Softwaredescription

LJU Automatisierungstechnik GmbH

ST794-3M-PS-SI-SB TF
Trolley Controller
Costumer: End costumer: Plant: WNR: Rofa Vinamilk SSI Schfer 628231

Version:

1.0

LJU Automatisierungstechnik GmbH Am Schlahn 1 DE 14476 Potsdam Tel.: +49 (0) 33201 / 414-0 Fax: +49 (0) 33201 / 414-19 E-Mail: info@lju-grenzebach.com Internet: www.ljuonline.de | www.grenzebach.com

The standard names, trade names, product names etc. used in this documentation may also be brand names even when not specially indicated and as such subject to the statutory stipulations. May 2011

Software description ST 794-3M-PS-SI-SB-TR V1.0

Table of contents

Table of changes
Subject to changes We reserve the right to make changes in the information contained in this document, which arise from our constant effort to improve our products.

Project : Rofa / SSI-Schfer Vinamilk Order No.: 120645 BV No.: 89073 Programmer: Hein Version 1.0 1.1 1.2 1.3 1.4 Date 10.08.12 29.08.12 08.09.12 24.09.12 20.12.12 Author Hein Hein Hein Hein Hein

Date :10.08.2012

Chapter Remarks / Index First version various Error correction General Entry for INI6030 6.2 Description Ini6012-1 Inputs 3.2 Description of parameter INF

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Software description ST 794-3M-PS-SI-SB-TR V1.0

Table of contents

Table of contents
1 General ..................................................................................... 7 1.1 Program description ................................................................ 8 1.1.1 Automatic mode ............................................................... 8 1.1.2 Position sensing with the OLM 708...................................... 8 1.1.3 The conveying process ...................................................... 8 1.1.4 Service mode ................................................................... 9 1.1.5 Manual mode ................................................................... 9 Error Messages ........................................................................ 2.1 Overview ............................................................................. 2.2 Description of error messages ................................................ 2.2.1 Message -0- .................................................................. 2.2.2 Error -1-: Sequence stop switch ....................................... 2.2.3 Error -14/ -15/ -16: Error 24 V initiator board.................... 2.2.4 Errors -17/ -18/ -19: Monitoring of brakes ........................ 2.2.5 Error -21: Inverter phase failure ...................................... 2.2.6 Error -23/ -24: Inverter over-voltage ................................ 2.2.7 Error -25/ -26: Inverter under-voltage .............................. 2.2.8 Errors -27/ -28/ -29: Fuses ............................................. 2.2.9 Error -30 Non-equivalence bypass switch .......................... 2.2.10 Error -32: No code strip .................................................. 2.2.11 Error -33: Stop position overdrive .................................... 2.2.12 Error -34: Code reading error .......................................... 2.2.13 Error -35: Monitoring OLM speed ...................................... 2.2.14 Error -36/ -37: Monitoring conveyor free profile ................. 2.2.15 Error -38: Code gap........................................................ 2.2.16 Error -3A: Drive direction command ................................. 2.2.17 Error -41/ -43: Motor over-temperature ............................ 2.2.18 Errors -51/ -52/ -53: Motor over-current ........................... 2.2.19 Error -54/ -55: Inverter overload ..................................... 2.2.20 Error -56/ -57: Inverter over-current ................................ 2.2.21 Error -61: PLC command plausibility ................................. 2.2.22 Error -62: PLC command without release rail ..................... 2.2.23 Error -63/ -64: Conveyor runtime..................................... 2.2.24 Error -65/-66: Relay defect ............................................. 2.2.25 Error -67: Soiled OLM or bar code tape ............................. 2.2.26 Error -68: Drive position outside range ............................. 2.2.27 Error -69: Drive direction ................................................ 2.2.28 Error -6A: Drive motor standstill monitoring ...................... 2.2.29 Error -71 / -72: High-level stage error of inverter............... 2.2.30 Error -74/ -75: Inverter over-temperature ........................ 2.2.31 Error -77/ -78: Chopper overload ..................................... 2.2.32 Error -8-: Tables CRC incorrect ........................................ 2.2.33 Error -81: Safety relay defect .......................................... 2.2.34 Error -87: System table error .......................................... 2.2.35 Error -9-: Parameter error ............................................... 2.2.36 Error -91 /-92 /-94 .. /-98: Communication error ............... BV89073_02_en.doc 10 10 12 12 12 12 12 13 13 13 14 14 14 15 15 15 16 16 16 17 17 17 18 18 18 19 19 19 19 20 20 20 21 21 21 22 22 22 22

Software description ST 794-3M-PS-SI-SB-TR V1.0

Table of contents

2.2.37 Error -99: Rail bus communications error .......................... 2.2.38 Error - Par ..................................................................... 2.3 Trolley-specific error codes from the data concentrator .............. 2.3.1 Message 88: Position not in system table .......................... 3 Parameter ............................................................................... 3.1 General ............................................................................... 3.2 Parameter overview .............................................................. 3.3 Parameter descriptions .......................................................... 3.3.1 Start delay [T0] ............................................................. 3.3.2 Acceleration and braking ramps [T1-T4/T6/T7] .................. 3.3.3 Speed factor [GED / GEF] ................................................ 3.3.4 Scaling of position sensor [SC1] ....................................... 3.3.5 IxR compensation [M1D/M3D/M1F] .................................. 3.3.6 Cut-off frequency [M2D/M4D/M2F] ................................... 3.3.7 Nominal current motor [InD/InF]...................................... 3.3.8 Configuration of OLM [CNF] ............................................. 3.3.9 Safe speed [VSF] ........................................................... 3.3.10 Positioning ramp [ACL/ACV] ............................................ 3.3.11 Positioning window of Drive [WIN] .................................... 3.3.12 Positioning window of standstill [TL1] ............................... 3.3.13 Tolerance [TL2] .............................................................. 3.3.14 Slow drive empty / full window [WIN] ............................... 3.3.15 Configuration distance regulation [CNF] ............................ 3.3.16 Stopping distance [ABA].................................................. 3.3.17 Ramp distance regulation [ACA] ....................................... 3.3.18 Trolley length [FzL] ........................................................ 3.3.19 Frequency for releasing or applying brakes [BOx/BCx] ........ 3.3.20 Standstill tolerance [FST] ................................................ 3.3.21 Time delay to speed control error [TSM]............................ 3.3.22 Timeout conveying [T8] .................................................. 3.3.23 Minimum runtime [T11] .................................................. 3.3.24 Time to conveyer slow [T12]............................................ 3.3.25 Delay stop loading [T13] ................................................. 3.3.26 Waiting time conveyor empty [T14] ............................... 3.3.27 Waiting time after releasing stop button [T5] ..................... 3.3.28 Sequence stop button configuration [CNF] ......................... 3.3.29 Signal lamp configuration [CNF] ....................................... 3.3.30 Configuration of vacuum cleaner [CCl] .............................. 3.3.31 Runtime cleaner after stop of trolley [T15] ........................ 3.3.32 Rated voltage [CUN] ....................................................... 3.3.33 Intermediate circuit frequency [CZF] ................................ 3.3.34 Release number [PAR] .................................................... 3.3.35 Offset [Off] .................................................................... 3.3.36 Configuration test outputs ............................................... 3.3.37 Configuration remote control [CNF] ..................................

