Delta Electric Servo Press - F Series Installation and Maintenance Instructions

(1)

㜓ὦ䔏㈲ⅱⅎ⮠勌㛰孱㛛Ə〼ᷴ⏍堳态䟌

Installation and Maintenance

Instructions

(2)

Safety Notice

This manual includes safety precautions on user safety and how to prevent the servo press from getting damaged, warnings and notes are used in this manual to describe how important these safety precautions are. Warnings are used to describe supplementary explanations, users must read the items in the warning, danger and stop carefully in order to prevent accidents or causing injuries to the staff.

The installation and transportation of the servo press should be executed by qualified personnel and should comply with the regional / country and local laws and regulation requirements.

The servo press is partly-completed machine accordance with Machinery Directive (2006/42/EC)pressing, the safeguards and related circuits are responsible by the final system integrator.

This servo press was designed only as an accessory for specific applications. We strongly suggest that this servo press should not be modified and/or used for any application processes other than what it was designed for. If you have any application problems, please do not use the servo press until you have received detailed explanations from your dealer.

The purpose of these introductions is to advise the customer and the operator on the design, construction, operation and maintenance of Servo Press. The attached illustrations, drawings and diagrams are intended to show the outstanding features, but are not binding for dimensional accuracy or further details. It provides extremely high machining accuracy. Be careful the properties of processing material, e.g. pressing, trimming or assemble of cold-metal, sheet or other likes, etc.

It is forbidden to process flammable, toxic or explosion materials.

Definition of operators

The definition of servo press operators is as follows.

Operator

‧ Able to perform operations such as powering the controller ON/OFF.

‧ Able to start the servo press from the final system integrated operation panel.

Program editor

‧ Performs the operations on the servo press.

‧ Uses manual mode to operate the servo press or teach points, etc. outside the safety fence.

Repair or inspection personnel

‧ Perform simple operations of the servo press.

‧ Uses manual mode to operate the servo press outside the safety fence.

‧ Performs operations such as maintenance, repairs, adjustment and replacement, etc. to the servo press and controller

FIRST RUN,

Product conforms to the Machinery Directive 2006/42/EC, Low Voltage Directive 2014/35/EU, EMC Directive 2014/30/EU and related standards EN ISO 12100, EN ISO 16092-1, EN ISO 16092-2, EN ISO 13857, EN 60204-1, EN 61000-6-2, EN 61000-6- 4, EN 61000-3-2, EN 61000-3-3.

Note: Please read the manual carefully before operating, maintaining or inspecting the servo press and controller, and make sure to follow the safety regulations. Please contact our company for details if you have any questions.

(3)

Servo press operators must receive training, read and understand how to use the safety measures, also to follow and execute all the rules described in this manual.

Meanings of the symbols “Danger”, “Warning” and “Prohibited”.

Means that danger is about to happen and may result in fatalities or severe injuries to the staff, if not prevented.

Means that there is potential danger and may result in fatalities or severe injuries to the staff, if not prevented.

Refers to activities that are absolutely prohibited; failure to comply may result in damage or malfunctions to the product causing the product to be unusable or it may result in injuries to the staff.

There is excessive noise that may affect the hearing when the servo press is operating; operators should wear earmuffs if feeling any discomfort.

(4)

Installation safety

◼ Please read this manual carefully before installing in order to make sure that the servo press and controller are installed at suitable usage locations and environments, to avoid affecting the mechanisms and usage life of the electronic components or encountering other safety problems.

◼ Please do not modify the machine or wiring by yourself or use with other controllers or servo press. Our company will not be held responsible for any injuries or fatalities caused by accidents that result from doing so.

◼ Please follow the instructions in this manual properly to transport and install the servo press and controller correctly; otherwise it might result in damage to the servo press or controller.

◼ Related licenses are required to operate stackers or fork lifts etc.

◼ Please wear proper safety work clothes, helmets, gloves and shoes when installing the servo press and controller in order to ensure the safety of personnel.

◼ Do not add additional cables or hoses etc. inside the servo press. When installing the exterior cables of the servo press, make sure to assess whether the cables and mechanisms will interfere with one another during operations.

◼ The servo press itself is applicable for environment IP20 and is able to resist solid matters with diameters over 12mm and lengths not exceeding 80mm, such as fingers; it is not protected against any liquid matter.

