RIMROCK 410 User manual

1. INTRODUCTION
SERVO DRIVE RECIPROCATOR WITH TRIANGLE
CONTROLS
1
1.1 GENERAL EQUIPMENT SAFETY _______________ 1
1.2 INSTALLATION SAFETY
________________ _
1.3 SET-UP AND OPERATION SAFETY
_____ _______ _ _
1.4 MAINTENANCE SAFETY 2
1.5 MACHINE DESCRIPTION 2
1.6 UNPACKING INSTRUCTIONS 3
1.7 MODES OF OPERATION 3
1.8 KEYPAD SECTIONS 5
1.9 SEQUENCE OF OPERATION 5
1.10 MACHINE POSITIONS 5
2. INSTALLATION 1
2.1 MOUNTING THE RECIPROCATOR ______________ 1
2.2 PROXIMITY SWITCH ADJUSTMENTS 1
2.2.1 REST POSITION PROXIMITY SWITCH: 1
2.2.2 CHECK POSITION: 1
2.2.3 RECIPROCATOR CLEAR: 1
2.2.4 CLOCKWISE PROXIMITY SWITCH 2
2.3 ELECTRICAL 2
2.4 INTERLOCKING* 3
2.4.1 INPUTS* 3
2.4.2 OUTPUTS* 5
2.5 PLUMBING CONNECTIONS: 5
2.6 DRY CYCLING: 6
2.7 HOMING SEQUENCE: 6
2.8 MACHINE SIZE SETUP 6
3. PROGRAMMING
2
3.1 GENERALALGORITHM ____ _________ _ __ _ 2
3.2 TYPICAL RECIPROCATOR CYCLE: 2
3.3 KEYPAD DESCRIPTION 3
3.5 AUTO TEACH:
13
4. COMPONENTS 1
4.1 ELECTRICAL- GENERAL _ _ ___ _ _______ _ _ _ _ 1
ELECTRICAL -SPECIFIC 1
TABLE OF CONTENTS 2/22/01 VERSION 3.21

SERVO DRIVE RECIPROCATOR WITH TRIANGLE
CONTROLS
5. MAINTENANCE & TROUBLESHOOTING 1
5.1 MAINTENANCE _____________________ !
5 .2 TROUBLESHOOTING 1
5.2.1
RECIPROCATOR FAULT LIST 2
5.2.2
COMM. FAULT CORRECTION 2
5.2.3 OPR. FAULT CORRECTION 3
5.2.4
5.2.5
5.2.6
5.2.7
5.2.8
I/0 DESCRIPTION __________________ 3
POWER SUPPLY: 4
ENCODERS: 4
CIRCUIT BOARDS: 5
KEYPAD: 5
5 .2.9 ELECTRICALSPAREPARTLIST __ _____ _______ 7
5
.2.10 MECHANICAL SPARE PART LIST 7
6. ELECTRICAL DRAWINGS
I/0 RACK RIBBON CABLE ______________ 306B11083-04
1-AXIS SERVO CARD CABLE TO IC PCB 411Cl6814-01
MICROPROCESSOR CARD ORA WINGS:
CPU BOARD _________________ 140B 11440-05(SHT 1-2)
SERVO BOARD 140B 11442-11
DIGITAL
I/0 BOARD, NOT USED ON ALL 140Bl1441-01
DIGITAL INTERFACE BOARD 140Bl1440-11
43,47, 60, 66, 72" MODULE SCHEMATIC AND ASSEMBLY 411Dl1450-17(SHT 1-
3)
HD60, HD80" MODULE SCHEMATIC ANDASSEMBLY _____ 411D11450-24(SHT 1-
3)
HD80" W/SLIDEBASEMODULE SCHEMATIC AND ASSEMBLY __ 411Dl1850-07(SHT 1-
4)
WIRING LAYOUT CONTROL CABLE IN BOX ________ 411 C11450-29
HEAT SINK ASSEMBLY FOR HD60 AND HD80" CONTROLS 411D 11429-19
CONTROL BOX AND MAIN PANEL SCHEMATIC AND ASSEMBLY __ 140D 11850-01( SHT 1-
3)
TRIANGLE INTERCONNECTIONS MEGA TABLE. ________ l40Dll850-100(SHT 1-2)
RECIPROCATOR MAIN CONTROL CABLE 411D11302-500
REMOTE KEYPAD BOX SINGLE AND DUAL ASSEMBLIES 140D11850-50(SHT 1-
2)
REMOTE VIDEO KEYPAD BOX ____________ 140D11850-65
KEYPAD CONTROL CABLE 140C16801-133
VIDEO CONTROL CABLE 140C16803-01
REMOTE KEYPAD AND VIDEO MOUNT ASSEMBLY 140D 11450 -101
REMOTE PUSH BUTTON
ENABLE KIT SCHEMATIC AND ASSEMBLY_140D16809-100(SHT 1)
REMOTE CONTROL BOX ASSEMBLY 306D 11367
TABLE OF CONTENTS 2/22/01 VERSION 3.21

SERVO DRIVE RECIPROCATOR WITH TRIANGLE
