Series 1100 Color TS Servo Manual Registration System for

Series 1100 Color TS Servo Manual
Registration System for Envelope and Cup
Machines
400 Oser Avenue
Hauppauge NY 11788
631 434 3700 phone
631 434 3718
fax
www.empregister.com
December 1, 2005
EMP Series 1100 Color TS Servo Manual
TABLE OF CONTENTS
TABLE OF CONTENTS .................................................... 2
1
GENERAL ................................................................................................................... 4
1.1
Unpacking and Inspection................................................................................... 4
1.2
Installation........................................................................................................... 4
1.3
Introduction......................................................................................................... 4
1.4
Initial Set Up ....................................................................................................... 4
1.5
Description of Operation..................................................................................... 4
1.6
Before the set button is pressed .......................................................................... 4
1.7
Once the Set button is pressed ............................................................................ 5
1.8
Alarm Conditions................................................................................................ 5
2 ACCESSING THE SETUP SCREEN. ........................................................................ 6
2.1
Splash Screen ...................................................................................................... 6
Main Screen.................................................................................................................. 7
2.2
Main Screen Password Entry.............................................................................. 7
2.3
Setup Screen (parameter entry).......................................................................... 8
2.4
Parameters........................................................................................................... 9
2.4.1 Width............................................................................................................... 9
2.4.2 Length Factor .................................................................................................. 9
2.4.3 Correction Factor ............................................................................................ 9
2.4.4 Alarm Area...................................................................................................... 9
2.4.5 Alarm Count.................................................................................................... 9
2.4.6 Encoder Resolution......................................................................................... 9
2.4.7 Motor Resolution ............................................................................................ 9
2.4.8 Reducer Ratio................................................................................................ 10
2.4.9 Draw Roll Dia ............................................................................................... 10
2.4.10
Jog Speed .................................................................................................. 10
2.5
Encoder and Motor Phasing.............................................................................. 11
2.5.1 Encoder phasing............................................................................................ 11
2.6
Motor Phasing................................................................................................... 12
2.7
Verifying the Jog Speed.................................................................................... 12
2.8
Check the I/O .................................................................................................... 13
3 RUNNING THE MACHINE ..................................................................................... 14
Main Screen................................................................................................................ 14
3.1
Entering Length ................................................................................................ 14
Length Input Screen ................................................................................................... 14
3.1.1 Entering the Length Directly ........................................................................ 15
3.1.2 Measuring the Length directly ...................................................................... 15
3.2
Entering a Sequence.......................................................................................... 16
3.3
Running the machine. ....................................................................................... 17
3.3.1 Run Mode...................................................................................................... 17
3.3.2 Maintaining Register..................................................................................... 18
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EMP Series 1100 Color TS Servo Manual
3.3.3 Normal Register Screen ................................................................................ 18
3.4
ALARMS.......................................................................................................... 19
3.4.1 No Marks in Active Area.............................................................................. 19
Clear Alarm Button .................................................................................................... 19
3.4.2 Out Of Tolerance. ......................................................................................... 19
Clear Alarm Button .................................................................................................... 19
3.4.3 Following Error............................................................................................. 20
3.4.4 Command Error. ........................................................................................... 20
4 Front Panel ................................................................................................................. 21
5 TL-U Scanner Operation............................................................................................ 22
5.1
Proper Position of Scanner................................................................................ 22
5.2
Scanner Set-Up ................................................................................................. 22
6 TROUBLE SHOOTING.............................................................................................. 23
6.1 Recommended Spare Parts .................................................................................... 24
Emergency Telephone Number ...................................................................................... 24
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EMP Series 1100 Color TS Servo Manual
1 GENERAL
1.1 Unpacking and Inspection
Although every precaution is taken to ensure the equipment is delivered in good
condition, a careful inspection should be made. EMP makes every effort to individually
box and label each component for easy identification of the shipment. Please report and
shortage immediately.
1.2 Installation
While most EMP Servo Systems come with all installation bracketing, please request the
installation manual from EMP for additional assistance.
