Instruction Manual, Aikawa DDR AW26-400 Remodeling / Modification

The modification work shall be along with the last guidance per SV from Aikawa, and with this manual referring to the drawings listed below.

Reference Drawings (Latest, all updated newly on May 10, 2019)

1 Before and After Re-modeling, Aikawa DDR AW26-400 (See the high lightened BLUE Cables to be removed
2 After Re-modeling, Aikawa DDR AW26-400 parts on the drawing) ORANGE Cables to be re-used
3 Aikawa DDR26-400 PLC Soft GREEN New Cables to be prepared and wired

CAUTION:
Safety procedures shall be taken carefully in order to avoid any damages to yourselves and machine itself and follow
your mill's safety regulations at the work.

1) Image of Existing DDR AW26-400, Local and Control Panel

DDR Local Panel

Old motor

Before starting the modification following notes shall be referred:

1 Existing Wirings, Each Number to be checked
2 Display Units and the other pasrts: to be checked whether they work correctly or not.
Control Panel
3 Operator's method of "Zero (0) Setting"

2) MEMOs On: Modification Parts Supplied by Aikawa via Suncosmo (Total: 8 Sets), Scope of Supply from Aikawa / Suncosmo

A. Scope of Supply / 1 DDR Modification

Descriptions on PO or Documents Remarks, Detailed Descriptions

MECHANICAL SERVO F/ AIKAWA

AW26-400
Material Number: 20151299 / set

PN. 16 Torque Motor, New Type

PN. 17 Reducer
assembled with cable terminal
PN. 18 Helco Coupling
PN. 19 Bearing
PN. 20 Precision Ball Screw MSD Motor, description in this manual

Mitsubishi Elec, PLC FX3U-16MT/ES x 1 pc

Modification Parts for MSD Motor and
for Local/ Operation Panel
B. PO No. & Dox No. (Our Ref Sale Note No.)
Mitsubishi Elec, PLC FX3U-4AD x 1 pc
Breaker, BW32AAG 2P 5A x 1 pc
IDEC, Circuit Protector, NC1V-2100-2AA x 1 pc
IDEC, Power Supply, PS5R-VC24 x 1 pc
TOYOZUMI, Transformer LD21-200E2 Cap. 200VA x 1 pc

PO No. Our Sale Note Quantity User

1 MJK-43122032 SNH18084 1 set Used at PM-5
Remarks Delivered to the mill correctly and with this ordered parts, during April 23 and April 25, 2019
the modification work was completed with SV from Aikawa, Mr. Takahashi and Miida / Suncosmo.
2 MJK-45734012 SNH18221 4 sets for PF-1 Undelivered parts have been found.
See remarks 1 & 2 below
3 MJK-45740549 SNK18329 3 sets for PF-1 Delivered to the mill correctly
Total: 3 orders8 sets

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 Remarks 1: There found undelivered parts under the PO No. MJK-4574012 (SNH18221), at our mutual inspection of
parts in Tjiwi Kimia Parts Center on April 23, 2019

Mitsubishi Elec, PLC FX3U-16MT/ES x 1 pc

Mitsubishi Elec, PLC FX3U-4AD x 1 pc
Breaker, BW32AAG 2P 5A x 1 pc
X 4 Sets
IDEC, Circuit Protector, NC1V-2100-2AA x 1 pc
IDEC, Power Supply, PS5R-VC24 x 1 pc
TOYOZUMI, Transformer LD21-200E2 Cap. 200VA x 1 pc

Remarks 2: Although Aikawa had dispatched 4 pcs of Speed Control Pack (Oriental) under this PO number of MJK-
4574012 they found "PRE-INSTALL" setting had not been installed in these packs. So Aikawa will include
these 4 packs with above undelivered parts, please keep them with uninstalled packs just as your spare
parts.

Oriental Motor, Speed Control Pack DSP501MD x 1 pc X 4 pcs

These parts sending shall be handled by Aikawa directly to the mill per door to door courier and the
dispatching schedule will be advised later.

3) Modification Work

Image of Modification

DDR Local Panel

New Parts Setting, Re-wiring

Change to New MSD Motor
↑　a. New Shield Cable (2 Core) within 10 m length

Remarks: b. New Normal Cable (6 Core) →

New MSD motor installation, re- wirings between Local Panel and Control Panel
Connecting to DCS from Control Panel shall be done by Tjiwi Kimia.
All cables shall be prepared by Tjiwi Kimia.
Ordinal and proper electric work tools and CALIBURATOR used for motion checks shall be prepared.