CONTROLS
7. MECHANICAL DRAWINGS
MOUNTING LAYOUT 410-60" ___________ __ SDRD47LA YOUT
MOUNTING LAYOUT 41 0-47'' SDRD60LA YOUT
MOUNTING LAYOUT 41 0-72" SDRD72L A YOUT
43, 47,60, 66, 72" MAIN BODY ASSEMBLY AND WIRING 410D11600-01(SHT 1-
4)
ARM ASSEMBLY, 60, 66, 72" ____________ 410Dl1600-22
ARM ASSEMBLY, 43, 47" 410D11600-23
HOSE ASSEMBLY, 2 LUBE 410D11600-63
HOSE ASSEMBLY, 3 LUBE 41 OD 11600-65
POWERBASE ASSEMBLY 1 0.5'' TRAVEL 41 OD 11600-41
MANUAL BASE ASSEMBLY 10.5' ' TRAVEL 410D11600-42
SHOCK MOUNT SUB-BASE ASSEMBLY 410D11600-91
SPRAY ARM ASSEMBLY, 1 LUBE 410D11600-81
SPRAY ARM ASSEMBLY, 2 LUBE 410D11600-84
HD60 ANDHD80" MAIN BODY ASSEMBLY AND WIRING 410D11602-01(SHT 1-
4)
HD 80" ARMASSEMBLY ______________ 410D11602-21
HD 60" ARM ASSEMBLY 410D11602-22
HD 80" HOSE ASSEMBLY 410D11602-63
POWER BASE ASSEMBLY 14.5" TRAVEL 41 0D11600-44
POWER BASE ASSEMBLY 18.5" TRAVEL 41 OD 11600-45
HD SLIDE BASE ASSEMBLY 45" TRAVEL2 LUBES 410D11579-2
HD SLIDEBASEASSEMBLY45" TRAVEL3 LUBES 410D11579-3
SPRAY ARM ASSEMBLY 2 LUBES 41 OD 11602-80
18" Q.R. EXTRUSION MANIFOLD 1 LUBE 025 NOZZLE 110D15911-125
18" Q.R. EXTRUSION MANIFOLD 2 LUBE 025 NOZZLE 110D15912-125
24" Q.R. EXTRUSION MANIFOLD 1 LUBE 025 NOZZLE 11 OD 15921-125
24" Q. R. EXTRUSION MANIFOLD 2 LUBE 025 NOZZLE 110D15922-125
PNEUMATIC ASSEMBLY (1 LUBE) 163D09381-33
PNEUMATIC ASSEMBLY (2 LUBE) 163D093 82-31
PNEUMATICASSEMBLY(3 LUBE) 163D09382-33
RIMROCK SPRAY CATALOG FRONT COVER
DIE CAST MACHINE SAFETY (NADCA #E-908) LAST SECTION
TABLE OF CONTENTS 2/22/01 VERSION 3.
21

MANUAL
VERSION
NUMBER
3.14
3. 15
3.16
3.19
3.20
3.2.1
3.21
SERVO DRIVE RECIPROCATOR WITH TRIANGLE
CONTROLS
MANUAL REVISION HISTORY
SOFTWARE
VERSION COMMENTS DATE
NUMBER
3.14 PRELIMINARY RELEASE, FIRST 9/22/94
FOR TRIANGLE
3.15 UPDATED KEYPAD DESCRIPTION 10/13/94
AREA
3.19 ADDED DOCUMENTATION
FOR 08/01/95
80" MACHINE
3.19 REVISE AND UPDATE 5/10/96
3.20 REVISE AND UPDATE TO 07/06/98
SOFTWARE
3.21 REVISE AND UPDATE TO 07/06/98
SOFTWARE
3.21 ADDED MECHANICAL SPARE 08/06/98
PARTS LIST
REVISION HISTORY 2/22/
01 VERSION 3.21
BY
RJM
RIM
RIM
MDI
IMH
ACY
ACY

1
Introduction

SERVO DRIVE RECIPROCATOR WITH TRIANGLE
CONTROLS
WARNING
Please read entire manual before attempting any installation or set up of this
machine. Failure to do so may result
in personal injury or machine damage.
The door interlock switch located inside the control panel does not remove power
from the entire control panel. This switch only disaoles 1/0 control power,
therefore use extreme caution when door is open.
410 SERVO DRIVE RECIPROCATOR
WARRANTY
For a period of six (6) months from the date of shipment or prior to the first
250,000 cycles, RIMROCK Corporation will repmr or replace, at it's option, any
part of the system that is found to be defective in workmanship or material.
