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NTN K-ECJ45 User manual

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1
・
Instruction Manual
(With Warranty Card)
Small Sized Frequency
Variable Controller
High Function Type
K-ECG25 (Control capacity 2A)
K-ECJ45 (Control capacity 4.5A)
Introduction
Thank you for your purchase of NTN small sized frequency controller (high function type). In order to correctly and
safely operate this controller, please read this instruction manual before using this device without fail. This instruction
manual with warranty card shall be delivered to end users without fail. In addition, user shall keep this manual at the
safe place where readily available wheneverneeded even after reading.
1. Before usage
In order for you to use this device correctly and
safely and to make the most of its function, notes
below and on the next page shall be observed.
 On receiving this device, please check if there is any
failure due to the transportation. If you find any
inconvenience such as a failure, do not hesitate to
contact the nearest sales office.
 This controller is only for NTN electromagnetic parts
feeder. Usage in other than this application or usage
exceeding the specification range is prohibited. It
may cause failures.
 The “parts feeder” described in this instruction
manual is the generic names for the bowl feeder, the
linear feeder and so on.
Introduction ・・・・・・・・・・・・・・・・・・・・・・・ 1
1. Before Usage ・・・・・・・・・・・・・・・・・・・・・・・・・ 1
2. Notes on Safety ・・・・・・・・・・・・・・・・・・・・・ 2 to 4
3. Function and Features・・・・・・・・・・・・・・・・・・・ 5
4. Appearance & Names of Portions・・・・・・・・・・・ 6
5. Installation・・・・・・・・・・・・・・・・・・・・・・・・・・・・ 7
6. For the first time use ・・・・・・・・・・・・・・・・・・・・ 8
7. Connection of Input/Output ・・・・・・・・・・・ 9 to 22
Wiring of vibration sensor ・・・・・・・・・・・ 13 to 14
8. Driving andAdjustment ・・・・・・・・・・・・・ 23 to 36
For Constant voltage mode ・・・・・・・・・・・・・・・ 26
For Constant amplitude mode ・・・・・・・・・ 28 to 30
For Resonance point tracking
+ Constant amplitude mode ・・・・・・・・・・・ 31 to 34
9. Setting of Functions・・・・・・・・・・・・・・・・ 37 to 51
F – V Curve ・・・・・・・・・・・・・・・・・・・・・・・・・・ 51
10. Protection/Warning Function ・・・・・・・・・ 52 to 53
11. Troubleshooting・・・・・・・・・・・・・・・・・・・ 54 to 56
12. Specification (Outside Dimensions) ・・・・ 57 to 59
Before use
Read this Instruction Manual to the last and
operate the machine correctly.
№PMPC035E-c
Page
Contents
K-ECG25
V.F. CONT ROLLER JAPAN
AC100-115 /200-230V 50 /60Hz 2A
FUNC
RESET
DATA
ENTER STOP
JOG
RUN
l
0
RoHS
Vib.ARUN Fre.A LIMIT
K-ECJ45
V.F. CONTR OLLER JAPAN
AC100-115/200-230V 50/60H z 4.5A
FUNC
RESET
DATA
ENTER STO P
JOG
RUN
RoHS
Vib.ARUN Fre.A LIMIT
l
0
ECG25 ECJ45
This Instruction Manual is applicable to Version 02.0 onward. Please use
after confirming information displayed immediately
after the power suppl
y
is turned ON.
(
Refer to P.24
)
2
2. Notes on Safety
As to the safety, users must have a great responsibility of their own. Be sure to begin any
operation after reading through this operation manual. In addition, in order to use this
controller with safe, be sure to obey the warning and caution labels of this device as well as
to observe the following notes.
Danger This description shows that not observing this remark and mishandling the device will
cause the death or serious injury of human body with high probability.
Warning This description shows that not observing this remark and mishandling the device will
cause the death or serious injury of human body.
Caution This description shows that not observing this remark and mishandling the device may
cause an injury of human body or property damage.
Danger
Please never work until the LED display of the operation panel turns. Please begin the work after two
minutes or more pass after power supply OFF.There is fear of an electric shock.
Please never drive with the panel opened (an emergency case is excluded). Moreover, please turn off
the power supply when you open the panel. It gets an electric shock, short-circuited, and is likely to ignite.
Please never do the wiring work without cutting off the primary side power supply or the main
breaker.
It gets an electric shock,short-circuited, and is likely to ignite.
