IRAM Manual - IRAM - HF - en

Manual
iRAM
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that it is intentionally. Any contraventions will bind on indemnifications. All rights are reserved with regard to
patent grant to provisionally patenting of model filed.
Should you have any proposals to improve this manual, we would be well prepared to accept them.
Harburg-Freudenberger Maschinenbau GmbH

Produktbereich Gummimischtechnik
Asdorfer Str. 60
D-57258 Freudenberg
Postfach 1180
D-57251 Freudenberg
Telefon (02734) 491 - 0 (Zentrale)

- 148 (Vertrieb Neumaschinen)
- 104 (Vertrieb Ersatzteile, Reparaturen)
Telefax (02734) 491 - 150 (Vertrieb Neumaschinen)

- 111 (Vertrieb Ersatzteile, Reparaturen)
24 / 7 Hotline:
Phone +49 (0)2734 491 -108
Änderungen vorbehalten
Printed in the Federal Republic of German
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1 Product Description ....................................................................................................... 5

1.1 Brief system description............................................................................................ 5
1.2 Ram control functional description ............................................................................ 5
1.2.1 Q-control of ram movement ...................................................................................... 5
1.2.2 Floating for ram ........................................................................................................ 5
1.2.3 Ram pressure control ............................................................................................... 6
1.2.4 Ram position control ................................................................................................. 7
1.2.5 Contamination of the ram ......................................................................................... 8
1.2.6 Fall back function for ram ......................................................................................... 8
1.3 Operating modes ...................................................................................................... 9
1.3.1 General .................................................................................................................... 9
1.3.2 "Manual" mode (manual operation)........................................................................... 9
1.3.3 "Pressure" mode....................................................................................................... 9
1.3.4 "Position" mode ........................................................................................................ 9
1.3.5 "Position and pressure" mode................................................................................... 9
1.4 Intended purpose...................................................................................................... 9
1.5 Technical data of the complete system ..................................................................... 9
1.6 SPCcompact 5 controller ........................................................................................ 10
1.7 Controller IDC32 ..................................................................................................... 10
2 Safety ............................................................................................................................ 11
2.1 General regulations ................................................................................................ 11
2.2 Correct utilisation .................................................................................................... 11
2.3 Non-compliance with the safety regulations ............................................................ 12
2.4 Fundamental safety precautions ............................................................................. 12
2.5 Local legislation, directives and regulations ............................................................ 12
2.6 Applicability ............................................................................................................ 12
2.7 Structure and meaning of the references ................................................................ 13
2.8 Graphic reference symbols ..................................................................................... 14
2.9 General safety regulations ...................................................................................... 14
2.9.1 State of the art technology ...................................................................................... 14
2.9.2 Removal of safety guards ....................................................................................... 15
2.10 Specific safety regulations ...................................................................................... 16
2.10.1 Mechanical hazards ................................................................................................ 16
2.10.2 Electrical hazards ................................................................................................... 16
2.10.3 Hydraulic hazards ................................................................................................... 16
2.11 Responsibilities and qualification requirements....................................................... 17
2.11.1 Authorised personnel/qualified employees.............................................................. 17
2.12 Duty of notification in the case of malfunctions and damage ................................... 18
2.13 Necessary protective clothing ................................................................................. 18
2.14 Prohibition of alterations and modifications to the machine ..................................... 18
2.15 Maintenance obligation ........................................................................................... 18
3 Packaging and Transport ............................................................................................ 19
3.1 Packing material ..................................................................................................... 19
3.2 Transport ................................................................................................................ 19
3.3 Unpacking the equipment ....................................................................................... 20
3.4 Storage ................................................................................................................... 20
4 Configuration and Installation ..................................................................................... 21
4.1 Information on Accident Prevention ........................................................................ 21
4.2 Installation .............................................................................................................. 21
4.3 Installing the electronics ......................................................................................... 21
4.3.1 SPCcompact 5........................................................................................................ 21
4.3.2 IDC32 ..................................................................................................................... 21
5 Commissioning ............................................................................................................ 22
5.1 ECU 01 ................................................................................................................... 22
5.2 Parameterisation of control system with ECU ......................................................... 22
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5.3 Keyboard and display unit ECU 01 ......................................................................... 22

5.3.1 Button functions of the green keypad (preselection of operating modes) ............... 23
5.3.2 Button functions of the blue keypad ........................................................................ 24
5.4 Operation (examples) ............................................................................................. 25
5.4.1 Displaying measuring point M001 ........................................................................... 25
5.4.2 Changing parameters ............................................................................................. 25
5.5 Control of operating modes .................................................................................... 26
5.6 PROFIBUS Coupling System (Master) - EMG (Slave)/Option................................. 28
5.6.1 SPCcompact 5 with PROFIBUS interface ............................................................... 28
5.7 CANopen coupling for EMG sensors ...................................................................... 31
5.7.1 Cable type, cable length and wiring ........................................................................ 31
5.7.2 120 ohm terminating resistor on the CAN-Bus ........................................................ 32
5.7.3 User address at CAN-Bus ...................................................................................... 32
5.8 Adjusting the operating modes using ECU01 .......................................................... 33
5.8.1 List of Parameters .................................................................................................. 34
5.8.2 Preselection of the application ................................................................................ 35
5.8.3 Setting the slow positioning speed for ram "up" and "down" .................................. 36
5.9 Adjusting the pressure cells on the ram .................................................................. 38
5.10 Abgleich der Wegerfassung am Stempel ................... Error! Bookmark not defined.
5.11 Adjusting pressure control ...................................................................................... 42
5.12 Adjusting position control (optional) ........................................................................ 44
5.13 "RAM-JAM" function ............................................................................................... 47
5.14 Ram contamination monitoring ............................................................................... 48
5.15 Setting the positioning speed for the discharge flap "up" and "down" ...................... 49
5.16 Signalaustausch über PROFIBUS-DP .................................................................... 50
6 Utilisation...................................................................................................................... 51
6.1 Operation/Interface ................................................................................................. 51
6.1.1 Moving the actuator in a controlled manner ............................................................ 51
6.1.2 Pressure control on ................................................................................................ 53
6.1.3 Position control on .................................................................................................. 54
6.2 Operating Sequence ............................................................................................... 55
6.2.1 Ram pressure control ............................................................................................. 55
6.2.2 Ram position control with switchover to pressure regulator.................................... 55
7 Maintenance and repair ............................................................................................... 56
7.1 Safety measures..................................................................................................... 56
7.2 General information ................................................................................................ 56
7.3 Maintenance intervals ............................................................................................. 56
7.4 Maintenance work .................................................................................................. 57
7.4.1 Check the condition of the equipment ..................................................................... 57
7.4.2 Checking the oil and water lines of the hydraulic system (visually) ........................ 57
8 Error correction ............................................................................................................ 58
8.1 Troubleshooting for standard programme ............................................................... 58
9 Disposal ........................................................................................................................ 61
9.1 General .................................................................................................................. 61
9.2 Materials ................................................................................................................. 61
10 Appendix ....................................................................................................................... 62
10.1 Addresses and DIL-switch settings ......................................................................... 62
10.1.1 iRAM controller ....................................................................................................... 62
10.2 List of parameters ................................................................................................... 64
10.3 List of measuring points .......................................................................................... 70
10.4 Data logger ............................................................................................................. 72
10.5 PROFIBUS-DP data exchange list.......................................................................... 73
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1 Product Description
1.1 Brief system description

Ram control for an internal mixer is described below with the following
components:
▪ Ram pressure cells 0 .. 10 V
▪ Digital controller SPCcompact 5
▪ Digital decentralised controller IDC32
▪ Ram position sensor 4 .. 20 mA
▪ Ram servo valve
▪ Proportional valve discharge flap
The pressure sensors are used to continuously measure the change of

forces in the cylinder. The signal is evaluated by the SPCc5 controller
and is used to activate the servo valve. The servo valve controls the
hydraulic cylinder to ensure the predetermined pressure value is
maintained. It is also possible to use the controller to approach a
predetermined position, in which case the current actual pressure value
is monitored. If a preset pressure is exceeded during operation, the
controller switches to pressure control.
Various production conditions call for various operating modes of the
system.
They are selected using the external or internal control systems.
1.2 Ram control functional description
1.2.1 Q-control of ram movement

The signals to the valve are specified via a ramp in this operating mode.
The slope of the ramp can be adjusted separately for each direction of
movement, namely "brake" and "accelerate". It is also possible to
preselect two speeds for each direction via the control system.
It is possible to change the speed for the fast "down" movement via
Profibus. The speed is thereby limited to the value which is set on the
controller. If "0" is specified via Profibus, the internal value is used.
1.2.2 Floating for ram

When the ram abuts against the material, the "floating" function can be
activated. The A-T valve is opened here and, after a waiting period of 1
second, the regulating valve is opened via a ramp in the 'lift' direction. If
the function is deactivated, the regulating valve is driven to the zero
position via a ramp. Upon reaching the zero position (approx. 1%) of the
regulating valve, the A-T valve is closed again.
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1.2.3 Ram pressure control

The pressure regulator is switched on after detecting a value of 90%
(adjustable) of the pressure set point. When it is switched on the AT
valve is opened and the pressure regulator is operated with basic gain.
The control loop gain is switched to a higher value after an adjustable
period of time. The pressure set point for the controller is generated via
a 500ms ramp (adjustable), which is always started from the current
actual pressure value. The parameters for the controller can be
switched via a Profibus signal, for example
- for bar up in order to counteract pressure peaks or
- switching to pressure control during position control
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1.2.4 Ram position control

During position control the ram follows the set point specified via
Profibus. If a specified pressure set point is exceeded, the controller
switches from position control to pressure control. In doing so, the
pressure set point for the controller is set to 80% (adjustable) of the
specified pressure set point. As soon as the position set point overruns
the actual ram value in the "lift" direction, the system switches back to
position control.
If the ram falls below 3mm (adjustable) during position control, the
system switches to the pressure regulator. In this situation the current
set point of the pressure regulator is reduced by 5% every 100ms. (To a
minimum of 5%). If the ram moves during this process, then the
alteration of the pressure set point is stopped. If the position value of

the ram now becomes larger than 3 mm (adjustable) +1 mm, the
position control procedure is reactivated and the pressure correction
value is reset.
Adjusting the zero point of the stroke transducer

