Inhaltsverzeichnis

1 ANTRIEBSEINHEIT ALPHA 488 BASIS MASCHINE SERVO AXIS ALPHA 488 BASE MACHINE .. 2

2 ANTRIEBSEINHEIT ALPHA 488 TWISTER SERVO AXIS ALPHA 488 TWISTER.............................. 3

3 MOTORREGLER / AXIS CONTROLLER ............................................................................................... 3

3.1 EMV EMC............................................................................................................................................ 3
4 NOTAUSKREIS / EMERGENCY CIRCUIT........................................................................................... 3

5 RCS MOTORREGLER / RCS AXIS CONTROLLER ................................................................................ 3

5.1 VERDRAHTUNG HW - KANAL IM BASIS - UND TWISTER - SCHRANK WIRING DIAGRAM HW-CHANNEL IN BASIC-
AND TWISTER -CABINET ..........................................................................................................................................
3
5.2 VERDRAHTUNG SW - KANAL / WIRING DIAGRAM SW-CHANNEL ................................................................... 3
5.2.1 SW - Kanal Basis - Schrank / SW-channel base cabinet................................................................. 3
5.2.2 SW - Kanal Twister - Schrank / SW-channel twister cabinet .......................................................... 3
5.3 VERKNPFUNG HW - KANAL UND SW - KANAL COMBINATION OF HW - AND SW - CHANNEL ........................ 3
6 GESAMTBERSICHT ............................................................................................................................... 3

7 FEHLERSUCHE / TROUBLE SHOOTING................................................................................................ 3

7.1 LED - DISPLAY ....................................................................................................................................... 3
7.1.1 Regler Zustand Controller State............................................................................................... 3
7.1.2 Fehler - Bedeutung Error description.......................................................................................... 3
7.2 KOMMUNIKATIONSFEHLER COMMUNICATION ERRORS................................................................................. 3
7.3 KRAFTMESSUNG / FORCE MEASUREMENT .................................................................................................. 3
7.4 KABEL - ENCODER / WIRE ENCODER .......................................................................................................... 3
7.5 HILFREICHE ACHSENPARAMETER HELPFUL AXIS PARAMETERS ..................................................................... 3
7.6 VERSCH. ABKRZUNGEN DIV. ABBREVIATIONS ........................................................................................... 3

Service_488.doc komax AG /Peter Flury 18. Oktober 2005

 S W IVE L U N IT 1 P U L L OF F U N IT 1 S W IVE L U N IT 2 P U L L OF F U N IT 2 KN I F E U N IT
N r. 1 N r. 2 N r. 3 N r. 4 N r. 5
ALPHA488

D AC 0 8 D AC 0 5 / X D AC 0 8 D A C 0 5 /X D AC 0 5 / X
K o m a x N r. 0 24846 K o m a x N r. 0 245 16 K o m a x N r. 0 245 17 K om a x N r. 0 245 1 6 K o m a x N r. 0 245 16

R S 422

Service_488.doc
zu P C C
d elta d rive d elta d rive d elta d rive d eltad rive d elta d rive

K a b elencoder

R S 48 5
ink l . F errit
L= 0 . 145 m
Stations -Adres s e N r. 0 2484 9
1 2 N r. 0 2485 1 N r. 0 248 5 2 3 4 N r. 0 248 5 3 N r. 0 248 5 4 5
N r. 0 2485 0

D C -B u s D C -B u s
3 x 220 V 3 x 220 V 3 x 22 0 V

komax AG /Peter Flury

E ncoderk ab el E ncoder k a b el E ncoderk a b el E nco derk a b el E ncoder k ab el
L nge = 4. 2m L nge = 4 . 2m L nge = 4. 4m L nge = 4. 2 m L nge = 4 . 2m
N r. 0 2479 1 N r. 0 2479 2 N r. 0 2479 3 N r. 0 247 9 4 N r. 0 2479 5
Servo axis Alpha 488 base machine
Service-Unterlagen Motorregler deltadrive

1 Antriebseinheit Alpha 488 Basis Maschine

Motork a b el Motor k a b el Motor k a b el

Mo tork a b el L nge = 4 . 3 m Motor k a b el L nge = 4 . 3m L nge = 4 . 3m
L nge = 4 . 3 m N r. 0 248 0 2 L nge = 4 . 3m N r. 0 2480 4 N r. 0 2480 5
N r. 0 248 0 1 N r. 0 248 0 3

SA C 9 0 L2 0 /3/T B /E Y -2 0 48 SA C 9 0 S2 5 /3/T B /F T /E Y -2 0 48 SAC 9 0 L2 0 /3/T B /E Y -20 48 SAC 9 0 S25 /3/T B /F T /E Y -20 48 SAC 9 0 S25 /3/T B /F T /E Y -2 0 48
K o m ax N r. 0 24844 K o m ax N r. 0 24845 K o m ax N r. 0 24844 K o m a x N r. 0 2484 5 K om a x N r. 0 2484 5

Motor m it K ab el k o m p let: Motor m it K ab el k om p let: Motor m it K ab el k o m p let: Moto r m it K a b el k om p let: Motor m it K a b el k om p let:
K o m ax N r. 0 249 0 1 K om a x N r. 0 24 9 0 2 K o m ax N r. 0 249 0 3 K o m ax N r. 0 24 9 0 4 K om a x N r. 0 249 0 5

