parallel-Interface (X15, HCC01) Digital I/O-Extension and SSI-Encoder evaluation MD2 (X10) MMC (X7, MultiMediaCard) Following hardware components are optional: Encoder interface on option slot 2 (X8) for measuring wheel encoder on the drive control section IndraDrive Advanced Safety Engineering S1 (X41) Starting lock L1 (X41) VCP 08 Serial interface cable RS232 (RKB0004) between VCP 08 (X3-SER1, 25 pins) and IndraDrive (X2, MiniDIN, 8 pins) Serial cable RS232 (IKB0053) for communication between commissioning PC and VCP 08

160 9-2 Commmissioning Rollfeed Extended 02VRS Ethernet cross link cable or Ethernet standard cable (RKB0007 or RKB0008) between PC and VCP for downloading the VCP application user interface Software Components Following software components are required: Drive firmware "MPH" with functional package Synchronization and IndraMotion MLD-S on MultiMediaCard (FWA-INDRV*-MPH-04VRS- D5-1-NNN-ML) Technology Function Block on MultimediaCard (FWS-MLDTFA-RFE-02VRS-D0) Engineering-Framework IndraWorks (SWA-IWORKS-D**-03VRS-D0-CD650) Following software components are optional: Application user interface on the VCP08 (RFE_02VRS_VCP0x0x.cb) The finished user interface for the operation terminal VCP 08 is available on CD or via the Internet (Rexroth portal). The access to the Rexroth portal is only possible if a registration is present. IndraMotion for Metal Forming - CD (SWA-IM*MLD-MF*-02VRS-D0-CD650-COPY) IndraMotion for Metal Forming - Internet /software_en/download_automationssysteme_en Note: The following files and documentation are additionally available in folder "\User" on the delivered MMC: VCP-HMI application (VCP 08) Description to the download of the VCP-HMI application Functional description - Rollfeed Extended 02VRS Release notes

161 Rollfeed Extended 02VRS Commmissioning Download of the VCP-Application on the VCP 08.2 To be able to execute the operation of the system solution Rollfeed Extended with the VCP 08, the provided application user interface must be load on the operation terminal. The download of the application user interface must take place via a FTP- Download using an Ethernet connection. The configuration of the Ethernet-Communication can either take place via an Ethernet crosslink cable, or if an Ethernet switch is available, via an Ethernet standard cable. Note: For the communication configuration via Ethernet crosslink cable or Ethernet standard cable, the assembled Rexroth cables with the order name RKB0007 or RKB0008 (see section Ordering Information) can be ordered. Fig. 9-1: Application-Download via FTP-Server General Notes For administration and configuration of the VCP-Devices the Setup-Main (Launch) dialog is available. This dialog can be called after switching on the VCP. For about 2 seconds the call dialog appears on the display of the VCP. The Setup-Main dialog is selected by pressing the Data entry- Key. Through this you reach the main menu of the launch. The following functions are available via the menu: Adjustment of the IP-Address, Subnet-Mask and device name Execution of firmware updates (Bootloader, Image) Display of device informations like actual IP-Address, MAC-Address, serial number Store performed registry settings Data entry - Key The Data entry-key on the VCP is identified by the symbol displayed on the left. Navigate and Operate With the VCP-Device VCP 08 navigation within the Setup Main can be achieved with the Cursor-Keys. Pressing the Data entry-key selects the desired menu item. The inputs of numbers and alphanumerical characters are made via the front keyboard.

162 9-4 Commmissioning Rollfeed Extended 02VRS Note: USB-keyboard can also be connected to the device to navigate and operate. Fig. 9-2: Main menu Setup Main Operation Instructions to the VCP-Application Download In the following operation instructions the several procedures are described that are required to transfer the VCP-Application to the VCP The required steps must be executed in the following listed order. Identification of the IP- Configuration of the Commissioning PC On the commissioning PC click to "Start" and then "Run...". In the displayed Run window enter "cmd". Now a DOS-Box appears. Enter "ipconfig" at the prompt and confirm with the "Enter - Key". Thereupon the actual IP-Configuration, i.e. the IP-Address and the Subnet-Mask are displayed in the DOS-Box. Fig. 9-3: IP-Configuration of the commissiong PC Switch-on the VCP Switch-on the VCP-Device or perform a restart. Call of thesetup Main Dialog After appearance of the Launch - Dialog on the display of the VCP press the Data entry-key to call the Setup Main - Dialog. Note: After switch-on, the Launch - Dialog appears only for about 2 seconds. In this time the Data entry-key must be pressed.

