WEISS WAS.handling User manual

WAS.handling Windows – Programm
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Last reviewed: April 2008
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WAS.handling Windows – Programm
Table of contents
1 Safety warnings .............................................................................................................................................1
1.1 Explanation of symbols and notes ............................................................................................................1
1.2 Safety and utilization notes........................................................................................................................1
2 Product description.......................................................................................................................................2
2.1 Device structure ........................................................................................................................................2
2.2 Software structure .....................................................................................................................................3
3 Installation......................................................................................................................................................4
3.1 Installing the PVI driver: ............................................................................................................................4
3.2 Installing the Windows program:...............................................................................................................5
4 Program operation.........................................................................................................................................6
4.1 File menu ..................................................................................................................................................7
4.2 Program menu ..........................................................................................................................................9
4.3 Options menu..........................................................................................................................................16
4.4 Test menu ...............................................................................................................................................35
5 Example project ...........................................................................................................................................38
5.1 Establish connection between PC and drive...........................................................................................38
5.2 Configuration of axes ..............................................................................................................................39
5.3 Parameterizing the interface to the customer PLC .................................................................................40
5.4 Drive to reference points and set machine zero point.............................................................................42
5.5 Teach positions and create drive sequences..........................................................................................43
6 Quick start ....................................................................................................................................................48
7 Frequently Asked Questions (FAQs) .........................................................................................................50
8 Troubleshooting ..........................................................................................................................................51
8.1 Common problems and error messages: ...............................................................................................51
8.2 How to proceed in case of errors ............................................................................................................53

1 WAS.handling Windows – Program
1 Safety warnings
1.1 Explanation of symbols and notes
This manual contains instructions to be observed for the safety of people and the avoidance of damages.
These warnings are emphasized by icons and look – according to danger level – as follows:
Minor personal injury or material damage may occur if appropriate
precautionary measures are not taken.
Useful information.
1.2 Safety and utilization notes
Validity:
This is the software documentation for WEISS controls for Pick & Place HP140 with B&R ACOPOS Servo
Drives. It is complete only together with the mechanical and electrical documentation. Depending on the
interface to the supervisory control system, please observe the interface description.
Purpose of the instruction manual:
This manual helps with the safe operation of the control system. It contains safety warnings that must be
observed and information necessary for trouble-free operation. Keep this manual close to the device. Make
sure that all people working with or operating the device have access to this manual at all times.
Keep this manual for future reference and pass it on to every subsequent owner, operator, and customer.
Operation of the HP140 must not be started before the entire machine and control system – especially the
safety system – complies with Machinery Directive 98/37/EC!
Target group:
This manual is intended for people who are assigned to planning, installation, deployment, maintenance and
service and who possess the appropriate qualification, competence and knowledge.
Trained personnel are people with the appropriate qualification who are familiar with the work described
above and the operation of the product.
All tasks in other areas such as transportation, storage or disposal must be carried out by people who are
appropriately trained.
The HP140 can be fully operated using the Windows program. While operating
the program, make sure that there is nobody within the danger zone.

WAS.handling Windows Program 2
2 Product description
2.1 Device structure
The device is made up of the following components:
•Mechanical setup
•Drive amplifier
•Cable set
•Option: digital I/O
internal CAN Bus
Customer interface:
digital inputs
Customer interface:
digital outputs
Motor line red
Encoder line red
Drive inputs:
- Enable
(emergency shut-off)
- Quickstop
- 24V power supply
Customer interface
- Profibus or
- CAN / DeviceNet
Option:
1 or 2 digital
I/O modules
each with 16
inputs and
outputs
Motor line blue
Encoder line blue
Parameterizing via
RS232 or Ethernet
Ethernet
Power supply
Drive stroke
Z axis
Drive horizontal
Y axis

