Expert SmartTurn User manual

Inhaltsverzeichnis
2016-08-15
Installation and operating instructions
Turntable control
SmartTurn
Dok-ID:EXPERT-0003-EN-2011 “Original operating instructions”

2 Dok-ID:EXPERT-0003-EN-2011
© Expert-Tünkers GmbH
Seehofstr. 56-58
64653 Lorsch
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
[e-mail]
Internet: www.expert-tuenkers.de

Turntable control SmartTurn
Table of contents
Dok-ID:EXPERT-0003-EN-2011 3
1General Information...............................................................5
1.1 Information about this manual .......................................5
1.2 Explanation of symbols..................................................6
1.3 Disclaimer......................................................................7
1.4 Copyright........................................................................7
1.5 Replacement parts.........................................................8
1.6 Guarantee terms............................................................8
1.7 Customer service...........................................................8
2Safety ......................................................................................9
2.1 Responsibility of the customer.......................................9
2.2 Personnel requirements...............................................10
2.2.1 Qualifications................................................10
2.3 Intended use................................................................11
2.4 Environmental protection.............................................12
3Technical data - turntable controller..................................13
4Structure and function ........................................................14
4.1 Overview......................................................................14
4.1.1 Device description........................................15
4.2 Functional description..................................................16
4.2.1 Standard mode.............................................17
4.2.2 Special mode................................................18
4.2.3 0-position optimization..................................20
4.2.4 Brake wear monitor ......................................22
4.2.5 Overrun monitor ...........................................23
4.2.6 System monitoring........................................23
4.2.7 Device settings - control unit........................24
4.3 Connections.................................................................27
4.3.1 Control unit, see Fig. ....................................27
4.3.1.1 Pin assignment control unit...........28
4.3.2 Sensor, see Fig. 1 ........................................30
4.3.2.1 Pin assignment sensor..................30
4.4 Optional components and accessories........................31
5Installation and commissioning.........................................32
5.1 Safety...........................................................................32
5.2 Mounting instructions...................................................33
5.2.1 Connecting to the power supply...................33
5.3 Electrical installation ....................................................34

Turntable control SmartTurn
Table of contents
4 Dok-ID:EXPERT-0003-EN-2011
5.3.1 Description - PLC signals .............................35
5.3.1.1 Inputs............................................ 35
5.3.1.2 Outputs......................................... 37
5.3.2 System integration in the plant control
system ..........................................................40
5.3.3 PLC programming.........................................46
5.4 Commissioning.............................................................49
5.4.1 Re-commissioning in the plant .....................52
6Faults.....................................................................................53
6.1 Safety...........................................................................53
6.2 Sequence faults ...........................................................53
6.2.1 Overrun forward / backward.........................53
6.2.2 Warning end lock angle (lock angle
reserve).........................................................55
6.2.3 End of lock angle reserve reached (end of
lock angle reserve) .......................................56
6.2.4 Input forward and backward on (Both
Inputs On).....................................................57
6.3 System faults................................................................57
6.3.1 Sensor fault (sensor defect) .........................58
6.3.2 Short circuit at output....................................59
6.3.3 Invalid sensor data (changed sensor
position) ........................................................60
6.3.4 Change mode (changed rotary mode) .........61
6.3.5 Change mode (changed rotary direction).....62
6.3.6 Changed lock angle......................................63
6.3.7 Wrong rotary direction (direction forward /
backward).....................................................64
6.3.8 Internal device fault (secure state) ...............65
6.4 Start up after corrected fault ........................................66
7SmartTurn – spare parts......................................................67
8Index......................................................................................69

