gefran ADV200 Series User manual

ADV200 - Flying Shear for Roll
Forming machines Application
English
Instruction manual
Rev. 0.1 – 8-5-2019
1S3E64EN

Flying Shear for Roll Forming machines – Instruction manual Pag. 2 / 29
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Thank you for choosing this Gefran product.
We will be glad to receive any possible information which could help us improve this manual.
The e-mail address is the following: [e-mail].
Before using the product, read the safety instruction section carefully.
Keep the manual in a safe place and available to engineering and installation personnel during the product functioning period.
Gefran Drives and Motion S.r.l. has the right to modify products, data and dimensions without notice.
The data can only be used for the product description and they can not be understood as legally stated properties.
All rights reserved.
Revision index Date Author Changes
0.0 4-2-2019 BRI New edition
0.1 8-5-2019 BNM Application V 1.x.1: add PARs 11612 and 11010,
mod description PAR 11000, update Table 7:
word mapping.

Flying Shear for Roll Forming machines – Instruction manual Pag. 3 / 29

Flying Shear for Roll Forming machines – Instruction manual Pag. 4 / 29
CONTENTS
1Introduction............................................................................................................................................... 5
1.1 Information about this manual............................................................................................................. 5
1.2 Drive Firmware / Application version Cross compatibility ................................................................... 5
1.3 Symbols used in the manual ............................................................................................................... 5
2Installing the application ......................................................................................................................... 6
2.1 Application key .................................................................................................................................... 7
3General description.................................................................................................................................. 9
4Sizing and commissioning .................................................................................................................... 10
4.1 Machine Data .................................................................................................................................... 10
4.2 ADV200 configuration ....................................................................................................................... 11
4.2.1 Basic parameters configuration ................................................................................................. 12
4.2.2 Digital I/O ................................................................................................................................... 13
4.2.3 Encoder...................................................................................................................................... 13
4.2.4 Fieldbus...................................................................................................................................... 15
4.3 Commissioning.................................................................................................................................. 17
4.3.1 Machine development................................................................................................................ 17
4.3.2 Check-up of movements ............................................................................................................ 17
5Description of functions and parameter list........................................................................................ 19
26.01 Application.......................................................................................................................................... 19
26.02 App Service........................................................................................................................................ 21
26.03 Enable ................................................................................................................................................ 22
26.04 Fast Stop............................................................................................................................................ 22
26.05 Jog ..................................................................................................................................................... 22
26.06 Homing............................................................................................................................................... 23
26.07 Move .................................................................................................................................................. 24
26.08 Auto .................................................................................................................................................... 24
26.09 Trolley ................................................................................................................................................ 25
26.10 Line .................................................................................................................................................... 26
26.11 Alarm.................................................................................................................................................. 26
26.12 Virtual ................................................................................................................................................. 27
26.13 About .................................................................................................................................................. 27
6Application alarms ................................................................................................................................. 29

Flying Shear for Roll Forming machines – Instruction manual Pag. 5 / 29
1 Introduction
1.1 Information about this manual
This document describes the Flying Shear for Roll Forming machines software, supplementing what is
described in the ADV200 drive manual (for asynchronous and synchronous motors) and the optional boards
for encoder acquisition and input expansion.
1.2 Drive Firmware / Application version Cross compatibility
Flying Shear for Roll Forming machines Application ADV200 Firmware
1.x.1 7.5.16 and higher
1.3 Symbols used in the manual
Indicates a procedure, condition, or statement that, if not strictly observed, could result in personal
injury or death.
Indicates a procedure, condition, or statement that, if not strictly observed, could result in damage to
or destruction of equipment.
The following operations require the machine in motion.
Unforeseen machine movement is always possible. Take this into account and take the necessary
precautions.
Indicates that the presence of electrostatic discharge could damage the appliance.
When handling the boards, always wear a grounded bracelet.
Indicates a procedure, condition, or statement that should be strictly followed in order to optimize
these applications.
Note !
Indicates an essential or important procedure, condition, or statement.

