ADV200 - Flying Shear for Roll

Forming machines Application

English

Instruction manual
Rev. 0.1 – 8-5-2019

1S3E64EN
 Revision index Date Author Changes

0.0 4-2-2019 BRI New edition

0.1 8-5-2019 BNM Application V 1.x.1: add PARs 11612 and 11010,
mod description PAR 11000, update Table 7:
word mapping.

------------------------------------------------------------------------------------------------------------------------------

Thank you for choosing this Gefran product.

We will be glad to receive any possible information which could help us improve this manual.
The e-mail address is the following: [email protected].
Before using the product, read the safety instruction section carefully.
Keep the manual in a safe place and available to engineering and installation personnel during the product functioning period.
Gefran Drives and Motion S.r.l. has the right to modify products, data and dimensions without notice.
The data can only be used for the product description and they can not be understood as legally stated properties.
All rights reserved.

Flying Shear for Roll Forming machines – Instruction manual Pag. 2 / 29

Flying Shear for Roll Forming machines – Instruction manual Pag. 3 / 29
 CONTENTS

1 Introduction............................................................................................................................................... 5
1.1 Information about this manual ............................................................................................................. 5
1.2 Drive Firmware / Application version Cross compatibility ................................................................... 5
1.3 Symbols used in the manual ............................................................................................................... 5
2 Installing the application ......................................................................................................................... 6
2.1 Application key .................................................................................................................................... 7
3 General description .................................................................................................................................. 9
4 Sizing and commissioning .................................................................................................................... 10
4.1 Machine Data .................................................................................................................................... 10
4.2 ADV200 configuration ....................................................................................................................... 11
4.2.1 Basic parameters configuration ................................................................................................. 12
4.2.2 Digital I/O ................................................................................................................................... 13
4.2.3 Encoder ...................................................................................................................................... 13
4.2.4 Fieldbus ...................................................................................................................................... 15
4.3 Commissioning .................................................................................................................................. 17
4.3.1 Machine development ................................................................................................................ 17
4.3.2 Check-up of movements ............................................................................................................ 17
5 Description of functions and parameter list ........................................................................................ 19
26.01 Application .......................................................................................................................................... 19
26.02 App Service ........................................................................................................................................ 21
26.03 Enable ................................................................................................................................................ 22
26.04 Fast Stop ............................................................................................................................................ 22
26.05 Jog ..................................................................................................................................................... 22
26.06 Homing ............................................................................................................................................... 23
26.07 Move .................................................................................................................................................. 24
26.08 Auto .................................................................................................................................................... 24
26.09 Trolley ................................................................................................................................................ 25
26.10 Line .................................................................................................................................................... 26
26.11 Alarm .................................................................................................................................................. 26
26.12 Virtual ................................................................................................................................................. 27
26.13 About .................................................................................................................................................. 27
6 Application alarms ................................................................................................................................. 29

Flying Shear for Roll Forming machines – Instruction manual Pag. 4 / 29

1 Introduction

1.1 Information about this manual

This document describes the Flying Shear for Roll Forming machines software, supplementing what is
described in the ADV200 drive manual (for asynchronous and synchronous motors) and the optional boards
for encoder acquisition and input expansion.

1.2 Drive Firmware / Application version Cross compatibility

Flying Shear for Roll Forming machines Application ADV200 Firmware

1.x.1 7.5.16 and higher

1.3 Symbols used in the manual

Indicates a procedure, condition, or statement that, if not strictly observed, could result in personal
injury or death.

Indicates a procedure, condition, or statement that, if not strictly observed, could result in damage to
or destruction of equipment.

The following operations require the machine in motion.

Unforeseen machine movement is always possible. Take this into account and take the necessary
precautions.

Indicates that the presence of electrostatic discharge could damage the appliance.
When handling the boards, always wear a grounded bracelet.

Indicates a procedure, condition, or statement that should be strictly followed in order to optimize
these applications.

Note ! Indicates an essential or important procedure, condition, or statement.

Flying Shear for Roll Forming machines – Instruction manual Pag. 5 / 29

2 Installing the application
The Flying Shear for Roll Forming machines application must be installed on the ADV200(/S) drive to be
used.

The operations to be performed are listed below.

• Run the rffs_x_x_47_x_setup.exe application to set up the installation on a PC.
• Open the GF_eXpress configurator (catalogue version > 2.42)
• Connect the PC to the drive using the serial cable.
• On the GF_eXpress, select the ADV200 inverter (for asynchronous motors) and ADV200S inverter (for
synchronous motors).
• Once communication with the drive has been established, select the Download Firmware item on the
command bar. Then the window depicted below will appear. In that window, select the Flying Shear
for Roll Forming machines application (A1 to load the application on memory sector 1, A2 to load
the application on memory sector 2).
During this operation, do not turn off the drive.

• Once the firmware has been loaded, the application has to be enabled on the drive:
- Select the “expert” mode using the Access Mode parameter (PAR 554, - DRIVE CONFIG menu).
- Select the application: Application 1 if the rffs _..._A1 application was loaded
Application 2 if the rffs _..._A2 application was loaded

o Save and reset the drive. At the start, the drive will show the message, “ADV200 rffs V…” on
the display to confirm that the drive has been loaded.

• Perform a default load of the application parameters (App load def, PAR 11524) and then save.
Restart GF_eXpress. This will automatically recognize the application version and select the
appropriate parameters.
Then, configuration can begin.
.

