EXTOL VORTEX PRECEDENCE G1 User manual

Vortex
®
Precedence
Servo Spin Welder
User Manual
G1, G3, & G5 models
User Manual Rev 3.6
extolinc.com
SA-D-723-11-18

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Vortex
®Servo Spin Welder User Manual Revision History
Revision
Number
Revision Changes
Date
1.0
Start
3-8-2006
1.1
Initial release
6-1-2006
1.2
New Base
8-7-2006
1.3
Addition of Hard Stop & Safety Trigger
9-21-2006
1.4
Addition of Appendix B – Remote SPC Data Collection Instructions
10-26-2007
2.0
Changed Controller
4-1-2008
2.1
Separated Appendices C, D, & E from this manual
4-18-2008
2.2
Added Max Collapse feature description
5-27-2008
2.3
Added Appendix C for custom features
3-11-2009
3.0
New PRECEDENCE Model
6-1-2011
3.1
Repositioned fuse and disconnect, Added alarm 3407 010C
5-4-2012
3.2
Updated table drawing on page 15
Updated spindle bolt pattern drawing on page 16
6-14-2012
3.4
Updated Moment of Inertia screenshots, Approach Speed
nomenclature, Vacuum or Pressure selection options/screenshots, FC
Weld ON/OFF and updated the Sequence Flow Chart
3-1-2014
3.46
Updated Fault Messages in Troubleshooting section. Updated voltage
range for 480 VAC as standard option.
10-31-2014
3.5
Added spindle pressure/vacuum switch
5-1-2015
3.6
Updated machine weight
6-26-2015

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Table of Contents
Quick Start Guide......................................................................................................................... 1
Chapter 1 – Introduction............................................................................................................ 3
Manual Organization..................................................................................................................... 4
Abbreviation of Terms.................................................................................................................. 5
Vortex Features............................................................................................................................ 6
Vortex Options.............................................................................................................................. 6
Warranty....................................................................................................................................... 7
Extol Inc. Contact Information..................................................................................................... 7
Chapter 2 – Safety....................................................................................................................... 9
Cautions & Warnings.................................................................................................................. 10
Operator Safety Tips .................................................................................................................. 10
Electrical Safety Notice............................................................................................................... 10
Standards Compliance................................................................................................................ 10
Plastics Health Notice................................................................................................................. 11
Chapter 3 – Unpacking & Installation ................................................................................... 13
Package contents ....................................................................................................................... 14
Location & mounting.................................................................................................................. 14
Power connections ..................................................................................................................... 14
Tool Leveling, Centering, & Mounting........................................................................................ 14
Tool I/O Connections ................................................................................................................. 17
Light Curtain Connection............................................................................................................ 18
Remote Interface Connection..................................................................................................... 19
Power On Sequence................................................................................................................... 21
Chapter 4 – Display Screens.................................................................................................... 23
All Screens.................................................................................................................................. 24
Home Tab................................................................................................................................... 24
Main Screen............................................................................................................................ 25
Password Screen..................................................................................................................... 26
About Screen .......................................................................................................................... 27
System Setup Screen.............................................................................................................. 28
Time/Date Setting Screen....................................................................................................... 29
Setup Tab (Recipe Setup).......................................................................................................... 30
Parameters Screen.................................................................................................................. 30
Machine Home Window ...................................................................................................... 31
Head Down Window............................................................................................................ 31
Weld Process (Revolutions Mode)....................................................................................... 32
Weld Process (Time Mode)................................................................................................. 32
Weld Process (Distance 1: Collapse Travel Mode).............................................................. 33
Weld Process (Distance 2: Total Travel Mode)................................................................... 33
Hold Settings....................................................................................................................... 34
Pass/Fail Screens.................................................................................................................... 35
Pass/Fail Screen 1............................................................................................................... 35
Pass/Fail Screen 2............................................................................................................... 36
Tool Screen............................................................................................................................. 37
SPC Tab...................................................................................................................................... 38
Local SPC Screen.................................................................................................................... 38
Local SPC Screen 1 ............................................................................................................. 38
Local SPC Screen 2 ............................................................................................................. 39
Remote SPC Screen................................................................................................................ 40
Machine Tab............................................................................................................................... 41

