Weiss Ts Control Card
Weiss Ts Control Card
Operating Instructions
Control card TS002
Control card TS003
Control card TS004
980-200117001 / EN 11/2007
This documentation is copyright-protected. Duplication (even of extracts) is not permitted without the prior written
consent of WEISS GmbH.
WEISS GmbH reserves the right to make alterations to this documentation (also without prior notice).
WEISS GmbH is not liable for any technical or printing errors in this document. We accept no liability for damages
directly or indirectly related to the provision or use of this documentation.
This does not include damages arising from death, personal injury or damage to health or to such damages resulting
from a grossly negligent or deliberate infringement of obligations.
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Table of Contents
1 Safety Instructions 4
4.1 Inputs 10
4.2 Outputs 12
5 Operating Controls 13
6 Installation Instructions 15
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1. Safety instructions
Validity:
These instructions apply to control cards in the model series:
TS 002 E
TS 003 E
TS 004 E
Symbols:
Warnings are emphasised by a safety symbol and are shown as follows depending on the degree of risk:
Minor injuries may occur if the appropriate safety measures are not taken.
Warning!
Electrical hazard
Warning against hazardous voltage
Useful information
The indexing table with the control card may only be started up when the whole machine and control system, in
particularly the safety system, correspond to the machinery directive 98/37/EC.
Target group:
The operating instructions are aimed at persons who are involved in the planning, installation, starting-up, and
maintenance of the system and who have the qualifications and know-how appropriate for this work. Qualified personnel
are persons who have the necessary qualifications and who are familiar with the execution of the work cited above and
the operation of the system. All work in other areas such as transport, storage and disposal must be carried out by persons
with the appropriate training.
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General:
Prior to installation and starting up, please carefully read and observe all safety instructions, technical documentation and
connection data accordingly. National accident prevention regulations and all internal company regulations must be
observed.
The control card must be protected against impermissible use. It contains components which are electrostatically
sensitive and which can easily be damaged by incorrect handling. Electrical components may not be damaged
mechanically or destroyed (possible health risk).
Depending on the type, some of the components (e.g. motor) may have hot
surfaces during operation. Operating temperatures > 60 °C (> 140 °F) can occur.
Skin contact will cause burns.
Warning!
WEISS devices conform to the relevant VDE regulations. The VDE regulations must also be observed in the case of
modification or extension of the devices.
This documentation contains instructions for an installation in accordance with the EMC regulations. Compliance with
the limit values stipulated by EMC legislation is the responsibility of the manufacturer of the system or machine.
Unauthorised alterations and the use of spare parts and additional devices which are not recommended by the
manufacturer can cause personal injury or damage to the mechanism and the control system.
Before switching on the control card you must ensure that the motor housing is correctly earthed (PE rail).
Control and power connections may be carrying voltage even if the motor is
standing still. Never connect or disconnect the electrical connections of the
device when it is live.
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EMERGENCY STOP:
Suitable protective devices in accordance with EN 60204 Part 1 must be used.
In the case of an EMERGENCY STOP the motor line must be reliably interrupted in order to stop the supply of energy and
to ensure protection against unintentional re-starting. Interruption of the terminal “2“ (RESET) alone is not sufficient, as
these terminals require a functioning circuit.
Designated use:
This device is designed for industrial and commercial systems and conforms to the valid standards and regulations. All of
the instructions regarding technical data and the permissible conditions at the place of installation must be observed.
This device is a component for installation in machines. Start-up (start of designated operation) is not permitted until it
has been established that the machine is in conformance with the EMC directive 89/336/EEC and the end product is in
conformance with the machinery directive 89/37/EC.
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2. Controlling with the electronic control card TS004 E
We provide this electronic control card for use in controlling our cam indexing tables (TC, TR and TS). This card monitors
the operation of the indexing table and also allows you to optimize the indexing time. The card provides for manual
operation as well as independent contol by your main PLC.
The indexing table is equipped with a control cam on the drive curve and a sensor. The sensor signals as soon as the
table is in the locked position. The control card will then stop the motor and signal to the main PLC.
