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PRESSPro Genesis manual - Advanced Micro Controls Inc

1. Figure 11 1 Limit Switch Setpoint Screen 2 When this screen first appears the blinking cursor will be positioned on the number 1 for the first ENTERT To program another channel enter the number from 2 to 6 of the channel and press ENTER 3 When the cursor is on the correct channel number press the right arrow key gt to move the cursor to the next field and select a specific type of output for the channel Press SELECT to toggle between Normal N Timed T and Output Disabled or Channel Not Used When the correct value is displayed press ENTER to move the cursor to the F ROM column 4 If you selected Normal or Timed output enter the angular position for the first ON setpoint in the FROM column then press ENTER twice to move the cursor to the T O column and enter an angular position for the OFF setpoint If the crankshaft is moving you can only press INC or DEC to change the setpoint values When an invalid setpoint is entered an error message will appear for three seconds and the cursor will return to the right most digit of the ON setpoint 5 Press ENTER again to enter the OFF setpoint into memory If you selected Normal output you may specify another setpoint pair or press the right arrow gt when you are done to go to the Advances screen If you selected Timed output the Advances screen will appear immediately after you enter the first OFF setpoint 6 Pressing NEXT will move the cursor to
2. Transducer Connector AMCI Part MS 16 Bendix MS3106A16S 1S Transducer Input Connector Included with Genesis Controller BELDEN 9873 Cable AMCI Part MS 8P For cable lengths greater than Phoenix MSTB1 5 8 ST 3 81 100 30 meters use BELDEN 9730 18 03 633 Figure 8 8 CTL x Wiring Diagram Article 800 of the National Electrical Code specifies that the transducer cable cannot be installed with the fol lowing wiring gt All conductors of electric light or power circuits gt Category 1 circuits Non power limited fire protective signaling circuits Article 800 also states that transducer cable can be installed with Category 2 or Category 3 circuit conductors and other communication cables All of these conductors are for low power low voltage devices such as optical and prox sensors There are listed exceptions to the ban on installing higher power conductors with the transducer cable but AMCI strongly recommends against following these exceptions The NEC is meant to protect individuals from hazardous situations not insure a noise free environment When installing the transducer cable follow the general guidelines given in chapter 7 in the System Layout Considerations section starting on page 29 AMCI Transducer Outline Drawings AMCI offers a broad line of resolver based transducers for use with the PRESSPro Genesis Outline draw ings for all of these transducers and full spec sheets for our most popular
3. m AA 488 ADVANCED Gli micro CONTROLS Inc Manual 940 0P012 Programmable Limit Switch GN3B1 01A 00 amp Indizione pre GENERAL INFORMATION Important User Information The products and application data described in this manual are useful in a wide variety of different applica tions Therefore the user and others responsible for applying these products described herein are responsible for determining the acceptability for each application While efforts have been made to provide accurate information within this manual AMCI assumes no responsibility for the application or the completeness of the information contained herein UNDER NO CIRCUMSTANCES WILL ADVANCED MICRO CONTROLS INC BE RESPONSIBLE OR LIABLE FOR ANY DAMAGES OR LOSSES INCLUDING INDIRECT OR CONSEQUENTIAL DAM AGES OR LOSSES ARISING FROM THE USE OF ANY INFORMATION CONTAINED WITHIN THIS MANUAL OR THE USE OF ANY PRODUCTS OR SERVICES REFERENCED HEREIN No patent liability is assumed by AMCI with respect to use of information circuits equipment or software described in this manual The information contained within this manual is subject to change without notice This manual is copyright 2008 by Advanced Micro Controls Inc You may reproduce this manual in whole or in part for your personnal use provided that this copyright notice is included You may distribute copies of this complete manual in electronic format provided that they are unaltered from t
4. 8 32 x 040 Stud 4 Places ee Door Scrap Paint Around Hole Wi or Panel 4 Places 8 Star Washer 3 Places 8 32 Nut 3 Places 8 Star Washer 2 Places an Nut Bonding Wire To Ground Bus Stranded 8 AWG Bonding Wire Recommended Figure 8 4 Mounting the PRESSPro Genesis Connecting Power An external 18 to 30Vdc supply typically 24Vdc is required to power the PRESSPro Genesis Power con sumption is ten watts This translates into 0 4A 24Vdc The power supply used to power the unit can also be used to power the five inputs if your application requires it NOTE The grounding wire shown in the figure from the Genesis to the ground bus is required even with the bonding wire run from a mounting stud to the ground bus The mounting studs pro vide a Protective Earth Connection while the grounding wire shown below is a Functional Earth Connection 18Vdc to 30Vdc solated Power Supply rh Grounding Strap maybe required by local safety codes Strap can be attached without the concern of forming a ground loop between the supply and Genesis because the negative side of the units power input is isolated from the chassis ground connection Ground Bus o O OOOO o Figure 8 5 PRESSPro Genesis DC Power Connections 20 Gear Drive Plymouth Ind Park Terryville C
5. In many applications a second step down transformer is used One transformer powers the input circuits and power supplies while the other powers the output circuits and power sup plies This provides additional noise immunity for the system 2 A surge suppression may be needed on the input of a DC power supply DC supplies do not draw power from the AC line during its entire cycle This non linear loading may cause noise in the AC line powering the DC supply 26 ADVANCED MICRO CONTROLS INC GENERAL INSTALLATION GUIDELINES Ey Al Surge EMI Suppression continued Inductive Loads NOTE gt All inductive devices in the system such as motors motor starters contactors relays and sole noids must have surge suppression devices installed across their coils This includes all devices that share a power supply with the PRESSPro Genesis have wiring in the unit s enclosure or wiring that is run in the same conduit as wiring connected to the unit DC loads are typically suppressed with a flyback diode while AC loads are typically suppressed with a RC network or varistor RC Networks are the preferred suppressor for AC loads The figure below show where surge suppression devices should be placed in the circuit Acceptable Connection Inductive The acceptable connection supresses noise at its source The DARI _ Device wiring that connects the load to the power supply and contacts n o will not radiate noise when the load is sw