Flying Shear for Roll Forming machines – Instruction manual Pag. 6 / 29

2.1 Application key
This application must be registered.
Register by entering a code supplied by Gefran.

Enter the code as follows:

• Connect to the drive using the GF_eXpress configurator or read the parameter indicated in the next point
using the keypad.

• Write down the Serial Number indicated in Regulation S/N (PAR 12106, ROLL FORMING FS \ About
menu).

• Contact Gefran support and provide the serial number you just read to obtain the application unlock
key.

• Enter the unlock code in the Application key parameter field (PAR 572, CONFIG DRIVE menu).

Flying Shear for Roll Forming machines – Instruction manual Pag. 7 / 29

 • Save and reset the drive. At the start, the drive will no longer show the “Key Expiring” message on the
display, confirming that the drive has been unlocked.

Flying Shear for Roll Forming machines – Instruction manual Pag. 8 / 29

3 General description
The blade or cutting assembly is fixed onto a carriage that can move forwards and backwards, piloted by the
application. The application measures the length of the material to be cut by a metric wheel binding onto the
material.

For each position of the material from zero up to the cutting length and according to other mechanical
parameters, the application produces the carriage position and therefore the blade position.

The speed profile is the relationship between the material speed and the carriage speed, see figure 1.
The speed profile consists of:

• At the line’s start up, the trolley moves to the end of the line, supporting the head of the material.
• Once the end of the line has been reached, a standby period can be set, during which the material runs
under the trolley.
• The first phase, when the trolley returns, is for positioning. The position is set based on the line speed,
the cutting time and any safety gaps.
• The second phase is called acceleration forward. During this phase, the trolley reaches the speed of the
material.
• The third phase is synchronization. The carriage proceeds synchronized with the material to reduce
as much as possible any positional error between the carriage and the material.
• The fourth phase is the cut, the application gives the command to let the cut start. The application
proceeds in synchronization with the material up to the end of the cutting space to then resume
immediately with the standby cycle.

Note:
1) Each phase provides for a defined shift using an electric cam, with its position set according to the
different parameters. The space used for each phase is calculated according to the maximum speed
allowed for the material.
2) The space used by the carriage and maximum speed vary depending on the set cutting length.

Figure 1: Speed profile

Flying Shear for Roll Forming machines – Instruction manual Pag. 9 / 29

4 Sizing and commissioning

4.1 Machine Data

The data in table 1 must be known before commissioning the shear. This table can be used as a reminder and
completed before or after commissioning.

UNIT OF
NAME VALUE PARAMETER
MEASURE
Line Kmec (PAR 11804),
Metric wheel advancement *
menu LINE /

Trolley Kmec (PAR 11702),

Trolley advancement shift *
menu TROLLEY /

Trolley limit pos (PAR 11704),

Usable length for the shear m
menu TROLLEY /

Max spd bck (PAR 11012),

Maximum trolley return speed. m/s
menu TROLLEY /

Trolley acc (PAR 11710),

Maximum acceleration m/s2
menu TROLLEY /

Trolley dec (PAR 11712),

m/s2
Maximum deceleration menu TROLLEY /

Sync time (PAR 11604),

Synchronization time before cutting s
menu AUTO /

Cut time (PAR 11706),

Cutting time s
menu TROLLEY /

Cut request (PAR 11800),

Cutting lenght m
menu LINE /

Table 1: Machine data

Flying Shear for Roll Forming machines – Instruction manual Pag. 10 / 29

4.2 ADV200 configuration
See the connection diagrams proposed for asynchronous or synchronous motors:

Figure 2: Typical connection diagram (Asynchronous motor)

Figure 3: Typical connection diagram (Synchronous motor)

Flying Shear for Roll Forming machines – Instruction manual Pag. 11 / 29

The following drive configurations are required:
• Basic parameters configuration
• Digital I/O
• Encoders
• Field bus

4.2.1 Basic parameters configuration

After loading the default application parameters (Load default, PAR 11100), the basic drive parameters are
configured.
Table 2 shows the configurations loaded.

PARAMETER
SETTING
PAR MENU PARAMETER
552 DRIVE CONFIG Regulation mode Flux vector CL
556 DRIVE CONFIG Control mode select Speed

752 RAMPS Ramp out zero src One

650 REFERENCES Dig speed ref 2 Dig spd ref1

1000 COMMANDS Commands remote sel Digital

1004 COMMANDS Enable/disable mode Off
1010 COMMANDS Commands safe start On
1018 COMMANDS Digital Enable src Pad 1
1020 COMMANDS Digital Start src Pad 1
1022 COMMANDS Fast Stop src Off

1314 DIGITAL OUTPUT Digital Output 3 src Pad 2

4452 WORD DECOMP Word decomp src Dig word decomp

4500 ALARM CONFIG Fault reset src Null

Table 2: Parameters loaded using Load Default

Flying Shear for Roll Forming machines – Instruction manual Pag. 12 / 29

4.2.2 Digital I/O

The drive hardware enable input must be connected to digital input 7.

The high and low blade inputs are used to indicate blade position. These are connected to sensors on the
blade as shown in figure 4:

Figure 4: High and low blade sensor operating logic

The output that controls the cut is the output listed in the table::

DIGITAL OUTPUT FUNCTION NOTES

13 DO3 Cut cmd Pad 2

4.2.3 Encoder

4.2.3.1 Encoder definitions

The encoder mounted on the carriage motor must be defined using the Trolley Enc Sel parameter (PAR
11700, menu TROLLEY).

