Rexroth Indramat Mannesmann DKC21.3 User guide

Application
DOK-SUPPL*-BTV04*ELW**-AW01-EN-P
DKC21.3 for Roll Feeds with
ELC and BTV04

Über diese Dokumentation
ELC and BTV04
Application
•120-2100-B327-01/EN
This document assists
•in the programming of an ELC via the BTV04
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previous editions Status Comments
Dok-SUPPL*-BTV04*ELW**-AW01-EN-P 08/2000
Rexroth Indramat GmbH, 1999
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model or design. (DIN 34-1)
All rights reserved with respect to documentation and delivery of products.
Rexroth Indramat GmbH
Bgm.-Dr.-Nebel-Str. 2 •D-97816 Lohr a. Main
Telefon [phone] •Tx 689421 •Fax [phone]
http://www.rexroth.com/indramat
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Application Contents I
DOK-SUPPL*-BTV04*ELW**-AW01-EN-P
Contents
1 Introduction 1-1
2 Standard Roll Feed 2-1
2.1 The Tasks of a Roll Feed...............................................................................................................2-1
2.2 The Hardware Needed...................................................................................................................2-1
2.3 Program Structure in the Control ...................................................................................................2-2
Feed before the Press (Program example) .............................................................................2-2
Press before feed (Program example).....................................................................................2-2
2.4 Programming with the BTV04........................................................................................................2-4
Selection Menu ........................................................................................................................2-4
Programming Feed Data (F1)..................................................................................................2-5
Number of pieces input (F2) ....................................................................................................2-5
Programmable outputs (Tool selection) (F3)...........................................................................2-5
Drive Information (F4)..............................................................................................................2-7
System I/Os (F5 by Firmware ELC).........................................................................................2-7
Free Use Inputs .......................................................................................................................2-8
Outputs and markers ...............................................................................................................2-8
Markers 33 to 64......................................................................................................................2-9
Markers 65 to 99......................................................................................................................2-9
Stroke Count/Load (only for FLP Firmware)............................................................................2-9
Operating mode (F6)..............................................................................................................2-10
F1 Operating mode selection (Password Protection Level 1 possible ................................2-10
F2 Current operating mode...................................................................................................2-11
F3 Contrast Settings .............................................................................................................2-12
Diagnoses..............................................................................................................................2-12
Service Menu.........................................................................................................................2-13
Language...............................................................................................................................2-13
Serial System Control............................................................................................................2-13
2.5 Parameter ELC ............................................................................................................................2-14
A100 Applications.................................................................................................................2-14
A101 Feed Constant.............................................................................................................2-14
A102 Gearbox.......................................................................................................................2-14
A106 Maximum Speed..........................................................................................................2-15
A107 Set-up Speed...............................................................................................................2-15
A108 Bipolar Acceleration.....................................................................................................2-15
A111 Switching Threshold, Positioning Window...................................................................2-16
A115 Monitoring....................................................................................................................2-16
A116 Feed Monitoring...........................................................................................................2-16

II Contents Application
DOK-SUPPL*-BTV04*ELW**-AW01-EN-P
A117 Monitoring encoder difference (measuring wheel mode only)....................................2-17
AA00 Tasks 2 & 3 .................................................................................................................2-18
AA05 Electrical Ventilating....................................................................................................2-18
AA07 Measuring wheel mode...............................................................................................2-18
B000 Display.........................................................................................................................2-18
2.6 Interface Parameter .....................................................................................................................2-19
B001 Interface Parameter.....................................................................................................2-19
B002 Interface Parameter.....................................................................................................2-19
B009 Serial Inputs and Outputs............................................................................................2-20
B010 System Control............................................................................................................2-20
2.7 Drive Parameter...........................................................................................................................2-21
C000 Working Polarity..........................................................................................................2-21
C004 Interface encoder 2 (measuring wheel mode only).....................................................2-21
C005 Position encoder type 2 (measuring wheel mode only)..............................................2-21
C006 Resolution 2 (measuring wheel mode only)................................................................2-22
C007 Feed constant 2 (measuring wheel mode only)..........................................................2-22
CR07 Kv Factor ....................................................................................................................2-22
2.8 Parameter List ELC......................................................................................................................2-23
3 Terminal diagrams 3-1
3.1 BTV-DKC Interface and Power Connections.................................................................................3-1
3.2 ELC I/Os.........................................................................................................................................3-2
3.3 Accessories and Firmware.............................................................................................................3-3