6. data or request specific functions For example the key in the top right corner of the keypad may be used to enter the number 3 or request the ADVANCE function The separate groups or types of keys are listed below Function Activation Key This key labeled FUNCTION is located in the top left corner of the keypad If you press FUNCTION to illuminate the red LED next to the key you may press any of the Function keys shaded in two colors to request the function identified at the top of each key gt Function Keys As noted above if you press the Function Activation key you may press any of these keys shaded in two colors to request the function identified at the top of each key Otherwise you may press a function key to enter the data or request the function specified at the bottom of the key A list of all the function keys is provided on the next page Arrow Keys These keys are located in the bottom left corner of the keypad Press these keys to move the cursor in the indicated direction on the operator display For example press the left or right arrow key to move the cursor to the previous or next data field respectively or the up or down key to move the cur sor up or down one line gt SELECT Press this key to select different available options in a specific data field ENTER You must press this key to enter new data words If you enter a new data word and press an arrow key to move the cursor
7. number and its value is saved when you switch tools Stroke Counter Use this tool to track the total number of strokes made by the press This counter is typically used to schedule machine maintenance lubricate and or change parts after a specific number of strokes This value is not tied to any tool program number For example if you run 500 strokes on tool program 1 and 450 strokes on tool 2 the Tool Counter will read 450 and the Stroke Counter will read 950 If you switch back to tool 1 the Tool Counter will read 500 and the Stroke Counter will still read 950 20 Gear Drive Plymouth Ind Park Terryville CT 06786 16 Tel 860 585 1254 Fax 860 584 1973 http www amci com CHAPTER 6 SPECIFICATIONS This chapter contains the specifications of the PRESSPro Genesis Included in it are mechanical electrical and environmental specifications of the unit as well as the specifications of the compatible AMCI transducers System Location NEMA 12 enclosure recommended NEMA Rating Front panel is washdown tight IP65 NEMA 4 when properly mounted The rest of the unit is IP20 NEMA 1 Required Panel Space Front panel dimensions are 5 00 square Behind the panel unit requires a clearance area of 6 00 square to a minimum depth of 4 00 for installation and removal of connectors and output relays Power Requirements 18 to 30Vdc 10 watts 24Vdc 400 mA nominal Compatible Transducers Any AMCI single resolver tra
8. 30 Vdc and it must be able to provide a minimum of ten watts of power This translates into roughly 0 4Adc 24Vdc If you are using the supply to power sensors attached to the Group and LS Enable Inputs add in these current requirements before sizing the supply A dedicated power supply can be used for the unit or power can be drawn from a larger system supply NOTE gt If a dedicated supply is used it should be mounted relatively close to the unit If a system sup ply is used this supply must not be used to switch large inductive loads such as relays or sole noids without proper surge suppression devices installed on these loads See Surge EMI Suppression on page 26 for additional information on installing surge suppression devices Some customers have contacted us to request a power supply recommendation We re hesitant to make such a recommendation because there are many reputable power supply vendors and we don t want to imply that a specific supply must be used with our products With that said AMCI has used the SOLA SDN 5 24 100 power supply in most of its testing It is a small DIN rail mountable 24Vdc 5A supply Panel Cutout for the PRESSPro Genesis The PRESSPro Genesis is designed to be mounted on a panel or the door of an enclosure Figure 8 1 shows the required panel cutout to mount the unit Maximum panel thickness is 0 150 inches Behind the panel the unit requires a clearance area of 6 00 square to a minimum d
9. 375 or 500 milliseconds After you choose the appropriate value press ENTER 52 ADVANCED MICRO CONTROLS INC INITIAL TOOL SETUP Co Entering Configuration Data continued Password Programming Screen 3 You may use the third configuration screen to enable or disable the password function and enter passwords for users at both the Master and Set Up levels NOTE gt Only a user at the Master access level can change data on this configuration screen when the password function is enabled and the software is in the Edit mode The password data on Configuration Screen 3 may be changed as follows 1 Press FUNCTION followed by CONFIG to request the first configuration screen 2 Press NEXT twice to page forward to the configuration screen illustrated below CONFI GURE 3 OF 4 DISABLE PASSWORD MASTER 1234 EDIT 2 P 357 SPM Figure 10 4 Configuration Screen 3 3 When Configuration Screen 3 first appears the blinking cursor will be positioned on the DI SABLE or ENABLE value Press SELECT to toggle between these two values to disable or enable the Genesis password function When the correct value is displayed press ENTER to move the cursor forward to the MASTER orSET UP value 4 When the blinking cursor is on either MASTER orSET UP on the third line of the screen press SELECT to toggle between these two values to view the password for either the Master or the Set Up access level When the correct value is dis
10. C 0 50z in 25 C 0 080z in 25 C 0 08 0z in 25 C 0 40z in 25 C Moment of Inertia 0z in sec 7 Weight 1 3 Ibs 0 7 Ibs 0 25 Ibs 0 25 1b 0 25 Ib Enclosure IP67 IP65 IP40 IP40 IP67 6 00X 1074 2 1X 1074 0 51X 104 0 51X1074 0 51X104 Environmental All Transducers Operating Temp Shock Vibration 20 to 125 C 50 G s for 11 milliseconds 5 to 2000 Hz 20 G s For all shaft loading specifications the bearing life is rated at 2X10 revolutions minimum at maximum shaft load Table 6 1 Single Turn Transducer Specifications Outline drawings of our transducers and full spec sheets for our most popular models are available on our website www amci com If you do not have internet access contact AMCI and we ll fax you the information 18 ADVANCED MICRO CONTROLS INC _ i AR Eizo _0 GENERAL INSTALLATION GUIDELINES This chapter gives general information on installing electronic controls in an industrial environ ment including the importance of proper wiring grounding and surge suppression If you are responsible for installing the PRESSPro Genesis make sure you are familiar with these practices and follow them when installing the unit These instructions assume a solidly grounded system which is used in a vast majority of modern industrial systems As defined by the IEEE a solidly grounded system is one in which the neutral of a generator power transformer or grounding transform
