IC2100 Manual - Find The Needle

IC2100 Manual - Find The Needle
THE IC2100
The IC2100 is a single axis control system designed specifically for the
Print finishing industry. It is flexible, reliable easy to use and can be retro
fitted to almost any guillotine with a suitable leadscrew capable of being
power driven.
The IC2100 has been developed by SP Electronics over the last 5 year's
and offers the performance and reliability of any other retrofit system but
at a fraction of the cost. It is currently available in 2 formats either Relay
control or AC inverter drive.
CONTENTS
Page
Contents.
2
A quick tour of the IC2100
Display
Numeric input
Mathematical input
Mode button
Soft keys
Power up and self-test
Auto - calibration
Manual mode
Calculator
Total cuts
Floating Passwords
3
3
3
3
4
5
5
6
6
7
7
Auto run mode
New program
Load program
Save program
Delete program
Rename program
Run program
Edit program
Sheet divide
Label cut
Auto learn mode
Emergency stop
Machine limits
Messages
Clock / daylight saving
Error messages
Connections
Servicing
Your settings
Installation notes
8
9
9
9
10
10
10
11
12
13
14
14
15
15
16
17
18
19
20
2
THE IC2100 QUICK TOUR
The IC2100 display
The IC2100 display is split up into 3 areas.
1) The top of the display shows the date, mode and time.
2) The middle of the display is the working area, the position, cut
number and status of the machine are shown here along with
program and error messages if applicable.
3) The bottom of the display is split into 4 areas, these areas are
known as softkeys, the function of the key may change as the mode
changes, for example, if you are in “MANUAL “ the “F1” softkey
is used to switching the air ON or OFF whilst in “AUTO RUN” the
“F1” softkey is used to run a current program
The IC2100 keyboard
The IC2100 keyboard is split up into 5 areas.
1) Numeric input ( 0 through 9 )
2) Mathematical input ( + , - , x , / )
These keys are used in conjunction with the calculator function.
3) Mode keys ( Units, Mode, Auto/Man and Delete )
The Units button allows the user to switch between units of
measurement, Inches, Centimetre’s and Millimetre’s
The Mode button opens the “options “ menu, within this menu you
have several options such as load, save and delete programs.
The Auto/man button allows the user to switch between Automatic
mode and manual mode, in Automatic mode you can load, run of
save programs. In manual mode, you can enter a position and goto
it or move using the forward/reverse keys.
3
4) Softkeys ( F1 , F2 , F3 , F4 )
Softkeys function is dependent upon the current mode of operation
5) Motion keys ( Move , Forward and Reverse )
These keys allow the user to move the backgauge forwards,
backwards or to an absolute position, the forward/reverse buttons
also move the cursor in menus INFORMATION ON SPECIFIC
FUNCTIONS CAN BE FOUND LATER IN THIS MANUAL
The move button is used to move to an absolute position such as
150 mm, there are 2 methods of moving to an absolute position.
a) Press move followed by the required position then press enter
b) Enter the required position then press enter
The IC2100 will then move the backgauge to the position entered by the
operator, unless the knife or clamp is down or partially down or the
position is outside the machine limits.
The backgauge can also be moved manually to a position by way of the
of the arrowed buttons (forward/reverse) located next to the move button.
To move the backgauge to a position rear of the current position use the
“ /\ “ button, to move forward of the current position use the “ \/ “ button.
If you press and hold either of the arrowed buttons for more than 2
seconds the backgauge speed will increase to reduce the time taken to
manually move the backgauge from one position to the next. If the button
is pressed and released before 2 seconds has elapsed the backgauge will
move in slow speed.
NOTE
The IC2100 is pre programmed with machine maximum and minimum
position limits (during installation) if you attempt to move outside of the
limits an error message will be displayed on the screen
4
POWER UP AND SELF TEST
When the IC2100 is switched on it will perform a number of self-tests
before allowing the user to operate the unit. These tests are shown on the
first screen, in the unlikely event that any of the tests fail, a cross will be
displayed, you should contact your authorised service agent or
DTS Engineering.
Quoting the software version, date and serial number of your unit along
with details of the error or fault, this will enable an engineer to diagnose
your problems faster.
( This information is shown on the self-test screen )
AUTO - CALIBRATE
Following the successful self test A "COMPANY logo is displayed, this
is then followed by a “REMINDER MESSAGE” if applicable or by
“BACKGAUGE CLEAR? “. At this prompt press OK, if it is safe to
move the BACKGAUGE, the IC2100 will now calibrate the system and
adjust the datum position if necessary.
If for any reason the backgauge has not calibrated correctly the user can
adjust it by pressing MODE followed by selecting (8) setup menu; you
now select (4) backgauge adjustment. The adjustment is limited to +\- 1
revolution of the leadscrew, if the error is greater than this you should
adjust in multiples of the leadscrew
Example
Displayed position = 500 mm
Actual position is = 590 mm
The leadscrew pitch is 25 mm
You would have to adjust by 25 mm 3 times and by 15 once.
If the Calibration is consistently incorrect you should contact your
supplier and advise them of the error, they will advise you of the quickest
method of rectifying your problem.
