Smart Arm Installatin and Setup Guide PS1E, PS2E and PS150E Objective: The guideline is intended t detail the installatin and setup instructins fr the Smart Mtin Smart Arms systems, including the PS1E, PS2E and PS150E mdels. Revisin Date: 08/08/12 1
Unpacking: Unpack all items and verify cntents. Items shuld include: Smart arm cntrller Smart arm with encders and encder cables Pillar fr munting the arm Interface cables fr cmmunicatin t driver cntrller r external PLC Tl Hlder Purchased ptins which can include: Smart bins Smart bit tray: 8 psitin r 4 psitin Barcde reader. Nte: PS2E arm is fully assembled at time f shipment. Larger PS1E and PS150E arms and shipped as tw pieces, the uter arm is remved frm the main bearing pst fr ease f shipment. Electrical Detail: The smart cntrl bx is specifically designed t wrk with either a tw encder r three encder smart arm. In bth cases, the arm is an X,Y psitin arm nly. The third encder mnitrs the change in arm psitin in Z but translates the change in length f the arm. The smart cntrller requires a pwer surce frm the driver cntrller, PLC r external pwer supply. The pwer requirement is 24VDC, 0.5A max. Pwer is supplied int the cntrller via the H10 cnnectin prt. The cnnectin prts f H7, H8 and H9 are used fr IO interface f ptins such as smart bits, smart bins r PLC interface. Each prt has 8 inputs and 4 utputs that can be wired as sinking r surcing. Revisin Date: 08/08/12 2
Installatin: 1.0 Munt Pillar t slid wrkbench r base using clamps r munting blts. 2.) Munt arm base t pillar. Depending n length f arm, munting plate fr the arm can have either 2 r 4 blts fr lcking 3.) Munt uter arm nt main bearing pst. Typically required nly fr PS1E r PS150E, depending n shipping requirements may als be required fr PS2E. Make sure arrw n shaft pints in directin f uter arm, this aids the hming prcess. When arm is shipped in tw pieces, H3 encder cable will need t be re-ruted thrugh cable clamps n side f main arm extensin. Arrw pinting in directin f uter arm 4.) Cnnect encder cables t smart cntrl bx. Encder cables shuld be labeled H1, H2 and H3. Cnnect t crrespnding prts n cntrller Revisin Date: 08/08/12 3
5.) Cnnect main pwer interface cable t Smart cntrller. Fr nrmal peratin this is ne cable frm driver cntrller t smart cntrller. Cable will be labeled H10. If using PLC mde yu will have a secnd cable cnnected t the H7 prt fr recipe selectin. Please reference apprpriate H10 cable drawing fr cnnecting t driver cntrller. 6.) Cnnect Accessry items. H7, H8 and H9 are used fr cnnecting smart bit and smart bin systems. Nt all cnnectins are required but yu must start with H7. If using bth smart bits and smart bins, the smart bits take precedence and must be cnnected t H7. Smart bins will be cnnected t H8 and H9 if required. If nly using smart bins then start with H7. 7.) Cnnect barcde reader int H6 if used. Nte pwer fr barcde reader must be cnnected int side f gray cable. 8.) Install driver and tl hlder, each mdel arm has different tl hlders which require a different munting interface. Pht t the left details tl hlder munting fr PS1E style arm. Revisin Date: 08/08/12 4
Setup: Typically each arm is pre-cnfigured prir t shipment. Belw are the details fr cnfiguring the smart arm. Cnfiguring the smart arm requires the user t lgin int the Maintenance menu using PIN 7439, this will add additinal items available in the Maintenance mde. Please see lgin details belw: Nte: The jg dial n the frnt f the cntrller is the main user interface t the menu items. Rtating the buttn changes the current selectin while pushing the jg dial buttn selects the current displayed item. Maintenance Mde Lgin: 1.) Scrll t MAINT, push jg dial 2.) LOGIN will flash and push jg dial a secnd time 3.) Cntrller will flash P 0***, scrll jg dial buttn until 7 appears in first digit, push jg dial t select secnd digit. 4.) Scrll jg dial buttn until 4 appears in secnd digit, push jg dial buttn t select third digit 5.) Scrll jg dial buttn until 3 appears in third digit, push jg dial buttn t select furth digit 6.) Scrll jg dial buttn until 9 appears in furth digit, push jg dial t cmplete prcess 7.) OK will appear n the display when prcess is successful. Output Type (Driver cnfiguratin) In Maintenance menu, scrll t OUTTYP and push buttn Current utput type will be displayed ptins are: MICRTC fr Micrtrque tl frm Atlas Cpc KLV d0 fr Klver and ASG ATLAS fr Atlas Cpc, Stanley and IR tls ECRA fr Ecra tls Rtate jg dial t select apprpriate tl and push buttn Display will flash Busy then yu will be ready Mde (Hw the arm functins during peratin) Three available ptins: Trque Mde: Fr a given set f fasteners in trque mde, the fasteners can be cmpleted in any given rder. Tl will be disabled when nt is a predefined lcatin, when arm is ver a defined lcatin, tl becmes enabled. Sequence Mde: Fr a given set f fasteners in sequence mde, the fasteners must be cmpleted in the rder in which they were defined during the recipe teaching. Tl will nly be enabled when at the prper fastener fr the given sequence PLC Mde: This mde f peratin is where an external PLC cntrls the sequence f mving frward and backward in a recipe. The PLC als has the ability t select the prper recipe in the smart cntrller via IO. This mde is firmware cnfigurable nly and is nt field enabled. T turn n Sequence mde, In Maintenance menu scrll t CH MOD and push buttn. Display will flash current mde, Sequence will be either ON r Off indicating it is in Trque Mde. T change scrll selectin and push jg dial. Revisin Date: 08/08/12 5