DCS Control Panel

↑　　c. Cable (25 Core) By Tjiwi Kimia PLC Control Setting

3 shield core Old PCB removing, Re-wiring
22 normal

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 Modification Work Flow, Contents

1 Existing Parts / Cables Checking 8 I/O Check

2 Preparation of Cables (by Tjiw Kimia) and DIN Rail 9 Motion Check
3 To shut off the Control Panel Power Supply 10 Position Adjustment of Press On Detect Sensor
4 To remove of Old Torque Motor, and to set New MSD Motor 11 How to set "0" Point
5 Modification of Local Panel 12 Operation Test at LOCAL MANUAL Mode
6 Modification of Control Panel 13 Motion Test at LOCAL AUTO Mode
7 Power Activation 14 Motion Test at REMOTE Mode

Detailed Modification Work

1 To check the parts on / in the Local Panel, whether these can be operated in normal or not,
and fix the problem, before this modification.

2 Preparation of Cables (by Tjiwi Kimia) and DIN Rail for Control Panel Modification

by Tjiwi Kimia, not Aikawa's Scope Please check if the wiring is correct or not first.

a. between DDR & Local Panel

--- 2 Core --- shield type within 10 m/ea.
b. between Local Panel & Control Panel
--- 6 Core --- normal type m/ea.
(c.) (between Control Panel & DCS)
--- 25 Core --- 22 core normal type
3 shield type m/ea.

3 To shut off the Control Panel Power Supply

4 To remove of Old Torque Motor, and to set New MSD Motor

How to change old torque motor to new MSD motor

Follow the procedures from 1 to 6 Below, after removing the all wires on the old motor.

1 Mark the original base position on the DDR side firstly.

old torque motor

marking position

Marked position will be the point where the new motor with the base to
be set. (The original base shall be re-used for the new motor.)(Usually
the original base edge is facing to the edge of DDR side.)

Fig. 1 Marking DDR Side Base (black)

2 Remove the Base with Old Motor from DDR by loosening their 4 hex bolts.

Relay Terminal Block, M.S. Unit

Following cables shall be removed:
* Cable to Local Panel
* Cable to M.S. Valve
* Cable to Potentiometer
* Cable to Press On Detect Sensor
Remarks:
* Remove Press On Detect Sensor itself from the base

Fig. 2 Relay Terminal Block, M.S. Unit

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 3 Remove the Base with Old Motor from DDR by loosening their 4 hex bolts

4 Hex Bolts, for fixing Torque Motor Unit

Separate the basement from the Torque Motor Unit
This base shall be re-used for the new MSD Motors its base

Fig. 3 Basement, view from back side

4 Remove Potentiometer from old motor and set it onto the new MSD Motor

Potentiometer

Fig. 4 Potentiometer

5 Fix the new MSD motor with base onto the DDR correctly

adjust the correct position

New MSD Motor marked marked
Base point New MSD Motor point
see Fig. 1 above Base see Fig. 1 above
DDR DDR

6 Cable Connecting of each cable to Relay Terminal Block

Cable Connecting of each cable to Relay Terminal Block

at the same time, wire the M.S. Valve, Press On Detector Sensor
Remarks:
Set the Press On Detect Sensor closer to the Press-Off side, at the forthcoming test run.
(It is for preventing a collision of Press Detect Sensor and the dog there.)

Fig. 5 Position of Press On Detect Sensor

5 Modification of Local Panel

How to modify it? Refer to the WIRING DRAWING and 1 and 2 below.

1 Inside of the Local Panel, put the new parts 1. Speed Control Pack and 2. Capacitor
2 Do each wiring referring to the drawing

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 6 Modification of Control Panel

How to modify it?

Refer to the WIRING DRAWING and 1 and 3 below.

1 Remove old - unnecessary parts (Trans, Sampling Controller & Capacitor) from the Control Panel
Also, the old unnecessary cable shall be removed

2 Put the new parts onto the Control Panel.

3 Do each wiring referring to the drawing

Remarks:
The number old motor's drive is 4 while the new motor has 3 wires, so the 1 wire shall not be used.
(See the drawing carefully)

7 Power Activation

Make sure the above mentioned modification work has been correctly done before switching on, and after power on check whether each
part work correctly without any problems.

