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Press Attendant - Toledo Transducers

1. GND Pin 5 For plant wide connection to the monitor COMPUTER RS232 SERIAL DATA PORT THESE ARE THE CONNECTIONS FOR 25 OR 9 PIN D CONNECTOR 9 PIN FEMALE D CONNECTOR CONFIGURATION SWITCH SETTINGS 25 PIN FEMALE D CONNECTOR COMPUTER SIDE MUST BE SET TO RS232 QUIK LEARN SIDE MUST BE SET TO RS422 9p gone o 120 OHM RESISTOR MUST eeeeeel CONNECTED AT THE CONVERTER BETWEEN THE COMMON AND THE Rx422 232 lt SHIELD gt Rx422 232 Senconine Rx422 232 7 Sg x Rx232 f Rx422 2 8 mem x 710 RTS4224232 0 BN 7 mgEZ RTS42 7 M WB 7 COMMON Z NRA W AW 1x422 B MIS 422 232 I Z 22 232 422 4 RTS422 N z RTS422 232 4 Aur RTS422 v NM COMMON COMMON 7 common e Oo 800 P t TO COMPUTER O PRESS ATTENDANT T RS232 INTERFACE RS422 485 INTERFACE FLASHES EACH TIME COMPUTER REQUESTS DATA FLASHES EACH TIME MONITOR RESPONDS PRESS ATTENDANT Tonnage Monitor Unit 232 485 Connections to Computer Chassis Figure 12 Doc 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE
2. 16 Section 3 Menu Seleet Screen o occae 18 Section JTOB C 19 Secon S View ParameferS u tede 21 5 1 Programmable 22 2 2 Die Proteci n ou qhi hupu 23 5 2 1 Die Protection Diagnostics 24 Brake Monitors s t 25 Debuomb Bdit Parameters bios 26 6 1 Programmable Limit Switches 28 6 2 Die Protections aeque dn 31 35 Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 2 Table of Contents continued Section 7 Edit Parameters cs ame u a eate nee 36 dt aun 37 DP NIMES aaah Sau 38 ku 39 T4 90 Deo Brake Test iate tibi dead ee Root eddie db iE 40 Section 8 DPPIus Calibration pe ieee aa Pr a e b dam 42 al EL Press male u aa 43 8 2 Speed Comp PES neta eid tet ect 44 8 5 Press Control CAM SO oos codd nb Q
3. Each option can be selected by either using the arrow keys or by pressing the alpha numeric key that corresponds with the appropriate menu option The alpha numeric keys that are currently valid will be illuminated When the display line for the correct selection is flashing press the lt gt key Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 22 SECTION 5 VIEW PARAMETERS 5 1 PROGRAMMABLE LIMIT SWITCHES After selecting Programmable Limit Switches from the View Parameters Screen the PLS Selection Screen shown above will be displayed Either use the alpha numeric keys or the arrow keys to select which PLS to display When the correct selection is flashing press the lt gt key The above screen which displays the settings for this PLS will appear The settings cannot be modified from this screen Pressing the lt BACK gt key will display whether the PLS is speed compensated Press the lt BACK gt key again to return to the PLS selection menu For an explanation of PLS settings refer to Section 6 1 Programmable Limit Switches Doc 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE 23 SECTION 5 VIEW PARAMETERS 5 2 DIE PROTECTION After selecting Die Protection from the View Parameters Screen the Die Protection Selection Menu shown above will be displayed Either use the alpha numeric keys 1 5 or the arrow keys to select which Die P
4. 21 DRILL NO DRILL THROUGH THE TWO SMALL CENTERED HOLES ROTATE FIXTURE 90 DEGREES Y S1 4 28 STEPS 6 7 METRIC 6 1 TAP THROUGH FOUR LARGE HOLES _ ANT TORQUE WASHERS STEP 9 1 4 28 x 3 4 LOC WEL BOLTS PUT RAISED RIB TO PRESS Doc 13949 Rev B STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7 STEP 8 STEP 9 Remove all paint and grease from sensor mount area If the machine surface is flat total indicated reading of 002 and smooth 125 in the load sensor can be bolted directly to the surface Drill and tap the center hole for mounting the fixture to the press member This hole should be inch 13mm deep Bolt the fixture to the press member using the 4 28 by 1 4 inch M6 1 x 35 long socket head cap screw in the center of the fixture Insert the number 3 drill Smm into the smaller corner hole and drill out all four holes to a depth of of an inch 19mm Loosen the fixture Rotate the fixture 90 degrees clockwise Tighten the center screw of the fixture Insert the number 21 drill into the small centered hole and drill out both holes to a depth of 3 8 of an inch These holes are for mounting the sensor enclosure The fixture does not allow for tapping these holes They are tapped without the fixture Enclosure mounting is not done in metric Loosen the fixture Rotate the fixture another 90 degrees clockwise such that the larger corn
5. Toledo Integrated Systems PRESS ATTENDANT PAGE 37 SECTION 7 SYSTEM SETUP 7 1 EDIT JOB NAMES After selecting Edit Job Names from the System Setup Menu the above screen will be displayed Use the up and down arrow keys to scroll to the desired Job Name When the Job Name to be changed is selected press the lt ENTER gt key The screen shown above will display the Job Name to be modified the new Job Name will be entered below Use the alpha numeric keys to enter the new Job Name For instructions on entering text refer to Section 11 Text Entry When the new Job Name is entered correctly press the lt ENTER gt key to apply the new name Press the lt BACK gt key to return to the previous screen to select more Job Names to edit To cancel changes press the lt BACK gt key at any time before pressing the lt ENTER gt key Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 38 SECTION 7 SYSTEM SETUP 7 2 EDIT PLS DP NAMES After selecting Edit PLS DP Names from the System Setup Menu the above screen will be displayed This screen lists the available Programmable Limit Switches and Die Protection names Use the up and down arrow keys to scroll to the desired name When the PLS DP Name to be modified is selected press the lt ENTER gt key The screen shown above will display the PLS DP Name to be modified the new Name will be entered below Use the alpha numeric keys to enter the new PLS D
6. 5 5 WHI BLUCD BLU WHTCre4 VDO ORG WHTCENC A RN WHTCENC WHT ORG Z P Press Attendont CONNECTIONS NEMA 1 ENCLOSURE WITH MEASUREMENTS NEMA 1 FRDNT VIEW SHAFT 1 50 CLEARANCE FOR REMOVING COVER 7 MS CONNECTOR 7 MS CONNECTOR a 71 MHT BRN NOT USED BRN WHT USED ORG WHT OIO ENC V VHT ORG 7 BACK SIDE OF AMPHENAL WHT BLU DC CUM BLU WHT 24VDC 1 ENCLDSURE VIEV PART 1662
7. Cycle the press so the ram goes to the top Insert the load cells and spacers Keep the load cells symmetrical with each other in the bed of the press Record their placement within 1 4 inch on a calibration sheet Cycle the press lowering the ram each time until you reach the tonnage rating capacity of the press gt load will increase approximately I ton for every 1 1000 inch begin to lower the ram Doc 13949 Try to obtain an even tonnage on each load cell once you are at the capacity of the press You can shim using 1 ton per sheet of notebook paper Fox example if you are calibrating a 200 ton OBI press you will want to achieve 100 tons on each side of the press If your ram is not level you will see an unbalanced loading To balance you can place a piece of notebook paper on top of a load cell and see the tonnage increase by approximately 1 ton Toledo Integrated Systems PRESS ATTENDANT PAGE 64 V Tonnage Monitor Unit Press Calibration Procedure Step 9 Step 10 Step 11 Step 12 Step 13 Step 14 Doc 13949 Once you have evened out the tonnage at capacity you are ready to adjust the readings in the Tonnage Unit Figure 13 shows the location of all the internal switches needed Put the unit in calibration mode by flipping dip switch 3 back located next to the threshold switch to ON and adjust the balance pots of both channels until bo
8. a 5 Ae 20 L z VA A VA WA LLL L LZ 7 ZZ 7 100 10 OFF THRESHOLD INTERFACE 8 ON OF CAPACITY x4 ES 2 1 TONNAGE MONITOR UNIT Capacity amp Threshold Settings Figure 13 Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 62 IV Tonnage Monitor Unit Initial Set Up 26 56 ON OFF 87654321 SWITCHES ABOVE SHOWN IN OFF OPEN POSITION ADDRESS SWITCH POSITION ADDRESS SWITCH POSITION 8 7 6 5 4 4 8 7 6 5 4 0 nnn OFF 16 OFF 2 nmm 2 ag an s 2 Wy s NER 2 mae 5 uam m 4 ung 25 2 gh s NNELEL NNNM 2 2 5 5 PRESS ATTENDANT Tonnage Monitor Unit Computer Interface Ad
9. 5 RESET KEY The red lt RESET gt Key 15 used to reset any faults that occur Refer to Section 9 Faults for an explanation The lt RESET gt Key is also used to reset the Parts Counter and the Stroke Counter For an explanation refer to Section 6 4 Counter Info 1 6 UP AND DOWN ARROW KEYS The Up and Down Arrow Keys are used to move the cursor around the screen When used on a menu screen the selected display line will blink 1 7 ENTER KEY The lt ENTER gt Key 1 used to submit information to the DPPlus 1 8 ALPHA NUMERIC KEYS The Alpha numeric Keys are used when making selections from the displayed options Only keys that currently have valid options will be illuminated The Alpha numeric Keys are also used to enter text Doc 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE 15 SECTION 2 HOME SCREEN STROKES PER MINUTE 2 9 PRESS POSITION 7 2 1 COUNTERS J A 2 4 DOWN ARROW 2 5 Pressing the lt gt key will bring up the Home Screen from any other screen This screen displays relevant information for the operator Pressing the lt HOME gt key from the Home Screen will display the Menu Select Screen 2 1 POS POSITION This display shows the current angle of the press in degrees 0 359 2 2 SPM STOKES PER MINUTE When the press is in motion this will display the current strokes per minute 2 3 COUNTERS Parts Counter This will displ
10. 61 IV Tonnage Monitor Unit Initial Set Up Step 1 Tonnage Unit Capacity Setting e The capacity of the press should be entered into the unit Refer to Figure 13 for the location of the capacity switches e The switch on the right is for the 10 s column and the switch on the left is for the 100 s column For example to enter 50 tons set the right switch to 5 and the left switch to 0 For 200 tons set the right switch to 0 and the left switch to 2 1 s column is assumed to be zero e The maximum capacity is 990 tons Ifa higher capacity is needed a special program is required to ignore the decimal point Step 2 Threshold Setting e Ifa cam input is not used to trigger the Tonnage Unit a threshold setting must be entered Figure 13 also shows the location of the threshold switches There are 10 settings 0 9 and each setting is multiplied by 4 Thus a setting of 2 means that 8 of tonnage triggers the unit gt If a cam input is used set the threshold to 0 to tell the unit to look for a cam signal Step 3 Computer Addressing e Ifthe computer interface option has been installed and there is more than one Tonnage Unit on the same serial line each unit must be given a five digit address 0 31 See Figure 14 for address information gt Use switches 4 8 of the computer address switch bank Ex 2 0 200 TONS OFF HHHHHH 57 8 HHHH 6
