SMART PUMP VACUUM MANAGEMENT SYSTEM SETUP AND INSTALLATION GUIDE

Transcription

1 SMRT PUMP VUUM MNMNT SYSTM STUP N INSTTION UI This Setup and Installation uide includes the following models: VUUM V STOR SWIT PRT PRSNT V STOR SWIT PRT PRSNT INITORS VMS XVMS VUUM STTUS INITORS VMS XVMS onfiguring the 1V Smart Pump Remove the ccess over 1. Remove the four cover screws. 2. ently lift cover and flip it over to expose the Smart Pump's printed circuit board. ocate the 2 elay djustments The two delay adjustments control the length of time the Smart Pump continues in blowoff after destroying the vacuum. (dapter oard) hannel 1 elay dj. (Main oard) hannel 2 elay dj. opyright 00 Norgren utomotive, Inc _24/

2 onfiguring the 24V Smart Pump Remove the ccess over oosen the four cover screws. ently lift the cover, flipping it over to expose the Smart Pump's printed circuit board. ocate Jumper K5 Jumper K5 configures the Smart Pump to accept current source or current sink control signals. The two delay adjustments control the length of time the Smart Pump continues in blowoff after destroying the vacuum. (dapter oard) SOUR K5 SINK Jumper K5 hannel 1 elay dj. (Main oard) xcept for Jumper K5, all other jumpers are factory set hannel 2 elay dj. onfigure the 24 V Smart Pump to ccept urrent Source or urrent Sink ontrol Signals by setting Jumper K5 I T ONTROR MNUTURR RQUIRS TIS TYP O ONNTION TO TIR P, I T ONTROR MNUTURR RQUIRS TIS TYP O ONNTION TO TIR P, Typical Output oard onnector Output 1 Output 2 Output 3 Output 4 Output 5 Output 6 Output 7 O SUPPY Typical Output oard onnector Output 1 Output 2 Output 3 Output 4 Output 5 Output 6 Output 7 O SUPPY Output 8 (common) Output 8 (common) Typical urrent So urce Output onnection Typical urrent Si nk Output onnection OR, I USIN RY ONTT WIR IK TIS, N.O. Relay ontact O SUPPY OR, I USIN RY ONTT WIR IK TIS, N.O. Relay ontact O SUPPY ST JUMPR K5 IK TIS, ST JUMPR K5 IK TIS, (UT STTIN ROM TORY) 2

3 Setting the On elay djustments Turning off the vacuum and turning on the blowoff destroys vacuum in the connected system. When the vacuum reaches a preset level, the Pump turns off the feedback signal then continues blowing off for a short period of time to eliminate residual vacuum. The two delay adjustments (one per channel, see diagram on front page for locations) dictate the length of time the Pump continues blowoff after destroying the vacuum. Some applications may require additional blowoff time to ensure that all residual vacuum in the system is destroyed before continuing with the manufacturing process. Turn clockwise to increase delay. Turn counterclockwise to decrease delay. Some Notes oncerning Vacuum 1. The maximum vacuum level the Smart Pump can create varies from area to area based on several items; the local barometric conditions and the altitude of the Smart Pump relative to sea level. If the Pump s target vacuum level is set higher than the vacuum it can create, the Pump's electronics will still attempt to achieve the set target vacuum level. When this occurs, the Smart Pump s vacuum solenoid turns on and stays on because the Pump s electronics are attempting to reach and maintain a vacuum level it cannot attain. To avoid this, do the following: Step 1. Step 2. etermine the maximum vacuum setting for your Smart Pump based on how high (altitude) your city is above sea level. o this by referring to the table below and finding the altitude closest to your city in the first column of figures. Read across the row of the next highest altitude to determine the highest recommended vacuum setting for that altitude. Your vacuum setting should not exceed this figure. 2. Setting the part present level 2.0 in/g less than the target vacuum level setting works well for the majority of Smart Pump applications (e.g., if the vacuum level is set for " g, (.61 bar) set the part present level at " g. (.54 bar)). ltitude in eet bsolute Pressure of tmosphere in lb per sq. in. Maximum Vacuum in inches of Mercury Maximum VMS2100 Vacuum Settings It is possible to set the part present level higher than the vacuum level (or the vacuum level lower than the feedback level). If this is done the feedback output will never turn on because the feedback level setting is never reached. Sea evel Set the Smart Pump Vacuum evel and the Part Present eedback evel Select the vacuum level you wish to maintain using the Vacuum evel Selector Switch. This setting affects both channels. Select the level of vacuum at which the Part Present feedback contact closes using the Part Present evel Selector Switch. This setting also affects both channels. Part Present evels 8"(.27), 10" (.34), 12" (.41), 14" (.47), and " (.54) of Mercury (bar). ccurate to within / 1.5" (/.05 bar) of Mercury. Vacuum evel 12" (.41), 14" (.47), " (.54), " (.61), and " (.68) of Mercury (bar). ccurate to within / 1.5" (/.05 bar) of Mercury. The two Part Present s indicate the closing of the Part Present relay contact. PRT PRSNT V Inches of Mercury oth hannels 14 NN 2 PRT PRSNT NN 1 12 VUUM STTIN Inches of Mercury oth hannels