The motor is stopped after a delay time which is set at the turn switch. This allows the drive to proceed to an ideal
starting position for the next cycle.
The drive must come to a standstill within the locking phase. This is monitored by the control card and in the event of an
error, reported as a fault (“Position overrun“). If this fault occurs, all processing stations must be immediately reset and the
motor voltage supply shut down, as the indexing table is not in the locked position (risk of crash).
The TS002 has been constantly upgraded. As of version TS003 the brake is controlled on a time-optimised basis and it
was possible to substantially reduce wear on the brake. As of version TS004 the motor temperature is monitored by a
temperature switch.
The control card remains downwards compatible, therefore in the event of replacement an earlier version can be
exchanged with the new TS004.
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3. Technical data
8
3.2 Terminal connection
9
4. Description of inputs and outputs
4.1 Inputs
Input “Terminal 2“ on the control card alone does not fulfil the requirements
for the specification of EMERGENCY STOP and door circuits as it requires a
functioning wiring. In order to achieve the full EMERGENCY STOP functionality,
Danger! “Terminal 2“ and the motor line must be interrupted.
Terminal 5: Stop
A HIGH level causes suppression of the start signal and an interruption of the drive movement.
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Terminal “G“: Manual mode brake
A HIGH signal opens the brake. The table cannot be started
Make sure that the motor line is properly disconnected to avoid hand injuries due
to the motor suddenly starting up.
Warning!
Danger Input “Terminal H“ on the control card alone does not fulfil the
requirements for the specification of EMERGENCY STOP and door circuits as
it requires functioning wiring. In order to achieve the full EMERGENCY STOP
Danger! functionality, “Terminal 2“ and the motor line must be interrupted.
The jumper “N-2H“ must be inserted on the right. Terminal “3“ will have
no effect.
This function is realised on the control card “TS004 E“. Older cards do not
have this input.
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4.2 Outputs:
Terminal 4: Automatic
This output signals HIGH when the front panel key switch is on “Automatic”.
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5. Operating controls
stop
delay
Rotary switch for stop delay
table in position
table rotating
return
motor-/table overload
position overrun
INCHING
AUTOMATIC
1. START key
The light (LED green) signals that there is 24 V at the control card. If the key switch is at “STEP“ (manual mode), a cycle can
be triggered by pressing the START key.
2. STOP/RESET key
The STOP/RESET key functions in all operating modes. When pressed it immediately stops the indexing table and signals
an alarm by illuminating the light (LED red).
The basic increments for the stop delay are 20, 40 or 80 ms. This is preselected with a sliding switch on the circuit card.
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The multiplicator of this time scale is set at the rotary switch “Stop delay“ (at the front panel) between 0 and 9.
0 = no delay
1 - 9 = delay factor in 1-9 x 20, 40 or 80 ms increments
Optimum setting
1. With the key switch on Inching (manual mode), press the green start button to run one cycle. If the alarm
“Position overrun“ does not occur, increase the value of the rotary switch by one.
2. Repeat point 1 until the alarm “Position overrun“ is signalled.
3. Confirm the alarm by pressing the STOP/RESET key and reduce the delay time by one increment.
4. Status displays
“Table in pos.“ lights up when the table is in position, i.e. the indexing plate is locked.
“Table rotating“ lights as long as the motor is running.
“Return“ lights when return signal appears.
“Short circuit“ lights when an overload or a short circuit is monitored in one of the outputs clamps
flashes when motor temperature is too high.
“Motor overload“ lights when the cycle has not reached the in-position sensor signal within 9 seconds, i.e. when
there is no stop 9 seconds after the start (drive time out).
“Pos. overrun“ lights when the position cam at the end of the cycle has overrun.
5. Key switch: Toggling the operating modes between “Automatic”, “Inching“ and “Release brake“
5.1 Release brake
Releasing the brake allows the indexing table to be turned by hand to the next locking phase provided that it is
not already in a locked position. The outputs “Forwards“, “Back“, “Start permitted“, “Sum of alarms“ are at Log. “0“.
Starting by terminal 3 or H is not possible.