11. CL GENS mete take for resolver motion to start after brake input goes from ON to OFF Possible causes 1 Faulty wiring 2 EMF noise 3 A defective resolver EEPROM FAULT EEPROM failure DEVICE NEEDS FACTORY INITIALIZATION EPROM failure HAS RICAMO EEPROM failure Table 12 2 Machine and Hardware Error Messages TRANSDUCER FAULT Hardware 62 ADVANCED MICRO CONTROLS INC ADVANCED MICRO CONTROLS INC 20 GEAR DRIVE TERRYVILLE CT 06786 T 860 585 1254 F 860 584 1973 LEADERS IN ADVANCED CONTROL PRODUCTS
12. Genesis CABLE SHIELD 10Vdc to 30Vdc solated Power SOURCING Supply DIE Can be the MONITOR same supply that SENSOR A powers the unit Grounding Strap maybe required by local safety DSYSD DM INPUT codes 1 1 C CONNECTOR NNNNO 4321M GROUND SHIELD OF SENSOR CABLE 1 Ground only one end of shield 2 Shield is usually grounded where the signal is generated If a good quality earth ground connection is not available at the sensor the shield can be grounded at the PRESSPro Genesis DC Sink DM Sensor SENSOR POWER Run a seperate wire from the power supply to each sensor Do Not pull power from the Power Supply Connector of the PRESSPro Genesis Grounding Strap maybe required by local safety codes 10Vdc to 30Vdc solated Power Supply Can be the same supply that A powers the unit CABLE SHIELD Lo SINKING DIE MONITOR P SENSOR DM INPUT CONNECTOR GROUND SHIELD OF SENSOR CABLE 1 Ground only one end of shield 2 Shield is usually grounded where the signal is generated If a good quality earth ground connection is not available at the sensor the shield can be grounded at the PRESSPro Genesis Figure 8 11 Die Monitor Input Wiring have too many shields to connect to the pin bond them to the enclosure s Ground Bus You can accomplish this by bonding them to one of the uni
13. an existing setup refer to the following Create a Tool Setup from an Existing Setup sub section below You may also create a completely new tool setup as follows 1 When the Select Tool screen is initially displayed the word S E L E CT will blink in the top left corner of the screen Press the SELECT key until the word N E W appears 2 Press ENTER to move the blinking cursor to the current tool setup number in the top left corner of the screen 3 Press the appropriate number keys to enter a number to identify the new tool setup 4 After you enter the number for the new tool setup press ENTER again 5 If you entered a tool setup number that already exists the error message TOOL ALREADY IN USE will appear at the bottom of the screen After this message disappears and the blinking cursor returns to the current tool setup number repeat Steps 3 and 4 Create a Tool Setup from an Existing Setup A new tool setup may be created from an existing setup as follows 1 When the Select Tool screen is initially displayed the blinking cursor will be positioned on SELECT in the top left corner of the screen Press the SELECT key until SAVE AS appears 2 Press ENTER to move the blinking cursor to the current tool setup number in the top left corner of the screen 3 Press the appropriate number keys to enter a number to identify the new tool setup 4 After you enter the number for the new tool setup press ENTER again 5 If you
14. are attached to their concrete footings by long anchor bolts These concrete encased anchor bolts serve as the elec trodes and the building s metal frame serves as a conductor Concrete Encased Electrodes Similar in construction to the concrete encased anchor bolts these electrodes are installed specifi cally for grounding electrical systems in the building Other components can be used in the Grounding Electrode System such as a Ground Ring rod and pipe elec trodes or other local metal underground systems The use of a Metal Underground Gas Piping System is strictly forbidden If you are using an underground pipe as the attachment point to your Grounding Electrode System verify that it is not a gas pipe CAUTION In America the National Electrical Code prohibits grounding electrical systems to the conductors and electrodes used to ground lighting rods Supplementary Grounding Electrodes Connection to the building s Grounding Electrode System should be made through existing electrodes When existing electrodes appear to be insufficient supplementary grounding electrodes are permitted These grounding electrodes are typically iron or steel rods of at least 5 8 diameter or stainless steel or copper rods of 1 2 to 5 8 diameter The rod is driven to a depth of at least 8 feet The upper end of the electrode must be flush with or below ground level or protected against physical damage It may be difficult to get adequate pe
15. away If the machine controller ties it s DC return to earth ground and the supervisor display ties its DC return to earth ground then the communications return signal itself is tied to earth ground at two points This situation is very similar to the Large Machine Ground Shift example shown in figure 7 4 except a bonding wire will generally not exist A ground shift at either end will force ground current through the communications conductor which could damage the cable and the equipment The only way to avoid this sce nario is to use an isolated communications port on one or both pieces of equipment High Impedance Grounds No real world electrical system is completely resistive This includes grounding systems There are always some inductive and capacitive components that you should be aware of and address when designing your grounding system The resistance of inductive and capacitive components depends on the frequency of the signal injected into them Inductive components offer a higher resistance to high frequency signals then low frequency or DC signals Sometimes a grounding system will appear to be functioning correctly An ohmmeter shows a low resistance from all points on the machine to the Grounding Electrode System and the Ground Fault Interrupts trigger correctly but the machine seems to have noise related issues Long grounding wires that are looped together add inductance to the grounding system and solid conductors offer a higher res