4 Piping Requirements in(mm).50 (12.70) h. 2 Vacuum Port 3/8 NPT (3/8 SPT) (2) places, both sides h. 2 Vacuum Port 1/4 NPT (1/4 SPT) ~ ~ h. 1 Vacuum Port 3/8 NPT (3/8 SPT) (2) places, both sides 6.72 (170.68) 4.72 (119.88) h. 1 Vacuum Port 1/4 NPT (1/4 SPT) 2.66 (67.56) 1.57 (39.87) 1.50 (38.10) Supply Port 1/4 NPT (1/4 SPT) Supply Port 1/4 NPT (1/4 SPT) Using proper hose or tubing lengths, oversize fittings, having few elbow or tee fittings, and making sure the lines have no kinks or sharp bends are some examples of nonrestrictive plumbing. Keep airflow restrictions on the output side of the Pump to a minimum. Restrictive plumbing increases response time and may cause false part present signals. The vacuum cups should be your largest restriction. ose/pipe Size Recommendations Minimum ir Supply 1 45 psi (566 3 bar) Size supply line accordingly Output lines from Pump: 3 /8 NPT to 1 /2 in. barbed hose fitting 1 /2 in. I.. hose 3/8 SPT to 12.7 mm barbed hose fitting 12.7 mm I.. hose Output lines to vacuum cups: MINIMUM 1/4 in. (6.35 mm) I.. Use oversize fittings to reduce airflow restrictions Vacuum istribution Mounting imensions in(mm) 7.70 (195.58) vacuation One channel evacuates 1 cubic foot (28) at sea level to " of Mercury (0.68 bar) in seconds (10 seconds with both channels coupled) (79.50) 5.22 (132.58) (328.67) 2.00 (50.80) ir onsumption 50 PSI ( bar) (both channels operating) iltration Requirements 40 Micron.281 (7.13) I thru holes, 4 places 12. (309.37).375 (9.52).50 (12.70) ubrication Medium wt. Petroleum based ubricating Oil 4

5 Setting the Smart Pump Setting the Smart Pump's Vacuum evel and Part Present eedback evel is a simple operation. fter making sure your Smart Pump is properly installed and you have a restriction free system, just follow the flowchart. PRT PRSNT V Inches of Mercury oth hannels 14 NN 2 PRT PRSNT NN 1 12 VUUM STTIN Inches of Mercury oth hannels The two Part Present s indicate the closing of the Part Present relay contact. 12 Make sure you follow the piping and air recommendations suggested earlier in this document. oing so ensures that you'll have all of the Pump's settings available to adapt the pump to new applications. NOT : NOT : fter setting the pump, grip a part to make sure the Part Present goes on. Next, blow off the part, making sure the part separates from the cups and that the Part Present goes off. When gripping a part, a pump that always cycles or does not shut off is an indication of a vacuum leak. Inspect the system and correct as needed. Modes of Operation Vacuum Mode: In this mode, the Smart Pump automatically creates and maintains the selected vacuum level. You enter this mode by turning O the signal, then turning ON the Vacuum signal. hannel operation is independent so you can have one channel in its Vacuum Mode and the other in its Mode. utomatic Mode: In this mode, the Smart Pump sensing circuitry monitors the pump's vacuum chamber for signs of vacuum. If the sensing circuitry detects vacuum, pressurized air is sent into the chamber to destroy the vacuum. You enter this mode by turning O the Vacuum signal and turning ON the signal for a minimum of msec (typically one scan), then turning the signal O. orced Mode: This mode places the Smart Pump into continuous blowoff. To enter this mode, turn O the Vacuum signal, then turn ON and leave ON the signal. When the Smart Pump loses power or the power supply drops below 95V ac (V dc), it disables all internal outputs controlling the blowoff, vacuum and the feedback signal. The Smart Pump does this because it can no longer determine what it should be doing and when that occurs, the safest thing it can do is nothing. If the Pump loses power while in the Vacuum Mode, the internal check valves will hold the vacuum for a nominal period of time. 5

