WENGER ELECTRIC BPV

The BPV can be sold with a

cart that will hold it when
not in use and it can also be
used to mount the BPV to
the extruder. A forklift can
be used to lift the cart up
and place the BPV in the
appropriate position. There
is also a hook on the top
that can be used to hoist the
BPV on to the extruder.
The black cable on the right
houses the cables that go
from the servo drive motor
to the controls. These can
be disconnected so the BPV
can be moved separate from
the controls. A customer
can order it with this cart or
with a hinge away post.
This BPV has the Die Relief
position on it. This position
will vent the Die to the
relief position so the
pressure behind the die will
not hurt the operator when
the die is taken off.

The customer can supply the 0-10 volt signal to control the open area of the BPV, or it
can be a stand alone BPV. We use a West controller that is set from 0-100%. This
percentage represents the open area of the valve.

To the left is the panel that holds the

servo drive and associated relays.
There is a transformer that we have
before this that provides isolation for
the electronics. Customer needs to
supply 460 volts, 10 amps to the
transformer and then hook this panel
to the transformer and it is ready to
go. Whether the BPV is on a PLC or
a stand alone unit, we will need to
provide this panel with its associated
relays. If it is different than 460
volts, please specify that to
engineering and we will supply the
correct transformer.
Communication Screen

This is the first screen that comes up when

Terminal youDrive
Screen
 Enable open the program.
Button: You
Enables thewill hook the
drive
Servostar to your computer serial
 Disable Drive Button: Disables the drive porttowith
makea changes to
3-core null-modem cable. Select
program theSetup
Basic com Screen
port that the
 Analog I/O Screen drive is hooked to.
 Position Screen
 Digital I/O Screen  Current OP Mode
 Encoder Screen  Current Screen
 Status of Drive: Tells if the drive Speed Screen
is faulted or OK
 I/O Expansion Card  Resolver Screen
Main Screen  Motor Setup Screen

The screen above comes up after the selecting the correct com port that the drive is
hooked to. This is like a main screen that you can go to different screens from.
The Current OP Mode tells you what state the drive is in. It will switch between the
following two tasks:
 8: Position Motion Tasks will tell the drive to look at the Motion Task Table to
tell it what location it needs to go to.
 5: Ext Pos. Nodes will tell the drive to look at the 0-10 volt signal. This signal
will adjust and the PBV will go up and down accordingly.
This switching is setup using an ASCII command that is put in from the Terminal screen.
A high signal to Digital input 1 will set the drive to OP Mode 5. A low signal will set the
drive to OP Mode 8.
ASCII entry into the terminal will be like below.
INHCMD = OPMODE 5
INLCMD = OPMODE 8
Basic Setup Screen

This is the Basic Setup Screen. This

screen tells you the software versions,
firmware versions, and the serial
number of the drive. You can also
change the input voltage from here.
All of the units should be 480 volts.
Do not change any of these values.

Position Screen

 Homing Screen
 Position Data Screen
 Gearing Screen
 Max Following
Error needs to be
raised to 26214400
for the X-Large BPV
This is the Position
Screen. There are some
bullets on the right that
need to be checked. From
here we have three
different screens we can
go to.
Homing Screen

This is the Homing Screen.

You can manually send the
drive to a home position from
here. It also allows you to set
up the home speed and the
direction of home.
Need to raise the velocity to
home position to 20000 um/s

Position Data
  Motion Task Table
Screen

The position data screen sets up the different outputs the drive has. These values are set
up under Limit Switch heading. The modulo start pos. and modulo end pos. are used to
set up the 0-10 volt control. The modulo start pos. is set to represent the 0 volt signal.
The modulo end pos. is set to represent the 10 volt signal. These are all set up in micro
meters. For your reference, the value 190159 is 190 millimeters. These values are
measured from the home position. From this screen you can also go to the Motion Task
Table.
Three inch insert: modulo start pos. = 190159
modulo end pos. = 260259
Position Register 1 x>position = 190159
Position Register 2 x>position = 87000
Position Register 3 x<position = 2000
Two inch insert: modulo start pos. = 190159
modulo end pos. = 237784
Position Register 1 x>position = 190159
Position Register 2 x>position = 87000
Position Register 3 x<position = 2000
X-Large BPV: modulo start pos. = 260000
5” insert modulo end pos. =379000
Position Register 1 x>position = 190159
Position Register 2 x>position = 87000
Position Register 3 x<position = 2000
V max = 20000
Motion Task Table

The motion task table sets up where the BPV will go when a motion task is set.
We use two motion tasks. Motion task 1 will send the BPV to the Reject position.
Motion task 2 will send the BPV to the Die Relief Position.

Regular BPV:
Task O_P O_V O_C O_ACC1 O_DEC1
1 88000 40000 8224 100 100
2 0 40000 8224 50 50

X-Large BPV:
Task O_P O_V O_C O_ACC1 O_DEC1
1 94000 20000 8224 50 50
2 0 20000 8224 50 50

O_P Position from Home

O_V Velocity
O_ACC1 Acceleration 1
O_CEC1 Deceleration 1
 This is the current screen. This sets
the limits of the drive output.
These will already be set up.
Current Screen

This the Current Screen that

shows the limits of the drive.
These values are already set.