1.3 Introduction
The Series 1100 Servo Register System is designed to provide a reliable and economical
solution to your registration control needs.
Based on information provided, EMP has preprogrammed your equipment for your
specific application. The program and equipment have been selected based on your
machine and web speed.
The EMP Servo System allows you to customize the program to set tolerances and all
alarm settings. Please refer to the manual for more information.
1.4 Initial Set Up
For proper operation of the Servo System, the Initial Setup procedure must be completed.
This one time setup provides vital information ( Draw Roller Diameter, Reducer Ratio,
Encoder and Motor Phasing) required for proper operation. See page 3 for assistance.
1.5 Description of Operation
Once a length is entered and the touch screen is in "Run" mode, the servo motor is ready
to follow the movement of the encoder. As the machine starts, the encoder will begin
rotating, the servo motor will follow and will maintain a 1:1 Relationship with the
encoder.
1.6 Before the set button is pressed
The Series 1100 will produce cut sheets based on the length entered.
No Active Area LED - Since no set point has been established, the led will not flash
Scanner LED - will flash- The scanner LED will flash while sensing any print in its path.
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EMP Series 1100 Color TS Servo Manual
1.7 Once the Set button is pressed
The Series 1100 is placed in a ready position awaiting the next scanner signal. Once the
scanner sees the register mark, an active area and a set point pulse are created.
The size of active area is established in the initial set-up procedures.
The active area LED will start to flash on the arrival of the 2nd register mark and the SET
point switch will be highlighted.
Both the scanner pulse and active area LED's will flash together.
The Series 1100 will correct the product length based on the arrival of the register mark
at the scanner and the set point pulse.
The register mark arriving at the scanner before the set point pulse will create an advance
correction.
The register mark arriving after the set point pulse will create a retard correction
Based on the trend of corrections, the Series 1100 will adjust the length.
The direction of corrections, size of corrections along with current and initial length can
be viewed on the production screen.
1.8 Alarm Conditions
EMP has preprogrammed various alarms that will help in determining particular
problems.
No Register Marks - The scanner is not seeing a register mark within the active area.
The number of missed register marks that will counted before an alarm condition is
established in the initial setup.
Out of Tolerance - The Series 1100 is not maintaining the desired tolerance. There are a
number of reasons for this error.
Following Error - The Series 1100 system will shut down when a following error exists.
When the relationship between the Motor's Resolver and the Knife's Encoder has been
changed. To avoid an unexpected Motor movement, a Following Error stops the machine.
The Machine must be set up again.
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EMP Series 1100 Color TS Servo Manual
2 ACCESSING THE SETUP SCREEN.
Splash Screen
The Done
Button can
be used to
move to the
main screen.
2.1 Splash Screen
On turning on the controller the Splash Screen above appears for a few seconds and is
replaced by the Main Screen. This indicates proper communications between the Touch
Screen and the Controller.
If the Main Screen does appear automatically, pressing the DONE button will force it to
appear, this is however an indication of faulty communication between the Touch Screen
and the Controller
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EMP Series 1100 Color TS Servo Manual
Main Screen
Push the SETUP Button and enter
the password ‘1 2 3 4’ to access
the Setup screen.
2.2 Main Screen Password Entry
Accessing this screen allows password entry to change the parameters on subsequent
screens
Enter the password
1 2 3 4 ; then press
Enter to get Setup
Screen.
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EMP Series 1100 Color TS Servo Manual
2.3 Setup Screen (parameter entry)
This is the Setup
Screen which is
used to enter the
machine
parameters, and
correctly phase the
Motor and Encoder.
This manual
describes the input
of the Length
parameter. A similar
procedure works for
all other parameters
Push Width
Setup Screen Width (of Active Area) entry
Simply enter
the Width of
the Active
Area in
Degrees, and
press Enter.
The Maximum
and Minimum
values are
shown
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EMP Series 1100 Color TS Servo Manual
2.4 Parameters
2.4.1 Width
This is the distance before the mark that the controller actively seeks a mark. For example
if the repeat Length is 12 inches and the width parameter is set to 300, then the controller
will start actively looking for a mark 12x30/360 = 1 inch before it arrives. Any value
between 5 and 90 degrees is allowed.
