PEM-300 Manual - Toledo Transducers
Contents
1. RUN Bypass Toggle Switch The RUN Bypass switch is used to disable the B 502 module When the switch is in the Bypass position the B 502 module will not stop the press even though an improper part ejection condition may exist It is used to disable the functionality of the module Placing the switch in the RUN position will allow the B 502 to monitor the proper die operation and stop the press during fault conditions See the timing diagram in section 6 for typical timing sequence for the B 502 single station part ejection module Document 11695 Rev 1 Page 6 PEM 300 User s Manual PEM 300 Compatible Modules Continued 5 2 B 504 CAM Input Timing Module B 504 READY CAM o Figure 5 2 B 504 Module Document 11695 Rev 1 The B 504 CAM input module is used to provide the system timing for the PEM 300 Part Ejection Monitor By monitoring the opening and closing of the rotary cam switch the appropriate timing for the other modules in the system is generated This module is standard with the PEM 300 system and is preinstalled at the factory This module must reside in the leftmost socket of the PEM 300 control board The following describes the functions of the B 504 module READY Yellow LED The READY LED indicates that the B 504 module has either detected that the reset switch has been pressed or that the closure of the rotary cam switch contacts has occurred When active it indicates tha2. ejection module The functionality of these modules will be described within section Five of this manual This section describes the front panel operation of the PEM 300 Refer to Figure 4 1 for the front panel operation description of the PEM 300 control unit 4 1 PEM 300 Front Panel Operation PEM 300 Part Ejection Monitor A B ON RUN Be aa A M O 7A I N W O 5 E AJA NO E BS OFF BYPASS ce u RESET Figure 4 1 PEM 300 Front Panel Document 11695 Rev 1 A Power Switch Used to apply and remove power from the PEM 300 control unit B Mode Switch Place the Mode Switch in the BYPASS position when setting up dies or loading stock material Placing the Mode Switch to the BYPASS position will allow the press to operate independently of the PEM 300 control unit Once all the sensors have been properly set and the material has been properly loaded in to the die area place the Mode Switch in to the RUN position The PEM 300 control unit is now ready to monitor all stations The press can now be operated in continuous mode C Reset Switch Once the PEM 300 is placed in to RUN mode the user must press the RESET switch within ten to twelve seconds in order to operate the press in continuous mode If this does not take place the PEM 300 will issue a FAULT and the RESET switch will have to be pressed again If a FAULT condition is detected in any monitored station the PEM 300 will
3. immediately shut the press down by activating its E STOP output relay Once the problem has been determined and corrected pressing the RESET switch will deactivate the E STOP relay The press can resume operation in continuous mode Page 5 PEM 300 User s Manual PEM 300 Compatible Modules 5 1 B 502 Single Station Part Ejection Module gt The B 502 single station PART EJECTION module can be used to detect B 50 proper ejection of material that takes place during the press operation The Sensor Q following describes the functions of the B 502 module Blocked Fault ene Q Sensor Blocked Red LED When active a fault condition has occurred that indicates the part ejection RUN _ sensor light screen beam is either blocked by the part blocked by an object is dirty or simply out of alignment at the time the rotary cam switch is closing a The press will stop if this condition is recognized P P Bypass Fault Red LED When the Fault LED 1s active an improper part ejection seguence has been recognized It is an indication that the part has not left the die area at the time the rotary cam switch 1s closing The press will stop during this condition Figure 5 1 B 502 Module Sensor Green LED The Sensor LED 1s active anytime a part passes through the beam This LED will also remain illuminated during light screen setup up It will turn off when correct sensor alignment is achieved