11. 9 Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 56 II Tonnage Monitor Unit Inside Panel Description Note Refer to Figure 10 1 Sensor Inputs Connect T400 sensors according to the color code for sensors in tension If mounted for compression loads reverse the red and white wires Pass the cable through the spade lug and crimp lug to shield SEE APPENDIX B Fasten spade lug to enclosure with 6 32 x 1 4 screw 2 Cam Probe Input Accepts NPN or PNP proximity device limit switch may also be used The Tonnage Unit supplies 12VDC to those devices needing external power 3 Computer Interface RS485 multi drop interface x10 x10 1 85485 GB Rx DATA IN PROBE Rx xe eal o GND gt 5 6 1 PNP Tx BGWR BGWR KO NPN DATAOUT L EXC SIG EXC SIG y SHIELD Q 4 ENCODER See appendix sswap THE R W WIRES FOR COMPRESSION LOAD 1 5 Amp Slo Blo Fuse REFER TO MANUAL FOR PROPER SENSOR CABLE TERMINATION PRESS ATTENDANT Tonnage Monitor Unit Inside Panel Figure 10 Doc 13949 Rev Toledo Integrated Systems PRESS PAGE 57 HI Connecting the Tonnaee Monitor Unit Step 1 Install the sensor s according to the T400 Sensor Installation Instructions in APPENDIX A The sensor cables do not necessarily need to be run in conduit unless the
12. Chassis a 60 13 Capacity amp Threshold Settings eee aed idet 61 14 Computer Interface Address Selection eese eese eene a 62 15 11 Crean Software dde du 69 T6 Press Net Software Screen ea Leg Rude RSEN eta Pn s 70 Appendix A T400 Sensor MS tall pelo di b a dede 73 Sensor Cable CODDOCUOH 81 C Press Calibration Data Shect ao oet aaa a 83 D 1662 Encoder Cable Pinout and Dimensions 87 Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 4 Limited Warranty This unit is warranted by the manufacturer Toledo Integrated Systems to be free of defects in workmanship and materials for one year from date of manufacturer s shipment This warranty is limited to repairing or replacing products which manufacturer s investigation shows were defective at the time of shipment by the manufacturer All products subject to this warranty must be returned for examination repair or replacement F O B to Toledo Integrated Systems 6834 Spring Valley Drive Holland Ohio 43528 The express warranty set forth herein is in lieu of all other warranties expressed or implie
13. e PressNet Software Page 70 e Above 990 Ton Press Applications Above 990 Ton Press requires a special ROM program which eliminates the decimal point This special program should be requested when ordering a new unit Doc 13949 Toledo Integrated Systems PRESS ATTENDANT PAGE 69 e TTGraph software allows you to download a time based signature of the last stroke louter otal otal LetRear Rear CornerMaxess 160 Part N A Ms 126 00 Outer 18 91 220 00 9 45 9 45 1110 00 Help Left Rear a 100 75 50 25 0 180 00 Right Rear 100 75 50 25 0 0 00 9000 180 00 27000 360 00 450 00 PRESS ATTENDANT TTGraph Software Screen Figure 15 Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 70 PressNet software allows you to monitor up to 32 Press Attendant Units from a central computer File Scroll Press 0 90 80 1 38 1 40 0 PPPEPEP m PRESS ATTENDANT PressNet Software Screen Figure 16 Doc 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE 71 IX Troubleshooting the Tonnage Monitor Unit Problem Always shows on displays Solution The unit is looking for a zero value Put unit in Calibration mode and see which channel is out of balance Adjust the balance pot until it shows zero If it is unable to b
14. screen has no function if a Press Pilot is not used with the DPPlus unit Doc 13949 Rev Toledo Integrated Systems PRESS PAGE 51 SECTION 9 FAULTS The Status Message area on the Home Screen see section 2 4 will display the appropriate fault message To reset the fault either press the red lt RESET gt key on the DPPlus unit or the REMOTE RESET push button if installed The DPPlus will display the Faults Display Screen Press the lt RESET gt key or the REMOTE RESET push button again to reset the fault If additional faults exist the next fault will be displayed and the above reset process will need to be repeated to clear that fault 9 1 DRIFT FAULT A Drift Fault occurs when motion 15 detected on the encoder without the clutch valve engaged 9 2 NO MOTION FAULT When the clutch valve is engaged we give the press 500mS to get above ISPM before declaring a NO MOTION FAULT The bottom display on the Home Screen will display this fault Press the lt RESET gt button to clear the fault 9 3 DIE PROTECTION PROBE FAULT This fault occurs if the sensor did not change state during a press cycle Sensor could be damaged 9 4 DIE PROTECTION STATION FAULT This fault occurs when the necessary event did not happen on a Die Protection Station 9 5 BRAKE MONITOR FAULT This fault occurs when the stopping time of the press exceeds the Allowable Stopping Time Refer to Section 6 3 Brake Monitor for a
15. switch may also be used RS485 multidrop interface PressNet 4 and TTGraph compatible Four digit display for a total measurement Flat to kHz Two span ranges to allow either weak or strong signals from the load sensor Low range provides a continuous variable gain range from 40 mv v to 4400 mv v Each channel has a separate span of gain pot This range is adjustable by a 25 turn potentiometer inside the unit Manual zero balance range is 1 mV V of offset at the transducer input and is adjustable by a 25 turn trimming potentiometer for each channel Accepts NPN or PNP proximity device supplies 12 VDC 45 mA maximum a limit switch may also be used This probe input tells the unit when to read tonnage 0 057 mv v to 6 25 mv v input 10VDC at 125 mA maximum 1 4 350 ohm wheatstone bridge strain sensors 0 400 SPM using threshold to trigger 0 2000 SPM using built in probe to trigger factory default Tension is the reading of force by the sensor or load cell elongating stretching apart Front of a C Frame press or on a column of a straight side press usually uses the tension forces Threshold is the starting point that triggers the monitor to begin reading a tonnage It is a force value that allows the unit to recognize a cycle The monitor will ignore all forces under threshold Toledo Integrated Systems PRESS ATTENDANT PAGE 68 Optional Features PRESS ATTENDANT options e Graph Software Page 69
16. switch outputs brake monitor parts and batch counters separate immediate stop and top stop outputs and configurable message inputs The DPPlus has the capability to store information for 50 jobs The above picture shows the operation keys that will be used throughout the manual 1 1 ADJUSTING THE CONTRAST If the screen is either too dark or too light the contrast can be adjusted by pressing and holding the lt ENTER gt key and pressing either the up or down arrow key To darken the text press the up arrow press the down arrow to lighten the text This can be done from any screen 1 2 DISPLAY BACK LIGHT The Back Light on the display screen will automatically go out after a period of inactivity Press any key to reactivate the Back Light Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 14 SECTION 1 DPPLUS OPERATION KEYS 1 3 HOME KEY Pressing the key will bring up the Home Screen from any other screen The Home Screen displays key information for the operator Pressing the lt HOME gt key from the Home Screen will display the Menu Select Screen The Menu Select Screen allows the operator to maneuver through the different screens and functions of the DPPlus 1 4 BACK KEY In most instances pressing the lt BACK gt Key will return control to the previous screen On specified screens pressing the lt BACK gt Key will show additional settings or return control to a specified screen 1
17. the FREQUENCY to 1 Ifthe event needs to happen every other stroke set the FREQUENCY to pa To set the Frequency press the lt ENTER gt key until the Frequency value is flashing enter a new value using the alpha numeric keys then press the lt ENTER gt key Doc 13949 Rev Toledo Integrated Systems CONT CONTACT PRESS ATTENDANT PAGE 33 SECTION 6 EDIT PARAMETERS Set this display to match the type of sensor that is being used Use the up and down arrows to toggle between N O Normally Open and N C Normally Closed When the correct selection has been made press the ENTER key N O states that the contact will be made when the event occurs N C states that the contact will be made until the event occurs LOOK The four different Looks that can be selected are Momentary Maintained Static With Window and Static Use the up and down arrows to toggle between these 4 Look types When the correct Look is displayed press the lt ENTER gt key to go to the next screen MOMENTARY MAINTAINED STATIC W WINDOW STATIC When using this method the event must happen momentarily during the Look Window The fault will not occur until after the Look Window OFF angle The probe must also switch state outside of the window or a probe fault will occur When using this method the contact must change state during the Look Window it must maintain that state throughout the rest of the window Th
18. to the Home screen Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 18 SECTION 3 MENU SELECT SCREEN From the Menu Select Screen you can maneuver to the different settings within the DPPlus The following five functions can be accessed from this screen Job Change View Parameters Edit Parameters System Setup and DPPlus Calibration To protect the system settings a password Is required for all functions except View Parameters A selection can be made by either using the arrow keys or by pressing the alpha numeric key that corresponds with the appropriate menu option The alpha numeric keys that are currently valid will be illuminated When the display line for the desired selection is flashing press the ENTER key q Doc 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE 19 SECTION 4 JOB CHANGE To load a different Job access the Menu Select Screen select Job Change and press the lt gt key You will be prompted for the password Type the password using the alpha numeric keys then press the lt ENTER gt key If the wrong password is entered the screen will flash PASSWORD Either retry to enter the correct password or press the lt gt key to return to the Menu Select Screen After the correct password has been entered the Job Change Screen will be shown NOTE JOB NUMBER 1 may be substituted with your Job names This