Turntable control SmartTurn
General Information
Dok-ID:EXPERT-0003-EN-2011 5
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1 General Information
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1.1 Information about this manual
This manual enables safe and efficient maintenance of the device.
The manual is a component of the device and must be kept
accessible to specialized personnel in the immediate vicinity of the
device at all times.
The basic prerequisite for safe work is compliance with all safety
instructions and handling instructions specified in this manual.
In addition, the local accident prevention guidelines and general
safety regulations for the devices's area of implementation apply.
Illustrations in this manual are provided for basic understanding
and can deviate from the actual model of the device.
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Turntable control SmartTurn
General Information
6 Dok-ID:EXPERT-0003-EN-2011
1.2 Explanation of symbols
Warnings Warnings are indicated by symbols in this operating manual. The
warnings are introduced by signal words that express the scope of
the hazard.
The warnings must be strictly heeded, you must act prudently to
prevent accidents, personal injury, and property damage.
DANGER!
… indicates an imminent dangerous situation that
can result in death or serious injury if it is not
avoided.
WARNING!
… indicates a possible dangerous situation that can
result in death or serious injury if it is not avoided.
CAUTION!
… indicates a possible dangerous situation that can
result in minor injury if it is not avoided.
CAUTION!
… indicates a possible dangerous situation that can
result in material damage if it is not avoided.
Tips and recommendations
NOTE!
... indicates useful tips and recommendations, as
well as information for efficient and trouble-free
operation.
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Turntable control SmartTurn
General Information
Dok-ID:EXPERT-0003-EN-2011 7
1.3 Disclaimer
All information and instructions in this operating manual have been
provided under due consideration of applicable guidelines, the
current state of technology, as well as our many years of
experience.
The manufacturer assumes no liability for damages due to:
Failure to heed the instructions in the manual
Non-intended use
Deployment of untrained personnel
Unauthorized conversions
Technical changes
Use of non-approved replacement parts
The actual scope of delivery can vary from the explanations and
graphic representations provided in this manual in the case of
special versions, if supplemental order options are desired, or on
the basis of the latest technical changes.
In all other respects the agreed obligations in the delivery contract,
the general terms and conditions, as well as delivery conditions of
the manufacturer, and the statutory regulations valid at the time the
contract was concluded, apply.
We reserve the right to make changes in the interest of
enhancements and improvement of the performance
characteristics.
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1.4 Copyright
Treat this operating manual with confidentiality. It has been
exclusively prepared for personnel working with the device.
Provision of the operating manual to third-parties without written
consent from the manufacturer is prohibited.
NOTE!
The content, texts, drawings, graphics, and other
presentations are protected by copyright and are
subject to commercial property rights Any improper
use is punishable.
Duplication in any form - including excerpts - as well as exploitation
and/or communication of the content are not permitted without a
written declaration from the manufacturer. Actions to the contrary
make damage compensation mandatory. We reserve the right to
enforce additional claims.

Turntable control SmartTurn
General Information
8 Dok-ID:EXPERT-0003-EN-2011
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1.5 Replacement parts
WARNING!
Safety risk if the wrong replacement parts are
used!
Incorrect or defective replacement parts can cause
damage, malfunction, or total failure; they can also
impair safety.
Therefore:
– Only use manufacturer's original replacement
parts.
Purchase replacement parts directly from the dealer. See page 2
for manufacturer's address
The replacement part list is in the Appendix
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1.6 Guarantee terms
The guarantee terms are included in the manufacturer's terms and
conditions, the order confirmation, or manufacturer's contract
documents.
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1.7 Customer service
Our customer service organization is available for technical
information. See page 2 for contact data.
Our employees are always interested in new information and
experiences associated with the application, and which could prove
valuable in improving our products.
For questions or ordering of replacement parts, please specify the
types and serial numbers.
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Turntable control SmartTurn
Safety
Dok-ID:EXPERT-0003-EN-2011 9
2 Safety
This section provides an overview of all the important safety
aspects for optimal protection of personnel, as well as for safe and
trouble-free operation.
Significant hazards can occur if the handling instructions and
safety instructions in this manual are not complied with.
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Comply with the instructions in the
Installation and Operating Manual -
Turntables
DANGER!
Danger of severe or fatal injuries!
Therefore:
– Strictly ensure that you have read the
Installation and Operating Manual - Turntables
NOTE!
The safety instructions in the Installation and
Operating manual - Turntables, and in the technical
documentation must be strictly complied with.
The turntable controller is included as a component
in the scope of delivery of a turntable.
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2.1 Responsibility of the customer
The device is used in industrial applications. Consequently the
owner of the device is subject to legal industrial safety obligations.
In addition, the customer is responsible to ensure that the system
is always in technically faultless condition.
Compliance with the instructions in the operating manual is the
prerequisite for trouble-free operation and the fulfillment of possible
guarantee claims.
The operating manual contains important service instructions
therefore it must be kept in a safe location.

Turntable control SmartTurn
Safety
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2.2 Personnel requirements
2.2.1 Qualifications
WARNING!
Danger of injury due to insufficient
qualification!
Improper handling can cause serious injury or
material damage.
Therefore:
– Only have activities performed by personnel
who are qualified to perform these activities.
Only persons from whom it can be expected that they reliably
execute their work are considered as personnel. Persons whose
capability to react is impaired, for instance through drugs, alcohol,
or medication, are not approved.
Comply with age-specific and job-specific regulations that are
applicable at the installation site when selecting personnel.
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Turntable control SmartTurn
Safety
Dok-ID:EXPERT-0003-EN-2011 11
2.3 Intended use
NOTE!
The following is prohibited unless the unit is
designed exclusively for the application:
Use in Ex areas.
Use in the vicinity of acids, gases, and fumes.
The use conditions have been specified in the
project planning.
WARNING!
Danger due to non-intended use!
Any use that extends beyond the intended use,
and/or any other use of the device can cause
dangerous situations.
Therefore:
– Only use the device as intended.
– Strictly comply with all instructions in this
operating manual.
Claims of any type due to damage arising from non-intended use
are excluded.
The customer is solely liable for all damage in the case of non-
intended use.
Turntable controller - SmartTurn The SmartTurn turntable controller is only designed to operate
EXPERT-TÜNKERS turntables with fixed indexing and lock angles
of 20, 30, 40 and 60 degrees. The step time must be greater than
1.5s.
Do not operate other turntables with the SmartTurn controller.