The metric wheel encoder selection is essential for the system to function properly. The choice depends on
the geometry of the metric wheel and of the carriage.

The encoder resolution used on the metric wheel must be greater than or equal to the encoder resolution of
the carriage motor.
In other words, the ratio between the advancement of the carriage and the carriage motor ppr encoders must
be similar to the ratio between the advancement of the metric wheel and the metric wheel ppr encoders.

The number of the required pprs on the metric wheel encoder can be calculated as follows:

𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀 𝑊𝑊ℎ𝑒𝑒𝑒𝑒𝑒𝑒 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 [𝑚𝑚𝑚𝑚]

𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀 𝑊𝑊ℎ𝑒𝑒𝑒𝑒𝑒𝑒 𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸 𝑝𝑝𝑝𝑝𝑝𝑝 = ∗ 𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀 𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸𝐸 𝑝𝑝𝑝𝑝𝑝𝑝
𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶𝐶 𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴𝐴 𝑝𝑝𝑝𝑝𝑝𝑝 𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀𝑀 𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅𝑅 [𝑚𝑚𝑚𝑚]

Flying Shear for Roll Forming machines – Instruction manual Pag. 13 / 29

 Suppose we have a cutting system with these specifications:
• The carriage advances 36 mm per motor revolution.
• The encoder on the carriage motor has 1024 ppr.
• The advancement of the metric wheel on the material is 314 mm.

In this case, an encoder with 8192 ppr is suitable.

4.2.3.2 Configuration with 2 Encoders

Enter the encoder data in the ENCODER CONFIG. menu.

Table 3 shows the encoder configurations to be used with 2 encoders..

CONFIGURATION FOR ASYNCHRONOUS MOTOR WITH TWO ENCODERS

Encoder 1 (yellow) digital encoder on the metric wheel

Encoder 2 (green) digital encoder on the carriage motor

Encoder sel src = One

CONFIGURATION FOR SYNCHRONOUS MOTOR WITH TWO ENCODERS

Encoder 1 (red) 5-track sin cos encoder on the carriage motor

Encoder 2 (yellow) digital encoder on the metric wheel

Encoder sel src = Null

Table 3: Configuration with 2 encoders

Flying Shear for Roll Forming machines – Instruction manual Pag. 14 / 29

4.2.4 Fieldbus

After loading the default application parameters (Load default, PAR 11100) the fieldbus is configured as
shown in table 4:

PARAMETER
PAR COMMUNICATION PARAMETER SETTING
MENU
4010 FIELDBUS CONFIG Fieldbus M->S enable Enable

4020 FIELDBUS M->S Fieldbus M->S1 PAR 11800 Required cut size [m]
4022 FIELDBUS M->S Fieldbus M->S1 sys Par 32
4030 FIELDBUS M->S Fieldbus M->S2 PAR 4450 Dig word decomp
4032 FIELDBUS M->S Fieldbus M->S2 sys Count 16
4040 FIELDBUS M->S Fieldbus M->S3 PAR 11002 Virtual line speed [m/s]
4042 FIELDBUS M->S Fieldbus M->S3 sys Par 32
4050 FIELDBUS M->S Fieldbus M->S4 PAR 11702 Trolley motor mechanical K
4052 FIELDBUS M->S Fieldbus M->S4 sys Par 32
4060 FIELDBUS M->S Fieldbus M->S5 PAR 11804 Line mechanical K
4062 FIELDBUS M->S Fieldbus M->S5 sys Par 32
4070 FIELDBUS M->S Fieldbus M->S6 PAR 0
4072 FIELDBUS M->S Fieldbus M->S6 sys Fill 32
4080 FIELDBUS M->S Fieldbus M->S7 PAR 11012 Maximum return speed
4082 FIELDBUS M->S Fieldbus M->S7 sys Par 32
4090 FIELDBUS M->S Fieldbus M->S8 PAR 11716 Cut time
[s]
4092 FIELDBUS M->S Fieldbus M->S8 sys Par 32

4180 FIELDBUS S->M Fieldbus S->M1 PAR 3708 Command status word
[See PAR 12054]
4182 FIELDBUS S->M Fieldbus S->M1 sys Par32
4190 FIELDBUS S->M Fieldbus S->M2 PAR 12052 Alarm status word
4192 FIELDBUS S->M Fieldbus S->M2 sys Par32
4200 FIELDBUS S->M Fieldbus S->M3 PAR 12046 Line speed monitor [s]
4202 FIELDBUS S->M Fieldbus S->M3 sys Par32
4210 FIELDBUS S->M Fieldbus S->M4 PAR 12056 Position error monitor
[m]
4212 FIELDBUS S->M Fieldbus S->M4 sys par32
4220 FIELDBUS S->M Fieldbus S->M5 PAR 12038 Shear position
[m]
4222 FIELDBUS S->M Fieldbus S->M5 sys Par32
4230 FIELDBUS S->M Fieldbus S->M6 PAR 12030 Cut time monitor
[s]
4232 FIELDBUS S->M Fieldbus S->M6 sys Par32
4240 FIELDBUS S->M Fieldbus S->M67PAR 12044 Maximum line speed [m/s]
4242 FIELDBUS S->M Fieldbus S->M7 sys Par32
4250 FIELDBUS S->M Fieldbus S->M8 PAR 12040 Length of last bar cut
[m]
4252 FIELDBUS S->M Fieldbus S->M8 sys Par32
Table 4: Fieldbus configuration

Flying Shear for Roll Forming machines – Instruction manual Pag. 15 / 29

Command mapping word

The word sent by the PLC containing the commands is written in the Dig word decomp parameter (PAR
4450). The different function commands are linked to the word bits by selecting the appropriate “bitxx decomp
mon”.