Application Introduction 1-1
DOK-SUPPL*-BTV04*ELW**-AW01-EN-P
1 Introduction
This document describes the standard program for roll feed applications
selected using the F functions.
This makes a quick and secure integration of a Rexroth Indramat system
for a functioning roll feed possible (Turnkey solution).
For applications with expanded functions, all services are available via the
Service menu of the single-axis control ELC for free programming. (See
documentation on single-axis control ELC DOK-ECODR3-FLP-01VRS**-
FK01-DE-P MN 287131 or DOK-ECODR3-FLP-01VRS**-FK01-DE-P
MN 287131).
The customer thus has at his disposal all options for a quick and flexible
application of the Rexroth-Indramat solution.

1-2 Introduction Application
DOK-SUPPL*-BTV04*ELW**-AW01-EN-P

Application Standard Roll Feed 2-1
DOK-SUPPL*-BTV04*ELW**-AW01-EN-P
2 Standard Roll Feed
2.1 The Tasks of a Roll Feed
It is the task of a roll feed to transport material (sheet-metal, wiring and so
on) under a press, cutter or stamper. The material may only be trans-
ported if the stamping or cutting tool is open. The synchronisation be-
tween feed and press is controlled with an external signal (feed area)
which signals the position of the press.
Fig. 2-1: Roll Feed
2.2 The Hardware Needed
The Indramat system for a standard roll feed with ELC control is made up
of the following hardware components:
Drive controller DKC21.3
Servo motor MKD o MHD
BTV04 operator terminal
M
gearbox
meas.wh.
MMD/
MHD
Imp/rev.
DKCBTV
3 x 400 to 480V
50/60Hz
mains
Indramat
does not
supply
wheel
Abb_022_ELW_en
Fig. 2-2: Block diagram

2-2 Standard Roll Feed Application
DOK-SUPPL*-BTV04*ELW**-AW01-EN-P
2.3 Program Structure in the Control
Feed before the Press (Program example)
The program sequence of a standard roll feed in the ELC control. The
feed takes place before the press hub (feed guides) and the press is op-
erated in a single hub.
ELC program
Block number
0000 JMP 0005 unconditional jump to block number 0005
0001 NOP
0002 NOP space
0003 NOP
0004 NOP
0005 APE 0 0000000000 outputs (press) switched off
0006 AKN 02 1 0009 query whether cycle stop applied
0007 JMP 0009 unconditional jump to block number 0009
0008 NOP
0009 AKN 01 1 query if press on top
0010 PSI 1 | +147,000 | 55,9 ;feed length and speed
0011 JMP 0015 unconditional jump to block number 0015
0012 NOP
0013 NOP
0014 NOP
0015 APE 0 0100000000 outputs (press) switched on
0016 AKN 01 0 query if press below
0017 JMP 0020 ; unconditional jump to block number 0020
0018 NOP
0019 NOP
0020 BAC 0005 +0000 00010 item counter
0021 APE 0 0000000000 outputs (press) switched off
0022 NOP
0023 NOP
0024 NOP
0025 JST 0000 block jump with stop
Press before feed (Program example)
Program sequence for a standard roll feed in the ELC control. The press
hub is ahead of the feed (press guides) and the press is operated in a
single hub.
ELC program
block number
0000 JMP 0004 unconditional jump to block number 0004
0001 NOP
0002 NOP empty
0003 NOP
0004 AKN 02 1 query if cycle stop applied
0005 APE 0 0100000000 outputs (press) switched on
0006 AKN 01 0 query if press below
0007 JMP 0015 unconditional jump to block number 0015
0008 NOP
0009 AKN 01 1 query if press above
0010 PSI 1 | +147,000 | 55,9, feed length and speed
0011 JMP 0020 unconditional jump to block number 0020
0012 NOP
0013 NOP
0014 NOP