In the position control process it is assumed that the lower cylinder end
position corresponds to 0 mm. To ensure this the actual position value
can be set to zero via the Profibus signal "Set zero point of stroke
transducer". This function can only be activated if neither the position
control nor the pressure control process is selected or activated. The
pressurised cylinder should be located at the lower mechanical stop.
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1.2.5 Contamination of the ram

When lifting and lowering the ram in the Q-mode, the preselection "fast
operation after 1s" causes a memory to be activated which saves the
maximum pressure difference required. These values are compared
with the specifications (which can be set separately for both directions)
and a message is issued via Profibus if they are exceeded. When
travelling "downwards" the memory is stopped after reaching the "slow"
position. (The "slow" position may or may not have been reached
depending on the filling, which can make the measured value
implausible). This is also applicable for the "upwards" direction.
However, as the movement is executed from the very bottom when
travelling "upwards", this value reflects a larger range of the stroke. The
measurement is conducted for every stroke. The message is not saved
and it only remains in effect until the next stroke is executed
1.2.6 Fall back function for ram

Q-control
The fall back function is active for the downwards direction after 5
seconds. If, after the 5 seconds, the ram does not move further than 2
mm (adjustable) in 2 seconds (adjustable), a fall back movement is
initiated. The ram moves upwards. If the ram exceeds the position
"Current ram position + approx. 50 mm (adjustable)" when doing so, the
downwards direction is automatically selected. The ram travels a
greater distance than specified as a result of the ramps. The function is
switched off and a message is issued after 3 attempts (adjustable). This
function is deactivated if the lower end position is less than 3mm
(adjustable). The counter is either reset via the signal "Ram up fast," or
by issuing an acknowledgment via Profibus.
Pressure control
If the ram does not subsequently move further than 2 mm (adjustable)
in 2 seconds (adjustable), a fall back movement is executed. The ram is
moved upwards and the pressure regulator is switched off. If the ram
exceeds the position "Current ram position + approx. 50 mm
(adjustable)" when doing so, the downwards direction is automatically
selected. After reaching the switch-on threshold of the pressure
regulator, it is reactivated. The function is switched off and a message
is issued after 3 attempts (adjustable). This function is deactivated if the
lower end position is less than 3mm (adjustable). The counter is either
reset via the signal "Ram up fast" or by issuing an acknowledgment via
Profibus.
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1.3 Operating modes
1.3.1 General
Various production conditions call for various operating modes of the
system. They are selected using the external control system.
1.3.2 "Manual" mode (manual operation)
The control system is in a manual operating mode if neither pressure
control nor position control is selected. It is now possible to execute all
movements in a controlled manner.
1.3.3 "Pressure" mode
The cylinder is moved in a downwards direction in the "Pressure" mode.
If a specified pressure value is exceeded here, the pressure regulator
assumes control. The pressure set point is then approached via a ramp.
The A-T valve is also opened at this time depending on release.
1.3.4 "Position" mode
The movement of the cylinder occurs at a position set point in this
mode. The position is approached and maintained by the controller
thanks to a continuous comparison between the set point and actual
value.
1.3.5 "Position and pressure" mode
The movement of the cylinder occurs after a position set point in this
mode. If a
specified actual pressure value is exceeded, the controller switches to
pressure control and saves the last position captured, in order to revert
back to position control if necessary.
1.4 Intended purpose

For industrial use in closed buildings.
1.5 Technical data of the complete system
Operating voltage: 110 .. 230 VAC (-15 ..+10 %) 50/60 Hz

Power consumption: 400 V A
Ambient temperature: 0 .. 50 degrees Celsius
Storage temperature: -20 .. 85 degrees Celsius
Protection type of SPCc5: IP20
Protection type of IDC32: IP65
For further information on technical data, please refer to the separate documentation
of the individual components!
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1.6 SPCcompact 5 controller
Please observe the component description for the SPCcompact 5 controller!
Software:
The system programme, which can be downloaded via PC, is
permanently stored in the central processing unit and is documented
using EMG-CAD 32. Permanently stored control parameters (operation
via the integrated keyboard) allow user intervention in the control circuit.
"Online Test" Option

By installing the additional "Online Test" software package on the
customer's PC, the status of inputs and outputs and of process
variables may be displayed on the PC. Furthermore, the user may also
force inputs and outputs and change parameters.
Examples of possible modular extensions:
▪ PROFIBUS coupling
By adding the AnyBus module insert card, the system can be coupled
with the higher-level computer system via PROFIBUS-DP; the EMG
system operates as a slave in this configuration.
Special feature:
The interface signals transmitted via the BUS can be selected and
displayed using the keyboard.
1.7 Controller IDC32
Please observe the IDC32 component description!
Software:
The system programme, which can be downloaded via PC, is
permanently stored in the central processing unit and is documented
using EMG-CAD 32. Permanently stored control parameters (operation
via the integrated keyboard) allow user intervention in the control circuit.
"Online Test" Option

By installing the additional "Online Test" software package on the
customer's PC, the status of inputs and outputs and of process
variables may be displayed on the PC. Furthermore, the user may also
force inputs and outputs and change parameters.
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2 Safety
WARNING
Improper work on the strip guiding system components

can result in death or serious bodily injury.
1. The chapter entitled "Safety" must be read and fully understood by
all persons who are responsible for operation, maintenance or
repair work.
2.1 General regulations

The person responsible for the plant must ensure that
▪ safety information and operating instructions are available and
observed,
▪ operating conditions and specifications are observed in accordance
with the order,
▪ protective equipment is used,
▪ prescribed maintenance work is carried out, and
▪ maintenance personnel are informed without delay or the electrical
component is stopped immediately if abnormal voltages, high
temperatures, noises, vibrations, etc. occur in order to determine the
cause.
This documentation contains the information which is required for

qualified personnel to utilise the control systems in industrial plants.
Additional information and references for non-qualified persons, and
information relating to the use of the components in non-industrial
plants, are not contained in this operating manual.
Only if this documentation is fully observed will the manufacturer’s

guarantee be valid.
2.2 Correct utilisation

This product may only be used for the intended purposes specified in
the chapter "Product Description". The details included in accordance
with the "Technical specifications" in the "Product Description" chapter
of this document are applicable as authoritative limitations of use and
characteristic data.
Any use of this product other than that specified is to be avoided. The
manufacturer is not liable for any damages resulting from unintended
use; the operator shall assume sole responsibility for the risk.
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2.3 Non-compliance with the safety regulations

EMG Automation GmbH accepts no responsibility for any damage
which results from non-compliance with the instructions and information
contained in this documentation.
This particularly applies to damage:
▪ caused by improper use or through faulty operation
▪ caused by ignoring the safety information contained in the operating
manual
▪ caused by unsatisfactory or non-implemented maintenance and
repair work
▪ caused by incorrect selection of the workpieces or tools
2.4 Fundamental safety precautions

▪ Only authorised personnel may work with components of the strip
guiding system.
▪ The strip guiding system may only be operated in good order and
condition in accordance with the operating manual and instruction
manual.
▪ Avoid any kind of work that could endanger the safety of personnel
or impair the safety of the strip guiding system.
▪ All maintenance and repair work should only be carried out in
principle when the system is at a complete standstill.
▪ The manufacturer must always be contacted in case of doubt.
2.5 Local legislation, directives and regulations

All generally applicable national and local safety and accident
prevention regulations as well as operator regulations are to be adhered
to in addition to this documentation.
2.6 Applicability
The details, instructions and safety-relevant information contained in
this documentation exclusively apply to the present strip guiding
system.
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2.7 Structure and meaning of the references

Important information concerning technical and operational safety is
indicated as follows in this operating manual:
DANGER
Refers to a dangerous situation which will result in death or serious

bodily injury.
WARNING
Refers to a dangerous situation which can result in death or serious

bodily injury.
CAUTION
Refers to a potentially dangerous situation which can result in minor to

medium bodily injury.
NOTE
Refers to a situation which can result in damage to property.
For application information and other useful information (tips & tricks).
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2.8 Graphic reference symbols

These symbols can be found in various places in the operating manual,
in the instruction manual and on the components. These informative
symbols are to be observed without fail!
The symbols (pictograms), warning- and information signs have the
following meaning:
Caution! Caution! Caution! Caution!

Electric shock Hot surface Danger of Hand injury
explosion
Caution! Caution! General hazard Caution!

Laser beam Rotating gears warning Risk of crushing
Caution! Caution! Wear a helmet Wear ear and

Risk of fire Suspended load eye protection
Wear protective Wear gloves!

goggles!
2.9 General safety regulations

2.9.1 State of the art technology
The entire system corresponds to state of the art technology and the
recognised safety regulations.
Risks and residual danger to life and limb still exist, particularly if the
strip guiding system's components are not operated in accordance with
the specifications and regulations, or if they are operated by
unauthorised personnel.
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2.9.2 Removal of safety guards

Safety guards and covers may only be removed if the system has been
electrically shut down and disconnected. The safety guards and covers
in particular may only be removed by authorised persons and they must
be reassembled before restarting the system.
WARNING
Unauthorised access
Possible serious bodily injury or death.
1. When performing maintenance work, set up a safety fence to
prevent access to unauthorised persons.
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2.10 Specific safety regulations

When performing any setting, maintenance or repair work on the
system, always observe the switch-off procedures described in the
respective chapters of this documentation.
2.10.1 Mechanical hazards
WARNING
Sharp Edges and Moving Parts

Cutting injuries and crushing of body parts possible.
1. Wear protective clothing and do not enter into the effective range of
the components of the strip guiding system.
2.10.2 Electrical hazards
DANGER
High Voltage
Death by electric shock.
1. Circuit components may only be accessed by trained personnel
using ESD protective measures.
2.10.3 Hydraulic hazards
CAUTION
Squirting Oil
Minor bodily injuries possible.
1. Make sure that the hydraulic system is depressurised before any
maintenance or repair work is started.
▪ Do not change the pump pressure specified in the hydraulic plan and
in the instruction manual.
▪ Regulating valves that are sealed or secured in another way must
not be adjusted.
▪ When performing any work on the hydraulic system (for example,
replacing the hydraulic hoses), prepare containers and collecting
pans to catch any hydraulic oil that drips or leaks.
▪ The hydraulic oil that has been replaced is to be filled into
appropriate refuse containers and disposed of in accordance with
environmental-protection regulations.
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2.11 Responsibilities and qualification requirements