5
MANUAL MODE
In manual mode the backgauge can be positioned either by keying in the
required dimension and pressing "move" or "enter", or by using the "/\" or
"\/" arrows.
The IC2100 will move the backgauge to the desired position, as each cut
is performed the cut total (if enabled) will be incremented by 1, the cut
total can be reset to 0 by pressing “F2” the zero cuts key
The air, calculator and brake may also be switched on or off by using: “F1” for the air
“F3” for the calculator ( see next page )
“F4” for the brake.
CALCULATOR
The calculator may be used for simple calculations or to calculate and
then "move" to a position. If the “move” button is pressed with the
calculator active the backgauge will move to the calculated value, if it is
within the machine limits.
Example
25.4 x 10 = 254
Press the “move” and the backgauge will goto the calculated position, in
this case 254
When using the calculator, the operator must bear in mind that whatever
units of measurement are in use (inches, centimetres or millimetres) will
be the used by the calculator thus the result of the calculation above could
be:1) 254 inches
2) 254 cm
3) 254 mm
If the calculated position is too large or too small for the machine the operator will be prompted, in
such a case the backgauge will not move to the calculated position
6
TOTAL CUTS
Total cuts information can useful for determining several things such as
the overall usage of a particular machine or for determining the average
life a blade.
Total Cuts can easily be displayed by pressing: 1) Press the "Mode" button
2) Press "8" Setup menu
3) Press "5" Show total cuts
To reset the total cuts press reset followed by your password (1066)
this will then reset to Total Cuts to Zero
FLOATING PASSWORDS
The Passwords on the IC2100 are continually changing based on an
algorithm that uses the date, time and several random multipliers to
provide a new password whenever required.
If for any reason you need to go into a secure menu you should contact
your dealer or installer for a password, to enable your dealer or installer
to give you a password you must provide the six-digit number from the
IC2100 screen.
NOTE
If you exit from a password menu the six digit number will change next
time you re-enter it, you should ensure that the exit key is not used while
you are contacting your dealer or installer. If the exit key is used the
password that you have been given will not be correct.
7
AUTORUN MODE
Autorun mode is used to run programs that have previously been created
on the IC2100, the operator can also create new programs edit, save,
delete or rename programs, this is done by using the MODE button.
NEW PROGRAM
1) Press the MODE button
2) Press 1 or enter if “New Program” is highlighted
3) Press “F1” ‘ins.step’ and type the first position then press ENT
Press ENT if 1 cut is required or type in the number of cuts
required then press ENT.
4) If only one cut is required simply type in your dimension then
press ENT
5) To enter more steps repeat 3 or 4 to end and run,
press the AUTO/MAN button followed by “F1” (RUN)
POSITION OFFSETS
This facility allows you to enter cuts as an offset from an absolute
position your program must NOT start with an offset i.e.
First cut is at 500 mm you then have several cuts to make for 30 mm
labels you could use "label mode" or offsets as the example shown
CUT 1 at 500 mm
Offset
- 30 (moves to 500 - 30 = 470 )
Offset
- 30 (moves to 470 - 30 = 440 )
Offset
-30 (moves to 440 - 30 = 410 )
To enter an offset you must start with an absolute position i.e. 500 mm
Then use the + or - button followed by the required offset
Whilst running the program if you find that a program step is in correct
you can edit it by using “F2” (EDIT STEP)
1) From Auto Run press “F2” (EDIT)
2) Press “F3” or “F4” to highlight the step to be edited
3) Press “F2” the cursor is now blinking on the position selected
for edit
4) Key in the correct dimension then ENT
8
5) If the number of cuts are correct press ENT if not type new
value then ENT
6) Press Auto/man to return to Auto run mode or repeat steps 2,3
and 4
LOAD PROGRAM
1) Press the MODE button
2) Press 2 or use “\/” to highlight “Load Program“ then press ENT
3) Any previously saved files will be displayed, select the file
required and by typing its number and press ENT ,the display
will now revert to Auto run
4) Press “F1” to run the loaded program
SAVE PROGRAM
1) Press the MODE button
2) Press 3 or use ‘\/’ to highlight “Save Program” then press ENT
3) Use the ‘\/’ ‘/\’ arrows to scroll through the alphabet and the
MOVE button to accept the letter and move onto the next once
the program name has been set use the ENT button to save
( PROGRAMS MAY BE SAVED WITH NUMBERS INSTEAD OF NAMES )
If you have previously saved a program, or edited an existing program
when you chose save you will be asked if you wish to overwright the
program. If you have changed a program to correct a previous error and
wish to retain the program and name press F1, ‘YES’. If you want to save
the modified program with a different name press F4, ‘NO’ you are then
asked if you wish to save as a new program F1 ‘YES’ will prompt you for
a program name, enter as step 3 F4 ‘NO’ you will return to the options
screen.
DELETE PROGRAM
1) Press the MODE button
2) Press 4 or use \/ to highlight “Delete Program” then press ENT
3) Select the program that you wish to delete and enter its number,
the program has now been deleted
9
RENAME PROGRAM
1) Press the MODE button
2) Press 5 or use \/ to highlight “Rename program” then press ENT
3) Use \/ /\ and move, as above to select the new program name or
number and ENT to complete the rename.