16. cases They have a capacitance of 0 5 uF and a resistance of 220 ohms The easiest way to accurately specify a R C network for other AC loads and power supplies is by following the recommendations of the load s manufacturer Most manufacturers have tested and specify standard R C networks and many sell networks that are designed to integrate with their products Minimize Voltages in the System Enclosure You will want to minimize the voltage in the HIGH Petes io Power Ne enclosure that houses your control system to minimize EMI and voltage transients In 3 PHASE ENCLOSURE many cases three phase is used to power BONER ONDUN the machine s motors and the control system ii Sign N is powered by one of the phases Ideally EN 5 the three phase power it s disconnect fuses TT o filtering and all three phase controls such s Lege as motor starters are housed in their own enclosure The single phase used to power the control system is then brought into a CONTROL ENCLOSURE separate enclosure built exclusively for the AC INPUTS cee HIGH POWER CONDUIT Single Phase Power Sensor and Control Inputs control system AC phase voltage levels lt o o o o o o ol si Power Supply Sizing i A properly sized power supply is vital to DC INPUTS oor Sensor and Control Inputs system operation The best guideline that DC and low voltage AC we can give
17. correct value is displayed press ENTER The LO and HI values define the input active state for the channel If you select LO the channel must transition from a positive voltage to zero volts for the input to turn ON and back to a positive voltage to turn OFF If you select HI the channel must detect a positive voltage to turn ON and transition back to zero volts to turn OFF 4 Press SELECT to choose the STATIC S PART Single Part IN POS In position or the CYCLIC mode for the input channel Note that the DIE MONITOR INPUT REQUIREMENTS chapter describes each mode starting on page 13 Remember that the first input channel is normally reserved for counting parts After you select an appropriate mode for the current channel press ENTER to move the cursor to the ON setpoint value 5 Unless you selected the Static input mode enter an angular position for the ON setpoint and press ENTER to move the cursor to the OFF setpoint value 6 Enter an angular position for the OFF setpoint and press ENTER to move the cursor to the type of FAULT output 7 Press SELECT to choose between the STOP FAULT also called the brake fault or the Die Fault output and the TOP STOP output then press ENTER to complete the programming entries required for the input channel 8 Repeat Steps 2 through 7 to program each DM input channel Up to four input channels may be programmed 60 ADVANCED MICRO CONTROLS INC _ i ji SOFTWARE ERROR ME
18. features available on the unit typical applications and com patible transducers PLS OUTPUT REQUIREMENTS Anyone new to the PRESSPro Genesis This chapter describes the what Programmable Limits Switch outputs are and how they are programmed in the PRESSPro Genesis BRAKE INPUT PROCESSING Anyone new to the PRESSPro Genesis This chapter describes how the PRESSPro Genesis uses its brake input to monitor the press brake DIE MONITOR INPUT REQUIREMENTS Anyone new to the PRESSPro Genesis This chapter describes how the Die Monitor Inputs can be used to verify correct operation during a press stroke COUNTERS Anyone interested in the various counters available on the PRESSPro Genesis SPECIFICATIONS Anyone that needs detailed information on the unit itself This chapter describes all of the unit s parameters their defaults and ranges GENERAL INSTALLATION GUIDELINES Anyone new to installing electronic controls in an industrial environment The chapter includes general information on wiring grounding and surge suppression that is applicable to any controls installation INSTALLING THE PRESSPro GENESIS Anyone that must install an PRESSPro Genesis on a machine Includes information on mounting grounding wiring and surge suppression spe cific to the unit SOFTWARE INTRODUCTION Anyone looking for information on navigating through the displays using passwords to secure programs and
19. four available DM input modes perform the specific functions listed below 1 Cyclic Verifies that a part moved past a monitor 2 Single Part SPART Determines if a part is ejected or inserted at the correct moment during the press stroke 3 In Position IN POS Verifies that the ejector and other automation parts were retracted to the home position 4 Static Determines if an event has taken place independent of the press stroke e g this input mode may be used to detect the end of stock Defining a Crankshaft Rotation Zone Input signals for the Cyclic Single Part and In Position modes are synchronized with the rotation of a crank shaft and must be detected within a crankshaft rotation zone This zone is called a window To verify that a part is inside a die before it is hit by a stroke you may program a DM input channel to expect a part detect signal within a specific window e g from 70 to 120 In the diagrams provided in the following sections each window is shown between an ON and OFF setpoint with an input signal illustrated as follows ON pe i ON OFF 7 _ gt ai a si Crankshaft rotation Figure 4 1a Rotation Zone Window Figure 4 1b Input Signal Transition 20 Gear Drive Plymouth Ind Park Terryville CT 06786 13 Tel 860 585 1254 Fax 860 584 1973 http www amci com Real DIE MONITOR INPUTS Cyclic Mode This is one of the most basic input modes that you may select
20. of the AC power that will feed the machine Check for adequate surge suppression on machines that will be near your new system A review of the electrical environment includes checking the quality of the AC power that will feed your new system as well as checking the quality of the point where your system will be connected to the building s Grounding Electrode System When checking the quality of the AC power for your system be sure to check every machine that may be powered by the same feeder circuit It has been in AMCT s experience that nuisance faults can be caused by another system on the same feeder circuit that does not have adequate surge suppression devices System Layout Considerations The first step to achieving a clean system layout is classifying the wires and cables used in your system based on the amount of power carried by the conductors Refer to the following table to help you categorize your wires and cables Category Description Examples Control and AC Power High power conductors AC power lines that are more tolerant of electrical noise but are High power digital AC I O lines also more likely to carry electrical noise than High power digital DC I O lines the other categories High power I O lines typically connect to Corresponds to IEEE levels 3 amp 4 devices such as mechanical switches relays and solenoids Signal and Communication Low power conduc Analog I O lines tors that are less tolerant of electri