◼ Please follow the manual to install the safety protection devices such as fence, light curtain etc. in order to prevent injuries or other dangers caused to the staff arising from impact by the servo press within the operating range of the servo press.

◼ Please install the final system integration of the user operating buttons and warning lights etc. outside the fence in order to ensure usage safety. The height of the operating interface should be a suitable (0.6m to 1.7m) range for

operators to touch.

◼ Please do not turn the power on and off frequently as doing so may result in damage to the controller.

◼ The servo press system should be installed under the specified conditions; in the foreseeable usage period, the servo press cannot be tilted or moved with uncontrolled methods during transportation, assembly, dis-assembly,

suspended or discarded periods.

◼ Please properly ground all servo press systems; they should all be grounded before connecting the power.

◼ The final system integrator should install protection devices in order to prevent users from getting close to the danger area.

◼ Do not bypass the interlock circuit.

◼ Removing or changing the locations of any safety warning labels is strictly prohibited as doing so may cause danger to the staff and to cause injuries.

◼ Performing any unsafe actions at the safety warning locations is strictly prohibited as doing so may cause injuries to the staff.

◼ Personnel must not stand beneath when stackers or fork lifts, etc. are used to

(5)

◼ Changing or modifying the servo press and controller is strictly prohibited as doing so may result in damages to the servo press or controller and danger to the staff. Our company will not be held responsible for any work accidents.

◼ Installing and wiring of the servo press by people without related professional knowledge or licenses is strictly prohibited.

(6)

Usage and operating safety

◼ Please read this manual carefully before usage in order to ensure proper usage and the safety of the maintenance staff.

◼ Due to operational environment and operator safety considerations, our company will provide dedicated training for the operators of different servo press applications in order to ensure usage safety. Please contact our company or your local dealers if training is needed.

◼ Please perform wiring properly according to this manual; wiring must be performed by personnel with related professional knowledge or licenses.

◼ Cannot be used on production lines that are flammable, explosive, toxic or has the risk of being sprayed by liquids.

◼ Please select a suitable model according to the load capability; do not overuse specifications that exceed the machine model specifications.

◼ The servo press is a partially completed machine; the assembly and

construction of the protection and safety circuit should be the responsibility of the final system integrator.

◼ All children and visitors should keep a safe distance from the processing area.

◼ Do not wear loose clothes, ties, rings or bracelets and wear protective nets to protect long hair as these things can easily get caught in the machine by accident and cause injuries to the staff or cause other dangers during operation.

◼ Please turn off the power, isolate the power properly and wait for the servo press to stop completely when the servo press is no longer used before you leave.

◼ Please confirm that there is no one along the fence before operating the servo press and performing operations.

◼ Do not laugh or talk to other workers while operating the servo press; such wrong behaviors may result in collision of the servo press or injuries to other workers.

◼ Please have the senior supervisor keep the internal/external mode selection switch key; do not place it randomly or leave it inserted on the selection switch as doing so may result in other personnel activating the servo press

accidentally, causing injuries to the workers.

◼ Please use slow speed operations when operating the servo press manually for the first time, otherwise being unfamiliar with the operations may result in damage to the servo press due to impact or cause injuries to other workers.

◼ Please do not turn the power on and off frequently as doing so may result in damage to the controller.

◼ Improper operations might damage the servo press.

◼ When collisions happen to the servo press, please turn off the power of the servo press first and then check the components and cables of the servo press to make sure they were not damaged before turning the power back on to perform operations again.

◼ Please use a safety lock on the fence switch when entering the fence to operate the servo press in order to prevent the fence from closing suddenly causing the

(7)

according to EN ISO 13857 standards.

◼ Do not operate the press when light curtain, safety guard, or safeguards are not provided.

◼ Do not operate the press under out of limit.

◼ Short-circuiting of any safety protection signals on the controller is strictly prohibited, otherwise our company will not be held responsible for any work accidents that may occur.

◼ When operating the servo press all personnel are prohibited from standing close or within the servo press working range; doing so will cause injuries to the other workers.

◼ Do not unplug any cables on the controller while the servo press is operating;

doing so will cause damage to the controller.

◼ Do not open the protective cover or protection device while the machine and servo press are operating.