RUN PROGRAM
In "AUTO RUN" once you have loaded a program you can press the F1
button to run it, the program will run from the highlighted step, for
example. F3 or F4 have been used to browse through the program and
step 3 is highlighted when run is pressed the program will start at step 3.
This allows the operator to stop a program at any point and resume it at
any point without the need to go to the beginning.
EDIT PROGRAM
In AUTORUN F2 is the EDIT button, the edit function allows the
operator to change the type of step or to change the position or number of
cuts for a step. If F2 is pressed you will see the following options.
F1 INS. STEP this allows the insertion of a new step into a current
program, the step is inserted BELOW a highlighted step
F2 EDIT STEP this allows a step to be edited you can edit the type of
step or simply the position or number of cuts.
F3 PREV. STEP this button is used to move the highlighted bar to the
previous line of a program. ( / takes you to the first step )
F4 NEXT. STEP this button is used to move the highlighted bar to the
next line of a program. ( * takes you to the last step )
EDITING A STEP
From Auto Run press F2 EDIT, select the step to be edited using F3, F4
then F2 EDIT STEP.
F1 EXIT. Exit returns you to auto learn if you have finished editing your
program press AUTO/MAN to return to auto run.
10
F2 LOAD. Load is used to allow the operator to insert the material into
the machine, but does not require a cut to be performed. Once the
material is in position run is used to move to the first cut position.
F3 PUSH OUT. Push out moves the work to a position in front of the
blade to allow it to be rotated safely the push out value can be changed if
required.
F4 WAIT. Wait is to delay the backgauge movement to the next step; its
delay is in seconds so a value of 5 equals a delay of 5 seconds.
SHEET DIVIDE
Sheet divide is a utility that is used to cut divide material into equal sized
pieces for example.
You have a sheet that is 500 mm long and has to be cut into 8 equal
pieces, instead of using the calculator to work out each step you simply
use this utility.
1)
2)
3)
4)
5)
Press the mode button
Press 6 sheet divide
Enter the sheet size (in our case 500)
Enter the required number of divisions ( 8 )
Press ok
You are now asked if you want to add the sheet divide to a current
program or if you want to create a new one. If you add to a current
program the sheet divide will be inserted above the highlighted step in
that program.
If you chose new you are prompted to save the program that was
previously being used .Yes will save the old program .No replaces the
program with the sheet divide information.
Include sheet trim if selected will perform a cut at the sheet size, in our
case 500mm, if you chose no the IC2100 will assume that the sheet has
already been cut to size and only needs dividing.
11
You will now be in Auto learn mode if you want to edit any steps do so
from this screen, if you want to run the program press the Auto/man
button followed by “F1” run.
NOTE
If you have a created or entered a long program, instead of using the
"prev. step" or "next step" buttons you can use the “ / “ button to take you
to the beginning of the program or the “ * ” button to take you to the end
of the program.
LABEL CUT
Label mode is very similar to Sheet divide; however, in label cut mode
you enter the size of the label and the space between the labels, the gutter.
The label cut utility will then calculate all the cut positions and create a
Program in the same way as sheet divide.
Example.
You have a sheet that is 500mm long and you want to cut labels
that are 37 mm with a space or gutter of 14 mm.
1)
2)
3)
4)
5)
6)
Press the mode button
Press 7 Label cut
Enter the sheet size
Enter the label size
Enter the gutter size
Press ok
As with sheet divide you are asked
If you want to add to a current program or create a new one.
If you want to save the current program
If you want to include sheet trim
After you have answered these questions you are left with a program to
create your labels. In the example above, you end up with a program
containing 19 cut positions. To move to the first program step you can
use the " / " button to move to the last step use the " * " button.
12
AUTO LEARN MODE
Auto learn mode is used during editing of programs OR to create
programs, programs can be created in 2 ways; 1) You can create a program by typing each step into the IC2100
and then running the program to see if the dimensions that have
been entered are correctly.
2) You can teach the IC2100 with a sheet or job that needs to be
cut to size
TEACHING
The IC2100 can be taught to position to a given dimension and perform
the required number of cuts simply by ;1) From Auto Run mode select new program (press mode, 1 )
2) Move the backgauge either by hand or using the ‘/\’ ‘ \/ ‘
buttons then press “ENT” OR perform a cut at the required
position.
3) Repeat step 2 until all dimensions have been entered then press
“AUTO MAN” to take you back to Auto Run mode
4) Press “F1” to run the program
Absolute positions can be entered at any time whilst teaching positions to
the IC2100 simply type the required position then press enter.
13
EMERGENCY STOP
During the normal coarse of operation the IC2100 can be stopped simply
by pushing ANY button on the keyboard, the operator can stop the
backgauge from moving forward by bringing clamp down. There are
however instances when it is not possible or safe to move the knife or
clamp, also if auto retry is enabled as soon as the knife or clamp
are in the correct position the IC2100 will continue to position the
backgauge.
NOTE
This function is designed to assist the operator and under no
circumstance should it be used as a failsafe emergency stop.
The system installer should be consulted if a true emergency
stop is to be fitted.
MACHINE LIMITS
The machine limits are set at the time of installation if for any reason they
are incorrect you must contact your machine installer.