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Manual Screen........................................................................................................................ 41
Input Status Screen................................................................................................................ 42
Output Status Screen.............................................................................................................. 43
Chapter 5 – Recipe Setup......................................................................................................... 45
Overview .................................................................................................................................... 46
1. Adjust Column Height ............................................................................................................ 46
2. Select Recipe Number............................................................................................................ 46
3. Enter Tool Parameters ........................................................................................................... 46
Recipe Name........................................................................................................................... 46
Tool Weight ............................................................................................................................ 46
Tool Inertia............................................................................................................................. 46
Position Gain........................................................................................................................... 46
Model Gain.............................................................................................................................. 47
Upper Valve ............................................................................................................................ 47
Pressure/Vacuum Sensor........................................................................................................ 47
Servo Accel............................................................................................................................. 47
Servo Decel............................................................................................................................. 47
Part Present Input Usage ....................................................................................................... 47
4. Enter Recipe Parameters........................................................................................................ 48
a. Machine Home........................................................................................................................ 48
Upper Load ............................................................................................................................. 48
Vacuum/Pressure Load ....................................................................................................... 48
Vac Pickup/Prs Pickup Load................................................................................................ 48
Detent Load......................................................................................................................... 48
Start Mode.............................................................................................................................. 48
Static start........................................................................................................................... 48
Dynamic start...................................................................................................................... 48
Start Angle.............................................................................................................................. 49
b. Head Down............................................................................................................................. 49
Speed Transition..................................................................................................................... 49
Approach Speed...................................................................................................................... 49
Trigger.................................................................................................................................... 49
Trigger Window ...................................................................................................................... 50
Max Collapse........................................................................................................................... 50
c. Weld Process.......................................................................................................................... 50
Weld Mode.............................................................................................................................. 50
1. Revolutions ..................................................................................................................... 50
Revolutions...................................................................................................................... 50
Orientation....................................................................................................................... 50
Final Angle....................................................................................................................... 50
2. Time................................................................................................................................ 51
Weld Time ....................................................................................................................... 51
3. Distance 1, collapse........................................................................................................ 51
Collapse........................................................................................................................... 51
4. Distance 2, total.............................................................................................................. 51
Total ................................................................................................................................ 52
Start Delay.............................................................................................................................. 52
Weld Force.............................................................................................................................. 52
Weld Speed............................................................................................................................. 52
d. Hold Settings.......................................................................................................................... 52
Hold Force............................................................................................................................... 52

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Hold Time ............................................................................................................................... 52
5. Enter Pass/Fail Parameters .................................................................................................... 53
Angle....................................................................................................................................... 53
Time........................................................................................................................................ 53
Collapse .................................................................................................................................. 53
Total........................................................................................................................................ 53
Revs........................................................................................................................................ 54
Alarm Mode............................................................................................................................. 54
No Latch.............................................................................................................................. 54
Latching............................................................................................................................... 54
Set up Safety Trigger ................................................................................................................. 54
Set up Mechanical Stop.............................................................................................................. 55
Chapter 6 – Operation............................................................................................................... 57
Power On Sequence................................................................................................................... 58
Sequence of Operation............................................................................................................... 58
Power Off Sequence................................................................................................................... 66
Chapter 7 – Tool I/O & Remote Interface............................................................................ 67
Tool I/O...................................................................................................................................... 68
Wiring ..................................................................................................................................... 68
Machine Setup........................................................................................................................ 68
Remote Interface ....................................................................................................................... 69
Wiring ..................................................................................................................................... 69
Programming sequence.......................................................................................................... 69
Chapter 8 – Troubleshooting................................................................................................... 73
Troubleshooting Guide............................................................................................................... 74
Fault Messages........................................................................................................................... 75
Controller and Servo Drive Alarms............................................................................................. 76
Controller Alarm List............................................................................................................... 76
Servo Drive Alarms................................................................................................................. 82
Servo Drive Warnings............................................................................................................. 85
Contact Extol.............................................................................................................................. 86
Chapter 9 – Care & Maintenance............................................................................................ 87
Periodic Maintenance ................................................................................................................. 88
Replacing Fuses.......................................................................................................................... 88
Main Power Fuses................................................................................................................... 88
Control Power Fuses............................................................................................................... 89
24 VDC Fuse........................................................................................................................... 89
Replacing Batteries..................................................................................................................... 90
Controller Battery.................................................................................................................... 90
Encoder Battery...................................................................................................................... 90
Appendices.................................................................................................................................. 93
Appendix A – Sample Application – Coffee Mug ........................................................................ 94
Appendix B – Remote SPC Data Collection................................................................................ 95
Appendix C – Custom Features.................................................................................................. 96
Index............................................................................................................................................ 97