This controller is a controller only for the NTN parts feeder (electromagnetic type vibration part
supply machine). It is not possible to use it for other usages such as a piezo-electric type parts
feeders and the single phase motors. It gets short-circuited and is likely to ignite.
Warning
Please ground the earth cables of the controller and the main body without fail. There is a fear of an
electric shock if you do not ground it.
Please never use it in the place with a gas ora liquid that explodes and ignites. It causes a fire.
Please a person other than the repair engineer never performs disassembling, repairing nor remodeling
this device. It may ignite or doabnormal motionto make him/her injured.
3
Warning
It must not be used in a place where it exposes to water, oil or chemicals, or outdoors, or in a
place of high temperature and humidity.
There is a fear of an electric shock, a fire or a failure.
Please do not scratch, pull or forcibly bend the wiring. Moreover, when a heavy thing is put on the wiring, or it
is pinched, the wiringwill be damaged. It causes a fire or an electric shock.
Please do not touch controller's output terminal during energizing the controller while even stopping.
There is a fear of an electric shock because the alternating current of maximum 200V is applied to the output
terminal.
Please do not connect AC power to the output terminal (1 and 2).
It causes a fire or the breakdown.
Foreign objects such as paper, waste wood or oil must not be allowed to enter the controller, and the
controller must not ruin its heat radiation by covering itwith such as the cloth.
There is a fear of the burn or a fire, etc.
Please do not operate the switch by a wet hand.
There is a fear of an electric shock.
Please do not use it with other than the specified voltage.
It causes a fire or the breakdown.
Please turn off the power supply or the main breaker on the primary side when you replace fuses. There is a
fear of an electric shock.
Caution
Temperature of heat dissipation fins and ambient of the controller box may become high (50~700C). Please
note that there is a fear of the burn. Moreover, please install a space for heat radiation in the surroundings.
(Refer to P.7)
Please do not do "ON" and "OFF" of the power supply frequently.
The controller will break down.
(Please refer to the paragraph 7.-(5) the wiring of external control input in P.15)
Please do not repeat "ON" and"OFF" of the power supplyin a short time.
Abig inrush current flows and there is a possibility thatthe controller breaks down.
Please do not install itin the place where the vibration or the impact is acting.
The controller breaks down.
4
Caution
Please refer to the note of caution on the margin below when doing the dielectric breakdown test and megger
test (measurement of the insulation resistance by the megohmmeter).
The controller breaks down when making a mistake.
Please do not do an operation such as switching of the displayed data or setting of the function etc. after
power supply OFF (during the period from power supply OFF to LED turning off).
When the subsequent power supply is turned on, it is likely to stop with Er2.
There is a distinction between the ground phase and non-ground phase in the power supply. Please confirm
the earth phase side of the power supply, and connect controller's specified terminal to the earth phase side.
(Refer to P.11).
There is a possibility ofcausing a fire when thewiring is grounded.
Please install the leak breaker or the leak detector on the primary side of power supply of the controller for the
ground fault protection. Especially, please install it surely when it is not possible to connect it to the ground
phase.
There is a possibility ofcausing a fire when thewiring is grounded.
Surely connect the earth clip of the welding machine to the bowl when welding to the bowl. An incorrect
connection of the earth for the welding may burn the earth cable that connects the main body and the
controller, and fears such as electric shock, leaks, andthe burn of the controller exist.
Please don’t conduct the welding work without turning off the power supply or the main breaker on the primary
side of the controller.There is a possibility ofcausing damage of the controller.
Please select and use an appropriate cable according to the voltage used, the current, and the environment.
There is a fear of a leakor a fire when a wrong cable is used.
It doesn't stop immediately even if the power is cut off. Moreover, the run/stop key is effective only when the
function is set. Therefore, when you urgently stop the machine when the driving is controlled from the outside,
please stop it by using the external control signal.
Please set the F/V curve and the current rating before drivingthe main body.
When making a mistake in thesetting, the magnet might be damaged by firing.
Mounting direction(Vibrating) of vibration sensor is predetermined. (Refer to P.13-14)
When making a mistake in setting the direction, adjustment can not be done. Please take care.
Be sure that noise does not get in wiring of vibration sensor. When noise gets in, controller may not
work or vibration amplitude may become large suddenly.
Please take care about wiring work and cable used. (Refer to P.13-14)
Be sure not to install or drive a damaged controller or a controller which is lack in parts.
There is a fear of an injury.
The noise is generated from the controller or wiring and equipments connected to the controller. Please take
care that neither a peripheral equipment northe sensor will malfunction. There is a fear of an accident.