WORD
WORD DECOMP
DECOMP DESCRIPTION
[HEX]
BIT NUMBER
0 0x0001 Enable
1 0x0002 Fast Stop
2 0x0004 Jog -
3 0x0008 Jog +
4 0x0010 Auto
5 0x0020 Homing
6 0x0040 Home sens
7 0x0080 Imm cut
8 0x0100 Blade close
9 0x0200 Blade open
10 0x0400 Virtual line
11 0x0800 Virtual blade
12 0x1000 Reset pos mat
13 0x2000 Not used
14 0x4000 Not used
15 0x8000 Not used
Table 5: Command mapping word

Flying Shear for Roll Forming machines – Instruction manual Pag. 16 / 29

4.3 Commissioning

4.3.1 Machine development

Start up is performed after machine development.

The drive is disabled:

• Start by inserting the mechanical data and metric wheel:

Refers to TROLLEY and LINE menues, and set all the values.

• Continue by setting speed and ramp times:

Refers to FASTSTOP, JOG, TROLLEY and HOMING and set all the values.

• Now enter the data for the cut:

Refers to TROLLEY and LINE and set all the values.

4.3.2 Check-up of movements

Enable the metric wheel simulator using the Virtual Line src parameter (PAR 11000).
We now continue by checking the data inserted and machine movements.

If the PLC has not yet been configured or connected, it is possible to set the Enable, Jog, Fast Stop and Auto
commands on the digital inputs, to test the machine movements.

The following operations require the machine in motion.

Unforeseen machine movement is always possible. Take this into account and take the
necessary precautions.

The operation described must be initially carried out with the motor disconnected from the machine.
Once the functions have been tested, the operations can be repeated with the motor connected to the

4.3.2.1 Direction checking

Jog forwards and Jog backwards. Check for movement in the correct direction. With Jog forward the carriage
advances in a positive direction and the Pos trolley mon (PAR 12038) increases.
Otherwise, reverse the motor phases and encoder channels A+ and A-.

4.3.2.2 Zero cycle positioning

Zero searching is to be checked out:

- Enable the drive.
- Enable the Homing command. The status of State mon (PAR 12000) must become Homing. The
carriage must move towards the zero position. Otherwise, remove Auto command and invert Home dir
(PAR 11400).
- Once the zero sensor has been engaged, the motor reverses its direction of travel to disengage the sensor
and move to the zero point
- The correct execution of the homing command is indicated by the Home found mon monitor (PAR 12014).

4.3.2.3 Carriage length development

The Jog command is used. After the zero cycle position measurement is active.
Mark the position on the carriage and register the Pos trolley mon (PAR 12038) position.
The carriage moves with JogPos or JogNeg depending on the direction desired.
Measure the distance travelled confronting the distance to the difference of the two Pos trolley mon positions.
Adjust the Trolley Kmec (PAR 11702) value if any errors occur.

Flying Shear for Roll Forming machines – Instruction manual Pag. 17 / 29

4.3.2.4 Metric Wheel Advancement
Check the correctness of the direction using the metric wheel. If the direction is incorrect use the metric wheel
encoder.

Flying Shear for Roll Forming machines – Instruction manual Pag. 18 / 29

5 Description of functions and parameter list

26.01 Application
The menu will display the version of the application installed on the drive.

MENU PAR Description UM Type Def Min Max ACCESS

26.01.01 12000 State mon * ENUM * * * R
Application status monitor:

0 Init
1 Disable
2 Standstill
3 Fast Stop
4 Jog +
5 Jog -
6 Homing
7 Auto
8 Move To
9 Heading

26.01.02 12002 Enable mon * BOOL * * * R

Monitors the drive enabling command.

26.01.03 12004 Fast Stop mon * BOOL * * * R

Monitors the fast stop command.

26.01.04 12006 Jog- mon * BOOL * * * R

Monitors the negative Jog command.

26.01.05 12008 Jog+ mon * BOOL * * * R

Monitors the positive Jog command.

26.01.06 12010 Homing mon * BOOL * * * R

Monitors the zero search (homing) command.

26.01.07 12012 Home sens mon * BOOL * * * R

Monitors the zero position sensor.

26.01.08 12014 Home found mon * BOOL * * * R

Monitors the zero position search status.

26.01.09 12016 Auto mon * BOOL * * * R

Automated cut command monitor.

26.01.10 12018 Blade down mon * BOOL * * * R

Monitors the blade in low position signal (in the end of cut position).

26.01.11 12020 Blade up mon * BOOL * * * R

Monitors the blade in high position signal (in the rest position).

26.01.12 12022 Imm cut mon * BOOL * * * R

Instantaneous cut manual command monitor.

26.01.13 12024 Virtual line mon * BOOL * * * R

Line simulator activation monitor.

26.01.14 12026 Virtual blade mon * BOOL * * * R

Flying Shear for Roll Forming machines – Instruction manual Pag. 19 / 29

 MENU PAR Description UM Type Def Min Max ACCESS
Blade simulator activation monitor.

26.01.15 12028 Reset line mon * BOOL * * * R

Material count reset monitor.

26.01.16 12030 Cut time mon s FLOAT * * * R

Cut time monitor, measured as the time elapsed between the command being sent
and the blade release.
The monitor is updated after a cut in “automatic cut” mode, or after an immediate cut.