(8)

Maintenance safety

◼ Please perform maintenance and inspection work properly according to the manual in order to prolong the usage life of the servo press.

◼ Please add a safety lock on the power switch of the power box when

performing maintenance or repair operations on the servo press, and place a

“Do not power on” safety warning at an obvious place.

◼ Make sure foreign objects do not get attached or enter the servo press when performing maintenance or inspection.

◼ Making random oil changes during maintenance may result in damaging the performance of the servo press or to the mechanical components.

◼ Protection devices and repair doors in the danger areas that need to be opened or removed regularly for the purpose of operations, maintenance, cleaning and configuration should be interlocking.

◼ Personnel performing maintenance or repairs on the servo press or servo press system should receive the necessary process training in order to execute the tasks required. Also use only genuine materials, or else it might cause grave danger to the users.

◼ The processing of waste materials should comply with local laws and regulations, and should be treated carefully.

◼ Random changes to the maintenance schedule of the servo press and maintenance oil are strictly prohibited.

◼ Maintenance and inspection to the controller and servo press are prohibited while power is being supplied or else it may cause electrical shocks or injuries to the workers.

◼ When a servo press component is damaged, replacing with other brand components is prohibited as doing so many result in damaging the performance of the servo press or the components.

◼ When internal components of the controller are damaged, replacing them with other brand components is prohibited; doing so may cause accidents or result in decreasing the safety performance levels.

◼ The power control box must not be opened within 10 minutes of powering off because the residual voltage in the driver may cause electrical shocks.

(9)

The servo electric cylinder has been filled with grease at the factory, please replenish the screw lubricating oil in time according to the usage conditions. Fill the oil hole as shown in the figure, and replenish it. In order to maintain the service life of the machine, oil needs to be replenished regularly (assuming that it operates 8 hours a day, it is recommended to refill oil once a year).

Mobil SHC220 grease is recommended. The operating temperature range of this grease is -40°C ~ +177°C

* Recommended oil gun: KCG-470H (Brand: Alba)

* Recommended nozzle: M6*1.0P, 40mm long

* Single oil injection volume_ E001 / E002 spindle: 5ml

* Single oil injection volume_ E005 / E010 spindle: 10ml

* Single oil injection volume_ E030 / E050 spindle: 40 ml Oil hole

(21)

Oil filling steps are as follows:

Step 1: Remove the outer cover of the cylinder block wire cover Step 2: Unscrew the screw plug of the oil injection hole

Step 3: Confirm the position of the oil nipple in the oil injection hole Step 4: Stop the motor and cut off the power

Step 5: Combine the grease nipple with the oil hole and inject grease into the grease nipple Step 6: Remove the grease fitting

Step 7: Screw on the screw plug

Step 8: Reinstall the cylinder block wire cover cover

Step 9: Turn on the power, and let the servo electric cylinder go back and forth for 2 to 3 full strokes

(22)

4.2 Load Cell Calibration

In order for the servo press to maintain precise quality, please perform load cell calibration if unusual force levels appear, or perform load cell calibration on a regular basis (after the warranty period expires). The load cell calibration tool is shown in the figure. Please follow the Operating Instructions while performing calibration and qualification or contact the Company (Delta Electronics) or contract service providers.

(23)

5. Wiring Instructions 5.1 Circuit Diagram

*During configurations, it is recommended that the signal line (green) and the motor power line (blue) be

(24)

5.2 Detailed Explanation of PLC External I/O Points

(25)

5.3 Wiring Instructions

(26)

5.4 Wire Table and Wire Size for Wiring

(27)

5.5 Details of Drive Power Distribution

#Suggest adding an NFB (No Fuse Breaker) circuit before the external power supply to prevent damage to the driver.

5.5.1 0.4 kW~1 kW

0.4 kW ~ 1 kW

R S T L

1C

L

2C

P1 P2

P3 D C U V W

External power supply (AC220V)

Motor power (Power Cable) Red

Write Black

(28)

5.5.2 2 kW~5.5 kW

External power supply (AC220V /380V)

Regenerativ e resistance (5.5-7.5kW)

Motor power (Power line)

2 kW ~ 5.5 kW

L

^1C

L

^2C

R S T P

¹

P

²

P3

C U V W

Red Write

Black

(29)

5.6 External Button

Cylinder type of servo press provide user to connect the button. The wires required for those button including the two hand trigger buttons, emergency stop button, reset button, alarm light and buzzing.