2.4.2 Length Factor
During normal operation the ratio of encoder rotations to Motor Rotations will change to
accommodate changes in tension, slippage at draw rollers, stretch in the web etc. This
parameter changes the rate at which the ratio changes. It can take any value between 0
and 1. Note 0 turns off length correction.
2.4.3 Correction Factor
When the Controller determines that the web is out of position a correction is applied to
bring it back in to position. Because machinery has cyclic errors (due to run out etc.) it is
not always desirable to move the web back into position. This factor determines how
much correction is actually made. The amount of correction made = Measured Error x
Correction Factor. For example an error of 0.020 inches with a CF of 0.6 makes a
correction of 0.012 inches on the first pass leaving 0.008 inches. Then on the next pass it
makes a correction of 0 .0048 inches leaving 0.0032 inches and so on. The allowed
values are between 0.2 and 1.
2.4.4 Alarm Area
This sets up a tolerance for the marks. If the mark does not occur within this tolerance of
where it is expected it is counted as an alarm event and enough alarm events will cause
an Out Of Tolerance alarm. If the mark does not occur in the Active Area it will cause a
No Register Mark alarm. The allowed values are between 50 and 100.
2.4.5 Alarm Count
This sets up the Number of Alarm events required to cause an alarm. The Alarm events
are no mark in the Alarm Area, and no mark in the Active area. The permitted values are
between 4 and 20.
2.4.6 Encoder Resolution
This sets up the resolution of the auxiliary encoder. Note for quadrature encoders the
resolution is equal to the line count x 4. So a 1024 line encoder has a resolution of 4096.
This parameter is usually factory set for your particular encoder. Values between 100 and
20000 are allowed.
2.4.7 Motor Resolution
This sets up the resolution of the Servo Motor Feedback. 6. This parameter is usually
factory set for your particular motor. Values between 100 and 20000 are allowed.
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EMP Series 1100 Color TS Servo Manual
2.4.8 Reducer Ratio
This is the Ratio between the Servo Motor and the Draw Rollers. It should include both
the reducer on the front of the Servo Motor (if one is used) and any further reduction
between the Servo motor and the Draw Rollers. Any value between 1 and 40 is allowed
.
2.4.9 Draw Roll Dia
This is the diameter of the roller that the web in inches. The controller uses this
information, the reducer ratio information, and the encoder position to determine the
required position of the motor. Values between 1 and 20 inches are allowed.
2.4.10 Jog Speed
This is the speed at which the controller jogs the motor when commanded to do so.
Values between 1 and 100 rpm are allowed.
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EMP Series 1100 Color TS Servo Manual
2.5 Encoder and Motor Phasing
Encoder Dir
button changes
Encoder Phase
Reset button,
Resets the
Encoder and
Motor Positions
to 0.
Current position
of encoder
Current Motor
Position
Motor Dir
button changes
Motor Phase
2.5.1 Encoder phasing
Push the Reset button to set the Encoder and Motor Positions to 0.
Jog the Machine slightly to turn the encoder.
The encoder position should be Positive and increasing, if it is not change the encoder
phase by pushing the Encoder Dir button.
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EMP Series 1100 Color TS Servo Manual
2.6 Motor Phasing
Push the Run Motor button. The Servo motor will now follow the encoder position. The
Buttons Caption changes to Stop Motor.
Jog the Machine. The draw roller and observe the draw roller. If it is rotating in the
wrong direction Push the Motor Dir button. The draw roller should now turn in the
correct direction.
Push the stop Motor button. The caption on the Stop Motor button changes to Run Motor
and the Draw rollers stop following the machine.
2.7 Verifying the Jog Speed.
Push the Jog Motor
Button. The draw rollers
will turn continuously at
jog speed. The Run Motor
button’s caption changes
to sop motor.
Change the jog speed
parameter to the desired
speed. It is calibrated in
Draw Roll rpm.
Push Stop Motor when
done.