Speed Screen

This is the Speed Screen. The

speed limits of the motor are
set up here. These values are
already set.
Resolver Screen

This is the Resolver Screen that

is used to setup the feed back
device that tell the drive where
the motor / cylinder at. These
values are already set.

Motor Screen

This is the Motor Screen. It is

where the specifics of the motor
are set up at.
The motor number and name
changes from the regular BPV
to the X-Large BPV.

Regular BPV:
767-AKM-42G-9R

X-Large BPV:
794-AKM-52G-9R
Analog I/O Screen
Analog setup screen is used to
offset the analog signal and
setup the scaling. These
values are already set.
Digital I/O
The digital I/O screen is used to setup what functions the digital inputs do.
 Digital In 1 should be set to 30: Cmd. Buffer 1. This tells the drive to switch between
OP Mode 5 and 8. When this input is high, the controls will look at the 0-10 volt.
 Digital In 2 is set to 16: Start_MT No.x with the value x = 2. This makes the
controller look at the Motion Task Table and it will start motion task number 2. This
will be the Home position or Reject position.
 PSTOP is set to 2:PSTOP. This is the extended limit of the cylinder.
 NSTOP is set to 12: Reference. This will look at the retracted limit of the cylinder. It
will also serve to set the Home position of the cylinder. When the drive is powered
up, it will drive to this position so it knows where it is at.

Encoder Screen

This is the encoder screen. We

do not use it. Leave the values
alone.
Terminal Screen

This is the Terminal

Screen where you can
type in ASCII commands.
The two commands below
are typed in here.

INHCMD = OPMODE 5
INLCMD = OPMODE 8

Be sure to type SAVE

after any changes to make
sure all changes done on
the terminal are saved.

I/O Expansion Card

Downloading the Program to the Drive

This is the I/O Expansion Card
Screen. You can look at the inputs
from the expansion card here.
 Now that you have an overview of the screens that are in the drive, the instructions below
will tell you how to download the program to the drive.
1. NSTOP
This is the Open thesensor.
Servo Star Drive
We use it tosoftware.
tell the
2. Click on the Com Port
drive where HOME POSITION is. The drivethat the drive is connected to your computer on. It should
and
be connected using a Null modem
cylinder will look for this when it powers up. These cable.
3. Theare
measurements software will look
taken from at the
the top drive
of the and see what the current settings are.
BPV
4. Disable the drive.
assembly to the bottom of the switches.
Regular5.BPV:Push16the Emergency
3/16” Stop button.
to the bottom of the NSTOP
sensor. 6. Click on and select the appropriate file that needs to be downloaded.
X-Large7.BPV:Double checkof
20 1/8” to the bottom thethe
file name and make sure the parameters are correct.
NSTOP
sensor. 8. Parameters are then transferred to the drive.
9. Click yes to save to the EEPROM and reset the drive.
10. The drive will reset and it is then ready to set up the limit switches.
This is the PSTOP sensor. It tells the
drive where to shut the drive off incase
the program drives it further than it is
suppose to.
Regular BPV: 4 ½” to the bottom of
the PSTOP sensor.
X-Large BPV: 3 ½” to the bottom of
the PSTOP sensor.

Setting up the Limit Switches

The switches are located on the side of the cylinder. This needs to be setup so the drive
knows where the home position and the extended limit position are at. The cylinders are
shipped fully retracted. The motor may have to be turned manually so that it is not past
the home switch. If the cylinder is past the home switch, it will ram into the end of the
cylinder and trip out on current limit. In the lower picture you can see what the top of the
cylinder looks like. Rotate the motor in a clockwise direction to move the cylinder down.

Operation of Electric BPV

The BPV is operated with the small panel as
shown in the picture below.
 Before power up, be sure to have the
black switch at the Die Relief position.
 Upon power up and pulling out the E-Stop, you will need to turn the green button to
the start position. This will energize the drive and allow the BPV to find its Home
position.
 You may now move the BPV to the desired position that you want to run the BPV at.
 Moving it to Process position will allow you to control the open area to the die with
the West controller that is in the upper left corner. This will be set up in a 0-100%
range.
 The other position it can be ran in is the Die Relief position. This position is used
after a run and allows the die and the extruder to vent to the relief valve. The electric
BPV never completely closes off the extruder.
 There is always flow no matter which position it is in.

The West controller is set up a little different than how we usually set them up. Below is
the Configuration and Setup for it.
Configuration Mode: Setup Mode:
inPt = 0_10 FiLt = .5
ruL = 0 Pb_P = 10.0
rLL = 100 ArST = 5.00
dPoS = 0 rAtE = 1.15
USE1 = rEtS SPuL = 100
tyPt = 0_10 SPLL = 0
ro1L = 100 PoEn = diSA
ALA2 = NONE
Inhi = NONE
diSP = 2