Application Standard Roll Feed 2-3
DOK-SUPPL*-BTV04*ELW**-AW01-EN-P
0015 APE 0 0000000000 outputs (press) switched off
0016 JMP 0009 unconditional jump to block number 0009
0017 NOP
0018 NOP
0019 NOP
0020 BAC 0004 +0000 00010 item counter
0021 APE 0 0000000000 outputs (press) switched off
0022 NOP
0023 NOP
0024 NOP
0025 JST 0000 block jump with stop
Application-related program changes can be inserted into the empty lines.
Note: The commands APE, PSI and BAC must be set in the block
numbers indicated in the program example as otherwise the
BTV program will not function.
In the programming examples above, Output 1 (X210/Pin 21) is used to
start the press. The feed range is transmitted via Input 1 (X210/Pin 7).
The program cycle is interrupted via Input 2 (X210/Pin 8). Using the cycle
interrupt, the program flow can be stopped at the current location, even if
the programmed piece count has not yet been reached. As soon as this
"on" signal (X210/Pin 8) goes back to zero, the program continues (with-
out a start command) from the same place it was stopped.

2-4 Standard Roll Feed Application
DOK-SUPPL*-BTV04*ELW**-AW01-EN-P
2.4 Programming with the BTV04
Note: The DKC programming module must be set to drive address
05.
Abb023_BTV_ELW_en.FH7
Barcode
0
1
2
3
4
5
6
7
8
9
0
1
2
3
4
5
6
7
8
9
H1
S1
S3 S2
0
1
2
3
4
5
6
7
8
9
0
1
2
3
4
5
6
7
8
9
Rotary Switch S2Rotary Switch S3
Drive Address
set to: 05
Fig. 2-3: Setting the Drive Address
Selection Menu
After the BTV 04 has been switched on, the following appears on the dis-
play.
Roll Feed
F1 = length and speed
F2 = item number
F3 = tool selection
F4 = drive information
F5 = I/Os
F6 = operating mode
Help = diagnoses
Shift + Help = service
Fig. 2-3: Selection menu
Since only six lines can be simultaneously displayed, the three lower sec-
tions of the text can only be reached by scrolling with NH\V
The relevant submenu can be called up by pressing the specified F-key or
scrolling with the arrows and then pressing the „OK key“. The return from
one menu back to the previous one is possible with the „ESC key“. With
the „Main menu“ key the user returns immediately to the selection menu.
All keys that have a function in a menu are illuminated.

Application Standard Roll Feed 2-5
DOK-SUPPL*-BTV04*ELW**-AW01-EN-P
Programming Feed Data (F1)
If the function „lengths and speed input“ is pre-selected, then the following
picture appears:
momentary length
+ XXXXX.XXX mm
velocity
XX % of Vmax
Vmax = XX m/min
Fig. 2-4: Feed data
Feed length and speeds can be programmed in the dark fields. Using the
NH\VLWLVSRVVLEOHWRPRYHEHWZHHQWKHILHOGV(DFKLQSXWPXVWEH
confirmed with “OK“. The maximum possible speed of the machine is
displayed in the lower line.
Number of pieces input (F2)
To input the number of pieces, the following appears with actual and set-
point number. The setpoint number can be changed in the dark field. This
input must be confirmed with the „OK“ key.
Number of pieces
Actual Setpoint
XXXXXX XXXXXX
Input XXXXX
Fig. 2-5: Feed data
Programmable outputs (Tool selection) (F3)
Four outputs can be set in this menu with which the press, scissors or
other tools can be controlled. The status of the outputs can be changed
once prior to the feed and once after the feed.
The following appears for this setting
Tool before feed
0001
tool no. 12345678
0112
tool after feed
Fig. 2-6: Feed data
The status of the eight outputs can be altered in the darkened field.

2-6 Standard Roll Feed Application
DOK-SUPPL*-BTV04*ELW**-AW01-EN-P
0 means the output is switched off
1 means the output is switched on
2 means the output remains unchanged
The place to be changed can be reached with the NH\7KHLQSXW
must be confirmed with the „OK“ key.