(1) The wires showed at the red block and enlisted the table below: (NPN)

Input (Buttons)

EMS (NC) Mode Light Curtain (NC) Reset Trigger-L Trigger-R

*Mode-OFF is internal control，ON is external control

Output

Buzz Alarm

(2) How to use the button functions:

⚫ Turn on the button function.

1. Please log in [Senior Engineer] access (PW:2222)，touch [Equipment Parameter] and choose [Other] 。

(30)

2. Please choose [Yes] with buttons, then press [Save].

3. Go back to main screen and touch the [IO Monitor] to check the status of the buttons

⚫ Trigger Start

The two hand start buttons have to be touched simultaneously to conduct the pressing process.

(<500ms). After the pressing finished, these two signal have to be released before next pressing process.

⚫ Light Curtain

If the light curtain hasn’t been turned on, the hand two start buttons have to be touched during the whole pressing process. If one of these buttons had been released, servo press will stop and go back to working origin after touching the reset button.

If the light curtain is on, the two hand start button can be released after the pressing process begin.

If the curtain light have been installed, please follow the above steps to turn on the light curtain function.

1. Please log in [Senior Engineer] access (PW:2222)，touch [Equipment Parameter] and turn on the light curtain.

(31)

(32)

Industrial Automation Headquarters

Taiwan: Delta Electronics, Inc.

Taoyuan Technology Center

No.18, Xinglong Rd., Taoyuan District, Taoyuan City 33068, Taiwan

TEL: +886-3-362-6301 / FAX: +886-3-371-6301

Asia

China: Delta Electronics (Shanghai) Co., Ltd.

No.182 Minyu Rd., Pudong Shanghai, P.R.C.

Post code : 201209

TEL: +86-21-6872-3988 / FAX: +86-21-6872-3996 Customer Service: 400-820-9595

Japan: Delta Electronics (Japan), Inc.

Industrial Automation Sales Department 2-1-14 Shibadaimon, Minato-ku Tokyo, Japan 105-0012

TEL: +81-3-5733-1155 / FAX: +81-3-5733-1255 Korea: Delta Electronics (Korea), Inc.

1511, 219, Gasan Digital 1-Ro., Geumcheon-gu, Seoul, 08501 South Korea

TEL: +82-2-515-5305 / FAX: +82-2-515-5302

Singapore: Delta Energy Systems (Singapore) Pte Ltd.

4 Kaki Bukit Avenue 1, #05-04, Singapore 417939 TEL: +65-6747-5155 / FAX: +65-6744-9228 India: Delta Electronics (India) Pvt. Ltd.

Plot No.43, Sector 35, HSIIDC Gurgaon, PIN 122001, Haryana, India

TEL: +91-124-4874900 / FAX: +91-124-4874945 Thailand: Delta Electronics (Thailand) PCL.

909 Soi 9, Moo 4, Bangpoo Industrial Estate (E.P.Z), Pattana 1 Rd., T.Phraksa, A.Muang,

Samutprakarn 10280, Thailand

TEL: +66-2709-2800 / FAX: +66-2709-2827

Australia: Delta Electronics (Australia) Pty Ltd.

Unit 20-21/45 Normanby Rd., Notting Hill Vic 3168, Australia TEL: +61-3-9543-3720

Americas

USA: Delta Electronics (Americas) Ltd.

5101 Davis Drive, Research Triangle Park, NC 27709, U.S.A.

TEL: +1-919-767-3813 / FAX: +1-919-767-3969 Brazil: Delta Electronics Brazil Rua Itapeva, 26 - 3°, andar Edificio Itapeva, One - Bela Vista 01332-000 - São Paulo - SP - Brazil TEL: +55-12-3932-2300 / FAX: +55-12-3932-237

Mexico: Delta Electronics International Mexico S.A. de C.V.

Gustavo Baz No. 309 Edificio E PB 103 Colonia La Loma, CP 54060

EMEA

EMEA Headquarters: Delta Electronics (Netherlands) B.V.

Sales: Sales.IA.EMEA@deltaww.com Marketing: Marketing.IA.EMEA@deltaww.com Technical Support: iatechnicalsupport@deltaww.com Customer Support: Customer-Support@deltaww.com Service: Service.IA.emea@deltaww.com

TEL: +31(0)40 800 3900

BENELUX: Delta Electronics (Netherlands) B.V.