Determination
of our obligation under this warranty will be made by RIMROCK
after
~xamination of alleged defective materials are returned to us transportation
prepaid.
The foregoing warranty is exclusive and in lieu of all other warranties whether
written, oral,
or impliea, including the warranty of merchantability and the warranty
of fitness for a partrcular purpose.
Any alteration, modification
or repair to any circuit board contained in the system
will VOID all warranties. All electronic repairs MUST be handled through
RIMROCK Corporation.
WARNING AND WARRANTY 2/ 2 2/ 01 VERSION 3.21

SERVO DRIVE RECIPROCATOR WITH TRIANGLE
CONTROLS
1. INTRODUCTION
1.1 GENERAL EQUIPMENT SAFETY
The invention of automatic equipment used on
die casting machines greatly enhanced the
production and efficiency of making quality
castings. Like any other machinery, if not used
safely it can pose a hazard to personnel as well
as damage to the equipment.
Safety of operation begins with trammg
personnel in the safe operation and maintenance
of this equipment. Operator and maintenance
people must understand how the equipment
works in order to operate it safely. The
owner/end user of this equipment is responsible
for the training to safely operate and maintain
this equipment. RIMROCK will provide
equipment training when requested.
Machine owners, operators, maintenance and
service personnel must be aware of the fact that
every day common safety practices are vital part
of their job and must be compiled with
constantly. Use of personnel protective
equipment and keeping the work area clean and
free of potential hazards will enhance any safety
program. In addition, all warning labels, signs
and guards must always be replaced if they are
removed for any reason. Safety violations
should always be reported to the proper
personnel.
Always remember automatic equipment starts by
a signal and gives you no warning. Always be
aware of this and make sure the equipment is
shut off and all power sources locked out before
you work on or around the equipment.
In addition to the safety precautions in the
manual, all the latest OSHA Instructions, Local,
Federal and National Safety Codes and Safety
Rules must be understood and followed to
operate equipment safely. For additions safety
information on die casting, refer to NADCA's
Die Casting SafetyManual E-908.
1.2 INSTALLATION SAFETY
Study the equipment's manual before attempting
to install this machine. The installation must be
made with only qualified personnel capable of
pos1t10ning, anchoring, making power
connections and interlocking this equipment with
other equipment. Failure to use qualified
personnel could result in personnel injury as well
as damage to your equipment. The electrical
connections must be made by a qualified
electrician who must be able to read and
understand electrical schematics in order to
assure a safe hook-up. Correct grounding of
interlock connections are explained and
illustrated in your manual. In addition, a safety
barrier must be installed to prevent personnel
from entering the path of moving equipment
while it is operating. It should also be noted that
proper clearance must be allowed for all
movements of your equipment. By following
these recommended steps your equipment should
operate safely and correctly.
1.3 SET-UP AND OPERATION SAFETY
Operator and maintenance personnel must read
the equipment manual and be trained in the
proper operation of this equipment in order to
set-up ant operate it safely. Always make sure
all control panel switches are "off' when power
is first applied. Never make any adjustments to
the equipment while it is operating. Remember,
the machine has the ability to strike you, pinch
or grab loose clothing which may result in injury
to you. In order to stay out of its path, you must
always know in which direction the machine is
going to move next. It should never be
necessary to make adjustments to this equipment
with the power"ON". If you find it necessary to
make an adjustment or for troubleshooting with
the power "ON", a second qualified person
should be at the operator panel operating the
equipment in "MANUAL" mode. The second
person should always have sight of the person
working on the equipment. Under NO
circumstances would any adjustments be made
while the equipment is moving. Never operate
the equipment before making sure the area is
clear and all safety guards and devices are in
place. Only authorized personnel should
modify the programming of this equipment and
it can never be operated without the
SECTION 1 PAGE 1 INTRODUCTION 2/22/01 VERSION 3. 21

SERVO DRIVE RECIPROCATOR WITH TRIANGLE
CONTROLS
recommended interlocks. Any unsafe conditions
of equipment operation should be reported to the
proper personnel immediately.
1.4 MAINTENANCE SAFETY
Do not attempt to perform any maintenance on
this equipment until you read and understand all
the safety instructions and all the power sources
are locked out according to OSHA's Lock Out
Procedures. Be sure the electrical power in the
interlock system is "OFF" when the machines
power is disconnected. these are usually yellow
wires and can supply power from another source
when the main disconnect
is off . Always tum
power "OFF" before removing the circuit boards
to prevent damage to the boards and also
"Electrical Shock" to yourself. Keeping your
equipment clean and the area
in which it is
located clean is a vital part of your safety
program. Developing a setperiodic maintenance
program
of your own, plus following
recommended maintenance in this manual will
extend your equipme
nt' s life and make it safer to
operate. Do not attempt to alter, bypass or short
circuit any safety device or systems on this
equipment. All guards, shie
ld s, barriers or
covers must be put back after any maintenance is
performed
or repairs are completed before the
equipment
is returned to service. The end user
of this equipment is responsible for the safe
operation
of the equipment and for the safety of
their plant operations and maintenance
personnel.
