Electric

Press-fitting
Unit

Electronics

Maintenance
Guide
Updated October 2020
V6A
 ®
MVAT is a trademark of FABRICOM Systèmes d'assemblage.
Other trade names are the property of their respective owners.

Warning:
FABRICOM Systèmes d'assemblage S.A. reserves the right to modify all or part of the technical
contents of this document without prior notice. FABRICOM Systèmes d'assemblage S.A.
declines all liability in the event of use of this document by a third party. Divulging the contents
of this document for any purposes whatever shall in no way constitute a user's license and shall
not be assumed to provide protection or guarantees to the user. In accordance with the Law
of 11 March 1957 (art.40-1°,41-2°,41-3°), reproduction, quotation from or use of all or part of this
document is subject to the prior written consent of:
FABRICOM Systèmes d'assemblage S.A.
10, rue La Fayette
Z.A.C. La Fayette, BP 1565
F 25 009 BESANCON Cedex 3

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 SOMMAIRE
1 Presentation of Equipment............................................................................................................ 6
1.1 FABRICOM Spindles - Dimensions 6
1.1.1 UE1500/B C… R Spindle 6
1.1.2 UE3000/B C… R Spindle 7
1.1.3 NG50kN365D/B C500, NG100kN365D/B C500, NG150kN220D/B C500,
NG200kN145D/B C500 Spindles 8
1.1.4 UG05kN330C300/B Spindle 9
1.1.5 UG15kN525C300/B to C500/B Spindle 10
1.1.6 UG30kN460C300/B to C500/B Spindle 11
1.1.7 UG60kN700C300/B to C500/B Spindle 12
12
1.1.8 UG100kN370C300/B to C500/B Spindle 13
1.1.9 Travel & position definition table 14
1.2 INFRANOR Servo-drive - CD1-a Type 16
1.2.1 Overview 16
1.2.2 Assignment Table 16
1.2.3 Dimensions 17
1.3 FABRICOM MVAT Servo control Electronics 18
1.3.1 Control Panels 18
1.3.2 Explanation of Indicator Lights on MVAT M2C control Panel 19
1.3.3 Dimensions 20
1.4 Equipment Part Numbers 21
1.4.1 OG Spindles (Old Generation): UE1500/B C…R to UE3000/B C…R. 21
1.4.2 NG Spindles (50kN to 200kN) 21
1.4.3 UG Spindles (2kN to 100kN) 21
1.4.4 MMT Spindles (200kN to 1000kN) 22
1.4.5 MVAT Electronics 23
1.4.6 FSA/INFRANOR part Numbers (Drives, motors and accessories) 23
1.4.7 Operating Panel Part numbers (UExp-MVAT and accessories) 23
1.4.8 Cables 24
1.5 Recommendations – Limits of Use 25
1.6 Handling the Spindles 25
2 Connection Diagram .................................................................................................................. 26
3 Preventive Maintenance ............................................................................................................ 27
3.1 Mechanical maintenance of UE type spindles (UE1500/B to UE10000/B) 27
3.2 Lubrication of UE type spindles (UE 1500/B à UE10000/B) 27
3.3 Mechanical maintenance of NG type spindles (50kN to 200kN) 28
3.4 Lubrication of NG type spindles (50kN to 200kN) 28
3.5 Mechanical maintenance of UG type spindles (5kN to 100kN) 28
3.6 Lubrication of UG type spindles (5kN to 100kN) 29
3.6.1 UG05 spindle 29
3.6.2 UG15 to UG100 spindle 29
3.6.3 Grease quantites 30
3.6.4 Greasing procedure 30
3.7 Electrical Maintenance 31
3.8 Screw Lubricator Positioning 31
3.8.1 Spindle Type UE or NG: 31
3.8.2 Spindle Type UG 31
4 Checks before the first Power ON ............................................................................................. 32
4.1 Checking cables 32
4.2 Checking the grounding 32
4.2.1 Spindle 32
4.2.2 MVAT 32

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 4.2.3 Drive 32
4.3 Checking the motor wiring 32
5 First Power ON .............................................................................................................................. 33
5.1 Power supply Voltage 33
5.2 Infranor SMTBD1 or CD1-A drive 33
5.3 MVAT Rack 33
5.4 MVAT controller 34
5.5 Equipment Validation 34
5.6 Getting the MVAT rack identification # 35
6 Replacing Equipment .................................................................................................................. 36
6.1 Equipment replacement Synoptic 36
6.2 Replacing the INFRANOR rack (only for SMTBD1 type) 37
6.3 Replacing the INFRANOR Variable Speed Drive (VSD) 37
6.3.1 Case of SMT-BD1 drive: hardware configuration before replacement 37
6.3.2 Replacing the INFRANOR Variable Speed Drive (VSD) 38
6.4 Replacing the MVAT Rack 38
6.5 Replacing the MVAT PW8M Power Supply 38
6.6 Replacing MVAT M2C EP controller board 39
6.7 Replacing the Spindle 39
6.8 Equipment validation 40
6.9 Setting the Drive 41
6.9.1 Loading the parameter file ( xxxxx.par) 41
6.9.2 Offset Compensation (for speed reference) 41
6.9.3 Auto-tuning 44
6.9.4 Encoder Resolution 46
6.9.5 Ending Auto tuning procedure 46
6.9.6 Index Centering by Zero pulse shifting 47
6.9.7 Ending the drive setting 48
6.9.8 Saving the new parameter file (xxxxx.par) 48
6.10 Activate the Enable signal of the Drive 49
6.10.1 Case #°1 : PC with Rhapsodie.Net directly connected on MVAT board 49
6.10.2 Case #°2 : A UExp-MVAT panel is used on the station 49
6.11 Calibration (of the scaled displacement axis) procedure 51
6.11.1 Calibration in compression mode 51
6.11.2 Procédure d'Etalonnage de la machine en traction 52
6.12 Deleting programs of MVAT board 53
7 Replacing particular parts of Old Spindles ............................................................................... 54
7.1 1.5 Tons Spindle : UE1500/B 55
7.1.1 Replacing the spindle motor 55
7.1.2 Replacing the Spindle Motor Coupling 56
7.2 3 Tons Spindle : UE3000/B 57
7.2.1 Replacing the Spindle motor 57
7.3 Spindles: 5 Tons - UE5000/B, 7,5 Tons - UE7500/B and 10 Tons - UE1000/B 58
7.3.1 Replacing the Spindle motor 58
7.3.2 Replacing the belt 59
7.3.3 Tension of the belt 61
7.3.4 Replacing the encoder 62
7.4 Spindles NG15kN to NG200kN 63
7.5 Spindles UG (5kN to 100kN) 63
7.6 Replacing other components 63
8 Recommendations ...................................................................................................................... 64
8.1 Electrical equipment 64
8.2 Electrical Wiring 64
8.3 Mechanical frame and compliance 66
8.4 Serviceability limit 66

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 8.5 Automatism 66
8.6 Safety 67
9 "Maintenance" sheet in "Specifications" page of Rhapsodie.Net ......................................... 68
10 Execution journal ......................................................................................................................... 70
11 Keyboard Commands (Reserved for the use of FABRICOM Customer Support)................. 71
11.1 "Esc +…" Commands 71
11.2 Direct Commands 74
12 Distance and Speed Diagram ................................................................................................... 76
13 Acquisition and Press-Fitting: Example ..................................................................................... 78
14 Glossary ........................................................................................................................................ 86
15 Analysis of malfunctions when first switched on ...................................................................... 87
16 List of faults ................................................................................................................................... 88
17 Analyse des défauts Contrôle Courbe ..................................................................................... 95
18 ELECTRICAL DRAWINGS ............................................................................................................... 97

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 Presentation of the Equipment

1 Presentation of Equipment
1.1 FABRICOM Spindles - Dimensions
1.1.1 UE1500/B C… R Spindle
517 + course

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 Presentation of the Equipment

1.1.2 UE3000/B C… R Spindle

517 + Course

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 Presentation of the Equipment

1.1.3 NG50kN365D/B C500, NG100kN365D/B C500, NG150kN220D/B C500,

NG200kN145D/B C500 Spindles

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 Presentation of the Equipment

1.1.4 UG05kN330C300/B Spindle

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 Presentation of the Equipment

1.1.5 UG15kN525C300/B to C500/B Spindle

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 Presentation of the Equipment

1.1.6 UG30kN460C300/B to C500/B Spindle

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 Presentation of the Equipment

1.1.7 UG60kN700C300/B to C500/B Spindle

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 Presentation of the Equipment

1.1.8 UG100kN370C300/B to C500/B Spindle

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 Presentation of the Equipment

1.1.9 Travel & position definition table

The dimensions given below have an accuracy of +/- 1mm
In the table below, "C" means the rated spindle stroke

Positions Comments UE1500/B UE3000/B NG50kN NG100kN NG150kN NG200kN UG05 UG15 UG30 UG60 UG100
TOP-1 Normal rear position of
(PR) the axis in automatic
mode. Corresponds to
the 1st resolver pulse 60 60 72 72 72 72 50,5 56,5 56 75,5 79
reached during axis
retraction, after axis
detection.
INDEX Rear position of the axis in
manual mode.
Corresponds to the point
63,5 64 77 77 75 74 53 60 60 83 83
where the rear position
detector switches to "1"
during axis retraction.
TDC Rear position of the axis
from which it is possible to
67 68 82 82 78 76 55,5 63,5 64 90,5 87
set any accurate axis stop
position.
Lower Corresponds to the max.
Safety possible axis extension 60+C 60+C 72+C 72+C 74+C 72+C 50,5+C 56,5+C 56+C 75,5+C 79+C
Point that can be selected.
BDC Corresponds to the
maximum possible 60+C 60+C 589 589 589 589 50,5+C 56,5+C 56+C 75,5+C 79+C
physical axis extension.

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 Presentation of the Equipment

Diagram showing the using Travel:

Generally, after servo-drive setup, the position of the index is centered between the TOP-1 and
the TDC.

TOP-1 (Idle Position in automatic mode)

Index (Idle Position in manual mode)
TDC (start of effective operating range)

Rated travel Usable Travel

Lower Safety Point (lower limit ofusable

operating range)

BDC (End of the usable operating range)

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 Presentation of the Equipment

1.2 INFRANOR Servo-drive - CD1-a Type

1.2.1 Overview

1.2.2 Assignment Table

List of Servo-drive used for the Electric Press-Fitting Units.

NG50 NG100 NG150 NG200

Unit Type UE1500 UE3000
kN kN kN kN
UG05 UG15 UG30 UG60 UG100

CD1 drive
70 70 70 100 100 100 7,2 45 45 90 90
current (A)

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 Presentation of the Equipment

1.2.3 Dimensions
Drive:

Discharging Resistor

52

40 145

278
290

Main Filter (only for CD1 90 and 100 A)

60

40 88

218

229

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 Presentation of the Equipment

1.3 FABRICOM MVAT Servo control Electronics

1.3.1 Control Panels

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 Presentation of the Equipment

1.3.2 Explanation of Indicator Lights on MVAT M2C control Panel

RS 232 - 38 400 bauds

 Display Terminal
RS 485 - 115 200 bauds
 Courbe sending
 Parameter receiving
Secured Communication Protocol

CPU board lights Communication board lights

Watchdog RS 232 data reception

Fault RS 232 data transmission

Cycle NOK RS 485 PC reception

Cycle OK RS 485 PC reception invalidated

Multiplexing RS 485 PC transmission active

Cycle running RS 485 MVAT reception

Ready Line MONOW1 active

Battery low Line MONOW2 active

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 Presentation of the Equipment

1.3.3 Dimensions
A clearance of at least 100mm must be left above and below the MVAT rack for the
connectors. In front face, 80mm are needed left for the communication cables.

Top view
Control - 37 pts HD

Com1 - RS232
Com2 - RS485

Measurement-15 pts HD

Bottom view

Inputs/Outputs - 26 pts HD

Travel- 9 pts

240 V power supply

── 182 ──
── 199 ──
For the compact 2 channels version
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 Presentation of the Equipment

1.4 Equipment Part Numbers

X Please check your equipment to keep in memory.

1.4.1 OG Spindles (Old Generation): UE1500/B C…R to UE3000/B C…R.

Rated Force Max Speed Sensor rated Drive type Index Centering
Part Number
(kN) (mm/s) Force (kN)
Motor type
(A/A) (mm)
x
UE 1500/B C300 R 15 400 15KN BLS115 35/70 3,5
UE 1500/B C500 R 15 400 15KN BLS115 35/70 3,5
UE 3000/B C300 R 30 360 30KN BLS144 35/70 4
UE 3000/B C500 R 30 360 30KN BLS144 35/70 4

1.4.2 NG Spindles (50kN to 200kN)

Rated Force Max Speed Sensor rated Drive type Index Centering
Part Number
(kN) (mm/s) Force (kN)
Motor type
(A/A) (mm) x
50KN365D/B C500 50 365 100KN BLS192 35/70 5
100KN360D/B C500 100 360 200KN BLS192 35/100 5
150KN210D/B C500 150 210 200KN BLS192 35/100 3
200KN140D/B C500 200 145 200KN BLS192 35/100 2

1.4.3 UG Spindles (2kN to 100kN)

Rated Force Max Speed Stroke Sensor rated Drive type Index Centering
Part Number
(kN) (mm/s) (mm) Force (kN)
Motor type
(A/A) (mm) x
UG02kN660C300/B 300
2 660 3 FSA UG05 3,6/7,2 5
UG02kN660C500/B 500
UG05kN330C300/B 300
5 330 7,5 FSA UG05 3,6/7,2 2,5
UG05kN330C500/B 500
UG15kN525C300/B 300
525
UG15kN525C500/B 15 500 20 FSA UG15 20/45 3,5
UG15kN525C800/B 460 800
UG30kN460C300/B 300
UG30kN460C500/B 30 460 500 40 FSA UG30 20/45 4
UG30kN460C800/B 800
UG60kN700C300/B 300
FSA
UG60kN700C500/B 60 700 500 100 35/90 7,5
UG100
UG60kN700C800/B 800
UG80kN460C300/B 300
FSA
UG80kN460C500/B 80 460 500 100 35/90 5
UG100
UG80kN460C800/B 800
UG100kN370C300/B 300
FSA
UG100kN370C500/B 100 370 500 100 35/90 4
UG100
UG100kN370C800/B 800

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 Schéma de raccordement

1.4.4 MMT Spindles (200kN to 1000kN)

Rated Force Max Speed Sensor rated Drive type Index Centering x
Part Number Motor type
(kN) (mm/s) Force (kN) (A/A) (mm)
MMT200kN900D600/B 200 900 300 PH1700 250/310 20
MMT300kN790D600/B 300 790 400 PH1700 250/310 17,5
MMT400kN560D600/B 400 560 500 PH1700 250/310 12,5
MMT500kN450D600/B 500 450 600 PH1700 250/310 10,0
MMT600kN335D600/B 600 335 750 PH1700 250/310 7,5
MMT800kN220D600/B 800 220 1000 PH1700 250/310 5,0
MMT1000kN175D600/B 1000 175 1200 PH1700 250/310 4,0

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 Presentation of Equipmentt

1.4.5 MVAT Electronics

Designation Part Number x Other Part # (check on equipment) x
Rack NPN 1 channel 3U 42E PLA EP 02/1 3U 42E PLA EP +Serial Number
Rack NPN 2 channels 3U 42E PLA EP 02/2
Rack NPN 3 channels 3U 42E PLA EP 02/3
Rack NPN 4 channels 3U 42E PLA EP 02/4
Rack NPN 5 channels 3U 42E PLA EP 02/5
Rack NPN 6 channels 3U 42E PLA EP 02/6
Rack PNP 42E 1 channel 3U 42E PLA EP 03/1
Rack PNP 42E 2 channels 3U 42E PLA EP 03/2
Rack PNP 42E 3 channels 3U 42E PLA EP 03/3
Rack PNP 42E 4 channels 3U 42E PLA EP 03/4
Rack PNP 42E 5 channels 3U 42E PLA EP 03/5
Rack PNP 42E 6 channels 3U 42E PLA EP 03/6
Rack PNP 28E 1 channel 3U 28E PLA EP 03/1
Rack PNP 28E 2 channels 3U 28E PLA EP 03/2
Power Supply MVAT PW8M
Control Card (Firmware < V10) MVAT M2C EP
Control Card (Firmware ≥V10) MVAT M2C EP EXT
Fieldbus Interface Profibus MVAT.Net Profibus
Fieldbus Interface Ethernet I MVAT.Net Ethernet ModBus/TCP
Fieldbus Interface Ethernet II MVAT.Net Ethernet/IP
Fieldbus Interface Profinet IRT MVAT.Net Profinet IRT

1.4.6 FSA/INFRANOR part Numbers (Drives, motors and accessories)

Designation Part Number x Other Part # (check on equipment) x
SMT Rack BF 400-45/2.2.E V01 FSA
SMT Drive 30/60 SMT-BD1/1A 400/60 r-T-BS FSA
SMT Drive 50/100 SMT-BD1/1A 400/100 r-T-BS FSA
SMT main Filter F 400/45A F 400/70A
SMT Discharging Resistor Ef/400V
CD1 Drive 3,6/7,2 CD1A 400/7,2 FSA
CD1 Drive 20/45 CD1A 400/45 FSA
CD1 Drive 35/70 CD1A 400/70-E 2X33/280 FSA
CD1 Drive 35/90 CD1A 400/90-E 2X33/280 FSA
CD1 Drive 35/100 CD1A 400/100-E PCD1-29 FSA
CD1 Drive 3,6/7,2 opt STO CD1A 400/7,2 STO FSA
CD1 Drive 20/45 opt STO CD1A 400/45 STO FSA
CD1 Drive 35/70 opt STO CD1A 400/70-STO E 2X33/280 FSA
CD1 Drive 35/90 opt STO CD1A 400/90-STO E 2X33/280 FSA
CD1 Drive 35/100 opt STO CD1A 400/100-E STO PCD1-29 FSA
CD1 Main Filter F 400/70A F 400/90A
Spindle Motor BLS 115 BLS 115 00 310E FSA
Spindle Motor BLS 144 BLS 144 00 310E FSA BLS 144V 00 310E FSA (fan)
Spindle Motor BLS 192 BLS 192 00 310E FSA
1.4.7 Operating Panel Part numbers (UExp-MVAT and accessories)
Designation Part Number x Other Part # (check on equipment) x
MVAT Webserver UExp-MVAT
Operating screen on Station Pan-MVAT
USB for Webserver USBKey-MVAT

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 Presentation of Equipmentt

1.4.8 Cables
« XX » has to be replaced by the required length.
« YY » has to be replaced by the required length among 5-10-15-20-25 m.
X Please check your equipment to keep in memory.