If the limits are not correct damage may be caused to your machine it is
recommended that they are checked periodically
14
MESSAGES
There is a total of 9 messages that can be used to advise the operator of
action required, for example a safety check is due, yearly maintenance is
due or simply to suggest that the machine should be lubricated.
The message type can be set to: 1)
2)
3)
4)
5)
6)
Daily
Weekly
Monthly
3 Monthly
6 Monthly
12 Monthly
( day selectable )
( date selectable)
(date selectable )
( date selectable)
( date selectable)
The message length can be upto 120 characters long and are only
accessible from the engineers menu, they should be set up at the time of
installation, once set if they are to be changed for any reason you must
contact your installer or DTS Engineering.
DAYLIGHT SAVING
The clock within the IC2100 will allow for daylight saving. The clock is
updated on the first Sunday in April and the last Sunday in October.
If required the clock can updated from the supervisor's menu.
15
ERROR MESSAGES
Message
Meaning or cause
Action aborted by operator
During backgauge movement a
button on the keyboard was pushed
Attempt to move past limit
During a manual move the
operator attempted to move the
backgauge past the min or max
machine size.
Invalid password
An attempt to enter a supervisor or
engineers password was made
however the number was incorrect
Motor error, no movement
The IC2100 has tried to move the
motor and did not seen any
movement this message can also
indicate a faulty or loose encoder.
Positioning error, overran
The IC2100 failed to find the
programmed position, this is often
caused by dry or worn leadscrew
No clamp
During a cut cycle either the clamp
did not move or the clamp switch
has moved or failed
Reposition Gauge
The backgauge has been moved
or knocked off position if "yes" is
pressed the backgauge will move
To the correct position.
Knife / Clamp
An attempt to move the backgauge
when the knife or clamp are down
will give this error.
Display flashing
This suggests that the program
Memory has been corrupted.
16
CONNECTIONS
ABC
A TO L
1
2
3 4
5 6 7
8
Mains input (240/110V AC)
1
a)
b)
c)
Live
Earth
Neutral
Low voltage inputs
2
RS 232
(Requires PC software, option)
3
4
5
6
Encoder input
Switch inputs
Switch inputs
Switch inputs
Relay outputs (C to L are voltage free contacts)
8
A
B
C+D
E+F
G+H
I+J
K+L
Analogue output
(INVERTER ONLY)
Analogue earth/common (INVERTER ONLY)
Forward relay
Reverse relay
Brake relay
Air relay
Slow relay
17
SERVICING
The IC2100 is a microprocessor controlled system which contains several
Microprocessors and a wide range of support components consequently
there are NO USER SERVICEABLE PARTS INSIDE
In the unlikely event of a failure you MUST contact your system installer
Installer details
Name ………………………………….
Address………………………………..
…………………………………………
…………………………………………
Contact ………………………………..
Tel …………………………………….
Fax……………………………………..
SP Electronics
11 Fulwood Ave
Tarleton
Preston
Lancashire
PR4 6RP
Tel
Fax
0870 321 5116
0870 321 5118
SP Electronics (TARLETON) cannot be held liable for any damage, loss or injuries as a result of
improper or incorrect use of our equipment. Nor can we be held liable for any damage, loss or injury as
a result of poor or improper installation carried out by a third party or as a result of equipment failure.
If you have any reservations you should contact us in writing stating the nature of your concern this
will enable us to look into it more deeply.
Every effort has been made to ensure correct operation of this equipment if you as a customer find
anything that you consider to be incorrect operation please advise us we can then endeavour to correct
it. Due to ongoing development we reserve the right to change specification without prior notice
18
YOUR SETTINGS
This section of the manual is for Engineer use only, it details all of the
settings that are applicable to your machine and may be needed at some
point in the future.
FUNCTION
MISC. SETUP
POWER UP UNITS
MIN POSITION DISTANCE
PUSHOUT DISTANCE
DISPLAY CUTS
AUTO REPOSITION
BRAKE TO STOP
CONFIG I/O
KNIFE UP
CLAMP UP
FALSE CLAMP IN
AUTO DATUM
BRAKE ON
AIR
AIR PULSE
CONFIG I/O BOARD (RELAY)
FORWARD RELAY
REVERSE RELAY
LEVEL FOR FAST
BRAKE LEVEL
CONFIG I/O BOARD (INVERTER)
NUDGE SPEED
FAST SPEED
PITCH & CONFIG
ENCODER PULSE / REV
LEAD SCREW PITCH
REVERSE DIRECTION
MACHINE DIMENSIONS
MAX POSITION
MIN POSITION
MIN POSITION IF CLAMP IN
AUTO DATUM POSITION
CURRENT POSITION
POSITIONING SETUP
No OF ATTEMPTS
POSITIONING TOLERANCE
DRIFT TOLERANCE
SLOW SPEED AT DISTANCE
SAMPLES UNTIL STALLED
APPROACH DIRECTION
DEFAULT
YOUR SETTING
mm (0.99)
20.00
0.00
YES
NO
NO
YES
NO
YES
(1)LOW
NO
NO
NO
HIGH
HIGH
HIGH
HIGH
20
127
360
10 mm
NO
3000 mm
10 mm
100 mm
0.00 mm
10 mm
4
0.09 mm
0.09 mm
10.00 mm
250
FORWARD
19
INSTALLATION NOTES
20
21
THE IC2100
The IC2100 is a single axis control system designed specifically for the
Print finishing industry. It is flexible, reliable easy to use and can be retro
fitted to almost any guillotine with a suitable leadscrew capable of being
power driven.