1.5 MACHINE DESCRIPTION
The RIMROCK Model 410 Reciprocator is a
fully programmable die spray system, using one
motor for the power source. This motor drives a
face mounted gear reducer that is directly
coupled to the main drive shaft. The main drive
shaft is attached to the Multi- Link arm which
holds the spray manifold.
The motor is controlled with a newly developed
computer control system. This computer system
allows complete control
of the reciprocator.
Each movement
of the machine has a wide range
of programmable position s, dwell times and
spray functions. All positions
ar e programmed
from the control panel allowing for easy and fast
adjustmen
ts.
The control system is mounted in one control
cabinet. The system consists of: keypad, cards,
card cage, motor controller, input/output rack,
powersupply, message center and relays.
THE COMPUTER SYSTEM CONSISTS OF
THE FOLLOWING:
Keypad -Mounted on the front of the operators
panel, it
is used to program the system and show
digital readouts
of all programmable functions of
the unit. It communicates to the CPU card via a
serial communication network. This allows the
Keypad to be located away from the main
control box.
Video Keypad -
As an option this machine is
available with a Video Touch Screen Operator
Interface, for use
as a Keypad. This Video
Interface utilizes a Capacitive Touch Screen on
front
of a Color LCD Flat Panel Display. All
RIMROCK Machines in a cell can be controlled
by this one interface. All functions are similar
to
utilizing a Standard Keypad. The only
exceptions are in the
te ach area, where this
device makes programming easie
r.
Card Cage -Uses a STD bus system for
communication between the various cards.
Servo Card -This card reads the output of the
encoder mounted on the motor, and feeds the
speed signals to the servo drive. The encoder
allows constant tracking
of the machine's
movement.
Central Processing Unit (CPU) -The CPU
Card
is the brain of the entire system. It handles
all information to and from the other cards. This
card al
so contains plug in chips (FLASH
EPROM), which contains the system software,
(Software is a computer program that tells the
system how to work). The software has been
electronically written into the EPROM. The
information written to the EPROM is retained
whether power
is applied or not. It does not
require battery back up to retain it's program.
The CPU card houses a set
of self contained
SECTION 1 PAGE 2 INTRODUCTION 2/22/ 01 VERSION 3.21

SERVO DRIVE RECIPROCATOR WITH TRIANGLE
CONTROLS
battery backed RAM chips that are the storage
chips for the operating parameters (the settings
that the customer programs in for his operation).
It has serial communications that allow it to
communicate to the Keypad and the Message
center.
It also has Digital l/0 that connects the
computer to the
l/0 rack. Which sends and
receives signals from the input/output modules
mounted
on the l/0 rack.
I
nput I Output Rack -This card-like rack
contains modules that connect the computer to
the outside world. All signals to and from the
die cast machine and reciprocator are connected
to plug
in modules which interface computer
signals to the die
cast machine and the
reciprocator.
Power Supply- The supply is the 5-24-12 VDC
regulated supply for the computer and
fo r the
key pad. The
24 volt DC supply feeds the
reciprocator limit switches and interlock circuits.
Message
Center The 410 features a
microprocess
or based message center that
communicates with the system CPU via a serial
link. This message
center is designed to make
the users
job easier and faster which increases
productivity. Diagnostics, cycle and
programming messages result in decreased set-
up time, faster troubleshooting and even simpler
programming. In the event
of a fault, the fault
number, as well as,
an explanation message is
displayed by the message center.
Multiple Lube Option -The 410 Reciprocator
is available with multiple lube capability. The
one lube is standard
and multiple lubes is a
customer option.
When the system is used with
multiple LUBES the other lubes are called
LUBE B, & LUBE C. If the second lube is used,
the spray program will use LUBE B DWELL-
SET TIME and LUBE B SWEEP-SET TIME for
it's spray functions. If a third lube is used, the
spray program will
use the auxiliary keys to
program it's spray functions. The outputs for
the spray functions are described in the SPRAY
FUNCTION section
of this manual.
Horizontal Drive - The reciprocator has a
horizontal drive assembly, either powered or
manual. This drive will move the reciprocator
parallel to the center line
of the die cast machine.
The manual unit uses a adapter tool that mounts
on the horizontal drive screw
at the rear of the
unit. A
W' wrench should be used to tum the
tool which will move the machine. If the
powered drive (a customer option) is selected, a
motor that drives the drive screw is mounted
on
the rear of the reciprocator. It is controlled by a
three position selector switch which is mounted
in the main control panel.
1.6
UNPACKING INSTRUCTIONS
After removing top and sides of shipping crate,
remove the spray package
and control panel.