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2/17
 O ption: P R E
T W IS TIN G L E N G TH TW IS TIN G H E A D TR A N S F E R BR ID G E TW IS TIN G H E AD W IR E P U L L
ALPHA488

N r. 1 N r. 2 N r. 3 N r. 4 N r. 6
D AC 0 8 D AC 0 5 /X D AC 0 8 D AC 0 5 /X D AC 0 8/F B K 10 0
K o m ax N r. 0 245 17 K o m ax N r. 0 245 16 K o m a x N r. 0 245 17 K om a x N r. 0 245 16 K om a x N r. 0 2484 6

Service_488.doc
R S 422
zu P C C
d eltad rive d eltad rive d eltad rive d eltad rive d eltad rive

K a b elencoder

R S 485
R S 485
ink l. F errit
ink l. F errit
L = 0 . 145 m
Station s -Adres s e L= 0 . 23m N r. 0 2485 5
1 N r. 0 24849 2 N r. 0 248 5 1 N r. 0 248 5 2 3 N r. 0 248 5 3 4 6
N r. 0 248 5 0 N r. 0 2 5 5 0 4

D C -B u s D C -B u s

3 x 220 V 3 x 220 V 3 x 220 V

Servo axis Alpha 488 twister

E ncoderk a b el E ncoderk ab el E ncoderk a b el

komax AG /Peter Flury

E ncoderk ab el
2 Antriebseinheit Alpha 488 Twister

E ncoderk ab el
L nge = 4. 5 m L = 9 . 0 m N r. 0 25 6 9 2 L nge = 4. 2 m s h ort N r. 0 2 5 6 9 4 L nge = 4 . 2m
N r. 0 25 6 9 1 L = 12. 5 m N r. 0 2 6 0 6 5 N r. 0 246 9 3 long N r. 0 2 5 6 9 8 N r. 0 25 6 9 6
L = 16 . 0 m N r. 0 2 5 6 9 7
Service-Unterlagen Motorregler deltadrive

Motork a b el

25 70 2
el
0 25 85 1
0 25 6 9 9
Motork a b el L nge = 4 . 3 m Motork ab el
L nge = 4. 5 m N r. 0 2 5 7 0 3 L nge = 4. 3m
N r. 0 25 70 6
Motork ab el
N r. 0 25 70 1

Motork ab
long N r. 0 25 70 0
s h ort N r. 0 25 70 4

L = 9 . 0 m N r. 0
L = 12. 5 m N r.
L = 1 6 . 0 m N r.
SA C 9 0 L20 /3/T B /E Y -20 48 SAC 9 0 S5 0 /3/T B /F T /E Y -20 48 SAC 9 0 S2 5 /3/T B /E Y -20 48 SAC 9 0 S2 5 /3/T B /F T /E Y -20 48 SAC 9 0 L20 /3/T B /E Y -2 0 48
K om ax N r. 0 24844 K om ax N r. 0 24810 K om ax N r. 0 24845 K o m ax N r. 0 2484 5 K o m a x N r. 0 24844

Motor m it K ab el k om p let: Motor m it K ab el k o m p let: Motor m it K ab el k o m p let: Motor m it K ab el k o m p let: Motor m it K ab el k om p let:
K om a x N r. 0 2 5 6 81 0 2 5 6 82 in k l . 0 25 70 2 K om a x N r. 0 2 5 6 83 K om ax N r. 0 2 5 6 86
0 2 6 0 6 4 ink l . 0 25 85 1

18. Oktober 2005

3/17

0 26 10 2 ink l. 0 25 6 9 9
 ALPHA488 Service-Unterlagen Motorregler deltadrive 4/17

3 Motorregler / Axis controller

24V Reglerspeisung Sicherung: F105 12,5 AT
24V Controller Power Supply Fuse: F105 12,5 AT

Stations A d r e s s e nE r k e n n u n g :
Ein Widerstand, vergossen in einem Gehuse, wird beim ersten Einschalten des Controllers vom
A/DWandler eingelesen und ausgewertet.
Station-Addre s -R e cognizing :
T h e s t a t i o n n u m b e r i s d e f i n e d b y a resistor value. The value will be read on the first Power Up.

S t a t i o n- R e sistor S t a t i o n- R e sistor S t a t i o n- R e sistor

Nr. [Ohm] Nr. [Ohm] Nr. [Ohm]
1 0 3 2200 5 4700
2 1200 4 3300 6 5 6 0 0

Bei offenem Eingang gilt die im Regler im Flash gespeicherte Stationsnummer.

An open Input activates the address stored in the internal parameter (flash).

U e b e r l a s t k o n t r o l l e d e r S e r v o a c h s e n m i t t e l s I 2t U e b e r w a c h u n g i m C o n t r o l l e r .
K e i n T h e r m o-K o n t a k t i m M o t o r .
= > B e i F e h l e r m e l d u n g " U e b e r t e m p e r a t u r M o t o r " , m u s s d er Motor nic h t gewec h s e lt werden, weil der
C o ntroller den Motor s c h tzt . ( A u s s e r b e i m e c h a n i s c h e m D e f e k t )
Overload control with the I2t supervisor in the axis controller.
There is no thermo contact in the motor.
=> If error message "temperature overload ..." appears, motor doesn't have to change, because the
controller protects the motor against overheating. (except for mechanical defect)

S e r i e l l e K o m m u n i k a t i o n R S-4 8 5 z w i s c h e n M a s c h i n e n s t e u e r u n g ( P C C -K a rte) u n d Gateway .