The IC2100 has been developed by SP Electronics over the last 5 year's
and offers the performance and reliability of any other retrofit system but
at a fraction of the cost. It is currently available in 2 formats either Relay
control or AC inverter drive.
CONTENTS
Page
Contents.
2
A quick tour of the IC2100
Display
Numeric input
Mathematical input
Mode button
Soft keys
Power up and self-test
Auto - calibration
Manual mode
Calculator
Total cuts
Floating Passwords
3
3
3
3
4
5
5
6
6
7
7
Auto run mode
New program
Load program
Save program
Delete program
Rename program
Run program
Edit program
Sheet divide
Label cut
Auto learn mode
Emergency stop
Machine limits
Messages
Clock / daylight saving
Error messages
Connections
Servicing
Your settings
Installation notes
8
9
9
9
10
10
10
11
12
13
14
14
15
15
16
17
18
19
20
2
THE IC2100 QUICK TOUR
The IC2100 display
The IC2100 display is split up into 3 areas.
1) The top of the display shows the date, mode and time.
2) The middle of the display is the working area, the position, cut
number and status of the machine are shown here along with
program and error messages if applicable.
3) The bottom of the display is split into 4 areas, these areas are
known as softkeys, the function of the key may change as the mode
changes, for example, if you are in “MANUAL “ the “F1” softkey
is used to switching the air ON or OFF whilst in “AUTO RUN” the
“F1” softkey is used to run a current program
The IC2100 keyboard
The IC2100 keyboard is split up into 5 areas.
1) Numeric input ( 0 through 9 )
2) Mathematical input ( + , - , x , / )
These keys are used in conjunction with the calculator function.
3) Mode keys ( Units, Mode, Auto/Man and Delete )
The Units button allows the user to switch between units of
measurement, Inches, Centimetre’s and Millimetre’s
The Mode button opens the “options “ menu, within this menu you
have several options such as load, save and delete programs.
The Auto/man button allows the user to switch between Automatic
mode and manual mode, in Automatic mode you can load, run of
save programs. In manual mode, you can enter a position and goto
it or move using the forward/reverse keys.
3
4) Softkeys ( F1 , F2 , F3 , F4 )
Softkeys function is dependent upon the current mode of operation
5) Motion keys ( Move , Forward and Reverse )
These keys allow the user to move the backgauge forwards,
backwards or to an absolute position, the forward/reverse buttons
also move the cursor in menus INFORMATION ON SPECIFIC
FUNCTIONS CAN BE FOUND LATER IN THIS MANUAL
The move button is used to move to an absolute position such as
150 mm, there are 2 methods of moving to an absolute position.
a) Press move followed by the required position then press enter
b) Enter the required position then press enter
The IC2100 will then move the backgauge to the position entered by the
operator, unless the knife or clamp is down or partially down or the
position is outside the machine limits.
The backgauge can also be moved manually to a position by way of the
of the arrowed buttons (forward/reverse) located next to the move button.
To move the backgauge to a position rear of the current position use the
“ /\ “ button, to move forward of the current position use the “ \/ “ button.
If you press and hold either of the arrowed buttons for more than 2
seconds the backgauge speed will increase to reduce the time taken to
manually move the backgauge from one position to the next. If the button
is pressed and released before 2 seconds has elapsed the backgauge will
move in slow speed.
NOTE
The IC2100 is pre programmed with machine maximum and minimum
position limits (during installation) if you attempt to move outside of the
limits an error message will be displayed on the screen
4
POWER UP AND SELF TEST
When the IC2100 is switched on it will perform a number of self-tests
before allowing the user to operate the unit. These tests are shown on the
first screen, in the unlikely event that any of the tests fail, a cross will be
displayed, you should contact your authorised service agent or
DTS Engineering.
Quoting the software version, date and serial number of your unit along
with details of the error or fault, this will enable an engineer to diagnose
your problems faster.
( This information is shown on the self-test screen )
AUTO - CALIBRATE
Following the successful self test A "COMPANY logo is displayed, this
is then followed by a “REMINDER MESSAGE” if applicable or by
“BACKGAUGE CLEAR? “. At this prompt press OK, if it is safe to
move the BACKGAUGE, the IC2100 will now calibrate the system and
adjust the datum position if necessary.
If for any reason the backgauge has not calibrated correctly the user can
adjust it by pressing MODE followed by selecting (8) setup menu; you
now select (4) backgauge adjustment. The adjustment is limited to +\- 1
revolution of the leadscrew, if the error is greater than this you should
adjust in multiples of the leadscrew
Example
Displayed position = 500 mm
Actual position is = 590 mm
The leadscrew pitch is 25 mm
You would have to adjust by 25 mm 3 times and by 15 once.
If the Calibration is consistently incorrect you should contact your
supplier and advise them of the error, they will advise you of the quickest
method of rectifying your problem.
5
MANUAL MODE
In manual mode the backgauge can be positioned either by keying in the
required dimension and pressing "move" or "enter", or by using the "/\" or
"\/" arrows.