26.01.17 12032 Trolley spd ref mon rpm FLOAT * * * R

Speed reference monitor.

26.01.18 12034 Trolley acc ref mon s FLOAT * * * R

Acceleration time monitor.

26.01.19 12036 Trolley dec ref mon s FLOAT * * * R

Deceleration time monitor.

26.01.20 12038 Pos trolley mon m FLOAT * * * R

Trolley position monitor.

26.01.21 12040 Bar Length mon m FLOAT * * * R

Monitor the length of the last cut tube.

26.01.22 12042 Pos line mon m FLOAT * * * R

Monitor of the material not yet cut that passed under the shear.

26.01.23 12044 Max line spd mon m/s FLOAT * * * R

Maximum permitted line speed monitor.

26.01.24 12046 Line spd mon m/s FLOAT * * *000 R

Line speed monitor..

26.01.25 12048 Auto state mon * ENUM * * * R

Automated cut status monitor:

Init
1-2-3 Dec fwd Shear deceleration at the end of the line.
4 Wait fwd Standby at the end of the line.
5-6-7 Acc rev Shear acceleration towards the tracking start point for cut.
8 Rev spd Constant shear speed to the tracking start point for cut.
9-10-11 Dec rev Shear deceleration to stop at the tracking start point for cut.
12 Wait rev Shear standby at the tracking start point for cut.
13-14 Acc fwd Shear acceleration at tracking start point for cut.
15-16 Sync Synchronization and cut phase.

26.01.26 12050 Cut req mon * FLOAT * * * R

Required cut length monitor.

26.01.27 12052 Word alarms mon * DINT * * * R

Alarm status word monitor.
(See Table 6 and Section 6 for more information)

26.01.28 12054 Word cmds mon * DINT * * * R

Command status word monitor.
(See table 7)

Flying Shear for Roll Forming machines – Instruction manual Pag. 20 / 29

 MENU PAR Description UM Type Def Min Max ACCESS
26.01.29 12056 Pos err m FLOAT * * * R
Position error monitor.

Command status word mapping (PAR 12052):

DIGITAL OUTPUT DIGITAL OUTPUT

DESCRIPTION
BIT NUMBER [HEX]
0 0x0001 Cut alarm
1 0x0002 Auto Alarm
2 0x0004 Cut length alarm
3 0x0008 Pos min alarm
4 0x0010 Pos max alarm
5 0x0020 Sync alarm
6 0x0040 Fast Stop
7 0x0080 Pos line max
8 0x0100 Not used
9 0x0200 Not used
10 0x0400 Not used
11 0x0800 Not used
12 0x1000 Not used
13 0x2000 Not used
14 0x4000 Not used
15 0x8000 Not used
Table 6: Alarm word mapping

Command status word mapping (PAR 12054):

DIGITAL OUTPUT DIGITAL OUTPUT

DESCRIPTION
BIT NUMBER [HEX]
0 0x0001 Enable
1 0x0002 Fast Stop
2 0x0004 Jog +
3 0x0008 Jog -
4 0x0010 Home sens
5 0x0020 Home OK
6 0x0040 Auto
7 0x0080 Cut cmd
8 0x0100 Blade close
9 0x0200 Blade open
10 0x0400 Spot cut
11 0x0800 Virtual line
12 0x1000 Virtual blade
13 0x2000 Cam status = 15 (cutting phase)
14 0x4000 Not used
15 0x8000 Not used
Table 7: Alarm word command status mapping

26.02 App Service

This menu allows the default parameters to be loaded and the speed reference destinations generated by the
application to be set.

MENU PAR Description UM Type Def Min Max ACCESS

26.02.01 11100 Load default * BOOL Off * * R/W
Load default application, reload only the default application values and configure
some system parameters to run the application (see Tables 2 and 4).

26.02.02 11102 Speed ref dest * ENUM Speed * * R/W

ref 1

Flying Shear for Roll Forming machines – Instruction manual Pag. 21 / 29

 MENU PAR Description UM Type Def Min Max ACCESS
Speed reference destination generated by the application .

26.02.03 11104 Cmds mon dest * ENUM Pad 5 * * R/W

Destination of the status word containing the commands generated by the application
(see Table 7).

26.03 Enable
This function allows the source of the enabling command software to be set and the possible destination of
the command monitor.
To enable the drive, it is always necessary to command the hardware enable (connected to terminal 7 of the
control board).

MENU PAR Description UM Type Def Min Max ACCESS

26.03.01 11200 Enable src * ENUM Decp * * R/W
bit0
Drive enable command source.

26.03.02 11202 Enable dest * ENUM Pad 1 * * R/W

Drive enable command monitor destination.

26.04 Fast Stop

The function performs an emergency stop. The menu allows the source of the fast stop and stop ramp
commands to be set.
When the FastStop command is applied, an indication in the alarm word (PAR 12052) is generated. Removing
the command restarts the drive.
The PLC manages the cancellation and reset of FastStop.

MENU PAR Description UM Type Def Min Max ACCESS

26.04.01 11204 Fast Stop src * ENUM Decp * * R/W
bit1
Source of the command to enable fast stop.

26.04.02 11206 Fast Stop dec m/s2 FLOAT 0.5 0.01 10.0 R/W
Stop ramp for emergency stop.

26.05 Jog
The function performs movements by manual command. The menu allows the source of the jog command,
the ramps and the speed references to be set.
When the hardware limit switches are reached, a FastStop must be commanded. Therefore, no trolley motion
should be possible.