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EMP Series 1100 Color TS Servo Manual
2.8 Check the I/O
Press the I /O Disp button to begin checkout.
The Diagnostic
window appears
Windows display
input states.
Note IN 1 is the
Scanner input
Output buttons.
The states of the inputs are shown in the I/O screen above. IN 1 is always used to show
the scanner state. If the output led on the scanner is on then the pickup LED should turn
on and the IN 1 display above should change to “ON”.
IN 2 .. IN 7 show the state on optional Jog and Reset switches.
The Output buttons are used to momentarily control the state of the Outputs. The A
Area controls the Active Area Led. The Alarm controls the alarm and can be used to
control external circuitry for checkout or diagnostic purposes. Press Main Screen to
return to the Main Screen.
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EMP Series 1100 Color TS Servo Manual
3 RUNNING THE MACHINE
Main Screen
Motor Run Stop
Buttons
Jog Buttons
Enter Length
Button
Sequence Button
3.1 Entering Length
Press the Length button. The Length Input screen below appears
Length Input Screen
There are two
methods to input
the length. One is
to Enter the Length
directly in inches
or millimeters.
The other method
is to have the
machine find the
Length directly.
This only works if
there is no print
between the
register marks
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EMP Series 1100 Color TS Servo Manual
3.1.1 Entering the Length Directly
To enter the Length in inches simply input the length in the above screen and press enter.
To input the Length in Millimeters push the mm button. The screen changes as shown.
Button to change from
inches to millimeters.
Input the length in the above screen and press enter.
3.1.2 Measuring the Length directly
Push the Find Length Button. The draw rollers will jog slowly until the second mark
reaches the scanner and stops. The controller now automatically determines the correct
length.
This method only works for print jobs with no Print in the path of the scanner except the
Registration marks.
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EMP Series 1100 Color TS Servo Manual
3.2 Entering a Sequence
The Sequence is used to make the Register system follow the same pattern as the original
print cylinder. For example if two repeat patterns were printed per rotation of the Print
Cylinder a sequence of two will cause the controller to look at every second mark,
thereby following the original print cylinder pattern. The controller may be programmed
to look at every mark Seq. = 1, every second mark Seq. = 2, every third mark Seq. = 3,
every fourth mark Seq. = 4, or every fifth mark Seq. = 5,
To program a sequence simply press Seq., input the desired sequence and press enter.
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EMP Series 1100 Color TS Servo Manual
3.3 Running the machine.
This screen appears a couple
of seconds after Turn On.
The Draw Rollers are in the
Stop Mode, and will not
follow the machine. The
Draw Rollers may be jogged
using the ADV or RET Jog
Buttons.
Push Run to Enter the Run
Mode. The Draw Rollers
begin to turn and Follow the
machine, at the
preprogrammed Length.
3.3.1 Run Mode
The Screen is in Run Mode.
Begin running the machine,
the draw rollers will feed
the correct amount of web
based on the previously
entered length.
The Adv and Ret Jog
Buttons may now be used
to get the web in register.
Press the Set button to
maintain register.
The RPM display shows the number of machine cycles per minute
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EMP Series 1100 Color TS Servo Manual
3.3.2 Maintaining Register
At this point the Set
button has been pushed
and the controller is
waiting to see the first
register mark. The Set
button will blink On and
Off until a mark is seen.
3.3.3 Normal Register Screen
After the first mark
arrives the Normal
Register Screen
Appears. The Jog
buttons no longer move
the print.
To Cancel the register
push CANCEL SET
To Adjust the register
push FORWARD
BACK
Correction shows the Register error in degrees.
% Length Change shows the current error in Length.
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EMP Series 1100 Color TS Servo Manual
3.4 ALARMS
Register alarms may be cleared but will recur unless the machine is put in register
3.4.1 No Marks in Active Area.
No marks appear in the active area and Register is not currently being controlled. Alarm
may be Cleared.
Clear Alarm Button
3.4.2 Out Of Tolerance.
Marks are occurring in the active area, but the register is not in normal tolerance. Alarm
may be cleared.