The IC2100 will move the backgauge to the desired position, as each cut
is performed the cut total (if enabled) will be incremented by 1, the cut
total can be reset to 0 by pressing “F2” the zero cuts key
The air, calculator and brake may also be switched on or off by using: “F1” for the air
“F3” for the calculator ( see next page )
“F4” for the brake.
CALCULATOR
The calculator may be used for simple calculations or to calculate and
then "move" to a position. If the “move” button is pressed with the
calculator active the backgauge will move to the calculated value, if it is
within the machine limits.
Example
25.4 x 10 = 254
Press the “move” and the backgauge will goto the calculated position, in
this case 254
When using the calculator, the operator must bear in mind that whatever
units of measurement are in use (inches, centimetres or millimetres) will
be the used by the calculator thus the result of the calculation above could
be:1) 254 inches
2) 254 cm
3) 254 mm
If the calculated position is too large or too small for the machine the operator will be prompted, in
such a case the backgauge will not move to the calculated position
6
TOTAL CUTS
Total cuts information can useful for determining several things such as
the overall usage of a particular machine or for determining the average
life a blade.
Total Cuts can easily be displayed by pressing: 1) Press the "Mode" button
2) Press "8" Setup menu
3) Press "5" Show total cuts
To reset the total cuts press reset followed by your password (1066)
this will then reset to Total Cuts to Zero
FLOATING PASSWORDS
The Passwords on the IC2100 are continually changing based on an
algorithm that uses the date, time and several random multipliers to
provide a new password whenever required.
If for any reason you need to go into a secure menu you should contact
your dealer or installer for a password, to enable your dealer or installer
to give you a password you must provide the six-digit number from the
IC2100 screen.
NOTE
If you exit from a password menu the six digit number will change next
time you re-enter it, you should ensure that the exit key is not used while
you are contacting your dealer or installer. If the exit key is used the
password that you have been given will not be correct.
7
AUTORUN MODE
Autorun mode is used to run programs that have previously been created
on the IC2100, the operator can also create new programs edit, save,
delete or rename programs, this is done by using the MODE button.
NEW PROGRAM
1) Press the MODE button
2) Press 1 or enter if “New Program” is highlighted
3) Press “F1” ‘ins.step’ and type the first position then press ENT
Press ENT if 1 cut is required or type in the number of cuts
required then press ENT.
4) If only one cut is required simply type in your dimension then
press ENT
5) To enter more steps repeat 3 or 4 to end and run,
press the AUTO/MAN button followed by “F1” (RUN)
POSITION OFFSETS
This facility allows you to enter cuts as an offset from an absolute
position your program must NOT start with an offset i.e.
First cut is at 500 mm you then have several cuts to make for 30 mm
labels you could use "label mode" or offsets as the example shown
CUT 1 at 500 mm
Offset
- 30 (moves to 500 - 30 = 470 )
Offset
- 30 (moves to 470 - 30 = 440 )
Offset
-30 (moves to 440 - 30 = 410 )
To enter an offset you must start with an absolute position i.e. 500 mm
Then use the + or - button followed by the required offset
Whilst running the program if you find that a program step is in correct
you can edit it by using “F2” (EDIT STEP)
1) From Auto Run press “F2” (EDIT)
2) Press “F3” or “F4” to highlight the step to be edited
3) Press “F2” the cursor is now blinking on the position selected
for edit
4) Key in the correct dimension then ENT
8
5) If the number of cuts are correct press ENT if not type new
value then ENT
6) Press Auto/man to return to Auto run mode or repeat steps 2,3
and 4
LOAD PROGRAM
1) Press the MODE button
2) Press 2 or use “\/” to highlight “Load Program“ then press ENT
3) Any previously saved files will be displayed, select the file
required and by typing its number and press ENT ,the display
will now revert to Auto run
4) Press “F1” to run the loaded program
SAVE PROGRAM
1) Press the MODE button
2) Press 3 or use ‘\/’ to highlight “Save Program” then press ENT
3) Use the ‘\/’ ‘/\’ arrows to scroll through the alphabet and the
MOVE button to accept the letter and move onto the next once
the program name has been set use the ENT button to save
( PROGRAMS MAY BE SAVED WITH NUMBERS INSTEAD OF NAMES )
If you have previously saved a program, or edited an existing program
when you chose save you will be asked if you wish to overwright the
program. If you have changed a program to correct a previous error and
wish to retain the program and name press F1, ‘YES’. If you want to save
the modified program with a different name press F4, ‘NO’ you are then
asked if you wish to save as a new program F1 ‘YES’ will prompt you for
a program name, enter as step 3 F4 ‘NO’ you will return to the options
screen.
DELETE PROGRAM
1) Press the MODE button
2) Press 4 or use \/ to highlight “Delete Program” then press ENT
3) Select the program that you wish to delete and enter its number,
the program has now been deleted
9
RENAME PROGRAM
1) Press the MODE button
2) Press 5 or use \/ to highlight “Rename program” then press ENT
3) Use \/ /\ and move, as above to select the new program name or
number and ENT to complete the rename.