Serial communication RS-485 between machine controller (PCC card) and gateway.

N e tzwer k zwi s c h e n den einzelnen Ac h s -C o ntrollern u n d Gateway .

Network between the axis controllers and gateway.

D i e D I P - Sc h a lter a u f der O b e r s e ite de s Motorregler s

ON
OF
mssen alle in der Stellung OFF stehen.
All DIP - switches on the controller must be in the OFF - Position.

3.1 EMV EMC

Elektromagnetische Vertrglichkeit:
Electromagnetic compatibility:

Die Motorkabel sind abgeschirmt. Die Abschirmung muss beidseitig

g r o s s f l c h i g a n M a s s e g e l e g t w e r d e n . B e i m M o t or wird die s d u r c h eine
E M V -S t o p f b u c h s e e r r e i c h t . I m S t e u e r s c h r a n k w i r d d i e K a b e l z u g e n t l a s t u n g
der Motorkabel auf den umgelegten Kabelschirm gedrckt und auf der C - Frontplatte

Sc h i ene u n ter h a l b der Motorregler b e fe s t igt .

The motor cable are shielded. The shield must be connected at both sides to ground.
On the motor side, this grounding is made by a emc-compatible cablepassage. In the control cabinet
the motor cables are connected with the pullrelieve below the axis controllers.

D i e E n c o d e r k a b e l s i n d b e i d s e i t i g m i t ei n e m H D -9 p o l D -SUB S t e c k e r v e r s e h e n . D i e
Befestigungsschrauben mssen immer gut angezogen sein, um eine gute Masseverbindung sicher
zu stellen.
The encoder cables are on both sides equipped with HD-9 pol SUB-D connectors. The connectors
must always be screwed well to ensure correct grounding.

D i e M o t o r r e g l e r m s s e n m i t d e r C -S c h i e n e ( M a s s e s c h i e n e ) g u t v e r s c h r a u b t s e i n . D i e S c h r a u b e
b e f i n d e t s i c h u n t e r d e r C -S c h i e n e , z w i s c h e n d e n S c h n e l l v e r l e g e r k l a m m e r n .

Service_488.doc komax AG /Peter Flury 18. Oktober 2005

ALPHA488 Service-Unterlagen Motorregler deltadrive 5 /17

The axis controllers must always be fixed well with the corresponding screw to the groundrail below
the controllers.

Schlechte, oder gar fehlende Masseverbindungen der Kabelschirme knnen zu Fehlern in den
Motorreglern f h r en .
Bad or even missing ground connections may cause errors on axis controllers.

4 Notauskreis / Emergency Circuit

Swivel1 P u llOff1 Swivel2 Pu llOff2 K nife WireD rive

4 4 4 4 4 4

G ateway
N othalt
5 N othalt
5 5 5 5 5
6 6 6 6 6 6
7 7 7 7 7 7
N ota u s 8 8 8 8 8 8
Emergency Stop R eady R eady-Signal B IO
R elais K 5 9 9 9 9 9 9 Inp u t 5
R eady
10 10 10 10 10 10
+24V D C 11 11 11 11 11 11
B IO
0 V D C 12 12 12 12 12 12 Ou tp u t 24
Start-P u l s

1 1 1 1 1 1
2 2 2 2 2 2 R E AD Y = +24V
3 3 3 3 3 3
E m ergency Stop = 0 V
4 4 4 4 4 4
5 5 5 5 5 5
6 6 6 6 6 6
7 7 7 7 7 7
8 8 8 8 8 8
9 9 9 9 9 9
10 10 10 10 10 10
1 1 1 1 1 1
2 2 2 2 2 2
3 3 3 3 3 3
4 4 4 4 4 4

Service_488.doc komax AG /Peter Flury 18. Oktober 2005

ALPHA488 Service-Unterlagen Motorregler deltadrive 6 /17

5 R C S M o t o r r e g l e r / RCS axis controller

5.1 V e r d r a h t u n g H W - Kanal im Basis - u n d Twister - S c h r a n k

Wiring d i agram HW-channel in basic- an d twister-cabinet
D a s f o l g e n d e D i a g r a m m z e i g t d i e V e r d r a h t u n g d e s S e t u p -K r e i s e s . V on d e r M R S ( C H 0 ) e r h l t d e r R e g l e r
" S w i v e l _ 1 " i m B a s i s s c h r a n k d e n 2 4 V -Pegel a u f den Gateway ( R J 4 5 -S t e c k e r ) f r " A u t o m a t i k " . I m
T w i s t e r s c h r a n k e r h l t d e r R e g l e r " W i r e P u l l " d e n 2 4 V -Pegel von der M R S ( C H 1) a u f den Gateway .

