Coretec BS Series User manual

BS Controller for AC SERVO PRESS
Instruction Manual Ver1.08
BS-M3A-1B
- 1 -
BS Controller for AC SERVO PRESS Instruction Manual
Introduction
Thank you very much for purchasing our Servo press.
This manual describes the hardware scheme, installation procedures, connections,
running, operations, communication, status display and daily inspections.
Make sure to thoroughly understand the contents and use the product properly.
Request
We have taken all possible measures to ensure the contents of this instruction
manual, however, please contact us if you have any questions or find any errors.
The product names, etc. are generally registered trademarks of various companies.
* To secure safety and quality, never fail to refer to this manual.

BS Controller for AC SERVO PRESS
Instruction Manual Ver1.08
BS-M3A-1B
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Table of contents
1.
For safe use................................................................................................................. 7
1.1. Regarding symbols .................................................................................................. 7
1.2. Observe the following for safety............................................................................. 7
1.3. Caution on attachment and use. .......................................................................... 8
1.4. Make sure to observe for sequencer circuit ........................................................... 9
1.5. EMC directive .......................................................................................................... 9
1.6. Others....................................................................................................................... 9
1.7. The relation with the Mitsubishi Electric servo system..................................... 10
2.
Before use ..................................................................................................................11
2.1. Characteristics of Servo press ...............................................................................11
2.1.1. Possible to record program execution result .................................................11
2.1.2. Programmable action possible .......................................................................11
2.1.3. Display of load and stroke during program execution and Graph display.11
2.2. The suiting tool.......................................................................................................11
2.3. Accompanying items ..............................................................................................11
2.4. About the model name and the version ............................................................... 12
2.4.1. Anybus option................................................................................................. 12
3.
Specifications.............................................................................................................13
3.1. Specifications of BS-M3A-1B................................................................................ 13
3.2. Specifications fo brake .......................................................................................... 13
3.3. Common specification of MR-J3A ........................................................................ 14
3.4. Specification peculiar to the tool type.................................................................. 14
3.4.1. BS100 series ................................................................................................... 14
3.4.2. BS200 series ................................................................................................... 15
4.
Construction ..............................................................................................................16
4.1. Name of each part of the controller...................................................................... 16
4.2. Outline.................................................................................................................... 17
4.3. Connection figure (include options) ..................................................................... 18
5.
Installation ................................................................................................................18
5.1. Procedures for installing to control panel............................................................ 20
5.1.1. Designing conditions for control box............................................................. 20
5.1.2. Cautions when installing BS......................................................................... 20

BS Controller for AC SERVO PRESS
Instruction Manual Ver1.08
BS-M3A-1B
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5.1.3. The interval with MR-J3A............................................................................. 20
5.1.4. Noise Filter of MR-J3A .................................................................................. 20
6.
Installing lines...........................................................................................................21
6.1. Load cell i/f(CN31)................................................................................................. 21
6.2. Origin sensor i/f(CN32) ......................................................................................... 21
6.3. MR-J3A parallel i/f(CN33) .................................................................................... 21
6.4. Emergency stop(CN34) ......................................................................................... 21
6.5. RS-232C(CN4) ....................................................................................................... 22
6.6. RS-232C(CN5) ....................................................................................................... 22
6.7. RS-485(CN6,7) ....................................................................................................... 22
6.8. Ethernet(CN8) ....................................................................................................... 23
6.9. Parallel I/O (CN9).................................................................................................. 23
6.9.1. Bit assignment ............................................................................................... 24
6.9.2. PIO connector pin assignment ...................................................................... 27
6.9.3. Wiring by the side of input ............................................................................ 27
6.9.4. Wiring by the side of output.......................................................................... 28
6.10. Control power supply (CN10) ........................................................................... 28
6.11. Backup battery（CN11）...................................................................................... 28
6.12. Anybus.................................................................................................................... 28
6.13. Brake ...................................................................................................................... 29
6.14. Motor cable............................................................................................................. 30
6.15. Encoder Cable........................................................................................................ 30
7.
Timing Chart.............................................................................................................31
7.1. Power supply injection .......................................................................................... 31
7.2. Alarm reset ............................................................................................................ 31
7.3. Origin ..................................................................................................................... 31
7.4. JOG......................................................................................................................... 32
7.5. Program execution................................................................................................. 32
7.6. Program execution using Post Judge................................................................... 33
7.7. Writing of a product name and a serial number ................................................. 34
7.8. Post Judge.............................................................................................................. 35
8.
Concept of stroke .......................................................................................................36
8.1. Semi closed loop..................................................................................................... 36
8.2. Direction................................................................................................................. 36