23 24 25 25 26 26 26 28 28 28 28 29 29 30 30 30 31 31 31 31 31 32 32 32 32 33 33 33 33 33 33 34 34 34 34 34 34 34 35 35 36 36 36 36 37

Configuration ........................................................................... 38 4.1 General ............................................................................... 38 BV89073_02_en.doc 5

Software description ST 794-3M-PS-SI-SB-TR V1.0

Table of contents

4.2 Configuration overview .......................................................... 4.3 Description........................................................................... 4.3.1 Motor temperature ......................................................... 4.3.2 IxR compensation measurement by the controller .............. 4.3.3 No error display ............................................................. 4.3.4 Unconditional manual mode ............................................. 4.3.5 Plausibility monitored ...................................................... 4.3.6 Error -62 ....................................................................... 4.3.7 Invert Conveyer motor direction ....................................... 4.3.8 Monitoring speed ............................................................ 4.3.9 FAB .............................................................................. 4.3.10 Overrun stop position ..................................................... 4.3.11 Profile is monitored......................................................... 5

38 39 39 39 40 40 40 40 40 40 41 41 41

Tables..................................................................................... 42 5.1 Speed table .......................................................................... 42 5.2 Clearance table ..................................................................... 43 Display ................................................................................... 6.1 General ............................................................................... 6.2 Display modes ...................................................................... 6.3 Other displays ...................................................................... 44 44 44 52

FB-606 remote control .............................................................. 54 7.1 General ............................................................................... 54 7.2 Button functions (Standard IR Konfiguration) ........................... 54 MU705 .................................................................................... 55 Display of Input Signals or Control Flags ..................................... 57

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Software description ST 794-3M-PS-SI-SB-TR V1.0

General

1 General
Read this description carefully before you use the device! It will ensure smooth operation of the system and prevention of errors, defects and damage to the system. If a controller ever needs to be replaced, please return it along with an error description that is as accurate as possible. This will help us minimize repair times and return the controller to you in the shortest possible time.

Display: Parameter set: MU 705: DKZ: Components Name IPM-1.6-TF IPM-2.5-TF CPU-805-6-TF

4-stellig (4x7 Segment) ST794-3MPS-SI-SB 89073_90 89073_00

CPU-IPM-MB3-TF

Bootloader BIOS User Bootloader BIOS USER Adr.: 0 Adr.: 0 Adr.: 1

BV -----_------_-94018_02 94083_18 94071_08 94088_02 94105_04 -----_-86546_00 86133_00 86133_00 -----_------_------_--

WNR 181114 181161 181189

BG 53586_04 53543_04 51296_01

181159 51522_01

IRDA-805-5-TF INI-6030-TF INI-6012-TF INI-6012-TF ESB-1-TF PH-1.6.1-TF B-1-TF

18754 18683 18698 18698 181014 181229 18968

56064 55267 55574 55571 57438 57901 57178

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Software description ST 794-3M-PS-SI-SB-TR V1.0

General

1.1 Program description

1.1.1 Automatic mode
In automatic mode the trolley receives command flags in a cyclic data exchange from the data concentrator or the PLC, to either drive or convey. Since the data concentrator knows the position of all the trolleys, it informs each trolley of the free route available to it in the drive direction. Flags in the system table are used to stop the trolley at a particular point. The PLC must set a bypass flag/bridging flag in order for the trolley to continue driving after a stop.

1.1.2 Position sensing with the OLM 708

A bar code scanner is used to determine the actual position. A barcode is placed in the system, which is read by the scanner. The positions are coded as absolute values in the system. For more information, please refer to the manufacturers handbook. If the scanner detects an error in the code (breaks), it signals this and the controller software continues to incrementally count the position of the trolley for a specific time period. The counting speed is based on the trolley speed, due to which the correct position is determined even in this case.

1.1.3 The conveying process

LS1 Gap control LS2 Stop when loading from left After switching on, an initial check is made of whether the conveyor is occupied by a pallet. If the light barriers for the position occupancy (LS2) are not free, then the conveyor is detected as occupied and an o (occupied) appears in the dis-

LJU LS 2 LS 1

Conveyer

Conveyer

Direction

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Software description ST 794-3M-PS-SI-SB-TR V1.0

General

play. If only one of these light barriers is occupied, then the load status is detected as undefined and a u (undefined) appears in the display. If profile monitoring has been selected (see parameter description), then the profile is monitored during the drive. If the conveyor is occupied, then it is monitored for possible pallet shifting (LS1 is occupied). If the conveyor is free, no light barriers may become blocked and the display shows a _ to signalize conveyor free. Various signals are used to synchronize an external conveyor with the conveyor on the trolley. The commands to load/unload are checked for plausibility. (See error descriptions.)

1.1.4 Service mode

In service mode, drive and convey commands can be set in the trolley using the PLC. During the drive, the trolley direction and speed may be selected. Trolley distance monitoring and relaying of the routing tables remain activated. The service module position is not monitored! The chain conveyor can only drive at slow speed in this operating mode. The light barriers and the load are not monitored!

1.1.5 Manual mode

Manual mode allows access to the various controller functions. In the manual mode, the controller works with limited error analysis. When the manual mode is activated or deactivated, all the errors are reset. !! In manual mode, the controller does not respond to data concentrator commands!!

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Software description ST 794-3M-PS-SI-SB-TR V1.0

Error Messages

2 Error Messages
2.1 Overview
Display -0-1- 14 - 15 - 16 - 17 - 18 - 19 - 21 - 23 - 24 - 25 - 26 - 27 - 28 - 29 - 30 - 32 - 33 - 34 - 35 - 36 - 37 - 38 -3A - 41 - 43 - 51 - 52 - 53 - 54 - 55 - 56 - 57 - 61 - 62 DCN Display 1 10 14 15 16 17 18 19 21 23 24 25 26 27 28 29 30 32 33 34 35 36 37 38 39 41 43 51 52 53 54 55 56 57 61 62 Meaning Bypass safety circuit Sequence stop 24 volt initiator board 6030 24 volt initiator board 6012-1 24 volt initiator board 6012-2 Drive motor brake Conveyer1 motor brake Conveyer2 motor brake Inverter phase error Inverter 1 over-voltage 1) Inverter 2 over-voltage 2) Inverter 1 under-voltage 1) Inverter 2 under -voltage 2) Fuse, initiator board 6030 Fuse, initiator board 6012-1 Fuse, initiator board 6012-2 Non-equivalence bypass switch No code strip Stop position overdrive Code reading error Monitoring OLM speed Monitoring conveyor1 free profile Monitoring conveyor2 free profile Code gap Drive direction command Motor over-temperature drive/ conveyor 1 Motor over-temperature conveyor 2 Drive motor over-current Conveyor1 motor over-current Conveyor2 motor over-current Inverter 1 overload 1) Inverter 2 overload 2) Inverter 1 over-current 1) Inverter 2 over-current 2) PLC command plausibility PLC command without release rail

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Software description ST 794-3M-PS-SI-SB-TR V1.0

Error Messages

- 63 - 64 - 65 - 66 - 67 - 68 - 69 - 6A - 71 - 72 - 74 - 75 - 77 - 78 -8- 81 - 87 -9- 91 - 92 - 94 - 95 - 96 - 97 - 98 - 99 PAR

63 64 65 66 67 68 69 6A 71 72 74 75 77 78 80 81 87 90 91 92 94 95 96 97 98 99 A0

Conveyor 1 runtime Conveyor 2 runtime Drive motor relay Conveyer 1 motor relay Soiled OLM / bar code tape Drive position outside range Drive direction Drive motor standstill monitoring High-level stage error of inverter 1 High-level stage error of inverter 2 Inverter 1 over-temperature Inverter 2 over-temperature Overload chopper inverter 1 Overload chopper inverter 2 Tables CRC incorrect Safety-relay defect System table error Parameter error Inverter 1 offline 1) Inverter 2 offline 2) Initiator board 6030 offline Initiator board 6012-1 offline Initiator board 6012-2 offline OLM offline FAB offline Rail bus communications error Controller not enabled

1) 2)

1) Inverter 1 = Drive / Conveyor1 2) Inverter 2 = Conveyor2

The control box is sending the error numbers in hex.

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Software description ST 794-3M-PS-SI-SB-TR V1.0

Error Messages

2.2 Description of error messages

Only negative flashing numbers are error messages!

2.2.1 Message -0Cause: - The switch for bypass the safety is activated Solution: - Release the switch

2.2.2 Error -1-: Sequence stop switch

Cause: - The palm button has been pressed. - No connection exists between shut-off switch and controller. Solution: - Unlock palm button switch; the trolley continues the drive after the parameterized follow-up time has expired. - Check that the cable connection between palm button switch and controller is well seated.