4. 1 Document 11695 Rev 1 ii PEM 300 User s Manual Introduction The purpose of this User s Manual is to describe the operation and installation of the MASA Toledo Transducer s PEM 300 Part Ejection Monitor herein referred to as the PEM 300 It is strongly recommended that this User s Manual be read entirely before placing the PEM 300 into operation Failure to follow the instructions given in this User s Manual may void your PEM 300 warranty Questions regarding any aspect of the PEM 300 should be referred to Toledo Transducers Inc Toledo Transducers Inc 6834 Spring Valley Drive Holland Ohio 43528 Phone 419 867 4170 Fax 419 867 4180 Document 11695 Rev I Page 1 PEM 300 User s Manual PEM 300 Part Ejection Monitor Description The PEM 300 Part Ejection Monitoring system 1s used to detect the occurrence of improper part ejections that could lead to the catastrophic destruction of the press Part ejection detection is accomplished through the use of multiple electronic modules used within the PEM 300 When a fault condition is detected the PEM 300 will immediately open its E Stop relay If the relay is connected to the press s E Stop circuitry the press will shut down The PEM 300 includes a B 504 cam check module that continuously monitors the state of the cam timing The B 504 module also produces the main timing for the part ejection module that is incorporated in to the system SPECIFICATION
5. S Power Requirements 115 VAC 60Hz Voltage Tolerance 10 VAC PEM 300 Control Unit 10 L x 742 H x 644 W B 504 Module CAM Check module standard with each PEM control unit monitors CAM timing Power Supply 18 VDC 180 mA MAX for sensors Outputs E STOP dry contact 10A at 120VAC 240VAC 30VDC Operational Speed Up to 1200 SPM Document 11695 Rev I Page 2 PEM 300 User s Manual PEM 300 Part Ejection Monitor Typical Installation CAUTION The location of the PEM 300 Part Ejection Monitor control unit should be as close as possible to the press controls allowing easy access to the press operator The unit should be located away from any oil or lubricant sprays The location chosen must be convenient for operation and for the safety of the PEM control unit PEM 300 Part Ejection Monitor p RUN m o fa o w A 8 ES a T T R or BYPASS login Deaton B Rubber shock mounts R 4 places BYPASS O UO 7 A Flexible Conduit AJ for 115VAC 9 Fi PEM 300 modules O J Figure 3 1 PEM 300 System Refer to Figure 3 1 for the following suggestions A Use 1 2 flexible conduit at this location for all 115V AC power 115VAC is required to power the PEM 300 control unit It may also be required for the E STOP circuitry in some applications B Rubber shock mounts should always be used as a precaution to applications that are prone to excessive vibration Dampening exces
6. Toledo Transducers PEM 300 Part Ejection Monitor User s Manual Rev 1 it eo ees b Scan to visit us on the web PEM 300 User s Manual PEM 300 Manual TABLE of CONTENTS 1 T troducti OU cs05 coe seeetece sts E Ea Page 1 2 PEM 300 Part Ejection Monitor Description eee Page 2 3 PEM 300 Part Ejection Monitor Typical Installation Page 3 4 PEM 300 Part Ejection Monitor Operation oeeereree Page 5 5 PEM 300 Compatible Modules ccsscsssessessessesseeseeseessee Page 6 6 PEM 300 Part Ejection Timing seese Page 9 7 PEM 300 Mechanical Dimensions oo oronononnnonnnonnn Page 10 8 PEM 300 Wiring Diagram e ec eeeeeseceseeeeeeeeneecsneeneeeeeee Page 11 9 Limited Warranty einir a a eee Page 12 Document 11695 Rev 1 1 PEM 300 User s Manual TABLE of FIGURES Preure 3 0 PEM 300 Systemen nis vediettnoastaeeseaee Page 3 Figure 3 2 PEM 300 Press Installation eee eee ence Page 4 Figure 4 1 PEM 300 Front Panel y 24 4 aso ai Page 5 Figure 5 1 B 502 Single Station Part Ejection Module Page 6 Figure 52 B 504 CAM Input Timing Module Page 7 Figure 53 LS 3 Light Screen Set cccssscssssesessscessssessneeees Page 8 Figure 6 1 Typical Part Ejection Timing Page 9 Figure 7 1 PEM 300 Mechanical Dimensions Page 10 Figure 8 1 PEM 300 Control Board Wiring Diagram Page 1