21. press machinery displayed in Strokes per Minute gt BRAKE Displays the total time in milliseconds required for the resolver to stop during the last braking cycle T 1 STROKE 55442 P 354 BATCH 3756 SPM 0 BRAKE 0 mS Figure 9 3 Main Display Screen 20 Gear Drive Plymouth Ind Park Terryville CT 06786 47 Tel 860 585 1254 Fax 860 584 1973 http www amci com PROGRAMMING OVERVIEW NOTES 48 ADVANCED MICRO CONTROLS INC CHAPTER 10 INITIAL TOOL SETUP This chapter describes how to select a tool setup and enter configuration data including trans ducer setup parameters counter and motion parameters password data and operator access data Selecting a Tool Setup If the Select Tool screen illustrated below is not displayed on the Genesis controller press the FUNCTION key on the operator keypad followed by the TOOL key You may make changes on this screen if the Edit mode is active as indicated by the word E DI T in the bottom left corner of the screen If VI E W is displayed at the bottom of the screen press the FUNCTION key followed by EDIT and the appropriate password You can then perform any of the operations described in the following sections NOTE gt The Genesis controller is shipped with a default tool setup 1 You may change this setup or use it as a tutorial to familiarize yourself with the operation of the software SELECT TOOL 2 1 2 3 4 3 6 7 8 EDIT 2 P 357 SPM 0 Figure 1
22. the channel number for the next channel This allows you to skip the Advances and Timed Output screens if you do not need these screens NOTE gt Placing the cursor on either the ON setpoint or the OFF setpoint and pressing the INC or DEC key will increase or decrease the selected setpoint by one Placing the cursor on the dash between the ON OFF setpoints and pressing the INC or DEC key will increase or decrease both setpoints by one 20 Gear Drive Plymouth Ind Park Terryville CT 06786 55 Tel 860 585 1254 Fax 860 584 1973 http www amci com N i CONTROLLER PROGRAMMING PLS Output Programming continued Advance Data You may use the Advances screen to enter advance data to compensate for fixed delays in your stamping press system as follows NOTE gt If the crankshaft is moving you cannot change any of the data on the Advances screen 1 If the Advances screen is not displayed press FUNCTION followed by ADVANCE to request this screen CH ADVANCES 1 ON Oms OFF 0 ms 2 ON Oms OFF 0 ms EDIT 2 P 357 SPM 0 Figure 11 2 Limit Switch Advances Screen 2 When the Advances screen first appears the blinking cursor will be positioned on the number 1 for the first channel or the number of the channel that you were editing viewing on the Limit Switch screen If you want to change the advance data for another channel either press the up or down arrow keys A or v or enter the number of th
23. the operator display 3 Press ENTER to enter the brake fault parameter NOTE amp A Brake Warni ng message will appear on the main screen when the stopping time is within 90 of the programmed stopping time 58 ADVANCED MICRO CONTROLS INC CONTROLLER PROGRAMMING F4 amp A Counter Programming Counter Data The two screens described in this section allow you to enter desired batch and job part counts and view actual part counts and machine maintenance data as follows 1 If the Parts Counter screen is not displayed press FUNCTION followed by COUNTERS to request this screen Note that you may enter desired part counts for each batch and the total job and view the actual batch and job part counts BATCH 0 TOTAL 0 EDIT 2 P2357 SPM Figure 11 5 Parts Counter Screen 2 When this screen first appears the blinking cursor will be positioned on the desired part count specified for each batch Key in the appropriate value and press ENTER to move the cursor to the number field for the desired total job count 3 Key in the appropriate value for the desired total job count in the TOTAL field and press ENTER 4 Press NEXT to go to the Machine Maintenance screen illustrated below You may only view or clear the data displayed on this screen The T OOL field represents the total number of stamps made by the press to monitor tool wear and the STROKE field specifies the total number of strokes completed by
24. the press Typically you may want to change the stamping die or tool after a certain number of stamps and perform machine maintenance lubricate and or change parts after a specific number of strokes To clear either of these counters when the screen is displayed use the up or down arrow keys A or v to select the counter value and press the CLEAR key TOOL STROKE EDIT 2 P 357 SPM Figure 11 6 Machine Maintenance Screen 20 Gear Drive Plymouth Ind Park Terryville CT 06786 59 Tel 860 585 1254 Fax 860 584 1973 http www amci com K di CONTROLLER PROGRAMMING Die Monitor Input Programming You may use the Die Monitor screen to enter data for each DM input channel including a DM input mode the active state of the input any required ON OFF setpoints and an appropriate fault output as follows 1 If the Die Monitor screen is not displayed press FUNCTION followed by DIE PROT to request this screen I NPUTILO MODE STATIC ON 0 0 OFF 0 0 ON FAULT DI SABLED EDIT 2 P 357 SPM 0 Figure 11 7 Die Monitor Screen 2 When this screen first appears the blinking cursor will be positioned on the number of the current INPUT channel on the top line Key in a value to select one of the input channels from 1 to 4 and press ENTER to begin entering parameters for the channel 3 The blinking cursor will move to the LO or HI value next to the channel number Press SELECT to toggle between LO and HI When the
25. to verify that parts are moving correctly through an automated stamping process You may use this mode to determine if an OFF ON OFF pulse from the input sensor occurs within the rotation window once during each press stroke For example this mode will detect if a part moved past a monitor The condi tions that apply to this input mode are listed below For this Expected A problem is detected when Condition the Input Signal Input signal turns 1 Stays ON beyond the window Input Active ON Setpoint OFF Setpoint Figure 4 2 Valid Cyclic Transition If a problem is detected the fault output is set after The end of the window ON then OFF within 2 Turns ON outside the window The input signal turns ON teow 3 Remains OFF for the entire cycle Single Part SPART Mode This input mode will detect if a part is ejected or inserted at the correct moment during each press stroke in an automated stamp ing process Use this mode to verify that the input signal was ON within the rotation window and OFF at any point before re entering the window That is the signal can turn ON within the window Case A or before it enters the window Case B but it must always turn OFF before the on setpoint occurs again during the next cycle The conditions that apply to this input mode are listed below For this Expected Aproblem is detected when Condition the Input Signal Input signal turns ON 1 Remains ON into next wind