2.2.3 Error -14/ -15/ -16: Error 24 V initiator board

Cause: - No 24 volt supply to the input boards. Solution: - Verify 24-volt supply voltage by measurement. - Check that the ribbon cables are well seated.

2.2.4 Errors -17/ -18/ -19: Monitoring of brakes

Cause: - Fuses for the brake defect - Brake lock defective - Brake line from motor missing - Incorrect cable type for motor cable -Mechanical jamming

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Software description ST 794-3M-PS-SI-SB-TR V1.0

Error Messages

Solution: - Check fuses for the brake on the inverter board - Check / replace brake locks - Check motor line - Check brakes

2.2.5 Error -21: Inverter phase failure

Cause: - At least one phase of the 460-volt supply voltage has failed. Solution: - Measure phase voltage. - Check system for short circuit. - Check fuses.

2.2.6 Error -23/ -24: Inverter over-voltage

If the controller is working in the generating mode, the intermediate circuit voltage increases. If it exceeds a certain value, the error is produced. Cause: - Defective chopper resistance. Solution: - Replace controller

2.2.7 Error -25/ -26: Inverter under-voltage

If the intermediate circuit voltage is under a defined limit. The Limit depends on the parameter for the rated voltage. Cause: - Wrong parameter value for rated voltage - Phase missing - Defective controller Solution: - Check the parameters - Check the three phases - Replace controller

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Software description ST 794-3M-PS-SI-SB-TR V1.0

Error Messages

2.2.8 Errors -27/ -28/ -29: Fuses

A multi-fuse on the initiator board has tripped. Cause: - Short circuit in an external device connected to the input board. Solution: - Check the connected sensors and/or external devices (initiators, sequence stop buttons etc.) for short circuits.

2.2.9 Error -30 Non-equivalence bypass switch

If so configured both contacts of the bypass switch are monitored if they are open or closed simultaneously. Cause: - The initiator /switch is not designed to be non-equivalent, although it is configured as such. - There is no configured initiator or the cable connections are loose. - If it is a non-equivalence initiator / switch, the contacts are both simultaneously open or closed (initiator defective). Solution: - Check the parameters of the initiator (see MU parameters). - Install an initiator or check that the connecting plug is securely seated. - Replace initiator.

2.2.10 Error -32: No code strip

The OLM has not found a valid code after the segment end+1000 mm of a segment in which the trolleys have to drive without any code strip. Cause: - Incorrectly adjusted OLM - Area without code strip too big - Missing flag for no code strip Solution: 14 BV89073_02_en.doc

Software description ST 794-3M-PS-SI-SB-TR V1.0

Error Messages

- Check adjustment of the OLM Clean OLM and code stripe Check system table

Note: Not used in this project!

2.2.11 Error -33: Stop position overdrive

In the positioning software, there is an option for a trolley to reverse and position itself within a certain range in case it overshoots its stop position. However if the trolley has overshot even this range, an error is generated. Cause: The controller or positioning has incorrect parameters (e.g. gear factor, positioning ramp) Dirt or defective OLM Dirt or ill-adjusted barcode strip

Solution: - Verify parameters - Check OLM - Check barcode strip

2.2.12 Error -34: Code reading error

This error occurs if the controller does not receive any valid position for more than 1000 mm. (position was only counted incrementally) Cause: Solution: Declutched/disengaged gear Loose driving wheel Incorrectly adjusted or dirt OLM

Check the position of the clutch lever Check that the drive wheel is firmly seated Check the adjustment of the OLM and the rails Clean the rails and OLM

2.2.13 Error -35: Monitoring OLM speed

The trolley controller monitors whether the actual speed matches with the specified value. This error indicates a deviation. Cause: BV89073_02_en.doc 15

Software description ST 794-3M-PS-SI-SB-TR V1.0

Error Messages

Incorrectly adjusted or dirty OLM Loose driving wheel, declutched gear, Gear factor has incorrect parameters

Solution: - Check that the driving wheel is firmly seated - Check the position of the clutch lever - Check parameters (see MU parameters)

2.2.14 Error -36/ -37: Monitoring conveyor free profile

If profile monitoring is selected, then profile freedom is monitored while the trolley has a conveyor command. If the conveyor is empty, no light barriers may become blocked. If the conveyor is full, none of the gap controls may become blocked. Cause: Shifted pallet Foreign object blocking the gap-control light barrier

Solution: - Check pallet position - Check region in which the fault occurred for foreign objects

2.2.15 Error -38: Code gap

This error occurs if the OLM has not sent two sequentially increasing or decreasing positions for a span of 700 mm. Cause: - Incorrectly adjusted OLM - Dirt OLM or code strip Solution: - Check adjustment of the OLM - Clean OLM and code strip

2.2.16 Error -3A: Drive direction command

It is only monitored if the corresponding software switch has been activated (see Configuration section). This error occurs if the controller got a drive backward command from the PLC. 16 BV89073_02_en.doc

Software description ST 794-3M-PS-SI-SB-TR V1.0

Error Messages

. Cause: - Wrong Configuration (SW11) - Wrong PLC drive direction command - Automatic mode active Solution: - Check configuration - Execute backward drive commands only in service mode

2.2.17 Error -41/ -43: Motor over-temperature

Cause: -

Motor has no temperature probe Motor has incorrect parameters Incorrect cable type for motor cable Mechanical jamming Motor defective

Solution: - Check - Check - Check - Check

motors type plate parameters (see MU parameters) the motor cable (Thermistor cabling must be shielded) motor and mechanics

2.2.18 Errors -51/ -52/ -53: Motor over-current

Cause: - Motor has incorrect parameters - Mechanical jamming - Motor defective Solution: - Check parameters (see MU parameters) - Check motor and mechanics

2.2.19 Error -54/ -55: Inverter overload

The maximum power of the inverter was exceeded. Cause: - Inverter capacity too low for the required power - Mechanical jamming Solution: BV89073_02_en.doc 17

Software description ST 794-3M-PS-SI-SB-TR V1.0

Error Messages

Check the load on the trolley Check mechanics

2.2.20 Error -56/ -57: Inverter over-current

In normal mode, the output current has exceeded the inverter modules nominal current. With automatic IxR compensation selected, an error is triggered if the current lies 200% above the nominal current parameter set for the motor. Cause: - Defective drive motor (short to winding) - Parameter for the motors nominal current incorrectly set Solution: - Check motor - Check parameter for the motors nominal current (set value from motors type plate)

2.2.21 Error -61: PLC command plausibility

Cause: - PLC sending simultaneous drive and convey commands - PLC sends simultaneous load and unload commands Solution: - Check PLC program, only one command may be received at a time

2.2.22 Error -62: PLC command without release rail

In order to work must supply (L1) on the 5th Rail / rail-sharing. Monitoring of this error can be selected or deselected. (See section configuration). Cause: - SPS gives a driving instruction although the release rail is not connected Solution: - Check the PLC program

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Error Messages

2.2.23 Error -63/ -64: Conveyor runtime

This error is only monitored if the corresponding software switch has been activated (see configuration section). Within a certain amount of time the trolley was not loaded or unloaded despite a pending command. The monitoring time is set via a parameter in a range of 0-32 s (see parameters section). Cause: - Broken chain - Tipped pallet Solution: - Check chain - Check conveyor - Check motor action

2.2.24 Error -65/-66: Relay defect

In the controller, it is monitored whether only the particular activated relay is activated (checked whether it is not stuck). Cause: - A relay reports activated though it is not activated Solution: - Check relay - Replace controller

2.2.25 Error -67: Soiled OLM or bar code tape

Cause: - OLM report a dirt error Solution: - Check OLM - Check code strip

2.2.26 Error -68: Drive position outside range

The controller software monitors whether the positions returned by the OLM lie within the allowed position range. Cause: - OLM returns an incorrect position BV89073_02_en.doc 19

Software description ST 794-3M-PS-SI-SB-TR V1.0

Error Messages

- Incorrect or damaged barcode strip Solution: - Check OLM - Check barcode strip

2.2.27 Error -69: Drive direction

This error occurs, if the driving motor is defective or turning in the wrong direction. Cause: The driving motor is defective Incorrect parameters The motor is connected incorrectly