RUN PROGRAM
In "AUTO RUN" once you have loaded a program you can press the F1
button to run it, the program will run from the highlighted step, for
example. F3 or F4 have been used to browse through the program and
step 3 is highlighted when run is pressed the program will start at step 3.
This allows the operator to stop a program at any point and resume it at
any point without the need to go to the beginning.
EDIT PROGRAM
In AUTORUN F2 is the EDIT button, the edit function allows the
operator to change the type of step or to change the position or number of
cuts for a step. If F2 is pressed you will see the following options.
F1 INS. STEP this allows the insertion of a new step into a current
program, the step is inserted BELOW a highlighted step
F2 EDIT STEP this allows a step to be edited you can edit the type of
step or simply the position or number of cuts.
F3 PREV. STEP this button is used to move the highlighted bar to the
previous line of a program. ( / takes you to the first step )
F4 NEXT. STEP this button is used to move the highlighted bar to the
next line of a program. ( * takes you to the last step )
EDITING A STEP
From Auto Run press F2 EDIT, select the step to be edited using F3, F4
then F2 EDIT STEP.
F1 EXIT. Exit returns you to auto learn if you have finished editing your
program press AUTO/MAN to return to auto run.
10
F2 LOAD. Load is used to allow the operator to insert the material into
the machine, but does not require a cut to be performed. Once the
material is in position run is used to move to the first cut position.
F3 PUSH OUT. Push out moves the work to a position in front of the
blade to allow it to be rotated safely the push out value can be changed if
required.
F4 WAIT. Wait is to delay the backgauge movement to the next step; its
delay is in seconds so a value of 5 equals a delay of 5 seconds.
SHEET DIVIDE
Sheet divide is a utility that is used to cut divide material into equal sized
pieces for example.
You have a sheet that is 500 mm long and has to be cut into 8 equal
pieces, instead of using the calculator to work out each step you simply
use this utility.
1)
2)
3)
4)
5)
Press the mode button
Press 6 sheet divide
Enter the sheet size (in our case 500)
Enter the required number of divisions ( 8 )
Press ok
You are now asked if you want to add the sheet divide to a current
program or if you want to create a new one. If you add to a current
program the sheet divide will be inserted above the highlighted step in
that program.
If you chose new you are prompted to save the program that was
previously being used .Yes will save the old program .No replaces the
program with the sheet divide information.
Include sheet trim if selected will perform a cut at the sheet size, in our
case 500mm, if you chose no the IC2100 will assume that the sheet has
already been cut to size and only needs dividing.
11
You will now be in Auto learn mode if you want to edit any steps do so
from this screen, if you want to run the program press the Auto/man
button followed by “F1” run.
NOTE
If you have a created or entered a long program, instead of using the
"prev. step" or "next step" buttons you can use the “ / “ button to take you
to the beginning of the program or the “ * ” button to take you to the end
of the program.
LABEL CUT
Label mode is very similar to Sheet divide; however, in label cut mode
you enter the size of the label and the space between the labels, the gutter.
The label cut utility will then calculate all the cut positions and create a
Program in the same way as sheet divide.
Example.
You have a sheet that is 500mm long and you want to cut labels
that are 37 mm with a space or gutter of 14 mm.
1)
2)
3)
4)
5)
6)
Press the mode button
Press 7 Label cut
Enter the sheet size
Enter the label size
Enter the gutter size
Press ok
As with sheet divide you are asked
If you want to add to a current program or create a new one.
If you want to save the current program
If you want to include sheet trim
After you have answered these questions you are left with a program to
create your labels. In the example above, you end up with a program
containing 19 cut positions. To move to the first program step you can
use the " / " button to move to the last step use the " * " button.
12
AUTO LEARN MODE
Auto learn mode is used during editing of programs OR to create
programs, programs can be created in 2 ways; 1) You can create a program by typing each step into the IC2100
and then running the program to see if the dimensions that have
been entered are correctly.
2) You can teach the IC2100 with a sheet or job that needs to be
cut to size
TEACHING
The IC2100 can be taught to position to a given dimension and perform
the required number of cuts simply by ;1) From Auto Run mode select new program (press mode, 1 )
2) Move the backgauge either by hand or using the ‘/\’ ‘ \/ ‘
buttons then press “ENT” OR perform a cut at the required
position.
3) Repeat step 2 until all dimensions have been entered then press
“AUTO MAN” to take you back to Auto Run mode
4) Press “F1” to run the program
Absolute positions can be entered at any time whilst teaching positions to
the IC2100 simply type the required position then press enter.
13
EMERGENCY STOP
During the normal coarse of operation the IC2100 can be stopped simply
by pushing ANY button on the keyboard, the operator can stop the
backgauge from moving forward by bringing clamp down. There are
however instances when it is not possible or safe to move the knife or
clamp, also if auto retry is enabled as soon as the knife or clamp
are in the correct position the IC2100 will continue to position the
backgauge.
NOTE
This function is designed to assist the operator and under no
circumstance should it be used as a failsafe emergency stop.
The system installer should be consulted if a true emergency
stop is to be fitted.
MACHINE LIMITS
The machine limits are set at the time of installation if for any reason they
are incorrect you must contact your machine installer.