Quick Start Guide
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Quick Start Guide
This quick start guide is intended to help you get your Vortex
PRECEDENCE spin welder running
in as little time as possible. This is not intended to be a substitute for reading the entire manual.
The manual should be read in its entirety to gain a full understanding of the operation of this
equipment.
1. Remove any shipping materials and mount
the Vortex on a flat level work surface. Use
10mm (3/8”) SHCS through the holes
provided in the machine base.
2. Connect appropriate electrical and air service.
a. 323-528 VAC 50/60 Hz 3ph, 15 A
(240V option: 180-253 VAC 50/60 Hz
3ph, 20 A)
b. 0.59 MPa (85 psi) minimum dry
compressed air, 10mm (3/8”) hose
3. Turn on the machine. Press the Reset button
on the HMI to retract the spindle and return
to the start position (if necessary).
4. Mount upper tool to the spindle using three
M6 x 1mm SHCS.
5. Mount the lower tool to the lower tool plate
using M8 x 1.25mm SHCS.
6. Use the Machine-Manual screen to jog the
head down and check alignment between the
upper and lower tool. If the tools are not
aligned follow the leveling and centering
procedure in Chapter 3.
7. Set the mechanical stop to prevent upper and
lower tooling contact when no part is present.
8. Set the safety trigger to allow the operator to
remove their hands from the dual opto-touch
start buttons when the spindle is down.
9. Select a recipe on the Main screen (Figure 0-
1).
10. Go to the Setup-Tool screen (Figure 0-2) and
enter the required tool information. It is
recommended to start with Posn Gain and
Model Gain set to High and Servo Accel &
Decel set to 100%.
11. Go to the Setup-Parameters screen (Figure 0-
3) and enter the parameters that are
appropriate for your part (Note: “Head Up”
does not have settable parameters).
12. Load Parts into the machine.
13. Activate the dual opto-touch start buttons to
begin the cycle. The dual opto-touch start
buttons must be held during the down stroke
Figure 0-1 Select Recipe
Figure 0-3 Setup-Parameters
Figure 0-2 Setup-Tool

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of the press and can be released once the
head down motion has stopped.
14. Wait for the cycle to complete then remove
the part. Evaluate the integrity of the weld
and adjust the setup parameters accordingly.
Refer to Appendix A for help adjusting the
parameters to achieve a good weld.

Chapter 1 – Introduction
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Chapter 1 – Introduction
In this Chapter…
• Manual
Organization
• Abbreviation of
Terms
• Vortex Features
• Vortex Options
• Warranty
• Extol Inc. Contact
Information

Chapter 1 – Introduction
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Manual Organization
Chapter 1 – Introduction explains the organization of the manual and commonly used terms.
It also contains the features and options of the Vortex, explains the warranty, and contains
Extol’s contact information.
Chapter 2 – Safety discusses safe procedures for machine installation and operation.
Chapter 3 – Unpacking & Installation explains proper location and mounting, tool
installation, and electrical connections for the Vortex.
Chapter 4 – Display Screens explains the information on each screen and the available control
functions.
Chapter 5 – Recipe Setup explains how to setup the weld control parameters and the pass/fail
criteria.
Chapter 6 – Operation explains machine startup, shutdown, and the machine sequence of
operations.
Chapter 7 – Remote Interface/Tool I/O connector contains connection diagrams for wiring
the DB9 connector on the side of the Vortex. It also explains how to program a PLC to control the
Vortex remotely and how to control Tool I/O through the DB9 connector.
Chapter 8 – Troubleshooting provides a guide to understanding and correcting faults that
may occur while using the Vortex.
Chapter 9 – Care & Maintenance explains how to keep your Vortex running smoothly so that
it will perform for years.
Appendix A – Sample Application (Coffee Mug) This is a sample application to help you
understand how to set up the parameters for a recipe.
Appendix B – Remote SPC Data Collection
Appendix C – Custom Features
Index