Note the interconnecting cable is permanently
attached to the reciprocator and should not be
removed. Care must be taken when handling the
reciprocator and cable assembly. Remove the
mounting bolts that secure the reciprocator
during shipping. Remove the covers to expose
the lifting lugs. Using a crane
of the appropriate
size, the machine weighs approximately 500
pounds (700 pounds for 80" version), place the
hook in the lifting lugs
on top of the reciprocator
and lift it
out of the crate.
1.7
MODES OF OPERATION
There are two modes of operation available on
the Servo Drive Reciprocator. The Reciprocator
can only be
in one mode of operation at a time.
These two modes are:
MANUAL with MANUAL TEACH
AUTOMATIC with AUTO TEACH
The mode
of operation is selected by pressing
either MANUAL or AUTO keys located
on the
keypad (SEE KEYPAD DRAWING IN
SECTION 3).
MANUAL MODE:
This mode of operation allows the operator to
run the Reciprocator in a
jog mode to determine
the correct position settings for AUTO CYCLE
with the die cast machine. In this mode of
operation the Die Cast Machine Clear interlock
must be present to extend the arm forward and
into the die. Manual teach is also available in
this mode.
SECTION 1 PAGE 3 INTRODUCTION 2/22/ 01 VERSION 3.21

AUTOMATIC MODE:
SERVO DRIVE RECIPROCATOR WITH TRIANGLE
CONTROLS
After the correct settings are found and input
from the MANUAL mode, the Reciprocator is
now ready to operate with the die cast machine
in full AUTO CYCLE. Auto teach is available
in
th is mode.
SECTION 1 PAGE 4 INTRODUCTION 2/22/01 VERSION 3.21

SERVO DRIVE RECIPROCATOR WITH TRIANGLE
CONTROLS
1.8 KEYPAD SECTIONS
PANEL DISPLAY:
The graphic display on the KEYPAD shows the
position and status
of the Reciprocator in all
modes and all settings
at all times. This graphic
display give the operator a convenient means
of
checking the status of the Reciprocator, even if
the Reciprocator is not currently visible. This
display contains the following readouts:
DISPLAY SECTIONS:
Each section contains a LED numeric display, a
set
key and a LED indicator. Each LED will
light up when the Reciprocator is in that
particular function and the LED numeric display
will show the current setting
of that function.
PLEASE REFER TO SECTION 3 FOR
PROGRAMMING INSTRUCTIONS
1.9 SEQUENCE OF OPERATION
The Reciprocator begins and ends each cycle at
the RESTposition. Unle ss the short cycle option
is activated the rest position is with the spray
arm completely retracted. Upon receiving a
RECIPROCATOR APPROACH signal from the
Die Cast Machine, the Reciprocator will move to
the Approach position.
It will remain there until
it receives the RECIPROCATOR START
interlock form the Die Cast Machine. At this
time it will cycle through the program steps that
are programmed into
the current memory area.
Upon completion
of the programmed cycle the
Reciprocator will return
to the Rest position and
give the CYCLE COMPLETE interlock output.
1.10 MACHINE POSITIONS
The following positions, shown on the keypad
Machine Status area, are the positions
of the
Reciprocator. The
LED's on this diagram shows
the current position
of the Reciprocator.
REST:
This position is the point where the Spray Arm is
at its fully retracted position. At this point the
Rest Position Proximity Switch is actuated. This
point is used as the ze
ro point for the encoder.
The RESTLED will
stay on as long as the arm is
in this position.
If Short Cycle is selected the
Rest Position is still with the arm fully retracted.
APPROACH POSITION:
This is a programmable position that the arm
will move to when the Reciprocator Approach
interlock is received.
It is also the position that
the Spray Arm will stop
at in cycle when the
Short Cycle option is activated.
IN DIE:
This led is activated any time the Reciprocator is
extended past the Approach Position, and
indicates the Spray Arm is in the die area.
SECTION 1 PAGE 5 INTRODUCTION 2/22/01 VERSION 3.21

2
Installation

SERVO DRIVE RECIPROCATOR WITH TRIANGLE
CONTROLS
2. INSTALLATION
2.1 MOUNTING THE RECIPROCATOR
Mount the reciprocator on top of the stationary
platen of the die cast machine on a flat surface.
Side to side location can be found by centering
the reciprocator spray manifold on the center
line of the die cast machine. Proper end to end
positioning of the reciprocator will place the arm
so it is centered in the die spray area. The
mounting blocks should be positioned in the
center of their adjustment on the side plate. This
will allow the reciprocator to be adjusted 5 Y.
inches each direction. At this time you can use
the crane to set the reciprocator on top
of the
machine, positioning it as explained above.