Power Cables (spindle motor  drive) Part Number X

Cable set (power+resolver) for BLS144 motor 144C 18/21 LGXXm FSA
For Spindle UG02kN and UG05kN MVAT CAB/PU EPUG0 LGXXm
For Spindle UG15kN and UG30kN MVAT CAB/PU EPUG1 LGXXm
For Spindle UG60kN, UG80kN and UG100kN MVAT CAB/PU EPUG2 LGXXm
For Spindle MMT MVAT CAB/PU EPMMT LGXXm

Resolver Cables (spindle motor  drive) Part Number X

For SMT-BD1 A drive only MVAT CAB/RES EP LGXXm
For Spindle UG02kN, 05, 15, 30, 60, 80, 100kN MVAT CAB/RES EPUG LGXXm

Encoder Cable (Spindle  drive) Part Number

For side-motor spindle only MVAT CAB/COD EP LGYYm
For MMT spindle MVAT CAB/COD EPMMT LGXXm

Control Cable (MVAT  drive) Part Number X

For SMT-BD1 A drive MVAT CAB/COM EP LG1,5m
For CD1-A drive (spindle with coaxial-motor)(NOT UG spindle) MVAT CAB/COM EP2 LG3m
For CD1-A drive (spindle with side-motor OR UG spindle) MVAT CAB/COM EP3 LG3m

Measurement Cable (Spindle MVAT) Part Number X

Standard MVAT CAB/MES EP LGXXm
Adaptor for Multi-Index box MVAT CAB/RAL EP LGXXm

Inputs/Outputs Cable (MVAT  P.L.C.) Part Number X

For MVAT rack type 02 (subD26HD  wires) MVAT CAB/ES2 EP LG3m
For MVAT rack type 02 or 03 Fieldbus (subD26HD  wires) MVAT CAB/ESP EP LG3m
For MVAT rack type 02 or 03 Fieldbus (subD26HD SubD26HD) MVAT CAB/ESP EP1 LG3m
For MVAT rack type 02 or 03 Fieldbus Multi-index (subD26HD wires) MVAT CAB/ESI EP LG3m

Communication cables
Com Communication Connection Connection Part number X
type Equipment type MVAT side equip. side
RS232 NI
ACKSYS Mini Din-9 M SubD-9 F MVAT CAB/232 LGYYm
ADV. EKI1522 et 1524
RS232 ADV. EKI 1526 et 1528 Mini Din 9 M RJ45 MVAT CAB/232 AD6/8 LGYYm
RS485 NI Mini Din-9 M SubD-9 F MVAT CAB/485 LGYYm
RS485 ACKSYS 2 channels Mini Din-9 M SubD-9 M MVAT CAB/485 A2 LGYYm
RS485 ACKSYS 4/8 channels Mini Din 9 M SubD-25 F MVAT CAB/485 A4/8 LGYYm
RS485 ADV. EKI 1522 et 1524 Mini Din 9 M SubD-9 M MVAT CAB/485 AD LGYYm
RS485 ADV. EKI 1526 et 1528 Mini Din 9 M RJ45 MVAT CAB/485 AD6/8 LGYYm
RS232  RS485 Advantech convertor AD400E FSA MVAT CAB/485 AD400E LG0,065m

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 Maintenancet

1.5 Recommendations – Limits of Use

This system should not be used in situations where it is subjected to impacts.

You are advised not to use the operating range above PLS-1 for returning to idle position.

You are advised not to extend the axis fully out without using a mechanical stop device.
In the manual mode, the "Manual Current" which is programmed in RHAPSODIE have to be
very low to avoid destruction (5% is recommended)

1.6 Handling the Spindles

The lifting rings are provided fixed on the spindle. In order to avoid spindle destruction, it has to
be handled with a synthetic sling supporting 500kg minimum (for all spindles except MMT
spindles which require 1000Kg minimum). This sling has to be shackled on the 2rings and
handled high over the motor by the hang of the lift equipment. The lifting rings haven’t to be
released or replaced.

Important:
If lifting rings are missing, it is strongly recommended to use and mount the following fixtures:
NORELEM 07750-10 or CODIPRO DSR M10 (tighten at 30Nm).

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 Maintenancet

2 Connection Diagram
Note: it is truly essential to wire ALL grounding connections (motor  rack  cabinet  ground).

Force signal + Index

Resolver

Power

Position Emulation 

 Control
Spindle

Power Amplificator :

INFRANOR

Monitoring (RS232) FSA control electronics:

MVAT® rack

Parametering and curve

reception (RS485)

24V API –PLC

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 Maintenancet

3 Preventive Maintenance
3.1 Mechanical maintenance of UE type spindles (UE1500/B to UE10000/B)
Item Action Machine status Time Frequency Tools
required required
Check Allen
Sleeve Off 00:01:00 Annual
attachment wrench
Front bearing scraper Visual
Check condition Off 00:00:30 Annual
seal Check

NB: The press-fitting unit must be returned to us every 8000 operating hours for inspection and
complete lubrication change

3.2 Lubrication of UE type spindles (UE 1500/B à UE10000/B)

Part to be lubricated Type of lubricant Machine status Frequency Quantity Tools
required

ISOFLEX TOPAS Every 2000

1: Bearing Off 5 cm3 Pump
NB152 grease H
2: Satellite roller screw ISOFLEX TOPAS Every 2000 See table
Off Pump
nut NB152 grease H below
The lubricators are shown on the spindle dimension drawings.
To access to the lubricator of the satellite roller screw nut, the shaft of the spindle should be at
the right position. Use jog mode to put the lubricator in front of the lubrication hole present in
the sleeve.
NB: The press-fitting unit must be returned to us every 8000 operating hours for inspection and
complete lubrication change

Quantities of grease to be used to lubricate the screw nut:

Type of Spindle Travel (mm) Required quantity of grease in cm3
UE 1500/B 300 4
UE 1500/B 500 4
UE 3000/B 200 6
UE 3000/B 300 6
UE 3000/B 500 6
UE 5000/B 500 35
UE 7500/B 500 35
UE 10000/B 500 35
UE 10000/B 600 35

It is essential to scrupulously respect the quantities and grease type specified for lubrication, as
this will invalidate the warranty.

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 Maintenancet

3.3 Mechanical maintenance of NG type spindles (50kN to 200kN)

Part to be lubricated Type of lubricant Machine status Time Frequency Tools
required required
Check Allen
Sleeve Off 00:01:00 Annual
attachment wrench
Splined shaft guide Visual
Check condition Off 00:00:30 trimestral
Bushing check

NB: The press-fitting unit must be returned to us every 8000 operating hours for inspection and
complete lubrication change

3.4 Lubrication of NG type spindles (50kN to 200kN)

Part to be lubricated Type of lubricant Machine Frequency Quantity Tool
status required
1 : Splined shaft guide ISOFLEX TOPAS NB152
Off trimestral 100 cm3 Pump
Bushing grease
2 : Satellite roller screw ISOFLEX TOPAS NB152
Off trimestral 45 cm3 Pump
Nut grease

The lubricators are shown on the spindle dimension drawings.

To access to the lubricator of the satellite roller screw nut, the shaft of the spindle should be at
the right position. Use jog mode to put the lubricator in front of the lubrication hole present in
the sleeve.
NB: The press-fitting unit must be returned to us every 8000 operating hours for inspection and
complete lubrication change

3.5 Mechanical maintenance of UG type spindles (5kN to 100kN)

Part to be lubricated Type of lubricant Machine status Time required Frequency Tools
Check Allen
Sleeve Off 00:01:00 Annual
attachment wrench
Splined shaft guide Visual
Check condition Off 00:00:30 trimestral
Bushing check

NB: The press-fitting unit must be returned to us every 8000 operating hours for inspection and
complete lubrication change

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3.6 Lubrication of UG type spindles (5kN to 100kN)

PAY ATTENTION : For all the UG range, before greasing, the rod has to be completely IN (on
index or TOP-1 position)
3.6.1 UG05 spindle
Part to be lubricated Type of lubricant Machine Frequency Quantity Tool required
status
1 : Splined shaft guide See
SKF LGHP 2 grease Off monthly Manual Pump
Bushing table
2 & 3 : (combined)
- Satellite roller screw ISOFLEX TOPAS See
Nut Off monthly Manual Pump
NB152 grease table
- Thrust bearing
(Rear bearing)

3.6.2 UG15 to UG100 spindle

Part to be lubricated Type of lubricant Machine Frequency Quantity Tool required
status
1 : Splined shaft guide See
SKF LGHP 2 grease Off monthly Manual Pump
Bushing table
2 : Satellite roller screw ISOFLEX TOPAS See
Off monthly Manual pump
Nut NB152 grease table
3 : Thrust bearing See
SKF LGHP 2 grease Off monthly Manual Pump
(Rear bearing) table

The lubricators are shown on the spindle dimension drawings.

NB: The press-fitting unit must be returned to us every 8000 operating hours for inspection and
complete lubrication change

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3.6.3 Grease quantites

It is essential to scrupulously respect the quantities and grease type specified for lubrication, as
this will invalidate the warranty.
Quantities of grease to be used to lubricate the screw nut and the thrust bearing (for indication,
depends of the frequency of the greasing):
Type of Spindle Travel 1 : SHAFT GUIDE 2 : SCREW NUT 3 : THRUST BEARING
(mm) Required qty of Required qty of Required qty of
grease in cm3 grease in cm3 grease in cm3
UG 05kN330C300/B 300 20 1 0
UG 15kN525C300/B 300 50 4 2
UG 15kN525C500/B 500 50 4 2
UG 30kN460C300/B 300 50 6 6
UG 30kN460C500/B 500 50 6 6
UG 60kN700C300/B 300 100 12 15
UG 60kN700C500/B 500 100 12 15
UG 100kN370C300/B 300 100 35 15
UG 100kN370C500/B 500 100 35 15
UG 100kN370C800/B 800 100 35 15

3.6.4 Greasing procedure

IMPORTANT : Greasing application procedure

1) Move the rod completely IN (index or Top-1 position)
2) Connect the grease plug of the pump to the grease nipple of the spindle
3) Pump slowy without force and STOP pumping as soon as you feel a resistance
4) Disconnect the pump
5) Move the shaft of the spindle in jog mode 5 to 10 times, to spread correctly the grease
6) Go back to 2) and make point until 4)

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3.7 Electrical Maintenance

Item Action Machine Required Frequency Tool
status time required
ARMOIRE
Functional test (checks that Production
Emergency Stop 00:00:30 Monthly
station effectively stops) Off
Manually check attachment Every 3 Screwdriv
Grounding Strip Power Off 00:01:00
and connections tightened months er
Check and ensure access is Production
Electrical Cabinet 00:02:00 Monthly
clear On
MACHINE
Check insulation. Check for Production Every 3 Visual
Connecting cables 00:05:00
wear Off months check

3.8 Screw Lubricator Positioning

This section is valid for all type of spindle. Lubricators are shown on the spindle dimension
drawings.
3.8.1 Spindle Type UE or NG:
Release the plastic plug of the sleeve greasing hole. Lubricator appears when the spindle shaft
in at home position.
If not, let move the shaft in jog mode (with PLC HMI)
After lubrication, replace the plug on the sleeve.
3.8.2 Spindle Type UG
For these spindles, the shaft has to be imperatively in home position before greasing (the
greasing of the screw nut is made by the top of the spindle)

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4 Checks before the first Power ON

4.1 Checking cables
Helping with electrical drawings, check the following cables:
- Measurement cable (15 pins male HD MVAT side, Amphenol 10 pins female press side),
- Only for SMTBD1 drive : Encoder cable (9 pins MVAT side , 12 pins female press side)
- Control cable (37 pins male MVAT side, 25 pins female NFRANOR drive side)

4.2 Checking the grounding

4.2.1 Spindle
Check that a grounding braid is connected between the spindle motor and the cabinet (the
shortest possible).
Check the electrical continuity between:
- The ground of cabinet and plant ground
- The spindle sleeve and the spindle motor,
- The spindle sleeve and the frame of the machine,
- The spindle sleeve and the ground of the cabinet.
Check that the shield of the power cable of the motor is well connected, in a circular shape.
4.2.2 MVAT
Check that the ground conductor of the MVAT rack power cable (230V) is well connected to
the ground of the cabinet.
4.2.3 Drive
Check the connection of:
- The ground conductor of the motor power cable on the ground of the drive
- The shield of the motor power cable on the fixture of the drive with a metallic collar.
Check that the motor power cable goes through the ferrite ring fixed on the fixture of the
drive.

4.3 Checking the motor wiring

Check that no motor conductor is inverted (compare drive output: U – V – W and motor input).
Check the motor power conductor insulation: no continuity between conductors and ground.
Check that the discharge resistor match with the drive: ref EF/400V, and that the wiring is
correct (electrical terminals #3, 4, 5 from the drive should be connected directly on the 3, 4, 5
electrical terminals of the discharging resistor).

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5 First Power ON
5.1 Power supply Voltage
Switch on the general breaker of the cabinet.
Check the following voltage:
- MVAT 24V power supply
- MVAT 230V power supply
- INFRANOR rack auxiliary 230V power supply.

Then push the “Power ON” button.

Check the following voltage:
- INFRANOR rack main 400V power supply.

5.2 Infranor SMTBD1 or CD1-A drive

For the SMTBD1 drives, after switching off the general breaker of the cabinet, introduce the
drive into the INFRANOR rack.
Switch ON the general breaker to switch on the auxiliary power supply off the rack (230V for
SMTBD1 drives and 24V for CD1A one).
The 4 LEDs off the drive turn in the clockwise direction. After 5 seconds, only 2 of them
remain on:

Then push the “Power ON” button, to switch ON the INFRANOR 400V main power supply. All the
red LEDs are off, and the green one above remains ON.

WARNING: if the auxiliary supply is switched off, it is essential to wait at least 30 seconds before
switching it on again.
When you switch off the main power supply, it is essential to wait at least 3 minutes before
disconnecting and working on the INFRANOR racks and variable speed drives.

5.3 MVAT Rack

Switch off again the general breaker, introduce into MVAT rack the MVAT power
supply module (MVAT PW8M), wait at least 30 seconds and then switch on the
general breaker.
The 3 green LEDs of MVAT PW8M flash then remain ON.

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5.4 MVAT controller

Do the operation again, but introduce this time the MVAT controller (MVAT M2C) into the MVAT
rack.
At the first power ON, only red LED #2 remains ON (or flashes if no terminal is connected to the
Com1 communication port of the board).
During the next power ON, if no equipment of the MVAT environment (MVAT rack, MVAT board,
Spindle, INFRANOR drive), only green LED #7 remains ON ("MVAT is ready").

5.5 Equipment Validation

Every part of a MVAT insertion unit (MVAT rack, MVAT board, Spindle, INFRANOR drive) is
equipped with an identification component that the MVAT board read at each power on or
at each reset.
When powering-up for the first time or each time a press-fitting unit component is replaced,
the equipment must be validated.
While this validation was not made, the card is blocked! (Red LED #2 ON or flashing)
To do this, open a terminal emulation on the PC (HyperTerminal or puTTY session), connect it to
the RS 232 serial port connected to the MVAT "COM1", then set the communication parameters
as shown below:
- Speed: 38400 bauds,
- Data bits : 8 bits per character,
- Stop bit : 1 stop bit,
- Parity : No parity,
- Flow control Hardware
Then Reset the MVAT. The text below is displayed:
Changement matériel
Châssis ou F P : Nouveau ! (ou "Identique" ou "Différent conforme")
Broche Emmanchement : Nouveau ! (ou "Identique" ou "Différent conforme")
Carte analogique : Identique !
Tiroir de puissance : Nouveau ! (ou "Identique" ou "Différent conforme")
Carte communication : Identique !
Status Tetas : 01 (ou 00)

Confirmer changement ? (O/N) :

Enter "O" for "Yes" then press 

If the message "Absent ou non conforme !" is displayed, the item concerned is either
incorrectly wired or it is not the same type as the replaced item.

- - - - attention - - - -"
Vous modifiez votre configuration matérielle"
Vous pouvez encore abandonner la procédure ! ! "
Confirmer changement ? (O/N) :

Enter "O" for "Yes" then press 

Entrer code d'accès :

Press  since no access code is initially provided

Code d'accès accepté !

Fusiblage OK

-------------------------------------*-------------------------------------
------------------------------------* *------------------------------------
--------------------------------- M V A T ---------------------------------
------------------------------- * U E E A * -------------------------------
----------------------------- F A B R I C O M -----------------------------
-------------------------- Systèmes d'Assemblage --------------------------

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___________________________________________________________________________
V XX.XX i 9 6 0 xx/xx/2000:xx/xx/2000

Ctrl(A) pour accéder au moniteur

Exécution emmanchement
Présence Index (ou Index NOK)
Position Origine NOK (ou OK)
Attente Départ Cycle

At this point, red LED No. 2 goes off and green LED No. 7 goes on. The MVAT board is now ready.

