Ternary Integrated Actuator
Maintenance and Troubleshooting Training
Tim Brennan
Proprietary information
© WITTENSTEIN
Outline
1.
2.
3.
4.
5.
System Components
Wiring – Power and Command
Programming – ProTern Commissioning Software
Command Data – Homing, moving, jogging
Troubleshooting – Error Reading, Handling, and other basics
Tim Brennan
Proprietary information
© WITTENSTEIN
2
Ternary System Configuration
Consists of:
1. Actuator (TLSA, TRSA, TSSA)
2. Power Cable (TCC 001-001)
3. Command cable (TCC 002-008)
4. Chaining terminal (TBG 002-003)
5. Programming Cable (TCC 002-001)
6. Bus Converter (TBG 001-001)
7. ProTern Software (TET 002-002)
8. PLC
9. 24 VDC Power Supply
10. Power Switching Circuitry
Tim Brennan
Proprietary information
© WITTENSTEIN
3
Ternary Actuator Components – Motor/Electronics
Motor with motor mounting plate Brushless motor
for long lifetime protected by seal
Feedback system
TTL Encoder for position feedback to close
position loop.
Optional Brake
Electro-magnetic motor holding brake for vertical
loads or holding position in loss of power
Logic PCB with integrated memory
Storage of 16 (STP) or 64 (BLM) points (w/ pos,
accel,vel and torque) and electronic commutation
Amplifier with heat sink
High Power Pulse signal generator for stepping
motor or PWM for Servo motor.
Housing with cabling
IP65 protection for complete integrated
system
Optional Fieldbus cabling
Devicenet, Profibus, or CAN Open
Tim Brennan
Proprietary information
© WITTENSTEIN
4
Ternary Actuator Components – Cylinder
Ballscrew with recirculating Ballnut – Maintenance Free
 3, 6 or 12 mm Pitch (Distance per 1 rotation)
 Up to 300 mm length
Stainless Steel Rod
Double-D Cut Rod and Bushing (for Anti-Rotation)
Flange or T-Slot Mounting
Dual Input bearings for added thrust support
Tim Brennan
Proprietary information
© WITTENSTEIN
5
Power Connection
Tim Brennan
Proprietary information
© WITTENSTEIN
6
Command Cable
Command Cable connects Ternary to PLC
through the Chaining Terminal
Command Cable Contains both RS485
Communication as well as Discrete IO
Tim Brennan
Proprietary information
© WITTENSTEIN
7
Breakout Board
CN1 – Serial Connection to Computer
CN3 – Serial Daisy Chain to other Actuator
CN2 – Connection to Ternary
PIO Terminal – Discrete IO to PLC
Tim Brennan
Proprietary information
© WITTENSTEIN
8
ProTern Commissioning Software
1.
2.
3.
4.
5.
6.
Installation of ProTern
Startup and connecting to a device
Program basics
Loading Prestored parameter files
Editing Parameters
Saving to EEPROM
Tim Brennan
Proprietary information
© WITTENSTEIN
9
Installation of ProTern
1. Install ProTern.msi
2. Installed to: C:\Program Files\alpha gear
drives\ProTern
3. ProTern.exe to start program
4. ProTern Folder contains Subfolders for:
1.“Doc” – contains ProTern manual
2.“Help” – Contains Help File
3.“Projects” – For stored files
4.“Traces” – For Stored Traces
Tim Brennan
Proprietary information
© WITTENSTEIN
10
Startup and Connecting to Device
1. When Program Starts, choose Network
Connection and Baud (115.2 Default)
2. Choose Device you are looking for
1. Scan for first found device
2. Specify Device Address
3. Search for All
Tim Brennan
Proprietary information
© WITTENSTEIN
11
Startup and Connecting to Device
1. After the devices are found, the data is
uploaded
2. You are given the choice to make a new
project. Select yes to view or edit
current parameters on the device.
Tim Brennan
Proprietary information
© WITTENSTEIN
12
Program Basics
1. Program Tree – Shows any actuators in
project as well as each point. Uses
Name Label.