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Abbreviation of Terms
The following abbreviations are commonly used in this manual.
Abbreviation
Definition of Abbreviation
Amp
Ampere
CR
Control relay
E-Stop
Emergency stop
Ext
Extend(s)
FR
Filter / regulator combination unit
GA
Gage Tube
I/O
Inputs / outputs
LH
Left hand
MCR
Master control relay
OEM
Original equipment manufacturer
OSHA
Occupational Safety And Health Administration
PB
Push button
PF
Press fit dowel
P/N
Part number
PLC
Programmable logic controller
PSI
Pounds / square inch
PSIG
Pounds / square inch gage
Prox
Proximity switch
Ret
Retract(s)
RH
Right hand
SCFH
Standard cubic feet / hour
SCFM
Standard cubic feet / minute
SF
Slip fit dowel
SHCS
Socket head cap screw
SS
Selector switch
VAC
Volts alternating current
VDC
Volts direct current

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Vortex Features
•Fully integrated power supply, controls, and operator interface
•Pneumatic actuated press with 100mm (3.875”) stroke
•Dual proportional pressure control for precise force and speed control
•7” color touch-screen HMI with intuitive graphical screen format and password protection
•Linear Voltage Displacement Transducer (LVDT) provides weld-by-depth control
•Standard on-board data logging for the previous 50 cycles
oMonitors final angle, weld time, collapse distance, total distance, torque, and
RPM’s
•Rigid square column with 430mm (17”) height adjustment
•Storage for 50 tool recipes
•Servo controlled spin motor: 3kW (4HP) 5000 RPM maximum
•Heavy-duty cast machine base with integrated start buttons
•Resettable and lifetime cycle counters
•Manual mode provides complete pneumatic and servo control to simplify the setup
process
•Easy automation integration
•Four weld modes available (Dynamic or Static Triggering):
oRevolutions mode – controls number of revolutions during welding and finishes
at a specified angle within +/- 1.0 degree
oTime mode – controls weld duration
oDistance mode (collapse travel) – controls weld joint displacement
oDistance mode (total travel) – controls final part height
•Time and Distance modes available with or without final orientation positioning.
•Five operation modes:
oDetent – Operator loads the components into the upper and lower tools. The
upper tool holds the part in place with a detent.
oVacuum – Operator loads the components into the upper and lower tools. The
upper tool holds the part in place with vacuum.
oVac Pickup – Operator loads all components into the lower tool. The upper tool
picks up the upper part before assembly.
oPressure - Operator loads the components into the upper and lower tools. The
upper tool holds the part in place with pressure.
oPrs Pickup – Operator loads all components into the lower tool. The upper tool
picks up the upper part before assembly.
•Utility requirements
oElectrical: 323-528 VAC 50/60 Hz, 3 phase, 15 A
(240V option: 180-253 VAC 50/60 Hz, 3 phase, 20 A)
oCompressed air: 0.59 MPa (85 psi) minimum, dry non-lubricated air
•Machine weight: 220kg (475lbs)
Vortex Options
•Stage II Ethernet data collection package
•3:1 or 5:1 gear reduction to provide more torque for large part/surface area applications
•Part presence sensing
•Adjustable height, powered work surface

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Warranty
The Extol Vortex PRECEDENCE Servo Spin Welder is warranted to be free from defect in
materials and workmanship for 2 years.
Extol Inc. Contact Information
Extol Incorporated
651 Case Karsten Drive
Zeeland, MI 49464 USA
Phone: [phone]
Toll Free: 1-800-324-6205
Fax: [phone]
Sales or general inquiries:
Phone: [phone] (M-F 8:00am – 5:00pm EST)
Email: [email protected]
Web: www.extolinc.com
Technical Support:
Phone: [phone]

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Chapter 2 – Safety
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Chapter 2 – Safety
In this Chapter…
• Cautions &
Warnings
• Operator Safety
Tips
• Electrical Safety
Notice
• Standards
Compliance
• Plastics Health
Notice