8 I/O Check

On / Off Signal
Firstly, check whether the communications between Local Panel - Control Panel - DCS are respectively in good manners.

Electric Power Present Value Signal (Analog Signal)

1 Remove No. 189 and No. 185 cables of Transducer Side from the External Terminal Block, and
set CALIBRATOR to these removed parts (No. 189 + Side, and No. 185 - Side.)

2 Check as follows

with 4 mA out put from CALIBURATOR

Electric Power Present Value display on the Local Panel check: "0 kW" to be display or not

with 20 mA out put from CALIBURATOR

Electric Power Present Value display on the Local Panel check: "full scale" to be displayed or not

Electric Power Setting Value Signal (Analog Signal)

1 Select Local Mode at Local Panel

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 2 Check and correct as follows

When 0 % setting of kW Creation at Local Panel check the display of Power Setting Value

if minimum value displaying OK, and Normal

if maximum value displaying Not normal, see below for correction

See below

When 100 % setting of kW Creation at Local Panel check the display of Power Setting Value

if maximum value displaying OK, and Normal

if minimum value displaying Not normal, see below for correction

Change the cable connections as follows for correct wiring in case not normal

Before re-connection

No. 192A Cable from P- Local Panel's No. 192A Cable from 1 kW Creation

No. 194 Cable from P+ Potentiometer No. 194 Cable from 3 Volume Resistance

NEW: After Changing the connections

No. 194 Cable from P- Local Panel's No. 194 Cable from 1 kW Creation

No. 192A Cable from P+ Potentiometer No. 192A Cable from 3 Volume Resistance

And then, confirm whether the figures on display is correct or not.

When 0 % setting of kW Creation at Local Panel check the display of Power Setting Value

if minimum value displaying OK, and Normal

When 100 % setting of kW Creation at Local Panel check the display of Power Setting Value

if maximum value displaying OK, and Normal

9 Motion Check

1 M.S. Valve Operation Check

1 Run Oil Pump

2 Turn on " Press On Test Switch" of Local Panel

Confirm whether M.S. Valve moves for the operation of "Press On" after switching on.
Confirm whether the Spool and the Bolt Head are touching each other.

Spool and Bolt Head touching after Press On Test Switch

Fig. 6 M.S. Valve "ON" Condition

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 3 Turn off " Press On Test Switch" of Local Panel

Confirm whether M.S. Valve moves for the operation of "Press Off" after switching off.

2 M.S. Motor Operation Check

1 Turn on the Local Panel's Press On Switch and check Press On motion.
At this time, close such as a metal spanner to Press On Detect Sensor while keeping "On" condition.

2 After above 1, press Local Panel's Increase Button.

Confirm M.S. Motor goes forward.

3 After above 2, press Local Panel's Decrease Button.

Confirm M.S. Motor goes backward.

4 Change the Press On Test Switch to OFF, and confirm the motion of Press Off.

10 Position Adjustment of Press On Detect Sensor

How to adjust it?

1 Change Local panel's Press On Switch to ON, and confirm the motion.
At this time, close such as a metal spanner to Press On Detect Sensor while keeping "On" condition.

2 After above 1, press Local Panel's Increase Button.

3 Confirm M.S. Motor motion and the displayed value of blade position are matching or not.

4 After the confirmation of above 3 function, stop MSD Motor motion by turning off Press Increasing Button.

5 Position adjustment of Press On Detector Sensor

by checking RED or YELLOW lamp's lighting
The correct position is a very close place whether RED or YELLOW lamp lights.

Find the lamp and Confirm RED or YELLOW lighting.

Fig. 7 Lamp light, Press On Detect Sensor

6 Push on Local Panel's Increase Button.

Confirm the light yellow or red keep lighting continuously while the MSD Motor goes forward.

7 After the confirmation of above 6, press Local Panel's Decrease Button.

Confirm MSD Motor motion and the displayed value of blade position are matching correctly.

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 8 Turn off the Local Panel's Press On Switch and check Press OFF motion.

11 How to set "0" Point

1 Turn on the Local Panel's Press On Switch and check Press On motion.

2 After above 1, press Local Panel's Increase Button continually.

When continuous press of Increase Button, soon the display of blade position goes showing same value and Press On Detect
Sensor becomes OFF condition. At this time the blades contact closely.

3 Press Local Panel's Decrease Button continuously.

When continuous press of Decrease Button, the display of blade position goes change and Press On Detect
Sensor becomes ON condition. At this time set the blade position as "0" point.