MENU PAR Description UM Type Def Min Max ACCESS

26.05.01 11300 Jog+ src * ENUM Decp * * R/W
bit3
Source of the jog to positive command.

26.05.02 11302 Jog- src * ENUM Decp * * R/W

bit2
Source of the jog to negative command.

26.05.03 11304 Jog speed m/s FLOAT 0.2 * * R/W

Speed reference for jog command.

Flying Shear for Roll Forming machines – Instruction manual Pag. 22 / 29

 MENU PAR Description UM Type Def Min Max ACCESS

26.05.04 11306 Jog acc m/s2 FLOAT 1.0 0.01 10.0 R/W
Acceleration ramp for jog command.

26.05.05 11308 Jog dec m/s2 FLOAT 1.0 0.01 10.0 R/W
Deceleration ramp for jog command.

26.06 Homing
This function allows the parameters for defining the zero point to be set.

MENU PAR Description UM Type Def Min Max ACCESS

26.06.01 11400 Home dir * ENUM Positi * * R/W
ve
Parameter that detects the first direction of the zero-position search when the POS 0
Search command is activated (DIGITAL INPUTs menu).

0 Positive The motor turns clockwise.

1 Negative The motor turns counter clockwise.

26.06.02 11402 Home src * ENUM Decp * * R/W

bit5
Source of the zero-search command.

26.06.03 11404 Home sens src * ENUM Decp * * R/W

bit6
Source of the zero sensor.

26.06.04 11406 Home sens edge * ENUM Rising * * R/W

Parameter that sets the activation edge of the zero sensor.

0 Rising The zero sensor is active on the rising edge.

1 Falling The zero sensor is active on the falling edge.

26.06.05 11408 Home enc index * ENUM Off * * R/W

Parameter that enables/disables index search (rotation pulse, zero mark) of the
position encoder during zero search.

26.06.06 11410 Home speed m/s FLOAT 0.1 * * R/W

Speed reference for zero-sensor search.

26.06.07 11412 Home fine speed m/s FLOAT 0.05 * * R/W

Speed reference adopted during the search for the absolute zero position.
This reference is applied when the zero sensor is activated and/or in encoder index
search phase.

26.06.08 11414 Home acc m/s2 FLOAT 1.0 0.01 10.0 R/W
Acceleration ramp for Homing command.

26.06.09 11416 Home dec m/s2 FLOAT 1.0 0.01 10.0 R/W
Deceleration ramp for Homing command.

26.06.10 11418 Home found dest * ENUM Null * * R/W

Destination of the zero-search status monitor.

Flying Shear for Roll Forming machines – Instruction manual Pag. 23 / 29

26.07 Move
This function allows the parameters for repositioning the shear at the zero point or at the head of the material
to be set, when the Drive is switched on, if the save function for the material present in the machine (PAR
11806) has been activated.

MENU PAR Description UM Type Def Min Max ACCESS

26.07.01 11500 Move Kp m/m/s FLOAT 0.22 * * R/W
Proportional gain setting of the position ring

26.07.02 11504 Move spd rpm FLOAT 50 * * R/W

Speed reference used for positioning.

26.08 Auto
This function performs the automated cut at a set length and the manual immediate cut.
The automatic cutting mode is dependent on the execution of the zero-point search. The homing procedure
can be checked through the Home found mon monitor (PAR 12014).
A series of operations are performed by activating the automatic cut:
1. Verifies if the zero sequence has been executed (PAR 12014). If this has not been done, the drive stands
by, otherwise it goes on to step 2.
2. A Move is made to the zero position.
3. The line starts up.
4. The trolley moves to the end position, supporting the head of the material.
5. Standby time can be set.
6. The trolley moves to the position determined by the algorithm to make the cut correctly.
7. Cut point standby.
8. The trolley accelerates to synchronize with the speed of the material.
9. Trolley speed stabilization phase.
10. Execution of the cut.
11. When the cut is finished, it resumes from point 5.

The operation status is shown in Auto state mon (PAR 12048).

By commanding an immediate cut the application will start the execution of a cut regardless of the dimension
reached, shifting the trolley at the maximum speed allowed and making the shortest possible cut.
An immediate cut can also be made to header the material before proceeding with the automated cutting.

MENU PAR Description UM Type Def Min Max ACCESS

26.08.01 11600 Auto src * ENUM Decp * * R/W
bit4
Cut automation command source.

26.08.02 11602 Imm cut src * ENUM Decp * * R/W

bit7
Immediate manual cut command source..

26.08.03 11604 Sync time s FLOAT 0.2 * * R/W

Trolley speed stabilization time during the synchronization phase.

26.08.04 11606 Sync Kp m/m/s FLOAT 0 * * R/W

Proportional gain of the position ring used during the synchronization phase of the
shear to the speed of the material.

26.08.05 11608 Imm cut spd m/s FLOAT -0.8 * * R/W

Speed reference used for immediate manual cut.
.

Flying Shear for Roll Forming machines – Instruction manual Pag. 24 / 29

 MENU PAR Description UM Type Def Min Max ACCESS

26.08.06 11610 Reset pos mat * ENUM Decp * * R/W

bit12
Manual reset of the material count.

26.08.07 11612 Max Line Spd m/min FLOAT 4.0 * * R/W

Setting the maximum line speed. The calculated line speed will be limited to this
parameter.