Application Standard Roll Feed 2-7
DOK-SUPPL*-BTV04*ELW**-AW01-EN-P
Drive Information (F4)
This menu can display information from the motor encoder or measuring
wheel encoder. The length and speed of the relevant encoder are speci-
fied. The clear key that is now illuminated can re-set the length back to
„000000,00“.
motor encoder
length + XXXXXX,XXX mm
speed +XXXX,XX rpm
measuring wheel encoder
length +XXXXXX,XXX mm
Fig. 2-7: Drive information
Note: The data referencing the measuring wheel are only displayed
is the measuring wheel mode is set in the ELC parameter
A100.
System I/Os (F5 by Firmware ELC)
The I/O menu can be used to check the current state of the system inputs
and outputs. System inputs support the ELC control and are permanently
assigned. The customer cannot use these for any other purpose. The
following inputs are assigned to the system inputs:
Parameter, manual/automatic, start, stop, jog forward, jog backward.
The customer cannot program system outputs that are status messages.
The following outputs are system outputs:
manual, automatic, interference and run.
Abb028_Syst_EinAusg_en
System inputs
110110
System outputs
0010
F1 = inputs F2 = outputs
Para
Auto.
Start
jog -
jog +
Hand
Auto. RUN
fault
Stop
Fig. 2-8: System I/Os
A „1“ shows that the relevant input is active and the „0“ displays inactive.
This menu can also be used to display the freely-programmable I/Os.

2-8 Standard Roll Feed Application
DOK-SUPPL*-BTV04*ELW**-AW01-EN-P
Free Use Inputs
The following appears if this menu is called up:
free-use inputs
110110 1101 1-10
Fig. 2-9: System I/Os
The switched on inputs are displayed as „1“ and the switched off ones
with „0“.
Outputs and markers
The outputs can be switched by the customer in the user program and
support the control of the external components. Markers can also be set
in the user program but do not lead outward. They can only be queried
internally in the program.
If this menu is called up, then the following appears:
outputs / marker 1-32
000111 110110 1101 1-16
000111 110110 1101 17-32
F1= marker 33-64
Fig. 2-10: Outputs and markers
The switched on outputs are displayed with “1”, those off with „0“.
Since not all 99 outputs or markers can be displayed at the same time,
they are distributed over three pictures. To move on, use the F1 key.

Application Standard Roll Feed 2-9
DOK-SUPPL*-BTV04*ELW**-AW01-EN-P
Markers 33 to 64
The following is visible in this menu:
Marker 33-64
000111 110110 1101 33-48
000111 110110 1101 49-64
F1= Marker 33-64
Fig. 2-11: Marker 33-64
The switched on markers are displayed with „1“ and those off with „0“.
Further markers can be displayed by actuating the F1 key.
Markers 65 to 99
The following appears in this menu:
Marker 65-99
000111 110110 1101 65-80
000111 110110 1101 81-96
010 97-99
Fig. 2-12: Marker 65-99
The switched on markers appear with a „1“, and those off with „0“. The
“ESC” key brings the user back to the previous menu.
Stroke Count/Load (only for FLP Firmware)
If the F5 key is pressed while using the FLP firmware, information about
the press stroke count and the required feed time as a percentage of the
feed distance is displayed. Activating the parameter for Feed Monitoring
(A116) is required for this to function.
Stroke Count
XXXX Strokes/min
Load
XX in %
Fig. 2-13: Stroke Count/Load

2-10 Standard Roll Feed Application
DOK-SUPPL*-BTV04*ELW**-AW01-EN-P
Operating mode (F6)
If the F6 is pressed in the main menu, then an operating mode is pre-
selected and the currently valid mode displayed. The contrast can also be
changed here. The following display appears.
F1 = operating mode selection
F2 = current operating mode
F3 = contrast setting
F1 Operating mode selection (Password Protection Level 1 possible
If F1 has been actuated, then it is possible to select an operating mode in
single steps in set-up mode and automatic mode. If one of the following
menus is selected, then complete programs are transmitted into the ELC.
The following appears:
Operating mode selection
F1 = single step in
set-up mode
F2 = automatic mode
If F1 single step in set-up mode is selected, then the following appears:
Operating mode selection
F1 = feed before
press (VvP)
F2 =press before
feed (PvV)
The F1 and F2 keys can be now used to select an operating mode and to
transmit the relevant program into the ELC. The message that the se-
lected operating mode has been transmitted comes after about five sec-
onds.