The following diagram shows the wiring of the setup loop. The HW-signal "Automatic / Setup" will be sent
from CH 0 and CH 1 from MRS-board. This signals will be analyzed in Swivel 1 and Wire Pull.
Au to/Setu p Ou tp u t
MR S C H 0 Au to/Setu p Inp u t
Base cabinet
Swivel1 Pu llOff1 Swivel2 Pu llOff2 K nife
Au to m atik = +24V
RJ45
(E na b le, B etrie b ) 4 4 4 4 4
G ateway

E nable
5 5 5 5 5
Setu p = 0 V 6 6 6 6 6
7 7 7 7 7
Betrieb
8 8 8 8 8
9 9 9 9 9
10 10 10 10 10
+24V D C
11 11 11 11 11
0 V D C
12 12 12 12 12

Au to/Setu p In p u t
Au to/Setu p Ou tp u t MR S C H 1
Twister cabinet
T wis ting T wis ting T wis ter
Length Head B ridge Wire Pu ll
RJ45 SW - C o m m and
4 4 4 4
G ateway

E nable
5 5 5 5
Betrieb

6 6 6 6 Au to m atik = +24V
7 (E na b le, B etrie b )
7 7 7
Betrieb
8 8 8 8
Setu p = 0 V
9 9 9 9
10 10 10 10
+24V D C
11 11 11 11
0 V D C
12 12 12 12

5.2 V e r d r a h t u n g S W - Kanal / Wiring d i agram SW-channel

Au f d e n b e i d e n s e r i e l l e n S c h n i t t s t e l l e n ( C H 0 , C H 1 ) w i r d j e d e m R e g l e r " A u t o m a t i k " g e m e l d e t .
D i e S W-K o m m a n d o s s i n d w i e f o l g t a u f d i e b e i d e n G a t e w a y s a u f g e t e i l t :

By the two communication lines (CH 0, CH 1), the controllers get the message "Automatic / Setup". This
comands are shared to the two gateways as follow:

Gateway 0 ab MRS / CH 0: Swivel 1 Achse 1

P u l l Off 1 Achse 2
Swivel 2 Achse 3
P u l l Off 2 Achse 4
Knife Achse 5

Gateway 1 ab MRS / CH 1: Wire P u l l Ach s e 6

Transfer Bridge Achse 3
Twisting Head Achse 2
T w i s t ing Lengt h Achse 1
Service_488.doc komax AG /Peter Flury 18. Oktober 2005
ALPHA488 Service-Unterlagen Motorregler deltadrive 7/17

5.2.1 S W - Kanal Basis - S c hrank / SW-channel base cabinet

S W IVE L U N IT 1 P U L L OF F U N IT 1 S W IVE L U N IT 2 P U L L OF F U N IT 2 KN IF E U N IT
Nr.1 Nr.2 Nr.3 Nr.4 Nr.5
D A C 0 8 D A C 0 5 / X D A C 0 8 D A C 0 5 / X D A C 0 5 / X
K om a x N r. 0 2484 6 K o m a x N r. 0 24 5 1 6 K om a x N r. 0 24 5 17 K o m a x N r. 0 24 5 1 6 K o m ax N r. 0 245 1 6

RS 422
z u P C C
Ch 0

d eltad rive d eltad rive d eltad rive d eltad rive d eltad rive

1 2 3 4 5

5.2.2 S W - Kanal Twister - S c hrank / SW-channel twister cabinet

TW I S TI N G L E N G TH TW IS TIN G H E A D TR A N S F E R B R I D G E W IR E P U L L
N r. 1 N r. 2 N r. 3 N r. 6
D AC 0 8 D A C 0 5 /X D AC 0 8 D AC 0 8/F B K 1 0 0
K om ax N r. 0 245 17 K om ax N r. 0 245 16 K om ax N r. 0 245 17 K o m ax N r. 0 2484 6

R S 422
zu P C C

d eltad rive d eltad rive d eltad rive d eltad rive

1 2 3 6

Service_488.doc komax AG /Peter Flury 18. Oktober 2005

ALPHA488 Service-Unterlagen Motorregler deltadrive 8/17

5.3 V e r k n p f u n g H W - Kanal u nd S W - Kanal

Combination of HW - a n d S W - channel
J e d e Z u s t a n d s n d e r u n g d e r H W - S e t u p - Leit u n g A S B wird a u c h via Sc h n itt s t elle an alle R e gler
ge m e ldet . Wird die HW-Leit u n g A S B a u f 2 4 V g e s e t z t u n d a l l e n b e t e i l i g t e n R e g l e r d a s S W-K o m m a n d o
" A u t o m a t i k " g e s en d e t , s c h a l t e n d i e R e g l e r i n d e n A u t o m a t i k -Mode .
So b a ld die HW-Leit u n g A S B a u f 0 -V g e h t , o d e r m i n d e s t e n s e i n R e g l e r d a s S W-K o m m a n d o " S e t u p "
erhlt, gehen alle beteiligten Regler in den Zustand "Setup".
D e r Pegel der AS B -L e i t u n g k a n n l e i d e r n i c h t m i t t e l s M u l t i m e t e r g e m e s s e n w e r d e n , d a k e i n e M e s s p u n k t e
v o r h a n d e n s i n d . D e r P a r a m e t e r I P 1 0 9 a u f d e m R e g l e r , w e l c h e r d i e G a t e w a y-K a rte tr g t, zeigt a b e r an,
ob die 24V korrekt beim Regler ankommen.
IP109 = 0x4F00 bei 24V.
IP109 = 0x4700 bei 0V.
W e n n a u f d e m R C S-Pri n t d i e g r n e L E D ( A S B ) l e u c h t e t , s o m u s s a u c h d e r I P 1 0 9 d e n W e r t 0 x 4 F 0 0
anzeigen . Wenn nic h t , i s t die R S 422-Leit u n g defe k t .