Solution: - Check cables - Check parameters (see MU parameters) Check if the motor is defective

2.2.28 Error -6A: Drive motor standstill monitoring

The error is output if the trolley is moving without a drive command. The range that is accepted can be adjusted by a parameter. Cause: Open clutch Defective break Wrong parameters

Solution: - Check clutch and break - Check parameters (see MU parameters)

2.2.29 Error -71 / -72: High-level stage error of inverter

The frequency inverters starting current was too high. Cause: Mechanical jamming Failed phase at drive motor Motor brake not released

20

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Software description ST 794-3M-PS-SI-SB-TR V1.0

Error Messages

Solution: - Check mechanics - Check cable connections to motor terminal board - Check brake

2.2.30 Error -74/ -75: Inverter over-temperature

Temperature probes for monitoring the chip temperature are integrated into the semiconductor components of the power circuit for driving the motor (skips). In particular, if it is necessary to drive synchronously over long distances, the skips can be subject to temperature increases. Cause: Inverter capacity too low for the required power Inverter has incorrect parameters

Solution: - Install an inverter of the next higher power class - Check the load on the trolley - Check parameters (see MU parameters)

2.2.31 Error -77/ -78: Chopper overload

If the controller is working in generating mode, the intermediate circuit voltage increases. If it exceeds a certain value, the intermediate circuit is discharged through a chopper resistor. Cause: Inverter capacity too low for the required power Defective chopper

Solution: - Check the load on the trolley - Replace controller

2.2.32 Error -8-: Tables CRC incorrect

A checksum (CRC) is saved with the tables in the data concentrator and in the trolley. These are compared with one another to determine any changes. Cause: Solution: BV89073_02_en.doc 21 Defective memory

Software description ST 794-3M-PS-SI-SB-TR V1.0

Error Messages

If the error occurs repeatedly replace controller

2.2.33 Error -81: Safety relay defect

The 5th Signal Rail is switched but the internal safety relay remains active Cause: Incorrect positions in the system table

Solution: - Replace safety relay

2.2.34 Error -87: System table error

The trolley attempts to assign itself to a segment of the system table based on its position. If it is unable to do this within a certain window, the trolley is stopped and an error is displayed. Cause: Incorrect positions in the system table

Solution: - Check system table

2.2.35 Error -9-: Parameter error

Cause: The controller is new and no parameters have been imported yet

Solution: - Import the parameters with the MU

2.2.36 Error -91 /-92 /-94 .. /-98: Communication error

Cause: A controller component is not registering itself on the bus The software switch for the FAB is selected, but no FAB is connected (-98)

Solution: - Check that the bus cables are securely seated 22 BV89073_02_en.doc

Software description ST 794-3M-PS-SI-SB-TR V1.0

Error Messages

Replace controller (component defective) Check software switch settings

2.2.37 Error -99: Rail bus communications error

Cause: An unregistered trolley is in the data concentrator area A cable to the data bus is loose or unplugged from the modem No 24-volt power supply to the data concentrator

Solution: - Check whether all the trolleys in the data concentrator area are registered. - Check that cabling is securely connected - Check supply voltage

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Software description ST 794-3M-PS-SI-SB-TR V1.0

Error Messages

2.2.38 Error - Par

Cause: The release code for the controller is incorrect

Solution: - Set correct code in the parameters in the MU, and then import it into the controller (see MU parameters) If a controller ever needs to be replaced, then while returning the controller, we request that you include an error description that is as accurate as possible. This will help us to minimize repair times and return the controller to you in the shortest possible time.

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Software description ST 794-3M-PS-SI-SB-TR V1.0

Error Messages

2.3 Trolley-specific error codes from the data concentrator

There are certain error situations that the trolley controller cannot detect automatically. In these situations, the data concentrator is able to generate trolley-specific error messages. These error messages are then sent in the error byte of the respective trolley to the PLC. Because the trolley controller itself does not detect the error, it cannot display it in the controllers display.

Error number 88

Meaning Position not in system table

2.3.1 Message 88: Position not in system table

Cause: The trolley reports a position to the Data concentrator, which is not present in the system table. There are errors in the system table.

Solution: - Correct the system table and re-send it to the data concentrator.

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Software description ST 794-3M-PS-SI-SB-TR V1.0

Parameter

3 Parameter
3.1 General

The parameters are used to influence the controllers major features. The smallest possible value for a parameter is zero. The maximum possible is 65535. For some parameters, this value range has been restricted to a range of allowed values. If a value that is below the lower limit is entered for a parameter, then the minimum value for this parameter will be used. If the set value is higher than the maximum permitted value, then the maximum permitted value will be used. Despite these limitations, changes to the parameter settings should be made only if their effect can be estimated.

3.2 Parameter overview

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 Name T0 T1 T2 T3 T4 BOL BCL BOV BCV InD M1D M2D M3D M4D GED SC1 G Gmn ABS CNF VSF ACL ACV Value Unit ms ms/Hz ms/Hz ms/Hz ms/Hz 1/10Hz 1/10Hz 1/10Hz 1/10Hz 100mA % Hz % Hz cm/min cm/kinc %/Inc % Meaning Delay on start Acceleration ramp of drive motor empty Decceleration ramp of drive motor empty Acceleration ramp of drive motor full Decceleration ramp of drive motor full Frequency open brakes of drive motor empty Frequency close brakes drive motor empty Frequency to open brakes of drive motor full Frequency to close brakes of drive motor full Nominal current of drive motor IxR compensation of drive motor Cutoff frequency of drive motor IxR compensation of drive motor at VSF Cutoff frequency of drive motor at VSF Speed at 50Hz drive motor Scaling position encoder Servo resolution * Servo amplification * servo regulation max regulation fault * Configuration OLM Save speed Positioning ramp empty Positioning ramp full

cm/min xm/s^2 xm/s^2

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Parameter

No. 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62

Name Win TL1 TL2 Win Win CNF ABA FzL ACA FST TSM T6 T7 BOF BCF Inf M1F M2F GEF VF0 VF1 T8 T11 T12 T13 T14 T9 T10 CNF T5 CNF CNF Cun CZF PAR CNF CCl T15 tst

Value

Unit mm mm mm mm mm mm mm xm/s^2 mm ms ms/Hz ms/Hz 1/10Hz 1/10Hz 100mA % Hz xm/min xm/min xm/min ms ms ms ms ms ms ms ms

kHz+1

ms

Meaning Positioning window on movement Positioning window on stand still Max. way backward forpositioning Slow drive windows empty Slow drive windows full Configuration Distance control Stopping distance Length of vehicle Ramp for distance control Standstill tolerance Time delay to speed control error Acceleration ramp conveyor motor Decceleration ramp conveyor motor Frequency to open brakes of conveyor motor Frequency to close brakes of conveyor motor Nominal current of conveyor motor IxR compensation of conveyor motor Cutoff frequency of conveyor motor Speed at 50Hz conveyor motor Slow speed of conveyor motor Fast speed of conveyor motor Maximum Runtime conveyor motor Minimum Runtime conveyor motor Time to change in slowly Delay stop loading Waiting time conveyor empty Reserved Reserved Reserved Waiting time after stop button Configuration stop button Configuration stop button Lamp Configuration Nominal voltage Intermediate circuit frequency Drive Release code of control box Configuration remote control Vacuum cleaner Configuration Vacuum cleaner overrun time Test outputs

*Not used in this Project

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Parameter

3.3 Parameter descriptions

3.3.1 Start delay [T0]
During this time, all the controller components are contacted and initialized. During the start delay, error messages are suppressed. Especially when external components are used (OLM, FAB, Extension Box etc.), it should be ensured that the power supply is setup, the participant has registered on the bus and its current status (inputs, position etc.) is evaluated. If the configured time is too short, the controller will receive various error messages each time it is switched on, which can simply be acknowledged. The start time must be bigger than 5,5 s. The OLM need this time for the initialization.