The responsibilities for the different activities must be clearly specified
and maintained by the operator of the plant in order to prevent any
ambiguities arising under the aspect of safety.
Dangers can arise from the components of the plant if they are
improperly fitted. This applies particularly to work on the
electrical/electronic and hydraulic equipment (see "Product specific
dangers and danger areas"). The operator must make sure that only
trained persons work on the plant or stay in the danger area.
2.11.1 Authorised personnel/qualified employees
DANGER
Non-authorised personnel
Death, serious bodily injuries, damage to property.
1. Only authorised personnel may carry out any kind of work.
Authorised persons satisfy minimum training and knowledge
requirements and have achieved a precisely defined level of
expertise.
The supplied equipment may only be transported, installed, connected,

put into operation, maintained and operated by qualified personnel that
have mastered the current safety regulations and mounting instructions.
All work must be checked by responsible, qualified personnel. The
qualified personnel must be authorised to do the necessary work by the
person legally responsible for the safety of the plant.
Qualified persons are those who:

▪ have the necessary training and experience
▪ are acquainted with the applicable standards, regulations, provisions
and accident prevention regulations
▪ have been trained and are fully familiar with the functionality and
operational conditions of the system
▪ are able to foresee risks and to take steps to avoid these dangerous
situations
For regulations and definitions concerning qualified personnel, see

VDE 0105 or IEC 364.
The appropriately trained personnel may only work within the scope of
their professional training.
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2.12 Duty of notification in the case of malfunctions and

damage
The plant operator is obligated to examine the components of the plant
at least once per shift for any signs of externally visible damage or
malfunction.
Any changes (including the operational behaviour), which can impair
safety must be announced immediately.
2.13 Necessary protective clothing

Where required the operating company must enforce the use of
protective clothing, gloves, goggles etc. by operating personnel.
2.14 Prohibition of alterations and modifications to the

machine
WARNING
Defective and/or missing safety equipment

1. Never switch off or remove the safety equipment!
2. Any kind of alterations and modifications to the components are
strictly prohibited for safety reasons!
3. Only spare parts and accessories approved by EMG or parts which
correspond to the original condition may be used!
2.15 Maintenance obligation

The operator of the plant is obligated to use it solely in a perfect and
undamaged condition. Maintenance and repair work is described in the
instruction manuals.
▪ Any traces of oil are to be eliminated immediately.
▪ Only original spare parts may be used.
▪ After disassembling casing components or after performing electrical
installation work, inspect the implemented safeguards with regard to
their correct functionality before restarting the system.
▪ A functional or operational examination must always be performed in
setup mode before restarting the system.
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3 Packaging and Transport
3.1 Packing material

The equipment must be provided with drying agents, sealed in foil and
packaged in seaworthy, lined crates. The crates are marked according
to customer specifications.
3.2 Transport
WARNING
Falling load
1. Only suitable and sufficiently dimensioned lifting accessories may
be used to secure the load-carrying equipment to the crane!
2. The carrying ropes must be secured in such a way so that they
cannot slip and cause the load to tilt and fall.
The crates may only be transported and stored in the designated

condition. Damage to the crates - particularly the packaging foil - is to
be avoided. The load must be wedged on the truck and secured against
shifting.
NOTE
Torn foil
Resulting in possible damage to the product.
1. Broken foil must be re-sealed to prevent subsequent damage to the
equipment. The drying agent is to be checked beforehand and
replaced if necessary.
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3.3 Unpacking the equipment
Unpack the equipment in enclosed and dry areas directly before starting
assembly.
Only remove the preservation agents shortly before the start-up
operation.
NOTE
Improper transport
Resulting in material damage to the product.
1. Examine the shipment immediately after receipt for any signs of
transport damage and completeness.
⇨ If the packaging is damaged, it must be removed in the presence of
a representative from the transport company.
Depending on the transport weight, an elevating platform truck, a forklift

truck or an indoor crane must be used for loading and unloading
purposes (see dimension sheet or shipping data).
3.4 Storage
The equipment must be stored in the factory packaging in dry halls that
are maintained at a moderate temperature (storage temperature
between 0 and 40 °C).
NOTE
Seals lose their elasticity and thus their full functional efficiency.
Resulting in possible damage to the product.
1. In the event of longer storage times, observe the regulations for
storage conditions and storage periods of rubber materials.
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4 Configuration and Installation
4.1 Information on Accident Prevention
The safety regulations described in the chapter entitled "Safety" must

be observed.
When connecting and operating the equipment, make sure that the
protective system prescribed by VDE 0100 is used.
The generally applicable safety regulations and instructions for
industrial safety are also to be complied with.
4.2 Installation
Only unpack the devices immediately before commencement of
installation in a closed and dry building. Check the rust-proofing of
components (bright parts, protective coats, etc.) and retouch as
needed.
Only remove protective devices used during transport and rust-proofing
measures shortly before commissioning.
4.3 Installing the electronics
4.3.1 SPCcompact 5
1. Be aware of the ambient conditions when installing the SPCc 5
control electronics.
2. Protect from direct thermal radiation, moisture, and severe shock.
3. Wiring must be carried out in accordance with the circuit diagram.
4.3.2 IDC32
1. Observe the ambient conditions when installing the IDC32 control
electronics.
2. Protect from direct thermal radiation, moisture, and severe shock.
3. Wiring must be carried out in accordance with the circuit diagram.
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5 Commissioning
5.1 ECU 01
Basic setting of parameters using the keyboard and display unit
ECU 01
The basic factory setting can be found as a printout of parameter file
IDC32.PRM in the chapter "Adjusting the Operating Modes using
ECU 01" in this operating manual.
All control directions and parameters are set during the initial operation.
These do not normally need to be changed and should be entered in
the list of parameters (appendix).
If an adjustment is nevertheless necessary (for example, in case of
replacement or readjustment of single components), you can access
and modify the respective parameter via the ECU 01 display unit.
It is strongly recommended to note and document the current

parameter settings.
5.2 Parameterisation of control system with ECU

The display has four lines. Two measured values, two parameters or
one measured value and one parameter can be displayed at the same
time.
M = Prefix measured value of process variable, followed by 3 digits
(e.g. M001 = measured value 1)
P= Prefix parameter value of process variable, followed by 3 digits
(for example, P001 = parameter 1)
5.3 Keyboard and display unit ECU 01
Membrane keyboard ECU 01
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5.3.1 Button functions of the green keypad (preselection of

operating modes)
Butt Meaning
on
EXTERN button with light-emitting diode (LED)
When the EXTERN LED is lighted, the mode selector keys are
locked.
By actuating the EXTERN key, the mode selector keys are
released.
Pressure control On button with LED
The LED indicates whether the pressure regulator is active.
If the EXTERN LED is not illuminated, the pressure control
mode is activated via the button.
MANUAL button with light-emitting diode (LED)
The LED indicates whether the manual mode has been
selected.
If the EXTERN LED is not lighted, the manual mode is activated
using the MANUAL key.
MANUAL RIGHT button
The MANUAL RIGHT button is released when the EXTERN
LED is OFF and the MANUAL LED is ON. By actuating the
MANUAL RIGHT button, the drive is moved at a selectable
speed.
MANUAL LEFT button
The MANUAL LEFT button is released when the EXTERN LED
is OFF and the MANUAL LED is ON. By actuating the MANUAL
LEFT button, the drive is moved at a selectable speed.
Position control button with LED
The LED indicates whether the position controller is active.
If the EXTERN LED is not illuminated, the position control mode
is activated via the button.
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5.3.2 Button functions of the blue keypad

(entry of parameters/selection of measured values)
Butt Meaning
on
▪ changeover to standard display (only from the basic mask)
▪ increment mask number (standard display)
▪ increment value of current variable or mask number (entry
mode)
▪ Akt. - Set current variable to 1-signal (entry mode, bit
variable)
▪ decrement mask number (standard display)
▪ decrement value of current variable or mask number (entry
mode)
▪ Akt. - Set current variable to 0-signal (entry mode, bit
variable)
▪ change active mask (toggle, standard display)
▪ right cursor (parameter entry, mask number)
▪ change displayed values/parameters of active mask (toggle)
▪ left cursor (parameter entry, mask number)
▪ completion of entry or acceptance of modified values/settings
▪ termination of function
▪ return to previous level
String of mode buttons:

Selection of interface (RS 232/RS 422)
status of ECU 01 (including preselection of language)
Status programme controller (basic mask)

(combinations which are not mentioned are not used)
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String of function keys:

Release entry mode (password to change
parameters)
Select entry mode (change of parameters)
Call input mask number
Reload old value (combinations not shown are not

used)
The blue keypad is reserved for operating the 4-line LCD display.
5.4 Operation (examples)
5.4.1 Displaying measuring point M001
1. Press the button.
2. Actuate the button once or twice until measuring point M0xx is

displayed.
3. Actuate the or button until measuring point M001 is

displayed.
5.4.2 Changing parameters
1. Press the button.
2. Actuate the button once or twice until parameter P0xx is

displayed.
3. Actuate the button until parameter P003 is displayed.
4. Actuate the button sequence + + + + .

⇨ The cursor flashes at the first position (sign)
5. Use the cursor button or to move the cursor to the digit

to be changed.
6. Alter the value using the or buttons.
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⇨ Change all digits if required
7. Use the cursor button or to move the cursor to the next

digit to be changed.
8. Alter the value using the or buttons.