Once the reciprocator is positioned correctly,
mark the mounting bolt holes. Now remove the
reciprocator from the platen and drill the proper
size holes for the mounting hardware (the holes
in the mount plate have clearance for W' bolts).
The last step is to re-position the reciprocator on
the platen and bolt it down.
NOTE: A spacer might be required under the
reciprocator if the spray nozzle assembly is to
clear the top of the platen on the die cast
machine.This will depend on the manifold
configuration and how you mount the
Reciprocator to the Die CastMachine.
2.2 PROXIMITY SWITCH ADJUSTMENTS
Proximity switches are used on the Reciprocator
to indicate physical positions of the arm. These
Proximity switches are mounted inside the body
of the Reciprocator, refer to mechanical
assembly drawings
for location of proximity
switches.
2.2.1 REST
SWITCH:
POSITION
(701-PS)
PROXIMITY
When this proximity switch is tripped the REST
POSITION LED on the control panel lights and
the Input #12 is activated. In this position the
arm is fully retracted and the REST POSITION
proximity switch (701-PS) will be tripped. This
is the only position of the arm that will allow the
Auto Mode to be entered. This proximity switch
is not adjustable.
It is also used to signal the servo drive card
that the arm has reached the full retracted
position (fully CCW motor rotation). If this
switch is tripped at an in-appropriate time a
Following Errorwill be generated.
To access this proximity switch, remove the
side cover's on the machine. There are four
proximity switches located under the cover's
in the same area. The rest position proximity
switch is the bottom one. The rest position
proximity switch is factory set and can not be
ad ju stment in the field. This proximity switch
is used to home the machine after power is
applied to the control panel (see Homing
Procedure).
2.2.2 CHECK POSITION:
(702-PS)
This position is used by the computer to check
the arm position during an Auto cycle. It uses
a factory set proximity switch (702-PS) that
activates Input # 13 . The function of the Check
Position is to insure the spray manifold is
repeating the same spray positions from cycle
to cycle.
If it is necessary to reset this position (and not
the proximity switch) see AUX 3 key
explanation in this manual.
To access this proximity switch, remove the
cover's from the machine. There are four
proximity switches located under the cover's
in the same area. The check position
proximity is in the second one up from the
bottom. This switch is factory set and is not
adjustable in the field.
2.2.3 RECIPROCATOR CLEAR:
(703-PS)
This proximity switch is used to signal th e Die
Cast Machine that the Reciprocator is clear of
the die area and any core pull cylinders. It is set
SECTION 2 PAGE 1 INSTALLATION 2/22/ 01 VERSION 3.21
;fu~. ]
s·ecf;t/1 J
~~~-<- tj

SERVO DRIVE RECIPROCATOR WITH TRIANGLE
CONTROLS
by the customer to actuate at the appropriate
position. Care must be taken not
to set it so that
the die could hit the spray arm as it closes.
If
Short Cycle is activated (see section 3) this
proximity switch must be set to allow it
to trip
when the arm stops at the Approach Position.
To access this proximity switch, remove the side
cover's on the machine. There are four proximity
switches located between the side plates in the
same area. The reciprocator clear proximity
switch
is the closest to the top of this cluster of
switches. This switch is adjustable and must be
setby the customer.
There are three sets
of contacts that trip at the
Requirements 80": 120 VAC, 5 amp, 1 phase
with ground, 220 VAC,
15 amp, 1 phase with
ground; conduit with interlock wires and power
wires. Refer
to electrical drawings for a guide to
the electrical installation.
All interconnections are made
on the connector
supplied at the bottom
of the control cabinet or
on panel mounted terminals in the control
cabinet. This machine may come equipped with
quick disconnects on the right hand side
of the
control box. The second connection position
from the top is where the machine wiring
connections are made and consist
of the motor,
encoder wires and limit switch wires. The other
end
of this conduit is
same time to be
used at the
customer's
convenience.
This proximity
switch should be
adjusted so it
trips when the
reciprocator
is
clear of the dies
and core pull
cylinders so the
dies will close
without
interfering with
the reciprocator.
CROUN O~~§~~~~~~~~~
ll ~ 48 0 VO LT
L2 - 3 PHA SE
L3 60 HZ
connected to
Reciprocator .
'
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The lower connector is
used for interlocking
connections. Power
connections are
connected inside the
control box on a
terminal strip.
Connect the power as
follows:
120 VAC to 7Ll
(Circuit Breaker)
I GURE2-1 POWER TRAN S FORMER
Neutral to 7L2
2.2.4
CLOCK
WISE PROXIMITY SWITCH
(706-PS)
This proxumty switch is used by the servo
control
sy stem , and alerts the computer system
when ever it is tripped.
It is factory set at the
extreme end
of the forward travel of the 410
SDR.
If this switch is tripped at an in-appropriate time
a Following Error will be generated
2.3
ELECTRICAL
Requirements 47, 60, 72": 120 VAC , 15 amp, 1
phase with ground; conduit with interlock wires
and 3 power wires.