When changing the state of the HW-channel ASB, this change will also be sent to all controllers by
communication-lines. As soon as the level of the HW-channel ASB rises to 24V and all controllers get the
message "Automatic", they switch to the state "Automatic". As soon as the level of the HW-channel ASB
falls down to 0V or any controller get the message "Setup", all controllers switch to the state "Setup".
The Parameter IP109 on the controller which contains the gateway shows us the presence of the 24V of
the ASB-Signal.
IP109 = 0x4F00 bei 24V.
IP109 = 0x4700 bei 0V.
If the green LED (ASB) on the RCS_board lights, the value of IP109 must show 0x4F00. Otherwise, the
RS422 wire, coming from the MRS-board is broken.

MRS:CH0

RSA ASB
Base cabinet
IP109
Gateway
RJ45

24 V 24 V 24 V 24 V 24 V

SW SW SW SW SW
5 5 5 5 5

HW 8 HW 8 HW 8 HW 8 HW 8

Swivel 1 P ul l O f f 1 Swivel 2 Pull Off 2 Knife

N o 1 N o 2 N o 3 N o 4 N o 5

MRS:CH1

RSA ASB
Twister cabinet IP109

Gateway
RJ45

24 V 24 V 24 V 24 V 24 V

SW SW SW SW SW
5 5 5 5 5

HW 8 HW 8 HW 8 HW 8 HW 8

Twisting Twisting Transfer Pre Twisting Wire Pull

Lengt h Head Bridge Head N o 6
N o 1 N o 2 N o 3 N o 4

Service_488.doc komax AG /Peter Flury 18. Oktober 2005

ALPHA488 Service-Unterlagen Motorregler deltadrive 9 /17

Betriebsart: A u t o m a t i k , w e n n S W-K o n t a k t g e s c h l o s s e n u n d HW-K o n t a k t g e s c h l o s s e n .

S e t u p , w e n n S W-K o n t a k t o f f e n u n d / oder HW-K o n ta k t offen .
Mode: Automatic, if SW-contact and HW-contact closed.
Setup, if SW-contact a n d / or HW-contact closed.

ASB: D e r R C S-P r i n t b r i n g t 2 4 V z u r M R S-K a r t e , w e n n H a u b e n g e s c h l o s s e n , a l s o B e t r i e b s a r t

A u t o m a t i k . A b M R S-K a r t e e r h l t d e r R e g l e r N o 6 ( W i r e D r i v e 1 ) d i e s e 2 4 V .
Wenn die ASB -Leit u n g 24 V -P e g e l b e s i t z t , l e u c h t e t a u f d e m R C S-Print die grne L E D A S B.
When covers are closed, the RCS-board brings 24V to the MRS-board. (Automatic-mode)
From MRS-board, the controller no 6 (wiredrive 1) gets this 24V. This 24V will be indicated
by the green LED ASB on the RCS-board.

SW: Auf den beiden seriellen Schnittstellen (CH0, CH1) wird jedem Regler "Automatik" oder
"Setup" gemeldet.
By the two communication-lines (CH 0, CH 1), the controllers get their messages
"Automatic" or "Setup".

RSA: Wenn b e ide K a n l e b e i allen Motorreglern vor h a nden s i nd, i s t der Set u p -K r e i s g e s c h l o s s e n .
Die Regler sind in der Betriebsart "Automatik". Das Signal RSB bringt 24V zurck zur MRS
u n d s o m i t a u f d e n R C S-Print . D i e g r n e L E D R S A le u c h t e t .
If both channels have the meaning "Automatic" ,the HW-loop on the controllers will be
closed.(24V on all connectors X5/pin 5 and X5/pin 8). The controllers are in Automatic-
mode. The signal RSA is on 24V, so the RCS-board gets this 24V as well, which is indicated
by the green LED RSA.

D e r Z u s t a n d d e r H W - S e t u p -L e i t u n g ( I n p u t a u f R J 4 5 ) w i r d i m P a r a m e t e r I P 1 0 9 a u f B i t 1 1 a b g e b i l d e t .
Der IP 109 kann auf dem TopWin unter "Werkzeuge / Achsen Debuggen / Schwenker 1" bzw.
" W e r k z e u g e / A c h s e n D e b u g g en / T w i s t er Wire P u l l" a b g efragt werden .
The state of the HW-channel can be seen on the parameter IP109 bit 11 in the axis controller.
The parameter IP109 can be shown on the TopWin under "Tools / Axisdebug / Swivel 1" resp. "Tools /
Axisdebug / Twister wirepull".

Z u s tand I P 109 [dez] I P 109 [hex] HW Pegel auf ASB

Setup 18176 0x4700 0 Volt
Automatik 20224 0 x 4 F 0 0 +24 Volt

D e r I P 2 4 9 W A T C H L A T C H zeigt die HW - u n d SW - Z u s t n d e i m R e g l e r a n .
The parameter IP249 WATCHLATCH shows the HW - and SW - states in the axis controllers.

MSB LSB
HW HW SW SW
SETUP NOTAUS SETUP NOTAUS
1=Auto 1=Notaus 1=Auto 1=Notaus

Die folgende Tabelle zeigt die typischen Werte bei den verschiedenen Maschinenzustnden.
Typical values of diffrent maschine modes.