3.3.2 Acceleration and braking ramps [T1-T4/T6/T7]

These ramps specify the step-width for the frequency change, if the desired frequency changes. They considerably influence the trolleys drive pattern. (Breaking and acceleration distances) In the interest of careful operation of the controllers, the ramps should not be set as steep as possible, rather as steep as necessary. The figure below serves to illustrate this. It shows an acceleration ramp of 10 ms/Hz.
Frequency [Hz] 50

500

Time [ms]

3.3.3 Speed factor [GED / GEF]

This factor specifies the speed at which the trolley drives at 50 Hertz. It depends on the rated motor speed, the diameter of the drive wheel, and the transmission ratio. In particular, the speed factor for the drive gear must be determined accurately. The factor is taken into the calculation of the current position during incremental counting and is determined for controlling the synchronous drive. The factor can be determined in the following manner.
GED = n * d * i d in mm n in U / min

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Parameter

The result gives the speed factor in mm/min. To get the value in cm/min it must divided by 10 If a different scaling is desired, the units must be changed accordingly (possibly using correction factors). The value determined in this way can now be entered into the MU as the speed factor value and fed into the controller.

3.3.4 Scaling of position sensor [SC1]

This specifies the resolution used by the positioning system. The scaling uses the relation way/1000incr. At 1000 mm/kincr, the position can be resolved to exactly 1 mm. If the speeds are specified in cm/min, the scaling must be specified in 100 cm/kincr. CRU PLS3 + DLS2 PLS3 PLA14 PLA14 OLM in cm OLM in mm OLM in 0,1 mm OLM in 0,1 mm Unit Speed at 50Hz (GEX) cm/min mm/min cm/min mm/min cm/min mm/min cm/min mm/min Value 200 2000 100 1000 100 1000 10 100

3.3.5 IxR compensation [M1D/M3D/M1F]

This parameter should be determined with the automatic IxR measurement (see SW switch description). It influences the modulation curve depending on the frequency. General explanation of the IxR compensation using an example of a configured IxR compensation of 0 % and 10 %:
100 % modulation

IxR-Compensation = 10 % IxR-Compensation = 0 % Cut-off freFrequency

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Parameter

If the drive seems to lack power, one can attempt to make up for this with a higher IxR compensation. If the IxR compensation is set too high this leads to motor heating!

3.3.6 Cut-off frequency [M2D/M4D/M2F]

This specifies the frequency at which 100 % modulation is reached. (See IxR compensation example.) It is either included in the motors data sheet (operating with frequency inverter) or is determined by the manner in which the motor is connected. Delta motors: 87 Hz Star motors: 50 Hz

3.3.7 Nominal current motor [InD/InF]

Here you need the nominal current from the type plate of the motor. If the motor current exceeds 140% of the nominal current, the trolley stops with a fault message.

3.3.8 Configuration of OLM [CNF]

Value 0 +1 +2 +4 +8 +16 +32 +64 +128 +256 +512 +1024 +2048
1 2

Function Operation without special functions Position resolution 0.1mm1 Invert counting direction Controller saves a variable reference value2 Calculate reference value at switching edge of a reference initiator2 Allow for position overrun in reference value2 Error in message from encoder Error in plausibility of encoder position2 Error in area of encoder position Error in speed monitoring Error in direction monitoring Error in stationary monitoring Referencing is done externally2

Resolution in this project 1mm! Not used in this project

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Parameter

3.3.9 Safe speed [VSF]

This parameter specifies the speed at which the trolley drives, when the system controller does not send the bit for the release of segment-based speeds.

3.3.10 Positioning ramp [ACL/ACV]

The positioning ramp differs from the braking ramp or acceleration ramp. The progress of the ramp is not linear, but drops severely at the beginning of the positioning, and trails off flatly towards the end. The shape of this ramp enables the speed to be reduced quickly and the exact positioning to be executed towards the end.

3.3.11 Positioning window of Drive [WIN]

This value sets the permissible deviation between the current trolley position and the required stopping position and nevertheless a message that the trolley is positioned is sent.

3.3.12 Positioning window of standstill [TL1]

This value sets the permissible deviation between the current trolley position and the required stopping position. It nevertheless sends a message that the trolley is positioned. This parameter is active only if the trolley is stationary and the inverter is off.

3.3.13 Tolerance [TL2]

If a trolley has driven past its stopping position, then up to a certain distance from this position it can attempt to reach the position by driving backwards. The tolerance parameter sets the area in which this reverse drive may take place.
Destination position Drive direction Positioning window

Tolerance Monitoring

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Parameter

3.3.14 Slow drive empty / full window [WIN]

It specifies the area in which the trolley drives at minimal speed while positioning. A distinction is made between empty and full trolleys. The size of the window depends on the mechanical conditions of the trolley. It must be dimensioned such that the trolley does not overshoot its position during the positioning. In case of conveyors without sensors, only the parameter slow drive window full is used.

3.3.15 Configuration distance regulation [CNF]

Value 0 1 +2 Function Distance maintaining without regulation ramp full speed until stop distance Distance maintaining with regulation ramp reducing speed until stop distance higher speed to close gaps (when the Only with function 1 function is enabled in system table and and synchronous the gap is smaller than Parameter drive trolley length) Given distance is drive distance (normally it is the stopping distance) Regulation with hysteresis Not used Not used Compensation for driven distance Only active with since the last distance value. asynchronous drive No distance maintaining

+4 +8 +16 +32 +64 128

3.3.16 Stopping distance [ABA]

It sets the distance between two trolleys. The distance should be dimensioned such that there are no contacts.

Trolley 1

Stopping distance

Trolley 2

3.3.17 Ramp distance regulation [ACA]

For keeping the stopping distance the control box uses a calculation, which works similar to the positioning routine. 32 BV89073_02_en.doc

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Parameter

The deceleration way is calculated by actual speed and ramp. This way is added to the stopping distance.

3.3.18 Trolley length [FzL]

To ensure correct operation, it is necessary to determine this parameter very precisely. Along with the stopping distance parameter (ABA), it significantly influences the calculation of free path and distance maintenance.

3.3.19 Frequency for releasing or applying brakes [BOx/BCx]

If a trolley must begin drive on upward slopes, then it makes sense to apply current to the motor a bit before releasing the brake. This parameter sets the frequency to drive the motor, to enable the release of the brake. The reverse case is the frequency at which to pre-apply the brake, meaning if the frequency falls below the set value, then the brake is applied. Thus it is also possible to stop at an exact point even on upward slopes.

3.3.20 Standstill tolerance [FST]

The parameter specifies the maximum movement of a trolley without a drive command. If the movement exceeds the value of this parameter an error is given.

3.3.21 Time delay to speed control error [TSM]

The parameter specifies the time delay for drive speed error.

3.3.22 Timeout conveying [T8]

If a convey command is pending for longer than this period of time, the error message conveyor running time will be generated. The running time will not be monitored, if the software switch SW3 is set [-].

3.3.23 Minimum runtime [T11]

The parameter specifies the minimum time the conveyor should have run before the empty status can be set.

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Parameter

3.3.24 Time to conveyer slow [T12]

This parameter specifies a time delay for changing from fast to slow speed. The time starts if the palette reaches the stop light barrier of the opposite site to the actual conveying direction.

3.3.25 Delay stop loading [T13]

This parameter specifies how long the conveyor motors must continue to run if the pallet has reached the stop light barrier.

3.3.26 Waiting time conveyor empty [T14]

This parameter specifies how long the conditions for an empty conveyer must be given before the control box is sending the status empty.

3.3.27 Waiting time after releasing stop button [T5]

If the stop switch is activated and released again, then the trolley is once again set in motion after this time expiries.

3.3.28 Sequence stop button configuration [CNF]

Value Functionality 0 Not present 1 Stop without error message to master 2 Stop with error message to master 3 Switched stop without error message to master 4 Switched stop with error message to master +128 Activation of stop button initialized the conveyer The sequence stop also resets all errors.