Turntable control SmartTurn
Safety
12 Dok-ID:EXPERT-0003-EN-2011
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2.4 Environmental protection
CAUTION!
Environmental hazard due to incorrect
handling!
Incorrect handling of environmentally hazardous
substances, particularly improper disposal, can
cause significant environmental damage.
Therefore:
– Always comply with the instructions cited below.
– If environmentally harmful substances should
inadvertently get into the environment, initiate
suitable measures immediately. If in doubt notify
the responsible municipal authority about the
damage.
Dispose of the controller as electrical and electronic waste.
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Turntable control SmartTurn
Technical data - turntable controller
Dok-ID:EXPERT-0003-EN-2011 13
3 Technical data - turntable controller
SmartTurn
sensor:
Dimensions (without plug
-in connector)
Ambient temperature
Enclosure material
Degree of protection
Operating voltage
Operational current
Short
-circuit protection
Connection
Approximately 130x 75x 32mm WHD
-
25 to +70 ℃
PBT
IP67
18
-30 V DC
0
-100mA
Clocked
M12x1 device plug
-in connector
SmartTurn
control unit:
Dimensions (without plug
-in connector)
Ambient temperature
Enclosure material
Degree of protection
Operating voltage
Operational current
Short
-circuit protection
Current carrying capacity outputs A1, A2
Current carrying capacity outputs A3
-A9
Connections
Approximately 150x 112x 33mm WHD
0 to +50
℃
PBT
IP65
18
-30 V DC
0
-150mA
Clocked
0 V
0 V
X1, M23x1 device plug
-in connector
X2. M12x1
device plug-in connector
X3
. M12x1 device socket
X4
, M12x1 device plug-in connector - codiert

Turntable control SmartTurn
Structure and function
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4 Structure and function
4.1 Overview
Sensor
Fig. 1 Sensor
Control unit
Fig. 2 Control unit
The SmartTurn turntable controller consists of the components:
Inductive sensor, incl. Position encoder.
Control unit.
Sensor cable.
Diagnostics cable (optional).
PLC interface cable (optional).
Connecting cable power unit (optional).