⇨ Change all other digits if required
9. Now confirm with .
M00 final amplifier output +1.0V

1
P013 Scaling actual position +300.0
mm
The parameters to be entered are checked for limit values.

If the entered value is above or below the permitted limit value (upper
or lower limit), the change is ignored.
5.5 Control of operating modes

The system offers the following possibilities of changing the operating
mode (auto, manual, centre):
1. Internal control using keypad ECU 01
2. External control using digital inputs
3. External control via PROFIBUS, in conjunction with Subprint Anybus
to 1:
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If external control is not selected via the "EXTERN" button

(ECU 01) (EXTERN LED does not illuminate), then the
operating modes are specified via the green button field of the
ECU 01 keypad.
The mode which was previously activated via the external
control or PROFIBUS remains in effect.
to 2 and 3:
When selecting external control via the "EXTERN" button
(EXTERN LED is ON), it is possible to control the unit via digital
inputs or PROFIBUS-DP.
The control via PROFIBUS-DP is released by ECU 01 using the

parameter P001.
P001 ⇒ Bit "1" Operating modes are controlled via
= release: PROFIBUS.
P001 ⇒ Bit "0" = lock: Operating modes cannot be controlled via
PROFIBUS-DP.
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5.6 PROFIBUS Coupling System (Master) - EMG

(Slave)/Option
5.6.1 SPCcompact 5 with PROFIBUS interface

Interface X18 provides communication with a higher-level system
computer as a SLAVE in PROFIBUS-DP.
The device master data file (HMS_1003.GSD) of SPCcompact contains
the system parameters required for the PROFIBUS-DP MASTER. It is
available as download from the EMG homepage www.emg-
automation.com.
1. Products A-Z
2. Select product.
3. Go to Downloads and select file.
Download the files as described.
The following points must be observed when planning the master

system:
▪ Copy the GSD file into the \\..\gsd directory.
▪ SPCcompact can be found in the network configurator of the
PROFIBUS system under OTHER FIELD SYSTEMS \ GENERAL \
ANYBUS_HMS...
▪ SPCcompact only operates in a word-oriented manner.
▪ All words must be individually projected (max. 62 data words per
data direction).
▪ The number of words to be projected in the PROFIBUS-DP master
system must be in line with the number of words in SPCcompact.
▪ The HIGH byte and the LOW byte are interchanged in S7 in
communication with Siemens S7.
▪ Before transmitting control signals (individual bits in one word),
HIGH byte and LOW byte must be interchanged in the S7 software.
– The command is: TAW (in the accumulator)
The front panel of the SPCcompact has 4 additional LEDs to signal the
status of the PROFIBUS-DP:
LED Position Meaning
H24 Error LED PROFIBUS side:
OFF no error detected on PROFIBUS side
red, flashing 1 Hz Error in configuration:
Data length send/receive at initialisation
not matching data length in network
configuration
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LED Position Meaning

red, flashing 2 Hz Error in user parameter data:
Data length at initialisation not matching
data length in network configuration
red, flashing 4 Hz Error in initialisation PROFIBUS-ASIC
SPC 3
H21 not used
H23 red, illuminated PROFIBUS module is offline, no data
OFF exchange is possible
PROFIBUS module not offline
H22 green, illuminated PROFIBUS module is online, data
OFF exchange is possible
PROFIBUS module is not online
PROFIBUS-DP user address

The rotary DIL switches S3 (LOW byte) and S4 (HIGH byte) determine
the user address in decimal coding. The highest user address is 99.
The new address is accepted after switching on the supply voltage for
SPCcompact again.
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Example:
User 7: S22 = 7 and S23 = 0
User 17: = 7 and S23 = 1;
S22
Control elements of the SPCcompact PROFIBUS-DP interface:

switch Positio Meaning
n
S21 ON/OFF Terminating resistor PROFIBUS-DP
S22 0 .. 9 Address setting PROFIBUS 0 .. 9
S23 0 .. 9 Address setting PROFIBUS 1x .. 9x
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5.7 CANopen coupling for EMG sensors

The optical and inductive EMG sensors are connected to the central
processing unit via the CAN-Bus. Communication is stable in all
operating modes if the following major basic conditions are complied
with:
Communication data
- baud rate = 250
kBaud/
- max. cable = 160 m
length
- max. number of = 12
users
5.7.1 Cable type, cable length and wiring

The following cables comply with this specification:
Make Lapp
▪ Unitronic Bus LD (2 x 2 x 0.22)
(EMG standard cable for RS 485, CAN-Bus) EMG part No.: 181948
▪ Unitronic Bus Device Net
(OVDA Device Net; industrial standard: max. 2 wire pairs)
▪ Unitronic Bus CAN (max. 2 wire pairs)
Technical specifications:
Characteristic 120 Ω
impedance:
Operating capacity: max. 60 nF/1000 m (800 Hz)
Wire cross section: min. 0.22 mm²/wire (<AWG24)
No. of wires: The wires are stranded in pairs:
pair 1..3 (P1..P3) 3x2 (P1:CAN_H/L,P2: 24 V/GND)
pair 1..2 (P1..P2) 2x2 (P1:CAN_H/L,P2: 24 V/GND) potential-free
Pair 1 CAN-Bus
1x2 (P1: CAN_H/L) potential-free CAN bus
Temperature range: -40....+ 80 °C
Maximum cable length

160 metres for baud rate of 250 kBaud
Wiring
The signals "CAN-high" and "CAN-low" must be transmitted in one pair
of wires. The CANopen network must be wired according to the
applicable circuit diagram.
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5.7.2 120 ohm terminating resistor on the CAN-Bus

A terminating resistor must be provided at the end of the bus line (first
and last user). The EMG sensors and EMG central processing units
have an integral terminating resistor which must be activated by a
jumper.
▪ IDC32 = jumper J3
5.7.3 User address at CAN-Bus

The CAN-Bus master (EMG central processing unit) has address 1 (set
permanently by the programme). The addresses of the other users
(slaves) are set on the respective device via DIL switch.
Address (Node ID) Rotary switch
IDC32 2 (specified by --
software)
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5.8 Adjusting the operating modes using ECU01
CAUTION
Moving parts.
There is a risk of injury.
1. Check whether the actuator can be moved safely.
The lists of parameters, measuring points and PROFIBUS signals

(optional) can be found in the appendix.
Furthermore, a list of addresses and DIL switch settings of the
SPCcompact controller can be found in the appendix.
+4095 or -4096 digits are maximum values for +10 V DC or -10 V DC
for the 12-bit resolution of the AD/DA converter.
1. Switch ECU 01 to INTERN.

⇨ LED in EXTERN button does not illuminate.
Content of parameter file IDC32.PRM (basic factory setting)

The following settings are default settings and serve as starting values
to commission the application.
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5.8.1 List of Parameters

Parameter Project 'SPCc5001v0' Date: 30.11.2011 16:50:33
Project status: 30.11.2011 16:45:18
P-No | Value | Unit | Name | Lower limit | Upper limit | Type

----------------------------------------------------------------------------------------------
P001 Bit: 1 REL. PROFIBUS B
P002 2 CYL QTY CODE 1 3 I0
P003 187.0 bar SCAL P-MAX SET 0.0 300.0 I1
P004 0.0 bar MIN PRESSURE 0.0 100.0 I1
P005 250.0 bar P-MAX SENSOR A 0.0 400.0 I1
P006 250.0 bar P-MAX SENSOR B 0.0 400.0 I1
P007 0.0 bar TARA -50.0 50.0 I1
P008 90 % TRG PRESSURE ON 0 100 I0
P009 200.0 bar SCALE PRE DISP 0.0 500.0 I1
P010 500 ms RAMP SET POINT 100 30000 I0
P011 500 ms A-T ON GAIN NOR 20 5000 I0
P012 2.0 GAIN PRE. NORM 0.5 200.0 I1
P013 0.6 GAIN PRE. RED. 0.5 200.0 I1
P014 200 ms I-PART PRE.NORM 0 10000 I0
P015 400 ms I-PART PRE.RED. 0 10000 I0
P016 5.0 bar TRG PRE. I ON 0.0 250.0 I1
P017 10 % LIMIT I PRE + 0 1000 I0
P018 10 % LIMIT I PRE - 0 1000 I0
P019 20 ms TIME PRE ON 0 2000 I0
P020 187.0 bar MAX SET PRE 0.0 300.0 I1
P021 70 % RAM UP FAST 0 1000 I0
P022 20 % RAM UP SLOW 0 1000 I0
P023 70 % RAM DOWN FAST 0 1000 I0
P024 30 % RAM DOWN SLOW 0 1000 I0
P025 1000 ms RAMPE UP + 50 30000 I0
P026 500 ms RAMPE UP - 50 30000 I0
P027 1000 ms RAMPE DOWN + 50 30000 I0
P028 500 ms RAMPE DOWN - 50 30000 I0
P029 100 mm DIAMETER PISTON 0 5000 I0
P030 70 mm DIAMETER ROD 0 5000 I0
P031 920.0 mm MAX RAM STROKE 0.0 3000.0 I1
P032 Bit: 1 REL. A-T ACTIVE B
P033 1000.0 mm SCAL.STROKE POS 0.0 3000.0 I1
P034 0.0 RESERVE 0.0 0.0 I1
P035 Bit: 1 DIR STROKE POS B
P036 0 RESERVE 0 0 I0
P037 Bit: 0 RESERVE B
P038 2.0 LIMIT GAIN POS 0.0 500.0 I1
P039 400 ms MIN I-PART POS 0 10000 I0
P040 20 % LIMIT I POS 0 100 I0
P041 10.0 mm TRG POS I ON 0.0 400.0 I1
P042 Bit: 1 REL. POS I ON B
P043 500 ms RAMP POS ON 100 1000 I0
P044 50 % LIMIT POS VALVE 1 100 I0
P045 2000 ms RAMP BACKSPACE 100 10000 I0
P046 3.0 mm CYL END PRESSUR 0.0 10.0 I1
P048 Bit: 0 REL POS-PRE ON B
P049 80 % REL POS-PRE ON 0 100 I0
P050 100 % DD OPEN FAST 0 1000 I0
P051 20 % DD OPEN SLOW 0 1000 I0
P052 100 % DD CLOSE FAST 0 1000 I0
P053 25 % DD CLOSE SLOW 0 1000 I0
P054 400 ms DD OPEN RAMP + 100 30000 I0
P055 400 ms DD OPEN RAMP - 100 30000 I0
P056 400 ms DD CLOSE RAMP+ 100 30000 I0
P057 400 ms DD CLOSE RAMP- 100 30000 I0
P063 0.0 RESERVE 0.0 0.0 I1
P064 0.0 RESERVE 0.0 0.0 I1
P065 1 SELECT ECU COMM 0 2 I0
P066 50.0 bar SET POINT PRE C 0.0 300.0 I1
P067 10.0 mm SET POINT POS C 0.0 3000.0 I1
P068 0 REL RAM JAM 0 2 I0
P069 3 QTY RAM JAM 1 10 I0
P070 2.0 mm POS RAM JAM 0.1 20.0 I1
P071 2 s TIME RAM JAM 1 20 I0
P072 50.0 mm STROKE RAM JAM 0.0 100.0 I1
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P080 40.0 bar TRG FRICTION DN 0.0 50.0 I1
P081 40.0 bar TRG FRICTION UP 0.0 50.0 I1
5.8.2 Preselection of the application

Description The number of cylinders on the ram can vary depending on the version.
This must be preset with the help of a parameter.
Setting Preselection of the application with parameter P002
1 = 1 cylinder and synchronous cylinder (P029 + P030)

2 = 2 cylinders or 4 cylinders
3 = 4 cylinders with two used piston surfaces
The release valve for the hydraulic system should always be active
(switched on) for commissioning via the ECU.
CAUTION
Moving parts.
There is a risk of injury.
1. Check whether the actuator can be moved safely.
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5.8.3 Setting the slow positioning speed for ram "up" and
"down"
Description The cylinder can be moved via the ECU 01 function buttons in the
"MAN" operating mode. The valve opening (positioning speed) can be
adjusted.
Precondition
⇨ LED in EXTERN button is off
2. Switch control on ECU 01 to "MAN".