26. to a different field the new word will not be recorded Figure 9 2 Genesis Operator Keypad 20 Gear Drive Plymouth Ind Park Terryville CT 06786 45 Tel 860 585 1254 Fax 860 584 1973 http www amci com PROGRAMMING OVERVIEW Using the Operator Display Keypad continued Using the Operator Keypad continued The specific function or data screen requested by each function key on the operator keypad is listed in the fol lowing table All of these keys are shaded in two colors with the function performed by each key identified by the word or code at the top Key Code Function Data Screen EDIT Activates the Edit operation mode TOOL Select Tool screen LIM SW Limit Switch screen ADVANCE Advances screen PREVIOUS Goes to the previous line or screen VIEW Activates the View operation mode BRAKE Brake Monitor screen TIMED Timed Output screen COUNTERS Parts Counter amp Machine Maintenance screens F7 Main Display screen CONFIG Configuration Screen 1 DIE PROT Die Monitor screen CLEAR Clears a fault condition and resets counters 7 1 Depending upon the screen that is currently displayed 2 Counters cannot be cleared on the Main Display screen The counters can only be cleared from the Parts Counter and Machine Maintenance screens Table 9 3 Genesis Function Keys Basic Operation Modes The Genesis software has two basic operation modes You may use the View mode to view information dis played o
27. total of the batch Like the Total Counter the Batch Counter has a maximum value of 9 999 999 parts If the trip value called DE SI RED on the display is left at zero the trip value is ignored and the press will only count parts If you do use the trip value you must press the CLEAR key to clear the BAT CH COMPLETED message on the display This clears only the Batch Counter Total Counter The Total Counter is used to track the total number of pieces made during the job It has a programmable maximum trip value of 9 999 999 parts If the trip value called DE S RED on the display is left at zero the trip value is ignored and the press will only count parts If you do use the trip value you must press the CLEAR key to clear the TOTAL COMPLETED message on the display This clears both the Total and Batch counters Machine Maintenance Counters These two counters help you monitor the number of strokes made by the press and are intended to help you monitor die wear and schedule regular maintenance on the machine Both of these counters increment by one when the position passes through zero Once triggered the shaft must rotate 90 before the counter will increment again This prevents mechanical motion or electrical noise from falsely triggering the counters Tool Counter Use this tool to track the number of strokes made by the machine with the present tool installed This counter is tied to the tool program
28. user at the Operator level from editing this information The default value is to disable edits Table 9 2 Access Level Privileges Using the Operator Display Keypad All the Genesis data screens appear on the operator display on the front of the controller unit You may use the keypad located under the display to enter all the data words required to program custom tool setups for your press control application Display Layout The operator display provides four lines with 20 characters on each line The type of information that gener ally appears on each line is described below gt Line 1 Identifies the title of the screen CONFIGURE 1 OF 4 gt Lines 2 and 3 Contain the data words or parameters entered to SF 1000 PRESET 0 program each tool setup DIR CW BI DIRECTION VIEW 1 P 90 SPM 0 gt Line 4 Specifies the current operation mode i e EDIT or VIEW the number of the current tool setup the resolver position Figure 9 1 Sample Display P i e the angular position of the crankshaft and a Strokes per Minute or SPM value indicating the speed of the stamping press If the software detects an error the appropriate error message will be displayed on this line 44 ADVANCED MICRO CONTROLS INC PROGRAMMING OVERVIEW 19 Using the Operator Display Keypad continued Using the Operator Keypad The Genesis operator keypad is illustrated below Most of the keys shaded in two colors may be used to enter
29. you is to buy the best supply J OUTPUT CONDUIT a J your budget allows Three Phase Control Output DC OUTPUTS CONDUIT J I Nes OUTPUTS CONDUIT When sizing system supplies take into con DC and low voltage AC Outputs Single Phase AC Outputs sideration the surge requirements of the Figure 7 9 System Enclosures components you are attaching to the supply Most devices draw a surge current for a brief time when they power up If your supply cannot accommo date these surge currents the output voltage may momentarily drop when a device turns on causing the PRESSPro Genesis and other electronic devices to reset The other thing to consider when choosing a supply is output filtering The better the supply s filtering the better it can absorb noise that may be induced into the power supply wiring 30 ADVANCED MICRO CONTROLS INC GENERAL INSTALLATION GUIDELINES Ey All System Layout Considerations continued Component Placement Once you have established the proper categories of all of the system s wires and cables and determined all of you components including surge suppressors you can determine proper component placement and conductor routing within the system enclosure CAUTION The following guidelines are for noise immunity only Follow all local codes for safety requirements There are three general guidelines to follow when placing components gt Keep as much physical space between the classe
30. 0 to open it Bookmarks of all the chapter names section headings and sub headings were created in the PDF file to help navigate it The bookmarks should have appeared when you opened the file If they didn t press the F5 key on Windows platforms to bring them up Throughout this manual you will also find green text that functions as a hyperlink in HTML documents Clicking on the text will immediately jump you to the referenced section of the manual If you are reading a printed manual most links include page numbers The PDF file is password protected to prevent changes to the document You are allowed to select and copy sections for use in other documents and if you own Adobe Acrobat version 4 05 or later you are allowed to add notes and annotations Manual Conventions Three icons are used to highlight important information in the manual NOTE gt NOTES highlight important concepts decisions you must make or the implications of those decisions CAUTION CAUTIONS tell you when equipment may be damaged if the procedure is not followed properly WARNINGS tell you when people may be hurt or equipment may be damaged if the pro cedure is not followed properly The following table shows the text formatting conventions Description Normal Font Font used throughout this manual Emphasis Font Font used the first time a new term is introduced DI SPLAY Highlights text shown on the PRESSPro Genesis display KEY Hi