Maschinen - Betriebsart Wert in hex

machine - m o d e values in hex
Setup und keine Lastspannung 0 x 1 0 0
Setup and no load voltage
Automatik und keine Lastspannung 0 x 3 0 2
Automatic and no load voltage

Automatik und Lastspannung 0 x 2 0 2

Automatic and load voltage
Setup und Lastspannung 0 x 0
Setup and load voltage

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6 G e samtbersicht
Cover Cover approval Cover Cover Mouse /
machine wire drive 1 button machine wire drive 1 return

Channel B Channel A

24 VDC

BIO Output 32-35

Output 32-35

5 5 5 5 5

8 8 8 8 8

Pre
Twisting Twisting Transfer Twisting
Length Head Bridge Wire Puller
Head

5 5 5 5 5

8 8 8 8 8

Swivel 1 Pull Off 1 Swivel 2 Pull Off 2 Knife

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7 Fe h l e r s uc h e / Trouble shooting

7.1 L E D - D i s p l a y
d e l t a d r i v e verfgt b e r ein Sel b s t diagno s e - u n d b e r w a c h u n g s s y s t e m , d a s a u f e i n e V i e l z a h l
vo n F e h l e r n r e a g i e r t , d i e i m B e t r i e b a u f t r e t e n k n n e n . D i e m e i s t e n F e h l e r w e r d e n d u r c h d i e
L E D s a n d e r F r o n t d e s d e l t a d r i v e angezeigt.
deltadrive has a self-diagnosis and supervising-system, which reacts on most errors and faults. Most of
the errors are displayed by the LED, mounted on the front panel of the axis controller.

L E D 2 g r n green S p eed Zero LED 1 gelb yellow

L E D 3 g r n green S t ation-Adress LED 0 rot red

L E D 7 g r n green P o wer On LED 4 rot red

L E D 6 g r n green C o ntroller R e ady LED 5 gelb yellow

Die grnen LED sind alle unabhngig voneinander.

The green LED are independent of each other.

L E D - Display Funktion der grnen LEDs Meaning of the green LEDs

Station-Addre s Blinkt mit den Anzahl Zyklen, welche der Flashes with the number of cycles
Stationsnummer entsprechen. that correspond to the station number.
S p e ed Zero Le u c h t et, wenn der Motor s t e h t . Lights, if motor stands still.
Drehzahl = 0 Velocity zero
Power On Leuchtet, wenn die Leistungsstufe Lights, if the power stage is switched
eingeschaltet ist. Motor wird bestromt. on. Motor is under control.
Controller Ready Leuchtet, wenn die Zwischenkreisspannung Lights, if the bus voltage (load
(Lastspannung) eingeschaltet i s t . voltage) is switched on.

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7.1.1 R e g l e r Z u s tand Controller State

L E D Display Z u s tands B e d e u t u n g State d e scription Maschine

Regler bereit, LED 6 leuchtet Controller ready, LED 6 lights
D r e h z a h l = 0 , L E D 2 leuchtet Speed = 0, LED 2 lights

Stations -A d r e s s e , L E D 3 b l i n k t Station-address, LED 3 flashes

(Anzahl Blinkzyklen = Adresse) (Number of flash cycles = address)
LED 2 , 6 leuchtet LED 2 , 6 light
Regler ein, LED 7 leuchtet Power On, LED 7 lights Maschine ist
Leistungsteil eingeschaltet Power stage is switched on rc k g e s t ellt
LED 2 , 6 leuchtet LED 2 , 6 light machine is reset
Drehzahl <> 0, Motor dreht Speed is not Zero , Motor turns
LED 7 , 6 leuchtet LED 7 , 6 light

Bremse aktiv, LED 1 leuchtet Break is activ, LED 1 lights

Generatori s c h e r B e trie b Generator State
LED 7 , 6 leuchtet LED 7 , 6 light
Stromgrenze erreicht, LED 5 leuchtet Current Overload, LED 5 lights
LED 7 , 6 leuchtet LED 7 , 6 light

N o t Stop, LED 4 leuchtet Emergency Stop, LED 4 lights Lastspannung Ein,

Motor gestoppt Motor has stopped Maschine noch
L E D 2 , 6 leuchtet nic h t rc k g e s t ellt .
LED 2 , 6 light
Load-voltage On
machine not yet
reset

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7.1.2 F e h l e r - B e d e u t u n g Error d e scription

L E D Display Fe h l e r B e d e u t u n g Error description Maschine

Rechner am initialisieren CPU is initializing Kommunikationsfehler
LED 1 blinkt LED 1 flashes Communication error

Fehler beim Prozessor Start Fault while CPU starts Kommunikationsfehler

LED 1 , 5 blinkt Controller blocked Communication error,
LED 1 , 5 flash Controller blocked
D C -Z w i s c h e n k r e i s -S p a n n u n g DC-Bus Voltage too low or missing Lastspannung Aus
z u niedrig oder fe h l t LED 0 , 1 , 5 flash Load-voltage off
LED 0 , 1 , 5 blinkt
D C -Z w i s c h e n k r e i s -S p a n n u n g DC-Bus Voltage too high
zu hoch (Speisespannung prfen) (Check Supply Voltage)
LED 1 , 4 , 5 blinkt LED 1 , 4 , 5 flash
Drehzahl zu hoch Speed too high
LED 4 , 5 blinkt LED 4 , 5 flash

Encoder Fehler Encoder Fault Encoder oder Kabel

(Anschluss prfen) (Check Connections) defe k t
LED 0 , 4 , 5 blinkt LED 0 , 4 , 5 flash defective encoder or
cable
R e gler z u lange in Stro m g renze Controller too long in Current Overload
LED 0 , 5 blinkt LED 0 , 5 flash