5.6 Getting the MVAT rack identification #

Before transmitting the parameters to the MVAT board using the RHAPSODIE application, the
fields "Rack Identification" and "Channel" must be entered in the "Press" page of the RHAPSODIE
application.

To know the rack identification, just get it from the terminal after a reset:
The following line is displayed, giving identification in red, and channel in blue:

IP = 000.000.004.236.065.170.001

You just have to update this information in Rhapsodie (Unit page: “Rack Identification” and
“Chan #”)

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6 Replacing Equipment
Make sure that the main power supply is switched off before replacing any item.

6.1 Equipment replacement Synoptic

Infranor Rack Infranor Drive Infranor Drive

SMTBD1-A SMTBD1-A
Spindle Motor Encoder
CD1-A

Drive Hardware
Config.

Equipment Validation (Terminal) (p.40)

Loading config file .par (VDsetup) (p.41)

Enable signal activation (Terminal)(p.49) - Offset Compensation and Auto-tuning (VDsetup)(p.41)

Calibration (HMI)

Index centering (shift the Drive Tops) (VDsetup) or rotate encoder (p.46)

Saving config file .par (VDsetup) (p48)

MVAT power MVAT.Net

MVAT Rack MVAT Board
supply Board

Equipment Validation (Terminal) Config.(adr.,

(p.40) name, etc...)

Available only From MVAT

MVAT card
Update ID rack V10 version
deletion
(Rhaps.)
(Rhaps.)

Send Configuration (Rhaps.)

Reset (MVAT)

Send
Programs
(Rhaps.)

Calibration (IHM)

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6.2 Replacing the INFRANOR rack (only for SMTBD1 type)

Switch off the main power supply then disconnect and remove the rack to be replaced. Check
that the part numbers are compatible, then wire the new INFRANOR rack into the electrical
cabinet. Retain the variable speed drive from the old rack and install it in the new rack.
Close the master cut-off in order to energize the INFRANOR 230V auxiliary supply.
The four variable speed drive LEDs light up one after the other in a clockwise
direction. After a few seconds, only 2 of these LEDs remain lit:

Now press the power ON button to energize the INFRANOR 400V main power
supply. All the red LEDs go off. Only the green LED remains on to indicate that the
auxiliary power supply is on.

WARNING: if the auxiliary supply is switched off, it is essential to wait at least 30 seconds before
switching it on again.
When you switch off the main power supply, it is essential to wait at least 3 minutes before
disconnecting and working on the INFRANOR racks and variable speeds drives.

6.3 Replacing the INFRANOR Variable Speed Drive (VSD)

WARNING: Before replacing a defected drive, do not forget to store the original parameters of
the drive, using VDSetup) (see chapter « Saving the drive parameters »)
6.3.1 Case of SMT-BD1 drive: hardware configuration before replacement
Before introducing the Infranor SMTDB1 into its rack, please check and correct the right
configuration of the following jumpers, compare to the following picture:

1234

Only for BLS192

motor

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Jumpers Configuration depending of the motor used:

Spindle without BLS192 Spindle with BLS192 motor
motor
JK Closed Closed
KL Open Open
MN Closed Open
OP Open Closed
E Open Open
F Open Open
G Open Open
0v Open Open
6.3.2 Replacing the INFRANOR Variable Speed Drive (VSD)
Switch off the main power supply then remove the variable speed drive to be replaced. Check
that the part numbers are compatible then install the new INFRANOR variable speed drive in
the rack.
Close the master cut-off in order to energize the INFRANOR 230V auxiliary supply.
The four variable speed drive LEDs light up one after the other in a clockwise
direction. After a few seconds, only 2 of these LEDs remain lit:

Now press the “POWER ON” button to energize the INFRANOR 400V main power
supply. All the red LEDs go off. Only the green LED remains on to indicate that the
auxiliary power supply is on.

WARNING: if the auxiliary supply is switched off, it is essential to wait at least 30 seconds before
switching it on again.
When the main power supply is switched off, it is essential to wait at least 3 minutes before
disconnecting and working on the INFRANOR variable speeds drives.

Then, following the “Equipment Replacement Synoptic”, you must first validate the new
equipment, then parameter the new drive, and then make the calibration of the unit.

6.4 Replacing the MVAT Rack

Switch off the main power supply. Disconnect the MVAT rack and connect the new rack.
Retain the MVAT PW8M power supply and the MVAT M2C EP servo board from the old rack
and install these in the new rack. Wait 30 seconds then close the master cut-off. The 3 green
LEDs of the MVAT PW8M power supply flash then remain on. The LEDs of the MVAT M2C EP servo
board flash then only red LED 2 remains flashing.
The equipment must now be validated and the new rack identification must be entered in the
RHAPSODIE application.

6.5 Replacing the MVAT PW8M Power Supply

Switch off the main power supply. Install a new MVAT PW8M power supply
module in its rack, wait 30 seconds then close the master cut-off.
The 3 green LEDs of the MVAT PW8M power supply flash then remain on.
The LEDs of the MVAT M2C EP servo board flash then only red LED No. 3 and
7 remains on (if “Drive Ready signal” is ON).

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6.6 Replacing MVAT M2C EP controller board

Switch OFF the main power supply, and wait 30 seconds.
Unplug the 2 communication cables from the M2C MVAT card (COM1 and COM2), then
untighten the 2 screws of the board, and release the MVAT board.
Place the new one, tight the 2 screws, and plug the 2 communication cables (BE
CAREFUL, the pins of the connectors are very fragile).
Switch ON the main power supply.
The 3 green LEDs of the MVAT PW8M power supply flash then remain on.
The LEDs of the MVAT M2C EP servo board flash then only red LED #2 remains on. (Or
keep on flashing if terminal is connected on COM1).
Then you must proceed successively to:
- Equipment validation (See §5.5 Equipment Validation p34),
- Send the configuration only from the MVAT board #1 (channel 1) (See Rhapsodie
guide)
- Reset (white button MVAT power supply)
And when the MVAT card is ready:
- Clear MVAT programs (to delete data from factory) (see §6.12 Deleting programs
of MVAT p53)
- Send programs to the MVAT ("Download to MVAT" using Rhapsodie.Net
application).
- Make the calibration of the machine (see §6.11 Calibration (of the scaled
displacement axis) procedure p51).

6.7 Replacing the Spindle

Switch OFF the general breaker. Wait at least 30 seconds.

WARNING:
The spindle motor could be very hot (>100°C) and the motor can be very hot and cause severe
burns if touched.
Wait for cooling and take the necessary precautions (gloves screen, etc.)

The weight of some spindle can be significant (up to 220kg depending on the type), it is
imperative to ensure the spindle with lifting rings designed for this use before dismantling..

Disconnect the measuring connector, power and resolver connectors, release the mounting
screws, replace the spindle and reassemble in reverse order. Turn ON the main breaker.

The 3 green LEDs of the MVAT PW8M power supply flash then remain on.
The LEDs of the MVAT M2C EP servo board flash then only red LED No. 2 remains on. (Or keep
on flashing if terminal is connected on COM1).
Then you must proceed successively to:
- Equipment validation (See §6.8 Equipment validation p40),
- Settling the drive (See §0 Setting the Drive p41),
- And make the calibration of the machine (see §6.11 Calibration (of the scaled
displacement axis) procedure p51).

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6.8 Equipment validation

Every part of a MVAT insertion unit (MVAT rack, MVAT board, Spindle, INFRANOR drive) is
equipped with an identification component that the MVAT board read at each power on or
at each reset.
When powering-up for the first time or each time a press-fitting unit component is replaced,
the equipment must be validated.
While this validation was not made, the card is blocked! (Red LED #2 ON or flashing)
To do this, open a terminal emulation on the PC (HyperTerminal or puTTY session), connect it to
the RS 232 serial port connected to the MVAT "COM1", then set the communication parameters
as shown below:
- Speed: 38400 bauds,
- Data bits : 8 bits per character,
- Stop bit : 1 stop bit,
- Parity : No parity,
- Flow control Hardware
Then Reset the MVAT. The text below is displayed:
Equipment validation
MVAT Rack : New ! (ou "Identical" ou "Different conforme")
Insertion Spindle : New ! (ou "Identical" ou "Different conforme")
Analogical board : Identical!
Servo Drive : New ! (ou "Identical" ou "Different conforme")
Communication board : Identical !
Status Tetas : 01 (ou 00)

Confirm changement ? (O/N) :

Enter "O" for "Yes" then press 

If the message "Absent ou non conforme !" is displayed, the item concerned is either
incorrectly wired or it is not the same type as the replaced item.

- - - - pay attention - - - -"

You’re going to modify the equipment configuration "
You can still cancel the procédure ! ! "
Confirm changement ? (O/N) :

Enter "O" for "Yes" then press 

Enter access code :

Press  since no access code is initially provided

Access Code accepted !

Flashing memory OK

-------------------------------------*-------------------------------------
------------------------------------* *------------------------------------
--------------------------------- M V A T ---------------------------------
------------------------------- * U E E A * -------------------------------
----------------------------- F A B R I C O M -----------------------------
-------------------------- Systèmes d'Assemblage --------------------------
___________________________________________________________________________
V XX.XX i 9 6 0 xx/xx/20xx:xx/xx/20xx

Ctrl(A) to access to monitor

Execution Insertion
Index Presence (or Index NOK)
Origin Position NOK (ou OK)
Pending for start cycle

At this point, red LED No. 2 goes off and green LED No. 7 goes on. The MVAT board is now ready.

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6.9 Setting the Drive

The INFRANOR VDSetup software will be used during the following steps. Icon:
A serial communication port of the PC is connected to the drive (X5 connector – Serial Link),
then you can launch VDSetup:
6.9.1 Loading the parameter file ( xxxxx.par)
To implement into the new drive the parameter file saved from the old drive, use VDSetup :
In the main page, choose menu « File / Load
Parameters », and select the « x x x x x.par » file
corresponding to the drive :

Then the procedure ends

with the following
message:

At this step, it’s opportune to move the rod OUT for about 50mm, using HMI panel to allow after
the auto-tuning without issue.
6.9.2 Offset Compensation (for speed reference)
This operation adjusts the 0V of the analogic speed reference of the drive to the 0V reference
of the MVAT controller.
Put first to “Off” the drive by opening the « Drive control » page using button

and by checking the « Off » checkbox :

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- Then, open the “Drive Setup” window with the button , and open the window “Speed
Limit” with the button “Modify”.

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Check first that the Accel/Decel time is settled to the minimum value (0,001 sec) :

To be able to perform the “Offset Compensation” procedure, you must :

- Activate "Enable" input of the drive (see p 49 for more details).
- In VDSetup software, as the drive is already in “Off” mode, launch the “Offset
Compensation” procedure by clicking on the button :

A message box appears, then click on OK (in

fact, as the « Enable » is already activated,
the speed analogic reference of the MVAT is
already set to 0V).

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At the end of the procedure (it takes a few seconds), a

message box informs the user that procedure has been
successfully executed :

6.9.3 Auto-tuning
The Auto-Tuning procedure adjusts the parameters of the servo motor in an automatic way.
This procedure is needed each time you replace the drive, the spindle or the motor, or when
you modify the tooling (changing the weight).
Before launching the Auto-tuning, please check that the shaft of the spindle is not entirely back.
If yes, please use the jog mode of the machine to let the shaft getting out of approximately
50mm.
WARNING: To avoid mechanical damages, you must ALWAYS try to introduce between the
nose of the press and the table (or tooling) a semi-resilient shim (in wood for example)
Then to run the Auto-tuning:
- Activate the “Enable” input of the drive (see §6.10 p 49 for more details).
- IMPORTANT : turn the drive in « Digital » mode with « Software Control » page (put first to
“Off”, then to “Digital”) :

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- In VDSetup software, open « Drive Setup » page with button and launch the Auto-
tuning procedure :

Then you go automatically to the « Servo Loop » sheet:

General case Specific case when a

press is used as a
reaction block

Make sure that the following checkbox are checked:

 « PI Speed» into the « Controller » area (Or PI² when the press is used as a reaction block)
 « Standard » into the « Filter» area
 « Low » into the « Bandwidth » area
 and « Autoselect » into the « Time interval » area

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Then click on OK button and a message box

asks to ensure that motor is standstill:

Pay attention : when you click on OK, if the following message

box appears, that means that « Enable » input is not set to 1
for the drive. Please check that the safety line of the machine
is not disabling this signal.

Then, when you click on OK, you can hear a thud near the motor. Auto-tuning procedure has
ended.

You can leave the procedure with the « Cancel » button of

the “Setup Window”

- Then put the drive back to « OFF » with the « Software Control » window
- Then disable the « Enable » signal by typing the « Esc » key in the terminal
- Then put the drive to « Analog » mode with the « Software Control » window
6.9.4 Encoder Resolution
In the “General Info” off the “Setup Window”, click on « Modify » in the « Encoder Output » area.
Then check that:
- « Output encoder Resolution » is set to 4096
- « Output encoder Dead band » is set to 8
- « Zero pulse origin shift » is set to 0
6.9.5 Ending Auto tuning procedure
To implement correctly the new parameters
calculated by the Auto-tuning procedure, you have to
« Store parameters to EEPROM », to be sure that these
new parameters have been stored into the memory of
the drive, to keep it resident even after shutting down
the drive.

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6.9.6 Index Centering by Zero pulse shifting

At the end of the calibration, chek the value “Index Centering” displayed in the terminal :

Calibration Force : 2811.1 daN

-------------------------------------------
Resolution depl. : 1212.050 I/mm
Press Opening : 275.033 mm
Index centring : 5.267 mm
Initial Offset : 9.14 %
Final Offset : -0.04 %
Calibration Force : 2811.1 daN
*******************************************

If the value is not close (± 0,3 mm) to the half thread of the screw (see screw thread table at
§1.4 Equipment Part Numbers p21), this procedure has to be launched alternatively with the
calibration procedure, until the resulting value “Index Centering" is as close as the half thread
of the screw.
Depending of the spindle type, equipped or not with an external encoder (the spindles with a
motor with the same axle than the spindle one have no extra encoder)
Let’s use example to explain this adjustment:
First Example : Spindle without external Encoder
Let’s say that the thread pitch of the screw is 8 mm.
After a first calibration sequence, the "Centrage Index" value is 6,245 mm. As the looked value
is 4 mm (8mm/2), there is 2,245 mm more.
As 8 mm correspond to the 32768 pulses of the drive, 2,245 mm correspond to 9196 pulses.
Then we have to subtract 9196 to the actual value of the drive.
To do that, we click in the “General Info” sheet on the « Modify » button and the following
screen appears (“Encoder Output” sheet):

In this example, the actual value is 0. Then, if you calculate 0 - 9196 = -9196, as a negative value
is not allowed, we complement with 32768, what gives – 9196 + 32768 = 23 572.
Then, we make a new calibration cycle, and we check that now the "Centrage Index" value is
much closed to 4 mm.

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If the new "Centrage Index" value is not 4,000 mm but 8,49 (6,245+2,245), or 0,49 (because we
overpass a Top of the drive), we mistake by subtracting 9196, we should add it to 0, then
replace the 0 value by 9196 instead 23 572.

Second Example: Spindle with external encoder

Let’s say that the pitch of the screw is 10 mm.
After a first calibration sequence, the "Centrage Index" value is 6,433 mm. As the looked value
is 5 mm (10 mm / 2), there is 1,433 mm more.
We know that 10 mm correspond to 1 turn, or 360°, then 1,433 mm correspond to 51,6°.

Then we have to turn the encoder of an angle equal to about 50° in the anti-clockwise
direction.

Then, we make a new calibration cycle, and we check that now the "Centrage Index" value is
much closed to 5 mm.
6.9.7 Ending the drive setting
To validate new parameters and to be sure to keep it
the memory of the drive, only click on "Store parameters
to EEPROM" of the “File” menu:

Then, in the “Drive Control”

window, DON’T FORGET to go
back in Analog.
A message box appears, then
click on “OK”.

Then, the drive is ready to work

with the spindle fitted with.

In the terminal, leave the "Esc-

m-M" keyboard command by typing the s key.
The insertion unit can now work correctly.
6.9.8 Saving the new parameter file (xxxxx.par)
To keep a backup of the parameters in case of changing
the drive, in VDSetup, we save the new parameter file by
choosing « File / Save Parameters » menu:

And we choose the backup directory and filename.

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6.10 Activate the Enable signal of the Drive

6.10.1 Case #°1 : PC with Rhapsodie.Net directly connected on MVAT board
The connection can be direct or trough Serial  Ethernet converter, ADVANTECH EKI for
example:
 For MVAT board with firmware version older than V10 :
o ATTENTION : Firstly uncheck the “Start Cycle Operating” checkbox in the
“Appendix” sheet of the “Specifications”, and send this modification to the
MVAT board
o Then type into terminal the keyboard command « Esc m M » (s M qM)
 Since the V10 version, you can type directly into terminal the keyboard command :
o « Esc m v M » (s M V qM).
o Then, if the MVAT board is ready (“Attente Depart Cycle” in terminal), you can
hear the park break of the spindle to be released, and you can see in the
terminal that the “Enable” command is activated:

Pending for Start Cycle

Escape keyboard!
MODE CLAVIER
ENABLE

For both versions, don’t forget to type the s key again to exit of the command an d come
back to « Pending for Start Cycle ».
6.10.2 Case #°2 : A UExp-MVAT panel is used on the station
On the panel, do :
- Type login password to be connected :
- Then Update the panel :

- And in the MVAT-Term page : touch the « Enable Signal Activation » button :
,

- Then, if the MVAT board is in “Attente Depart Cycle”, …

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… the “Activated” window is opened, ), you can hear the park break of the spindle to be
released, and you see in back page that the “Enable” command is activated:

To exit this mode, just touch the « Exit » button to come back in « Attente Départ Cycle ».