3.3.29 Signal lamp configuration [CNF]

Set value 0 1 Functionality Normally off, flashing on error, on during sequence stop Normally on, flashing on error, slowly flashing during sequence stop

3.3.30 Configuration of vacuum cleaner [CCl]

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Parameter

Depending on the requirement, the vacuum cleaner can be configured in its function. Value 0 1 2 +64 +128 Function No vacuum cleaner Activation during motor running and overrun time T15 Activation during motor running During the servo control, the vacuum cleaner remains off * During the manual mode, the vacuum cleaner remains off

*Not used in this project

3.3.31 Runtime cleaner after stop of trolley [T15]

In some modes the cleaner has to run longer than the drive motor.

3.3.32 Rated voltage [CUN]

Value 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Mains voltage 480V 460V 440V 420V 400V 380V 360V 340V 320V 300V 280V 260V 240V 220V 60V 40V

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Parameter

3.3.33 Intermediate circuit frequency [CZF]

Value 3 4 5 6 7 8 9 10 11 12 13 14 15 Intermediate circuit frequency 4kHz 5kHz 6kHz 7kHz 8kHz 9kHz 10kHz 11kHz 12kHz 13kHz 14kHz 15kHz 16kHz

3.3.34 Release number [PAR]

Before you can work with the controller, you must set the parameters according to the operating conditions of your installation. To make the controller ready for operation, set the Key parameter to the value: 8231.

3.3.35 Offset [Off]

If higher trolley numbers are required than the number that can be set with the FAB (max. 255), then an offset can be set with this parameter. This is added to the number set by the FAB to give the resulting trolley number. This parameter is only valid when FAB is used! (FAB selected see following section)

3.3.36 Configuration test outputs

Only for testing do not set this parameter for normal operation!
Bit 07 sets the outputs 07 of the ini6012-1 Bit 813 sets the outputs of the ini6012-0 Bit 14,15 sets the outputs of the ini6030 X7_5 & X10_5 Value Meaning 0 The outputs are set by software 36 BV89073_02_en.doc

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Parameter

1 2 4 8 16 32 64 128 256 512 1024 2048 4096 8192 16384 32768

Inverter release Relay Q1 +(drive motor) Relay Q2 +(conveyor 1 motor) Enable PKR Enable SICK

X7_5 Error lamp X10_5 Vacuum cleaner

3.3.37 Configuration remote control [CNF]

The function of the remote control can be parameterized in a range of possibilities. Value 0 1 2 64 128 Meaning No special function Drive forward with V14 and positioning Drive forward with V15 and positioning Change direction of conveyer 1) Change direction of drive 1)

Combination of the values is possible.

1) Only in Hand mode

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Configuration

4 Configuration
4.1 General
The Configuration helps in selecting or deselecting particular functions in the controller software. There are up to 16 Configuration switches supported [SW116]. They will be transmitted to the controller along with the parameters.

4.2 Configuration overview

Bit 2^15 2^14 Name Motor temperature Auto IxR Meaning [+] Motor temperature monitoring selected [-] Motor temperature monitoring deselected [+] IxR compensation automatic measurement selected [-] IxR compensation automatic measurement deselected [-] [+] [+] [-] Error-code display selected Error-code display deselected Unconditional manual mode Conditional manual mode

2^13 2^12 2^11

2^10 2^9 2^8 2^7

SW 14 No error display Unconditional manual mode Error if autom. backw. Plausibility monitored Error -62

2^6 2^5 2^4

2^3

[+] Error message on backward drive (Automatic) [-] No error message on backward drive (Automatic) [+] PLC Plausibility enabled [-] PLC Plausibility disabled [+] Error -62 is monitored [-] Error -62 is not monitored Nonequiva- [+] enabled lence bypass [-] disabled safety circuit SW 7 SW 6 Invert Con- [+] Invert conveyer motor direction veyer motor [-] Normal conveyer motor direction direction FAB [+] FAB available [-] FAB not available; trolley number must be set via MU BV89073_02_en.doc

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Configuration

2^2 2^1 2^0

Overrun stop pos SW2

[+] Stop position overrun monitored [-] Stop position overrun is not monitored [+] Conveyor Empty flag delayed

Profile moni- [+] Profile is monitored tored [-] Profile is not monitored 1 Not used in this project

4.3 Description
4.3.1 Motor temperature
If activated the temperature of the connected motor is monitored. If the temperature is too high (or the motor is not properly connected) a error is generated.

4.3.2 IxR compensation measurement by the controller

4.3.2.1
-

Preconditions
The appropriate parameter for the motors rated current (GRx) must be set to the rated current (can be read from the motors type plate). To take the measurement, activate the corresponding display mode of IxR compensation of the respective motor. Preset the appropriate parameter Mx for motor IxR compensation to a value that approximately corresponds to the required IxR compensation. Recommended starting value: 10%

4.3.2.2

Operation:

Before the drive begins, the inverter generates a voltage corresponding to 2/3 of the set IxR compensation with a frequency of 0 Hz. This voltage value is then increased (by internally increasing the configured IxR compensation) until the motor current reaches the parameter setting for the rated motor current. Using the IxR compensation attained at that moment, the motor begins drive in accordance with the given drive command. If the voltage increases such that it equals 200 % of the set IxR compensation and the motor current has not reached the rated motor current, then the inverter outputs the error Inverter over current.

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Configuration

As long as the corresponding software switch remains selected, this measurement is repeated for each new drive command before the motion begins.

4.3.2.3

Follow-up action:

After successfully measuring the IxR compensation, the displayed value must be entered as the new parameter Mx for the IxR compensation using the MU.

4.3.3 No error display

As per standard, the error messages superimpose over the normal displays. To make a diagnosis with the help of displays in the event of error, the error displays can be deactivated with the help of the software switch. This does not deactivate the error evaluation! After completion of the work, the error messages should necessarily be reactivated.

4.3.4 Unconditional manual mode

In absolute manual operation, all software limit switches and most of the error evaluations are deactivated and it is possible to move a trolley despite error messages. All hardware limit switches (emergency end positions) continue to be active.

4.3.5 Plausibility monitored

With this switch, the plausibility analysis of the PLC command can be activated or deactivated.

4.3.6 Error -62

This switch activates the monitoring of error -62.

4.3.7 Invert Conveyer motor direction

If selected the transport direction for unload/ upload is inverted.

4.3.8 Monitoring speed

This switch activates the monitoring of drive speed. 40 BV89073_02_en.doc

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Configuration

4.3.9 FAB
If this option is activated, then the controller accepts the number set in FAB as its current trolley number. If the option is active and no FAB is connected, then a communication error is displayed. If this option is deactivated, the communication is not monitored and the trolley number must be set with the MU.

4.3.10 Overrun stop position

This setting activates or deactivates the error -33.

4.3.11 Profile is monitored

If the switch is activated, the conveyor profile is monitored based on the load state and the load state is displayed in the controllers display.

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Tables

5 Tables
The tables in the MU correspond to the system table in the following manner: Set MU = system-table index + 1

5.1 Speed table

A correct speed table is absolutely necessary for trouble-free operation of the trolleys! Set 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Index 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Value: Valid for:

Automatic Fast Speed Driving

Min speed Service mode slow Service mode fast Manual mode with remote control slow Manual mode with remote control fast

All Speeds must be calculate in cm/min

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Tables

5.2 Clearance table

Set 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 Index 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Value: Valid for: Default

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Display

6 Display
6.1 General
Using the various display modes, a very accurate diagnosis of the controller state can be carried out. The display consists of a four-digit display in the controller. If it is necessary to carry out a diagnosis for a pending error, then the error display must be deselected (see Configuration), since it permanently overwrites the normal display.