6 Typical Sequence of Operation or the following sequence of operation, we are moving a part from Point to Point using an array of vacuum cups. The procedure below assumes the use of both channels and covers only those routines needed by the Smart Pump. 1. egin monitoring the feedback signal. Move the Vacuum up array near the part located at Point and turn ON the vacuum. 2. rip the part by moving the Vacuum up array onto the part. s the cups grip the part, the Smart Pump's feedback signal turns ON when the Part Present vacuum level reaches its preset value. 3. If the feedback signal remains on, begin moving the part to its new location at Point. 4. Release the part in its new location by turning O the vacuum and placing the Smart Pump into its utoblowoff mode (turn ON the blowoff for a minimum of msec, then turn it O). This eliminates the vacuum and releases the part from the vacuum cup array. oss of the feedback signal tells you when this is accomplished. s you move the vacuum cup array off the part you may wish to enter the orcedblowoff mode (turn ON the blowoff and leave it on) to ensure the release of the part. Some examples of where you would want to use the orcedblowoff mode include moving glass or when large diameter vacuum cups are being used. Programming pplication Notes Norgren recommends that programmers take the following suggestions into consideration when adding Smart Pump control routines to existing application software. The controlling P must halt all movement if the feedback signal from the Smart Pump is lost while the vacuum is on. In applications that do not require the Smart Pump, you can leave the Smart Pump in its utoblowoff mode. hanging from a Vacuum Mode to a Mode, or vice versa, should be done within the same P scan. When powering up the Smart Pump, all of its internal outputs are disabled until the power supply reaches 95V ac (V dc). Whenever the Smart Pump's voltage supply drops below 95V ac (V dc), the internal outputs are disabled and the Pump enters its ault Mode. It is up to the P's application program to provide the proper fault handling routines necessary for the safe operation of the automation or process the P is controlling. 6

7 Smart Pump to P Interface able Pinout able Part No. VMS 00 able Part No. VMS 00 (lex cable) ( foot length standard, other lengths available) Pin T: T: K: K: P: P: J: J: Wire olor ode lue Red/lack reen/lack Orange/lack lue/lack Red/White reen/white lue/white Red Red lack/red lack/red Orange/Red lack lack White White 12 Wire olor ode lack k. rown Red Orange Yellow reen lue Violet ray ray White White Pink t. rown t. rown n/a n/a Signal Type Input Relay ontact eg 1 Relay ontact eg 2 Input Input Relay ontact eg 1 Relay ontact eg 2 Input Supply Not Used ommon ommon hassis round Not Used Supply Output Output Signal unction h2 h 2 eedback Source h2 eedback Signal h2 Vacuum On/Off h1 h1 eedback Source h1 eedback Signal h1 Vacuum On/Off 1 Not Used 2 ommon 24 V ommon hassis round Not used 24 V Supply Voltage Monitor Voltage Monitor lectrical haracteristics Power Requirements Supply Voltage 1 V 50/60 z Supply Power 12 Watts ontrol Inputs (two per channel) Optical Isolation 1500 V Min. Turn On Voltage 80 V Max. Turn Off Voltage 35 V Input Impedence 34K Ohms Normally Open ry ontact Relay Max. oad urrent 110 V Typical Wiring iagrams (urrent Source Output Signals) Independent hannel Operation Simultaneous hannel Operation O = ON = orced O = ON = orced T SMRT PUMP 1ontrol 1 orced 2 ontrol 2 orced J T J See Note. See Note. K O = ON = orced SMRT PUMP 1ontrol 1 orced 2 ontrol 2 orced K 1 eedback 1 eedback 1/4 mp 1/4 mp 2 eedback 2 eedback 1/4 mp 1/4 mp SSIS SSIS eakage currents exceeding 6m on the interface outputs may require the use of a dropping resistor. ontact Norgren for additional information. Note : Pin J may be used to power a warning lamp (shown above), as an input to a P or to power a solenoid with the Norgren ir Pilot Overide Kit (refer to Norgren publication PK/). Note : To maintain vacuum during emergency stop situations, the Smart Pump, its power supply and control signals must be wired above the Master ontrol or Power On relays. 7

8 lectrical haracteristics Power Requirements Supply Voltage 24 V Supply Power 12 Watts ontrol Inputs (two per channel) Optical Isolation 1500 V Min. Turn On Voltage 17 V Max. Turn Off Voltage 9 V Input Impedence 6.5 K Ohms Normally Open ry ontact Relay Max. oad urrent 24 V Typical Wiring iagrams (urrent Source Output Signals) Independent hannel Operation Simultaneous hannel Operation 24 V 24 V ommon 24 V 24 V ommon SMRT PUMP SMRT PUMP P J P J See Note. See Note. O = ON = orced O = ON = orced 1ontrol 1 orced 2 ontrol 2 orced K O = ON = orced 1ontrol 1 orced 2 ontrol 2 orced K 1 eedback 1 eedback 1 mp 1 mp 2 eedback 1 mp 2 eedback 1 mp SSIS SSIS eakage currents exceeding 6 ma on the interface outputs may require the use of a dropping resister. ontact Norgren for additional information. Note : Pin J may be used to power a warning lamp (shown above), as an input to a P or to power a solenoid with the Norgren ir Pilot Overide Kit (refer to Norgren publication PK/). Note : To maintain vacuum during emergency stop situations, the Smart Pump, its power supply and control signals must be wired above the Master ontrol or Power On relays. P.O. ox 787 Mt. lemens, MI Sales Support Phone: (800) ax: (800) Our policy is one of continuous research and development. We therefore reserve the right to amend, without notice, the specifications given in this document.