3 WAS.handling Windows – Program
2.2 Software structure
The software to be installed consists of two program modules: The PVI driver and the WAS software. The
PVI driver by B&R implements the interface to the control system. This PVI driver must be installed
separately. The WEISS Application Software (WAS) accesses the driver amplifier control via the PVI
interface. The connection can be established using a serial RS232 cable or Ethernet.
System Requirements:
The software was implemented using Microsoft Visual Studio and requires a PC or laptop for installation.
Windows 95 or higher is required as operating system. The color quality must be set to "true color“ (32 bit)
and Internet Explorer 5.5 or higher should be available.
PVI driver
The PVI driver is the interface between the Windows program and the control computer. It is supplied by the
manufacturer of the drive (Bernecker & Rainer). The PVI driver runs for two hours without a license. After two
hours a reminder is displayed. After starting WAS.handling again, the program can be operated for another
two hours.
The driver has a broad range of functions. It connects the PC via the interface available under Windows
(RS232 / Ethernet) with a PLC or a servo drive.
If your PC does not have a serial interface, you can use a USB to RS232 adapter.
For a serial connection, a cable with the following pin assignment is needed:
Pin 2 <-----> Pin 3
Pin 3 <-----> Pin 2
Pin 5 <-----> Pin 5
This cable is supplied together with the CD.
When installing the PVI driver, an OPC driver may be installed to connect the drive to a professional
visualization program (WinCC, Intellution, Wonderware...), achieving the same functionality as with
WAS.handling.
The PVI driver is automatically started together with WAS.handling.
When the PVI interface is active, a symbol is displayed in the Windows task bar.

WAS.handling Windows Program 4
3 Installation
The installation of the Windows program is done in two parts:
•Installation of the PVI driver for communication between control system and the Windows computer
•Installation of the program "WAS.Handling“
3.1 Installing the PVI driver:
Run the "AS2523103_PviRT_Eng.exe" file in the "PVI_Eng" directory from the supplied CD.
In the following a number of components to be installed can be selected. It’s sufficient to confirm the pre-
selected modules.

5 WAS.handling Windows – Program
3.2 Installing the Windows program:
From the CD, run the "setup.exe" file in the “Win_Prog“ directory.

WAS.handling Windows Program 6
4 Program operation
The program operation follows the usual Microsoft Windows standard. However, note the following:
•Confirm input in text boxes by pressing ENTER.
(Many parameters are applied directly in this way – even during operation)
•Several dialog boxes may be open simultaneously.
(Very useful if you are, for example, programming sequences)
•All parameters are stored on the slot-CPU. In most cases, the data is immediately transferred there
after input. With position data and sequences, the transfer must be started manually.
Drive status Connection Interface status
Menu bar
Tool bar
(When the pointer is moved
over the icons, a tooltip is
displayed.)
Status bar

7 WAS.handling Windows – Program
4.1 File menu
Use the File menu to save all parameters that can be set in this software to a file and recall them. Saving and
recalling parameters is only possible after a connection to the control system has been established. It is also
possible to view a set of parameters "offline" by selecting Simulation in the Connection dialog box.
The Entry “Connections…” is only shown, if connection type ethernet is selected => see below.
4.1.1 Connection to the control computer
The connection to the drives is usually established via a serial RS232 connection. Optionally, an Ethernet
connection can be used. For this, however, the interface (IP address etc.) must be configured => cf. chapter
4.3.4 - Ethernet configuration
You can configure the connection using the File – Connection menu:
For a serial connection, only the interface of the PC must be selected.
For a connection via Ethernet (TCP/IP), enter the connection number and INA node number. The IP address
is only necessary if the control system belongs to a different subnet than the PC, otherwise enter 0.0.0.0. If
there is an IP Address entered, the node number is not necessary.
The connection number can also be called the station address of the PC/laptop. The INA node number refers
to the station address of the drive control.
By activating Simulation, the software can be operated without being connected to the control system. Thus
you can load and read saved parameter files.

WAS.handling Windows Program 8
Dialogbox Connections:
Devices in a network can be searched and managed.
4.1.2 Load and save parameters
After a connection has been established, all parameters that can be set with this program can be saved and
recalled.
When loading parameters, you can select which parameters are actually applied.

