NETRONICS HS3500 CONTROLLER

NETRONICS HS3500 CONTROLLER CUSTOMER NAME CONTROLLER SERIAL # CONTROLLER PART # PERSONALITY SWITCH SETTINGS BULLET PRESS CONFIGURATION DELIVERY DATE Contact the factory for help setting up your application. Our applications team will help with the initial setup.they will require the type of material being cut, the length of the cuts, thickness of the material and the weight of the moving tool holder. Remember that the lower the tool weight the higher the velocity and the more efficient the process. Controller Part Number Guide HS3500-1-CE-3P-60 Operating voltage 3P= 3 phase Line Frequency 1=208-240 volts AC 1P= Single phase 2=440-480 volts AC 3=385 volts AC Constant Energy CE = Includes Constant Energy Feature Blank = No Constant Energy Feature The Constant energy feature measures the ram velocity and automatically adjusts the power level so as to produce the same velocity each stroke. The velocity is displayed when the control is in the CE ON mode allowing the operator to set the velocity to the desired value. 1

OVERVIEW The Netronics Electromagnetic Bullet Press converts electrical energy into mechanical energy which is then used to punch holes, bend, form, coin or otherwise do work on a wide variety of materials. The HS3500 Control uses the normal power available in a factory and converts it to a form that is usable by the Electromagnetic Bullet Press. The control regulates the flow of energy so as to provide a wide variety of performance features as well as protect the system from possible harms. The control also can be used to monitor a complete process in both a stand-alone or slave mode. The energy to the engines in the Electromagnetic Bullet Press is delivered in high current short duration pulses. The peak current can be as high as 300 amps however the "on time" is usually less than 30 milliseconds. The power level setting determines the length of time that the current flows. The control also provides signals to manage air or electric feeders, alarms, counters and light curtains. The HS3500 can also provide status signals to host computers so that the Electromagnetic Bullet Press can be easily integrated into a wide variety of installations. MODES: The HS3500 controller can operate in 3 modes. A brief description of each follows: MASTER SINGLE STROKE MODE The HS3500, using the Dual Touch Sensor Bar. This configuration uses an anti-tie down dual touch sensor bar to activate each firing of the press. The HS3500 Control can be configured to manage the feeds, alarms, an internal parts counter, part batch set point as well as a wide variety of material sensors. (See Caution Below) MASTER CONTINUOUS MODE The HS3500, using the Dual Touch Sensor Bar to start the process, can be set up to run completely unattended by placing the control in the continuous mode. Any process sensors connected that are not satisfied will automatically stop the process. The control has provisions for an alarm to alert the supervisor. Includes an internal parts counter and part batch set point. (See Caution Below) SLAVE MODE The HS3500 Control can be set up to act as slave to a host PLC or computer. Status signals as well as stop, reset, and fire command signals turn over as much of the process control to another system as the process engineer dictates. (Custom Factory programming is available) CAUTION CAUTION CAUTION CAUTION CAUTION CAUTION The Dual Touch Sensor Bar is not to be used as a safety device. All Guarding must be in place before the press is activated. It is the responsibility of the end user to install guards that prevent the operator from coming in contact with any moving parts or other hazards that may be present. The user supplied safety system must also insure that all power is disconnected from the press when the guarding is removed. (See Power connection information Fig. 1.) Netronics does not supply guarding devices. 2