Clear Alarm Button
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EMP Series 1100 Color TS Servo Manual
3.4.3 Following Error.
The servo motors are out of position. Normally caused by a jam at the drawrollers, but
can also (though rarely) be caused by a hardware fault in the system. To clear this fault
recycle the power.
3.4.4 Command Error.
Caused by a program fault, normally indicates damage to the control board. Recycle the
power to clear the fault.
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EMP Series 1100 Color TS Servo Manual
4 Front Panel
Power On
Green Switch -Turns on the Servo System.
Power Off
Red Switch – Shuts power off to the Servo System.
Active Area
Red LED – Once “SET” is pressed, an active area is established.
The active area LED will flash “ON” when the encoder is in its
active area.
Scanner Pulse
Green LED – Will flash when the scanner sees the register mark.
The Scanner will also flash when seeing any other print in its path.
These extra scanner pulses are outside the Active Area and do not
generate corrections.
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EMP Series 1100 Color TS Servo Manual
5 TL-U Scanner Operation
(Ready) Green LED – Always “ON” when set-up is done
properly.
(Output) Red LED – Flashes when scanner has sensed print.
(Mark)
Learns the color of the register mark.
(Bkgd) Learns the color of the web’s background. The
background is the clear area directly in front of the register
mark.
5.1 Proper Position of Scanner
1. The Scanner should be 3/8” (9mm) from the preprinted web.
2. The connector can be rotated in three positions by loosening the locking screw.
Tighten the locking screw when finished.
3. The beam direction may be changed by swapping the cap and lens.
5.2 Scanner Set-Up
1. Position the register mark under the light spot of the scanner. Press and hold the
MARK key until the GREEN LED turns off.
2. Position the label’s background under the light spot of the scanner. Press and hold
the BKGD key. The GREEN LED will blink briefly.
3. The GREEN LED stays on continuously. This indicates the register mark and
background acquisition was correct and the TL-U is ready.
At the end of the above operations the following settings are made:
• The light emission was set for red or green to maximize the contrast
between the mark and the background reading.
• The dark or light function was selected on the basis of the reading of a
darker or lighter mark with respect to the background.
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EMP Series 1100 Color TS Servo Manual
6 TROUBLE SHOOTING
Problem
Cause
No Register Mark Error
Scanner Signal is not being
received during the Active
Area Zone
Solution
1. Verify Touch Screen’s
Scanner Pulse LED is
flashing.
2. Verify Scanner Output
LED is flashing.
No Active Area LED.
No Active Area
1. Press Set Point.
2. Verify Encoder is
rotating.
3. Verify encoder cable
LED is flashing.
4. Check Direction of
encoder
SET does not appear
System not in RUN mode.
Redo set-up procedure
including Step 7.
No normal register screen.
Check encoder direction
counts positive see page 9.
Follow encoder phasing
procedure page 9
Check scanner sees mark
Check scanner location.
Servo System walks out of
register
Incorrect length entered.
Encoder Failure.
1. Verify correct length
is being entered. Using
a ruler, measure the
distance between
Register marks.
2. Performs “System
Checkout” .
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EMP Series 1100 Color TS Servo Manual
6.1 Recommended Spare Parts
EMP maintains a file by serial number of each Servo System sold. The serial number will
supply details on the:
1.
2.
3.
4.
5.
Servo Program
Motor Amplifier
Style of Alarm Relay and Components Used
Motor Type
Reducer Ratio
Before contacting EMP, please obtain the serial number.
The Serial Number can be obtained by:
Check the label on the door o the control panel .
Recommended Spare Parts
SE 141
Power Supply
SE 329
B 3149
TL - U
C 1772 M
SE 313
1415 Control Board
Encoder - 10 pin
Scanner
Motor
6 Amp
Emergency Telephone Number
EMP provides service assistance Monday to Friday 8:30 AM (EST) to 6:00 PM (EST).
After normal business hours, an emergency phone number, 917.215.4639, should be called.
The EMP web site www.empregister.com also provides trouble shooting assistance.
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