19. 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE 83 Appendix C PRESS CALIBRATION DATA SHEET Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 84 Doc 13949 Rev Toledo Integrated Systems TOLEDO TRANSDUCERS INC PRESS CALIBRATION TEST DATA HOLLAND OHIO U S A COMPANY DATE PRESS SERIAL No PRESS Type and amp No CONTACT PRESS CAPACITY PHONE LOAD MONITOR MODEL SERVICE ORDER CC MONITOR SERIAL No SLIDE ADJUST INDICATOR LINEARITY PLOT USING TONS SHOWN ON TOTAL DISPLAYS TOTAL LOAD DISPLAYED ON MONITOR L J _ Jl e TOTAL APPLIED TO LOAD CELLS ON PRESS F1224 Rev A DRAWIN e CHANNEL NUMBER e SENSOR LOCATION e MONITOR LOCATION e LOAD CELL LOCATION e DIRECTION OF MATL FLOW SHUNT RESISTORS ONE YES OTHER RESISTORS CHAN 1 CHAN 2 CHAN 3 CHAN 4 TYPE OF LOAD CELLS _ MATERIAL FLOW draw arrowhead FRONT OF PRESS BED TYPE OF LOAD CELL READOUT TONNAGE SENSORS CALIBRATION LOAD CELLS CAPACITY TONS SERIAL NO CCMOFFSET STI DEGREES IN CHANNEL No 1 STI REFERENCE NUMBER LOW TRIGGERED FROM PROBE YES NO TRIPPED ALARM RELAY STOPS PRESS YES ALL STICKERS AND DOCUMENTS FILLED OUT YES NO IF NOT EXPLAIN W
20. 3949 PRESS ATTENDANT PAGE 77 SHOSN3S MOHS M3IA ONISNOH LNAWLSNrav 391 ACIS ONIAOW dO LNO 2 Waal 1 LXAN OL LINGNOS 13 81S ZL 1 04 OL L1O8 HOSN3S X 80 HOV3 ANDYOL 5 9 NOLIVNIASH3 E Aan 7SC SOVZ MOOT HOLO3NNOO 491195 NIVELS 88 ALON 3435 ONIGNLNOOSAL Ul vL 7SC E0VC H3HSVM ANDYOL dNV1O 3 18V9 ANDYOL 3 0 3 ALISOddO 9338934 08 Q31V901 GAYINDAY SHOSN3S OML HOSN3S 0 0100 1 AINO 33H 1 318VO LNAWLSANPOV aql1S OL S3AON NAHM Q3Q33N MOVIS 318V9 SI dOO 138n AHL LON Toledo Integrated Systems Rev B 13949 Doc PRESS ATTENDANT PAGE 78 USING THE T400 SENSOR INSTALLATION FIXTURE KIT No 1977 749 METRIC INSTALLATION FIXTURE KIT No 1974 749 DRILL AND TAP METHOD FOR MOUNTING SENSORS BE SURE THE SENSOR LOCATION FOLLOWS THE BEST LOCATION DESCRIBED ON THE PREVIOUS PAGES 3 DRILL 5mm STEP 2 14 28 6 1 466 gt 3 DRILL d Smm IO SQ DRILL THROUGH FOUR SMALL HOLES STEPS 3 4 1 4 28 X 1 1 4 SCREW METRIC 6 1 X 35 ROTATE FIXTURE 90 DEGREES 2041 STEP 5 en di x
21. Diagram q Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 7 i TEE y Nn v Figure 3 PLS Relay Labels Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 8 10 A 31 E 5 nod 2d E al E E 1 a 223 LIED 120VAC UPP STOMER S Ia Figure 4 Die Protection and PLS Unit Wiring Diagram Doc 13949 Rev Toledo Integrated Systems CU Doc 13949 PRESS ATTENDANT PAGE 9 mmm Figure 5 Tonnage Monitor Unit Toledo Integrated Systems PRESS ATTENDANT PAGE 10 Front VOLTAGE SELECT 115V 220V ANALOG PCB Back Figure 6 Front and Back of Tonnage Monitor Unit m Doc 13949 Rev B Toledo Integrated Systems PRESS PAGE 11 PRESS ATTENDANT ENCLOSURE MOUNTING DIMENSIONS SHOCK MOUNT ASSEMBLY 5 16 18 STUD 125 8 10 00 32mm 254mm lt 14 50 15 625 368 4 NEN 38 12 50 7 53 9 7 mm 318mm 191
22. EY MAY NOT BE USED IN CONJUNCTION WITH ANY OTHER APPLICATION THAT REQUIRES A CONTROL RELIABLE CAM Doc 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE 47 SECTION 8 DPPlus CALIBRATION 8 4 MESSAGE CENTER SET After selecting Message Center from the Calibration Menu the above screen will be displayed From the Message Center Screen the system can be programmed to recognize the message center inputs as Individual or Binary Inputs When Individual Inputs is selected the lowest message number input that is on will be displayed When Binary Inputs is selected the message with the value of the on inputs will be displayed MSG 0 1 MSG 1 2 MSG 2 4 MSG 3 8 MSG 4 16 MSG 5 32 Use the up or down arrow keys to select the correct style for the application Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 48 SECTION 8 DPPlus CALIBRATION 8 5 RESTORE DEFAULTS After selecting Restore Defaults from the Calibration Menu the above screen will be displayed To restore the factory Defaults press the red lt RESET gt key This will reset all the settings in the entire unit to factory default including the Press Control Cams A confirmation screen will be displayed Press the red lt RESET gt key to continue to restore the factory defaults A message confirming that the defaults are restored is displayed Control will return to the Calibration Menu To qui
23. Frequency to 1 If the switch needs to be turned on with every other stroke set the Frequency to 2 To program the Frequency setting press the ENTER key until the Frequency value is flashing enter a new value using the alpha numeric keys then press lt ENTER gt key TIME When using the Time feature the switch will turn on according to the ON setting and turn off after the amount of time in milliseconds specified in the Time display has elapsed or the OFF angle has been achieved whichever comes first This feature can be used with functions such as lube and air blow off to prevent problems caused if the press is stopped for any length of time while at a degree where the switch is still enabled A setting of 0 will disable the time feature The Time value is entered in milliseconds To program the Time setting press the ENTER key until the Time value is flashing enter a new value using the alpha numeric keys then press the lt ENTER gt key The value entered is in milliseconds After all values are correct press the lt BACK gt key NOTE Always use surge suppression on the coils of devices driven by the PLS Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 30 SECTION 6 EDIT PARAMETERS The above screen will appear to allow the Speed Compensation to be set on or off for the PLS If Speed Compensation 15 required select Yes otherwise select Use the up a
24. HY HIGH2 LOW 2 COMMENTS HGH4__ 10 4 Show threshold value if not triggered from probe HIGH NO EXPLAIN HGH6 ___ LOW6 HIGH8 LOW 8 TESTS MADE BY MAIL ADDRESS TOLEDO TRANSDUCERS INC P O BOX 10 HOLLAND OHIO 43528 TESTS ACCEPTED BY SHIPPING ADDRESS TOLEDO TRANSDUCERS INC PHONE 1 419 867 4170 6834 SPRING VALLEY DR FAX 1 419 867 4180 HOLLAND OHIO 43528 PRESS ATTENDANT PAGE 87 Appendix D 1662 ENCODER CABLE PINOUT AND DIMENSIONS Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 88 Doc 13949 Rev Toledo Integrated Systems ENCODER CABLE PART PPIQO ENC CABLE WHT BRN NOT USED ORG WHT A BRN WHT USED 4 GRN WHT ENC B WHT BLU DC CUM BLU WHT 24VDC WHT ORG Z PULSE BACK SIDE OF AMPHENAL 9 9 55062 55 55 9 eS 9 9 9 2252 25969 55 55 55 55059 oS LSS E e e eS e 9 9 9 e 9 eS e C 5 5 5 5 lt 4 lt 4 2 5 CX 52 Q2 5 55 lt 5 2 lt gt 25555 SKK 55506 555505062 55 50 Q2 5 5 xX eS 5 eS e 5
25. NCORRECT PASSWORD Either retry to enter the correct password or press lt BACK gt to go back to the Menu Select Screen NOTE This password is a different password than the one used for access to the other screens After the correct password has been entered the Calibration Menu screen shown above will be displayed The following 5 options will be listed Set Press Angle Speed Compensation PLS Press Control Cams Message Center Setup and Restore Defaults Use either the alpha numeric keys or the arrow keys to select which Calibration Procedure to perform When the correct selection is flashing press the lt ENTER gt key Doc 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE 43 SECTION 8 DPPlus CALIBRATION 8 1 SET PRESS ANGLE After selecting Set Press Angle from the Calibration Menu the above screen will be displayed Steps to set the Press Angle 1 Inch the press around and make sure that the PRESS ANGLE is moving in the correct direction If it is not switch the and B Encoder wires 2 Inch the press to a known position the most common is either 0 or 180 3 When the press is at a known position use the alpha numeric keys to type in the current press angle 4 When the correct angle is displayed press the lt ENTER gt key Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 44 SECTION 8 DPPlus CALIBRATION 8 2 SPEED COMP PLS After selec
26. ONI SAYNSOTONS 3S3HL Sq9nvo 5 0071 JHL 1O31OMd SSSHL SAYNSOTONS HOSN3S 2 z qaasinoas sHOSN3S 2 L SALON Toledo Integrated Systems Rev B Doc 13949 PRESS ATTENDANT PAGE 76 H31S1O8 HO JHL Wows H LGIM NWN109 L NVH L H3S019 SHOSNAS SNI1VOO1 318ISSOd 41 93999 TIY 438 3534 SV S31OH GIOAV NOLLO3S SSOHO 1SV31 JO NV NI SHOSN3S TIVLSNI 3 3l Vid AAV3H HO 3 534 3 LSY dO JIN agg 4319109 SS3s8d NI LANO 115 S31OH AHL 30 3903 3904 dOL JHL NVH L 3S0 19 SHOSN3S ONITIVLSNI GIOAV SSaud TYM 318n00 V SIII T TIVM 553244 3 NO SHOSN3S 318ISSOd 41 1 38 TIIM 3ONVIHOdH3d ii 3H SO10N3 ANY dO 131138 SHLGOMSILSHL HOSN3S QVO1 HI5N31 OL SI HOSN3S V Y3S019 SHL 3 dO JHL dO 31QGIIN JHL NI SI HOSN3S 1538 1 9 SONIN3dO 4 YVAN LINGNOO LON OG NOILOVO NO HOSN3S QVO 1104 LINGNOO SS3Md JO d E X LAN GO3 SIL Toledo Integrated Systems Rev B Doc 1
27. P Name For instructions on entering text refer to Section 11 Text Entry When the new PLS DP Name is entered correctly press the lt ENTER gt key to apply the new name Press the lt BACK gt key to return to the previous screen to select more PLS DP Names to edit To cancel changes press the lt BACK gt key at any time before pressing the lt ENTER gt key T Doc 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE 39 SECTION 7 SYSTEM SETUP 7 3 EDIT MESSAGES After selecting Edit Messages from the System Setup Menu the above screen will be displayed This screen will permit the modification of the Messages that are displayed in the Message Center Use the up and down arrow keys to scroll to the desired Message When the Message to be changed is selected press the lt ENTER gt key Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 40 SECTION 7 SYSTEM SETUP The screen will display the Message to be modified the new message text will be entered below the current message Use the alpha numeric keys to enter the new Message For instructions on entering text refer to Section 11 Text Entry When the new Message text is entered correctly press the ENTER key to apply the changes Press the lt BACK gt key to return to the previous screen to select more Messages to modify 7 4 90 DEG BRAKE TEST After selecting 90 Deg Brake Test from the System Setup Menu the above screen
28. Press Attendant Automation and Control By Toledo Integrated Systems User s Manual 12429A PRESS ATTENDANT USER S MANUAL Doc 13949 Rev Toledo Integrated Systems Doc 13949 Toledo Integrated Systems PRESS PAGE 1 PRESS ATTENDANT Table of Contents Limited Warranty 4 5 System ser e P DR 5 A Die Protection amp PLS DPPlus Unit OVETVIE Q a 12 Section 1 DPPlus Operation Keys can ot 13 ll Adj sting the Contrast a hua 13 1 2 Displaying BackobdpHt a 13 HORIS aaa ma ahua 14 154 tnde 14 MeN CSC IE 14 1 6 Up and Down Arrow Keys 14 cuis Pn 14 1 8 Alpha S u a 14 Section 2 Home Scree yi u NP e a 15 2 b POS 15 2 2 SPM Strokes Per Minute 15 SN 15 2 tatis 16 2 SDOW OATIOW S CY 16 2 6 Back Key Edit Reset Counters