Application Standard Roll Feed 2-11
DOK-SUPPL*-BTV04*ELW**-AW01-EN-P
In single step set-up mode a new start signal must come after every step.
If “operating mode select” F2 for automatic mode has been selected, then
the following appears:
Operating mode selection
F1 = feed leads / single
F2 = feed leads / continuous
F3 = press leads / single
F4 = press leads / continuous
Using keys F1 to F4 it is now possible to select various operating mode
combinations (feed leads, press leads, press single hub and press con-
tinuous run). After actuating the relevant key, the required program is
transmitted into the ELC and a message that states that the transmission
is completed comes after about five seconds.
Note: For the transmitted programs to work in set-up and automatic
modes and for the operating mode display to be correct on the
BTV, task3 of the ELC in block number 0035 must be re-
leased.
Parameter AA00 = XXXX 0035 X
F2 Current operating mode
If „Operating mode“ has been selected with F2, then the currently pro-
grammed operating mode selected appears, as is shown below:
Current operating mode
automatic mode
press single hub
feed leads
Note: To correctly display the operating mode, markers 40 to 46 are
processed in task3. The commands for this are automatically
sent with the operating mode.

2-12 Standard Roll Feed Application
DOK-SUPPL*-BTV04*ELW**-AW01-EN-P
F3 Contrast Settings
If the contrast setting was selected in menu „Operating mode“ with F3,
then the following appears:
Parameter set-up
F1-Serial Port Parameter
F2-System Parameter
F3-Save Values and Reboot
F4-Exit without Changes
6HW/&' Contrast
Fig. 2-13: Contrast setting
Using the arrows WKHGLVSOD\FDQEHDGMXVWHGWRWKHDFWXDOOLJKWFRn-
ditions. If this setting is to be stored, then it is necessary to leave this
menu using the F3 key. If this menu is left using the F4 key, then the con-
trast is not stored. The previous contrast setting is retained. All other pa-
rameters that can be selected in this menu can be protected in the BTV
system parameters by inputting a password.
Diagnoses
To receive information about the drive, then it is possible to branch off into
the diagnoses menu with „HELP“.
Operating mode
XX automatic mode
DKC21.3
ECODR3-ELC-01A09
Fig. 2-14: Operating mode
The present operating mode with status number is displayed in this menu.
The connected DKC type with the firmware version also appears. Both
status messages and warnings are also displayed here.
In the event of a fault, not warnings, the diagnostics menu is automatically
switched into and the following picture appears.

Application Standard Roll Feed 2-13
DOK-SUPPL*-BTV04*ELW**-AW01-EN-P
status display
XX „error message“
to clear error
press „CLEAR“
Fig. 2-15: Status display
The presently pending error is displayed in clear text along with the error
code number. The “Clear key” is also illuminated.
It is not possible to leave this menu until the error has been cleared and
acknowledged via the „Clear key“.
Exception: service menu call up via the key combination „SHIFT“ and
„HELP“.
Service Menu
The service menu permits complete programming and parametrization of
the ELC control. This menu can be protected in the BTV by allocating a
password to it.
This menu is called up with key combination „SHIFT“ and „HELP“ in the
main menu. This is followed by the request to input the password if this is
activated in the BTV’s system parameters.
Language
The BTV automatically goes to the language set in the ELC parameter
B000.
B000 00 = German
01 = English
02 = French (in preparation)
03 = Spanish (in preparation)
04 = Italian (in preparation)
05 = Dutch (in preparation)
Serial System Control
If serial system control is activated in Parameters B009 and B010, the
drives can be jogged using the 'jog keys' (Jog+/Jog-) on the BTV. The
operating mode can be selected by using the 'Auto' key. The automatic
program can then be controlled using the 'Start' and 'Stop' keys. Then, the
hardware inputs (system inputs) via the DIO card are no longer neces-
sary.
B009 1 200 / B010 1

2-14 Standard Roll Feed Application
DOK-SUPPL*-BTV04*ELW**-AW01-EN-P
2.5 Parameter ELC
The most important parameters for a roll feed are listed below. These
must be adapted to the situation and conditions in and at the facility. The
precise definition of the parameters and the complete parameter descrip-
tions are listed in the ELC documentation.
A100 Applications
0 0
Function encoder 2 (optional measuring wheel):
0 = none
3 = measuring wheel
motion type
0 = rotary (infinitely turning)
A101 Feed Constant
0100.0000 feed constant in EGE
Input min : 0.1000
Input max: 5000.0000
The length resulting from one motor revolution to be run is entered here if
the encoder ratio is not to be given especial consideration (parameter
A102 = 0001 0001).
If the gear ratio is entered in parameter A102, then the feed constant is
the circumference of the draw-off roll.
A102 Gearbox
1000 2000 load gear output revolutions
load gear input revolutions
Input min : 1
Input max: 9999
gear ratio between motor and draw-off roll