If the limits are not correct damage may be caused to your machine it is
recommended that they are checked periodically
14
MESSAGES
There is a total of 9 messages that can be used to advise the operator of
action required, for example a safety check is due, yearly maintenance is
due or simply to suggest that the machine should be lubricated.
The message type can be set to: 1)
2)
3)
4)
5)
6)
Daily
Weekly
Monthly
3 Monthly
6 Monthly
12 Monthly
( day selectable )
( date selectable)
(date selectable )
( date selectable)
( date selectable)
The message length can be upto 120 characters long and are only
accessible from the engineers menu, they should be set up at the time of
installation, once set if they are to be changed for any reason you must
contact your installer or DTS Engineering.
DAYLIGHT SAVING
The clock within the IC2100 will allow for daylight saving. The clock is
updated on the first Sunday in April and the last Sunday in October.
If required the clock can updated from the supervisor's menu.
15
ERROR MESSAGES
Message
Meaning or cause
Action aborted by operator
During backgauge movement a
button on the keyboard was pushed
Attempt to move past limit
During a manual move the
operator attempted to move the
backgauge past the min or max
machine size.
Invalid password
An attempt to enter a supervisor or
engineers password was made
however the number was incorrect
Motor error, no movement
The IC2100 has tried to move the
motor and did not seen any
movement this message can also
indicate a faulty or loose encoder.
Positioning error, overran
The IC2100 failed to find the
programmed position, this is often
caused by dry or worn leadscrew
No clamp
During a cut cycle either the clamp
did not move or the clamp switch
has moved or failed
Reposition Gauge
The backgauge has been moved
or knocked off position if "yes" is
pressed the backgauge will move
To the correct position.
Knife / Clamp
An attempt to move the backgauge
when the knife or clamp are down
will give this error.
Display flashing
This suggests that the program
Memory has been corrupted.
16
CONNECTIONS
ABC
A TO L
1
2
3 4
5 6 7
8
Mains input (240/110V AC)
1
a)
b)
c)
Live
Earth
Neutral
Low voltage inputs
2
RS 232
(Requires PC software, option)
3
4
5
6
Encoder input
Switch inputs
Switch inputs
Switch inputs
Relay outputs (C to L are voltage free contacts)
8
A
B
C+D
E+F
G+H
I+J
K+L
Analogue output
(INVERTER ONLY)
Analogue earth/common (INVERTER ONLY)
Forward relay
Reverse relay
Brake relay
Air relay
Slow relay
17
SERVICING
The IC2100 is a microprocessor controlled system which contains several
Microprocessors and a wide range of support components consequently
there are NO USER SERVICEABLE PARTS INSIDE
In the unlikely event of a failure you MUST contact your system installer
Installer details
Name ………………………………….
Address………………………………..
…………………………………………
…………………………………………
Contact ………………………………..
Tel …………………………………….
Fax……………………………………..
SP Electronics
Tarleton
Tel
Fax
0870 321 5116
0870 321 5118
Email sp@sp-electronics.co.uk
SP Electronics (TARLETON) cannot be held liable for any damage, loss or injuries as a result of
improper or incorrect use of our equipment. Nor can we be held liable for any damage, loss or injury as
a result of poor or improper installation carried out by a third party or as a result of equipment failure.
If you have any reservations you should contact us in writing stating the nature of your concern this
will enable us to look into it more deeply.
Every effort has been made to ensure correct operation of this equipment if you as a customer find
anything that you consider to be incorrect operation please advise us we can then endeavour to correct
it. Due to ongoing development we reserve the right to change specification without prior notice
18
YOUR SETTINGS
This section of the manual is for Engineer use only, it details all of the
settings that are applicable to your machine and may be needed at some
point in the future.
FUNCTION
MISC. SETUP
POWER UP UNITS
MIN POSITION DISTANCE
PUSHOUT DISTANCE
DISPLAY CUTS
AUTO REPOSITION
BRAKE TO STOP
CONFIG I/O
KNIFE UP
CLAMP UP
FALSE CLAMP IN
AUTO DATUM
BRAKE ON
AIR
AIR PULSE
CONFIG I/O BOARD (RELAY)
FORWARD RELAY
REVERSE RELAY
LEVEL FOR FAST
BRAKE LEVEL
CONFIG I/O BOARD (INVERTER)
NUDGE SPEED
FAST SPEED
PITCH & CONFIG
ENCODER PULSE / REV
LEAD SCREW PITCH
REVERSE DIRECTION
MACHINE DIMENSIONS
MAX POSITION
MIN POSITION
MIN POSITION IF CLAMP IN
AUTO DATUM POSITION
CURRENT POSITION
POSITIONING SETUP
No OF ATTEMPTS
POSITIONING TOLERANCE
DRIFT TOLERANCE
SLOW SPEED AT DISTANCE
SAMPLES UNTIL STALLED
APPROACH DIRECTION
DEFAULT
YOUR SETTING
mm (0.99)
20.00
0.00
YES
NO
NO
YES
NO
YES
(1)LOW
NO
NO
NO
HIGH
HIGH
HIGH
HIGH
20
127
360
10 mm
NO
3000 mm
10 mm
100 mm
0.00 mm
10 mm
4
0.09 mm
0.09 mm
10.00 mm
250
FORWARD
19
INSTALLATION NOTES
20
21
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