1
2. Status Area – Shows status of Inputs
and Outputs.
3. Real-time Data – Shows Position,
velocity and temperature data.
4. Project Area – Shows actuator
parameters and allows for actuator
commands to be issued.
Tim Brennan
4
2
3
Proprietary information
© WITTENSTEIN
13
Programming Basics – Units of measure
1. View allows you to change the units of
measure between inch, metric and native
units.
Tim Brennan
Proprietary information
© WITTENSTEIN
14
Program Basics - Project Window
1. Actuator Parameters – Includes Homing,
Software Limits, I/O Mode, and
Communication Parameters.
1
2
3
2. Point Parameters – Change Positions,
speeds, acceleration rates.
3. Command Page – Allows generation of
movement (homing, move to point, jog
and teach, scope function).
Tim Brennan
Proprietary information
© WITTENSTEIN
15
Loading from a file
1. To Open File choose
1.File/Open or
2.Open File Icon
2. Choose the Program file you want to
open.
Tim Brennan
Proprietary information
© WITTENSTEIN
16
Saving Existing Parameters to a file
1. To Save an existing parameter set from
the actuator into a file that can be loaded
to a device select:
1.File/Save As or
2.Click on Disk Icon to Save
2. Name the actuator and hit save for future
use.
Tim Brennan
Proprietary information
© WITTENSTEIN
17
Factory Default Parameters
In case there is an error in parameter values
that can not determined, you can also
load factory default parameters.
1. Choose “Tools/Reload from EEPROM
File”
2. Save to EEPROM.
Tim Brennan
Proprietary information
© WITTENSTEIN
18
Editing Parameter Data
1. Click on the field you would like to edit.
2. #2 Notes the min and max values in the
current measuring units.
3. #3 Notes the min and max values in the
native units
1
4. #4 Notes the current value in native
units.
5. Only data in software will be changed,
not on Permanent Memory (EEPROM).
2
Tim Brennan
Proprietary information
3
4
© WITTENSTEIN
19
Saving to EEPROM
1. When the correct parameter values are
in the ProTern Project, they must be
saved to the EEPROM for permanent
memory storage in the actuator.
2. This can be done by selecting
Tools/Recall or using the Red Diamond
Icon.
Tim Brennan
Proprietary information
© WITTENSTEIN
20
Saving to EEPROM
1. Click checkbox to designate what you
would like to save to. All boxes
underneath will automatically be
checked.
2. Choosing Project writes to all parameters
in every actuator in the project.
3. Choosing A0 writes to all parameter in
Actuator 0.
4. You can also download selectively to
specific points or to actuator level only.
Tim Brennan
Proprietary information
© WITTENSTEIN
21
Command Page
Command Page allows motion. The
following areas are found in the screen
capture on the right:
1
1. Shows data for each point
2. Change view between what is in
software (proTern) vs what is stored in
EEPROM.
3. Allows Servo to be turned on and off
2
4. Issue commands
5. Generate Moves
6. Configuring Trace Data to be captured
(view by clicking graph icon)
3
4
6
7
5
7. Jog and teach function
Tim Brennan
Proprietary information
© WITTENSTEIN
22
Command Page - Moves
1
1. Moves are not allowed until axis has
been homed (area 4)
2. Moves can be generated by double
clicking Black boxes in area 1 or clicking
one of the Move commands in area 5.
3. The GoTo Px in area 5 and Teach Px are
changed to different point number by
single clicking in area 1.
4. Jog In or out in area 7 to move actuator
to correct position. Teach stores the data
in the Program point only. It must still be
saved to EEPROM.
Tim Brennan
2
3
Proprietary information
4
6
7
5
© WITTENSTEIN
23
Troubleshooting
1.
2.
3.
4.