De Witbogt 20, 5652 AG Eindhoven, The Netherlands Mail: Sales.IA.Benelux@deltaww.com

TEL: +31(0)40 800 3900

DACH: Delta Electronics (Netherlands) B.V.

Coesterweg 45, D-59494 Soest, Germany Mail: Sales.IA.DACH@deltaww.com TEL: +49(0)2921 987 0

France: Delta Electronics (France) S.A.

ZI du bois Challand 2, 15 rue des Pyrénées, Lisses, 91090 Evry Cedex, France Mail: Sales.IA.FR@deltaww.com TEL: +33(0)1 69 77 82 60

Iberia: Delta Electronics Solutions (Spain) S.L.U Ctra. De Villaverde a Vallecas, 265 1º Dcha Ed.

Hormigueras – P.I. de Vallecas 28031 Madrid TEL: +34(0)91 223 74 20

Carrer Llacuna 166, 08018 Barcelona, Spain Mail: Sales.IA.Iberia@deltaww.com Italy: Delta Electronics (Italy) S.r.l.

Via Meda 2–22060 Novedrate(CO) Piazza Grazioli 18 00186 Roma Italy Mail: Sales.IA.Italy@deltaww.com TEL: +39 039 8900365

Russia: Delta Energy System LLC Vereyskaya Plaza II, office 112 Vereyskaya str.

17 121357 Moscow Russia Mail: Sales.IA.RU@deltaww.com TEL: +7 495 644 3240

Turkey: Delta Greentech Elektronik San. Ltd. Sti. (Turkey) Şerifali Mah. Hendem Cad. Kule Sok. No:16-A

34775 Ümraniye – İstanbul Mail: Sales.IA.Turkey@deltaww.com TEL: + 90 216 499 9910

MEA: Eltek Dubai (Eltek MEA DMCC) OFFICE 2504, 25th Floor, Saba Tower 1, Jumeirah Lakes Towers, Dubai, UAE

Delta Electric Servo Press - F Series Installation and Maintenance Instructions

Installation and Maintenance

Instructions

Safety Notice

Installation safety

Usage and operating safety

Maintenance safety

Contents

1. Safety Information... 2

2. Comprehensive System Structure ... 4

3. Installation Setup ... 5

4. Equipment Care and Maintenance ... 12

5. Wiring Instructions ... 15

Delta Electronics Servo Press

(External Electric Cylinder)

Installation and Maintenance

Instructions

1. Safety Information

1.1 Safety Information Before Use

1.2 Safety Information During Use

1.3 Safety Information During Maintenance and Under Other Circumstances

1.4 Powering System

2. Comprehensive System Structure 2.1 Model & Electronic Control Panel

3. Installation Setup 3.1 Fixed Way

3.1.1 AM-ESP-E050-XXXX/AM-ESP-E030-XXXX models

3.1.2 AM-ESP-E010-XXXX / AM-ESP-E005-XXXX models

3.1.3 AM-ESP-E002-XXXX / AM-ESP-E001-XXXX models

3.2 Loading and Unloading Spindle Punch

3.2.1 AM-ESP-E050-XXXX / AM-ESP-E030-XXXX models

3.2.2 AM-ESP-E010-XXXX / AM-ESP-E005-XXXX models

3.2.3 AM-ESP-E002-XXXX / AM-ESP-E001-XXXX models

3.2.4 Restrictions of Jig

4. Equipment Care and Maintenance 4.1 Applying Oil to Equipment

4.2 Load Cell Calibration

5. Wiring Instructions 5.1 Circuit Diagram

5.2 Detailed Explanation of PLC External I/O Points

5.3 Wiring Instructions

5.4 Wire Table and Wire Size for Wiring

5.5 Details of Drive Power Distribution

#Suggest adding an NFB (No Fuse Breaker) circuit before the external power supply to prevent damage to the driver.

5.5.1 0.4 kW~1 kW

0.4 kW ~ 1 kW

R S T L

L

P1 P2

P3 D C U V W

5.5.2 2 kW~5.5 kW

2 kW ~ 5.5 kW

L

L

R S T P

P

P3

C U V W

5.6 External Button