3. Set parameter P065 ⇒ to "1"
4. Switch on the hydraulic system.
5. Release valve for the hydraulic system is on.
Settings
M00 Output regulating 1.0 volt
1 valve ram
P021 Manual speed up fast 70 %
P022 Manual speed up slow 30 %
P023 Manual speed down 70 %
fast
P024 Manual speed down 30 %
slow
P025 Ramp time 1000 ms
acceleration up
P026 Ramp time brake up 500 msec
P027 Ramp time 1000 ms
acceleration down
P028 Ramp time brake 500 msec
down
4
1. Actuate the MAN RIGHT button (ECU 01).

⇨ The cylinder of the actuator must rise.
If NOT:
Check the wiring.
2. Set the desired positioning speed by using parameter P022 ⇒.
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3. Actuate the MAN LEFT button (ECU 01).

⇨ The cylinder of the actuator lowers.
5. The "down" ramp times for activation of the valve are effected via
parameters P027 and P028, and the "up" ramp times are effected
via parameters P025 and P026.
6. Set the desired speed for fast "up" and fast "down" via
parameters P021 and P023.
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5.9 Adjusting the pressure cells on the ram
Description The pressure values are measured continuously and supplied to the
pressure regulator via the pressure cells on the cylinder of the ram.
Precondition

3. Set parameter P065 ⇒ to "1".
4. Set parameters P005 and P006 to the pressure value specified on
the rating plate of the pressure cell.
6. Release valve for the hydraulic system is on
Settings
M00 Output regulating valve ram 1.0
1 volt
M00 Actual pressure value A 100.0
2 (piston side) bar
M00 Actual pressure value B 100.0
3 (ring side) bar
P005 Scaling actual pressure 250.0
value A (piston side) bar
P006 Scaling actual pressure 250.0
value B (ring side) bar
P029 Piston diameter 120
mm
P030 Piston rod diameter 80 mm

⇨ Drive the cylinder of the ram to its mechanical stop and keep the
button depressed.
⇨ The maximum system pressure should now be displayed at
measuring point M003 "Actual pressure value A".
If NOT:
Check parameter P006 ⇒ (pressure indication of the pressure cell)
If it IS:
Check the wiring and the switch position of IDC32 in accordance
with the list in the appendix.
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⇨ Drive the cylinder of the ram to its mechanical stop and keep the
button depressed.
⇨ The maximum system pressure should now be displayed at
measuring point M002 "Actual pressure value B".
If NOT:
Check parameter P005 ⇒ (pressure indication of the pressure cell)
If it IS:
Check the wiring and the switch position of IDC32 in accordance
with the list in the appendix.
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5.10 Adjusting the position sensor on the ram

Description The position sensor detects the current position of the ram and is used
for position control (optional)
Precondition

4. Enter the cylinder stroke at parameter P031.
Settings
M00 Output regulating 1.0 volt
1 valve ram
M01 Actual position reset 200.0 mm
1 to zero
M01 Actual position (raw 250.0 mm
2 value)
P031 Ram travel 1000.0 mm
P033 1000.0 mm
Scaling ram position
P035 1
Effective direction
actual position value
(1 = 4 mA bottom / 0
= 4 mA top)
1. Press button MAN RIGHT (ECU 01).

Preselect measuring point M012.
⇨ Drive the cylinder of the ram to its lower mechanical stop and
keep the button depressed.
The value at measuring point M012 "Raw actual position" should
be greater than 10.0 mm.
If NOT:
Move the stroke transducer mechanically.
If it IS:
Press the two buttons and together for approximately

5 seconds.
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Select measuring point M011 "Actual position reset to zero".

⇨ The cylinder travels upwards.
Observe measuring point M011 when doing this. The displayed
value should become greater from approximately 0.0 mm
onwards.
3. Drive the cylinder upwards to the end of the ram stroke. Enter the
value displayed at measuring point M011 in parameter P031 "Ram
stroke" with a desired safety value. (The external and internal set
point setting for the position controller is limited to this value.)
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5.11 Adjusting pressure control

Description The pressure cells on the cylinder of the ram continuously detect the
pressure values, which they
feed to the pressure regulator. This regulates the pressure as a function
of the pressure set point.
Precondition

Switch control to "MAN" on the ECU 01 control unit.
Settings
M00 Output regulating valve ram 1.0 volt
1
M00 Ram pressure 50.0
4 bar
M00 Pressure set point 50,0
5 bar
M00 Differential pressure for PID 1.0 bar
6 regulator
P004 Minimum pressure set point 0.0 bar
P007 Tare 0.0 bar
P008 Trigger value for activation of 90 %
pressure control
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P010 Ramp pressure set point for 500

start of pressure control msec
P012 KP - PID pressure regulator 1.0
norm
P013 KP - PID pressure regulator 0.5
reduced
P014 TI - PID pressure regulator 500
norm msec
P015 TI - PID pressure regulator 500
reduced msec
P016 Trigger I-part on for Rdiff. less 4.0 bar
than
P017 Pos. limitation I-part - PID 100 %
pressure regulator
P018 Neg. limitation I-part - PID 100 %
pressure regulator
P020 Maximum possible pressure set 100.0
point bar
P066 Specification of pressure set 50.0
point for commissioning bar
P011 Delay A-T valve on up to KP 500ms
norm
P032 Release function of valve A – T 0
active
The function to relieve the non-pressure side after the tank during
pressure control should be switched off. Set parameter P032 to "0".
1. Switch control on ECU 01 to "AUTO".

⇨ The "Auto" LED flashes if the applied pressure is below the
trigger threshold (pressure regulator release) (set at P008).
Pressing the button again switches the pressure regulator
off once more.

⇨ Drive the cylinder of the ram downwards until the "Pressure
regulator" LED stops flashing.
The pressure regulator is now activated and it remains operational
until the "Pressure regulator" button is pressed again.
3. Activate the controller by changing the pressure set point P066
"Internal pressure set point" and optimise the PID regulator by
using the aforementioned parameters and measuring points.
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P013 P-part, P015 I-part and P016 trigger release I-part.

Set the ramp set point P010 to 100ms for this setting.
4. After optimisation transfer the parameter value P013 to P012 and
the parameter value P015 to P014.
5. The function 'A-T valve active' can now be switched on with
parameter P011.
6. Reset the controller to pressure control, if necessary, and check the
settings of the PID regulator; if necessary, optimise the parameters
P012 P-part and P014 I-part.
3. Final optimisation measures are conducted in production.
Set the ramps for the pressure set point, switching values,
controlled speeds and the corresponding ramps.
5.12 Adjusting position control (optional)
Description The position sensor on the cylinder of the ram continuously detects the
position, which it
feeds to the position controller. This regulates the position for the
specified set point.
Another function is a superimposed pressure regulator.
If the set pressure threshold is reached during position control, the
controller switches to pressure control. When the position set point
becomes greater than the actual position of the ram, the system
switches back to position control. If the actual position is less than 3mm
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45
(adjustable),
the pressure regulator is activated in order to prevent pressure peaks at
the cylinder end position.
Precondition

7. Set P-gain of Profibus to 10.0.
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Settings
M00 Output regulating valve ram 1.0 volt
1
4 bar
M01 actual position 100.0
1 mm
P037 Effective direction of position 0
controller
P038 Limitation P-gain position controller 5.0
P039 TI - PID-position controller min 2000
msec
P040 Limitation I-part - PI-position 30 %
controller
P041 I-controller on (P-error smaller than 1000
parameter setting = I-part on) digit
P042 Release I-controller 0
P043 Ramp valve up with position control 1000
on ms
P044 Limitation valve control position 50 %
control
P045 Ramp set-point with ram return 500
msec
P048 Release switch position and force 0
control
P049 Factor pressure set point for 80 %
pressure regulator on
P046 Trigger pressure regulator on at 3.0 mm
cylinder end
P067 Specification of position set point for 200.0
commissioning mm
The switching function between pressure and position control should be

deactivated.
• Set parameter P048 to "0" for this purpose
• Switch off the I-controller via parameter P042
• Use P067 to specify a set point close to the cylinder position
(M011).
• Set P043 to 1000 ms.
• Set P044 to approx. 50% for the time being
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1. Switch control to "CENT" on the ECU 01 control unit.