Smart Bit cnfiguratin In Maintenance menu scrll t BITCNT and push buttn Current available quantity will flash, scrll t required number and push buttn Tw types f bit trays available, 8 Bit r 4 bit. The type f tray must als be cnfigured In Maintenance menu scrll t BITTYP and push buttn Current type will be displayed, scrll t desired type and push buttn. Smart Bin cnfiguratin In Maintenance menu scrll t BINCNT and push buttn Current available quantity will flash, scrll t required number and push buttn System Calibratin (SETORG) This prcess defines the rigin and crdinate system fr each smart arm. Prir t running this prcess, tw calibratin pints must be defined, Pint A and Pint B. It is recmmended that pint A be inline with the Arm pillar if pssible. The distance away frm the main pillar is nt as critical but a gd place t start wuld be abut ½ the ttal reach f the arm. The secnd hle, Pint B shuld be lcated t the right and inline with pint A. The default distance between the pints is 450mm, we recmmend a value between 250-450mm. Belw shws tw typical layuts fr calibratin pints. In rder t accurate cmplete the SETORG prcess fur parameters must be accurately measured and entered int the Smart cntrller: LINK1: Distance in mm between H1 and H2 encders LINK2: Distance in mm between H1 encder and centerline f tl. LINK3: Distance in mm between H3 encder and frnt pivt pint fr uter arm CALLEN: Distance in mm between Pint A and B. Revisin Date: 08/08/12 6
LINK3 H3 Encder H2 Encder H1 Encder LINK2 LINK1 T enter link lengths, in Maintenance menu scrll t LINK1 press jg dial. Display will shw current length, cycle thrugh digits using jg dial t enter LINK1 dimensin. Repeat prcess fr LINK2, LINK3 and CALLEN. NOTE: As part f the SETORG prcess LINK2 actually gets calculated, the value yu enter int the LINK2 needs nly t be clse. Other values must be measured as accurately as pssible. T run the SETORG prcess, in Maintenance menu scrll t SETORG and press jg dial Display will shw ORIG-Z, mve arm up s that it is cmpletely hrizntal and press buttn Display will shw ORIG-L, mve tl bit t pint A s arm is in left rientatin, i.e. arm bent t the left, press buttn. This will becme the rigin, pint 0,0. Display will shw ORIG-R, rtate arm t right rientatin, i.e. arm bent t the right and maintain the tl bit in pint A, press buttn. Display will shw ORIG-b Keeping the arm in the right rientatin as the last pint, mve the tl bit t pint B, and press buttn. This pint is calibratin pint B and will becme crdinate ddd,0 where ddd is distance frm the calibratin pint A as detailed in the CALLEN value. The Smart bx sftware will estimate the psitin measurement errr and display it as E x.x where x.x is estimated errr in millimetres. Fr example E 1.6 means that the errr is apprximately 1.6 millimetres. Under nrmal perating cnditins an errr f less than 4mm shall be acceptable. If the dwnlad ptin is being used, this errr shuld be 2.0mm r less. The dimensin f Link 2 will be calculated and stred in the Smart cntrller. Revisin Date: 08/08/12 7
Barcde Reader Setup The barcde reader (Symbl LS2208 1D linear scanner) is used t select the recipe that is required, this replaces manually selecting via the jg dial buttn. Each reader is precnfigured prir t shipment belw is the details f the precnfiguratin prcess. Cmmunicatin t the Smart Arm cntrller is via the RS232 prt fund n H6 f the cntrller. The fllwing are the required cm prt settings f the cntrller. Baud Rate: 19200 Parity: Nne Stp Bits: 1 Data Bits: 8 Flw Cntrl: Nne These settings with the exceptin f the baud rate are the default settings fr the LS2208. T change the baud rate t the required value f 19200, scan the barcde belw: In rder fr the Smart Bx cntrller t recgnize the barcde string, the reader must be prgrammed t prvide a carriage return / line feed as part f the data string. In rder t cnfigure the LS2208 scanner fr this features scan the fllwing barcdes in sequence: (Nte: These is cnfigured by KlverUSA if reader is purchased with smart arm system.) Revisin Date: 08/08/12 8 1
Barcde Reader Setup, string barcdes Frm Maintenance menu scrll t TCH bc, press buttn. Select the required recipe number t stre the barcde, press buttn Scan the required barcde, reader shuld beep and display shuld respnd with saved Cntinue until all barcdes are assigned. When cmplete, scrll until yu see Exit and press buttn. Barcde Reader Setup, deleting barcdes Frm Maintenance menu scrll t del bc, press buttn. Select the required recipe number t delete the barcde, press buttn. Once the crrect recipe is selected, press the buttn and yu will see the recipe number with an N, scrll t change t Y, press buttn. This will nly delete the barcde assciatin, nt the recipe itself. T delete all barcde recipe assciatins, scrll and select All rather than a specific recipe number. Revisin Date: 08/08/12 9