WARNING : Don’t stay in “Enable” mode more than 5mn to avoid motor heating.

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6.11 Calibration (of the scaled displacement axis) procedure

6.11.1 Calibration in compression mode
This procedure has to be done IMPERATIVELY at the starting-up of the machine, and at each,
changing of the MVAT environment (frame modification, tooling modification, spindle, drive,
MVAT board).

The calibration procedure is made when machine is not producing. It is launch by the PLC. The
hard Start Cycle (door switch or light curtain switch) has to be ON during all the sequence. The
speed used for the calibration is the one that is programmed in Rhapsodie.Net (Specification
page)

At the end of the calibration procedure, the MVAT system knows:

- The Zero position of the machine, and the working area of the press,
- The practical resolution for displacement axis (pulses / mm). To calculate this value, 2
gages are used: a lower gage to determine Zero position, and an Upper gage, which
exact height is entered in Rhapsodie, to determine the practical resolution:
Nb. puls. measured during upper gage - Nb. puls. during lower gage
 Resolution (puls./mm)
Upper gage height in mm - Lower gage height in mm

- The flexion of the frame and Spindle extension depending of the applied force.

Steps:
Firstly, check that values for lower and upper height have been entered correctly in Rhapsodie
in the Specifications page. (Remark: it’s possible to use only the upper gage, if the height of
the lower gage is define to 0)
1- Put the Lower gage in the machine. If there’s no lower gage, the shaft of the spindle will
apply the force directly on the 0 reference.
2- Start cycle, and hold the start cycle signal until the end of the sequence (shaft in home
position). If an emergency stop occurs, put the shaft back in home position and start
again.
3- When the lower gage sequence is finished, you have to launch directly the upper gage
sequence, with no other movement between.
4- Release the lower gage, and put the upper gage instead.
5- Launch the upper gage calibration.
At the end, calibration results are displayed in the terminal. (See §10 Execution p70)

To have a good calibration, you need :

- Resolution calculated has to be between the max and the min resolution defined in
Rhapsodie in Specification page
 If this value is out of tolerances, check the height of the gages compare to Rhapsodie
definition, check the mounting of the gage. Check there is no hard spot during the
calibration sequence (before the nose of the press touch the gage).
- Top Dead Center calculated has to be between the max and the min T.D.C. defined in
Rhapsodie in Specification page.
 If this value is out of tolerances, check the height of the lower gage, compare to the
last calibration. Check there is no hard spot during the calibration sequence (before
the nose of the press touch the gage).

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Calculation of theoretical resolution: (to enter min and max in Rhapsodie)

 With resolver : 4096 / pitch of the screw (in mm)
 With external encoder: 5000 / pitch of the screw (in mm)

6.11.2 Procédure d'Etalonnage de la machine en traction

Cette fonction est destinée à l’acquisition de la fonction des déformations de la machine en
traction, pour garantir une très bonne précision y compris dans le cas d’un cycle en traction
qui applique un effort sur le produit.

Si la machine ne comporte pas de cycle de travail à l’effort en traction, où la précision de

positionnement sous effort est nécessaire, il n’est pas nécessaire de faire un étalonnage
traction.

Etapes
Un outillage mécanique est nécessaire pour l’exécution de cet étalonnage.
1- Le cycle de traction utilise le programme N° 1. Ce cycle permet d’avancer le nez de
Broche à un point donné (paramétrable), afin de disposer l’outillage de traction.
2- Envoyer le départ cycle qui doit être maintenu. La Broche exécute le cycle
correspondant au programme N° 1 (arrêt sur cote de déclenchement).
3- Lorsque la Broche est arrêtée sur la cote de déclenchement, mettre la cale qui va servir à
la traction. Envoyer une impulsion sur l’entrée ES9 pour que la Broche continue son cycle.
4- La Broche exécute le cycle de traction et déclenche à la force d’étalonnage traction
paramétrée dans le menu "spécifications". Dès que l’effort est atteint, la Broche revient à
la position basse de l’étape précédente.
5- Arrêt de la Broche en position basse. Enlever la cale qui a servi à la traction. Envoyer une
impulsion sur l’entrée ES9 pour que la Broche continue son cycle.
6- La Broche exécute le cycle de rappel en position initiale.

Remarque :
Si le cycle est interrompu (arrêt urgence), la broche reste toujours en étalonnage traction. Il
faut alors recommencer le cycle étalonnage traction, soit :
a/ envoyer un cycle de remontée Broche
b/ relâcher le départ cycle
c/ envoyer le départ cycle pour un nouveau cycle étalonnage traction.

On peut recommencer les opérations a, b, c, autant de fois que l’on veut, tant que le cycle
n’est pas réalisé correctement.

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6.12 Deleting programs of MVAT board

Each time you change a MVAT board, to avoid to upload old programs stored in the board,
you have first to delete all the programs of the MVAT board.
To do that, first open the project with Rhapsodie, and go on “Maintenance sheet” of the
“Specifications” page (you must log at the 3rd level minimum):

Then double-click on the text « Reserved for future features » (or « Reserve to ASS» depending
of Rhapsodie version), and a new contextual menu « SAV Function » appears if you type a right-
click on this text. (Warning, if the double-click has not be done, this menu still appears, but it is
not enabled !) :

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And if you click on this menu, 2 new buttons appear : (You can use these features only for MVAT
V10 or more)

Clear All Progr. : Send a request of deleting all programs (specifications and calibration are not
deleted)
Defrag. MVAT : Reserved to FSA after sales service, because Rhapsodie manage automatically
the defragmentation of the memory of the MVAT board.

7 Replacing particular parts of Old Spindles

UG spindle range is not concerned by this section, as NO ELEMENT can be changed on these
spindles by the customer.

In a general way, as spindle are composed of very accurate mechanical parts, it is strongly
advised to replace completely the spindle, and to let FSA repair spindle with the good tooling.
All spindles, new one or refitted one, are extensively tested on a test bench at FSA plant before
to be delivering, following a procedure of 18 hours or 10000 cycles.

The customer who conducts himself with disassembly / reassembly, assumes all responsibility
for repairs and replacements during replacement operations described in this manual. Once
the repairs or replacements completed, the user must perform all operating controls and safety
precautions.
Interventions on spindles that are not described in this manual may cause injury and / or
property damage and therefore are not authorized by Fabricom which assumes no
responsibility and will deny any claim or warranty.

Before replacing a component of the spindle, the spindle must be removed from its frame and
carefully deposited on a solid work plan, if possible on a cradle for the guide and prevent
rolling.

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7.1 1.5 Tons Spindle : UE1500/B

7.1.1 Replacing the spindle motor
After replacing the spindle motor, you have to follow the variable speed drive parameter
setting procedure. (See "Setting the Variable Speed Drive Parameters" p40)

- - Lift up the plastic plug on the intermediary bearing rep. A947 31 02 133
- - Turn the chuck to let the screw of the coupling CENTRAFLEX CF4X PRUD’HOMME in front
of the opening
- - Unscrew and remove the 3 screws CHc M8-30 of fixing of coupling on the semi coupling
rep. A947 31 02 336
- - Unscrew and remove the 4 screws CHc M8-25 of fixing of the motor BLS 115 V 00 310E 00
INFRANOR
- - Remove the motor
- - Unscrew the screw Hc M5-10 which fixes the semi coupling rep. A947 31 02 336 on the
motor
- - Remove the semi coupling.

The reassembling will be accomplished reversing the order of the removing operations.

When assembling the motor, beware to align it to all the connections.

Before screwing the 3 screws CHc M8-30 of fixing of the coupling CENTRAFLEX CF 4X
PRUD’HOMME stick these to the brake thread 222 LOCTITE.

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7.1.2 Replacing the Spindle Motor Coupling

After replacing the spindle motor coupling, you have to follow the variable speed drive
parameter setting procedure. (See "Setting the Variable Speed Drive Parameters" p40)

- Lift up the plastic plug on the intermediary bearing rep. A947 31 02 133
- Turn the chuck to let the screw of the coupling CENTRAFLEX CF4X PRUD’HOMME in front of
the opening
- Unscrew and remove the 3 screws CHc M8-30 of fixing of coupling on the semi coupling
rep. A947 31 02 336
- Unscrew and remove the 4 screws CHc M8-25 of fixing of the motor BLS 115 V 00 310E 00
INFRANOR
- Remove the motor
- Unscrew and remove the 3 screws CHc M8-30 of fixing of the coupling on the lower semi
coupling rep. A947 31 02 337
- Remove the coupling

The reassembling will be accomplished reversing the order of the removing operations.

When assembling the motor, beware to align it to all the connections.

Before screwing the 6 screws CHc M8-30 of fixing of the coupling CENTRAFLEX CF 4X
PRUD’HOMME stick these to the brake thread 222 LOCTITE.

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7.2 3 Tons Spindle : UE3000/B

7.2.1 Replacing the Spindle motor
After replacing the spindle motor, you have to follow the variable speed drive parameter
setting procedure. (See "Setting the Variable Speed Drive Parameters" p40)

- Rotate ring P/N A941 02 01 328 to align the 3 Ø20 holes with the 3 Ø30 holes in motor
mount P/N A941 02 01 227.
- Rotate the spindle to align the 3 screws of the CENTRAFLEX CF.8X.0 PRUD’HOMME
coupling with the holes.
- Unscrew and remove the 3 CHc M10-35 screws attaching the coupling to upper half-
coupling A941 02 01 330.
- Unscrew and remove the 4 CHc M10-30 screws attaching the motor INFRANOR BLS 144 V
00 3 1 E.
- Retain the M10 washers.
- Remove motor.
- Remove the Hc M6-10 screw attaching upper half-coupling P/N A941 02 01 330 to the
motor.
- Remove the upper half-coupling.

To reassemble, repeat the above dismantling operations in the reverse order.

When installing the motor, make sure it is correctly aligned with all the connections.
Before inserting the 3 CHc M10-35 screws on the CENTRAFLEX CF.8X.0 PRUD’HOMME coupling,
apply 222 LOCTITE weak hold.

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7.3 Spindles: 5 Tons - UE5000/B, 7,5 Tons - UE7500/B and 10 Tons - UE1000/B
7.3.1 Replacing the Spindle motor
After replacing the spindle motor, you have to follow the variable speed drive parameter
setting procedure. (See "Setting the Variable Speed Drive Parameters" p40)

- Unscrew and remove the 2 screws FHc M5-10 of fixing of the case rep. A943 01 01 249
(keep the 2 tub washers M5)
- Remove the case
- Unblock the 4 screws CHc M8-20 that strengthen the motor plate rep. A943 03 01 243
- Unblock then unscrew the screw Hc M6-15 on the piece rep. A943 01 01 341
- Unscrew the tension screw rep. A943 01 01 340 to release the cog belt SYN 100 AT 10/890
BINDER
- Unscrew and remove the screw CHc M8-140 that secures the maintaining of the motor
coupling (keep the washer rep. A943 03 01 337)
- Unscrew and remove the 4 screws CHc M8-25 of fixing of the motor BLS 192 00 310E 00
INFRANOR
- Remove the motor
- Remove the spacer rep. A943 03 01 339.
The reassembling will be accomplished reversing the order of the removing operations.

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When assembling the motor, beware to align it to all the connections.

Before screwing the screw CHc M8-140 of fixing of the motor coupling stick it to the brake
thread 222 LOCTITE.
While reassembling, screw the tension screw rep. A943 01 01 340 with a torque indicator
handle wrench with a couple of 1,6 Nm.
7.3.2 Replacing the belt
After replacing the belt, you have to follow the variable speed drive parameter setting
procedure. (See "Setting the Variable Speed Drive Parameters" p40)

- Unscrew and remove the 2 screws FHc M5-10 of fixing of the case rep. A943 01 01 249
(keep the 2 tub washers M5)
- Remove the case
- Unblock the 4 screws CHc M8-20 that strengthen the motor plate rep. A943 03 01 243
- Unblock then unscrew the screw Hc M6-15 on the piece rep. A943 01 01 341
- Unscrew the tension screw rep. A943 01 01 340 to release the cog belt SYN 100 AT 10/890
BINDER
- Unscrew and remove the screw CHc M8-140 that secures the maintaining of the motor
coupling (keep the washer rep. A943 03 01 337)
- Unscrew and remove the 4 screws CHc M8-25 that strengthen the bearing guide plate
rep. A943 01 01 245 (use an axle Ø5 to strengthen the lower masts rep. A943 01 01 344
during unscrewing)
- Remove the bearing guide plate rep. A943 01 01 245
- Remove the motor wheel rep. A943 03 01 335 and the axle rep. A943 03 01 338
- Unscrew the screw CHc M4 of the coupling E60065 IFM that secures qui assure the support
of the threaded cotter pin GT 6-20
- Unscrew and remove the 4 screws CHc M6-55 that strengthen the encoder support rep.
A943 01 01 336 (keep the 4 encoder support axles rep. A943 01 01 352)
- Remove the encoder support rep. A943 01 01 336
- Unscrew and remove the 4 screws CHc M8-35 that strengthen the bearing guide plate
rep. A943 01 01 253 (use a 19 flat wrench to strengthen the axles rep. A943 01 01 351 and
rep. A944 03 01 328 during the unscrewing)
- Remove the bearing guide plate rep. A943 01 01 253
- Change the belt

The reassembling will be accomplished reversing the order of the removing operations.

Before screwing the screw CHc M8-140 of fixing the motor coupling stick it to the brake
thread 222 LOCTITE.
While reassembling, screw the tension screw rep. A943 01 01 340 with a torque indicator
handle wrench with a couple of 1.6 Nm.
After this operation, the encoder must be reset.

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7.3.3 Tension of the belt

- Unscrew and remove the 2 screws FHc M5-10 of fixing of the case rep. A943 01 01 249
(keep the 2 tub washers M5)
- Remove the case
- Unblock the 4 screws CHc M8-20 that strengthen the motor plate rep. A943 03 01 243
- Unblock the screw nut Hm M6 that blocks the screw Hc M6-15 on the piece rep. A943 01
01 341
- Unscrew the screw Hc M6-15
- Unscrew the tension screw rep. A943 01 01 340 to release the cog belt SYN 100 AT 10/890
BINDER
- Screw in the tension screw rep. A943 01 01 340 with a torque indicator handle wrench
with a couple of 1,6 Nm

The reassembling will be accomplished reversing the order of the removing operations.

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7.3.4 Replacing the encoder

After replacing the encoder, you have to follow the variable speed drive parameter setting
procedure. (See "Setting the Variable Speed Drive Parameters" p40)

- Unscrew and remove the 2 screws FHc M5-10 of fixing of the case rep. A943 01 01 249
(keep the 2 tub washers M5)
- Remove the case
- Unscrew the screw CHc M4 of the coupling E60065 IFM that secures the support of the
encoder axle RU5000 105 K/1001.4 RADIAL IFM
- Unscrew and remove the 3 screws CHc M4-12 of fixing of the 3 clamps E60041 IFM (keep
the 3 clamps)
- Remove the encoder

The reassembling will be accomplished reversing the order of the removing operations.

After this operation, the encoder must be reset.

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7.4 Spindles NG15kN to NG200kN

NG Spindles are not dismountable and rebuildable without the proper tools.
A return to FSA plant is required to any intervention.

Attention FABRICOM recalls that:

Disassembly / reassembly risky and potentially makes the spindle mechanically dangerous for
the user. The torque of the spindle can reach 320Nm with 35 kilowatts of power.

Interventions on spindles that are not described in this manual may cause injury and / or
property damage and therefore are not authorized by Fabricom which assumes no
responsibility and will deny any claim or warranty.

7.5 Spindles UG (5kN to 100kN)

UG Spindles are not dismountable and rebuildable without the proper tools.
A return to FSA plant is required to any intervention.

Attention FABRICOM recalls that:

Disassembly / reassembly risky and potentially makes the spindle mechanically dangerous for
the user. The torque of the spindle can reach 320Nm with 35 kilowatts of power.

Interventions on spindles that are not described in this manual may cause injury and / or
property damage and therefore are not authorized by Fabricom which assumes no
responsibility and will deny any claim or warranty.

7.6 Replacing other components

Any work on the ball screw, the bearing or the instrumented shaft must be carried out by FSA
ONLY.

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8 Recommendations
8.1 Electrical equipment
A regulated power supply 24V, which has to be galvanically isolated from the main power
supply is recommended for MVAT I/O. The maximum current to supply is 1A. However, a fuse of
100 mA is recommended.
For old installation, with wired I/O, you must use the following relay for the 5 MVAT outputs :
Brand : PHOENIX CONTACT
Reference : EMG 22 - REL/KSR - G24/TRN35

These relay are not provided by FABRICOM Systèmes d'assemblage S.A..

The Life Time given by the constructor is more than 5.107 cycles.