Flying Shear for Roll Forming machines – Instruction manual Pag. 6 / 29
2 Installing the application
The Flying Shear for Roll Forming machines application must be installed on the ADV200(/S) drive to be
used.
The operations to be performed are listed below.
•Run the rffs_x_x_47_x_setup.exe application to set up the installation on a PC.
•Open the GF_eXpress configurator (catalogue version > 2.42)
•Connect the PC to the drive using the serial cable.
•On the GF_eXpress, select the ADV200 inverter (for asynchronous motors) and ADV200S inverter (for
synchronous motors).
•Once communication with the drive has been established, select the Download Firmwareitem on the
command bar. Then the window depicted below will appear. In that window, select the Flying Shear
for Roll Forming machines application (A1 to load the application on memory sector 1, A2 to load
the application on memory sector 2).
During this operation, do not turn off the drive.
•Once the firmware has been loaded, the application has to be enabled on the drive:
- Select the “expert” mode using the Access Mode parameter (PAR 554, - DRIVE CONFIG menu).
- Select the application: Application 1 if the rffs _..._A1 application was loaded
Application 2 if the rffs _..._A2 application was loaded
oSave and reset the drive. At the start, the drive will show the message, “ADV200 rffs V…” on
the display to confirm that the drive has been loaded.
•Perform a default load of the application parameters (App load def, PAR 11524) and then save.
Restart GF_eXpress. This will automatically recognize the application version and select the
appropriate parameters.
Then, configuration can begin.
.

Flying Shear for Roll Forming machines – Instruction manual Pag. 7 / 29
2.1 Application key
This application must be registered.
Register by entering a code supplied by Gefran.
Enter the code as follows:
•Connect to the drive using the GF_eXpress configurator or read the parameter indicated in the next point
using the keypad.
•Write down the Serial Number indicated in Regulation S/N (PAR 12106, ROLL FORMING FS \ About
menu).
•Contact Gefran support and provide the serial number you just read to obtain the application unlock
key.
•Enter the unlock code in the Application key parameter field (PAR 572, CONFIG DRIVE menu).

Flying Shear for Roll Forming machines – Instruction manual Pag. 8 / 29
•Save and reset the drive. At the start, the drive will no longer show the “Key Expiring” message on the
display, confirming that the drive has been unlocked.

Flying Shear for Roll Forming machines – Instruction manual Pag. 9 / 29
3 General description
The blade or cutting assembly is fixed onto a carriage that can move forwards and backwards, piloted by the
application. The application measures the length of the material to be cut by a metric wheel binding onto the
material.
For each position of the material from zero up to the cutting length and according to other mechanical
parameters, the application produces the carriage position and therefore the blade position.
The speed profile is the relationship between the material speed and the carriage speed, see figure 1.
The speed profile consists of:
•At the line’s start up, the trolley moves to the end of the line, supporting the head of the material.
•Once the end of the line has been reached, a standby period can be set, during which the material runs
under the trolley.
•The first phase, when the trolley returns, is for positioning. The position is set based on the line speed,
the cutting time and any safety gaps.
•The second phase is called acceleration forward. During this phase, the trolley reaches the speed of the
material.
•The third phase is synchronization. The carriage proceeds synchronized with the material to reduce
as much as possible any positional error between the carriage and the material.
•The fourth phase is the cut, the application gives the command to let the cut start. The application
proceeds in synchronization with the material up to the end of the cutting space to then resume
immediately with the standby cycle.
Note:
1) Each phase provides for a defined shift using an electric cam, with its position set according to the
different parameters. The space used for each phase is calculated according to the maximum speed
allowed for the material.
2) The space used by the carriage and maximum speed vary depending on the set cutting length.
Figure 1: Speed profile