⇨ Position control is activated immediately. Pressing this again
switches the controller off once more. The ram should travel to the
specified position.
3. Activate the controller by changing the position set point of
parameter P067 "Internal position set point" and optimise the P-
controller by using the aforementioned parameters and measuring
points.
4. Now release and set the I-controller with the corresponding
parameters P039, P040 and P041.
5. The limit for the valve should be below the slope change in the
valve.
6. If the specified maximum pressure set point is exceeded after
optimisation, the function "Switch to pressure control" should be
checked.
5.13 "RAM-JAM" function
Description If the controlled "downwards" movement is in effect and pressure

control is active, the cylinder is checked for stoppage. If a stoppage
occurs (time window), the system assumes a ram jam and the ram is
automatically driven upwards with a limited stroke. If a position trigger is
exceeded, the ram controller returns to normal control. The function is
switched off and a message is issued after a number of fall back
attempts (adjustable). The function is released again with the command
"Ram up fast" or an acknowledgment via Profibus.
Precondition
Stroke transducer is present
Settings
P068 Release of "RAM-JAM-FUNCTION" 0
P069 Number of attempts until message 3
and function "off"
P070 Hysteresis of "RAM-JAM- 2.0 mm
FUNCTION"
P071 Time delay until "RAM-JAM- 2 sec
FUNCTION"
P072 Jump size for "RAM-JAM- 50.0
FUNCTION" mm
This function is activated with parameter P068.
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If the ram moves less than the value entered in parameter P070 during
the time set under P071, a fall back stroke is activated. If the current
actual position value exceeds the jump height entered at P072 (current
value + P072), the function is deactivated again.
5.14 Ram contamination monitoring
Description The driving pressure of the cylinder is measured during controlled

upward and downward operations. If a set driving pressure is exceeded,
the message "Ram contaminated" is issued.
The evaluation is only performed after the ram is in motion.
Precondition
An actual value must have been previously recorded with a clean ram.
Settings
4 bar
M01 Maximum pressure difference when 10 bar
5 travelling downwards
M01 Maximum pressure difference when 10 bar
6 travelling upwards
P080 Trigger contamination reached in 30.0
direction down bar
P081 Trigger contamination reached in 25.0
direction up bar
The required pressure values for this movement are determined

through upward and downward movements of the clean ram.
The currently required pressure can be read at measuring point M004
and the maximum measured values (after each stroke) can be viewed
at measuring points M015 and M016. (The sign can be ignored here).
Set the read values + a safety margin at parameters P080 and P081.
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5.15 Setting the positioning speed for the discharge flap

"up" and "down"
Description The cylinder can be moved via the ECU 01 function buttons in the
"MAN" operating mode. The valve opening (positioning speed) can be
adjusted.
Precondition

5. Release valve for the hydraulic system is on.
Settings
M01 Output prop. valve 1.0 V
8 EKL
M01 Test signal EKL 1.0 V
9
P051 Manual speed up slow 30 %
P052 Manual speed close 70 %
fast
P053 Manual speed close 30 %
slow
P054 Ramp open fast 2000
msec
P055 Ramp open slow 2000
msec
P056 Ramp close fast 2000
msec
P057 Ramp close slow 2000
msec

⇨ The cylinder of the actuator must lower.
If NOT:
Check the wiring and valve connection. (Hydraulic system ?)
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⇨ The cylinder of the actuator must rise.
5. The ramp time for activation of the valve is effected via parameters
P054 and P055.
7. Set the desired speed for fast "up" and fast "down" via parameters
P050 and P052.
5.16 Signalaustausch über PROFIBUS-DP

- In Verbindung mit Subprint IDC32_Anybus-IC
Die Befehle über den PROFIBUS-DP müssen Dauersignale sein.
Parameter P001 = Bit : "1“ setzen.
1. ECU 01 auf EXTERN schalten.

⇨ LED EXTERN leuchtet
Der Signalaustausch erfolgt über den PROFIBUS.
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6 Utilisation
6.1 Operation/Interface
General information
The operating mode remains in effect for as long as the external signal.
If the 'ready for operation' state fails, the valve controls are set to "0".
The selected operating mode will be maintained if the field bus fails.
6.1.1 Moving the actuator in a controlled manner
Precondition ▪ no signal position control on
Description ▪ The actuators can be moved using the commands actuator "UP" and
"DOWN".
▪ All of the highlighted functions can be executed.
PROFIBUS inputs
Ram UP - slow Bit 0 1 DW 0
Ram UP - fast Bit 1 0 DW 0
Ram DOWN - slow Bit 2 1 DW 0
Ram DOWN - fast Bit 3 0 DW 0
Pressure control ON Bit 4 0 DW 0
Position control ON Bit 5 0 DW 0
Discharge flap UP - slow Bit 8 0 DW 0
Discharge flap UP - fast Bit 9 0 DW 0
Discharge flap DOWN - slow Bit 10 0 DW 0
Discharge flap DOWN - fast Bit 11 0 DW 0
PROFIBUS outputs
remote ON (ECU 01) Bit 0 1 DW 0
Ready for operation Bit 1 1 DW 0
Pressure control active Bit 2 0 DW 0
Position control active Bit 3 0 DW 0
iRAM
52
PROFIBUS outputs
A-T valve UP Bit 4 0 DW 0
Discharge flap active Bit 7 1 DW 0
Pressure sensors ok Bit 8 0 DW 0
Position sensor ok (if available) Bit 9 0 DW 0
Regulating valve ok Bit 10 0 DW 0
iRAM
53
6.1.2 Pressure control on
Precondition
▪ Ready for operation
▪ Pressure sensors ok
▪ Regulating valve ok
Description ▪ The command "Pressure control on" activates the controller if a

specified pressure threshold is reached with the command "Ram
DOWN".
PROFIBUS inputs
PROFIBUS outputs
iRAM
54
6.1.3 Position control on
Precondition
▪ Ready for operation
▪ Pressure sensors ok
▪ Regulating valve ok
Description ▪ The command "Position control on" switches the controller to

position control.
A switch is made from position control to pressure control depending
on the internally specified operating mode.
PROFIBUS inputs
PROFIBUS outputs
iRAM
55
6.2 Operating Sequence

6.2.1 Ram pressure control
After filling the mixer with the appropriate materials, the ram is driven
downwards in a controlled manner. Upon reaching a waypoint or a
specified operating time, the speed is reduced and the pressure
regulator is switched on. When the set pressure is reached (when
impacting against the material), the pressure regulator takes over
proceedings. The pressure regulator maintains the actual pressure at
the set pressure level. When the mixing procedure is complete the
pressure control process is deactivated and the ram is driven to its
initial position.
6.2.2 Ram position control with switchover to pressure

regulator
After filling the mixer with the appropriate materials, the ram is driven
downwards in a controlled manner via a position set point. If the
specified pressure set point is exceeded, the system switches over to
the pressure regulator to ensure the maximum pressure level is not
exceeded. As soon as the position set point is back above the current
actual value again, the pressure regulator is deactivated and the
position controller resumes its task. If the pressure regulator has been
activated, it remains in this operating mode for at least 1 second.
iRAM
56
7 Maintenance and repair
7.1 Safety measures

The following safety measures must be observed before performing any
maintenance work:
1. De-energise the system and secure it against being accidentally
switched on again!
2. Always observe the local safety regulations and operational safety
directives.
3. Depressurise the system prior to working on the hydraulic
equipment.
4. Clean any parts that have been contaminated with hydraulic oil as
soon as possible.
5. Prevent prolonged, frequent, and intensive contact between
hydraulic oil and your skin.
6. Thoroughly wash any areas of skin that have become contaminated
with oil using water and skin-care cleaning products.
7. When disposing of used oil, pay attention to the legal requirements.
7.2 General information

Maintenance work is limited to an absolute minimum. Except for the
hydraulic power pack and visual inspection and cleaning, no special
maintenance is required.
Components need only be replaced in case of failure.
7.3 Maintenance intervals

Maintenance work Maintenance intervals
Examine oil Regular intervals depending on operating
composition. conditions.
To guarantee operational reliability of the
EMG servo valve SV1-10 / ...
Check the condition of Check on a weekly basis.
the equipment
iRAM
57
7.4 Maintenance work
NOTE
No Maintenance / Incorrect Maintenance

Can lead to damages and failure of the system.
Observe the maintenance information (separate documentation) for
the system components!
▪ Observe the operational safety regulations!

▪ The work should only be performed by appropriately trained,
specialised personnel!
7.4.1 Check the condition of the equipment

1. Perform a visual check of the strip guiding system for signs of
damage.
2. Replace damaged cover plates.
3. Check cable connections and plug and socket connectors for tight fit.
4. Check cables for signs of damage.
5. Replace any defective cables.
6. Clean the equipment of any dust and deposits.
7. Check the lubrication components (if available).
1. Check the exterior conditions of the lubrication cartridge and
check the hose for leak tightness.
2. Visually inspect the fill level of the lubrication cartridge.
7.4.2 Checking the oil and water lines of the hydraulic system
(visually)
▪ Check the oil and water lines for damage and leaks. Look out for
leaks.
▪ Check the quality of the oil on a regular basis to ensure operational
safety of the EMG servo valve.
If necessary, change oil and filter inserts!
iRAM
58
8 Error correction
8.1 Troubleshooting for standard programme
Display Status Error Remedy

SPCcompa Check voltage supply +/- 24 V
ct not ready and +/- 15 V
for Check the hardware (replace
operation if necessary; the jumper and
DIL switch positions must be
kept unchanged when doing
this!).
see measuring point M017 –
messages
Error EVK
Error LIC
PROFIBUS error
Error with 24 V external
SPCcompa Execute initial start on
ct is ready SPCcompact (DIL switch S3).
for Reset the sensor
operation Check CAN bus wiring
but the Check terminal resistances of
CAN-Bus is CAN-Bus
not
operating.
ECU 01 LED only Press the "EXTERN" button
LED "EXTERN" internal on card ECU 01
"EXTERN" does not communica
illuminate tion
possible
ECU 01 LED "MAN" Manual Press the "MAN" button during
LED does not operation is the internal operating mode
"MAN" illuminate not In the external mode, connect
possible the "MAN" digital input or
PROFIBUS
("EXTERN" must have been
selected!)
ECU 01 LED Centre has Press the "CENTRE“ button in
LED "CENTRE" not been the internal operating mode
"CENTRE" does not selected
illuminate
iRAM
59