INSTALLATION MOUNTING: To limit mechanical shock, mount the HS3500 Control on a bench or stand that is not subject to the vibration caused by the press. Isolation can be improved by using a foam rubber mat between the control stand and the control. Do not mount the control on the press stand or bench because the impact forces may cause serious internal damage to the controller. POWER CONNECTION: (SEE FIGURE 1.) The user must provide a 25 amp branch service with a fused disconnect switch that includes a supervisory loop circuit for guard related sensors and interlocks that will disconnect, via a contactor relay, the power to the HS3500 controller if the loop is opened. The panel must also have provisions for a lock at the point of connection to the HS3500 power cord. This is necessary because all power to the system must be removed when any work is being done to the controller, bullet press, the feed mechanisms and any other system components. The HS3500 is factory configured for EITHER 208/230, 385 or 440/480 volts AC, 50 or 60 hertz, single or 3 phase. Refer to the ratings listed on the controller before installing this equipment. The peak current drawn during press operating cycles can be 20 to 300 amperes. The peak current duration is only 1 to 38 milliseconds depending on the press type and power setting. This results in an RMS or effective current used during press firings being less than 20 amperes. The power required by the controller electronics is less than 50 watts. WIRE SIZE REQUIREMENTS: The relatively high peak currents require adequate branch circuit wiring. Use the following chart to determine the wire size for your installation. Measure the length of the wiring required between the main panel and the HS3500 Controller installation and then look up the wire size required. Up to 30 feet 12 gauge 30-50 feet 10 gauge 50-75 feet 8 gauge 75-125 feet 6 gauge 125-200 feet 4 gauge 200-250 feet 3 gauge 250-300 feet 2 gauge 300-400 feet 1 gauge VOLTAGE SELECTION: If a user has 480 service, we suggest using a 480v control. As a general rule, the highest voltage available is to be used on the HS3500 Control. If a transformer must be used, be sure that it has a rating of at least 75-100 KVA and that no other loads are placed on the same transformer. The operating voltage of the HS3500 is found on the rear panel. 3

PRESS CONNECTION: The Electromagnetic Bullet Press is connected to the controller using the supplied connecting cable. It may however be necessary to provide an armored jacket in some applications. Please refer to National and local codes. PRESS GROUNDING: (SEE FIGURE 1.) Electromagnetic Bullet presses may be connected to earth ground at the site. Consult the National Electric Code as well as local codes. FIGUIRE 1 4

PROCESS CONTROL INPUT/OUTPUTS: All process control inputs and outputs are connected to the HS3500 Control via The 6 removable plug-in connectors supplied. Light Curtain Interface: (Not intended for operator access during normal operation) The HS3500 Bullet Press output connection is controlled by 2 normally open Force Guided Safety relays. These relays are not activated if an error in the normally closed supervisory contacts included in the safety relay circuit is detected or if a CPU controller error is detected or if the light curtain (If used) signals the L/C Alarm input that the light curtain is not functioning properly or if the Anti Tie-Down Palm switch is not operational or if they are activated outside the 150 mili-second Anti Tie-Down window or if the L/C MPCE inputs are not closed. The Light Curtain MPCE relay outputs are connected to the L/C MPCE inputs on the HS 3500. When these relay contacts are open the HS3500 cannot be activated. If an attempt is made to activate the press while the L/C is not clear the HS3500 controller will deactivate the HS3500 Safety Relay, display a Safety Error message and will require a system reset. When a Light Curtain is not used the L/C MPCE RELAY 1 & 2 Inputs + the L/C Alarm input must have wire Jumpers installed. Custom programming available for this feature 5

Anti Tie-Down Palm Switch I/O The HS3500 controller includes 2 palm button inputs that are used to activate the SINGLE STEP and CONTINUIOUS mode operations. 2 normally open momentary switches (dry contact) are to be used for this task. These inputs must be closed within 150 ms of each other in order to create a valid activate signal. If only one is held down for more that 150 ms the display will indicate that PALM ERROR has occurred. Opening both palm inputs for at least 200 ms clears this error. Cycle Stop Input There are 2 ways to access the cycle stop feature. The first is the CYCLE STOP button located on the front panel. The second is to connect a normally open momentary switch (open collector or dry contact) to the cycle stop input. Bullet Press Input/outputs The Bullet Press Actuator has 2 cables. The Press power cable is a 12-gauge 3wire cable that is terminated in a 3 pin Amphenol military style power connector. This connector plugs into the Press Actuator Output connector on the rear panel of the HS3500 Controller. The second cable is a 6-wire control cable that connects the Bullet Press velocity transducer and temperature sensor to the HS3500 Controller. The second cable plugs into the PRESS INPUTS connector located on the HS3500 rear panel. Remote Reset Input The HS3500 controller can be reset remotely with a closure at the REMOTE RESET INPUT located on the rear panel. The system begins the reset process when the Remote Reset Input is open circuited. (Dry or Open Collector switch) 6