26.09 Trolley
This function allows the parameters that manage the trolley and the immediate manual cut to be set..

MENU PAR Description UM Type Def Min Max ACCESS

26.09.01 11012 Max spd bck m/s FLOAT 0.5 * * R/W
Maximum speed the trolley can return from the end of the line to the beginning to
perform a cut.

26.09.02 11014 P gain pos m/m/s FLOAT 1 * * R/W

Proportional gain of position ring.

26.09.03 11016 Trolley stop space m FLOAT 0.07 * * R/W

The space used by the shear to stop once the cut has been completed. This space
is added to the Trolley Limit pos (PAR 11704) to set the maximum stroke of the
shear.

26.09.04 11700 Trolley Enc sel * ENUM Enco * * R/W

der1
Encoder source mounted on the motor for shear movement.

26.09.05 11702 Trolley Kmec * FLOAT 0.065 * * R/W

Mechanical coefficient to define the metric advancement per motor shaft revolution..

26.09.06 11704 Trolley Limit pos m FLOAT 1 * * R/W

Trolley movement limit, with respect to the zero-point defined by Homing. This
parameter defines the useful stroke for the trolley..

26.09.07 11706 Cut time s FLOAT 0.6 * * R/W

Cut time.

26.09.08 11708 Margin cut time s FLOAT 0.1 * * R/W

Safety margin for the cut time (the total cut time will be given by the sum Cut time +
Margin cut time).

26.09.09 11710 Trolley acc m/s2 FLOAT 2 * * R/W

Acceleration ramp for trolley movement..

26.09.10 11712 Trolley dec m/s2 FLOAT 3 * * R/W

Deceleration ramp for trolley movement.

26.09.11 11714 Trolley Overacc m/s2 FLOAT 1.1 1.1 10 R/W

Possibility of defining an over-acceleration that can be used when the trolley returns..

26.09.12 11716 Wait time end line m FLOAT 0 * * R/W

The amount of material that runs out of the machine to support the header, once the
cut has been made, with the shear in standby.

Flying Shear for Roll Forming machines – Instruction manual Pag. 25 / 29

 MENU PAR Description UM Type Def Min Max ACCESS
26.09.13 11718 Blade Close src * ENUM Decp * * R/W
bit8
Source of the low blade sensor, i.e. in the end of cut position.

26.09.14 11720 Sens Blade Open * BOOL Off * * R/W

Enabling the high blade sensor.

26.09.15 11722 Blade Open src * ENUM Decp * * R/W

bit9
Source of the high blade sensor, i.e. in the rest position.

26.09.16 11724 Cut Cmd dest * ENUM Pad 2 * * R/W

Cut command destination..

26.10 Line
This function allows the parameters that manage the line to be set.

MENU PAR Description UM Type Def Min Max ACCESS

26.10.01 11800 Cut request m FLOAT 6 0.1 30 R/W
Required cut size.

26.10.02 11802 Line enc sel * ENUM Enco * * R/W

der2
Encoder source mounted on the metric wheel to measure the material at the shear
input..

26.10.03 11804 Line Kmec * FLOAT 0.05 * * R/W

Mechanical coefficient to define the metric advancement per metric wheel revolution.

26.10.04 11806 Line save pos * ENUM Null * * R/W

Selection of the mode for saving the length of the material present in the machine
after switching it off..

0 Null Function not active

1 Always The measurement is saved in each phase of shear movement.
2 Return The measurement is only saved during the return phase (from the
end to the start of the line).
This allows more precise repositioning the next time the drive is
started up again.

26.11 Alarm
This function allows the application alarm signals to be managed.

If an application alarm is tripped, it has no effect on the drive. The PLC makes the decision on the
action to be taken

MENU PAR Description UM Type Def Min Max ACCESS

26.11.01 11900 Dly blade cut s FLOAT * * R/W
Maximum permissible delay between the command and the execution of the cut.

26.11.02 11902 Cut tolerance m FLOAT 0.005 * * R/W

Flying Shear for Roll Forming machines – Instruction manual Pag. 26 / 29

 MENU PAR Description UM Type Def Min Max ACCESS
Maximum tolerance allowed on the bar cut. If this is exceeded the alarm is tripped
by the appropriate bit of the word alarms.

26.11.03 11904 Trolley pos max m FLOAT 2 * * R/W

Maximum permissible trolley position. If this is exceeded the alarm is tripped by the
appropriate bit of the word alarms.

26.11.04 11906 Trolley pos min m FLOAT -0.1 * * R/W

Minimum permissible trolley position. If this is exceeded the alarm is tripped by the
appropriate bit of the word alarms.

26.11.05 11908 Max diff sync m FLOAT 0.5 * * R/W

Maximum misalignment allowed between the actual shear position and the drive-
generated reference. If this is exceeded the alarm is tripped by the appropriate bit of
the word alarms.

26.11.06 11910 Alarm dest * ENUM Pad6 * * R/W

Alarm status word destination.

26.12 Virtual
The function manages the metric wheel and cut simulator. The menu allows the metric wheel specifications
and the cut command execution times to be set. See section 6 in this manual for more details.
This is used to test the machine in the absence of material. The material feed measurement signal is generated
by the same application.

MENU PAR Description UM Type Def Min Max ACCESS

26.12.01 11000 Virtual Line src * ENUM Decp * * R/W
bit12
Start / stop of the virtual metric wheel.

26.12.02 11002 Virtual Line spd * FLOAT 0.2 * * R/W

Simulator line speed.

26.12.03 11004 Virtual Line acc m/s2 FLOAT 2 * * R/W

Line acceleration simulator..