LED Actuator Activate the "CENTRE" digital
"CENTRE“ moves input or PROFIBUS in the
flashes towards the external operating mode
centre ("EXTERN" must have been
selected!)
ECU 01 LED "AUTO" Automatic Press the "AUTO“ button in
LED does not operation is the internal operating mode
“AUTO“ illuminate not Activate the "AUTO" digital
possible input or PROFIBUS in the
external operating mode
("EXTERN" must have been
selected )
LED "AUTO“ Automatic "READY“ or "SENSORIK OK“
flashes mode has signal is not available (see
been items 1 – 2)
preselected
No Selection Switch off P001 (REL.
communicati via dig. PROFIBUS) (Bit: 1)
on via inputs or
PROFIBUS "INTERN"
operation is
possible
No Selection Switch off P001 (REL.
communicati via PROFIBUS) (Bit: 0)
on via dig. PROFIBUS
inputs or
"INTERN"
operation is
possible
No Incorrect Set slave address on S23/S22
communicati slave switch. The setting is in
on via address for decimals. S23 – high/S22 –
PROFIBUS DP network low
LED H22 Status green, PROFIBUS module is online,
PROFIBUS illuminated data exchange is possible
H23 LED Status red, PROFIBUS module is offline,
PROFIBUS illuminated no data exchange is possible
H24 LED No Error LED PROFIBUS side:
communicati
on via
PROFIBUS
OFF no error detected on
PROFIBUS side
iRAM
60

red, Error in configuration:
flashing 1 Data length send/receive at
Hz initialisation not matching data
length in network
configuration
red, Error in user parameter data:
flashing 2 Data length at initialisation is
Hz different from data length in
network configuration
red, Error in initialisation
flashing 4 PROFIBUS-ASIC SPC 3
Hz
iRAM
61
9 Disposal
9.1 General
The customer must dispose of the relevant material in accordance with
the local applicable legal regulations while observing ecological
aspects.
When disposing of components which have not been produced by the
manufacturing company, the corresponding instructions in the relevant
"company documentation" are to be observed.
9.2 Materials
Materials must be sorted according to material group (aluminium, steel,
plastic, electronic components etc.) and transferred to the appropriate
collecting points.
iRAM
62
10 Appendix
10.1 Addresses and DIL-switch settings
Application : Ram pressure control for internal mixer

Controller : SPCc 5
Programme : SPCC5001v0
Dated : 30-Nov-11
10.1.1 iRAM controller
Jumper settings, DIL switches for SPCc 1-1 motherboard

Settings Settings
Function Meaning
ex-works On-site
Power supply J1 - Jumper 1 .. 2 Default: J1 =
for digital (external +24V) Jumper 2 .. 3
outputs - Jumper 2 .. 3 (internal
+24V)
Power supply J100 = ON (internal 0V) Default: J100 =
for digital J100 = OFF (external 0V) ON
inputs
CAN interface J2, J3 = OFF (external +24V) Default: J2, J3 =
J2, J3 = ON (internal +24V) ON
AnyBus J4, J5 = ON - release Anybus Default: J4, J5 =
module J4, J5 = OFF - release ON
release analogue off
Jumper Settings, DIL Switches for Subprint IDC 32-13

Settings Settings
Function Meaning
ex-works On-site
DIL switch S3 S3.1: trigger initial start = ON Switch S3.4 = ON
S3.2: activate download = Switch S3.1 - S3.3
ON = OFF
S3.3: Baud rate CAN-Bus
500 kB = ON
250kB = ON
iRAM
63
Jumper Settings, DIL Switches for Subprint IDC 32-13

Settings Settings
Function Meaning
ex-works On-site
CAN interface S1  CAN a ddre s s Low User address: 0
Byte (HEX) Mode: Master
S2  CAN a ddre s s High J3 = ON
Byte (HEX)
J 3 = CAN-Bus terminating
resistor
interface for J1 and J2 J1, J2 = SSI
digital sensors preselection of SSI or SST
(start / stop)
Analogue Voltage ranges are set via J4, J5, J6, J7 =
inputs software. OFF
For current signals:
Channel 1:
0.. 20 mA at J4 = ON
Channel 2:
0 .. 20 mA at J5 = ON
Channel 3:
0 .. 20 mA at J6 = ON
Channel 4:
0 .. 20 mA with J7 = ON
Analogue The current output is set via Current output:
outputs software from 200 mA to
1000 mA
iRAM
64
10.2 List of parameters
Selection via keyboard of diagnostic unit ECU 01

Password for starting parameter input: key sequence "F", "","M", "F",
"ENTER"
Range of
Parameter Settings Meaning
values
P001 1 0 .. 1 Release of control via PROFIBUS-DP
1 = Release
0 = Control using ECU 01 or ext.
outputs
P002 2 1 .. 3 Application preselection
(1 or 2 cylinder ext.)
1 = 1 cylinder and synchronous cylinder
(P029 + P030)
2 = 2 cylinders or 4 cylinders
3 = 4 cylinders with two used piston
surfaces
Scaling ram pressure values
P003 187.0 0.0 .. 300.0 bar Scaling pressure set point analogue
(P-Max. set point)
P004 0.0 0.0 .. 100,0 bar Minimum pressure set point
(Min pressure)
P005 250.0 0.0 .. 400.0 bar Scaling actual pressure value A (piston
side) (P-Max. sensor)
P006 250.0 0.0 .. 400.0 bar Scaling actual pressure value B (ring
side) (P-Max. sensor)
P007 0.0 -50.0 .. Tare
+50.0 bar
P008 90 0 .. 100 % Trigger value for activation of pressure
control
[Percent of pressure set point]
(switch-on pressure)
P009 200.0 0.0 .. 500.0 bar Scaling analogue output differential
pressure (+/-10VDC)
(scal. act. no.)

P010 500 100 .. 30000 Ramp pressure set point
msec (ramp pressure set point)
iRAM
65
Range of
values
P011 500 20 .. 5000 msec Delay A-T valve on up to P-
amplification norm
PID – ram pressure regulator
P012 2.0 0.0 .. 200.0 KP- PID pressure regulator norm
(Kp positive/negative)
P013 0.6 0.0 .. 200.0 KP-PID pressure regulator reduced
(activation via Profibus or pressure
regulator for position control)
P014 200 0 .. 10000 msec TI - PID pressure regulator norm
(Ki value)
P015 400 0 .. 10000 msec TI-PID pressure regulator reduced
(activation via Profibus or pressure
regulator for position control)
P016 5.0 0.0 .. 200.0 bar Release I-part via Rdiff. less than
P017 10 0 .. +100 % Pos. limitation I-part - PID pressure
regulator
P018 10 0 .. -100 % Neg. limitation I-part - PID pressure
regulator
P019 20 20 .. 2000 msec Min. time pressure reached until
pressure regulator on
P020 187.0 0.0 .. 300.0 bar Maximum possible pressure set point
(limitation)
Controlled ram movement
P021 70 0 .. 100 % Correcting variable up FAST
(corr var. up fast)
P022 20 0 .. 100 % Correcting variable up SLOW
(corr var. up slow)
P023 70 0 .. 100 % Correcting variable down FAST
(corr var. down fast)
P024 20 0 .. 100 % Correcting variable down SLOW
(corr var. down slow)
P025 1000 100 .. 30000 Accelerate ramp up (ramp +
msec up)
P026 500 100 .. 30000 Brake ramp up (ramp - up)
msec
P027 1000 100 .. 30000 Accelerate ramp down
msec (ramp + down)
iRAM
66
Range of
values
P028 500 100 .. 30000 Brake ramp down (ramp -
msec down)
Ram cylinder data
P029 140 0 .. 3000 mm Piston diameter
(D-piston)
(enter 10 mm for synchronous cylinder)
P030 90 0 .. 3000 mm Piston rod diameter (D-
rod)
(enter 0 mm for synchronous cylinder)
P031 1000.0 0.0 .. 3000.0 Ram travel
mm
P032 1 0 .. 1 Release function of valve A – T active
Scaling ram actual position value
P033 1500.0 0.0 .. 3000.0 Scaling ram position
mm
P034 0 Reserve
P035 1 0 .. 1 Adjustment actual position value (1 = 4
mA bottom / 0 = 4 mA top)
P036 0 Reserve
Controller ram position control
P037 0 Reserve
P038 2.0 0.5 .. 500.0 Limitation P-amplification position
controller
(Specification of P-amplification via
Profibus)
P039 400 0 .. 10000 msec TI - PID-position controller min
(limitation)
P040 20 0 .. 100 % Limitation I-part - PID-position controller
P041 10.0 0 .. 400.0 mm Release I-controller via Controldiff. less
than
P042 1 0 .. 1 Release function I-controller
P043 500 100 .. 10000 Ramp valve up with position control on
msec
P044 35 0 .. 100 % Limitation valve control position control
P045 2000 100 .. 10000 Ramp set-point with ram return
msec
iRAM
67
Range of
values
P046 3.0 0.0 .. 10.0 mm Trigger pressure regulator on with
cylinder end in position control
P047 0 Reserve
P048 1 0 .. 1 Release function automatic change
between position and force control
P049 80 0 .. 100 % Reduction of pressure set point with
pressure regulator on in position control
[Percent of pressure set point]
Controlled movement of discharge flap
P050 100 0 .. 100 % Correcting variable up FAST
(df up fast)
P051 20 0 .. 100 % Correcting variable up SLOW
(df up slow)
P052 100 0 .. 100 % Correcting variable close FAST
(df close fast)
P053 25 0 .. 100 % Correcting variable close SLOW
(df close slow)
P054 400 100 .. 30000 Ramp open FAST (df up
msec ramp +)
P055 400 100 .. 30000 Ramp open SLOW (df up
msec ramp -)
P056 400 100 .. 30000 Ramp close FAST (df
msec close ramp +)
P057 400 100 .. 30000 Ramp close SLOW (df
msec close ramp -)
Ram valve data
P058 0 Reserve
P059 0 Reserve
P060 0 Reserve
P061 0 Reserve
P062 0 Reserve
P063 0 Reserve
P064 0 Reserve
Commissioning preselection
iRAM
68
Range of
values
P065 0 0 .. 2 Function of ECU buttons < > only for
"internal use"
0 = Button has no function
1 = Button drive ram
2 = Button drive flap
P066 50.0 0.0 .. 300.0 bar Specification of pressure set point for
commissioning only for "internal
operation"
P067 10.0 0.0 .. 3000.0 Specification of position set point for
mm commissioning only for "internal
operation"
"RAM-JAM-FUNCTION"
of the ram with pressure control and Q control "off"
P068 0 0 .. 2 Release of "RAM-JAM-FUNCTION"
0 = Function off
1 = Function with "controlled off" active
2 = Function with "controlled off" and
"pressure regulator" active
P069 3 0 .. 10 Attempts until message and function