Schleppfehler Position Lag

LED 5 blinkt LED 5 flashes

Applikationsfehler Application Fault

LED 0 , 1 , 4 blinkt LED 0 , 1 , 4 flash

IGBT Fehler IGBT Fault

Fehler im Leistungsteil Fault in Power-stage
LED 0 , 1 , 4 , 5 blinkt LED 0 , 1 , 4 , 5 flash

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7.2 Kommunikationsfehler communication errors

Da alle Regler parallel am Netzwerk hngen, kann ein Regler das gesamte Netzwerk stren. Der
Achsensatz der Alpha 488 ist in 2 Netzwerke unterteilt. Beim Aufstarten testet die Steuerung die
K o m m u n i k at i o n z u d e n M o t o r r e g l e r n i m B a s i s s c h r a n k i n d e r R e i h e n f o l g e " G a t e w a y 0 , R e g l e r 1 , 2 , 3 , 4 ,
5" und im Twisterschrank in der Reihenfolge "Gateway 1, Regler 6, 3, 2, 1". Damit kann Schritt fr Schritt
d u r c h nac h e inander an s c h l ie s e n der Motorregler der Strer gef u n den werden .
Solange die Meld u n g " B a u d rate not fo u n d for init gateway " oder " N o co m u n ication to gateway"
erscheint, hngt der Strer im Netzwerk. Ansonsten erscheint die Meldung "No communication to axis no
x". x ist der Regler, welcher nicht anges chlossen oder defekt ist.

Acht u n g: V o r d e m E i n - und Ausstecken immer Sicherung F105 ziehen!! ( 24V Regler)

Damit werden Schden an den Netzwerktreibern vermieden und die Fehlermeldungen
erscheinen korrekt.
N a c h d e m E i n s e t z e n d e r S i c h e r u n g F 1 0 5 i m m e r P C C -K a r t e r e s e t t e n .

All controllers are connected parallel on the controller network. Any defective controller is able to disturb the
whole network communication. The axis controllers in the Alpha 488 are shared into two networks. After power
on, the machine controller checks the communication to each axis controller in the order of their mounted place.
Starting in the base cabinet with the one which is nearest to the gateway 0, (controller no 1 up to controller no 5),
it is possible to find the defective controller, by plugging one by one onto the network. In the twister cabinet, the
machine controller starts the communication on CH 1 to gateway 1, which is mounted in the controller no 6. Then,
the communication to no 3, 2, and 1 is established.
As long as the error message "Baudrate not found for init gateway" or "No communication to gateway" appears, a
defective axis controller is connected to the network.
Otherwise, the errormessage "No communication to axis no x" appears. x is the controller, which is not connected
to the network or defektive.

Attention: Before connecting and disconnecting network cables, first unplug the fuse F105! (24V for the
Controllers).
This prevents from damages on network drivers and the error messages will occur in the right
way.
After putting in the fuse, the pcc-card always has to be reset.

S W IVE L U N IT 1 P U L L OF F U N IT 1 S W IVE L U N IT 2 P U L L OF F U N IT 2 KN IF E U N IT O ption: P R E

N r. 1 N r. 2 N r. 3 N r. 4 N r. 5 T W IS TIN G L E N G T H TW IS TIN G H E A D T R A N S F E R B R ID G E TW IS TIN G H E A D W IR E P U L L
D AC 0 8 D AC 0 5 /X D AC 0 8 D AC 0 5 / X D AC 0 5 /X N r. 1 N r. 2 N r. 3 N r. 4 N r. 6
K o m a x N r. 0 2484 6 K o m a x N r. 0 24 5 1 6 K o m ax N r. 0 24 5 17 K o m a x N r. 0 24 5 1 6 K o m a x N r. 0 24 5 1 6 D AC 0 8 D A C 0 5 /X D AC 0 8 D AC 0 5 /X D AC 0 8/F B K 10 0
K om ax N r . 0 24 5 17 K o m a x N r. 0 24 5 1 6 K om ax N r . 0 24 5 17 K o m a x N r. 0 24 5 1 6 K o m ax N r . 0 2484 6
RS 422
z u P C C R S 422
Ch 0 zu P C C

d elta d riv e d elta d rive d elta d r ive d elta d rive d elta d rive

d elta d rive d elta d rive d elta d rive d elta d rive d eltad rive

1 2 3 4 5 3 6
1 2 4

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7.3 Kraftmess u n g / force meas u r ement

D i e K r a f t m e s s d o s e i s t h i n t e r d e m H a l t e g r e i f e r m o n t i e r t . S i e w i r d v o m L a du n g s v e r s t r k e r i m
Twisterschrank aufbereitet. Die Spannung, welche sich proportional zur gemessenen Kraft verhlt, wird
z u m R e g l e r "Twisting L e ngth" a u f den gra u e n Stec k e r X 5 / P i n 1 u n d 2 ( A D 1 + u n d A D 1-) g e f h r t .
Hier kann mittels Voltmeter die Funktion der Kraftmessung berprft werden.
Whrend dem Verdrillen muss sich hier die Spannung im Bereich 0 ... +10V bewegen.
Wenn die Polaritt wie unten angegeben eingehalten wird, muss die Spannung whrend dem Verdrillen
p o s i t i v s e i n . A n d e r n f a l l s s i n d d i e b e i de n L i t z e n a u f A D + u n d A D - z u t a u s c h e n .