163 Rollfeed Extended 02VRS Commmissioning 9-5 Fig. 9-4: Launch dialog Fig. 9-5: Setup Main dialog Call of the IP-Settings Dialog Navigate in the Setup Main - Dialog via the Cursor-Keys to menu item IP- Settings and press the Data entry-key. Fig. 9-6: IP-Settings dialog Call of the Fix Settings Dialog Navigate in the IP-Settings - Dialog via the Cursor-Keys to menu item Fix Settings and press the Data entry-key. Abb. 9-7: Fix Settings dialog

164 9-6 Commmissioning Rollfeed Extended 02VRS Call of the IP Address Dialog Navigate in the Fix Settings - Dialog via the Cursor-Keys to menu item IP-Address and press the Data entry-key. Thereupon a Password - Dialog is displayed. Fig. 9-8: Password dialog Enter " " for the password and confirm the dialog with the Data entry-key. Now the dialog for entering the IP-Address and Subnet-Mask appears. Fig. 9-9: Fixed IP dialog Input of the IP-Address and Subnet-Mask Insert in the IP - Dialog in inputfield IP the IP-Address for the VCP. With use of an Ethernet crosslink cable an IP-Address increased by one compared to the IP-Address of the commissioning PC can be inserted (see Identification of the IP-Configuration of the Commissioning PC). Example: IP - Address of the PC: IP - Address of the VCP: With use of a standard Ethernet cable (connection via switch) a free IP-Address in the network must be entered for the VCP. In inputfield Mask the Subnet-Mask which was determined via Identification of the IP-Configuration of the Commissioning PC must be be entered. After entering the IP-Address and Subnet-Mask navigate with the Cursor- Keys to the OK-Button and close the dialog with the Data entry-key.

165 Rollfeed Extended 02VRS Commmissioning 9-7 Return to Setup Main Dialog Navigate via the Cursor-Keys to the home-button and confirm all further dialogs with the Data entry-key until the Setup Main - Dialog appears again. Abb. 9-10: Setup Main dialog Close Setup Main Dialog Navigate via the Cursor-Keys to the Exit-Button and close the dialog with the Data entry-key. Then a dialog for saving the made changes in the registry appears. Confirm this dialog with the Data entry-key. Subsequently the VCP reboots. Note: The changed IP-Configuration for the VCP is not yet active after the reboot. Fig. 9-11: Registry dialog Switch VCP off/on The VCP-Device must be switched off/on again. Only now the changed IP-Address and the Subnet-Mask on the VCP are active. Copy Application Files to the VCP via a FTP-Connection For downloading the application user interface, a FTP-Connection to the VCP-Device must be established. Via the Windows-Explorer or via a FTP-Client software, a FTP-Connection to the device can be established. With the use of the Windows-Explorer, the previously determined IP- Address (e.g. "ftp:// ") must be entered in inputfield Address. Note: In order that a FTP-Connection can be established via the Windows - Explorer, in dialog Internet Properties in Tab Advanced the option "Enable folder view for FTP-Sites" must be selected. This dialog is reachable in Windows via Start Settings Control Panel Internet Options.

166 9-8 Commmissioning Rollfeed Extended 02VRS Fig. 9-12: Internet Options After a successful link connection the application data on the flash of the VCP are displayed. In folder TSVisRT there are the corresponding data which are transferred to the terminal by the application download (projectfile, INI-file, protocol driver, runtime-file). Fig. 9-13: FTP-Connection via Windows-Explorer