Feed Complete Input (N/C input) The HS3500 Press controller provides signals to activate both air and electric air feeds. Some feeds include a signal that signal the controller that the feed process has completed. A dry contact relay or an Open Collector sinking PLC output must provide the signal required at the Feed Complete Input. A jumper across this input is required in the event that a feed complete signal is not provided. Buckle Sensor Input (N/O input) Before every stroke and again during a feed the Buckle sensor inputs tests for a closure at this input. If a closure is sensed the press cycle is terminated and a Buckle Error is displayed. A dry contact relay or an Open Collector sinking PLC output must provide the signal required at the Buckle Sensor input. If this feature is not used simply leave the input open circuited Pilot Sensor Inputs (N/O input) Before every stroke and again after a press stroke the Pilot Sensor inputs tests for a closure at this input. If a closure is sensed the feed cycle is terminated and a Pilot Error is displayed. A dry contact relay or an Open Collector sinking PLC output must provide the signal required at the Pilot Sensor input. If this feature is not used simply leave the input open circuited Extra Input 1 (N/O input) Before every stroke in the Master Mode the Extra input 1 input is tested for a closure. If a open is sensed the press cycle is terminated and a Extra Input 1 Error is displayed. A dry contact relay or an Open Collector sinking PLC output must provide the signal required at the Extra input 1 input. If this feature is not used simply place a jumper at this input. Feed Outputs (Open Collector and AC TRIAC) The HS3500 Controller Provides the correct signals to operate either a standard air operated feed or a servo type electric feed. An air feed requires a signal that arms the feed just after the press is down. Activating the feed s electric solenoid does this. After ½ of the cycle time has passed the electric solenoid is deactivated. This results in the material being advanced the proper amount. An Electric feed usually simply requires a minimum of a 30 ms switch closure to begin the feed process. If your feed requires that you activate a relay we suggest that you use the Feed Triac Switch. This switch can switch up to 240 VAC at 2 Amps. If your feed requires a low voltage open collector (24v at 25ma. max) we suggest that you use the FEED OUT (Open Collector) output. 7

Alarm Outputs (Open Collector and AC Triac) The HS3500 Controller Provides output signals to operate either a low voltage alarm output suitable to signal a PLC or a 30-240 VAC alarm device such as a flashing light. If your alarm requires that you activate a relay or lamp we suggest that you use the Alarm Triac Switch. This switch can switch up to 240 VAC at 2 Amps. If your alarm requires a low voltage open collector (24v at 25ma Max) we suggest that you use the Alarm (Open Collector) output. USER OUTPUTS (Open Collector) The HS3500 controller includes 3 user (open collector outputs) Outputs 2 & 3 are used for signaling/handshaking used in Slave mode applications User Output 1 (Open Collector) Custom applications User Output 2 (Open Collector) Slave or custom applications User Output 3 (Open Collector) Slave or custom applications SYSTEM OPERATION When the system CPU power is activated (Front Panel CPU Power Switch or Main system power is turned on) the system CPU is reset. This activates: 1. Main Safety Relays open test 2. Palm Switch Safety relays test 3. SCR drive off test 4. Press Temperature test 5. Palm switch tests 6. Light Curtain Alarm tests. If any safety tests fail the system will not boot on. An error message indicating the error detected is displayed. All power is to be removed until the error is corrected. If all safety tests are passed the system will boot to a Master Screen displaying that the system is in the MASTER mode, Constant Energy ON or OFF and the selections that are available: MODE, Prior Act (Single stroke) or CONT (Continuous) If the system is set to the SLAVE Mode the display will indicate that the unit is in the slave mode waiting for a reset. NOTE: Pressing the MENU switch while Pressing and releasing the reset SW will initialize the controller initial settings. This may be necessary if the display becomes garbled MASTER MODE 8