8.2 Electrical Wiring

It is strongly recommended to respect the wiring recommendations given by INFRANOR
("XtrapulsCD1-a", rev. 8.16_1 of april 2016, chapter 4.2 p29, and chapter 4.3 p33)
The INFRANOR documentations are provided on the installation CD-ROM of Rhapsodie, and
also available after Rhapsodie.Net installation on the following directory:
C:\Rhapsodie.Net\Documentation\INFRANOR

The following recommendations have to be strongly respected to avoid fault occurrence:

1. Good quality of the plant ground,
2. Check the good electrical continuity of the ground between the cabinet and the frame,
3. Check the ground wire of the MVAT power cable is well connected to the ground,
4. Wire between the motor and the ground of the cabinet a ground braid (minimum 1cm
width)
5. Do the same between the motor and the sleeve of the spindle,
6. Do the same with a simple ground wire between the motor and the connection box of
the spindle,
7. PLEASE DO NOT WIRE SIDE TO SIDE power cable and control cables (resolver cable,
measurement cable, encoder cable). A minimum distance of 50 cm is necessary,
8. The length of cables mustn’t exceed 15 m,
9. The measurement cable must ABSOLUTELY NOT turn around or near the motor,
10. The power cable of the motor has to be skinned on the shortest length possible (see
INFRANOR documentation "XtrapulsCD1-a", rev. 8.13 of feb2012, chapter 4.2 p30, and
chapter 4.3 p34),
11. If a contactor is inserted between the drive and the motor, the wiring has to conform to
the drawing next page firstly, and the opening of this contactor can NEVER occur during
the spindle shaft moves, or during spindle is applying force, under penalty of destruction
of this one.
12. NO cut off other cable between the spindle and the drive or MVAT is accepted (NO
bulkhead pass through).

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The power cable can be cut only for station where operator has to work under the press at
each cycle. In this case, a safety contactor will be inserted on this cable to avoid unexpected
restart. But in this case, the shield braid and the ground wires of this cable MUST IN NO CASE be
cut (see drawing above)

WIRING OF THE “ANTI-RESTART CONTACTOR”

shortest possible Wires and braid have to

be protected without
cut it

WIRING THE GROUND BRAID AND WIRES ON THE SPINDLE

To cabinet (shortest
possible)

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8.3 Mechanical frame and compliance

If the frame of the machine is a C-frame, the mechanical rigidity of the frame has to be
sufficient in order to avoid being out of parallelism.
The shaft with the tooling mounted has to be able to:
- Travel out of a distance more than twice the screw pitch,
- Accept during calibration cycle a lower gage and upper gage, that height difference
has to be at a minimum of 60 mm.
During calibration cycle, only elasticity of the frame and of the press can be learned. No
compliance in the tooling is accepted because of the non-repeatability of this kind of
mechanics.

To prevent injuries, the maintenance documentation provided to the final customer has to
specify the use of a platform to access lubricators when those one which are over 2m height.
This documentation has also to explain how to extract the spindle in case of replacement.

8.4 Serviceability limit

Shock working is not allowed to warranty the life time of the screw.

If the axis of the shaft is not the same than the axis of the insertion, the measurement of the real
force applied is wrong and the life time of the shaft guiding is reduced.
MVAT electronics works only with 1 calibration. Then if the unit is working with different tooling
depending on the part type to assembly, it is recommended to make the calibration with the
tooling where the highest accuracy is needed for assembly.

It is not allowed to travel the shaft completely out without mechanics to resist. The manual
speed has to be low (5%), and the manual intensity also (5%) to avoid degradations.

8.5 Automatism
The PLC program has to include the following features:
- To able to launch a simple sequence which only aim is to let the shaft come back in
home position after a manual return,
- Count (for station where operator has to cut off the light curtain at each cycle) the
number of emergency stop (not allowed light curtain cutting) when the shaft of the press
was moving. This counter has to be displayed for the maintenance team who has to
check the wear of the brake when 15000 times is reached.

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8.6 Safety
The safety force checked during the approach phase of a cycle, or during jog mode in
compression is the “Pressing Safety Force” that you can parameter in Rhapsodie.Net in the “Set
point” sheet of the “Specifications” page.
The safety force checked during jog mode in traction is the “Pulling Safety Force” that you can
parameter in Rhapsodie.Net in the “Annexe” sheet of the “Specifications” page.

It is strongly advised to NOT USE an electrical press on a station with light curtain, as these one
doesn’t prevent the risk of bursting and projection.

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9 "Maintenance" sheet in "Specifications" page of Rhapsodie.Net

A lot of parameters of this sheet are reserved to FSA technician, or Maintenance department
for the greasing, or Quality department for the force adjustment.

Working Mode area: see Rhapsodie.Net user Guide

Quality Department area:

In this area, you can make a linear adjustment of the force sensor to match the force given by
the MVAT (press) and the force given by an external checking sensor.
You can use it when a bad application of the force generates a linear and repetitive error. In
no case, you can correct an offset between the 2 values. If you observe a constant offset
between the 2 values, check that as soon as the tool touch the frame, the checking sensor
start to see a force signal.

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Max. Force correction: This is the maximum correction in % that you can apply. This will is
automatically set to 10%, as soon as you enter the 2 other values.
Press sensor Measurement: This is the value for force displayed by the MVAT during the
checking cycle. Please prefer the residual value after a holding time, to the peak value.
Checking sensor Measurement: This is the value for force displayed by the external checking
sensor during the checking cycle.
Remarks:
- You have to enter both previous values, 0 value for both.
- Please parameter a holding time for the checking cycle, to let you see the value of the
checking sensor. Do NOT put your checking sensor display in “MAX” mode.

Example: 2 823 MVAT measurment

Spindle: UG30kN
MVAT after corr.
Reference value MVAT: 2 800 daN 2 746 Checking measur.
MVAT Measurement: 2 823 daN
Checking Measurement: 2 746 daN

Maintenance department area:

Greasing Warning threshold: When the press has run this number of sequences, a message
“Alerte Graissage” appears in the terminal at the beginning of the sequence block:

*****************************************
Poste/Voie/Adr. : 000.000.001.237.160.136.001
J/M/A , H/M/S : 29/03/2013 20/01/49,79
Alerte Graissage
Temps total séq. : 7,26 s
Temper. Broche : 23,03 Deg.
Temper. Bâti : 22,99 Deg.
Temper. Module : 37,05 Deg.
Numéro séquence : 1
Séquence BONNE
Résultat Numéro : 318
Nb seq av Graiss : 2000
Numero de courbe : 17
Nombre de cycle : 1
-----------------------------------------
Numéro de cycle : 1
...
...

The number of sequences left before reaching the “Greasing Shut down threshold” is displayed:
“Nb seq av Graiss”.

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 69 / 97

 Fil de l'eau durant l'exécution

Greasing shut down threshold: When the press has run this number of sequences, a message
“Arrêt Graissage” appears in the terminal at the beginning of the sequence block:

*****************************************
Poste/Voie/Adr. : 000.000.001.237.160.136.001
J/M/A , H/M/S : 29/03/2013 20/01/49,79
Arrêt Graissage
Temps total séq. : 7,26 s
Temper. Broche : 23,03 Deg.
Temper. Bâti : 22,99 Deg.
Temper. Module : 37,05 Deg.
Numéro séquence : 1
Séquence BONNE
Résultat Numéro : 318
Nb Seq av Graiss : 0
Numero de courbe : 17
Nombre de cycle : 1
...

The number of sequences left before reaching the “Greasing Shut down threshold” is now
equal to 0.
Shut down if threshold reached: If this checkbox is checked, the press will stop as soon as it has
run this number of sequence. To start again, you need to proceed to the greasing, and to click
on the button.

If you use a UExp-MVAT panel, you can also directly validate the greasing to start again.

10 Execution journal
See the Rhapsodie.Net documentation.

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 70 / 97

 Keyboard Commands

11 Keyboard Commands (Reserved for the use of FABRICOM

Customer Support)
All these commands are executed on the terminal.

WARNING: certain of these commands (in red) must be used with caution, in particular
commands, which induce movement of the spindle axis and could cause injuries and/or
equipment damages.
The user has to be quite capable of judging an checking there’s no remanent risk, otherwise
he has to refrain from using this commands.
He’s assuming alone the responsibility of their use.

11.1 "Esc +…" Commands

To use these commands, it is necessary to first press "Esc".
Press "Esc" again to exit "Keyboard Commands" mode.

Key Function Comments and conditions of use

c Carries out the following tests: To be carried out after loading the
- Tests the load sensor power supply up to specifications into the RHAPSODIE
the spindle connectors application.
- Tests the current set point transmitted to See details after
the variable speed drive up to the
MVAT connector
- Tests the speed set point transmitted to
the variable speed drive up to the
MVAT connector
- Checks that the load sensor is
balanced
- Checks that the offset is lower than the These tests are also run each time a
threshold indicated in the cycle is started
specifications.

d Displays the fault in course

i Displays the inputs status

j Displays the date and the temperature See details after

k Runs the MVAT calculation Cycle number 1 and curve number 1

have to be defined
Activates manual mode "Start cycle button enable" must be set
m "–" to retract the axis to "NO"
"+" to extend the axis Pressing this key repeatedly accelerates
"R" to retract the axis slowly the speed
"D" to extend the axis slowly
"M" activates the "Enable" input of drive Allows Auto-tuning without the use of a
"" or "space" or "A" to stop the axis blanking plug
"S" Enable/Disable CV0 command
It's possible to change the check type in
n Runs the check calculation on the curve
Rhapsodie, send the change to the
MVAT board and execute this
command to know the new result of the
checking.

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 71 / 97

 Keyboard Commands

o Displays the offset value Displays the offset value on the

HyperTerminal
LED 4 is on when no force is applied
LED 3 goes on if the axis is pressed
LED 5 goes on if the axis is drawn
q Check the MVAT outputs The MVAT outputs go on turn by turn. If
at the first switching on off the MVAT, the
"light caterpillar" speed is too high, it's
useful to execute the "Esc k" command

r Displays a sequence or calibration results See the display description after

u Send the curve buffer to the PC

v Displays the force value and the See details after

displacement in following mode

w Displays the Sensor rated value and the See details after
sensibility

x Check the RS485 communication Displays "TEST 485" on the RS232

HyperTerminal

 Description of the results displayed after using the command "Esc c":
Contrôle OK
Sortie mode

Or if a fault appears :

Contrôle NOK ALIM (or OFF or DESI or INT or VIT or NOMI)

Sortie mode
Description of the fault messages :
ALIM : Sensor powering fault (cable, spindle box, board, rack)
OFF : Offset fault (cable, spindle box, board, rack, mechanics)
DESI : Unbalanced sensor (calibration missing, cable, spindle box, board, rack)
INT : current fault (board)
VIT : speed fault (board)
NOMI : Sensor rated value fault (programs)
 Description of the results displayed after using the command "Esc i":
PRESENCE INDEX OUI (axis at least retracted on the fallback position)
ENTREE E0 OUI (VSD ready)
ENTREE E1 NON (Start cycle)
ENTREE E2 NON
ENTREE E3 NON
ENTREE E4 NON
ENTREE E5 NON
ENTREE E6 NON
ENTREE E7 NON

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 72 / 97

 Keyboard Commands

 Description of the results displayed after using the command "Esc j":
18/10/2000 15/04/42,55
24,83 deg. (board temperature)
40,42 deg. (internal spindle temperature. Warning: if 327,55 displayed, the t° circuit is not active)
21,25 deg. (frame temperature if connected)
 Description of the results displayed after using the command "Esc o":
Test offset :
5,6 daN
 Description des résultats affichés après "Esc w" :
030,000 (nominal Broche lu dans le circuit d'identification)
1,00000 (sensibilité Broche lue dans le circuit d'identification)
3000,0 (nominal théorique)
1,000 (classe saisie dans Rhapsodie)
1,000 (sensibilité calculée)
3000,0 (nominal utile calculé = nominal théorique x classe)
1,400 (coefficient de charge limite saisi dans Rhapsodie)
4200,0 (charge limite calculée = nominal théorique x coeff. charge limite)

 Description des résultats affichés après "Esc v" :

En mode standard :
DEPLACEMENT 0,000 mm TOUR 000 FORCE - 0,5 daN FORCE AUX - 2,9 daN
En mode semi-manuel :
DEPLACEMENT 0,000 mm FORCE - 0,5 daN
 Description of the results displayed after using the command "Esc r":
After a press-fitting cycle:

1 371,409 371,416 2084,1 2021,3 0,007 4,012 B/M 1

Selection Previous Distance Peak force Residual force Distance Index Cycle quality Cycle No.
distance reached (daN) (daN) difference centering (B : good; M :
(mm) (mm) (mm) (mm) bad)

1874,1 48,2 7,455 -8,121 ( ) ( ) ( ) 2805,6 5,17

Force at Return force Idle position Lambda For For For Calibration Offset
distance from (daN) (mm) coefficient adjustment adjustment adjustment force (daN)
end (daN)
(daN)

000000 ARDEP FFEEE7 6,462 7853 2106,2

Displacement Stop type Displacement For For Auxiliary force
set point adjustment adjustment value (daN)

After a calibration cycle:

1 512,17 455,622 2084,1 2021,3 0,007 4,012 B/M 1

Selection Resolution Top Dead Peak force Residual Distance Index Cycle Cycle No.
(pulses/mm) Center (daN) force (daN difference centering quality
(mm) (mm) (mm)

1874,1 48,2 7,455 2063 ( ) ( ) ( ) 2805,4 5,17

Force at Return Idle position Sigma For For For Calibration Offset
distance force(daN) (mm) coefficient adjustment adjustment adjustment force (daN) (daN)
from end
(daN)

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 73 / 97

 Distance and Speed Diagram

11.2 Direct Commands

For these keyboard commands, it is not necessary to first press "Esc".

E Displays the last 5 lines of the calibration Only the first 3 lines are significant
results block (see p70) (Resolution, TDC and Index centering)

R Displays the results block of the last

sequence run

F Displays all the force values used in the The display will vary according to the
curve check type of check selected

Command E:
-------------------------------------------
Resolution dépl. : 512,050 I/mm
Point Mort Haut : 275,033 mm
Centrage Index : 5,267 mm
Offset Initial : 0,00 %
Offset Final : 0,00 %
*******************************************
Command R:
The results blocks displayed are the same as those displayed during the cycle.

Command F: these windows results blocks are also displayed after each sequence after the
result s block, if the field "Sending Windows results" of the "Appendix" sheet of the "Specification"
page is set to "YES".
Example 1: "ALL" type check in 2-points mode (4 windows defined)
**********************************************************
Contrôle Courbe Compression Mode Tous
----------------------------------------------------------
F 1; Fmax : 8,1 daN ; TP ; Fmin1 : 0,0 daN ; TP
F 2; Fmax : 7,5 daN ; TP ; Fmin1 : 0,0 daN ; TP
F 3; Fmax : 5,7 daN ; TP ; Fmin1 : 0,0 daN ; TP
F 4; Fmax : 18,4 daN ; OK ; Fmin1 : 3,1 daN ; TP
**********************************************************
Example 2: "RELATIVE" type check in 2-points or 3-points mode according to the window (8
windows defined)
*********************************************************************************
Contrôle Courbe Compression Mode Relatif
---------------------------------------------------------------------------------
F 1; Fmax : 8,1 daN ; TP ; Fmin1 : 0,0 daN ; TP; Fmin2 : 0,0 daN ; TP
F 2; Fmax : 7,5 daN ; TP ; Fmin1 : 0,0 daN ; TP; Fmin2 : 0,0 daN ; TP
F 3; Fmax : 5,7 daN ; TP ; Fmin1 : 0,0 daN ; TP; Fmin2 : 0,0 daN ; TP
F 4; Fmax : 18,4 daN ; OK ; Fmin1 : 3,1 daN ; TP; Fmin2 : 3,1 daN ; TP
F 5; Fmax : 8,3 daN ; TP ; Fmin1 : 0,0 daN ; TP; Fmin2 : 0,0 daN ; TP
F 6; Fmax : 288,1 daN ; OK ; Fmin1 : 123,3 daN ; OK; Fmin2 : 111,3 daN ; OK
F 7; Fmax : 32,9 daN ; TP ; Fmin1 : 0,0 daN ; TP; Fmin2 : 0,0 daN ; TP
F 8; Fmax : 8,6 daN ; TP ; Fmin1 : 0,0 daN ; TP; Fmin2 : 0,0 daN ; TP
*********************************************************************************

Example 3: "PEAK" type check (4 windows defined)

**************************************
Contrôle Courbe Compression Mode Tous

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 74 / 97

 Distance and Speed Diagram

--------------------------------------
F 1; Fmax : 8,1 daN ; TP
F 2; Fmax : 7,5 daN ; TP
F 3; Fmax : 5,7 daN ; TP
F 4; Fmax : 18,4 daN ; OK
**************************************

Example 4: "MEAN" type check (3 windows defined)

**************************************
Contrôle Courbe Compression Mode Tous
--------------------------------------
F 1; Fmoyenne : 8,1 daN ; TP
F 2; Fmoyenne : 7,5 daN ; TP
F 3; Fmoyenne : 5,7 daN ; TP
**************************************

Example 5: "POINT" type check (5 windows defined)

**************************************
Contrôle Courbe Compression Mode Tous
--------------------------------------
F 1; Fpoint : 8,1 daN ; TP
Checking window starting mode
F 2; Fpoint : 7,5 daN ; TP
F 3; Fpoint : 5,7 daN ; TP
F 4; Fpoint : 18,4 daN ; OK
F 5; Fpoint : 8,3 daN ; TP Checking window ending mode
**************************************

Example 6 : « PROFIL » checking mode Checking Mode

*****************************************
Controle Courbe:Profil
-----------------------------------------
Debut Seuil Croissant - Fin Largeur Fixe - Mode Inclusion
F 01; Fmax : 44,3 daN; Crb <= Max : OK; Fmin1: 0,0 daN; Crb >= Min : OK

Debut Absolu - Fin Largeur Fixe - Mode Inclusion

F 02; Fmax : 42,6 daN; Crb <= Max : OK; Fmin1: 0,0 daN; Crb >= Min : OK

Debut Largeur Fixe - Fin Fin Cycle - Mode Inclusion

F 03; Fmax : 20,1 daN; Crb <= Max : OK; Fmin1: 0,0 daN; Crb >= Min : OK

*****************************************

Max value between start Min value between start

and end of chk window and end of chk window

OK : the curve has OK : the curve has

always been under always been over the
the top of chk wnd bottom of chk wnd

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 75 / 97

 Distance and Speed Diagram

12 Distance and Speed Diagram

PRESSING
ACQUISITION AND
CALIBRATION AND
PRESS-FITTING
ACQUISITION

Idle position (PR)

Pressing
calibration Starting
Index
speed speed
(position sensor)
TDC (256.325)

Pressing Calibration Travel speed Return speed

calibration return speed
speed

Press aperture

Approach distance (104)

Before press-fitting

Working speed
H2 = zz.zzz mm
Upper gauge

Deceleration distance (55.0)

Trip speed
Trip distance (52.211)
After press-fitting

The difference
in height must
be at least 60
mm
Lower gauge
H1= xx.xxx mm
or H1 = 0

PTR or PRV
0 point
(reference point defined during
machine calibration)

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 76 / 97

 Distance and Speed Diagram

DRAWING ACQUISITION AND CALIBRATION

Idle position (PR)

Starting Starting
Index
speed speed
(position sensor)
TDC

Drawing tool
Travel speed Return speed

Press aperture

Drawing
calibration
speed

Trip distance

PTR or PRV
0 point
(reference point defined during machine
calibration)

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 77 / 97

 Acquisition Example

13 Acquisition and Press-Fitting: Example

1: acquisition cycle with end 2: the initial distance is 3: return to idle position 4: part ready for press-
part in stacker detected (acquired) fitting

5: start of press-fitting 6: press-fitting completed. 6 b: press-fitting completed.