The load cell is mounted behind the holding gripper. The charge amlifier converts the measured force into
a voltage between 0V and +10V. This voltage can be measured, while twisting, at pin 1 and 2 on X5 on
the Twisting Length controller. The voltage must be positiv if the voltmeter is connected as shown below.
Otherwise, the wires to AD+ and AD- must be changed.

Voltmeter

+
V 1 AD+
Kraft - - 2 AD -
Mess - Ladungs -
D o s e Verstrker
load cell Charge amp.

Motor
Regler
axis
controller

Mgliche Fehlerflle:

Leit u n gen werden nic h t ge s p a nnt .

1. G r e i f e r m i t K ra f t m e s s d o s e s t r e i f t a n i r g e n d w e l c h e n A b d e c k u n g e n , o d e r k a n n s i c h s o n s t w i e
nic h t frei b e wegen .
2. Kraftmessdose defekt.
3. Ladungsverstrker defekt.
4. Verkabelung defekt oder falsch.
5 . Motorregler defe k t .

Leitungen reissen whrend dem Verdrillen.

1. E i n g e s p a n n t e L e it u n g e n t s p r i c h t n i c h t d e r j e n i g e n v o m T o p W i n g e l a d e n e n L e i t u n g . ( F a l s c h e r -
Durchmesser).
2. Kraftmessung funktioniert nicht.
3. Kraftmessdose oder Ladungsverstrker defekt.
4. Verkabelung defekt oder falsch.

Twistlngsachse verkrzt zu schnell. Leitungen werden w hrend dem Verdrillen entspannt.

1. Eingespannte Leitung entspricht nicht derjenigen vom TopWin geladenen Leitung. (Falscher
Durchmesser).

Possible errors:
Wire will not be tightened
1. Holding gripper with load cell touches some mechanical surface
2. Load cell defect
3. Charge amplifier defect
4. Wiring defect or wrong
5. Axis controller defect
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Wires wrenches while twisting

1. Actual wire is not equal the loaded one from TopWin (wrong diameter)
2. Force measurement is out of order
3. Load cell or charge amplifier are defect
4. Wiring defect or wrong

Twisting Length runs too fast forward. Wires will be untighten while twisting.
1. Actual wire is not equal the loaded one from TopWin (wrong diameter)

7.4 Kabel - E n coder / Wire enco d e r

D i e k o r r e k t e F u n k t i o n d e s K a b e l-E n c o d e r s k a n n m i t t e l s Pa r a m e t e r I P 2 4 0 ( X E N C _ A N G L E ) b e r p r f t
werden. Wird das Messrad von Hand verdreht, so muss sich der Wert im IP 240 verndern.

D e r E n c o d e r d e r W i r e l i n e A w i r d v o m R e g l e r S w ivel 1 im Basisste u e rschrank eingele s e n .

D e r E n c o d e r d e r W i r e l i n e B w i r d v o m R e g l e r W ire P u l l im Twisterschrank eingele s e n .
Dazu wird das Fenster fr Achsendebug geffnet. (siehe TopWin)

The correct function of the two wire encoders can be checked by reading the parameter IP 240
(XENC_ANGLE). While turning the measure weel, the value on IP240 must change.

The wire encoder of wire line A is conected to the axis controller Swivel 1 in the base cabinet.
The wire encoder of wire line B is connected to the axis controller Wire Pull in the twister cabinet.

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7.5 Hilfreiche Achsenparameter helpful axis parameters

W i e b e r e i t s i m K a p i t e l F e hler! Verweisq u e lle konnte nicht gef u n den werden. b e s c h r i e b e n , k n n e n i m
T o p Win u n ter "Wer k z e u g e / Ac h s e n de b u g gen" alle Para m e ter der Ac h s e n angezeigt werden . Hier die
w i c ht i g st e n Pa r a m e t e r :

As described in chapter Fehler! Verweisquelle konnte nicht gefun d e n wer d e n. all parameters can be
shown under "Tools / axes debug". Here are the most important parameters:

Parameter Bezeichnung Funktion Aktion

IP109 RJ45 Pegel der HW-L e i t u n g siehe Kapitel 5 . 3
Level of HW-Wire see Chapter 5.3
IP202 BUS_VAL Zwischenkreisspannung 230V * v 2 = 3 2 5 V D C
Bus voltage
IP210 ENC_ANGLE Win k e l de s Motorencoder s D i e s e r Wert n dert, wenn die Motorac h s e
Angle of motor encoder dreht.
This value changes if motor axis turns.
IP240 XENC_ANGLE Winkel des Kabelencoders D i e s e r Wert n dert, wenn der K a b e lencoder
Angle of wire encoder dreht. (Nur bei Wiredrive Achsen)
This value changes if axis of wire encoder
turns (for wire drive axes only)
IP249 W A T C H L A T C H N o t a u s -u n d siehe Kapitel 5 . 3
Setupzustnde see Chapter 5.3
Emergency and setup
mode

7.6 Versch. Abkrz u n gen d i v. abbreviations

HW Hardware hardware
SW Software software
MRS Verteiler Karte (Multi RS485) distribution board
R C S R e d u n d a n t e s S t e u e r u n g s -Sy s t e m redundant control system
ASA Auslsen Schalter A activate switch A
RSA R c k m e l d u ng Sc h a lter A response switch A
ASB Auslsen Schalter B activate switch B
RSB Rckmeldung Schalter B response switch B
WD1 Wire Drive 1 (Kabelantrieb) wire drive 1
CPU Zentrale Recheneinheit central processing unit
IP Interner Para m e ter internal parameter

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