Flying Shear for Roll Forming machines – Instruction manual Pag. 10 / 29
4 Sizing and commissioning
4.1 Machine Data
The data in table 1 must be known before commissioning the shear. This table can be used as a reminder and
completed before or after commissioning.
NAME
UNIT OF
MEASURE
VALUE PARAMETER
Metric wheel advancement * Line Kmec (PAR 11804),
menu LINE /
Trolley advancement shift * Trolley Kmec (PAR 11702),
menu TROLLEY /
Usable length for the shear m Trolley limit pos (PAR 11704),
menu TROLLEY /
Maximum trolley return speed. m/s Max spd bck (PAR 11012),
menu TROLLEY /
Maximum acceleration m/s2Trolley acc (PAR 11710),
menu TROLLEY /
Maximum deceleration m/s2Trolley dec (PAR 11712),
menu TROLLEY /
Synchronization time before cutting s Sync time (PAR 11604),
menu AUTO /
Cutting time s Cut time (PAR 11706),
menu TROLLEY /
Cutting lenght m Cut request (PAR 11800),
menu LINE /
Table 1: Machine data

Flying Shear for Roll Forming machines – Instruction manual Pag. 11 / 29
4.2 ADV200 configuration
See the connection diagrams proposed for asynchronous or synchronous motors:
Figure 2: Typical connection diagram (Asynchronous motor)
Figure 3: Typical connection diagram (Synchronous motor)

Flying Shear for Roll Forming machines – Instruction manual Pag. 12 / 29
The following drive configurations are required:
•Basic parameters configuration
•Digital I/O
•Encoders
•Field bus
4.2.1 Basic parameters configuration
After loading the default application parameters (Load default, PAR 11100), the basic drive parameters are
configured.
Table 2 shows the configurations loaded.
PARAMETER
SETTING
PAR
MENU
PARAMETER
552
DRIVE CONFIG
Regulation mode
Flux vector CL
556
DRIVE CONFIG
Control mode select
Speed
752
RAMPS
Ramp out zero src
One
650
REFERENCES
Dig speed ref 2
Dig spd ref1
1000
COMMANDS
Commands remote sel
Digital
1004
COMMANDS
Enable/disable mode
Off
1010
COMMANDS
Commands safe start
On
1018
COMMANDS
Digital Enable src
Pad 1
1020
COMMANDS
Digital Start src
Pad 1
1022
COMMANDS
Fast Stop src
Off
1314
DIGITAL OUTPUT
Digital Output 3 src
Pad 2
4452
WORD DECOMP
Word decomp src
Dig word decomp
4500
ALARM CONFIG
Fault reset src
Null
Table 2: Parameters loaded using Load Default

Flying Shear for Roll Forming machines – Instruction manual Pag. 13 / 29
4.2.2 Digital I/O
The drive hardware enable input must be connected to digital input 7.
The high and low blade inputs are used to indicate blade position. These are connected to sensors on the
blade as shown in figure 4:
Figure 4: High and low blade sensor operating logic
The output that controls the cut is the output listed in the table::
DIGITAL OUTPUT
FUNCTION
NOTES
13 DO3 Cut cmd Pad 2
4.2.3 Encoder
4.2.3.1 Encoder definitions
The encoder mounted on the carriage motor must be defined using the Trolley Enc Sel parameter (PAR
11700, menu TROLLEY).
The metric wheel encoder selection is essential for the system to function properly. The choice depends on
the geometry of the metric wheel and of the carriage.
The encoder resolution used on the metric wheel must be greater than or equal to the encoder resolution of
the carriage motor.
In other words, the ratio between the advancement of the carriage and the carriage motor ppr encoders must
be similar to the ratio between the advancement of the metric wheel and the metric wheel ppr encoders.
The number of the required pprs on the metric wheel encoder can be calculated as follows:
 ℎ   =  ℎ  []
     []∗  

