OPERATION SET GUIDE

(CASTER)

Prepared By : Bright Engineering

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 Manu

Manu Bar: There is six options available is menu bar. Following are the options:

 OVERVIEW
 SERVO SETTING
 COILER BYPASS
 BASIC SETTING
 BENDING STATUS
 TABLE STATUS

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 Overview

Coiler No Start Time Elapse Time Rod Dia Total Weight(kg) Reset
Coiler 1
Coiler 2
Coiler3
Coiler4
Coiler5
Coiler6
Coiler7
Coiler8
Coiler9
Coiler10
Coiler11
Coiler12
Coiler13
Coiler14
Coiler15
Coiler16
Description:

 Here S1 is front side Servo motor. It’s showing the line speed of Coiler 1 to 8.
 S2 is back side servo motor. Its showing line speed of coiler 9 to16.

Coiler 1 On/ off (button)

 Coilers 1 to Coiler 16 Tabs are use for on/off (button) for coiler motor.

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 SERVO SETTING

Servo 1 Servo 2
Pull Distance(mm)
Pull half (Sec)
Push distance (mm)
Push Half(Sec)
Servo Speed (%)

Important Notes:
1. Before switching the servo motor must require to on cooling tower (1&2) and

Both water pump. Water pressure must be ok according to requirement. If any of this function may off
then servo motor will not run.

2. If water pressure is not ok then alarm will shows in the HMI display for 90 sec. after that caster will
automatically up.

3. Pull distance range for 8mm dia is 3 to 5. 5 is ok.

4. Pull Half (Sec) max range (0.020 to 9.00) sec. If it does reduce to mili sec. then servo motor speed
will increase.

5. Push distance (mm) always shows zero value. If its shows any value then line speed will decrease.

6. Servo speed (%) its max range is (50 to 100) %.

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 COILER BYPASS

Notes:

 If any Motors drive become faulty. Then the communication error can bypass by following
function.

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 Basic Setting

Coiler speed (S1) 33% (S2) 33%

Time for coiler stop 3 sec.
Material Density 8.89 g/cm^3
Speed correction factor (S1) .90 (S2) .90
Power on delay for relay o/p 30.0 sec.
Pressure switch control Disable
Float Mode Manual

Notes:

1. Coiler speed (S1) &S2 max range 0-100%.

2. Time for coiler stop is speed controller stop time for coiler motor. It’s Max. range (1-10Sec.).If the
coiling layer is not organized then timing must have change.
3. Materials Density is constant for this. If any change in this value then Weight will be changed.
4. Speed correction factor (S1&S2) is a combination of line speed & Actual speed.
5. Power on delay for relay o/p means a relay on after 30sec.and its bypass voltage for controlling.
6. Pressure switch controller –Enable/Disable
If pressure switch is Enable then it will alarming when pressure become low. if it’s in Disable mode
it will never shows alarm.

7. Float Mode –Auto/Manual

 Auto Mode- Caster up and down by level sensor.
 Manual Mode- Caster up and down by push button.

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 Timing for Bending Motor

Bending Motor Time:

Dia Time
8mm 1-2 sec
12mm 2-3 sec.
16mm 3- 4 sec.
20mm 3-4 sec.

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 Bending Motor Status

Notes:

 Coiler - Auto/Manual

 Rotation Proxy –When Coiler is On C will blink.

 Limit Switch –F R.If value is close to F then it will on .if value close to R then it will on.

 Bending Motor – F …………. R (Its works on manual mode only)

 Coil max. rotation - 99

 Repeat action on - 1 for 8mm, 2 for 12mm, 3 for 16mm and 4 for 20mm.

 BM 1to BM 16 all motor has follows the same process.

 If pulse incremented then motor is in reverse mode. If pulse decremented then motor is in
forward mode.

 All bending motor must be run in Auto mode otherwise coiling will not uniform.

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 Table Status

Table no Current Coil Dia VFD Rod Dia Min Dia Max Dia Reset
length Ref(Hz)
Table 1 8.0
Table 2 8.0
Table 3 8.0
Table 4 8.0
Table 5 8.0
Table 6 8.0
Table 6 8.0
Table 7 8.0
Table 8 8.0
Table 9 8.0
Table 10 8.0
Table 11 8.0
Table 12 8.0
Table 13 8.0
Table 14 8.0
Table 15 8.0
Table 16 8.0

Notes:

 If current length is not increasing then it’s may be fault in counter sensor. Counter
sensor always give 4 pulses in one rotation. If sensor do not shows four pulses then
coil layer will not uniform.

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 Table Setting

 Table 1 to Table 16 – Enable/Disable.

1. Enable Mode: If enable mode is running then table motor works on automatically.

2. Disable Mode: If its disable then table motor will not run then must remove the driving belt and
table motor become off. Then coiling will do by upper side bending motor.

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 Coiling & Bending Motor

 Coiler on/Off: Coiler can on manually by following On/Off push button.

 Coiler Jog Reverse: Manually speed up by Jog selector and also run in reverse selection.

 Bending Small Big: Trolley can size small and big by this selector.

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 Bending motor setting

 There are two sensors available for bending motor one is inner and other is
outer side of the motor.
 Stand by option for table motor:

Table status Setting Change the setting Enable to Disable.

Caution: In maintenance time if the sensor interchanged by fault like

forward put in reverse and reverse put into forward then sensor & motor both
will damaged.

Probable faults:

1. Counter sensor
2. Glass fuse
3. Capacitor

 Bending status must in auto mode. If it’s in manual mode then it will be not in operation and
layer by layer coil stand in same.

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 Pressure Regulator

 Pressure Regulator (for machine):

1. Dia cooler air pressure- Minimum- 3 Kg
Maximam-4.5 Kg

2. Pinch roller air pressure- Starting time- 2.5 Kg

Running time-1 to 1.5 Kg

Caution: pinch roller air pressure if high then rod diameter will change and also become hard.

3. Coiler pressure gauge- For, 8mm - 0.5 to 1 Kg

12mm- 0.5 to 1.5 Kg
16mm -1.5 to 3 Kg
20mm -2.5 to 4 Kg

Die cooler flow switch logic:

1. Water must be require for dia cooler run purpose.

2. Before change new dia must be check the outlet water pressure.
3. When dia cooler set in the machine and its inlet water valve is close that time dia cooler must not
going to down. In case if it’s go down then check separate flow meter and clean it.
4. Never press the emergency switch if press then flow meter will not work.

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