9 WAS.handling Windows – Program
4.2 Program menu
4.2.1 Teach positions
The dialog for teaching a position also includes functions for manual operation. Use this to go to and save the
desired positions.
The positions table has room for 127 positions.
Setting the values:
Highlight the position number you want to teach with the blue bar. Then move the axis to the target position
by pressing “+” and “-“ (step mode). Double click the blue cursor in the "Pos" column to transfer the current
position to the input box. Optionally you can set the values by using the right mouse button – Set position.
You can also enter the values manually and confirm by pressing ENTER.
Speed:
Enter the maximum speed to be used on the way to the position in the central area of the input table.

WAS.handling Windows Program 10
Target window:
Entering a target window causes a smoothing of the movements in the sequence. Strictly speaking, the
confirmation for the completion of this movement is given earlier. The set position is nevertheless reached
with the highest possible precision.
Transferring the positions to the control system:
Use the PC  PLC button to transfer the positions to the PLC. There, the positions are permanently stored.
Alternatively you could teach each position via one of the customer interfaces (cf. chapter 4.3.3 - I/O
configuration).
Check positions:
After the positions have been stored in the PLC, they can be reached using Jog to Pos. Then the axes will
move to the position highlighted by the blue cursor. The Jog to Pos button must be pressed until the position
has been reached. Upon releasing the button, the axes stop immediately.

11 WAS.handling Windows – Program
4.2.2 Build drive sequences
Save drive sequences using the menu item Program -> Sequences. A sequence consists of a sequence of
commands. 32 drive sequences can be saved. Each drive sequence may consist of a maximum of 32
commands.
Building a sequence:
1. Enter sequence number (number between 1…32).
2. Enter commands 1...32. (see below on how to select commands)
3. Save sequence to PLC (PC PLC)
Right-clicking on the “Command xx” column displays a menu to add or delete rows.
4.2.3 Demo sequence
The difference between the demo sequence and a drive sequence is that the demo sequence is
automatically restarted. It must be terminated explicitly with STOP.
The dialog to edit the demo sequence can also be opened using Program -> Sequences. This dialog holds all
important functions to operate the HP140. The demo sequence was mainly designed for presentations.