31. 0 1 Sample Select Tool Screen Select an Existing Tool Setup You may select an existing tool setup as follows 1 Make sure that SELECT is displayed in the top left corner of the Select Tool screen If this word is not displayed press the SELECT key until this word appears 2 Press the ENTER key to move the blinking cursor to the current tool setup number in the top right corner of the screen e g the number 2 above 3 Press the appropriate number keys to select an existing tool setup Note that if the number of programmed setups exceeds the number of setups that can be displayed on the middle two lines of the screen MORE will appear on the screen as shown above Press the down arrow key w or the NEXT key to display the next sequence of tool setups 4 After you enter the number of the tool setup that you want to select press ENTER 5 If you entered a tool setup number that does not exist the errormessage TOOL NCORRECT will appear at the bottom of the screen After this message disappears and the blinking cursor returns to the current tool setup number repeat Steps 3 and 4 20 Gear Drive Plymouth Ind Park Terryville CT 06786 49 Tel 860 585 1254 Fax 860 584 1973 http www amci com 10 INITIAL TOOL SETUP Selecting a Tool Setup continued Create a New Tool Setup There are two different methods that may be used to create a new tool setup If you want to create a new setup that is very similar to
32. 24 from any category 1 conductor of any amperage of the circuit is greater than 100 kVA gt Route at least 5 ft away from high voltage enclosures or sources of rf microwave radiation Route these conductors external to all raceways in the enclosure or in a raceway separate from all category 1 conductors Use the same spacing rules given for category 2 conductors Table 7 3 Conductor Routing Guidelines 32 ADVANCED MICRO CONTROLS INC GENERAL INSTALLATION GUIDELINES Ey All System Layout Considerations continued Conduits to Enclosure continued In hopes of helping you avoid common installation problems a problem installation is given below As before this example is based on a real world installation CONTROL ENCLOSURE CONTROL ENCLOSURE mie o EET o DC INPUTS CONDUIT Sensor and Control Inputs DC and low voltage AC Pa AC INPUTS CONDUIT a Sensor and Control Inputs AC phase voltage levels le LEFT CONDUIT O RIGHT SA 000000 oocood INN i AT AC DC Control Inputs AC DC Control Inputs AC DC Control Output AC DC Control Output Ay DC OUTPUTS CONDUIT AC OUTPUTS CONDUIT DC and low voltage AC Outputs Single Phase AC Outputs PROBLEM SOLUTION Figure 7 11 Conduit Layout Problem Problem In or
33. 5 1254 Fax 860 584 1973 http www amci com rs e INTRODUCTION Unit Description Figure 1 2 shows the layout of the panels on the PRESSPro Genesis controller Note that the unit ships with mating connectors for the Power Input and the Transducer Input connectors These connectors are not shown for clarity The PRESSPro Genesis is designed to be mounted on a panel or enclosure door using its four 8 32 studs A neoprene mounting gasket is included with the unit The recommended panel cutout and mounting method is given in chapter 8 INSTALLING THE PRESSPro GENESIS starting on page 35 LEFT TOP RIGHT BOTTOM ELI HA tit i SH Ue gag gang pol Mi Epp PME pan PONE pa A A HHEH A HHHH HHEOHHHE L e HHHEHHEHHEH PRODUCT GENESIS SERIAL NO 606424 x J STOP TIME MONITOR BRAKE INPUT ked GENE b tol SERIAL PORT EET Prag EPS i 5 POWER INPUT AND CHASSIS GROUND OUTPUT RELAYS 8 Places m a oe oe P PRESS ro TRANSDUCER INPUT MOUNTING STUDS GENESIS CONNECTOR 8 32 X 0 5 4 Places Accepts 1 Single Resolver Transducer ee Lo SmROKE gt Uses an AMCI CTL x Transducer Cable SERIAL PORT SPM S Not Implemented B 0 BRAKE Om TRANSDUCER FAULT FAUL
34. 8 09 Throughout this manual the bi level keys have two names one for a STI n pe when the Function LED is on and one when it is off For example PRGSEL and 1 refer to the same key Figure 1 4 Genesis Keypad 8 ADVANCED MICRO CONTROLS INC INTRODUCTION ay a Unit Description continued Operator Interface Display and Keyboard continued NOTE These instructions do not constantly remind you to make sure the Function LED is on or off before pressing a key If the instructions give the name of the key that is on the blue level the Function LED must be on before pressing the key The four arrow keys are used to navigate around the screens The right and left arrows switch between param eters on the display while the up and down keys switch between limit switches when programming parame ters for these outputs Some parameters such a Limit Switch Type have a limited number of values The SELECT key is used to cycle through the values of these parameters The ENTER key works the way you d expect Changes to programming are not stored in memory until the ENTER key is pressed If you change a parameter value and then switch to another parameter without press ing the ENTER key the new value will not be stored and the parameter will revert back to its original value Power Input The PRESSPro Genesis requires 24Vdc to operate The Power Input Connector is on the bottom of the unit It has two contacts for
35. C to DC converters between the power supply and the controllers This approach is shown in the figure below 18Vdc to 30Vdc Isolated Power Supply Circuitry Circuitry Isolated Isolated rh rh Controller 1 rh Controller 2 Converter Converter O GROUND BUS Figure 7 3 Use of DC DC Converters to Avoid Ground Loops AMCI does not connect the DC Return of a Genesis controller to its chassis This avoids ground loop prob lems and gives you the flexibility to decide where the DC Return path is attached to your Ground Bus In many cases this is done at the power supply but check your local codes Ground Shifts Ground Shifts can occur on large machines with two different grounding points such as two driven rods A voltage potential can exist between these points due to resistance between the rods and earth if they are not properly bonded together A similar problem can exist on smaller machines that have a poor electrical con nection in the grounding system The resistance of this connection allows there to be a voltage potential between the two parts of the machine Incorrectly installed sensor or communications cables that run between these systems can be damaged by these Ground Shift potentials The problem occurs when the shield of the sensor or communication cable is connected to ground at both end
36. INC INSTALLATION n I O Wiring continued Die Monitor Input Wiring continued Figure 8 11 shows how to connect a three wire source or sink sensor to a Die Moni tor Input You can use the power supply for the PRESSPro Genesis to power the sensors If you do DO NOT connect the negative side of the supply to earth ground chassis at the sensor Use a continuity tester to verify that the side of the sensor s power is not connected to the body of the sensor before installing DO NOT attach the power supply leads of the sensor to the Power Con nector of the PRESSPro Genesis Connect the sensors directly to your power supply If you make the con nection at the PRESSPro Genesis any noise that may be injected into the sensor cable can be coupled into the unit The shield of a cable is usually grounded where the signal carried by the cable is generated Therefore the shield is usually grounded at the sensor However if you do not have a quality bonding point at the sensor ground the shield at the PRESSPro Genesis If you are using one or two Die Monitor Inputs and you are not using the Stop Time Monitor Input then ground the shields at the Shield Ground pin of the Stop Time Monitor Input Connector See figure 8 9 on the previous page If you DC Sourcing DM Sensor SENSOR POWER Run a seperate wire from the power supply to each sensor Do Not pull power from the Power Supply Connector of the PRESSPro