*Note: Please execute the dielectric breakdown test with AC1500V or less between AC line and the earth, and
DC500V or less between DC line and the earth. The leakage of current shall be 10mA or less. Moreover,
during the test, the high pressure is charged in the internal capacitor. Be careful enough so as not to get an
electric shock.
5
Terms appearing frequently in this Instruction Manual
1. "Parts feeder" means generic names of such as bowl feeders and linear feeders, and for NTN products only.
2. The one only written as main body indicates “Vibration main body of parts feeder”.
3. The one onlywritten as LED indicates the data display portion on the operation side (Refer to P.6).
4. Original NTN terms such as “air blow during driving” is used. Please inquire of NTN for details of the operation.
3.Function and Features
(1) High precision digital control with micro processor
As various settings and operations are controlled digitally, highly precise and highly stabilized control is achieved. At
the same time, as a set value is displayed digitally, resetting of values is easy.
(2) Wide input “responding to wide voltage of power supply”
The input voltage ranges widely as AC100-115/200-230V±10% (50/60Hz ±10%). The output voltage automatically
changes to 100V output or 200V output according to the power-supply voltage. When the AC200V output is
necessary for theAC100V input, please changeto the type equipped withAC100V power source unit K-UE083.
(3) Installation of Constant amplitude function (Refer to P.28)
Constant amplitude function is installed to control output voltage so as to feedback signals from sensor and to make
amplitude of parts feeder constant.
(4) Installation of Resonance point tracking function (Refer to P. 31)
Resonance point tracking function to feedback drive frequency so as to operate always at resonance point is installed.
When resonance point trackingis selected, constant amplitude function is also ON automatically.
(5) Multi-speed function (Refer to P.20, Function H11 to 20 in P.40, and P.50)
Three kinds of speed data can be memorized internally, and the speed can be changed by the switch signal from the
outside. Moreover, non-step (1V or 1%unit) speed control of the output voltageby the analog voltage is possible.
(6) Enhancement of the protection function
Various kinds of protection function enhancing output short-circuit, overload etc. are installed as standard equipment.
Moreover, outputting of signalsaccording to protectionoperation is possible.
(7) Panel lock (Refer to P.49)
The operation from the operation panel can be prohibited if necessary. Awrong operation by an operator or unintended
change of setting by his/her contact etc. can be excluded. Two kinds of locks, the operation lock and the knob lock, are
installed according to therestricted range.
(8) Timer for air-blow and input/output terminal are equipped (Refer to P.17 to 19 and P.45 to 46)
Because the control circuit of the solenoid valve for the air blow is installed as standard equipment, the control of
air-blow during driving or two rowsAND air-blow etc. can be easily used.
(9) Work shortage detection function (Refer to P.21, Function H08 to H10in P.46 to 47)
The work shortage detection timer is installed.
(10) New development of vibration sensor with high resistance against noise (Refer to P.13 to 14)
Vibration sensor was made small and high performance. Extension up-to 5m by normal cabtire cable is possible. But,
shield wire may be necessary depending on the wiring environment.
6
4. Appearance and Names of Portions
The following diagram is explained about K-ECG25. But the layout of parts is same with K-ECJ45.
(1) Appearance diagram(Please refer to P.59 for dimensions)
(2) Terminal board(the panel is open)
Terminal board layout (Magnified diagram)
Terminal names are printed on the board
Signal terminal board
Power terminal board
Earth bar
Speed control knob
Operation panel
Warning seal
Power switch
Rubber bush
Cable ground
Production No.(Ser.№)
Data display
Pilot lamp
K-ECG25
V.F. CONTROLLER JAPAN
AC100-115/200-230V 50/60Hz 2A
FUNC
RESET
DATA
ENTER STOP
JOG
RUN
l
0
RoHS
Vib.ARUN Fre.A LIMIT
Accessory (Vibration sensor)
P1398
NTN
Signal terminal board Power terminal board
Pilot signal
Alarm signal
Emergency signal
Output
Power supply
Fuse
Y1A
Y1C
AL1
C1
EM
C2
2
1
N
L
0
1
2
3
4
5
6
7
24V
+V
X1
0V
24V
0V
IN1
IN2
0V
B1
B2
A1
0V
24V
P0
24V
P1
24V
P2
External control input
Sensor input
Speed switch input
Analog input
Valve control output
ECG25/3
A
ECJ45/5A
Soft switch
Connector for vibration sensor
K-P1398
Fixing leg
7
5. Installation
(1) Installation place
① Please install it on a firm material such as metals (nonflammable material) having no vibration.