29. V 45 84 Message atas ute 47 So Restore Defaults y u d toten nei ede uM ea 48 8 6 Password Setup aya e es a be due 49 8 7 Dedicated OUDDULS eer etre eerte asa ahua 49 8 8 Prox CHECK SOU str v anie d a A ER Tu 50 8 9 Press Pilot E Qu a at i el od a ta sy 50 section D ar E 0 51 de MM ELM 51 9 2 No Motion Fault uu aqa aaa 51 9 3 Die Protection Probe uuu aaa 51 9 4 Die Protection Station Faull be a Oe 51 9 3 Brake Monitor Fault ay tabe dan 51 9 5 Remote Reset bata 51 9 7 Prox Check Probe Fault disset 51 9 Sd rom C heck s aS un detti 51 Section TU Coll Changes cse 52 Section LT SEE ENY etn a Rue e 52 B Tonnage Monitor Unit CUu M une M M NE s 53 I Front Panel do eot e env diee aea 55 H Inside Panel DOSCCIDUOTE s n is Ce spore eio to te deer ua ct Manca aa 56 HI Connecting the Tonnage Monitor Uni t OR RE Rd 57 Choosing Compression or Tension 57 IV Tonnage Monitor Unit Initia
30. alance it could be a bad sensor Unplug the sensor and attempt to balance If sensor proves faulty try to plug it into the other channel and see if the results are the same Replace sensor if it is faulty Don t allow lubrication and water to enter the sensor Moisture in the sensor will result in corrosion This corrosion responds like a resistor across the gauge and prevents the unit from balancing The result is a readout of zero tonnage Problem Shows two readings from every stroke Solution Either a limit switch is double triggering the unit or a threshold value is set too low If the threshold is set to zero this indicates that you are using a cam switch to trigger the unit Check the cam switch If the threshold is set above the zero value adjust it one notch higher and see if that eliminates the double readings You may have to connect the unit to a cam switch if this proves unsuccessful See Figure 11 Cam Switch Wiring Connections for details Problem Monitor does not update Solution The press is not generating enough tonnage to trigger the monitor to read Doc 13949 If threshold is set to zero check cam switch for proper operation If threshold is set above zero lower the setting until monitor starts updating Toledo Integrated Systems PRESS ATTENDANT PAGE 72 X Definition of Terms Alarm Balance Benchmark Calibration Number Calibration Cam Input Compressi
31. ay the number of parts produced since the last Parts Counter reset occurred For an explanation of how to reset the Parts Counter refer to Section 6 4 Counter Info Batch Counter The Batch Counter will count up as the press strokes When the accumulated counter reaches the setpoint the press will top stop and indicate that the Batch Counter is finished The operator will need to reset the counter to continue running If the Batch Counter preset is set to 0 the unit will ignore the Batch Counter For an explanation of how to reset the Batch Counter refer to Section 6 4 Counter Info Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 16 SECTION 2 HOME SCREEN 2 4 STATUS MESSAGE The Status Message display line will show the name of the currently loaded Job if no faults are present If the coil change Input 15 on it will display CHANGE ON If a fault is present it will display the fault 2 5 DOWN ARROW KEY Pressing the Down Arrow key from the Home Screen will display the Message Center These messages are based on the status of the message inputs The DPPlus is delivered from the factory pre loaded with the fault messages from the Press Pilot 100 These messages can be customized to suit individual needs For an explanation of how to customize the messages refer to Section 7 3 Edit Messages and Section 8 4 Message Center Set For a complete list of the Press Pilot 100 fault messages see the Pres
32. bottom of holes are free of weld flash Mount the sensor with the raised rib to the press The anti torque washers should go between the screw and the sensor body Torque each 4 28 x in long socket head screw to 150 LB IN or 12 5 LB FT q Toledo Integrated Systems PRESS ATTENDANT PAGE 80 SENSOR ENCLOSURE MOUNTING USE 10 32 IN THE TWO 3 8 DEEP RUN SENSOR CABLE THROUGH CONDUIT PLACE HOLES THAT WERE DRILLED WITH THE SENSOR ON MOUNTING HOLES PLACE ANTI FIXTURE IN THE PREVIOUS INSTRUCTIONS TORQUE WASHERS OVER SENSOR HOLES MOUNT THE ENCLOSURE TO THE PRESS SCREW IN SENSORS BOLTS 4 EACH FINGER MEMBER AND RUN 1 2 INCH CONDUIT TIGHT USE ONLY 1 4 28 x 3 4 LOC WEL TO THE LOAD MONITOR ENCLOSURE BOLTS THAT ARE IN THE SENSOR PACKAGE 10 32 x 3 8 PAN HEAD MACHINE SCREW Z Doc 13949 TORQUE 1 4 28 x 3 4 SCREW TO 150 LB IN OR 12 5LB FT ASSEMBLE BOX COVER og E _ z 52 E 272 2 E E J E E E CONDUIT TAP THESE HOLES WITH 10 32 TAP T MODEL 7400 SIN E 1 SIL lt 5 E 22 RES 114 28 x 3 4 SOC HD SCREW 7 yo SENSOR ENCLOSURE Toledo Integrated Systems PRESS PAGE 81 Appendix B SENSOR CABLE CONNECTION Connecting Sensor cable to the Tonnage Monitor Unit Sensor Connection Guidelines 1 Strip the sensor cable as shown in Figure A Be sure not to
33. by toggling OFF the Low Alarms toggle switch The Tonnage Unit has the computer interface capabilities found on the more advanced load monitors This allows the monitor to be connected and controlled with a remote computer or PLC Information such as tonnage signatures and plant wide tonnage monitoring can be accessed by means of computer interfacing and software This manual provides instructions for rapid installation set up and calibration Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 54 ALWAYS TOTAL TONS HIGHALARM HIGH ALARM INCREASING 8 5 4 INCREASING ON TARGET ON TARGET DECREASING 4 2 5 4 2 9 DECREASING LOWALARM s LOWALARM LEFT SIDE OF PRESS RIGHT SIDE OF PRESS REVERSE HIGH ALARM TRIP POINT TONNAGELS DEVIATION Q FORMING TONS LOW ALARM TRIP POINT RUN ANALOG OUT 20 25 SETUP 510 30 1 35 5 Ww 40 OFF 2 50 LOWALARMS TOLERANCE BAND plus amp minus RESET PRESS ATTENDANT Tonnage Monitor Unit Front Panel Figure 8 PRESS ATTENDANT Tonnage Monitor Unit Typical Signal from Analog Jack Figure 9 Doc 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE 55 I Tonnage Monitor Unit Front Panel Description Note Refer to Figure 8 1 Total Tons Display Displays the total tonnage of the left side and the right side of the press Left Side and Right Side of Press Displays Ton
34. cables will be in an area where they could be damaged They are designed to be electrically noise free as long as there are no cuts or splicing done to the cable If you have custom designed load cell s that fits into your press the T400 Sensor Installation Instructions do not apply When routing your sensor cable make sure it does not snag anything as the press cycles To prevent a weak spot make sure it does not kink or bend in any one area Choosing Compression or Tension Step 2 If the sensors are being placed on the columns of a straight side press the sensor will be stretched or elongated in tension Sensors placed on the Pitman arms or in the rear of a C Frame press will be compressed When connecting the sensor cable to the Press Attendant the sensor s red and white wires need to be reversed if you are using compression See APPENDIX B for sensor cable connection The top stop circuit from the press should be connected to the Top Stop terminal inside the enclosure See figure 4 The contacts of the shutdown relay have a 10 amp rating at 120 VAC If controlling a motor of than 10 amps another relay should be put into the circuit Step 3 We recommend connecting a cam or proximity switch to trigger the unit when it should look for tonnage D01 output is used as a probe signal to trigger the tonnage monitor unit It is pre wired at the factory If an external probe is used see Figure 11 for proper conn
35. d including without limitation any warranties of merchant ability or fitness for a particular purpose All such warranties are hereby disclaimed and excluded by the manufacturer Repair or replacement of defective products as provided above is the sole and exclusive remedy provided thereunder The manufacturer shall not be liable for any further loss damages or expenses including incidental or consequential damages directly or indirectly arising from the sale or use of this product Any unauthorized repair voids this warranty There are no warranties that extend beyond those expressly set forth herein Doc 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE 5 INTRODUCTION The Press Attendant integrates tonnage monitoring die protection programmable limit switches brake monitoring and motion detection into a encoder based unit This unit is comprised of two basic sections the Die Protection and PLS DPPlus section and the Tonnage Monitor Unit SYSTEM INSTALLATION The Press Attendant comes in a 14 x 12 x 7 5 beige enclosure and should be mounted on or near the press so as to be easily seen by an operator USE THE 4 SHOCK MOUNTS PROVIDED when mounting the enclosure to protect the electronic assemblies from excessive vibration See Figure 7 All wiring connections to the Press Attendant are made through the bottom of the enclosure and should use flexible conduit At least four separate conduits must enter
36. dress Selection Figure 14 Doc 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE 63 V Tonnage Monitor Unit Press Calibration Procedure Step 1 Step 2 Step 3 Step 4 Step 5 Step 6 Choose the best sensor and unit location If the front of an O B S press is 3 1 2 times thicker than the back place the sensors in the back If placed in the back they should be in compression instead of tension Install and use 150 in lb or 12 5 ft Ib for the torque on the sensor screws This should have been done already in Step 1 of Connecting the Tonnage Monitor Unit section Record shut height of the press and the serial numbers of the load cells and load monitor The Toledo Integrated Systems Field Engineers use the Press Calibration Data Sheet located in the appendix section of this manual You may wish to copy this and use it for data collection Connect the top stop relay Enter the total capacity of the press into the Tonnage Unit Connect a cam switch if a cam switch is available to trigger the unit and adjust the threshold to 0 Without load cells in the press cycle the press and stop it at BDC Measure between the ram and the bed to determine the size of the spacers needed Be careful to allow at least a 1 8 inch gap between the ram and the load cells Damage to the press could occur if the ram locks up the load cells due to improper measurement Step 7 Step 8