6.2 Display modes

0: Frequency in Hz with preceding sign 1: Motor current in 100 mA unit W 4: Chip temperature [C] 5: Intermediate circuit voltage in volts 6: Motor temperature unscaled 7: Inverter power rate 8: Display of inverter control commands Display Meaning 0001 Selection of parameter set 0002 Selection of parameter set 0004 Selection of parameter set 0008 Monitor It 0010 Monitor Overcurrent 0020 Monitor intermediate circuit voltage 0040 Compensate intermediate circuit voltage 0080 No clipping 0100 Neg. half-wave report 0200 Pos. half-wave report 0400 Release brake 0800 Servo drive 1000 Hand-held mode (restricted error evaluation) 2000 Initialize servo trip 4000 Activation command 8000 Release inverter 9: Inverter speed presetting 10: Display IxR compensation

[1/10 %]

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Display

11: Display inverter status Display Meaning 01 Phase failure 02 Inverter drive release 04 Hardware lock released 08 Load contactor switched on / intermediate circuit loaded 10 Inverter running 20 Parameters OK 40 Inverter warning 80 Inverter error pending 12- 18 Diagnosis repair (LJU - internal) 17: Servo trip 18: Servo modulation (amplitude) 19: Current drive speed 20: Frequency in Hz with preceding sign 21: Motor current in 100 mA unit W 24: Chip temperature [C] 25: Intermediate circuit voltage in volts 26: Motor temperature unscaled 27: Inverter power rate 28: Display of inverter control commands Display Meaning 0001 Selection of parameter set 0002 Selection of parameter set 0004 Selection of parameter set 0008 Monitor It 0010 Monitor Overcurrent 0020 Monitor intermediate circuit voltage 0040 Compensate intermediate circuit voltage 0080 No clipping 0100 Neg. half-wave report 0200 Pos. half-wave report 0400 Release brake 0800 Servo drive 1000 Hand-held mode (restricted error evaluation) 2000 Initialize servo trip 4000 Activation command 8000 Release inverter 29: Inverter speed presetting 30: Display IxR compensation

[1/10 %]

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Display

31: Display inverter status Display Meaning 01 Phase failure 02 Inverter drive release 04 Hardware lock released 08 Load contactor switched on / intermediate circuit loaded 10 Inverter running 20 Parameters OK 40 Inverter warning 80 Inverter error pending 32-34, 36 Diagnosis repair (LJU - internal) 38: Input ports, initiator board 1 (6030) Display Terminal Meaning 0001 X5/ 4 0002 X6/ 2 0004 X6/ 4 0008 X9/ 4 0010 X7/ 2 0020 X7/ 4 0040 Initiator board fuse 0080 Monitor output ports for short circuit 0100 X8/ 2 0200 X8/ 4 Sequence stop button 0400 X8/ 5 0800 X10/ 4 39: Output ports, initiator board 1 (6030) Display Terminal Meaning 01 X7/ 5 Signal lamp sequence stop 04 X10/ 5 Cleaner

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Display

40: Input ports, initiator board 1 (6012) Display Terminal Meaning 0001 X15/ 10 Reserve 0002 0004 0008 0010 0020 0040 Initiator board fuse 0080 Monitor output ports for short circuit 0100 (Q1_E1) Monitoring Q1 (option)1) 0200 (Q1_E2) Monitoring Q2 (option)1) 0400 X15/ 8 Reserve 0800 X15/ 9 Reserve
1) Function not used in this project

41: Output ports, initiator board 1 (6012) Meaning Display Terminal 01 02 04 08 42: Input ports, initiator board 2 (6012) Meaning Display Terminal 0001 X15/ 7 Light barrier 5 conveyor 2 speed 0002 X15/ 8 Light barrier 6 gap control conveyor 2 0004 Q1 /42 (SICK NO) 0008 Q2 / M1 (PKR) 0010 X16/ 5 Status Safety Switch inactive (NC) 0020 X16/ 6 Status Safety Switch active (NO) 0040 Initiator board fuse 0080 Monitor output ports for short circuit 0100 X15/ 3 Light barrier 1 gap control conveyor 1 0200 X15/ 4 Light barrier 2 conveyor 1 speed 0400 X15/ 5 Light barrier 3 conveyor 1 stop 0800 X15/ 6 Light barrier 4 conveyor 2 stop

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Display

43: Output ports, initiator board 1 (6012) Display Terminal Meaning 01 Inverter 1 release (SICK) 02 Relay Q1 +(drive motor) 04 Relay Q2 +(conveyor 1 motor) 10 K1_A1 (SICK) 20 K2_A2 (PWR) 44: Inputs of brake Display Terminal 01 B1 02 B2 04 B3 08 B4 voltage monitoring (B-1) Meaning Brake activation inverter 1 (drive / conveyor 1 motor) Brake activation Q1 (drive motor) Brake activation Q2 (conveyor 1 motor) Brake activation inverter 2 (conveyor 2 motor)

46: OLM status Display Meaning 0002 Temperature 0008 No barcode 0010 Error distance to code strip 0020 Soiled OLM 0080 OLM overflow 47: OLM dirty status 48: OLM position (unfiltered position sent directly from the OLM) 49: Trolley number (sent by Prodat) 50: Infrared command (manual remote control) 51: Drive commands Display Meaning 2 Hand mode slow forward 3 Hand mode slow backward 4 Hand mode fast forward 5 Hand mode fast backward 6 Setup mode forward 7 Setup mode reverse 10 Automatic forward or reverse 52: Drive flags

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Display

Display 01 02 04 08 10 53 & 54 Display 2 3 4 5 6 7 10 11

1)

Meaning Drive release (MS_Lauf) Direction flag (MS_Dir) Positioning

: Conveyor commands 1) Meaning Hand mode slow loading Hand mode slow unloading Hand mode fast loading Hand mode fast unloading Service mode loading Service mode unloading Automatic loading Automatic unloading

Direction for loading unloading depends on Config_SW5

55: Conveyor flags (Hex) Display Meaning 01 Conveyor1 running 02 Conveyor1 direction 10 Conveyor2 running 20 Conveyor2 direction

56: Data concentrator number 57: Trolley number (controller)

58: Conveyor load status Display Meaning 01 Conveyor 1 free 02 Conveyor 1 occupied 04 Conveyor 1 loading 10 Conveyor 2 free 20 Conveyor 2 occupied 40 Conveyor 2 loading

60: 62: 64: 65:

Absolute trolley position in the installation (x_pos_ist) Free path in direction of drive (x_freier_weg) Next target for trolley positioning using system table (x_atab_ziel) Trolley target position (x_ziel_pos) BV89073_02_en.doc 49

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Display

66: Difference from trolley target position (anz_pos_diff) 67: Last absolute trolley position (used when the controller is switched on again) 70: Position point of the Routing table 71: Configuration for the actual position point 72: Next positioning point in the Routing table 73: Configuration for the next positioning point in the Routing table 74: Actual value routing pointer. 75: Incrementally counted trolley position (pos_speed) 76: Number of data sets used in the routing table 77: Number of targets 78: Index of the routing table 80: Target position 90: Number of possible sets in the current system table 91: Current value of the system table pointer (processed entry in the system table) 92: Next positioning point in the system table 93: First position of the current segment (absolute) 94: Last position of the current segment (absolute) 95: First position of the Next 1 segment in the system table 96: Last position of the Next 1 segment in the system table 97: First position of the Next 2 segment in the system table 98: Last position of the Next 2 segment in the system table 99: First position of the Prev 1 segment in the system table 100: Last position of the Prev 1 segment in the system table 101: First position of the Prev 2 segment in the system table 102: Last position of the Prev 2 segment in the system table 103: Number of the Next 1 segment in the system table 104: Number of the Next 2 segment in the system table 105: Number of the Prev 1 segment in the system table 106: Number of the Prev 2 segment in the system table 110: Current position point

115: Status report A Display Meaning 01 Vehicle requests table comparison 02 Vehicle in position 04 Speed Conveyor 1 (Slow / Fast) 08 Message see below 10 20 Error has occurred 40 80 New destination

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Display

10 1 1 0 0

08 1 0 1 0

Remark Conveyer Conveyer Conveyer Conveyer

1 1 1 1

motor is running is occupied empty undefined

116: Signal flags (Rotating Box) Display Meaning 01 General error 02 Drive motor is running 04 State of bypass switch 08 Stop due 5th rail 10 Stop due stop button 20 Stop due to anti-collision initiator 40 Stop due to distance maintenance 80 Manual operation (IR- remote operation) 117: Actual Cycle-index DKT-> Trolley 118: Actual Cycle-index Trolley _ DKZ 119: Cycle time of the rail-bus connection Regarding the following points, see also the rail-bus system specifications! 120: current control commands A & B (display: BB AA see following points)