Flying Shear for Roll Forming machines – Instruction manual Pag. 14 / 29
Suppose we have a cutting system with these specifications:
•The carriage advances 36 mm per motor revolution.
•The encoder on the carriage motor has 1024 ppr.
•The advancement of the metric wheel on the material is 314 mm.
In this case, an encoder with 8192 ppr is suitable.
4.2.3.2 Configuration with 2 Encoders
Enter the encoder data in the ENCODER CONFIG. menu.
Table 3 shows the encoder configurations to be used with 2 encoders..
CONFIGURATION FOR ASYNCHRONOUS MOTOR WITH TWO ENCODERS
Encoder 1 (yellow) digital encoder on the metric wheel
Encoder 2 (green) digital encoder on the carriage motor
Encoder sel src = One
CONFIGURATION FOR SYNCHRONOUS MOTOR WITH TWO ENCODERS
Encoder 1 (red) 5-track sin cos encoder on the carriage motor
Encoder 2 (yellow) digital encoder on the metric wheel
Encoder sel src = Null
Table 3: Configuration with 2 encoders

Flying Shear for Roll Forming machines – Instruction manual Pag. 15 / 29
4.2.4 Fieldbus
After loading the default application parameters (Load default, PAR 11100) the fieldbus is configured as
shown in table 4:
PARAMETER
SETTING
PAR
COMMUNICATION
MENU
PARAMETER
4010
FIELDBUS CONFIG
Fieldbus M->S enable
Enable
4020
FIELDBUS M->S
Fieldbus M->S1 PAR
11800
Required cut size [m]
4022
FIELDBUS M->S
Fieldbus M->S1 sys
Par 32
4030
FIELDBUS M->S
Fieldbus M->S2 PAR
4450
Dig word decomp
4032
FIELDBUS M->S
Fieldbus M->S2 sys
Count 16
4040
FIELDBUS M->S
Fieldbus M->S3 PAR
11002
Virtual line speed [m/s]
4042
FIELDBUS M->S
Fieldbus M->S3 sys
Par 32
4050
FIELDBUS M->S
Fieldbus M->S4 PAR
11702
Trolley motor mechanical K
4052
FIELDBUS M->S
Fieldbus M->S4 sys
Par 32
4060
FIELDBUS M->S
Fieldbus M->S5 PAR
11804
Line mechanical K
4062
FIELDBUS M->S
Fieldbus M->S5 sys
Par 32
4070
FIELDBUS M->S
Fieldbus M->S6 PAR
0
4072
FIELDBUS M->S
Fieldbus M->S6 sys
Fill 32
4080
FIELDBUS M->S
Fieldbus M->S7 PAR
11012
Maximum return speed
4082
FIELDBUS M->S
Fieldbus M->S7 sys
Par 32
4090
FIELDBUS M->S
Fieldbus M->S8 PAR
11716
Cut time
[s]
4092
FIELDBUS M->S
Fieldbus M->S8 sys
Par 32
4180
FIELDBUS S->M
Fieldbus S->M1 PAR
3708
Command status word
[See PAR 12054]
4182
FIELDBUS S->M
Fieldbus S->M1 sys
Par32
4190
FIELDBUS S->M
Fieldbus S->M2 PAR
12052
Alarm status word
4192
FIELDBUS S->M
Fieldbus S->M2 sys
Par32
4200
FIELDBUS S->M
Fieldbus S->M3 PAR
12046
Line speed monitor [s]
4202
FIELDBUS S->M
Fieldbus S->M3 sys
Par32
4210
FIELDBUS S->M
Fieldbus S->M4 PAR
12056
Position error monitor
[m]
4212
FIELDBUS S->M
Fieldbus S->M4 sys
par32
4220
FIELDBUS S->M
Fieldbus S->M5 PAR
12038
Shear position
[m]
4222
FIELDBUS S->M
Fieldbus S->M5 sys
Par32
4230
FIELDBUS S->M
Fieldbus S->M6 PAR
12030
Cut time monitor
[s]
4232
FIELDBUS S->M
Fieldbus S->M6 sys
Par32
4240
FIELDBUS S->M
Fieldbus S->M67PAR
12044
Maximum line speed [m/s]
4242
FIELDBUS S->M
Fieldbus S->M7 sys
Par32
4250
FIELDBUS S->M
Fieldbus S->M8 PAR
12040
Length of last bar cut
[m]
4252
FIELDBUS S->M
Fieldbus S->M8 sys
Par32
Table 4: Fieldbus configuration