37. e alpha numeric keys The valid range for Allowable Stop Time is 0 1000 milliseconds i e 1000mS 1 Second When the correct Allowable Stop Time is displayed press the lt ENTER gt key Press the lt BACK gt key to return to the Edit Parameters screen If the Stop Time the time it takes from when the power to the clutch valve is removed until the ram comes to a complete stop is longer than the Allowable Stop Time an alarm will occur To set the Allowable Stop Time the Global Password must be entered from the Edit Parameters Page Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 36 SECTION 7 SYSTEM SETUP From the Menu Select Screen select System Setup and press the lt ENTER gt key You will be prompted for the password Type the password using the alpha numeric keys then press the lt ENTER gt key If the wrong password is entered the screen will flash INCORRECT PASSWORD Either retry to enter the correct password or press the lt BACK gt key to return to the Menu Select Screen After the correct password has been entered the System Setup Menu screen shown above will be displayed The following 4 options will be displayed Edit Job Names Edit PLS DP Names Edit Messages and 90 Degree Brake Test Use either the alpha numeric keys or the arrow keys to select which System Setting to edit When the correct selection is flashing press the key Doc 13949 Rev
38. e probe must also switch state outside of the window or a probe fault will occur The fault will not occur until the Look Window OFF degree if the switch doesn t turn on Once the switch turns on the fault will occur immediately if it turns off again within the window When using this method the contact must turn on during the entire Look Window The probe must also switch state outside of the window or a probe fault will occur The fault will occur immediately in this window if the switch is not on This method sets the event to happen during the entire stroke The look window is ignored Note To reset a die protection alarm when Static is selected the station must be on or in the non fault state before a fault can be reset Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 34 SECTION 6 EDIT PARAMETERS OF STOP If a fault occurs on a Die Protection Station the press will stop according to the type of stop chosen Press the up and down arrow keys to scroll through the choices TOP STOP The press will stop on top IMMEDIATE STOP The press will stop immediately Press the ENTER key when you have the stop type that you want COIL CHNG BYPASS Use the up and down arrow keys to toggle between Yes and No The Coil Change Bypass setting specifies whether the Die Protection Station is bypassed when the unit is in Coil Change Mode Press the ENTER key when you have the c
39. e tonnage varies more than 1 ton without a quality problem it will shut down the press excessively The highest percent at deviation is 50 Percent of capacity would be an option in this case Simply flip dipswitch 1 of the small four selection dip switches toward the back of the unit See figure 13 It sets the limits around the benchmark according to the percent of 30 tons If the tonnage is 19 tons the 2 would set limits of 3 above and below the 2 tons shown as the benchmark 2 3 tons and 1 7 tons This allows limits to go as high as 15 tons from the benchmark This provides more range and less erratic shutdowns on lighter tonnage jobs Doc 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE 67 Specifications Tonnage Monitor Unit Analog Signal Output Automatic Zero Balance Calibration Shunt Cam Input Computer Interface Display Frequency Response Gain Span Ranges Manual Zero Balance Probe Input Sensitivity Sensor Excitation Sensor Inputs Speed Tension Threshold Doc 13949 Rev B 1 4 inch stereo phono jack 0 2 5vdc maximum capacity of display per channel Auto zero circuit maintains true zero during periods between measurements This assures sensor and instrument accuracy regardless of ambient temperature excursions 1 Megohm 1 precision shunt resistor Accepts 10 to 24 VDC NPN of PNP proximity device Supplies 12VDC at 45 mA maximum Limit
40. ection of cam input If using an external probe we recommend that the cam or prox turns ON at 150 degrees and OFF at 220 degrees when you want the monitor to read the peak tonnage developed during a stroke of the press Without a cam or proximity switch it may give double readings for one stroke This is especially true with dies that have more than one function or station For example see Figure 9 This signature shows piercing forming and striping It causes double updates unless a cam switch is used gt When using input move threshold setting to 0 to tell monitor to use switch Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 58 HI Connecting the Tonnaee Monitor Unit SOURCING PROBE SINKING PROBE REMINDER WHEN USING A CAM INPUT SET THE THRESHOLD TO 0 THRESHOLD A SETTING X 4 PRESS ATTENDANT Tonnage Monitor Unit Cam Switch Wiring Connections qi Doc 13949 Rev Toledo Integrated Systems Figure 11 PRESS ATTENDANT PAGE 59 HI Connecting Monitor Unit Step 4 The RS485 plug is used for connecting either an RS232 or an RS485 computer interface to the Tonnage Unit For wiring instructions see Figure 12 Connection information of the Sencon converter for plant wide connection e Selector switches on the top of the converter should be set to 422 on the monitor side 232 on the compute
41. een will be displayed Either use the alpha numeric keys or the arrow keys to select which PLS to be modified When the correct selection is flashing press the lt ENTER gt key The following screen will be displayed These switch settings can be modified from this screen ON OFF degree setting the Frequency and the Time To move the cursor between settings press the ENTER key Doc 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE 29 SECTION 6 EDIT PARAMETERS ON OFF The ON setting 15 the degree of the stroke at which you want the switch to turn on and the OFF setting is the degree of the stroke at which you want the switch to turn off To cycle once per stroke program the and settings The switch be programmed to cycle twice per stroke by using the ON2 and OFF2 addition to ON1 and OFF1 The valid range for ON and OFF settings is 1 359 When this screen first appears the ON1 value will be flashing Use the alpha numeric keys to enter the desired value then press the lt ENTER gt key If the existing value 18 correct press the lt ENTER gt key to go to the next setting NOTE To prolong the life of the output relays set limits for unused limit switches to 0 for both on and off FREQUENCY Frequency is how often you want the switch to turn on The value entered is in strokes and the maximum setting is 99 If the switch needs to be turned on with every stroke set the
42. er holes line up with the holes drilled in Step 4 Insert a tap to be sure the holes line up Lock the fixture in place by tightening the center screw Insert the tap into the larger tap guide holes and tap each hole BE SURE TO USE PLENTY OF TAPPING FLUID Remove the fixture and repeat Steps 1 7 for each additional sensor mounting position Mount the sensor with the raised rib to the press The anti torque washers should go between the screw and the sensor body Torque each 28 x in long socket head cap screw to 150 LB IN or 12 5 LB FT Toledo Integrated Systems STEP 2 PRESS ATTENDANT PAGE 79 USING THE 400 SENSOR INSTALLATION FIXTURE KIT 1977 749 WELD PAD METHOD FOR MOUNTING SENSORS BE SURE THE SENSOR LOCATION FOLLOWS THE BEST LOCATION DESCRIBED ON THE PREVIOUS PAGES 3 DRILL 1 4 28 TAP STEP 3 21 DRILL TWO SMALL HOLES FOR STEP 4 HCM ROTATE FIXTURE 90 DEGREES ENS i 1 4 28 X 1 1 4 SCREW CENTERED ENCLOSURE 1 4 28 X 1 SCREWS STEP 5 14 28 X 1 1 4 SCREW WELD SIDES ONLY Br _ANTI TORQUE A _ WASHERS STEP 7 I 1 4 28 x 3 4 LOC WEL BOLTS PUT RAISED RIB TO PRESS Doc 13949 Rev B STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7 Remove all paint grease and or rust from surface to be welded Surface should be flat T I R 1 32 of an inch Drill and ta
43. ke These outputs can be used for controlling items such as tonnage monitor probes top zone of a press to reset hydraulic overloads machine lube systems etc Once set the degrees at which they turn on and off won t change with the job After selecting Dedicated Outputs from the Calibration Menu these settings can be edited Pressing the lt ENTER gt key will move between setpoints These setpoints are the degrees 0 359 at which the outputs 00 03 will turn on and off NOTE Always use surge suppression on the coils of devices driven by the Dedicated Outputs Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 50 8 8 PROX CHECK SETUP This input is used to check for encoder slippage The prox should be mounted so it will cycle in the same spot every stroke Set the STPT ON OFF so it will alarm if the encoder slips These settings are set up the same way as a Die Protection station with static with window and N O Contact See Section 6 The STATUS and LAST ON OFF are diagnostics to aid in setting the proper setpoints To disable this input set both ON and OFF to Zero 8 9 PRESS PILOT VERSION From this screen the Press Pilot messages can be set for either a PP100 or PP150 Set this according to the model of the Press Pilot by selecting the correct model using the up down arrows and press the return button This will load all of the BCD message text corresponding to either the PP150 or PP100 This
44. l Set Up asss 61 V Tonnage Monitor Unit Press Calibration Procedure 63 VJ Operator s CUI a Fede secre Nba d 65 MIL SpeclticatlOls x st ue ve pe tO c a dud ama 67 Doc 13949 Rev Toledo Integrated Systems PRESS PAGE 3 Table of Contents continued MATIS Optional AH S 68 IX Troubleshooting the Tonnage Monitor Unit a 71 X itid a aQ Na aha uqa 72 Table of Figures 1 Main Power Connections L1 L2 and GND lies 5 2 Entire DPPl us Wiring Diagram aa a mn anan huu 6 3 PLS Relay T 4 Die Protection and PLS Wiring Diagram 8 Tonnage Monitor aa a ana Shu 9 6 Tonnage Monitor Front and 10 Ts Dimensions oe cna 11 8 Front n n una m l 54 9 Typical Signal from Analog Jack doe Rea a n 54 aa aaa amas 56 11 Cam Switch Wiring Connections ose o e oe CE e EO PA bc No ta fac ots 58 12 232 485 Connections to Computer