Ref er to electrical drawings
for a guide to the electrical installation.
Ground
to GND
As with all computers, a proper ground
connection is require
d. To check the power,
read the voltage between
7Ll and 7L2, the
voltage should be 120 VAC. The voltage
between 7L2 and GND should not exceed 1.0
V
AC at any time during the cycle. Refer to
Figures
2-1 and 2-2 for a power connection
guideline.
We strongly suggest using a dedicated 3.0 KVA
machine tool transformer as a power source for
the Reciprocator. Do not use a general purpose
transformer because it will not regulate the
current, causing the voltage to vary when the
transformer
is near its saturation point. See
Figure 2-1 for 410-47, 60, 72 inch transformer
connection recommendations, and electrical box
SECTION 2 PAGE 2 INSTALLATION 2/22/
01 VERSION 3.21

SERVO DRIVE RECIPROCATOR WITH TRIANGLE
CONTROLS
assembly drawings for transformer connection
for the 410-80 inch. A non-dedicated
transformer may cause noise and/or spikes on the
Reciprocator power line which will cause
various computer related problems while
cycling.
Note to PLC user:
All the interlocks required are
dry contacts, since
a dry contact draws very little current, triac type
outputs
may not shut off. This is due to the
nature
of a triac, which requires a minimum of
terminals in the control cabinet. All contacts
must be 120 VAC
dry contacts, meaning that
there will
be no electrical link between the
D.C.M. and the reciprocator (isolated with
relays). The interlock LED's on the keypad
show whether or not the interlocks are present.
2.4.1 INPUTS*
RECIPROCATOR START : (SLOT# 10)
Wire
#'s 703 & 707 N/0 contacts are activated
(closed) when the reciprocator is to start its
cycle.
Run this from the PART SENSED signal
if an extractor is used, from an operator push
button or from a doorswitch.
DIE START OPEN: (SLOT #9)
Wire
#'s 703 & 708 N/0 contacts are activated
current draw to
shut off
.------------------- ..... (closed) on die start
completely.
STAR GROUND TECHNIQUE FOR PROPER
GROUNDING OF EQUIPMENT IN A WORK CELL
open, deactivated
(opened)
on die full
open. This contact
signals the
reciprocator to
move
To prevent this
type of problem it
is suggested that
either a load
resistor
be tied
across the output
or an interface
relay
be driven by
the PLC output.
Some PLC
manufacturers
have already taken
care
of this
problem by
including an
CONTROL
TRANSFORMER
AN EARTH GROUND
F OR EACH CELL
IS RECOMMENDED
Ll~~~--,
/
/
/~O N TROL
TRANSFORMER
to the Approach
Position. (Recip.
Approach)
DIES FULL OPEN:
(SLOT #8)
isolated interface
for each I/0
I FIGURE 2-2 PROPER GROUNDING
Wire #'s 703 & 709
N/0 contacts are
activated (closed)
when dies are full
open. (O.K. to
Extend)
contact within the PLC - be aware of which type
you have.
2.4 INTERLOCKING *
Referencing Electric~! drawings.
The following input interlocks are designed for
the safe operation
of the Reciprocator and should
be used in all cases, not defeated or jumped out.
All connections for interlocks are located
on the
right
hand side of the control box in the low er
quick disconnect fitting or on panel mounted
DIE LOCKED:
(SLOT #11)
Wire
#'s 703 & 710 N/0 contacts are activated
(closed) when dies are locked up, deactivated
(opened) on die unlock. (Recip. Reset)
EXTERNAL SAFETY:
Can be used with contacts from safety gates,
mats, beams, etc. and connected across wires
701 and 702. If this connection is not closed
(I.E. safety violated) there will be no power to
the Interlocks and motor controls, but there will
SECTION 2 PAGE 3 INSTALLATION 2/22/
01 VERSION 3.21

SERVO DRIVE RECIPROCATOR WITH TRIANGLE
CONTROLS
be 120 VAC Present at the 24 and 5 volt power
supplies. To restore power the safety must be
made and the manual on key must be pressed.
This interlock is used
to provide a method of
stopping the movement of the Reciprocator by
turning off the Servo motor controller.
Note: This interlock has the same effect
as
opening the control box door and can also be
used as a remote shutdown.
SECTION 2 PAGE 4 INSTALLATION 2/22/
01 VERSION 3.21

SERVO DRIVE RECIPROCATOR WITH TRIANGLE
CONTROLS
CONTINUE FROM WAIT #1: (SLOT #15)
Wire No. 703 and 749 N/0 contacts are activated
(closed) when the reciprocator is to continue
from the programmed wait #1 function. See
Section 3 for programming of the wait #1
function. This wait function is typically used for
the movement of hydraulic die core slides during
an automatic spray cycle.