Max. diff. < final distance – Final distance > initial
initial distance < Min. diff. distance

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 78 / 97

 MVAT chronogrammes
1 2 3 4 5 6 7 8

MVAT Presse
D
Principe Exemple D

Gamme A Gamme 3
Hard Soft Hard

Position d'origine Position d'origine

Sélection 1 Sélection 43
Cycle X Cycle X+1 Cycle X+n Cycle 23

Synchro Synchro

C C
Séquence 1 Trace X Séquence 43 Trace 3

Synchro Hard Synchro Hard

Sélection N Cycle Y Cycle Y+n Sélection 121 Cycle 2

Synchro

Séquence N Trace Y Séquence 121 Trace 11

Sélection N Sélection N

B B
Synchro Hard
Rappel Synchro Hard
Cycle Z Cycle Z+1 Cycle Z+2 Cycle Z+n
Sélection N+1 Auto Sélection 513

Synchro Synchro Synchro

Séquence de
Rappel en position
Séquence N+1 Trace Z d'origine 513

Rappel
Synchro Hard
Chaîné
Sélection 513

Séquence de
Rappel en position
A d'origine 513 A

Préliminaire d'étude : Affectations d'E/S et définitions temporelles susceptibles d'évoluer sans préavis et sans appel.
Titre
Diagramme E/S MVAT Presse F.S.A.
Ets SORMEL
Ce document non contractuel ne peut être reproduit en tout ou partie sans l'autorisation écrite de FABRICOM Systèmes d'Assemblage
6,rue Becquerel
Format: A3 Numéro: Par : Z.I. de Châteaufarine
Révision: 25009 BESANCON
Fichier: C:\CAO\..\DIAG_ES0.SCH Date: 29-Mar-2000 Heure: 16:42:45 Folio0 of 0
1 2 3 4 5 6 7 8

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 79 / 97

 1 2 3
MVAT
4
chronogrammes
5 6 7 8

D
Diagramme E/S MVAT Presse D

avec Automate
Séquence d'emmanchement
Etape 1 Etape n+1 Fin cycle
S4
Pret/NonPret
Tack

C
E1 C
Start Cycle/Arurg Arrurg
Erreur de Selection ou de Calcul de fiches,vérouillé en attente d'Arrurg Tapi Option Infosys B.0 (31) = 1
S5
DebCyc/FinCyc (Top-1) Top-1
TRmin

Tack Tack TRmin

S6 = 0, Chaînage Soft (prioritaire) TRmin Tack TRmin
Envoi Courbes
S6
GenOK/GenNOK Etape OK/NOK Etape OK/NOK Res Gen OK/NOK
TRapi Tapi TRmin
S Résultats disponibles
E2->E5
Select_ext Entrées B0..B3 B5..B8 Entrées N.U. Entrées Entrées
Tapi E6 = 0, sélection libre Tack

B
E6 B
Extra Entrée B4 B9 N.U. Entrée
TRapi E7 = 1, code étendu E7 = 0, Chaînage Automate (non-prioritaire) E7 = 1, Fin de Chaînage Automate
E7
Sync Etape Aquittement
Tack Tack TRapi Tcmin Tapi Tack TRmin Tcmin TRapi Turg Tack

S7 E7 & A.6(20) = 1, Pas d'attente Automate

FinEtape Position Origine Ok Crc (B.1) Crc (B.1) StepReq en chaînage Soft uniquement Anomalie Position Origine Ok
Tack

S3
Cntl Variateur Prêt Crc (B.0) Crc (B.0) Anomalie Variateur Prêt
Tack

A S0 A
StrtB
Préliminaire d'étude : Affectations d'E/S et définitions temporelles susceptibles d'évoluer sans préavis et sans appel.
Tack Temps de reponse MVAT TRmin Temps de boucle MVAT Tapi Temps de reponse API TRapi Temps de boucle API
Titre
Diagramme E/S MVAT Presse F.S.A.
Turg Temps de maintien Non-Prêt Tcmin Temps de cycle min Ets SORMEL
Ce document non contractuel ne peut être reproduit en tout ou partie sans l'autorisation écrite de FABRICOM Systèmes d'Assemblage 6,rue Becquerel
Format: A3 Numéro: Par : Z.I. de Châteaufarine
Révision: 25009 BESANCON Error : SIGL_FAB.BMP File Not Found
Fichier: C:\CAO\..\DIAG_ES1.SCH Date: 8-Dec-2000 Heure: 11:33:34 Folio0 of 0
1 2 3 4 5 6 7 8

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 80 / 97

 MVAT chronogrammes
1 2 3 4 5 6 7 8

Diagramme E/S MVAT Presse sans Automate (Info Générales @31(A.7 = 0)

Séquence manuelle forcée (montée/descente)
D Séquence d'étalonnage forcée (compression: cale b./h.) D

Séquences manuelles de 1 à 32 (chaînage soft uniquement)

S4 Cycle en cours Fin cycle
Pret/NonPret
Tack

E1
Start Cycle/Arurg Arrurg
Tack

S5 Turg

DebCyc/FinCyc
Tack TRmin
C C
S6
GenOK/GenNOK Frc OK Res OK/NOK
TRmin Tack TRmin

E2->E6
Entrées Entrées On Off
A.7(31) = 0 & E7 = 1, code direct seq. 1 à 32 (pas de mux) Synchronisation manuelle
E7
Sync Etape Acquittement

E7 = 0, code direct E/S avec ou sans automate, (pas de mux) .

S7
Position Origine Ok Anomalie Position Origine Ok
FinEtape
Tack Tack Tack
B B
S3
Cntl Variateur Prêt Anomalie Variateur Prêt

S0
StrtB

Séquences manuelles forcées Séquences manuelles de 1 à 32

Code Roues Codeuses Légende Code Roues Codeuses
E7 E6 E5 E4 E3 E2 E7 E6 E5 E4 E3 E2
@E1 0 1 1 x x 1 (26d) Etalonnage Compression Cale Haute E2 = Etalonnage/Manuelle @E1 1 0 0 0 0 0 Séquence N°1
@E1 0 0 1 x x 1 (10d) Etalonnage Compression Cale Basse E3 = Descente @E1 1 0 0 0 0 1 Séquence N°2
@E1 0 1 0 x x 1 (18d) Etalonnage Traction E4 = Montée "
A
@E1 0 0 0 x x 1 (02d) Etalonnage Traction E5 = Compression(Desc)/Traction(Mont) @E1 1 1 1 1 1 0 Séquence N°31
A
@E1 0 1 0 x x 0 (17d) Montée Manuelle avec CdF E6 = Caleh./Caleb. @E1 1 1 1 1 1 1 Séquence N°32
@E1 0 1 1 x x 0 (25d) Descente Manuelle avec CdF CdF = Contrôle de Force
@E1 0 0 0 1 0 0 (05d) Montée Manuelle directe, avec CdF * Préliminaire d'étude : Affectations d'E/S et définitions temporelles susceptibles d'évoluer sans préavis et sans appel.
Titre F.S.A.
@E1 0 0 0 0 1 0 (03d) Descente Manuelle directe, avec CdF * Diagramme E/S MVAT Presse Ets SORMEL
Ce document non contractuel ne peut être reproduit en tout ou partie sans l'autorisation écrite de FABRICOM Systèmes d'Assemblage
6,rue Becquerel
* Si E5=1, Mont/Desc sans CdF (pour sortie de défaut de mesure de force) Format: A3 Numéro: Par : Révision:
Z.I. de Châteaufarine
25009 BESANCON
Fichier: C:\CAO\..\DIAG_ES2.SCH Date: 29-Mar-2000 Heure: 15:58:06 Folio0 of 0
1 2 3 4 5 6 7 8

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 81 / 97

 1 2 3 4 MVAT chronogrammes
5 6 7 8

D
Diagramme E/S MVAT Presse D

avec Automate
Séquence d'emmanchement
Etape 1 Etape n+1 Fin cycle
S4
Pret/NonPret
Tack

E1
C C
Start Cycle/Arurg Arrurg
Erreur de Selection ou de Calcul de fiches,vérouillé en attente d'Arrurg Tapi Option Infosys
S5
DebCyc/FinCyc (Top-1) Top-1
Tack Tack TRmin Chaînage Hard TRmin TRmin Tack TRmin
Envoi Courbes
S6 Tack
GenOK/GenNOK Etape OK/NOK Etape OK/NOK Res Gen OK/NOK
TRapi Tapi Chaînage Soft (Voir Diag_ES1) TRmin
S Résultats disponibles
E2->E5
Select_ext Entrées B0..B3 B5..B8 Entrées B0..B3 B5..B8 Entrées Entrées
Tapi E6 = 0, sélection libre
B
E6 B
Extra Entrée B4 B9 B4 B9 Entrée
E7 = 1, code étendu E7 = 1, Fin de Chaînage par Automate
TRapi E7 = 0, Chaînage par Automate
E7
Sync Etape Aquittement
Tack Tack TRapi Tcmin Tapi TRapi Tack Tack Tcmin TRapi Turg Tack

S7
FinEtape Position Origine Ok Crc (B.1) Crc (B.1) StepReq Crc (B.1) Crc (B.1) Anomalie Position Origine Ok
TRapi Tack

S3
Cntl Variateur Prêt Crc (B.0) Crc (B.0) Crc (B.0) Crc (B.0) Anomalie Variateur Prêt
Tack

A S0 A
StrtB
Préliminaire d'étude : Affectations d'E/S et définitions temporelles susceptibles d'évoluer sans préavis et sans appel.
Tack Temps de reponse MVAT TRmin Temps de boucle MVAT Tapi Temps de reponse API TRapi Temps de boucle API
Titre
Diagramme E/S MVAT Presse F.S.A.
Turg Temps de maintien Non-Prêt Tcmin Temps de cycle min Ets SORMEL
Ce document non contractuel ne peut être reproduit en tout ou partie sans l'autorisation écrite de FABRICOM Systèmes d'Assemblage
6,rue Becquerel
Format: A3 Numéro: Par : Z.I. de Châteaufarine
Révision: 25009 BESANCON Error : SIGL_FAB.BMP File Not Found
Fichier: C:\CAO\..\DIAG_ES3.SCH Date: 8-Dec-2000 Heure: 11:34:41 Folio0 of 0
1 2 3 4 5 6 7 8

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 82 / 97

 1 2 3 4
MVAT chronogrammes
5 6 7 8

Diagramme E/S MVAT Presse avec Automate

D
Séquence manuelle figée (montée/descente) 2 modes D

Séquence d'étalonnage figée (compression: cale b./h.)

Séquence d'étalonnage figée (traction cale unique)
Séquence de rappel figée
Cycle en cours Fin cycle
S4
Pret/NonPret
Tack

E1
C C
Start Cycle/Arurg Arrurg
Tapi

S5
DebCyc/FinCyc
Tack TRmin

S6
GenOK/GenNOK Frc OK Res OK/NOK
TRapi Tack TRmin

E2->E5
Select_ext Entrées B0..B3 B5..B8 On Entrées Off Entrées
Tapi Tapi
B.9 = 1, sélection figée
B
E6 B
Extra Entrée B4 B9 Entrée Entrée
TRapi E7 = 1, code étendu TRapi TRapi Tack TRapi Tack TRmin

E7
Sync Etape Aquittement
Tack Tack Turg Tack

S7
FinEtape Position Origine Ok Crc (B.1) Crc (B.1) Anomalie Position Origine Ok

S3
Cntl Variateur Prêt Crc (B.0) Crc (B.0) Variateur Prêt Anomalie Variateur Prêt

A S0 A
StrtB
Préliminaire d'étude : Affectations d'E/S et définitions temporelles susceptibles d'évoluer sans préavis et sans appel.
Tack Temps de reponse MVAT TRmin Temps de boucle MVAT Tapi Temps de reponse API TRapi Temps de boucle API
Titre
Diagramme E/S MVAT Presse F.S.A.
Turg Temps de maintien Non-Prêt Tcmin Temps de cycle min Ets SORMEL
Ce document non contractuel ne peut être reproduit en tout ou partie sans l'autorisation écrite de FABRICOM Systèmes d'Assemblage
6,rue Becquerel
Format: A3 Numéro: Par : Z.I. de Châteaufarine
Révision: 25009 BESANCON
Fichier: C:\CAO\..\DIAG_ES4.SCH Date: 29-Mar-2000 Heure: 16:00:17 Folio0 of 0
1 2 3 4 5 6 7 8

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 83 / 97

 1 2 3 4 MVAT chronogrammes
5 6 7 8

Diagramme E/S MVAT Presse

avec Automate
Séquence d'emmanchement avec contrôle
D D
S3 MVAT API ROBOT
Rotation
de force pour detection cannelure E1
E7
R
S5
Mode Cntl FRC Mode Cann.

Etape 1 Etape n+1 Fin cycle

S4
Pret/NonPret
Tack

E1
C C
Start Cycle/Arurg Arrurg
Erreur de Selection ou de Calcul de fiches,vérouillé en attente d'Arrurg Tapi Option Infosys
S5
DebCyc/FinCyc (Top-1) Top-1
Tack Tack TRmin Chaînage Hard TRmin TRmin Tack TRmin
Envoi Courbes
S6 Tack
GenOK/GenNOK Etape OK/NOK Etape OK/NOK Res Gen OK/NOK
TRapi Tapi Chaînage Soft (Voir Diag_ES1) TRmin
S Résultats disponibles
E2->E5
Select_ext Entrées B0..B3 B5..B8 Entrées B0..B3 B5..B8 Entrées Entrées
Tapi E6 = 0, sélection libre
B
E6 B
Extra Entrée B4 B9 B4 B9 Entrée
E7 = 1, code étendu Tapi Cannelure (API) E1 = 1, Fin de Chaînage par Automate
TRapi E1 = 0, Chaînage par Automate
E7
Sync Etape Aquittement
Tack Tack TRapi Tcmin Tapi TRapi Tack Tack Tcmin TRapi Turg Tack

S7
FinEtape Position Origine Ok Crc (B.1) Crc (B.1) StepReq Crc (B.1) Crc (B.1) Anomalie Position Origine Ok
Cannelure (Robot+API) mode CNTL FRC TRapi Tack

S3
Cntl Variateur Prêt Crc (B.0) Crc (B.0) Crc (B.0) Crc (B.0) Anomalie Variateur Prêt
Tack Tack

A S0 A
StrtB
Préliminaire d'étude : Affectations d'E/S et définitions temporelles susceptibles d'évoluer sans préavis et sans appel.
Tack Temps de reponse MVAT TRmin Temps de boucle MVAT Tapi Temps de reponse API TRapi Temps de boucle API
Titre
Diagramme E/S MVAT Presse F.S.A.
Turg Temps de maintien Non-Prêt Tcmin Temps de cycle min Ets SORMEL
Ce document non contractuel ne peut être reproduit en tout ou partie sans l'autorisation écrite de FABRICOM Systèmes d'Assemblage
6,rue Becquerel
Format: A3 Numéro: Par : Z.I. de Châteaufarine
Révision: 25009 BESANCON Error : SIGL_FAB.BMP File Not Found
Fichier: C:\CAO\..\DIAG_ES5.SCH Date: 8-Dec-2000 Heure: 11:35:27 Folio0 of 0
1 2 3 4 5 6 7 8