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121: Control command A Display Meaning 01 Speed select 02 Speed select 04 Bypass positioning 08 Error Reset 10 Conveyor release 20 Drive release 40 80 Automatic release 122: Control command B Display Meaning 01 Forward drive 02 Drive reverse 04 Conveyer 1 load 08 Conveyer 1 unload 10 Conveyer 2 load 20 Conveyer 2 unload 40 Fast speed 80 127: Last received control command A (used for drive without communication) 128: Last received control command B (used for drive without communication) 129: Last calculated free route (used for drive without communication)

6.3 Other displays

Dot Dot Dot Dot Dot in in in in in the the the the the 1st position from the left: 1st (flashing) : 2nd position from the left: 3rd position from the left: 4th position from the left: No free path in direction of drive Vehicle in position IR communication OLM position OK Tables loaded Hx (manual mode)
1)

Left two positions in display flashing: Left two positions o on the 1st position from the left: _ on the 1st position from the left: U on the 1st position from the left: 52

Conveyor 1 occupied Conveyor 1 empty Conveyor 1 unknown occupancy

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Display

o on the 2st position from the left: _ on the 2st position from the left: U on the 2st position from the left:

Conveyor 2 occupied Conveyor 2 empty Conveyor 2 unknown occupancy

Caution! The load status is only shown if profile monitoring is activated (see configuration section).

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FB-606 remote control

7 FB-606 remote control

7.1 General
On pressing a button, the red LED must flash quickly. If not, the remote control is working with an incorrect infrared protocol. To switch to remote control mode, the buttons must be pressed simultaneously until the LED flashes quickly. If the LED glows steadily, then the battery is empty.

7.2 Button functions (Standard IR Konfiguration)

The remote control supports three operating modes H1, H2 and H3. Switching throw the Modes can be done by pressing the key again after entering the hand held mode. Button # Functionality Select Hand-held mode Normal mode Convey to right slow 1) Convey to left slow 1) Convey to right fast 1) Convey to left fast 1) Forward drive slow Reverse drive slow Forward drive fast Reverse drive fast

1)

Accessed conveyor depends on Hand held mode

The three modes differs only which conveyor is accessed by pressing convey commands. In mode H1 conveyer 1 is under control of the remote control. In mode H2 conveyer 2 is under control of the remote control. In mode H3 both conveyers 1 & 2 executes the requested convey commands. If all buttons on the remote control are released, the last remote control command continues to be processed in the controller for 800 ms. If you want the controller to stop immediately, you have to press the star button.

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MU705

8 MU705
The software in the MU 705 is organized into menus. A menu item is selected by pressing the corresponding number or by the arrow keys and Enter. You can switch to the next higher menu with the Esc key. The MU can be switched off by a long press of Esc key. The most important menu commands and paths are as follows: Main menu 1. Parameters 1.1. Write data: To transmit the parameters, the controller and the MU must be set to the same parameter set. 1.2. Read data: Before reading the parameters, it is checked if the parameter set matches. 1.3. Change data: Use the keys to switch between the various parameters. 1.3.1. Data: The values for the parameters can be entered here. 1.3.2. Configuration: Different functions can be selected and deselected here. 1.3.3. Type: If it is an MU for multiple controller types, these can be selected here. 1.4. Verify data: Here, the parameters are read out of the controller and compared with the data in the MU. The checksum is calculated and displayed together with the checksum of the parameters in the MU. This function serves to check whether the parameters in the MU and those in the controller are identical. If they arent equal you can search for the values of the different parameters by pressing F1 ( view). 2. Test 2.1. PCM signal: 1 2.2. Remote control: The MU must be pointed directly at the controller to perform all the operations described here. (Distance approx. 30 cm) - The display shows which keys are used for the functions of the remote control. Refer to chapter: FU706 Function of the keys. - Only one key can be pressed at the time. Key combinations are realized by saving . (When the display shows a Mark at , the MU uses the combined remote commands) 2.3. IR test: The MU shows the received Signal from another LJU IR device that is in range. 2.4. BIOS Exceptions: Only LJU internal! 2.5. Error log: The LJU Box saves a log of the last 29 faults. 2.6. Memory: Only LJU internal!

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MU705

3. Destination/number: 3.1. Tag: A destination can be read or written here. 3.2. Number: The trolley number can be read or written here. Warning! If the FAB is activated (see Configuration), the number of the FAB is used! 3.3. Display: The display mode can be read or written here. 3.4. WNR/Ser-No: The plant number and the serial number of the controller can be written here. Warning! Only LJU-internal! 3.5. HW Configuration: Only LJU internal! With the following functions it is possible to read, to modify and again write into the various tables of the trolley. You can switch between the table records using the keys. 4. Tables: All tables can be read from and written to the LJU Box. they can be checked and modified in the MU. 4.1. Some tables are defined in this menu. 4.2. Some tables are summarized in Table groups. By selecting the Table group you are accessing the next menu level. 4.3. All tables: Here al tables can be read, written or the checksums compared together. 5. MU Config: 5.1 Language 5.2 Switch off time 5.3 Polling delay 5.4 Display illumination 6. Information 6.1. BIOS info: Provides information about the plant number and serial number of the controller and the transmission time of BIOS 6.2. USER Info: Provides information about the version number, and the transmission time of user software 6.3. MU Info: Provides information about the version number, and the transmission time of MU software 7. Program 7.1. Program manager: The firmware can be stored and downloaded to the LJU Box by the MU 7.2. Password: The download is restricted to instructed persons. 7.3. Memory: Only LJU internal! More information on the MU-705 or the FB-606 has to be taken from the corresponding device operating instructions!

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Display of Input Signals or Control Flags

9 Display of Input Signals or Control Flags

An input or flag can have one of two states: 0 or 1. This corresponds to one digit in the binary number system. Computer technology works with bits and bytes. One bit corresponds to one binary digit. Eight bits are combined to one byte. Therefore, one byte corresponds to an eight-digit binary number: e.g. 10010111b. Conversion to a decimal number is carried out bit-by-bit using the formula: D = B x 2n. n indicates the position in the binary number. The 0 (zero) position is on the right, then we count up moving to the left. The sum of all values equals the decimal number. 1 0 0 1 0 1 1 1 | | | | | | | 20-1x1 | | | | | | 21-- -----1x2 2 | | | | | 2 -- ------ -----1x4 3 0x8 | | | | 2 -- ------ ------ -----4 | | | 2 -- ------ ------ ------ -----1 x 16 | | 25-- ------ ------ ------ ------ -----0 x 32 6 | 2 -- ------ ------ ------ ------ ------ -----0 x 64 7 2 -- ------ ------ ------ ------ ------ ------ -----1 x 128 = 151d In the hexadecimal number system, a digit can have any one of 16 values (0 .. 9 + A.F). These represent all possible combinations of four bits. A byte can therefore be represented by two hexadecimal digits. The weight or significance of the bits is as follows: Bit Bit Bit Bit 0: 01 1: 02 2: 04 3: 08 Bit Bit Bit Bit 4: 10 5: 20 6: 40 7: 80

As long as only one of these bits is active, the displayed number can be allocated directly to the input / flag belonging to it. If multiple bits are active, their weights or significance are added together. For reasons of simplicity only the lower four bits / right hex digit are shown in the following examples. Display: 9 Display: 7 = 1 + 8 => bit 0 and bit 3 are active = 1 + 2 + 4 => bit 0, bit 1 and bit 2 are active

The letters A..F stand for the numbers 10 .. 15: Display: A (10) = 2 + 8 Display: d (13) = 1 + 4 + 8 Display: F (15) = 1 + 2 + 4 + 8

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The advantage of this logic is that it is closely related to the way processors operate. In this way, a substantial amount of information can be represented with very little expenditure.

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