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6. Installation instructions
197
(din rail mounting)
145
130
The card holder is designed for installation fixing to din rails in rear of electrical panel. It has screw wiring terminals on the
left and right hand sides for the connection of the 24V and the control wires.
Rear
68
Basis
Card guide
2,5
25
15
Versions:
front panel mounting installation fixing onto din rails screw fastening
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7. Wiring
3 x 400V
24 V inputs and outputs
indexing table TC or TR
terminal C
electronic
contactor
terminal D
terminal F
motor line
E-STOP
brake
sensor
The motor line is switched by use of an electronic relay (solid state relay). Following this the two obligatory E-Stop
contactors must be connected to ensure a reliable shutdown in the event of an E-STOP.
Please see the motor name plate for the dimensioning of the motor protection switch. The motor line is a simple
non-screened line 4 x 1.5 mm².
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8. Trouble shooting and fault finding
In the event of an alarm the red LED “STOP“ key illuminates. Outputs 6, 7 and 8 indicate the alarm.
The alarm can be reset using the “STOP“ key or by a LOW signal at terminal 2.
Position HIGH LOW HIGH Indexing table overruns the end position.
overrun Causes:
- Turn switch stop delay time is too high
- Brake is worn Readjust brake
see documentation: mechanical system
Drive time LOW HIGH HIGH Indexer does not arrive within the timeout period (10 sec).
timeout/ - Rotating plate is restricted
overload - E-STOP contactors have switched off the motor
- E- STOP contactors are no longer providing
the right contact
- Star / delta bridge incorrectly wired in the motor
- Brake is not fully opened (check 24 V)
- No feedback from sensor (terminal F)
Short circuit LOW LOW HIGH - 24 V outputs overloaded
(output current > 100 mA / resp. > 2 A)
- Voltage peaks > 30 V on signals
- Supply voltage > 30 V
High motor LOW LOW HIGH - Motor too hot
temperature - Temperature switch interrupted
WEISS GmbH
Siemensstraße 17
D-74722 Buchen/Odw.
Tel.: +49 (0)6281/5208-0
www.weiss-gmbh.de
service@weiss-gmbh.de
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9. Appendix
The initial operation of this product is prohibited until conformity with the EC Machine Guideline of the total
machine in which this product is installed has been declared.
Applicable EC directives:
98 / 37 / EG Machinery directive
Changes to the design which affect the technical data contained in this product description and the intended
purposes, i.e. which mean significant changes, render this conformity declaration invalid!
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+ 24V L1 L1
GND L2 L2
L3 L3
PE PE
Stop
Motor protection
Q 1.0 I> I> I>
switch
Start (edge)
K 0.1
E-Stop
Direction CW/CCW
- -
Enable (RESET/STOP)
- - K 0.2
+ -
+ -
1 +
2 +
A2 1 3 5
3 +
4 + Electronic relay
-K 1.0 One direction
5 A
6 B A1 2 4 6
Motor ON
TS 004
7 C
Brake
8 D
9 E
Sensor
10 F
H G
T M
24V
GND
V
U
W
PE
blue
white
white
brown
black
brown
blue
M
3~
Automatic
Limit switch
Indexer in position Motor: 230V / 400V
See motor name plate
Stop
Motor protection
Q 1.0 I> I> I> switch
Start (edge)
K 0.1
E-Stop
Direction CW/CCW
- -
Enable (RESET/STOP)
- - K 0.2
+ -
+ -
1 + -K 1.0
2 + A1 1 3 5
3 +
4 + Electronic relay
B2
5 A Two direction (oscillating)
6 B
Motor CW
TS 004
7 C
Brake A2 2 4 6
8 D
Motor CCW
9 E
Sensor
10 F
H G
T M
24V
GND
V
U
W
PE
blue
white
white
brown
black
brown
blue
M
3~
Automatic
Limit switch
Indexer in position Motor: 230V / 400V
See motor name plate
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Notes
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WEISS – worldwide
EUROPE ASIA
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www.grafikus.de
WEISS 11/2007 -980-200117001