"off"
P070 2.0 0.1 .. 10.0 mm Hysteresis of "RAM-JAM-FUNCTION"
P071 2 1 .. 10 s Time delay until "RAM-JAM-
FUNCTION"
P072 50.0 0.0 .. 100.0 mm Jump size for "RAM-JAM-FUNCTION"
P073 0 Reserve
P074 0 Reserve
P075 0 Reserve
P076 0 Reserve
P077 0 Reserve
P078 0 Reserve
P079 0 Reserve
Ram contamination monitoring
P080 50.0 0.0 .. 50,0 bar Trigger contamination reached in
direction down
P081 50.0 0.0 .. 50,0 bar Trigger contamination reached in
direction up
iRAM
69
Range of
values
P082 0 Reserve
P083 0 Reserve
P084 0 Reserve
P085 0 Reserve
P086 0 Reserve
P087 0 Reserve
P088 0 Reserve
P089 0 Reserve
P090 0 Reserve
P091 0 Reserve
P092 0 Reserve
P093 0 Reserve
P094 0 Reserve
P095 0 Reserve
P096 0 Reserve
P097 0 Reserve
P098 0 Reserve
P099 0 Reserve
P100 0 Reserve
iRAM
70
10.3 List of measuring points

Selection via keyboard of diagnostic unit ECU 01
Measuring Range of values Meaning

point
Ram pressure control
M001 -10.0 .. 10.0V Output for regulating valve ram
M002 0.0 .. 300.0 bar Actual pressure value A
M003 0.0 .. 300.0 bar Actual pressure value B
M004 -300.0 .. 300.0 bar Actual ram pressure
(evaluated with area ratio and
application)
M005 0.0 .. 300.0 bar Ram pressure
M006 -300.0 .. 300.0 bar System deviation pressure
M007 - 4095 .. 4095 digit P-part  pre s s ure re gula tor
M008 - 4095 .. 4095 digit I-part  pre s s ure re gula tor
M009 -10.0 .. 10.0V Feedback position of ram regulating valve
M010 - 3000.0 .. 3000.0 Difference position of ram
mm
M011 0.0 .. 3000.0 mm Actual position + zero point (scaled)
M012 - 3000.0 .. 3000.0 Actual position (raw value)
mm
M013 0.0 .. 3000.0 mm Position set point
M014 0 Reserve
M015 0.0 .. 200.0 bar Maximum friction when travelling
downwards
M016 0.0 .. 200.0 bar Maximum friction when travelling upwards
M017 0 .. 32000 Stroke counter (M017 * 100)
Controlled movement of discharge flap
M018 -10.0 .. 10.0V Output prop. valve EKL
M019 -10.0 .. 10.0V Test signal EKL
M020 0 Reserve
M021 0 Reserve
iRAM
71
Measuring Range of values Meaning

point
M022 Messages
Bit 0: Not ready for operation
Bit 1: Error position sensor
Bit 2:
Bit 3:
Bit 4:
Bit 5: Error Profibus
Bit 6: Flap active
Bit 7:
Bit 8:
Bit 9:
Bit 10:
Bit 11:
Bit 12:
Bit 13:
Bit 14:
Bit 15: Error in error memory
M023 Inputs and outputs SPCc 5
Bit 0 .. 7 : input 1 .. 8
Bit 8 .. 15 : output 1 .. 8
M024 Profibus-DP inputs (only active when parameter P001 = Bit 1)
M025 Profibus-DP outputs
iRAM
72
10.4 Data logger

Jumper settings, IDC32 DIL switches
Settings Settings
Function Meaning
ex-works On-site
DIL switch S3 S3.1: trigger initial start = ON Switch S3.4 = ON ON

S3.2: activate download = ON Switch S3.1 - S3.3 = OFF
S3.3: Baud rate CAN-Bus 500 OFF
kB = ON
250kB = ON
CAN interface S1  CAN a ddre s s Low Byte User address: 0 2
(HEX) Mode: Master
ON
S2  CAN a ddre s s High Byte J3 = ON
(HEX)
J 3 = CAN-Bus terminating
resistor
interface for J1 and J2 J1, J2 = SSI
digital preselection of SSI or SST
sensors (start / stop)
Analogue Voltage ranges are set via J4, J5, J6, J7 = OFF J6 = ON
inputs software.
For current signals:
Channel 1:
0.. 20 mA at J4 = ON
Channel 2:
0 .. 20 mA at J5 = ON
Channel 3:
0 .. 20 mA at J6 = ON
Channel 4:
0 .. 20 mA with J7 = ON
Analogue The current output is set via Current output:
outputs software from 200 mA to 1000
mA
iRAM
73
10.5 PROFIBUS-DP data exchange list
Application : Ram pressure control for internal mixer

Controller : SPCc 5
Programme : SPCc5001v0
Dated : 17-Nov-11
EMG is always the slave on the PROFIBUS-DP network.
Data Range of Data

Name type values word
Digital inputs binary
Ram UP - slow Bit 0 0/1 DW 0
Ram UP - fast Bit 1 0/1 DW 0
Ram DOWN - slow Bit 2 0/1 DW 0
Ram DOWN - fast Bit 3 0/1 DW 0
Pressure control ON Bit 4 0/1 DW 0
Position control ON Bit 5 0/1 DW 0
Floating ON Bit 6 0/1 DW 0
With ramp set point for position control Bit 7 0/1 DW 0
Discharge flap UP - slow Bit 8 0/1 DW 0
Discharge flap UP - fast Bit 9 0/1 DW 0
Discharge flap DOWN - slow Bit 10 0/1 DW 0
Discharge flap DOWN - fast Bit 11 0/1 DW 0
Acknowledgement (fall back function Bit 12 0/1 DW 0
counter)
Set zero point of actual position value Bit 13 0/1 DW 0
Gain switching pressure regulator Bit 14 0/1 DW 0
Lock local operation for ECU 01 (optional) Bit 15 0/1 DW 0
Analogue inputs
Pressure set point integer 0 .. 3000 digit DW 1
[0.1 bar]
Position set point integer 0 .. 10000 digit DW2
[0.1mm]
P-gain position controller integer 5 .. 100 digit DW 3
[0.1]
I-part position controller integer 0.. 30000 digit DW 4
[1ms]
Q-control, down fast integer 0.. 100 digit DW 5
(If "0" is specified, the internal value is [1%]
effective)
iRAM
74
Data Range of Data

Name
type values word
Digital outputs binary
Remote ON (ECU 01) Bit 0 0/1 DW 0
Ready for operation Bit 1 0/1 DW 0
Pressure control active Bit 2 0/1 DW 0
Position control active Bit 3 0/1 DW 0
A-T valve UP Bit 4 0/1 DW 0
Pressure control for position control Bit 5 0/1 DW 0
active
Floating active Bit 6 0/1 DW 0
Discharge flap active Bit 7 0/1 DW 0
Pressure sensors ok Bit 8 0/1 DW 0
Position sensor ok (if available) Bit 9 0/1 DW 0
Regulating valve ok Bit 10 0/1 DW 0
Contamination level reached Bit 11 0/1 DW 0
Fall back function more than ... function Bit 12 0/1 DW 0
off
Actual position value is reset to zero Bit 13 0/1 DW 0
Initial start has been triggered (5s pulse) Bit 14 0/1 DW 0
1 Hz flashing cycle (life sign) Bit 15 0/1 DW 0
Analogue outputs
integer 0 .. 3000 digit DW 1
Applied pressure [0.1 bar]
integer 0 .. 3000 digit DW2
Actual pressure value of piston surface [0.1 bar]
integer 0..30000 digit DW 3
Actual pressure value of ring surface [0.1 mm]
integer -1000 .. 1000 DW 4
Output final amplifier analogue in % digit
[0.1 %]
integer 0 .. 30000 digits DW 5
Cylinder actual position [0.1 mm]
Active pressure set point [0.1 bar]
iRAM
75
Data Range of Data

Name
type values word
Active position set point [0.1mm]
integer -1000 .. 1000 DW 8
Actual value ram valve digit
[0.1 %]
P-gain position controller [0.1]
integer 0.. 30000 digit DW 10
I-part position controller [1ms]
Index parameter (step every 100ms) integer 1 .. 100 DW 11
integer 0.. XXXX digit DW 12
Parameter according to the index
iRAM

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Manual

Verbesserungsvorschläge, die dieses Handbuch betreffen, nehmen wir gerne entgegen.

Harburg-Freudenberger Maschinenbau GmbH

Telefon (02734) 491 - 0 (Zentrale)

Telefax (02734) 491 - 150 (Vertrieb Neumaschinen)

Phone +49 (0)2734 491 -108

Printed in the Federal Republic of German

1 Product Description ....................................................................................................... 5

5.3 Keyboard and display unit ECU 01 ......................................................................... 22

1.1 Brief system description

The pressure sensors are used to continuously measure the change of

1.2 Ram control functional description

1.2.1 Q-control of ram movement

1.2.2 Floating for ram

1.2.3 Ram pressure control

1.2.4 Ram position control

alteration of the pressure set point is stopped. If the position value of

Adjusting the zero point of the stroke transducer

1.2.5 Contamination of the ram

1.2.6 Fall back function for ram

1.3 Operating modes

1.4 Intended purpose

1.5 Technical data of the complete system

Operating voltage: 110 .. 230 VAC (-15 ..+10 %) 50/60 Hz

1.6 SPCcompact 5 controller

Please observe the component description for the SPCcompact 5 controller!

"Online Test" Option

Examples of possible modular extensions:

1.7 Controller IDC32

Please observe the IDC32 component description!

"Online Test" Option

Improper work on the strip guiding system components

2.1 General regulations

This documentation contains the information which is required for

Only if this documentation is fully observed will the manufacturer’s

2.2 Correct utilisation

2.3 Non-compliance with the safety regulations

2.4 Fundamental safety precautions

2.5 Local legislation, directives and regulations

2.7 Structure and meaning of the references

Refers to a dangerous situation which will result in death or serious

Refers to a dangerous situation which can result in death or serious

Refers to a potentially dangerous situation which can result in minor to

Refers to a situation which can result in damage to property.

2.8 Graphic reference symbols

Caution! Caution! Caution! Caution!

Caution! Caution! General hazard Caution!

Caution! Caution! Wear a helmet Wear ear and

Wear protective Wear gloves!

2.9 General safety regulations

2.9.2 Removal of safety guards

2.10 Specific safety regulations

2.10.1 Mechanical hazards

Sharp Edges and Moving Parts

2.10.2 Electrical hazards

2.10.3 Hydraulic hazards

2.11 Responsibilities and qualification requirements

2.11.1 Authorised personnel/qualified employees

The supplied equipment may only be transported, installed, connected,

Qualified persons are those who:

For regulations and definitions concerning qualified personnel, see

2.12 Duty of notification in the case of malfunctions and

2.13 Necessary protective clothing