② Please have a space in surroundings without fail so asnot to ruin heat radiation and install it vertically.
③ Oils and fats and chemicals, etc. may hurt the resin, painting, and the cable of BOX. These liquid and mist
must not splash directly on the controller.
(2) Installation hole and surrounding space
Please refer to the figure below for the dimension concerning controller's installation. Moreover, it is necessary
to leave a space shown in the figure below in the surroundings of the controller for heat radiation (Unit: mm)
[Installation dimension]
高温部の近く
横向きにする
木材
水平にする
液体がかかる
上下逆さにする
正しい取付け
振動や衝撃のある場所
Placing horizontally
Placing under spillage of liquid
Placing correctly
Placing near hot temperaturePlacing on wood
Placing sidewaysPlacing upside down Placing in environment
with vibration or impact
[Space to the surroundings]
K-ECG25
V.F. CONT ROLLER
RUN
JAPAN
AC100-115/200- 230V 50/60Hz 2A
FUNC
RESET
DATA
ENTER STOP
JOG
RUN
l
0
RoHS
取付足
取付面
30
60
510
Vib.A Fre.A LI MIT
Fixing face
Fixing leg
K-ECG25
V.F. CONTROLLER
RUN
JAPAN
AC100-115/200-230V 50/60Hz 2A
FUNC
RESET
DATA
ENTER STOP
JOG
RUN
l
0
RoHS
60(82)
30(60)
140
160
170
2-φ5
5
15
30(60)
2-R2.5
Vib.A Fre.A LIMIT
15(12.5)
Figures in () are dimensions for ECJ45
To mount the controller on the bowl feeder base,
purchase the separate optional unit.
Base mounting bracket: K-PZ0466
For details, ask NTN.
8
6. For the first time use
When you use the controller first time after the purchase, please make connections of input-output, and set all kinds of
functions according to the followings. In case that you purchase it as a completed product, setting etc. is not necessary.
But please check connectionsand settings without fail before driving.
Frequency adjustment
Frequency is adjusted so that
the amplitude of parts feeder
is appropriate.
The frequency is set manually
to an appropriate rangewhile
the parts feeder is driving.
(Refer to P.26)
Connection of input-output
Connect the parts feeder use, input-output signal cable or
vibration sensors (Only for constant amplitude mode and
resonance point tracking mode). (Refer to P.9 onward)
Flow for driving
Speed adjustment
In case that the driving was stopping, the driving is restarted and it is adjusted to outpu
t
an appropriate amplitude with the speed adjustment knob. If the speed adjustmen
t
knob is turned clockwise, amplitude increases. (Refer to P.34)
Setting of function
Function is set to match the using
condition.
<Basic setting>
・Setting of current rating⇒J01
・Selection of driving method⇒J02
・F-V curve⇒J04
・Driving condition⇒J06
・Polarity of vibration sensor⇒J07
(Refer to P.37 onward)
適正範囲
振
幅
低
周波数(Hz)
高
共振点
Avoid here
Setting mark
<Constant voltage mode><Constant amplitude mode><Resonance point tracking mode>
Resonance search/gain adjustment
Driving is stopped and J05 is set to “4”.
Resonance frequency search and gain
are adjusted automatically.
(Refer to P.31 onward)
For this controller, it is possible to select from three driving modes depending
on the application. Please refer to P.25 onward fo
r
the detail of every mode.
<Basic connection>
・Power supply cable
→P.11
・Load cable→P.12
<Connection for the using condition>
・Vibration sensor→P.13~14
・External control→P.15~16
・Connection of sensor or valve etc.
→P.17~19
Setting of function
Function is set to match the using condition.
<Basic setting>
・Setting of current rating⇒J01
・Selection of driving method⇒J02
・F-V curve⇒J04
(Refer to P.37 onward)
Depending on function, the driving
of controller must be stopped.
Gain adjustemnt
The driving is stopped and J05 is se
t
to ”3”. Gain is adjusted
automatically.(Refer to P.28 onward)
A
mplitude
Low
High
Frequency (Hz)
Resonance point
A
ppropriate range
9
7. Connection of Input-Output
External connection diagram (Also refer to the block
diagram in the next page)
(Details of each wiringare described in the page shown
in the notes written below, therefore please refer to them)
Caution
Please refer to the descriptions in caution for safety in P.2 to 4 and explanations for each item below for the wiring
method and cautions when wiring.