45. larm occurred clear an alarm turn the selector switch on the door to RESET position momentarily This closes the contact of the relay to allow the press to cycle The last press cycle continues to show on the displays until the press cycles again e Low alarms can be disabled by turning the LOW ALARMS switch to the OFF position avoid nuisance alarms and shutdowns while adjusting the press put the Tonnage Unit in SETUP until the adjustment has been made This mode still protects the press on a beyond capacity of press hit by opening the relay and flashing an alarm It will not shut the press down under the capacity of the press This switch position disables HIGH amp LOW alarm settings but shuts down the press if capacity is exceeded e Reverse mode if installed is used to display the snap through tonnage values that occur during blanking operations To see the reverse tonnage of the last cycle switch to the Reverse position or you can leave the switch in the Reverse position and cycle the press When in this mode no alarms are active qi Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 66 e Percent of Capacity Tonnage Limits will set shutdown limits to form a percentage of the forming tonnage It sets them from the capacity of the press on that side For example a stamper is making a good part at 4 tons on his 60 tons press 2 tons on each side is shown on his displays If th
46. mm FIGURE 7 Mounting the Enclosure Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 12 Die Protection amp PLS DPPlus Unit OVERVIEW The DPPlus Unit Press Automation System includes a controller with operator interface output relays die protection inputs and brake Input The operator Interface includes a 2 line alphanumeric display along with 2 columns of programming keys along the right side The DPPlus Unit offers 8 Programmable Limit Switch PLS outputs that can be used to control press automation equipment such as feeders feed and pilot release air blow off part lubricators and more The Die Protection inputs allow sensors to be fed into the controller to monitor the strip progression short and long feeds part eJection buckle detection and other events to prevent crashes The brake monitor can be used to monitor the stopping performance of the brake each time it is activated The system incorporates batch and total counters that be used to shut the press down upon reaching the count as well as tool and stroke counters that can be reset All settings can be stored in one of 50 jobs Doc 13949 Rev Toledo Integrated Systems PRESS PAGE 13 SECTION 1 DPPLUS OPERATION KEYS UP ARROW KEY 1 6 ENTER KEY 1 7 DOWN ARROW KEY 1 6 Alpha Numeric Keys 1 8 DPPlus comes standard with 4 die protection inputs 8 programmable limit
47. n explanation on setting the Allowable Stop Time NOTE If Prove Sensor Reset is set to Yes the sensor will have to be made in order to reset the fault 9 6 REMOTE RESET The Remote Reset is a normally open button that can be placed in a remote location to reset the faults on the unit It is wired to DC Common and input RST NOTE The input RST is a SINKING input and must have DC Common wired on the opposite side of the Remote Reset button Any other voltages will cause damage to the unit and is not covered under warranty 9 7 PROX CHECK PROBE FAULT This fault occurs if the sensor does not change state outside of the window 9 8 PROX CHECK FAULT This fault occurs if the prox is off at any time inside the window Sensor could be damaged T Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 52 SECTION 10 COIL CHANGE While loading the stations in a progressive die some of the sensors may not make causing nuisance faults Also it may not be desirable to count parts during this time To compensate for this a Coil Change feature has been incorporated into the DPPlus unit The Coil Change feature can bypass Die Protection sensors if selected to do so and stop the counters if selected to do so The Coil Change feature can be enabled by turning on the Coil Change input The Coil Change will remain on while the input is on and will turn off when the input turns off An example of this would be to wire to
48. nage Deviation Indicators Shows a bar graph deviation from the target tonnage Each light represents 33 from the benchmark tonnage Tonnage Deviation Selection Switch Allows the monitor to display either the actual forming load or the percent of deviation from the target tonnage A reference to Optional Features may be found in Section VIII Show Alarm Points Switch The user can display either e High alarm set points e The low alarm set points e Forming tonnage Tolerance Band Switch Allows the user to choose the percentage of the benchmark or target load to determine the high and low set points Reset Alarms Selector Switch If an alarm condition occurs and the press shuts down normal operation can be resumed by momentarily turning selector switch to reset This clears the alarm condition and closes the shutdown relay contacts allowing the press to start up again It continues to hold the last press cycle tonnage until the press is cycled again even if power is cycled OFF and ON Low Alarms Switch This switch allows the low set points to be disabled This prevents low loads from opening the shutdown relay and stopping the press If low loads or empty press strokes cannot be tolerated this switch should be OFF Analog Output Jack This jack provides electrical signals that are directly proportional to the load This signal can be viewed using an oscilloscope or track recorder 2 5 VDC Capacity in each Channel See Figure
49. nd down arrows to change the setting When the correct value is displayed press the lt ENTER gt key to save the changes For an explanation of Speed Compensation refer to Section 8 2 Speed Comp PLS A confirmation screen will be displayed before the settings are saved To save the settings use the arrows to change the value to Yes then press the lt ENTER gt key A confirmation message will appear stating that the changes have been saved and control will return to the PLS Menu where you can select another PLS for editing To cancel the changes select No and press the lt ENTER gt key A confirmation message will appear stating that the changes have not been saved and control will return to the PLS Menu Changes made during the editing process will not take effect until the settings are saved NOTE Speed Compensation is used to counteract the mechanical and electrical delays in systems that are controlled by the Programmable Limit Switch The Speed Compensation will advance the angle for the PLS if Speed Comp is set to Yes for that PLS setup For example if the DEGREES 100SPM is set to 2 and the press is traveling at 150 SPM the PLS will be advanced by 3 degrees Doc 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE 31 SECTION 6 EDIT PARAMETERS 6 2 DIE PROTECTION After selecting Die Protection from the Edit Parameter Screen the above screen will be displayed Either use
50. nick any of the signal conductors or strip the shield completely away At least gt inch of cable shield should be exposed for proper insertion in to the wire lug approx 3 0 inches approx 5 inch lt CABLE JACKET CABLE SHIELD SIGNAL CONDUCTORS Figure A 2 Insert the cable through the lug as shown in Figure B Make sure the cable shield is aligned with the portion of the wire lug which will be crimped 3 Next crimp the lug on to the cable shield do not crimp too tight and risk smashing the wires This could cause them to short to ground Figure C shows a side view of the completed operation after crimping CRIMP THE LUG IN THIS DIRECTION CABLE SHIELD ALIGNED WITH PORTION OF WIRE LUG WHICH WILL BE CRIMPED Figure B mmm Figure C Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 82 4 Attach the wire lug to a ground terminal on the inside panel of the Press Attendant Use 6 32 4 screw for the grounding lug connection If you have a Toledo Transducers sensor attach the signal wires to the proper channel phoenix connector following the color code shown in figure D and on the back of the Tonnage Unit enclosure G Switch R amp W wires for compression load Figure D Note If your sensor cable is not double shielded with both foil and a braid electrical noise may affect your output readings Doc
51. on Gain Span Reverse Load Shut Height Signature Doc 13949 A reading that is out of the high or low limit range causing the relay to de energize Once alarmed the relay opens to stop the press machine The balance adjustment equalizes the sensor to the monitor The balance pot is used to bring the display to zero The tonnage of a good part made during the last cycle in SETUP PEAK mode A reference value dialed in during the calibration process When the calibration number is correct the gain span settings are correct The process in which the Tonnage Monitor mounted on the machine is adjusted to read the same tonnage as the reference load cells in the bed of the press A switching input to the unit allowing tonnage to be read at a certain position in the stroke It is usually obtained from a rotary cam wheel or a programmable limit switch The force generated by the sensor or load cell by compressing It is usually found in the rear of a C Frame press or on a Pitman arm Gain also called Span is the amplification used by the monitor A small amount of elongation of the sensor needs a large amount of gain to show a high reading The gain is adjusted during calibration The snap through or damaging negative forces occurring in the machine Typically the snap through rating is 10 of the capacity of the press The distance from the top of the bed of the press to the bottom of the ram when on BDC M
52. orrect setting For an explanation of Coil Change Mode refer to Section 10 Coil Change PROVE SENSOR RST The Prove Sensor Reset setting specifies whether the sensor has to be toggled on then off in order to reset the fault This is to test the sensor to verify that it is functioning properly Yes would indicate that this action must be performed and No indicates that it doesn t need to be done Press lt ENTER gt when you have the correct setting A confirmation screen will be displayed before the settings are saved To save the settings use the arrows to change the value to Yes then press the lt ENTER gt key A confirmation message will appear stating that the changes have been saved and control will return to the Die Protection menu where another Die Protection Station can be selected for editing Doc 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE 35 SECTION 6 EDIT PARAMETERS To cancel the changes select No and press the lt ENTER gt key A confirmation message will appear stating that the changes have not been saved and control will return to the Die Protection menu NOTE If you have the Prove Sensor Reset set to Yes the sensor will have to be made in order to reset the fault 6 3 BRAKE MONITOR After selecting Brake Monitor from the Edit Parameter Screen the following screen will be displayed The Allowable Stop Time value will be blinking Enter a new value by using th