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 84 / 97

 1 2 3 4 5 6 7 8
MVAT chronogrammes

MVAT Presse
Code sélection étendu
D D
/ E1 E7 \ Valeur
E6 E5 E4 E3 E2 E6 E5 E4 E3 E2 Hex/Dec
Selection Libre fiches de cycle Entrées actives
b9 b8 b7 b6 b5 b4 b3 b2 b1 b0
0 0 0 0 0 0 0 0 0 0 000H/000 Code = 001 Cycle 1 à 384 E1
0 0 0 0 0 0 0 0 0 1 001H/001 Code = 002 Cycle 1 à 384 E1
" " E1
0 1 0 1 1 1 1 1 1 0 17EH/382 Code = 383 Cycle 1 à 384 E1
0 1 0 1 1 1 1 1 1 1 17FH/383 Code = 384 Cycle 1 à 384 E1
Selection Scratch
0 1 1 0 0 0 0 0 0 0 180H Code = 485
0 1 1 0 0 0 0 0 0 1 181H Code = 486
" "
C 0 1 1 1 1 1 1 1 1 0 1FEH Code = 511 C
0 1 1 1 1 1 1 1 1 1 1FFH Code = 512
Selection Figée Entrées actives
1 0 0 0 0 0 0 0 0 0 200H/512 Code = 513 Rappel pos. origine @E1 E1
1 0 0 0 0 0 0 0 0 1 201H/513 Code = 514 Calibr.Comp. Cale haute @E1 E1
1 0 0 0 0 0 0 0 1 0 202H/514 Code = 515 Calibr.Comp. Cale basse @E1 E1
1 0 0 0 0 0 0 0 1 1 203H/515 Code = 516 Calibr.Tract. @E1 E1
1 0 0 0 0 0 0 1 0 0 204H/516 Code = 517 Calibr.Tract. @E1 E1
1 0 0 0 0 0 10 010 1 205H/517 Code = 518 Montée Manuelle @E1 E1
1 0 0 0 0 0 10 011 0 206H/518 Code = 519 Descente Manuelle @E1 E1
1 0 0 0 0 0 10 011 1 207H/519 Code = 520 Mont/Desc E1|E6|E2|(E4+E3)
Prépositions et spéciales
1 0 0 0 0 0 1 1 0 0 208H Code = 521 Pré-position N°1
B B
1 0 0 0 0 0 1 1 0 1 209H Code = 522 Pré-position N°2
" "
1 0 0 0 0 1 1 1 1 0 21EH Code = 542 Pré-position N°23
1 0 0 0 0 1 1 1 1 1 21FH Code = 543 Pré-position N°24
1 0 0 0 1 0 0 0 0 0 220H Code = 544 Rsrv 3
" "
1 1 1 1 1 1 1 1 1 0 3FEH Code = 1023 Rsrv 481
1 1 1 1 1 1 1 1 1 1 3FFH Code = 1024 Rsrv 482

A A

Préliminaire d'étude : Affectations d'E/S et définitions temporelles susceptibles d'évoluer sans préavis et sans appel.
Titre
Diagramme E/S MVAT Presse F.S.A.
Ets SORMEL
Ce document non contractuel ne peut être reproduit en tout ou partie sans l'autorisation écrite de FABRICOM Systèmes d'Assemblage
6,rue Becquerel
Format: A3 Numéro: Par : Z.I. de Châteaufarine
Révision: 25009 BESANCON
Fichier: C:\CAO\..\DIAG_ES6.SCH Date: 29-Mar-2000 Heure: 16:03:57 Folio0 of 0
1 2 3 4 5 6 7 8

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 85 / 97

 Lexique

14 Glossary

Idle Position (PULSE-1)

Index

Top Dead Centre

(PULSE 0)

Top Dead
Centre

Shaft travel

Lower Safety Point

Bottom Dead
Centre
Idle Position : Default position of the shaft at the start of each cycle. This position is only active
after an initial cycle each time the equipment is switched on. This position may be configured
between the Index (position given by the MVAT after calibration under the title "Index
centring") and the position of PULSE-1. See "Specifications" However, it is recommended to
operate with the field "Idle position from TDC" set to 0.
Index: The position of PULSE 0 and PULSE-1 must be either side of the position of the Index and
at an equal distance for safe operation (i.e. "Index centring" equal to half of the screw pitch).
This is the return position of the shaft until the pin has been initialised (by an initial cycle after
power on).
Top Dead Centre: This is the effective starting point of displacement measurements.
Bottom Dead Centre: This is the maximum physical position the shaft can reach when it is fully
extended.
Lower Safety Point: This is a limitation on this position obtained by programming in order to
avoid damaging the pin

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 86 / 97

 This document is the property of FABRICOM SYSTEMES D'ASSEMBLAGE and may
not be reproduced or communicated without their authorisation

15 Analysis of malfunctions when first switched on

The application runs for the first time or after hardware replacement

Symptom of malfunction Message on RS232 Hyper terminal Cause and solution

Shaft exits or returns at maximum speed Motor phases reversed relative to those of the synchro resolver
Pressing calibration: the shaft does not rise Force sensor wired wrong way round: check by command
back up after application force "Esc O"(see keyboard commands)
Or current limited by RHAPSODIE.NET (calibration current) or by the
speed controller settings.
Pressing calibration: shaft exits then stops "Force before pulse fault" Mechanical problem (sticking point, obstacle, etc.)
Pressing calibration: shaft exits then stops after Check whether the brake has been disabled or whether the
a short distance INFRANOR speed controller is not malfunctioning
"Displacement change fault" Resolver or coder pulses absent or PULSE absent
Or travel time between the index release and the 1st PULSE is greater
than 1 sec: increase the pressing calibration speed
"Index change fault" The index remains present all the time
Cannot start a cycle or carry out calibration "Index NOK" The shaft has not returned sufficiently or the index is absent.
"Offset fault" Sensor absent or wiring fault. Check using command "Esc C"
"Unbalancing fault" Force sensor wiring fault
"Force before index release The max. force entered, protecting between PULSE-1 and the
fault" approach position, is too weak

During a cycle, the shaft stops on approach Current limitation in the cycle (see RHAPSODIE.NET)
Current limitation in speed controller (see BPCW 2.6)
If speed controller fault I2t => holding time too long for the trip force
requested

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A page 87/97

 Fault Analysis

16 List of faults
The fault number given in the sequence result block on the 3rd row is the number in the 1st column of the table

Fault Message on RS232 Hyper terminal Cause and solution

no.

1 EMERGENCY STOP FAULT Execution fault: cycle start release (E1) during sequence

2 EXIT TIME FAULT Programming or execution fault: Programmed "Cycle time" in cycle page exceeded

3 SEQUENCE TYPE FAULT Execution fault: start of the pulling calibration sequence was incorrect

4 OFFSET FAULT Execution fault: the force sensor offset is greater than the "Offset Fault Threshold" setpoint
Remedy:
- Check the offset using the command "ESC o"
- Increase the offset default threshold setting in the specification file (slightly)
- Carry out calibration again
5 INDEX NOT PRESENT AT START FAULT Execution fault: detector not present before pin motor starts
Cause: Remedy:
- the pin is not in fallback position - Put the pin shaft back using manual mode
- the index has not been seen by the MVAT - Check the wiring of the index
6 FORCE BEFORE INDEX RELEASE FAULT Execution or programming fault: force encountered during detector presence. The force measured is greater than the
"Safety force" or the "Maximum force" setpoint or, if calibrating, the "Pressing Calibration Force". It could also be an
incorrect force measurement.
Remedy:
- Clear the tip of the pin
- Check the force using the command "ESC o"
7 FORCE BEFORE PULSE FAULT Execution fault: force encountered before the PULSE has been received (between the detector and the PULSE). The
force measured is greater than the "Safety force" or the "Maximum force" setpoint or, if calibrating, the "Pressing
Calibration Force".
It could also be an incorrect force measurement.
Remedy:
- Clear the tip of the pin
- Check the force using the command "ESC o"
8 FORCE BEFORE APPROACH FAULT Execution fault: the MVAT measures a force before the "Approach position" setpoint. The force measured is greater than
the "Safety force" setpoint or the "Trip force" setpoint or the "Maximum force" setpoint
Remedy:
- Clear the tip of the pin
- Check the approach position
9 STOP ON LOWER SAFETY IN CALIBRATION MODE FAULT Execution fault:
- Maximum displacement reached in calibration mode (displacement measurement overflow 10000mm depends on the
number of pulses)
- Phase wiring reversed (IN+ and IN-) in this case the fault appears on the first PULSE
Note:
in the case where signals from the speed controller are used for displacement, if the direction of the motor is reversed in
the Infranor program (Reverse movement), the IN+ and IN- wiring must also be reversed.

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 Fault Analysis

10 STOP ON LOWER SAFETY IN CYCLE FAULT Execution fault: max. displacement reached in calibrating "Lower Safety
Position" setpoint
11 STOP ON MAX FORCE FAULT Execution fault: no "Trip Force" programmed
stop on max end stop force ("Safety Force" setpoint or "Maximum force" setpoint)
12 STOP ON LOWER SAFETY ON INERTIA FAULT Execution fault: during the "Holding time", the pin reaches the "Lower Safety Position" setpoint

13 LINE SELECTION FAULT Programming fault: test whether the curve selection is between 0 and 16

14 SETTINGS NOT CORRECT WITH THE CYCLE DEFINITION Programming fault: this is in the case of a positioning sequence (the
sign of the value must relate to the cycle type
15 PIN POSITIONING ERROR Execution fault: detector not present on the cycle start

16 INDEXER BEFORE PULSE ON RETURN FAULT Execution fault: during the return phase, the MVAT see the presence of the "index presence" inductive detector
Cause: interference of the indexer by the motor or the environment.
Remedy:
- Check the wiring, in particular the grounds, proximity of the measuring cable to the motors or power cable
- Increase the index filtering time (Index filter field in the specification page).

17 RECOVERY OF PULSE BEFORE INDEXER ON RETURN FAULT Execution fault: the MVAT sees PULSE-1 or the "Idle position from TDC" setpoint before seeing the presence of the
detector.
Cause:
- Problem of coder coupling on UE with belt drive, check the coupling bellows
- Index Centring incorrectly centred between the two resolver or coder pulses. Check the centring of the TOPs in the
calibration result. (command "e" in the hyperterminal)
18 STOP ON INDEXER MANUAL CONTROL indicates that the MVAT stopped on the detector

19 STOP ON SAFETY FORCE MANUAL CONTROL Indicates that the MVAT stopped on the Safety Force or 10% of the true rated force

20 CALIBRATION NOT DONE FAULT Execution fault: the MVAT card has not recorded a pressing calibration

21 RATED FORCE PROGRAMMING FAULT Programming fault: "Sensor Rating" setpoint incorrect

22 CALIBRATION FORCE PROGRAMMING FAULT Programming fault: "Pressing Calibration Force" setpoint incorrect

23 SPEED PROGRAMMING FAULT Programming fault: the speeds on the specification screen page or the cycle screen page

24 CYCLE DEFINITION PROGRAMMING FAULT Programming fault: the mode relating to the type of cycle is not defined or inconsistent

25 FORCE BEFORE PULLING APPROACH FAULT Execution fault: the MVAT measures a force during the pulling approach phase. The force measured is greater than the
"Trip force" setpoint or the "Maximum force" setpoint
26 TRIP POSITION > APPROACH POSITION PROGRAMMING FAULT Programming fault: the pressing "Trip Position" setpoint is greater than the pressing "Approach Position" setpoint

27 CALIBRATION FORCE < PRESSING FORCE PROGRAMMING Programming fault: the pressing "Trip Force" setpoint is greater than the "Pressing Calibration Force" setpoint
FAULT
28 SELECTION PROGRAMMING FAULT Programming fault: the selection of the cycle is incorrect

29 NUMBER OF PULSES INCORRECT FAULT Execution or programming fault: the resolution (number of pulses/mm) found during pressing calibration is greater or less
than the "Max. Resolution" and "Min. Resolution" setpoints
30 APPROACH POSITION < WORKPIECE MAX HT POSITION Programming fault: the "Approach position" setpoint is less than the "Max. Position" (max. workpiece position)
PROGRAMMING FAULT

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 Fault Analysis

31 CALIBRATION REQUEST PROGRAMMING FAULT Programming fault: the "Pressing Calibration Force" is greater than the value of the pressing calibration force for the last
recorded calibration (correct calibration)
32 TRIP < APPROACH ENTERED PROGRAMMING FAULT Programming fault: the pulling "Trip Position" setpoint is less than the pulling "Approach Position" setpoint

33 APPROACH DISPLACEMENT < TABLE OPENING PROGRAMMING Programming fault: the pressing "Approach position" setpoint is less than the "Top Dead Centre" (the opening of the UE)
FAULT found during calibration
34 OPERATING MODE PROGRAMMING FAULT Programming or execution fault: the selected operating mode is incorrect

35 SLOWING DOWN POSITION < TRIP POSITION PROGRAMMING Programming fault: the pressing "Slowing down Position" setpoint is less than the pressing "Trip Position" setpoint
FAULT
36 MAX CHAINING > 100 CYCLES PROGRAMMING FAULT Execution fault: the number of chained cycles is greater than 100

37 APPROACH > WORKPIECE MIN POSITION ENTERED Programming fault: the pulling "Approach position" setpoint is greater than the "Min. Position" (min. workpiece position)
PROGRAMMING FAULT

38 SPEED OFFSET FAULT not active

39 MEASUREMENT OVERFLOW FAULT Execution or programming fault: the allowed offset + the measurement exceeds the true rated force (useful force)
example: offset = - 200 daN; true rated force = 3000 daN, measurement without offset correction = 2900 daN, true
measurement = 2900 – (-200) = 3100 daN = exceeds the true rated force. This test is carried out when the value is stored.
During execution, the saturation of the measurement is checked.
40 SETPOINT OVERFLOW FAULT Execution or programming fault: the offset + requested force setpoint exceeds the true rated force (useful force)

41 STOP ON RETURN FORCE FAULT Execution or programming fault: the MVAT measures a force during the return phase which is greater than the "Safety
Return Force" setpoint
Remedy:
- Check the force using the command "ESC o" (warning, offset display does not work just after a RESET)
- Increase the safety return force parameter in the specification tab
42 EXTERNAL CHAINING PROGRAMMING FAULT not active

43 PULLING TRIP POSITION > DISPLACEMENT CARRIED OUT Programming fault: the pulling "Trip Position" is greater than the current pin displacement
PROGRAMMING FAULT
44 SEMI-MANUAL MODE =>E3 OR E4 FAULT Keyboard command execution fault: if in SEMI-MANUAL MODE, inputs E3 or E4 must be active

45 PULLING APPROACH POSITION > DISPLACEMENT CARRIED OUT Programming fault: the pulling "Approach Position" is greater than the current pin displacement
PROGRAMMING FAULT
46 CHAINING SELECTION NUMBER PROGRAMMING FAULT Programming fault: the number of chained cycles is greater than 384

47 INPUTS (E3+E4) AT THE SAME TIME FAULT Keyboard command execution fault: on the start of the cycle, inputs E3 or E4 are simultaneously active

48 CHAINING CONTINUATION AS CYCLE NOT OK FAULT Execution or programming fault: chaining is requested on a bad cycle although the "Cycle resume if Nok" flag is not
enabled (box checked)
49 SELECTION 0 ON CHAINING BY PLC FAULT Execution or program fault: automatic chaining but no cycle no.

50 PULLING CALIBRATION FAULT Execution fault: pulling calibration not saved or initialised

51 DISPLACEMENT CHANGE FAULT Execution or programming fault: safety time relating to the release of the detector and change in displacement
measurement elapsed. Safety time = 2 secs.
Cause: not enough pulses during a covering time delay.
Remedy:
- check the coupling in the case of a belt-driven press-fitting unit
- check the encoder wiring in the case of a belt-driven press-fitting unit

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 90 / 97

 Fault Analysis

- check the programming of the number of pulses (infranor speed controller) in the case of a direct drive press-fitting
unit
52 NO AUTOMATIC RETURN FAULT Execution or programming fault: where the "Auto Return" flag is not enabled (the box is not checked) and the cycle
requested is not 513 in non-automatic return mode, cycle 513 must be called to carry out the return
53 AWAITING AUTHORISATION TO CONTINUE CYCLE FAULT not active

54 INDEXER CHANGE FAULT Execution or programming fault: safety time relating to the start of the pin motor and release of the detector elapsed.
Safety time = 2 secs.
Cause: the index does not disappear after the pin starts, it is therefore impossible to raise it back up in manual mode.
Remedy: check the wiring to the index

55 SENSOR UNBALANCE FAULT Execution fault: before starting the pin, the MVAT card carries out a test on the force sensor and the measuring chain.
This test involves unbalancing the sensor by a known amount (50% of the true rated value) and checking this value
56 INDEXER FAULT DURING PULLING Execution fault: the MVAT sees the presence of the detector during the pulling phase

57 STORAGE BUT NO TRACE SEQUENCE FAULT Programming fault: tracing has been requested by setting the flag "Store the Curve" to YES, but there is no curve number
associated
58 NO PROGRAM CYCLE START FAULT Execution or programming fault: indicates no program cycle start indicated

59 CALIBRATION FORCE TOO SMALL FAULT Programming fault: indicates that the "Pressing Calibration Force" setpoint
is less than 25% of the true nominal force (useful force)
60 SPLINE HOLDING TIME FAULT Execution or programming fault: "Holding time" expired but no splines found

61 NEW CALCULATED TRIP POSITION < LOWER SAFETY POINT FAULT Programming fault: the "Trip Position" setpoint calculated relative to the current displacement (positioning sequence) is
less than the "Lower Safety Position" setpoint
62 TABLE OPENING CALIBRATION FAULT Execution or programming fault: the pressing elasticity measurement is greater than the "Pressing elasticity" setpoint

63 FILE ERROR FAULT Programming fault: indicates that there are one or more incorrect values in the cycle file selected

64 MAX DISPLACEMENT REACHED ON PULLING Execution fault: where there is no programmed pulling trip position indicates that the MVAT reached position 0 which is
the starting PULSE
65 RATED CALCULATION FAULT Programming fault: the useful calculation force is not valid. The "Rated Calculation Error" message runs round in a loop.
RATED CALCULATION ERROR: 01 sensitivity entry error
02 load limit overrun error (warning, the new rated value calculated
with the "Overload max. factor" must be greater than the true rated value calculated
with the sensitivity. In this case an Overload max. factor >1 must be entered, for
example, 1.2)
03 class entry error
04 sensor power supply overrun error (15 volts)
05 sensor power overrun allowed (15 volts)
06 requested force correction > positive authorised percentage error
07 requested force correction > negative authorised percentage error (if in the
Quality Department menu a value is entered in the Max. force correction field and
nothing in the other fields, you will have this fault which scrolls on the screen with the
nearest output flashing
66 APPROACH > OPENING FAULT Programming fault: the "Approach position" setpoint is greater than the "Top Dead Centre" (the opening of the Ue) found
during calibration
67 MEASUREMENT SATURATION Execution or programming fault: indicates that the force measured exceeds the true rated force (useful force)