(See process flow charts pages 12-13) If MENU is selected the user is invited to: 1. Change the power level Using the UP/DOWN arrows the power level can be set to any level between 1 and 250 2. Change the SPS (Strokes per Second) setting. Using the UP/DOWN arrows the SPS can be set to any value between.1 and 9.9 NOTE that in fact the SPS setting is limited by the controller to a value that will limit the temperature rise of the Bullet Press Actuator. 3. Change the CE mode ON or OFF, again using the UP/Down arrows. With the CE ON the display will indicate the velocity of the press ram and will adjust the power level so as to keep the ram velocity constant as the press warms up or the line voltage changes. When the CE is OFF the display will indicate CE OFF 4. Reset the Current Part Count to 0 5. Set The Parts Batch count on or off. If off is selected, pressing the menu button again will return the user to the Master menu. 6. Set first digit of the batch count to 0-9 7. Set second digit of the batch count to 0-9 8. Set third digit of the batch count to 0-9 9. Set fourth digit of the batch count to 0-9 10. Set fifth digit of the batch count to 0-9 11. Set sixth digit of the batch count to 0-9 Note: Holding the Mode Switch down for 3 seconds will return the operator to the Master Menu PRIOR ACT MODE (SINGLE STROKE MODE) Selecting the PA switch places the unit in the Single stroke (SS) mode. This allows the operator to activate the press using the Palm 1 and Palm 2 switch inputs. Before the switches can be activated all safety tests are preformed. The Cycle times are as follows: 1. The system relays are closed (.15 sec) 2. The Press is activated 3. The system relays are opened (.15 sec) 4. The display is updated 5. Ready for next Cycle 6. Pressing Cycle Stop returns the Program to the Master Menu Note: IF the Prior Act (Single Stroke) mode is not activated for 2 minutes, the program resets the system to the Master Display. CONTINUIOUS MODE 9

Selecting the CONT switch followed by the Prior Act switch places the unit in the continuous cycle mode. This allows the operator to activate the press system using the Palm 1 and Palm 2 switch inputs. Before the switches can be activated all safety tests are preformed. The Cycle times are as follows: 1. The system relays are closed (1 sec) 2. The Press is activated 3. The Press cycles at the rate determined by the SPS setting 4. Pressing Cycle Stop stops the press cycle after the feed cycle is completed 5. The system relays are opened (1 sec) 6. The display is updated 7. The program returns to the Master Menu Note: IF the CONT (Continuous) mode followed by the Prior Act switch is not activated in 10 seconds the program resets the system to the Master Display. SLAVE MODE OPERATION (See process flow charts page 11) If the slave mode is selected the controller will boot up in the slave mode. In this mode the host PLC will be asked to reset the controller by closing the palm 1 & 2 input circuits. When the HS3500 is reset the Extra input 1 input controls the process. This input must start open and then remain closed for 50 ms before opening. This prevents the system from starting with out a valid signal from the host controller. The Slave, via User outputs 2 & 3 signals the status of the slave to the host. 1-1, user outputs 2 & 3 both open indicates that the either the power is off or that an error condition exists. 0-0, user outputs both closed, indicates that the slave is busy, 0-1 indicate that the slave is waiting for a valid input at the Extra input 1. If user outputs 2 & 3 are.1-0 this indicates that the slave is waiting to be reset at palm inputs. Please see the Slave mode flow chart. Page 11 SETTING THE POWER LEVEL (With the Constant Energy feature enabled) It is suggest that when setting up an application that the user starts at a power level below 50. Increase the power slowly until the desired velocity / energy is achieved. If the CE is in the ON position the velocity will be displayed in the display window. The press will operate at that velocity until the power level is changed. You must be able to increase the velocity by 20 % to insure that you will be operating in a range that allows proper CE corrections. Note: If proper correction is not possible an error occurs. It may be necessary to increase the stroke or to reduce the weight of the tool holder plate slightly and retest. Then reduce the power level to the new lower setting. Note that each time the power level is changed the resulting velocity becomes the CE velocity standard. Contact the factory for help setting up the application. Our applications team will help with the initial setup. They will require the type of material being cut, the length of the cuts, thickness of the material and the weight of the moving tool holder. Remember that the lower the tool weight the higher the velocity and the more efficient the process. 10

Slave Mode Operation In this mode the Bullet controller is a slave to a Host PLC or another system controller Power On or System Reset Front Panel or Remote STATUS OF USER OUTPUTS 2 & 3 User 2-3 (1-1) System Error or No Power Slave Mode selected SW 5-6 ON Wait for reset Palm 1-2 closed Error if Palm inputs NG User 2-3 (1-0) Wait reset Menu Sw pressed Change Power Setting Was Cycle Stop Pressed No Yes Change SPS setting Change Constant Energy on or off Closed only Input 1 mode open/closed or closed SW 5-1 Test Input 1 for Open then Closed User 2-3 (0-1) Wait in 1 Wait for input 1 Open Time-out in 2 min. Adjust Power if required Wait for input 1 closed Time-out in 2 min. Adjust Power if required Acticvate the Bullet Press Measure and display the velocity if CE is ON Test pilot input Air or Electric feed Cycle SW 5-5 Test for Systen or CE Errors Display Errors User 2-3 (0-0) Busy Test Buckle input Test Feed complete input Wait for System Reset Front Panel or Remote 11