53. ost OBI OBS presses have a shut height of approximately fifteen inches and a ram adjust of approximately four inches A waveform generated by the compression or tension of the press as the part is being made seen at the analog output or downloaded by software from the computer output T Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 73 Appendix SENSOR PLACEMENT amp INSTALLATION T Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 74 Doc 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE 75 NOISN3 L SSANMOIHL LNO J NOISS3HdlNOO SSANMOIHL YVAN E uolsu jo JO uonoeuuoo y jsn py 189 y Josues eu usu si SSAUYOIU OU JI sow y 1 6141 u u sjosues US uey Je Jeuis s ss uyol u 110 eui Jl INOHJ SSANMOIHL AHL 33 S V3IN dvd SSANMOIHL V3 3H L AYNSVAW 1538 3 3NIINSH3 LSO OL MOH AAYHL AIdILINW ease pepeus au Ul UMOUS sseJd eu JO 186 JO BY peuiuuejep eq 1snui uoneoo Josu S IN3IN3OV ld YOSNAS S310H LNO MOONM JHL NI S4473 NIVYLS 2 1 9NISn LS3SSnS 3M aasn SI dl S3 Ik ANI
54. p the center hole for mounting the fixture to the press member This hole should be 2 inch deep Optional Bolt the fixture to the press member using the 4 28 by 1 inch long socket head cap screw in the center of the fixture Orient the fixture as shown and drill out the 21 holes to a depth of 3 8 of an inch for the enclosure mounting The fixture is not used for tapping these holes Optional Remove the fixture from the press member Bolt the weld pads to the fixture with 74 28 by 1 inch long socket head cap screws provided Reattach the fixture with the weld pads bolted on using the center hole as in Step 3 Orient the fixture as shown Weld the weld pads to the press member BE SURE TO ONLY WELD THE WELD PADS ON THREE SIDES AS SHOWN A single pass is sufficient Do not remove the fixture until slag is removed and or assembly has cooled When welding cast iron use a dry nickel rod such as Lincoln Electric Soft Weld Hobart NI Cast 99 or MB Weld Prod MG 210 Strike arc on steel then puddle into the cast iron Remove the weld fixture DO NOT WELD AFTER FIXTURE IS REMOVED The 4 screws holding the pads to the fixture and the 1 center screw may be discarded DO NOT USE THE FOUR 1 INCH LONG SCREWS TO ASSEMBLE SENSOR The sensor kit contains four 74 inch long screws for assembling the sensor to the press member Weld pad surface must be clean no weld bumps scratches etc Be sure the weld pad tapped holes are clean and
55. r side e 120 resistor must be connected at the converter between the common and the Rx4224 232 e The third LED from the top flashes every time the computer asks for information The bottom LED flashes when the monitor responds gt Cable shield connection must continuous from end to end electrical noise damage your computer gt Use Belden 8103 or equivalent interface cable TT 2038 222 Step 5 Step 6 The Tonnage Unit is protected by a 1 5 amp Slo Blo fuse on the inside panel If replacement becomes necessary an identical fuse must be used The size of the fuse is 25 x 1 25 Each time the Tonnage Unit is powered up all LED s and displays light up for approximately one second then a four digit number is displayed This number is the ROM used to determine the firmware version of the internal program The monitor is also auto zeroing the sensor inputs When auto zeroing it shows horizontal lines When completed the relay closes and the unit awaits a press cycle Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 60 HI Connecting the Tonnage Monitor Unit To computer chassis For one connection to your computer TX232 Pin 2 RX232 Pin 3 GND Pin 7 a TX232 R rT GND GND RX232 Pin 2 amp s I 4 4 TX232 Pin 3
56. rd the numbers shown These are the calibration numbers Record them on the inside door of the Press Attendant and also on the calibration sheet for your files Flip dip switch 3 forward OFF and record any other switch settings on the door of the unit The calibration is complete Toledo Integrated Systems PRESS ATTENDANT PAGE 65 Operator s Guide ALWAYS TOTAL TONS HIGH ALARM HIGH ALARM INCREASING INCREASING ON TARGET ON TARGET WM 105 400 LOW ALARM LOW ALARM LEFT SIDE OF PRESS RIGHT SIDE OF PRESS REVERSE HIGH ALARM TRIP POINT TONNAGE ES DEVIATION 9 FORMING TONS VORMA LOW ALARM TRIP POINT R ANALOG OUT 20 25 15212 30 SETUP 6 10 2 35 5 OFF 2 50 LOW ALARMS TOLERANCE BAND plus amp minus UN i D RESET e While setting a die in the press switch the Tonnage Unit to SETUP and run material through After a good part is formed switch to RUN e Once turned to RUN it takes the last tonnage seen in SETUP and makes it the benchmark tonnage It compares following hits during the production run with this benchmark tonnage The Tonnage Unit establishes high and low set points based on the percentage setting of the TOLERANCE BAND SWITCH It sets them around the benchmark tonnage e The HIGH and LOW set points can be displayed by toggling the SHOW ALARM POINTS SWITCH Ifan alarm occurs the display will flash on the side of the press on which the a
57. rotection Station or the diagnostics screen to be displayed When the correct selection is flashing press the lt ENTER gt key The above screen will now be displayed This screen displays the settings for this Die Protection Station The settings cannot be modified from this screen For an explanation of Die Protection settings refer to Section 6 2 Die Protection Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 24 SECTION 5 VIEW PARAMETERS Pressing the lt BACK gt key will display these additional settings Press lt BACK gt key to return to the Die Protection Selection Menu 5 2 1 DIE PROTECTION DIAGNOSTICS From the Die Protection Selection Menu Page either press 5 or scroll down until Diagnostics is selected then press lt ENTER gt The die protection diagnostics screen will show the degree at which the sensor last turned on the degree at which the sensor last turned off and the current state of the die protection input for that station Pressing the up or down arrow key will scroll through the four individual die protection stations Doc 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE 25 SECTION 5 VIEW PARAMETERS 5 3 BRAKE MONITOR After selecting Brake Monitor from the View Parameters Screen the above screen will be displayed This screen shows the last Stop Time and the Allowable Stop Time Press the lt BACK gt key to return to
58. s Pilot 100 manual 2 6 BACK KEY CHANGE RESET COUNTERS To Change focus from one setting to another press the lt ENTER gt key PARTS To reset the Parts Counter press the red lt RESET gt key when the cursor lt is next to the Parts Counter Value To move the cursor to the Stroke Counter press the lt ENTER gt key Doc 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE 17 STROKE To reset the Stroke Counter press the red lt RESET gt key when the cursor lt is next to the Stroke Counter Value This can only be reset if the Global Password is active If the Setup Password is active press the ENTER key to edit BATCH SET BATCH SET When the Batch Set is flashing enter in a number for the Batch Counter Setpoint A 0 disables the Batch Counter function After the correct number is displayed press the lt ENTER gt key When the Batch Counter accumulated number of strokes reaches the setpoint the DPPlus will open the Top Stop relay and keep it open until the DPPlus unit is reset COIL CHG COUNT The Coil Change Count setting controls whether the unit s counters increment while in coil change mode Use the up and down arrow keys to toggle between Yes and No Press the lt ENTER gt key when the desired value is displayed For an explanation of Coil Change Mode refer to Section 10 Coil Change When all settings on this page are acceptable press the lt BACK gt key to return
59. screen displays the Job names and assigns a number for selection There 50 job storage locations available Scroll through the vartous Jobs using the up and down arrows keys they will be illuminated or enter the desired Job number 1 50 using the alpha numeric keys When the desired Job 15 displayed use the alpha numeric keys to enter the job number that is in front of the job name and press the ENTER key Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 20 SECTION 4 JOB CHANGE The following screen will be displayed to verify the Job that has been chosen Either press the lt gt key to confirm that ts the correct Job to be loaded or press the lt BACK gt key to back to the previous page and change the selection to another job The new Job is now loaded The following screen will display the name of the new job that was loaded Press the lt BACK gt key to return to the Menu Select Screen To return to the Home Screen press the lt HOME gt key Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 21 SECTION 5 VIEW PARAMETERS To view the current program settings access the Menu Select Screen select View Parameters and press the lt ENTER gt key You will be taken to the following screen While in View Parameters no edits will be allowed The following 3 options will be listed Programmable Limit Switches Die Protection and Brake Monitor
60. t before restoring the factory defaults press the lt BACK gt key Control will return to the Calibration Menu Factory Defaults BCAM ON 10 BCAM OFF 190 TCAM ON 170 TCAM OFF SLOW 300 CAM OFF FAST 300 Job Name 1 50 JOB NUMBER 1 50 PLS Name 1 8 PLS 1 8 Die Protection Name 1 8 DIE PRO 1 4 Message Center Messages restored to Binary Coded Messages Doc 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE 49 SECTION 8 DPPlus CALIBRATION 8 6 PASSWORD SETUP After Selecting Edit Passwords from the Calibration Menu the user will be able to change the passwords The unit comes with 2 levels of passwords 1 Setup This level gives the user access to all functions except for DPPlus Calibration Brake Monitor Setpoint and Stroke Counter Reset 2 Global This level gives the user access to all functions of the DPPlus The unit comes factory set with the passwords disabled set to 0 Make sure to change these passwords to protect the data from accidental changes To disable either password enter a 0 in for the password NOTE Entering a 0 for global disables both passwords When restoring defaults see Section 8 5 the passwords are unaffected 8 7 DEDICATED OUTPUTS The DPPlus comes equipped with 3 dedicated outputs These outputs are non job specific programmable limit switches with only one on degree and one off degree They will cycle once every stro