Chapter 2 – Safety
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Cautions & Warnings
Please read and be aware of all caution and
warning messages that appear throughout this
manual. The following symbols are used to alert
your attention to areas where special
consideration is required to insure the safety of
personnel operating or working around this
equipment. A yellow triangle indicates a hazard
(Figure 2-1). A red circle with a slash indicates a
prohibited action to avoid the hazard (Figure 2-
2). A blue circle indicates mandatory action that
must be taken to avoid the hazard (Figure 2-3).
Operator Safety Tips
•Read and understand this manual
before operating the machine.
•Follow all safety procedures as
described by this manual.
•Do not wear loose clothing while
operating this piece of equipment.
Clothing may get caught in the rotating
tool and cause injury to the operator.
•Long hair must be tied back to prevent
getting caught in the rotating tool and
causing injury.
•Do not operate this machine with any
guard removed.
•Do not attempt to bypass the two hand
anti-tie down feature either
mechanically or electrically.
•Do not operate while under the
influence of drugs or alcohol.
Electrical Safety Notice
This machine contains hazardous voltages that
can cause serious injury or death. Unplug the
machine and follow appropriate lockout/tagout
procedures before removing any guard or
working on this equipment.
Standards Compliance
This machine was designed in compliance with
the following standards.
•Risk assessment ANSI B11.TR3
•UL 508A
•EN 954-1
•EN 574 Two Hand Control
Figure 2-1 Hazard
Figure 2-2 Prohibited
Action
Figure 2-3 Mandatory
Action
WARNING
Read and understand operator’s
manual before using this
machine. Failure to follow
operating instructions could
result in personal injury or
damage to equipment.
WARNING
Moving parts can crush and cut.
Do not operate with guard
removed. Follow lockout
procedures before servicing.
WARNING
Hazardous Voltage
Contact may cause electric shock
or burn. Unplug and lock out
system power before servicing.
WARNING
Rotating tool can cause injury.
Keep hands, loose clothing, and
long hair away while tool is
rotating.

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Plastics Health Notice
Be aware of any governmental regulations
concerning the plastic(s) you are assembling.
Certain types of plastics may emit hazardous
fumes or gases while being processed. Proper
ventilation or respiratory protection should be
utilized where necessary.

Chapter 2 – Safety
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Chapter 3 – Unpacking & Installation
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Chapter 3 – Unpacking & Installation
In this Chapter…
• Package Contents
• Location &
mounting
• Power Connections
• Tool Leveling,
Centering, &
Mounting
• Tool I/O
Connections
• Light Curtain
Connection
• Remote Interface
Connection
• Power On Sequence

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Package contents
Remove all shipping material and inspect the
contents for damage. Notify the shipping
company immediately if any damage is found.
Contact Extol to arrange for repair if necessary.
Compare the contents of the package with the
packing list provided.
Location & mounting
•To lift the Vortex attach a 2000lb strap
to the lifting loop on top of the machine
column.
•Lift with a forklift or crane and place the
Vortex on a flat, level, & stable work
surface capable of supporting the
machine‘s weight (approximately 325lbs
or 150kg).
•Use the mounting holes provided in the
base of the machine to secure it to the
work surface with 10mm (3/8”) bolts.
Power connections
•Use a plug to connect the required
electrical service to the machine. The
Vortex is capable of operating within the
range of 323-528 VAC, 50/60 Hz, 3
phase (240V option: 180-253 VAC,
50/60Hz, 3 phase). The Vortex is
internally fused at 12 Amperes (240V
option: 20 A).
•The SCCR (Short Circuit Current Rating)
of this machine is 100,000 Amps.
•Use a quick disconnect fitting to connect
the compressed air supply to the
machine. The Vortex requires 0.59 MPa
(85 psi) minimum of non-lubricated
dry air. A 10mm (3/8”) air line is
recommended to achieve adequate air
flow in applications where vacuum is
used.
•Set the main air regulator to 0.59 MPa
(85 psi).
Tool Leveling, Centering, &
Mounting
Each Vortex is leveled and centered by Extol at
assembly and does not require re-alignment by
the customer. However, if the lower tool plate or
WARNING
Hazardous Voltage
Contact may cause electric shock
or burn. Installation should only
be performed by qualified
personnel.
WARNING
Lifting and the use of a Hi-Lo
should only be performed by
trained personnel. Do not use
straps that are worn or frayed.