BS Controller for AC SERVO PRESS
Instruction Manual Ver1.08
BS-M3A-1B
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8.3. System home position ........................................................................................... 36
8.4. User home position................................................................................................ 36
8.5. System stroke limit ............................................................................................... 36
8.6. User stroke limit.................................................................................................... 36
8.7. If the stroke limit is exceeded............................................................................... 37
8.8. A motion of the ram at the time of servo off........................................................ 37
9.
Connection with Personal Computer ........................................................................38
9.1. Spindle number setup ........................................................................................... 38
9.2. IP address setup of BS controller......................................................................... 38
9.3. IP address setup of a personal computer............................................................. 38
9.4. LAN cable............................................................................................................... 39
9.5. Communicative check ........................................................................................... 39
9.5.1. Setup of operational authoority .................................................................... 39
9.5.2. Setup of receive filter..................................................................................... 40
9.5.3. Collection setup.............................................................................................. 40
9.5.4. Check of status ............................................................................................... 40
9.6. Starting of two Configurators............................................................................... 41
9.7. Use of two or more network interface cards........................................................ 42
9.8. Arbitrary IP address setup ................................................................................... 42
9.8.1. Notes ............................................................................................................... 42
9.8.2. The communication method with an IP address unknown controller ....... 43
10.
Starting ..................................................................................................................44
10.1. Starting procedure of BS controller ..................................................................... 44
10.1.1. Attachment to equipment.............................................................................. 44
10.1.2. Wiring.............................................................................................................. 44
10.1.3. Control power supply injection ..................................................................... 44
10.1.4. Attachment of a backup battery ................................................................... 44
10.1.5. Parameter setup of MR-J3A.......................................................................... 44
10.1.6. Parameter setup of BS................................................................................... 44
10.1.7. Re-starting of a power supply ....................................................................... 44
10.1.8. Check of a brake............................................................................................. 44
10.1.9. Check of an emergency stop .......................................................................... 44
10.1.10. Origin .......................................................................................................... 44
10.1.11. Build a program.......................................................................................... 44
10.1.12. Execution of a program .............................................................................. 45

BS Controller for AC SERVO PRESS
Instruction Manual Ver1.08
BS-M3A-1B
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10.2. Parameter setup of MR-J3A ................................................................................. 45
10.3. Parameter setup of BS controller......................................................................... 49
10.4. Re-injection of a control power supply................................................................. 50
10.5. Check of the brake................................................................................................. 50
10.6. Check of emergency stop....................................................................................... 51
10.7. Origin ..................................................................................................................... 51
10.8. Program creation................................................................................................... 51
10.9. Execution of a program ......................................................................................... 52
11.
Troubleshooting .....................................................................................................53
11.1. The state display by LED ..................................................................................... 53
11.2. Alarm code table.................................................................................................... 54
12.
Regeneration..........................................................................................................61
12.1. Lowering regeneration frequency ........................................................................ 61
12.2. Regeneration option .............................................................................................. 61
13.
Absolute encoder system........................................................................................62
13.1. Setup....................................................................................................................... 62
13.1.1. Setup to BS controller.................................................................................... 62
13.1.2. Setup to MR-J3A ............................................................................................ 62
13.1.3. Wearing of a backup battery ......................................................................... 62
13.2. The alarm release method .................................................................................... 62
14.
Load-Sensor-less System .......................................................................................63
15.
Tool Type Discernment ..........................................................................................64
16.
Stole .......................................................................................................................65
17.
Others ....................................................................................................................66
17.1. The options of the servo press .............................................................................. 66
18.
Article of Consumption ..........................................................................................67
18.1. Battery ................................................................................................................... 67
18.1.1. The detection method..................................................................................... 67
18.1.2. The exchange method .................................................................................... 67
18.1.3. Management................................................................................................... 67
18.1.4. Clock setup ..................................................................................................... 67

BS Controller for AC SERVO PRESS
Instruction Manual Ver1.08
BS-M3A-1B
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18.2. Parts having service lives of MR-J3A .................................................................. 67
19.
Maintenance of Tool ...............................................................................................68
20.
Cautions on abandonment.....................................................................................68

BS Controller for AC SERVO PRESS
Instruction Manual Ver1.08
BS-M3A-1B
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1.
For safe use
1.1.
Regarding symbols
Symbols are used to provide warnings in this instruction manual and for indication for
proper product use and to prevent danger to the user or other people and damage to
property from occurring. Understand the indication meanings before reading this
manual.
1.2.
Observe the following for safety
This symbol assumes the possibility that accidental
death or serious injury may occur immediately to the
user, if the symbol is neglected and the product is
incorrectly handled.
The power source is as high as 200V. Look out for electric shock.
This symbol assumes that there is a potential for
personal death or injury if this expression is ignored
and this product is mishandled.
In a case where the product is used in an application in which an accident resulting in
death or injury or a serious expansion of damage is predictable, take safety measures such
as installing a fail-safe device.
Do not use around combustible gas. If disregarded, it may lead to an explosion.
In a case of handling cables and connectors, etc., cut off the power temporarily without fail.
If disregarded, it may lead to an electric shock.
Do not remove the cover, disassemble, repair or modify the product. If disregarded, it may
lead to an electric shock.
Make sure to connect the protection conductor terminal to ground.
Electric shock might be caused.
Do not touch the power supply terminal in this equipment within five seconds after the
power is turned off. It could cause the electric shock.
Do not forcibly twist, pull or scratch the power cord or cord of the AC plug.
DANGER
WARNING