Flying Shear for Roll Forming machines – Instruction manual Pag. 16 / 29
Command mapping word
The word sent by the PLC containing the commands is written in the Dig word decomp parameter (PAR
4450). The different function commands are linked to the word bits by selecting the appropriate “bitxx decomp
mon”.
WORD
DECOMP
BIT NUMBER
WORD DECOMP
[HEX] DESCRIPTION
0
0x0001
Enable
1
0x0002
Fast Stop
2
0x0004
Jog -
3
0x0008
Jog +
4
0x0010
Auto
5
0x0020
Homing
6
0x0040
Home sens
7
0x0080
Imm cut
8
0x0100
Blade close
9
0x0200
Blade open
10
0x0400
Virtual line
11
0x0800
Virtual blade
12
0x1000
Reset pos mat
13
0x2000
Not used
14
0x4000
Not used
15
0x8000
Not used
Table 5: Command mapping word

Flying Shear for Roll Forming machines – Instruction manual Pag. 17 / 29
4.3 Commissioning
4.3.1 Machine development
Start up is performed after machine development.
The drive is disabled:
•Start by inserting the mechanical data and metric wheel:
Refers to TROLLEY and LINE menues, and set all the values.
•Continue by setting speed and ramp times:
Refers to FASTSTOP, JOG, TROLLEY and HOMING and set all the values.
•Now enter the data for the cut:
Refers to TROLLEY and LINE and set all the values.
4.3.2 Check-up of movements
Enable the metric wheel simulator using the Virtual Line src parameter (PAR 11000).
We now continue by checking the data inserted and machine movements.
If the PLC has not yet been configured or connected, it is possible to set the Enable, Jog, Fast Stop and Auto
commands on the digital inputs, to test the machine movements.
The following operations require the machine in motion.
Unforeseen machine movement is always possible. Take this into account and take the
necessary precautions.
The operation described must be initially carried out with the motor disconnected from the machine.
Once the functions have been tested, the operations can be repeated with the motor connected to the
4.3.2.1 Direction checking
Jog forwards and Jog backwards. Check for movement in the correct direction. With Jog forward the carriage
advances in a positive direction and the Pos trolley mon (PAR 12038) increases.
Otherwise, reverse the motor phases and encoder channels A+ and A-.
4.3.2.2 Zero cycle positioning
Zero searching is to be checked out:
- Enable the drive.
- Enable the Homing command. The status of State mon (PAR 12000) must become Homing. The
carriage must move towards the zero position. Otherwise, remove Auto command and invert Home dir
(PAR 11400).
- Once the zero sensor has been engaged, the motor reverses its direction of travel to disengage the sensor
and move to the zero point
- The correct execution of the homing command is indicated by the Home found mon monitor (PAR 12014).
4.3.2.3 Carriage length development
The Jog command is used. After the zero cycle position measurement is active.
Mark the position on the carriage and register the Pos trolley mon (PAR 12038) position.
The carriage moves with JogPos or JogNeg depending on the direction desired.
Measure the distance travelled confronting the distance to the difference of the two Pos trolley mon positions.
Adjust the Trolley Kmec (PAR 11702) value if any errors occur.

Flying Shear for Roll Forming machines – Instruction manual Pag. 18 / 29
4.3.2.4 Metric Wheel Advancement
Check the correctness of the direction using the metric wheel. If the direction is incorrect use the metric wheel
encoder.