WAS.handling Windows Program 12
Table of commands:
- Move to Pos abs (all axis)
- Move to Pos abs axis X
- Move to Pos abs axis Y
- Move to Pos abs axis Z
- Move to Pos abs axis A
- Move to Pos abs axis X,Y
- Move to Pos abs axis X,Z
- Move to Pos abs axis Y,Z
- Move to Pos abs axis X,Y,Z
- Move to Pos abs axis Y,A
- Move to Pos rel (all axis)
- Move to Pos rel axis X
- Move to Pos rel axis Y
- Move to Pos rel axis Z
- Move to Pos rel axis A
- Move to Pos rel axis X,Y
- Move to Pos rel axis X,Z
- Move to Pos rel axis Y,Z
- Move to Pos rel axis X,Y,Z
- Move to Pos rel axis Y,A
- Waittime (msec)
- goto line
- goto mark
- define mark
- link axis speed X/Y/Z
- unlink axis speed X/Y/Z
- End
- Output A1 = ON
- Output A2 = ON
- Output A3 = ON
- Output A4 = ON
- Output A5 = ON
- Output A6 = ON
- Output A7 = ON
- Output A8 = ON
- Output A1 = OFF
- Output A2 = OFF
- Output A3 = OFF
- Output A4 = OFF
- Output A5 = OFF
- Output A6 = OFF
- Output A7 = OFF
- Output A8 = OFF
- Wait Input1 = ON (msec)
- Wait Input2 = ON (msec)
- Wait Input3 = ON (msec)
- Wait Input4 = ON (msec)
- Wait Input5 = ON (msec)
- Wait Input6 = ON (msec)
- Wait Input7 = ON (msec)
- Wait Input8 = ON (msec)
- Wait Input1 = OFF (msec)
- Wait Input2 = OFF (msec)
- Wait Input3 = OFF (msec)
- Wait Input4 = OFF (msec)
- Wait Input5 = OFF (msec)
- Wait Input6 = OFF (msec)
- Wait Input7 = OFF (msec)
- Wait Input8 = OFF (msec)
- If Input1 = ON goto mark
- If Input2 = ON goto mark
- If Input3 = ON goto mark
- If Input4 = ON goto mark
- If Input5 = ON goto mark
- If Input6 = ON goto mark
- If Input7 = ON goto mark
- If Input8 = ON goto mark
- If Input1 = OFF goto mark
- If Input2 = OFF goto mark
- If Input3 = OFF goto mark
- If Input4 = OFF goto mark
- If Input5 = OFF goto mark
- If Input6 = OFF goto mark
- If Input7 = OFF goto mark
- If Input8 = OFF goto mark
- set "var_a" =
- set "var_b" =
- set "var_c" =
- set "var_d" =
- "var_a" = "var_a" +
- "var_a" = "var_b" +
- "var_a" = "var_c" +
- "var_a" = "var_d" +
- "var_a" = "var_a" –
- "var_a" = "var_b" –
- "var_a" = "var_c" –
- "var_a" = "var_d" –
- if "var_a" >= ... jump 1 line
- if "var_b" >= ... jump 1 line
- if "var_c" >= ... jump 1 line
- if "var_d" >= ... jump 1 line
- if "var_a" < ... jump 1 line
- if "var_b" < ... jump 1 line
- if "var_c" < ... jump 1 line
- if "var_d" < ... jump 1 line
- generate alarm
- start stopwatch
- stop stopwatch
- part Counter + 1

13 WAS.handling Windows – Program
4.2.4 Commands in detail:
The various commands can be selected from list boxes. Depending on the command, there are various
options.
Move to Pos abs With this command the taught position number is moved to using
absolute coordinates. Depending on the command, each axis can be
moved separately or several axes together. Enter the position number
from the position table into the “Option” column.
Move to Pos rel As above, but movement is carried relative to the current position.
Waittime (msec) A waiting period is inserted. The number in the "Option“ column gives the
waiting time in milliseconds. A maximum value of 32,000 milliseconds
can be entered.
goto line Jumps to the command with the row number entered in "Option".
goto mark Jumps to a specific mark. This mark is defined with “define mark”.
define mark A mark is set that can be jumped to using "goto mark".
Link axis speed X/Y/Z All axes reach their target simultaneously. This means that the speed is
determined by the slowest axis or the one with the longest distance to
travel. This function is valid for all commands between this one and the
„unlink axis speed X/Y/Z“ command.
unlink axis speed X/Y/Z The synchronization of the axes to reach their targets simultaneously is
switched off by this command.
Output A1…A8 = ON The selected output A1 through A8 is set to logically HIGH.
Output A1…A8 = OFF The selected output A1 through A8 is set to logically LOW.
Wait Input1…8 = ON (msec) At this point, the program will wait until the required input is set to logically
HIGH. The number in the "Option“ column gives the timeout in
milliseconds. If the input is not HIGH, after this time has passed, the
sequence is aborted and an error message is generated. The maximum
waiting period is 32 seconds. (Use it, e.g. for gripper open/close)