61. tems PRESS ATTENDANT PAGE 46 SECTION 8 DPPlus CALIBRATION TCAM SPD and TCAM OFF The TCAM Speed and TCAM OFF settings can be modified on this screen shown above The is speed compensated so that the press stops at or near top regardless of the speed To adjust the top stop speed compensation 1 2 3 4 Set the Slow and Fast SPD to the same speed This is to temporarily disable the speed comp calculation while setting it up Use the lt ENTER gt key to toggle between setpoints Adjust the TCAM OFF and TCAM ON to the same degree Run the press and stop it on top Adjust the angle until the press stops at top Be sure to keep them both the same for this step Run the press at the Fast speed a speed near or at the fastest and top stop the press Note the degree that the press stops at Take this difference and subtract it from SLOW TCAM OFF degree and enter that into the FAST TCAM OFF degree Enter the speed that the press ran in the FAST TCAM SPD Run the press again at the fast speed and topstop it Adjust the FAST TCAM OFF degree until the press stops on top When the press stops at top at both speeds and the top stop speed compensation 15 satisfactory press the lt BACK gt key This will return control to the DPPlus Calibration Menu page NOTE THESE CAMS ARE ONLY FOR USE WITH THE PRESS PILOT 100 CLUTCH AND BRAKE CONTROLLER THE PRESS PILOT 100 USES A CAM CHECK PROX FOR REDUNDANCY TH
62. th displays read nearly zero Flip dip switch 3 forward OFF select reset and cycle the press Make the Tonnage Unit read the same as the load cells within 98 or closer by adjusting the gain pots The Tonnage Unit should match the load cell readings Turning it clockwise adjusts the gain higher There is a x10 x1 Jumper that can be adjusted depending on how much gain you need After you adjust the gain cycle the press to see the results of your adjustments Keep adjusting and cycling until the Tonnage Unit matches the load cell s tonnage Once the calibration is complete back off the ram adjustment little by little and record the results This should be done at least 4 times to see the accuracy at lower tonnage We call this the linearity check 100 75 50 and 25 of capacity Cause the unit to alarm by flipping it to Tonnage Unit Run mode and vary the tonnage by adjusting the ram Does it stop the press after an alarm If not the wiring of the shut down relay should be checked Remove the load cells and install the die The production run may now begin If you see erratic readings check the cam switch timing It should be ON from at least 4 o clock to 7 o clock 160 degrees 200 degrees in the stroke If you are not using a cam switch consider adjusting the threshold to 4 or 5 16 20 percent of capacity Put the unit back into the calibration mode as in Step 9 Turn selector switch to reset position and reco
63. the View Parameters Screen Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 26 SECTION 6 EDIT PARAMETERS If it is necessary to modify any of the parameter settings access the Menu Select Screen select Edit Parameters and press the lt ENTER gt key The following screen will appear Type the password using the alpha numeric keys then press the lt ENTER gt key If the wrong password is entered the screen will flash INCORRECT PASSWORD Either retry to enter the correct password or press the lt BACK gt key to return to the Menu Select Screen Doc 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE 27 SECTION 6 EDIT PARAMETERS After entering the correct password you will see the Edit Parameters screen shown above There 3 choices on what settings to edit Programmable Limit Switches Die Protection and Brake Monitor Each option can be selected by either using the arrow keys or by pressing the alpha numeric key that corresponds with the appropriate menu option The alpha numeric keys that are currently valid will be illuminated When the display line for your menu selection is flashing press the lt gt key Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 28 SECTION 6 EDIT PARAMETERS 6 1 PROGRAMMABLE LIMIT SWITCHES After selecting Programmable Limit Switches from the Edit Parameter Screen the above scr
64. the alpha numeric keys or the arrow keys to select the Die Protection to be modified When the correct selection is flashing press the lt ENTER gt key Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 32 SECTION 6 EDIT PARAMETERS The following screen will appear To move between settings press the lt ENTER gt key ON OFF The ON setting 15 the degree of the stroke at which the Look Window will start and the OFF setting is the degree of the stroke at which the Look Window will stop The Look Window is the angle of the press in degrees that the event should or should not happen The valid range for ON and OFF settings is 0 359 For Example the part should eject from the press between 190 and 350 degrees In this case the ON should be set at 190 and the OFF should be set at 350 The degrees between the ON and OFF will be referenced as Look Window When this screen first shows the ON value will be flashing Use the numeric keys to enter in the desired value then press the lt ENTER gt key If the existing value is correct press the lt ENTER gt key to go to the next setting NOTE If the die protection station is not being used set both On and Off to 0 This will cause the DPPlus to ignore the station FREQ FREQUENCY The Frequency is how often in strokes the event should take place The value entered is in strokes and the maximum setting is 99 If the event needs to happen every stroke set
65. the enclosure There are four holes provided for 1 1 8 conduit for power and relay wires The power should be in its own conduit as well as the relay connections It is absolutely essential that the sensor cables are run in conduit separate from the relay or power wires The Press Attendant requires continuous and filtered 115 VAC power at 60 Hz for proper operation To expose the AC power connections open the Press Attendant enclosure door The AC power line connections are located near the upper left corner inside the enclosure The AC power is connected to the 2 leftmost terminals labeled L1 and L2 see figure 1 Connect a good earth ground to the terminals labeled GND which are located 5 terminals to the right of L2 also shown in figure 1 Connect the hot side of the AC line to the terminal labeled L1 and the neutral side to L2 Jumper J3 can be changed to allow 220 VAC operations See figure 6 A 1 5 amp Slo Blo 25 x 1 25 fuse protects the system and is electrically connected on the L1 or hot side The fuse protects both the DPPlus unit and the Tonnage Monitor unit Figure 1 Main Power Connections L1 L2 and GND Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 6 Doc 13949 Co Ge r2 G HU MIY A dM ML Imm Figure 2 Entire DPPlus Wiring
66. the inch mode selector switch of the press control Note This input is 24VDC sinking SECTION 11 TEXT ENTRY Use the alpha numeric keys to enter the text For example if the number 2 is pressed the letter A will appear If pressed immediately again it will change to the letter B then C then 2 then back to Pausing for two seconds will take the cursor to the next position If the next letter uses a different key pressing the next key will automatically move the cursor to the next position BACKSPACE down arrow key SPACE up arrow key When text is correctly displayed press the lt ENTER gt key Doc 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE 53 Monitor Unit Overview The Tonnage Unit is a two channel compact inexpensive and simple to use tonnage monitor It Is capable of displaying the load for both sides of the press as well as the total press tonnage Both the left side and the right side displays have a bar graph that visually shows the deviation from the benchmark tonnage This allows the operator to easily watch the repeatability of forming loads The Tonnage Unit automatically sets high and low set points by using the percentage value from the Tolerance Band switch When a load is detected to exceeded either of these set points the Tonnage Unit s shutdown relay is opened which in turn stops the press or alerts the operator Low alarms may be disabled
67. ting Speed Comp PLS from the Calibration Menu the above screen will be displayed Speed Compensation is used to counteract the mechanical and electrical delays in systems that are controlled by the Programmable Limit Switch The Speed Compensation will advance the angle for the PLS if Speed Comp is set to Yes for that PLS setup For example if the DEGREES 100SPM is set to 2 and the press is traveling at 150 SPM the PLS will be advanced by 3 degrees All 8 Programmable Limit Switches use this setting for their compensation value To set the Speed Compensation for the PLS s type in a value 0 6 using the alpha numeric keys When the correct value is displayed press the lt ENTER gt key Doc 13949 Rev Toledo Integrated Systems PRESS ATTENDANT PAGE 45 SECTION 8 DPPlus CALIBRATION 8 3 PRESS CONTROL CAMS After selecting Press Control Cams from the Calibration Menu the above screen will be displayed The default settings are shown in the above example Note that the TCAM OFF cannot be modified on this screen Refer to the Press Pilot 100 manual for the proper settings To change a setting use the up and down arrow keys until the value to be modified is flashing Use the alpha numeric keys to enter a new number 0 359 then press the lt ENTER gt key When all settings on this screen are correct press the lt BACK gt key to proceed to the next screen q Doc 13949 Rev B Toledo Integrated Sys
68. will be displayed This Brake Test is used to test Stop Time when an immediate stop signal is given to the press control when the press is at 90 degrees The bottom line of the display indicates the stopping time from the last time the test was performed Brake tests should be performed periodically to check the condition of the brake Doc 13949 Rev Toledo Integrated Systems PRESS PAGE 41 SECTION 7 SYSTEM SETUP Steps to perform a brake test 1 2 3 4 5 6 7 8 9 Set the counterbalance pressure according to the upper die weight Put the press at top of the stroke Put the press in continuous or single mode Run the main motor at its fastest speed Press 0 to activate the brake test Run the press When the press passes 90 degrees the immediate stop output will open up giving a signal to the press control to stop Once the press comes to a complete stop the bottom line will display the stopping time Brake test is complete To cancel a 90 Degree Brake Test press the lt BACK gt key at any time during the process Doc 13949 Rev B Toledo Integrated Systems PRESS ATTENDANT PAGE 42 SECTION 8 DPPlus CALIBRATION From the Menu Select Screen select DPPlus CALIBRATION and press the ENTER key You will be prompted for the password Enter the required password then press the lt ENTER gt key If the wrong password is entered the screen will flash I

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