4 Set "0.00" of the blade position display as "0" position by adjusting the SPAN of Potentiometer Transducer in Local Panel.

Potentiometer Transducer Span

Fig. 8 Potensiometer Transducer Span

5 After the above adjustment of blade position on display, press Local Panel's
Decrease Button continuously in order to backward the blade until 3.00 mm on

6 Change Press On Test Switch to OFF and check Press Off motion.

12 Operation Test at LOCAL MANUAL Mode

How to test it?

1 Select "LOCAL" and "MANUAL" at Local Panel.

2 Make short circuits at External Terminal Block in Control Panel with electrical clips
1 between 140 & 141 (Stock Flow Detect) and
2 between 101 & 103 (DDR Running Signal)

3 Turn on Press On Button of Local Panel and activate it.

4 Confirm motions below after reaching Press On Point;

1 at the time pressing Increase Button (Local Panel) blade goes forward
2 at the time pressing Decrease Button (Local Panel) blade goes backward

5 Press OFF Button and activate Press OFF motion

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 6 IMPORTANT NOTICE

Again, press ON Button and activate Press ON motion

Confirm whether the position of Press On Point moves backward position than position of the Press Off Button motion.
In case of no backward motion, blade goes instantly to Beating point by Press On motion, and then following
may happen;
1 over loading of DDR or
2 "metal touch" of blades.

Countermeasures: (How to solve it.?)

1 Check whether Timer, T102 (Dec. Rotation Timer at Press ON) is correctly set or not.
2 In case Timer T102 has in normal connection (no missing line), and in case of no motion,
have re-wiring T102 connectors with timer socket No. 5 & No. 8 .

Fig. 9 T102 (Dec. Rotation Timer at Press OFF)

13 Motion Test at LOCAL AUTO Mode

How to test it?

1 Select "LOCAL" and "AUTO" at Local Panel.

2 Make short circuits at External Terminal Block in Control Panel with electrical clips as follows;
1 between 140 & 141 (Stock Flow Detect) and
2 between 101 & 103 (DDR Running Signal)

3 Remove No. 189 and No. 185 cables of Transducer Side from the External Terminal Block, and
set CALIBRRATOR to these removed contacts (No. 189 + Side, and No. 185 - Side.)

4 Make 12 mA out put from CALIBRATOR, after connecting with CALIBRATOR.

5 Turn on Press On Button of Local Panel and activate it.

6 Change Electric Power Setting Value by kW Creation of Local Panel after reaching at Press On Point,
and confirm the motions below.

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 Remarks:
In case of Local Mode, Electric Power setting Value is reflected by a set value from kw Creation on Local Panel.
and note that a value set at DCS Electrical Power Setting Value does not reflects.

1 in case of Electric Power Setting Value > Electric Power Present Value Blades goes forward

2 in case of Electric Power Setting Value ≒ Electric Power Present Value Blades goes stopping

3 in case of Electric Power Setting Value < Electric Power Present Value Blade goes backward

7 Turn on Press Off Button of Local Panel and activate it.

14 Motion Test at REMOTE Mode

How to test it?

1 Select "REMOTE" at Local Panel.

2 Make short circuits at External Terminal Block in Control Panel with electrical clips as follows;
1 between 140 & 141 (Stock Flow Detect) and
2 between 101 & 103 (DDR Running Signal)

3 Remove No. 189 and No. 185 cables of Transducer Side from the External Terminal Block, and
set CALIBRATOR to these removed contacts (No. 189 + Side, and No. 185 - Side.)

4 Make 12 mA out put from CALIBRATOR, after connecting with CALIBRATOR.

5 From DCS, turn on Press On Signal and check the Press On motion.

6 Change Electric Power Setting Value by Electric Power Setting Value of DCS, and confirm whether the blade moves
correctly as follows.

Remarks:
In case of Remote Mode, Electric Power setting Value is reflected by a setting through DCS.
and note that a value set at kw Creation on Local Panel does not reflects.

1 in case of Electric Power Setting Value > Electric Power Present Value Blades goes forward

2 in case of Electric Power Setting Value ≒ Electric Power Present Value Blades goes stopping

3 in case of Electric Power Setting Value < Electric Power Present Value Blade goes backward

7 From DCS, turn off Press On Signal and activate it.

Suncosmo Co., Ltd. For Aikawa Iron Works Co., Ltd.

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