Troubleshooting Steps
How to find Error Code
Error Code Definition
Typical modes of failure
Tim Brennan
Proprietary information
© WITTENSTEIN
24
Troubleshooting Steps
1. If actuator isn’t moving, check:
1. Is the LED on back of actuator green, red, or off
1. Green = No Error detected, Go to step 2
2. Red = Check Alarm Code (see page 26)
3. Off = Check if power source and power cable are OK, replace if
necessary.
2. If Green and not moving, remove load and try moving again.
1. If moves without load,
1. check for mechanical misalignment of load
2. Check Protern to determine if input signals are reaching actuator; if
not check for break in command cable or loose wire on chaining
terminal
3. If signals are reaching actuator, actuator moves, but PLC doesn’t
recognize position complete, home or alarm
1. Check Command cable or breakout board if OK return to Wittenstein for replacement of Output
Optocouplers
Tim Brennan
Proprietary information
© WITTENSTEIN
25
Troubleshooting Steps (continued)
2. If doesn’t move w/o load when commanded, remove power and try to
move by hand.
1. If it moves by hand, return to Wittenstein to have motor evaluated.
2. If doesn’t move by hand, return to Wittenstein to have cylinder
evaluated.
3. Not possible to swap motor or cylinder in the field.
2. If Actuator is moving but slowly:
1. Check for mechanical misalignment
2. Verify load weight is not “too much”
3. If not too heavy or misaligned, remove load to determine if actuator still
moves slowly.
1. If yes, return Ternary to Wittenstein for cylinder Evaluation
2. If moves slowly in one direction only, probable crash, return to Wittenstein
for encoder re-alignment.
3. If moves OK without Load, check again for mis-alignment or load weight.
Tim Brennan
Proprietary information
© WITTENSTEIN
26
Checking Error Codes
•Real-time Statistics must be on
In case the LED is Red, check alarm code.
1. Realtime Statistics must be on
2. Alarm code can be read out of real time
data
3. Consult Error code data on next page
Tim Brennan
Proprietary information
© WITTENSTEIN
27
Error Codes
Alarm
Items
Check and repair
B0
Data error in Bank30 ( Bank0)
Download default data from PC from file.
B1
Data error in Bank31 (Bank1)
Download default data from PC from file.
B8-B9
The relation with encoder and motor is wrong (
connection, circuits ...)
Check the internal friction without power. Check the motor cable. This can be caused if
motor rotor or cylinder is locked (internally or due to external jam). Return for Repair
BB-BE
Error at origin return (Homing)
Check the movement and load condition at homing. Increase homing current if
necessary. If error continues, Return for repair.
C0
Over velocity
C1
Motor abnormal movement
D0
Over voltage input
This can be caused by power supply. If the actual power level is OK, return for repair.
D1
Internal over voltage by regenerative power
Check the movement with default data. If this doesn't fix error, return for repair
D8
Positional deviation counter overflow
Due to continuously movement in 1 direction (for rotary only). Set shortest travel bit to
allow for rollover. If error remains, return for repair.
E0
Over heat (85degC)
Change the load condition. If it is not caused by load condition or excessive ambient
temperature, return for repair.
E8-EC
Encoder error
Return for Repair.
F8
Check sum error in EEPROM
Re-write default data. If "F8" error still happens, Return for repair.
Tim Brennan
Can be caused by vertical falling axis (drive runaway). If can't remove condition that
causes this, return for repair
Proprietary information
© WITTENSTEIN
28
Other Modes of failure
1. Damaged or pinched cables. Do not
bend cables past maximum bend radius
(see chart at the right)
2. Rotated cylinder. Do not apply
rotational force to output rod. Always
apply counterforce to prevent internal
bushing from being damaged.
Tim Brennan
Proprietary information
© WITTENSTEIN
29
Other Modes of failure
3. If positioning repeatability goes down, check for rotational play in output rod.
This can be a sign of wear on the output bushing.
4. If Cylinder makes loud or grinding noise, typically due to damaged input
bearings, normally caused by crash. Return for repair.
Tim Brennan
Proprietary information
© WITTENSTEIN
30
Thank you for your attention
Tim Brennan
Proprietary information
© WITTENSTEIN