WAS.handling Windows Program 14
Wait Input1…8 = OFF (msec) At this point the program will wait until the required input is set to logically
LOW. The number in the "Option“ column gives the timeout in
milliseconds. If the input is not LOW after this time has passed, the
sequence is aborted and an error message is generated. The maximum
waiting period is 32 seconds.
If Input1…8 = ON goto mark If the input is logically HIGH, the program will jump to a defined mark.
If Input1…8 = OFF goto mark If the input is logically LOW, the program will jump to a defined mark.
Set "var_a"…”var_d” = A value is assigned to the selected variable.
"var_a" = "var_a" +
"var_b" = "var_b" +
"var_c" = "var_c" +
"var_d" = "var_d" +
The specified value is added to the variable.
"var_a" = "var_a" –
"var_b" = "var_b" –
"var_c" = "var_c" –
"var_a" = "var_d" –
The specified value is subtracted from the variable.
if "var_a" >= no. jump 1 line
if "var_b" >= no. jump 1 line
if "var_c" >= no. jump 1 line
if "var_d" >= no. jump 1 line
If the selected variable is greater or equal than the value in “Option”, the
next command line is skipped
if "var_a" < no. jump 1 line
if "var_b" < no. jump 1 line
if "var_c" < no. jump 1 line
if "var_d" < no. jump 1 line
If the selected variable is smaller than the value in “Option”, the next
command line is skipped.
generate alarm An alarm is generated that can be further processed by the customer. 6
different alarm numbers (50…55) can be entered.
start stopwatch With this command the stopwatch is started. The time to be measured
remains valid even if the sequences are changed.
stop stopwatch The stopwatch is stopped. The time can be read as cycle time in the
Tools – Parameter dialog.
part Counter + 1 The command counter is incremented by one. The value will be displayed
in the Tools – Parameters dialog.
End End of drive sequence.
Do not forget to save the drive sequence by pressing the "PC 

PLC" button.

15 WAS.handling Windows – Program
4.2.5 Demo sequence
In principle, the demo sequence works like the drive sequence. Difference: At the end of the sequence the
program jumps back to line 1. The demo sequence is used for presentations at trade shows and for starting
up of operations so the axes „can simply be moved“. Furthermore, the most important functions for operating
the HP140 can be found here.
Functions in detail:
Cycle time: Drive time of the axis with active stopwatch function.
Step no.: Displays the active step.
Reference point: When the machine knows its reference point, TRUE is displayed.
Override: This denotes a speed override "over all." This means that all speed values are
multiplied by this override (0.01 per cent…100.00 per cent).
PC PLC: For saving the demo sequence to the PLC.
Start: Starts the demo sequence.
Stop: Stops after the last command.
Quick Stop: The sequence is aborted immediately.
Reference: A reference drive is carried out.
Ackn: Acknowledge error.
Save: Save this demo sequence to PC harddrive.
Load: Load this demo sequence from PC harddisk.
(It must then be transferred to the control system using "PC PLC").
Delete: Deletes all entered commands.

WAS.handling Windows Program 16
4.3 Options menu
Use the Options menu to access all functions for parameterizing the axes and to configure the interface to
customer PLC.
4.3.1 “Parameter” dialog box
This dialog box shows all important parameters for the operation of the HP140.
timeout move: Maximum allowed time for a single motion (Move to Pos...)
If “0” is entered, the time is calculated automatically (default).
cycle time: The cycle time is displayed if the stopwatch function of the sequences is active.
Otherwise the last measured value will be displayed.
operating hours: Operating hours counter
commands: If the command „part counter + 1“ is called up in the sequences, the counter is
displayed here.
Lubrication: - When selecting "manual“ for Lubrication, parameters can only be read. When the
given operation time is reached, a signal may be sent to the supervisory control. To
reset the operation time, press the “Manual lubrication” button or set an appropriate
input signal.
- If a central lubrication system is selected, appropriate inputs and outputs must be
wired. The exact wiring can be seen from the corresponding documentation.

17 WAS.handling Windows – Program
4.3.2 Hardware configuration
Here the following parameters are set:
•Select device type (usually preset)
•Assign input and output signals to hardware or Profibus
•Parameterizing Ethernet interface of slot CPU
•Parameterizing all interfaces to customer PLC
If the device type is newly selected, all parameters are reset after a confirmation
prompt and the PLC is restarted.
Setting up the digital inputs and outputs is described in the following. For parameterizing and functionality of
the fieldbus system, freeASCII and TCP/UDP, please refer to the respective interface documentation.
The Ethernet interface of the slot PLC can be configured on the “Ethernet” tab.