Flying Shear for Roll Forming machines – Instruction manual Pag. 19 / 29
5 Description of functions and parameter list
26.01 Application
The menu will display the version of the application installed on the drive.
MENU
PAR
Description
UM
Type
Def
Min
Max
ACCESS
26.01.01
12000
State mon
*
ENUM
*
*
*
R
Application status monitor:
0
Init
1
Disable
2
Standstill
3
Fast Stop
4
Jog +
5
Jog -
6
Homing
7
Auto
8
Move To
9
Heading
26.01.02
12002
Enable mon
*
BOOL
*
*
*
R
Monitors the drive enabling command.
26.01.03
12004
Fast Stop mon
*
BOOL
*
*
*
R
Monitors the fast stop command.
26.01.04
12006
Jog- mon
*
BOOL
*
*
*
R
Monitors the negative Jog command.
26.01.05
12008
Jog+ mon
*
BOOL
*
*
*
R
Monitors the positive Jog command.
26.01.06
12010
Homing mon
*
BOOL
*
*
*
R
Monitors the zero search (homing) command.
26.01.07
12012
Home sens mon
*
BOOL
*
*
*
R
Monitors the zero position sensor.
26.01.08
12014
Home found mon
*
BOOL
*
*
*
R
Monitors the zero position search status.
26.01.09
12016
Auto mon
*
BOOL
*
*
*
R
Automated cut command monitor.
26.01.10
12018
Blade down mon
*
BOOL
*
*
*
R
Monitors the blade in low position signal (in the end of cut position).
26.01.11
12020
Blade up mon
*
BOOL
*
*
*
R
Monitors the blade in high position signal (in the rest position).
26.01.12
12022
Imm cut mon
*
BOOL
*
*
*
R
Instantaneous cut manual command monitor.
26.01.13
12024
Virtual line mon
*
BOOL
*
*
*
R
Line simulator activation monitor.
26.01.14
12026
Virtual blade mon
*
BOOL
*
*
*
R

Flying Shear for Roll Forming machines – Instruction manual Pag. 20 / 29
MENU
PAR
Description
UM
Type
Def
Min
Max
ACCESS
Blade simulator activation monitor.
26.01.15
12028
Reset line mon
*
BOOL
*
*
*
R
Material count reset monitor.
26.01.16
12030
Cut time mon
s
FLOAT
*
*
*
R
Cut time monitor, measured as the time elapsed between the command being sent
and the blade release.
The monitor is updated after a cut in “automatic cut” mode, or after an immediate cut.
26.01.17
12032
Trolley spd ref mon
rpm
FLOAT
*
*
*
R
Speed reference monitor.
26.01.18
12034
Trolley acc ref mon
s
FLOAT
*
*
*
R
Acceleration time monitor.
26.01.19
12036
Trolley dec ref mon
s
FLOAT
*
*
*
R
Deceleration time monitor.
26.01.20
12038
Pos trolley mon
m
FLOAT
*
*
*
R
Trolley position monitor.
26.01.21
12040
Bar Length mon
m
FLOAT
*
*
*
R
Monitor the length of the last cut tube.
26.01.22
12042
Pos line mon
m
FLOAT
*
*
*
R
Monitor of the material not yet cut that passed under the shear.
26.01.23
12044
Max line spd mon
m/s
FLOAT
*
*
*
R
Maximum permitted line speed monitor.
26.01.24
12046
Line spd mon
m/s
FLOAT
*
*
*000
R
Line speed monitor..
26.01.25
12048
Auto state mon
*
ENUM
*
*
*
R
Automated cut status monitor:
Init
1-2-3
Dec fwd
Shear deceleration at the end of the line.
4
Wait fwd
Standby at the end of the line.
5-6-7
Acc rev
Shear acceleration towards the tracking start point for cut.
8
Rev spd
Constant shear speed to the tracking start point for cut.
9-10-11
Dec rev
Shear deceleration to stop at the tracking start point for cut.
12
Wait rev
Shear standby at the tracking start point for cut.
13-14
Acc fwd
Shear acceleration at tracking start point for cut.
15-16
Sync
Synchronization and cut phase.
26.01.26
12050
Cut req mon
*
FLOAT
*
*
*
R
Required cut length monitor.
26.01.27
12052
Word alarms mon
*
DINT
*
*
*
R
Alarm status word monitor.
(See Table 6 and Section 6 for more information)
26.01.28
12054
Word cmds mon
*
DINT
*
*
*
R
Command status word monitor.
(See table 7)