Turntable control SmartTurn
Structure and function
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4.1.1 Device description
Sensor, Fig. 1 The sensor is equipped with:
A connection for the control unit.
One green LED and two yellow LEDs.
All three LEDs are illuminated when the sensor is connected to the
control unit.
Control unit, Fig. 2 The controller is equipped with:
Four connections for 24 V supply and PLC signals (X1), power
unit (X2), sensor (X3), diagnostics connection (X4).
Eight LEDs that enable fast and easy diagnosis. Faults are
indicated through flashing red LEDs. More information about
faults is provided in the section -> Faults.
LED Function Color
H1 System fault Red
H2 Overrun forward Red
H3 0-position Yellow
H4 Overrun backward Red
H5 End lock angle Red
H6 Start forward on Yellow
H7 Start backward on Yellow
H8 Not assigned -
H9 24 V power supply Green
More extensive diagnoses is possible with the diagnostics
software, via the diagnostics connection (X4).
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Turntable control SmartTurn
Structure and function
16 Dok-ID:EXPERT-0003-EN-2011
4.2 Functional description
The SmartTurn turntable controller is used to control Expert-
Tünkers fixed indexing turntables with any desired indexing.
The turntable can be operated in reverse mode and continuous
mode.
The drive motors can be actuated directly via contactors or
frequency converters.
The position encoder is mounted on the drive roller determined by
position. This ensures a unique position of the drive roller, as well
as of the turntable.
The sensor analyses the position encoder and transfers the
position value to the control unit.
The control unit monitors the position value and the PLC signals.
With each activation the drive roller is rotated 360 degrees forward
or backward. Thus the turntable is always cycled one index.
In special mode, depending on activation, 1-4 cycles will be rotated
simultaneously per activation.
With each activation the drive roller is rotated 360 degrees forward
or backward. Thus the turntable is always cycled one index.
If the turntable is in the 0 position, this is signaled to the PLC.
In reverse mode the forward and backward positions are output as
a signal to the PLC.
Additional position sensing is necessary for turntables with more
than 2 indexes or for continuous mode. For this possibility position
sensing is supplied for the turntable plate as an option. In this case
inductive sensors with individually-coded actuators are used.
Position sensing, standard:
Up to 15 positions are possible if there are no safety requirements.
Position sensing – safety:
1 to X positions with category 4 safety sensors.
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Turntable control SmartTurn
Structure and function
Dok-ID:EXPERT-0003-EN-2011 17
4.2.1 Standard mode
In standard mode, continuous operation and reverse operation are
differentiated.
Continuous mode
NOTE!
In normal operation the turntable only turns
forward. The turntable controller cycles the
turntable one clock cycle further with each
"Forward on" activation.
The "Reverse on" activation should only be
possible in jog mode in the PLC.
With "Reverse on" activation in continuous mode
there is no switch off of the turntable movement
through the turntable controller.
Necessary settings – continuous mode:
Securely connect input E4 to 24 V DC.
Set lock angle on switch S1 to setting 1 - 4 in accordance with
EXPERT specification, see chap. 4.2.7.
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Reverse mode
NOTE!
The turntable turns forward/backward between
2 positions (usually 180 degrees). The turntable
controller cycles the turntable into the other
position.
Necessary settings – reverse mode:
Securely connect input E4 to 0 VDC.
Set lock angle on switch S1 to setting 1 - 4 in accordance with
EXPERT specification, see chap. 4.2.7.
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Turntable control SmartTurn
Structure and function
18 Dok-ID:EXPERT-0003-EN-2011
4.2.2 Special mode
The turntable rotates depending on the selection via the PLC, 1 to
4 cycles forward or backward per activation. It can be rotated
forward or backward as often as desired. The lock angle in special
mode is fixed at 30º.
Necessary settings - special mode:
Securely connect input E4 to 0VDC.
Set lock angle on switch S1 to position 9.
Pre-select the number of cycles.
Input E5 =LOW and E6 = LOW -> rotate 1 cycle
Input E5 = HIGH and E6 = LOW -> rotate 2 cycles
Input E5 = LOW and E6 = HIGH -> rotate 3 cycles *
Input E5 = HIGH and E6 = HIGH -> rotate 4 cycles *
* In preparation
NOTE!
In operation, the outputs, “0-position”, „“In lock
angle”, and “In position forward” or “In position
back”, will only be output after reaching the
activated index, in accordance with the cycling:
After activation with one clock cycle for the first
index, after activation with two cycles for the
second index, and so on.
However, if the movement is interrupted, e.g.
through emergency stop, before reaching the
activated position, and restarted, then first,
regardless of the status of inputs E4/E5, the
system will be stopped at the first 0 index of the
drive roller.
Consequently, additional position sensing is
necessary for turntables with more than 2 indexes.

Turntable control SmartTurn
Structure and function
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Functional principle diagram
Fig. 3 Functional principle
A: PLC plant controller
1 "Start forward"
2 "Start backward"
3 "Slow ON"
4 „"Operating mode"
5 "Pre-select cycles bit 1"
6 "Pre-select cycles bit 2"
7 "0-position"
8 „Overrun forward"
9 „Overrun back"
10 „End of the lock angle"
11 "Position forward"
12 „Position back"
13 „In the lock angle"

14 „System fault"
B: SmartTurn
– control unit
"Position analysis – controller"
C: SmartTurn
– sensor
"Turntable position"
D: „
Turntable drive"

Turntable control SmartTurn
Structure and function
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4.2.3 0-position optimization
With "Forward on" or "Backward on" the turntable controller checks
the activated direction and the momentary position. If the result is
OK, the output "Forward start" or "Backward start" is enabled.
The turntable will then start to rotate.
When the switch-off angle is reached, the output "Forward start" or
"Backward start" is switched off and the turntable is stopped
immediately.
With each rotation the turntable controller calculates the switch-off
angle for the next rotation so that the turntable comes to a stop in
the optimal 0-position.
When first switched on, a default value is used that is specific to
the lock movement. Thereafter deviation from the optimal 0-
position is determined and the switch-off angle is determined for
the next rotation.
The 0-position is present when the position deviation does not
exceed +/- 8 degrees based on the optimal 0-position.
If the turntable is in this position, the "0-position" signal is output to
the PLC.
Calculation and optimization occur separately for forward and
backward. Thus time-intensive settings at start-up are not
necessary.
The turntable controller is self-adjusting and self-optimizing.
If, when switching on the operating voltage, a deviation to the last
saved position is detected, then this results in a system fault.
All d ata i s s ave d fai l s afe.
NOTE!
See section -> System fault - note invalid sensor
data, for additional instructions.