Master Mode Operation Single Step Mode In this mode the Bullet controller controls the press operations using the Anti-Tiedown Palm switch inputs (System Safety is to be controlled using a separate approved guarding system) MENU Power On or System Reset Front Panel or Remote MASTER MODE SELECTED SW 5, POSITION 6 ON SELECT PRIOR ACT OR CONTINUIOUS SW 5, POSITION OFF (SLAVE MODE) Menu Sw pressed SINGLE STEP MODE SELECTED CONTINUIOUS MODE SELECTED Note: Holding the Menu Switch down for 3 second returns user to the Master menu. Change Power Setting Change SPS setting SINGLE STEP OPERATION If Prior Act or Continuious switches are selected while in the menu mode the system goes directly to the mode selected Set Constant Energy on or off Reset Part counter to Zero Set Batch Count On or OFF On Set first batch digit Set second batch digit Off Waiting for Prior Act switch to be pressed Waiting for anti-tiedown Palm Switch Was Cycle Stop selected Acticvate the Bullet Press Yes Time-out in 2 min. Adjust Power if required Set third batch digit Measure and display the velocity if CE is ON Set forth batch digit Set fifth batch digit Set sixth batch digit Test pilot input Air or Electric feed Cycle SW 5 POSITION 5 Test Buckle input Test Feed complete input Test for Systen or CE Errors Display Errors SET ALARM OUTPUT Wait for System Reset Front Panel or Remote 12

Master Mode Operation Continuious Mode In this mode the Bullet controller controls the press operations using the Anti-Tiedown Palm switch inputs (System Safety is to be controlled using a separate approved guarding system) MENU Power On or System Reset Front Panel or Remote MASTER MODE SELECTED SW 5, POSITION 6 ON SELECT PRIOR ACT OR CONTINUIOUS SW 5, POSITION OFF (SLAVE MODE) Menu Sw pressed SINGLE STEP MODE SELECTED CONTINUIOUS MODE SELECTED Note: Holding the Menu Switch down for 3 second returns user to the Master menu. If Prior Act or Continuious switches are selected while in the menu mode the system goes directly to the mode selected Change Power Setting Change SPS setting Set Constant Energy on or off Reset Part counter to Zero Set Batch Count On or OFF On Set first batch digit Set second batch digit Off CONTINUIOUS MODE OPERATION Continuious selected (wait for prior act sw) Waiting for Prior Act switch to be pressed Waiting for anti-tiedown Palm Switch Was Cycle Stop selected Acticvate the Bullet Press Yes Time-out in 10 SEC. Adjust Power if required Time-out in 10 SEC. Adjust Power if required Set third batch digit Measure and display the velocity if CE is ON Set forth batch digit Set fifth batch digit Set sixth batch digit Test pilot input Air or Electric feed Cycle SW 5-5 Test Buckle input Test Feed complete input Test for Systen or CE Errors Display Errors Wait for System Reset Front Panel or Remote INPUT-OUTPUT SPECIFICATIONS 13

OUTPUTS: Press output... 1 to 38 milliseconds of full wave rectified line input.. Alarm Triac Switch... Normally open, user provides power, 30/240 volts AC at 2-amp max. (Use AC only) Feed Triac Switch... Normally open, user provides power, 30/240 volts AC at 2-amp max. (Use AC only) Open Collector outputs: 24 volts @15 ma max 24 V supply 100 ma max INPUTS: Power... 208/240, 385 and 440/480 volts 60 Hz. Single phase or optional 3 phase (factory adjustable only). Inputs... All inputs require a switch or relay capable of switching 24 volts DC at 12 MA. If you are using a relay, use a small low current variety to insure reliable switching.. CONTROLLER DIMENSIONS Height: 4.75 Width: 14.25 Depth; 13 + Allow 3.5 for cable connections Weight: 20 Lbs --## -- EN 14