26.12.04 11006 Virtual blade src * ENUM Decp * * R/W

bit11
Enable blade command simulator.

26.12.05 11008 Virtual Cut time s FLOAT 0.6 * * R/W

Simulated blade cut time.

26.12.06 11010 Virtual enable src * ENUM Decp * * R/W

bit10
Enabling the virtual metric wheel

26.13 About
The menu will display the version of the application installed on the drive.

MENU PAR Description UM Type Def Min Max ACCESS

26.13.01 12100 App version * FLOAT * * * R
Application version.

Flying Shear for Roll Forming machines – Instruction manual Pag. 27 / 29

 MENU PAR Description UM Type Def Min Max ACCESS
26.13.02 12102 Build date * FLOAT * * * R
Date when the application was compiled.

26.13.03 12104 MDPlc version * FLOAT * * * R

MDPlc version used to compile the application.

26.13.04 12106 Regulation S/N * DWORD * * * R

Serial Number of the control board.
Use to activate the application.

Flying Shear for Roll Forming machines – Instruction manual Pag. 28 / 29

6 Application alarms
The application carries out a series of checks on itself while it is functioning. The information is stored in the
Word alarm mon (PAR 12052) parameter.

The table shows the application-specific alarms:

APPLICATION APPLICATION
ALARM CAUSE ALARM CAUSE DESCRIPTION ACTION
BIT NUMBER [HEX]
Consistency check between cut
0 0x0001 Cut Signalled
commands and blade position.
1 0x0002 Auto Alarm during the automated cycle. Signalled

Cutting does not meet the required

2 0x0004 Cut length Signalled
tolerances.
3 0x0008 Pos min Trolley exceeds minimum position. Signalled

4 0x0010 Pos max Trolley exceeds maximum position. Signalled

Trolley movement not synchronised with
5 0x0020 Sync Signalled
the line.
6 0x0040 Fast Stop Fast Stop commands active. Stop during ramp
The length of the material (in progress)
7 0x0080 Pos line inside the machine is excessive and will Stop during ramp
not allow the cut.
8 0x0100 Not used

9 0x0200 Not used

The alarms indicated as “Signalled” are not generating any direct action on the drive. The PLC will
decide on what action to take.

Flying Shear for Roll Forming machines – Instruction manual Pag. 29 / 29

 Gefran worldwide
GEFRAN DEUTSCHLAND GMBH GEFRAN BENELUX NV GEFRAN SIEI - ASIA
Philipp-Reis-Straße 9a ENA 23 Zone 3, nr. 3910 31 Ubi Road 1
D-63500 Seligenstadt Lammerdries-Zuid 14A #02-07, Aztech Building,
Ph. +49 (0) 61828090 B-2250 OLEN Singapore 408694
Fax +49 (0) 6182809222 Ph. +32 (0) 14248181 Ph. +65 6 8418300
[email protected] Fax +32 (0) 14248180 Fax +65 6 7428300
[email protected] [email protected]

SIEI AREG - GERMANY GEFRAN UK LTD GEFRAN INDIA

Gottlieb-Daimler Strasse 17/3 Clarendon Court Survey No. 191/A/1,
D-74385 - Pleidelsheim Winwick Quay Chinchwad Station Road,
Ph. +49 (0) 7144 897360 Warrington Chinchwad,
Fax +49 (0) 7144 8973697 WA2 8QP Pune-411033, Maharashtra
[email protected] Ph. +44 (0) 8452 604555 Ph. +91 20 6614 6500
Fax +44 (0) 8452 604556 Fax +91 20 6614 6501
[email protected] [email protected]

SENSORMATE AG GEFRAN MIDDLE EAST ELEKTRIK VE GEFRAN INC.

Steigweg 8, ELEKTRONIK SAN. VE TIC. LTD. STI 8 Lowell Avenue
CH-8355 Aadorf, Switzerland Yesilkoy Mah. Ataturk WINCHESTER - MA 01890
Ph. +41(0)52-2421818 Cad. No: 12/1 B1 Blok K:12 Toll Free 1-888-888-4474
Fax +41(0)52-3661884 D: 389 Bakirkoy /Istanbul Fax +1 (781) 7291468
http://www.sensormate.ch TURKIYE [email protected]
Ph. +90212 465 91 21
Fax +90212 465 91 22

GEFRAN FRANCE SA GEFRAN SIEI GEFRAN BRASIL

PARC TECHNOLAND Drives Technology Co., Ltd ELETROELETRôNICA
Bâtiment K - ZI Champ Dolin No. 1285, Beihe Road, Jiading Avenida Dr. Altino Arantes,
3 Allée des Abruzzes District, Shanghai, China 201807 377 Vila Clementino
69800 Saint-Priest Ph. +86 21 69169898 04042-032 SÂO PAULO - SP
Ph. +33 (0) 478770300 Fax +86 21 69169333 Ph. +55 (0) 1155851133
Fax +33 (0) 478770320 [email protected] Fax +55 (0) 1132974012
[email protected] [email protected]

GEFRAN S.p.A.
Via Sebina 74 GEFRAN DRIVES AND MOTION S.R.L.
25050 Provaglio d’Iseo (BS) ITALY Via Carducci 24
Ph. +39 030 98881 21040 Gerenzano [VA] ITALY Technical Assistance :
Fax +39 030 9839063 Ph. +39 02 967601 [email protected]
[email protected] Fax +39 02 9682653 Customer Service :
www.gefran.com [email protected] [email protected]