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

extolinc.com
User Manual ii Vortex
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User Manual iii Vortex
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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

Quick Start Guide
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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