CONTINUE FROM WAIT #2: (SLOT #22)
Wire No. 703 and 750 N/0 contacts are activated
(closed) when the reciprocator is to continue
from the programmed wait #2 function. See
Section 3 for programming of the wait #2
function. This wait function is typically used for
the movement of hydraulic die core slides during
an automatic spray cycle.
DCM IN AUTO: (SLOT #23)
* This is only a recommendation and is in no
way the only way to interface a Reciprocator
with a die cast machine. RIMROCK accepts no
liability for actual interlocking of our equipment
with the die cast machine. Wire No. 703 and 762
N/0 contacts are activated (closed) when the
DCM is in AUTO mode. If properly
programmed, absence of this signal will prevent
the reciprocator from going to AUTO mode. The
loss of this signal while the reciprocator is in
AUTO will result in a 9.03 fault. See Section 3
for programming of check DCM in AUTO (Aux
4.7).
2.4.2 OUTPUTS*
CYCLE COMPLETE: (SLOT #1)
Wire #'s 714 & 715 N/0 contacts are closed
when spray cycle is complete. This contact is a
momentary contact, released when the
reciprocator receives the reset interlock (die
locked).
RECIPROCATOR CLEAR:
Wire #'s 736 & 737 and 738 & 739 and 741 &
742 are N/0 contacts that close when the
reciprocator is clear of any interference with the
die cast machine. These contacts are for
machine interlocking. Thes e contacts are directly
controlled by PS-703. (See Section 2 & 3 - Arm
Positions for more information.)
RECIPROCATOR IN AUTO: (SLOT #16)
Wire No. 743 and 744 are N/0 contacts that
close when the reciprocator is in AUTO
mode.Wiring can be done by customers to their
specifications. This output can signal the die
cast machine or tum on a light, etc.
RECIPROCATOR WAIT #I: (SLOT #7)
Wire No. 747 and 748 are N/0 contacts that
close when the reciprocator is programmed into
a wait state. The contact is maintained closed
until the Continue from Wait #1 Input is
activated. See Section 3 for programming of the
Wait #1 function. This wait function is typically
used for the movement of hydraulic die core
slides during an automatic spray cycle.
RECIPROCATOR WAIT #2: (SLOT #21)
Wire No. 759 and 760 are N/0 contacts that
close when the reciprocator is programmed into
a wait state. The contact is maintained closed
until the Continue from Wait #2 Input is
activated. See Section 3 for programming of the
Wait #2 function. This wait function is typically
used for the movement of hydraulic die co re
slides during an automatic spray cycle.
RECIPROCATOR FAULTED: (SLOT 17)
Wire No. 745 and 746 are N/0 contacts that
close if the reciprocat or has a fault condition
occur. Wiring can be done by customers to their
specifications. This output can signal the die
cast machine or turn on a light, etc.
* This is only a recommendation and is in no
way the only way to interface a Reciprocator
with a die cast machine. RIMROCK accepts no
liability for actual interlocking of our equipment
with the die cast machine.
2.5 PLUMBING CONNECTIONS:
SPRAY BLOW: Spray on a one lube unit has
(4) hoses:
1. Pilot Air ------
2. Spray Air ----------->For lube (lube A) spray
SECTION 2 PAGE 5 INSTALLATION 2/22/
01 VERSION 3.21

3. Lube ------------
SERVO DRIVE RECIPROCATOR WITH TRIANGLE
CONTROLS
4. Blow-- --------------> For blow air
A two lube system will have (3) additional
hoses:
1. Pilot Air -------
2. Spray Air-- ---------> Forlube (lube B) spray
3. Lube ------------
A three lube system will have (3) additional
hoses:
1. Pilot Air-------
2. Spray Air-----------> For lube (lube C) spray
3. Lube ------------
2.6 DRY CYCLING:
This machine may be dry cycled by insuring that
the Die Cast Machine clear input is active and
giving a cycle start input.
2.7 HOMING SEQUENCE:
With the machine in the manual mode, up to two
LED's could be flashing, depending on where the
machine was positioned when the machine was
turned off. The MANUAL LED will be flashing
and possibly the AUX 5 LED.
If both are
flashing, home the machine
by pressing the
AUX 5 key. If the AUX 5 LED is not flashing,
the arm must be retracted
to the Rest Position
(using the retract key). The AUX 5 LED should
now be flashing.
If so pressing the AUX 5 key
will automatically home the machine. When the
machine homes it
is fmding the "0" position for
the arm. Pressing the manual key during homing
will stop the homing process.
2.8 MACHINE SIZE SETUP
The machine is shipped with the default settings
as explained in Section 3
of this manual. You
will have to program settings that will work for
yourapplication. Remember to select the correct
machine size before starting programming.
SECTION 2 PAGE 6 INSTALLATION 2/22/ 01 VERSION 3.21

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4"