*1 Wiring of power supply P.11 Refer to paragraph “Connection to power supply”
*2 Wiring of load P.12 Refer to paragraph “Connection to load line”
*3 Wiring of vibration sensor P.13 to 14 Refer to paragraph “Wiring of vibration sensor”
*4 Wiring of external control signal P.15 to 16 Refer to paragraph “Wiring of external control input”
*5 Wiring of overflow sensor P.17 to 19 Refer to paragraph “Connection of sensor/solenoid valve”
*6 Receiving of drive signal P.21 Refer to paragraph “Wiring of drive instruction output”
*7 Others Multi-speed control P.20 Refer to paragraph “Multi-speed function”
Valve wiring P.18 to 19
Alarm/emergency signal P.21
パーツ
フィーダ
赤
白
緑電源ケーブル
ワーク確認
 センサ
振動センサリード線
*1
*2
*3
負荷リード線
*5
Caution
Please select an appropriate type to the
kind and the size of the cable used and
responding to use conditions and the
environment.
Danger
Do the wiring work after cutting off the
main breaker without fail. It is likely to get
an electric shock.
It is connected to the single phase AC
power. Please connect it to AC100-115V
orAC200-230V according to the voltage
of the main vibration body. The
frequency is both for 50 and 60Hz.
Connect green or yellow/green to the
earth.
【Array of terminal board】
24V
+V
X1
0V
24V
0V
IN1
IN2
0V
B1
B2
A1
0V
24V
P0
24V
P1
24V
P2
Y1A
Y1C
AL1
C1
EM
C2
2
1
N
L
0
1
2
3
4
5
6
7
*1
*2
*4
*5
*6
*7
*7
*7
Signal terminal board Power terminal board
Pilot signal
Power
Load
Emergency
signal
Alarm signal
External control signal
Sensor signal
Speed
switch signal
Analog signal
Valve control signal
*1 Power suppl
y
Green
Red
White
Parts
feeder
*2 Load cable
*3 Vibration sensor cable
※Connecting method of input/output in the following pages is explained basically for ECG25, but the same
specification is also applied toECJ45.
*5
Work confirming
sensor
10
電源
電源
スイッチ
FUSE
3A(ECG25)
5A(ECJ45)
出力
アース
直流電源
BOX
L
N
12C1EM C2Y1CY1A
Relay
コントローラ K-ECG25(ECJ45)
インバータ
 回路
AL1
突入電流抑制回路
Relay
制御信号出力
(ねじ端子台)
BOX
}
制御回路
0V
+24V
IN2
IN1
+V
X1
(実際の端子配列とは順番が違います)
}
B1
B2
A1
P0 P1 P2
制御信号出力
(ばね式端子台)
+24V
3.3k
3.3k
10k
アナログ入力
(ばね式端子台)
制御信号入力
(ばね式端子台)
0V
負荷
}
}
サービス電源
(ばね式端子台)
コネクタ
(振動センサ用)
CPU
Controller block diagram(Refer to the previous page for wiring)
*1 The array of the terminal in the above figure is different in sequence order from the actual terminal array.
*2 0V of the input circuitand 24V of the input/output circuit are all common.
*3 The input circuit of IN1, IN2, B1 and B2, and the circuit configuration of the output circuit of P0, P1 and
P2 are the same circuit configuration respectively.
(1) Remove the panel
①Loose two fixing M3-screws on operation panel
and remove operation panel. They are drop-out
protection types and if they are turned 3 to 4 times,
they will come off. If they are turned excessively,
they may drop out.
②Operation panel is connected to internal main
circuit board with cable. Pull out connector of
operation panel side, then remove operation
panel.
Note) Wiring work while operation panel remains
connected, may load to the connector of main
circuit board side and result in loose connection.
Be sure to perform wiring work after cable is
removed from operation panel.
Danger
Do the wiring work after cutting off the
main breaker without fail.
K-ECG25
JAPAN
①Loose
Controller K-ECG25 (ECJ45)
(Sequence order is different from the actual terminal array)
Service Power
(Spring terminal board)*2
Control signal input
(Spring terminal board)*3
Connector
(for vibration sensor)
Rush current
restrainin
g
circuit
Power
Earth
Power
switch
Load
DC
Power
Inverter
circuit Control circuit
Control signal output
(Screw terminal board) Control signal output
(Screw terminal board)
A
nalog input
(Spring terminal board)
Output
Cable
Connector
②Pull out
connector
Operation panel