BS Controller for AC SERVO PRESS
Instruction Manual Ver1.08
BS-M3A-1B
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This symbol assumes that there is a potential for
personal death or injury if this expression is ignored
and this product is mishandled.
Please use this product under the environment of overvoltage category II specified in IEC
60664-1.
Please use this product under the environment of Pollution Degree II specified in IEC
60664-1.
For the operation, stop, and emergency stop shall be done in the final machinery into which
this equipment is incorporated.
This product will surely be in a servo off state, when it is in an alarm state.
However,
battery alarm is excepted.
Set up the emergency stop and interlock circuit with the external circuit.
This allows to prevent expansion of damage.
Use the input voltage, frequency and output voltage, and current within the standard. If
disregarded, it may lead to an accident or electric shock.
Do not use the product at over the specified ambient temperature. If disregarded, it may
lead to fire or electric shock.
Use in an environment without condensation due to water or moisture. If disregarded, it
may lead to an electric shock.
When output cannot be obtained, or any other abnormality is found during operation, stop
use immediately. It may lead to electric shock. Contact the distributor where you purchased
the product or our company’s sales office without fail.
1.3.
Caution on attachment and use.
This symbol assumes that there is a potential for
personal death or injury if this expression is ignored
and this product is mishandled.
Installation, connection, driving and operation, check and failure diagnosis shall be done by
a qualified technician.
Do not move, install, connect and check this equipment while the power is on. Please make
sure the power is turned off for conducting these works.
For installation requirements of this equipment, protection against electric shock is class
Ⅰ，and equipment mobility is a stationery equipment for indoor installation. Please make
sure this equipment is grounded when installed. (PE should be marked at the protective
earthing terminal.)
This equipment shall be stored in a dustproof and drip-proof controlled box. (IP54 class) If
the performance of dustproof and drip-
proof is not strong enough, dielectric strength shall
be decreased, and the potential of dielectric breakdown shall be increased.
The cross-sectional area of the protective bonding conductor shall be the same size as the
input power wire for this equipment.
Do not tighten the Servo press control cable excessively with binding band. Malfunction
might be caused.
The electric shock protection from the power supply terminal block of this equipment to
final machinery shall be provided in the final machinery.
For 24 VDC power supply, use SELV power supply which comply with IEC standard.
A breaker that comply with IEC Standard shall be installed in the final machinery into
which this equipment is incorporated,for the short-circuit protection of this equipment.
The methods of the ground fault protection of this equipment are as follows:
a) For the TT grounded system: Use an earth leakage breaker (Type A or B shall be used)
b) For the TN grounded system: Use an over current breaker generally. (The fault loop
CAUTION
WARNING

BS Controller for AC SERVO PRESS
Instruction Manual Ver1.08
BS-M3A-1B
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impedance in the final equipment shall satisfy the overcurrent characteristics of the
breaker so that the breaker shall be interrupted within 0.4s or less when earth fault is
occurred.)
This symbol assumes that there is a potential for
personal death or injury if this expression is ignored
and this product is mishandled.
When attaching the CPS body, allow a space of 25 mm or more for the right and left
directions and 80 mm or more for up and down directions for cooling.
Do not apply more load on the Servo press tool than allowed.
The life might be considerably shortened.
For connection to the protective earthing terminal, one wire should
be provided for each
terminal.
The insulation’s color of the protective earthing conductor shall be green-and-yellow.
Design the sequencer circuit under consideration of safety measure such as emergency stop.
1.4.
Make sure to observe for sequencer circuit
Safety measure
This symbol assumes that there is a potential for
personal death or injury if this expression is ignored
and this product is mishandled.
Insert or pull off the connector only after turning off the power.
Otherwise, controller might fail.
Improper understanding of stroke might cause serious accident. Please understand the
Section 8 in this manual to handle.
1.5.
EMC directive
The EMC directive applies not to the servo units alone but to servo-incorporated
machines and equipment.
This requires the EMC filters to be used with the servo-incorporated machines and
equipment to comply with the EMC directive.
Please ask a concrete solution to our office.
1.6.
Others
This equipment is classified into the partly completed equipment according to
Machinery Directive (2006/42/EC). Therefore, after this equipment is incorporated into
the final machinery, conformity with Machinery Directive (2006/42/EC) shall be needed
in the final machinery.
WARNING
CAUTION

BS Controller for AC SERVO PRESS
Instruction Manual Ver1.08
BS-M3A-1B
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CE marking based on Machinery Directive is not done to the partly completed
machinery. Therefore, for the case that circulates by the partly completed machinery
until this equipment is incorporater into the final machinery in Europe. It is necessary
for the declaration of incorporation and the manual of this equipment to be appended to
this equipment
1.7.
The relation with the Mitsubishi Electric servo system
BS controller works as a higher rank controller of Mitsubishi Electric servo system
MR-J3A.
Please refer to the manual of the Mitsubishi Electric issue about the details of a
MR-J3A system.