7. at the factory Document 11695 Rev 1 Page 8 PEM 300 User s Manual 6 PEM 300 Part Ejection Timin After the installation of the PEM 300 has been completed sensor placement cable routing etc the CAM timing must be setup in order for the part ejection system to correctly work To begin this task start jogging the press Take notice of the point where the material has been completely passed through the light beam of the LS 3 light screen The LS 3 light screen should be placed as close as possible to the part ejection area so that part travel is minimized Once these points have been determined jog the press an additional 20 to 30 degrees then set the rotary CAM switch to close its contacts at this position The rotary CAM switch closing dwell time should always be between 150 and 180 degrees for proper part ejection operation of the PEM 300 system Refer to Figure 6 1 for typical part ejection timing A Typical range of initial closing of rotary cam switch B Part ejection typically A takes place during this interval Lil between 180 and 330 Figure 6 1 Typical Part Ejection Timing Document 11695 Rev 1 Page 9 PEM 300 User s Manual m 10 50 9 20 V ia NU fa k E a 7 a 7 Eai I gt I PEM 300 Part Ejection Monitor ON RUN PS ea s M O AN tan o 6 00 v 0 8 6 75 aS F NS NOE OFF BYPASS w BYPASS 1 Pan aS D Fig
8. sive vibration will prolong the operating life of the PEM 300 control unit Document 11695 Rev 1 Page 3 PEM 300 User s Manual PEM 300 Part Ejection Monitor Typical Installation Continued C Rotating CAM PA a provides timing to the PEM 300 4 E Press control box power and E STOP interlocks for PEM 300 D J Boxes used for probe sensor wiring Figure 3 2 PEM 300 Press Installation Refer to Figure 3 2 for the following suggestions C The PEM 300 control unit must be timed to the crankshaft of the punch press The timing relationship between the press crank and the PEM 300 must be a 1 1 ratio If the timing ratio is not 1 1 the PEM 300 will not monitor the press die at the correct crank position This could ultimately lead to catastrophic destruction of the press D Any standard junction box can be used for installation of the sensors used in conjunction with the PEM 300 The use of junction boxes is left to the discretion of the system installer E The existing press control box will provide A C power and an E STOP interlock to the PEM 300 control unit For good electrical noise immunity the A C power must be routed through separate conduit than that of the sensor wires Document 11695 Rev 1 Page 4 PEM 300 User s Manual PEM 300 Part Ejection Monitor Operation The PEM 300 Part Ejection Monitor that you purchased has been pre installed with a standard CAM input module and a part
9. t the module is ready to monitor press activity If the PEM 300 front panel reset switch has been pressed the user has approximately twelve seconds to start the press If the user has not started the press during this allotted time the B 504 module will reset and the READY LED will turn off The PEM 300 system will not operate until the front panel reset switch is once again pushed CAM Yellow LED The CAM LED is active anytime the rotary cam switch contacts are closed Page 7 PEM 300 User s Manual PEM 300 Compatible Modules Continued 5 3 LS 3 Light Screen Set GHT BEAM LIGHT EMITTER LIGHT DETECTOR PAIR Figure 5 3 LS 3 Light Screen The LS 3 LIGHT SCREEN SET consist of an infrared light emitting and an infrared light detector pair These units are used in conjunction with the B 502 part ejection module For correct operation of the PEM 300 part ejection system the part must pass completely through the beam each cycle If this does not occur the PEM 300 will stop the press The LS 3 light screen set should be placed as close as possible to the part ejection area for quick part ejection detection Placing the LS 3 light screen in close proximity to the part ejection area minimizes travel time of the part being monitored The emitter can be placed up to 48 inches from the detector The LS 3 light screen is connected to the PEM 300 part ejection system via a 15 ft cable This cable is pre wired
10. uential 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 Document 11695 Rev I Page 12
11. ure 7 1 PEM 300 Mechanical Dimensions Document 11695 Rev I Page 10 PEM 300 User s Manual PEM 300 Wiring Diagram PEM 300 Control Board 1 3 4 5 6 78 KSAS KESAS N OY Y Y IA S Y PRE WIRED AT FACTORY 115VAC E STOP Power Relay S CAM Figure 8 1 PEM 300 Control Board Wiring Diagram Document 11695 Rev 1 Page 11 PEM 300 User s Manual Limited Warranty This unit is warranted by the manufacturer Toledo Transducers Inc 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 to F O B Toledo Transducers Inc 6834 Spring Valley Drive Holland Ohio 43528 The express warranty set forth herein is in lieu of all other warranties expressed or implied 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 conseq
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