68 FORCE BEFORE END YES BUT NO TRACING Programming fault: indicates that the "Force before stop result" is enabled (box checked) although the "Store the Curve"
flag is disabled (box not checked)

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 Fault Analysis

69 TABLE OPENING OFFSET FAULT Programming fault: indicates that the "Offset from Actual Working Plane (PRV)" is positive and greater than the Top Dead
Centre (the opening of the UE) found during calibration
70 DISPLACEMENT POSITION CALCULATION OVERFLOW FAULT Programming fault: indicates that there is a positive position setpoint greater than the opening of the UE for the
sequence requested (cycle+curve). Example: opening 249.418mm; programmed position 250mm
71 PULLING CURVE FAULT (POSITION FAULT IN THE CURVE CHECK; Execution or programming fault: expansion case: indicates that the number of
NO. OF PULLING WINDOWS NOT EQUAL TO NO. OF PRESSING pulling windows which have been executed is not equal to the number of pressing windows executed in order to carry
WINDOWS) out the curve check in pulling mode. The number of windows executed in pulling mode must equal the number in
pressing mode.
72 WINDOW FAULT (POSITION FAULT IN THE CURVE CHECK) Marker with the same address twice
A window has been defined which could not be drawn (window outside the cycle) or the marker has been stored which
should not have been
73 NO. EXEC WINDOW FAULT The number of windows executed differs from the number of windows programmed

74 PULLING CURVE RELOAD FAULT Programming fault: the sequence is trying to reload a curve on a pulling cycle in which storage has been requested

75 ACCELERATION OVERFLOW FAULT Programming fault: the acceleration setpoint is too large

76 SPEED AND ACCELERATION INCONSISTENCY Programming fault: The requested speed and acceleration distance are inconsistent

77 POSITIONING CYCLE FAULT Programming fault: the first cycle in the sequence is a positioning cycle.

78 INDEX SELECTION EXECUTION FAULT Execution fault: the index has been moved (case of multiple indexes)

79 INDEX SETPOINT EXECUTION FAULT Execution fault: the index has been moved (case of multiple indexes)

80 PLC STOP FAULT Execution fault: The PLC is no longer responding

81 CURVE RELOAD AUTHORISATION FAULT Programming fault: Curve reloading is not authorised during a sequence

82 OPENING FAULT Execution fault: The Top Dead Centre calculated at the end of calibration is outside tolerances (TDC Max and TDC Min
in the "Setpoints" tab of the "Specifications" page

83 MAX NO. OF PROFILE WINDOWS FAULT Programming fault: In profile mode, a maximum of 5 recording ranges is allowed.

84 WINDOW MARKER FAULT Execution fault: An internal error has occurred in calculating the position of the check window.

85 FORCE BEFORE STOP IN PROFILE MODE FAULT Programming fault: in advanced curve mode (Profile), the "Force before Stop Result" on the Cycle page may not be
requested.

86 WIN/CYCLE CONSISTENCY FAULT Programming fault: on a complete sequence, if one of the cycles has its "Force Before Stop per Cycle" box checked, it
must be the same for all cycles in the sequence and the "Per cycle" box on the Curve page must also be checked for
the curve associated with this sequence. In this mode, curve reload is possible with Hard chaining (but only for standard
curves - curve prog. from 1 to 16)
Similarly, on a complete sequence, if one of the cycles has its "Force Before Stop per Cycle" box unchecked, it must be
the same for all cycles in the sequence and the "Per cycle" box on the Curve page must also be unchecked for the
curve associated with this sequence.

87 TRIP BY EXTERNAL INPUT Indicates that the trip has been carried out by an external input, ON/OFF input E5

88 NO. OF RECORDINGS EXECUTED NOT EQUAL TO NO. OF Fault linked to a curve reload => curve reload not possible. In PROFIL Mode, to reload a curve, a test must be made that
RECORDINGS PROGRAMMED FAULT all programmed recordings have been executed

89 CALIBRATION FILE ERROR FAULT Programming fault: indicates that there are one or more incorrect values in the calibration file selected

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 Fault Analysis

90 RESOLUTION MESSAGE ENTERED Calibration result message without gage

91 HARDWARE RESOLUTION MESSAGE Calibration result message without gage

92 SPEED DIRECTION FAULT The direction of the speed setpoint is not equal to the direction of the force measured

93 CALIBRATION FUSE VALUE FAULT Calibration fuse value fault in the flash memory

94 STOP MESSAGE ON THE POSITION IN CONTROL MODE In control mode, indicates that the stop is carried out on the position

95 POSITION DISPLACEMENT NOT VALID IN CONTROL MODE FAULT This fault occurs in control mode:
- If an absolute or relative ascent is requested after power on, then the shaft is not at its origin
- If an absolute or relative descent is requested after power on, then the shaft is not at its origin
- If a change is made to this mode without having started by descending

96 NO POSITION IN CONTROL MODE FAULT This fault occurs in control mode:

- If an absolute or relative ascent or descent is requested when no position has been entered

97 MAX THRESHOLD TRIP FAULT A trip has occurred on the max threshold setpoint. The sequence is interrupted

98 SPEED DECIMAL PLACES FAULT The MVAT has received a speed setpoint with 3 decimal places while the maximum is 2 decimal places

99 FORCE BEFORE END BUT NO DISTANCE BEFORE END SETPOINT A force before end is requested although no distance before end setpoint has been programmed
FAULT

100 FORCE BEFORE END BUT NO CALCULATION FAULT Programming fault: the force before end is requested but the force before end has not been able to be calculated as:
- we are in window/sequence mode ("Per Cycle" field in profile program not checked) while the recording windows
have not all been run through
- a force before end is requested while the curve check took place in the previous cycle
- we are in window/sequence mode, and it is only possible to have the force before end at the same time as the
curve calculation. i.e. once all windows have been executed.

101 HARD CYCLE START NOT ACTIVE IN CONTROL MODE FAULT In control mode, the Hard cycle start (On/Off input E1) must be raised.

102 CONTROL MODE NOT AUTHORISED FAULT Programming fault. The "Keyboard controlling enabled" box in the Appendix Specifications page is not checked.

103 ABSOLUTE DESCENT POSITION IN CONTROL MODE FAULT In control mode, programming fault associated with the absolute descent command:
- positive set point: Descent setpoint > table opening (TDC)
- negative setpoint: Descent setpoint < Lower safety position

104 ABSOLUTE ASCENT POSITION IN CONTROL MODE FAULT In control mode, programming fault associated with the absolute ascent command:
- positive set point: Ascent setpoint > table opening (TDC)
- negative setpoint: Ascent setpoint < current position

105 RELATIVE ASCENT POSITION IN CONTROL MODE FAULT In control mode, programming fault associated with the relative ascent command:
- positive set point: Ascent setpoint > current position
- negative setpoint: Relative ascent setpoint must not be negative

106 RELATIVE DESCENT POSITION IN CONTROL MODE FAULT In control mode, programming fault associated with the relative descent command:

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 Fault Analysis

- positive set point: New descent position > safety setpoint

Relative descent setpoint too big => overflow
- negative setpoint: Relative descent setpoint must not be negative

107 SPEED CONTROLLER NOT READY IN CONTROL MODE FAULT Execution fault. The speed controller is not ready

108 SEQUENCE FINISHED In control mode only, the « MESSAGE » numbers are used by the UExp-MVAT panel to translate the message

109 SPEED CONTROL FAULT IN FORCE FOLLOWING MODE In force following mode, a speed control fault occured.Check the parameters of this mode.

110 CURRENT CONTROL FAULT IN FORCE FOLLOWING MODE In force following mode, a current control fault occured.Check the parameters of this mode. :
- Either the current reference value is > than 50% max current when the press is triping under force
- Or the current reference value calculated to compensate the force loosing is > than 50% of max. current.

111 FORCE POSITIONNING CYCLE FAULT In Force incremental mode, an overflow calculation occured for the new force reference

112 TEMPERATURE CORRECTION FAULT Could occure when temperature correction is activated, and if the external temperature sensor is missing during
claibration or cycle.

113 FORCE FOLLOWING MODE & SLOPE TRIPPING MODE TOGETHER The 2 incompatible working mode have been selected at the same time.

114 SLOPE TRIPPING MODE PARAMETERING FAULT In Slope tripping mode,a parametering fault is present :
- Eitehr the loop is too big
- Or the tripping coefficient is too big

115 MISSING CALIBRATION FAULT When you update from version MVAT V10.05 to V10.06, a calibration sequence is needed

116 TEMPERATURE CORRECTION ACTIVATED WITHOUT TEMPERATURE Occurs when temperature correction is activated (a value in the field "Deform. Correct." has been entered) and there is
SENSOR (CIT) no temperature circuit,
OR the card has been updated from 10.05 version to 10.06 version, and the parameters havn't been send again to the
MVAT card.
Remark : when the MVAT card is updated from 10.05 version to 10.06 version, a full downloading is needed
from Rhapsodie.Net.
117 TEMPERATURE CORRECTION FAULT Occurs when temperature correction is activated (a value in the field "Deform. Correct." has been entered) and the
frame deformation calculated with the actual temperature is too high.
118 INCREMENTAL FORCE MODE FAULT When the Incremental Force mode is used :
- the type of cycle has to be "Insertion" (logically, Rhapsodie doesn't allow to do otherwise)
- the incremental Force mode has been used on the 1st cycle of the sequence.
119 LUBRICATION STOP FAULT The "Greasing Shut down threshold" (Specifications page, Maintenance tab) is reached, and the "Shut down if threshold
reached" checkbox has been checked, then the MVAT stops, and doesn't want to continue.
Please proceed to the lubrication of the spindle, then validate by "Greasing Done" button in Rhapsodie, or on the MVAT
panel.

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 94 / 97

 Fault Analysis

17 Analyse des défauts Contrôle Courbe

Le N° de défaut donné dans le bloc résultat fenêtre en 2ème ligne est le N° en 1ère colonne du tableau
*****************************************
Controle Courbe:Profil Courbe N0: 57

Numero de defaut courbe : 02

-----------------------------------------
Debut Largeur Fixe - Fin Fin Cycle - Mode Inclusion Compression
F 01; Fmax : 216,0 daN; Crb <= Max : OK; Fmin1: 203,9 daN; Crb >= Min : OK

Debut Seuil Croissant - Fin Seuil Croissant - Mode Inclusion Traction

F 02; Fmax : -117,8 daN; Crb <= Max : OK; Fmin1: -184,6 daN; Crb >= Min : OK

Debut Seuil Croissant - Fin Largeur Fixe - Mode Moyenne Traction

F 03; FMoyenne: -64,2 daN;OK
*****************************************

N° de Message sur terminal RS232 Description Cause et solution

défaut

1 DEFAUT PARAM DEB > FIN Défaut paramétrage fenêtre Début > Fin Défaut contrôle fenêtre marqueurs : le marqueur début déplacement > marqueur fin
déplacement : vérifier la programmation

2 DEFAUT SEUIL DEB CROISSANT Défaut contrôle fenêtre : Seuil de décl. Défaut contrôle fenêtre : indique que le seuil d'effort croissant pour le début de la fenêtre n'a
croissant pour le début de la Fenêtre non pas été atteint. Vérifier la programmation de la zone d'observation, ou la valeur du seuil.
atteint

3 DEFAUT SEUIL DEB DECROISSANT Défaut contrôle fenêtre : Seuil de décl. Défaut contrôle fenêtre : indique que le seuil d'effort décroissant pour le début de la fenêtre n'a
décroissant pour le début de la Fenêtre pas été atteint. Vérifier la programmation de la zone d'observation, ou la valeur du seuil.
non atteint

4 DEFAUT SEUIL FIN CROISSANT Défaut contrôle fenêtre : Seuil de décl. Défaut contrôle fenêtre : indique que le seuil d'effort croissant pour la fin de la fenêtre n'a pas
croissant pour la fin de la Fenêtre non été atteint. Vérifier la programmation de la zone d'observation, ou la valeur du seuil.
atteint

5 DEFAUT SEUIL FIN DECROISSANT Défaut contrôle fenêtre : Seuil de décl. Défaut contrôle fenêtre : indique que le seuil d'effort décroissant pour la fin de la fenêtre n'a pas
décroissant pour la fin de la Fenêtre non été atteint. Vérifier la programmation de la zone d'observation, ou la valeur du seuil.
atteint

6 DEFAUT DEB > DEB PLAGE Défaut début fenêtre contrôle > Début Défaut contrôle fenêtre : La consigne dans le cas d'un début de la plage d'enregistrement
plage enregistrement positif : une des cotes de la fenêtre est supérieure à la cote début enregistrement

7 DEFAUT MARQUEURS PLAGE Défaut marqueur plage enregistrement Défaut plage enregistrement : Aucun marqueur de fin de plage d'enregistrement

8 DEFAUT DEB > FIN Défaut début fenêtre contrôle > fin fenêtre Défaut contrôle fenêtre : le marqueur du début de la fenêtre de contrôle est supérieur au
contrôle ou fin plage enregistrement marqueur de fin de la fenêtre ou de la plage d'enregistrement. Vérifier votre programmation.

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 95 / 97

 Fault Analysis

9 DEFAUT FCTRL HORS PLAGE Défaut fenêtre contrôle en dehors de la Défaut contrôle fenêtre : les marqueurs de la fenêtre de contrôle calculés sont en dehors de la
plage d'enregistrement plage d'enregistrement. Vérifier la programmation par rapport à l'exécution physique.

10 DEFAUT FCTRL PRECED ABSENTE Défaut Fenêtre de Contrôle précédente Défaut fenêtre de contrôle : une fenêtre de contrôle doit être positionnée par rapport à la
n'existe pas fenêtre de contrôle précédente, mais cette fenêtre de contrôle est soit non positionnée, soit
absente.

11 DEFAUT FCTRL SUIVANT ABSENTE Défaut Fenêtre de Contrôle suivante Défaut fenêtre de contrôle : une fenêtre de contrôle doit être positionnée par rapport à la
n'existe pas fenêtre de contrôle suivante, mais cette fenêtre de contrôle est soit non positionnée, soit
absente.

12 DEFAUT EN NEG, DEB FEN > PLAGE Défaut en cote négative, le début de la Défaut de consigne de la fenêtre de contrôle : Cas d'une plage d'enregistrement dont la cote
fenêtre de contrôle > plage de début est négative. On teste si le début de la fenêtre de contrôle n'est pas supérieur au
d'enregistrement début de la plage d'enregistrement. Vérifier la programmation, et l'exécution physique.

13 DEFAUT FCTRL HORS PLAGE Défaut fenêtre de contrôle en dehors de la Défaut contrôle fenêtre marqueurs : La fenêtre de contrôle n'appartient pas à la plage
plage d'enregistrement d'enregistrement à laquelle elle est affectée. Vérifier la programmation, et l'exécution physique.

14 RESERVE Défaut réservé Défaut non affecté - Réserve

15 DEFAUT INCLUSION STRICTE Défaut d'Inclusion stricte En inclusion stricte la fin de la courbe doit être à l'intérieur de la fenêtre de contrôle, sans quoi ce
défaut apparait. Si l'inclusion stricte n'est pas nécessaire au process, corriger votre
programmation.

16 DEFAUT SEUIL INFL. DEB Défaut contrôle fenêtre : Seuil de décl. Le début de la fenêtre doit être placé par rapport à un changement de pente de la courbe,
pour une recherche d'inflexion en début de hors ce phénomène n'a pas été détecté. Vérifier les paramètres de recherche de ce
Fenêtre non atteint phénomène.

17 DEFAUT SEUIL INFL. DEB Défaut contrôle fenêtre : Seuil de décl. La fin de la fenêtre doit être placé par rapport à un changement de pente de la courbe, hors
pour une recherche d'inflexion en fin de ce phénomène n'a pas été détecté. Vérifier les paramètres de recherche de ce phénomène.
Fenêtre non atteint

18 NON DISPONIBLE Défaut non disponible Défaut non affecté - Réserve

19 DEFAUT CALCUL SEUIL REGRESS Défaut contrôle fenêtre : le calcul du seuil Le début de la fenêtre doit être placé par rapport au calcul de la cote de départ par régression
par régression linéaire est en dehors de la linéaire entre le début et la fin de zone d'observation. Or ce calcul donne un départ en dehors
plage d'enregistrement de la plage d'enregistrement. Vérifier les paramètres de recherche de ce phénomène par
rapport à l'exécution physique.

20 DEFAUT SENS REGRESS Défaut contrôle fenêtre : le sens de le Le début de la fenêtre doit être placé par rapport au calcul de la cote de départ par régression
régression Linéaire est négatif linéaire entre le début et la fin de zone d'observation. Or la force en fin de zone d'observation
est inférieure à la force en début de cette zone, ainsi le sens de régression est négatif. Vérifier les
paramètres de recherche de ce phénomène par rapport à l'exécution physique.

21 DEFAUT POSITION FEN PRECED Défaut contrôle fenêtre : la position de la Défaut fenêtre de contrôle : une fenêtre de contrôle doit être positionnée par rapport à la
fenêtre précédente n'a pas pu être établie fenêtre de contrôle précédente, mais cette fenêtre de contrôle n'a pas pu être positionnée, par
exemple dans le cas d'un seuil.

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 96 / 97

 Electrical drawings

18 ELECTRICAL DRAWINGS
See the technical folder of the project.

Electric Press-Fitting Unit Maintenance - UPDATE 2020-10 V6A Page 97 / 97