37. SSAGES This chapter describes each error message that may be output by the PRESSPro Genesis soft ware Error messages appear on the bottom line of the operator display Error Messages Error messages are listed in the following tables along with the type of message i e if the message occurred due to a programming error a machine problem or a hardware problem and the exact conditions that caused the message The following table lists all programming error messages The table on the following page lists all machine and hardware error messages Programming Error Messages ERROR MESSAGE SCALE FACTOR ERROR Programming Value gt 1000 or lt 2 PRESET VALUE ERROR Programming Value gt Scale Factor MULTIPLIER ERROR Programming Value gt 4 or lt 1 LIMIT SWITCH ON ERR Programming Value gt Scale Factor 1 LIMIT SWITCH OFF ERR Programming Value gt Scale Factor 1 CHANNEL ERROR Programming Value gt 6 or lt 1 TOOL INCORRECT Programming Selected tool setup not programmed TOOL ALREADY IN USE Programming Entered an existing tool number during the NEW or SAVE AS function INCORRECT ACCESS Programming Attempted to edit data in the View mode or entered an incorrect password EDITS NOT AVAILABLE Programming Attempted to edit data while the resolver position was changing INPUT POSIT ON ERR Programming Attempted to ente
38. T 06786 37 Tel 860 585 1254 Fax 860 584 1973 http www amci com E INSTALLATION Transducer Input Connector The Transducer Input Connector labeled RESOLVER has eight contacts The mating connector is supplied with the PRESSPro Genesis The AMCI part number for the mating connector is MS 8P while the Phoenix Contact part number is MC1 5 8 ST 3 81 order number 1803633 Figure 8 6 shows the connector pinout to AMCTI s cable colors and industry standard resolver designations RESOLVER 12345678 PIN 1 A Hi Cable Colors Designations B RED R1 RED R2 R1 R2 Reference Winding SHIELDS Shields gt S1 S3 COS Winding WHT amp B GRN S1 amp S2 gt S2 S4 SIN Winding GRN S4 B WHT S3 Not Used Not Used Not Used Not Used Figure 8 6 Transducer Input Connector Pinout B color denotes the black wire of the black color pair Transducer Connector Pinouts Figure 8 7 shows the connector pinouts for all AMCI single transducers that have connectors except for the following H25 transducers that are designed as replacements for Allen Bradley Bulletin 846 Resolvers The part number of these transducers ends in R3A or Figure 8 7 Transducer Connector Pinout R3N HT 400 transducers with an AVG Autotech style connector Note that some AMCI transducers have integral cables or conduit connections For a complete listing of
39. T STOP TOP STOP amp PLS OUTPUT 1 PLS OUTPUTS 2 6 G 6 6 E N DIE MONITOR INPUTS FLUORESCENT DISPLAY 4 Line X 20 Characters KEYPAD Bi Level Keys for Screen Selection and Data Entry FUNCTION LED Figure 1 2 Genesis Layout Operator Interface Display and Keyboard The operator display provides four lines of text that are twenty charac ters long Figure 1 3 shows a typical PRESSPro Genesis display SF ee l i o i E E i i 0 Line 1 Identifies the screen being displayed DIR CW BI DI RECTION VIEW 1 P 90 SPM 0 Lines 2 and 3 Shows parameters and their values Line 4 Displays the unit s status Figure 1 3 Sample Display Usually line 4 displays the current mode View or Edit the number of the current program and the machine s current position and speed This information is replaced with an error message if a problem occurs The keypad is made up of twenty keys that perform various functions Thirteen of the keys are bi level with blue on the top and white on the e fcon CA PRGSEL LiM sw ADVANCE me DL bottom When the red Function LED next to the FUNCTION Key is on 20030 pressing one of these keys selects the function listed on the blue level TIMED STATUS while pressing one of these keys when the Function LED is off selects JLS U6 J the function or enters the data listed on the white level The CONFIG GROUPS FUNCTION Key simple toggles the state of the Function LED
40. T _ Sensor and Control Inputs 4 Sensor and Control Inputs DC and low voltage AC J DC and low voltage AC Hossood OUTPUT CONDUIT OUTPUT CONDUIT Three Phase Control Output Three Phase Control Output ni L AC OUTPUTS conu 4 DC OUTPUTS CONDUIT AC OUTPUTS CONDUIT DC OUTPUTS CONDUIT Single Phase AC Outputs DC and low voltage AC Outputs Single Phase AC Outputs DC and low voltage AC Outputs PROBLEM SOLUTION Figure 7 10 System Layout Problem Problem The disconnect for the three phase system voltage is in the upper right corner of the control panel The single phase isolation transformer is to its left and two 3 phase contactors are located on the bottom of the enclosure Three phase power runs from the disconnect to the transformer continues along the top of the enclosure down the left side and then along the bottom of the enclosure to the contactors This route puts the 3 phase volt in close proximity to about 85 of the control signals including low voltage DC inputs The customer was experiencing noise related nuisance faults Solution The panel layout was changed to put the contactors on the right side of the enclosure under the main disconnect Three phase power was rewired and kept to the right side of the enclosure only 20 Gear Drive Plymouth Ind Park Terryville CT 06786 31 Tel 860 585 1254 Fax 860 584 1973 http www amci com NA GENERAL INSTALLATION GUIDELINES System Layout Considerations continued Condui
41. all AMCI transducers visit our website at http www amci com Transducer Cable Installation Pre assembled and tested cables are available from AMCI The part number for the cable is CTL x where x is the length in feet Figure 8 8 on the following page is the wiring diagram of the CTL x cable NOTE gt 1 The National Electrical Code cable type used for the transducer cable is CM Communica tions General Purpose cable Therefore the installation of the cable falls under Article 800 of the National Electrical Code unless your local code or company policy is more restric tive 2 The shields of the transducer cable must be grounded at the PRESSPro only The Shields pin on the Transducer Input Connector is brought to the chassis pin on the power supply connector 3 When installing the cable treat the shield as a signal carrying conductor If you must splice the cable it must be done in a junction box Follow these guidelines Connect only category 2 conductors in the junction box Do not strip the shield back any further than needed to make the splice Do not connect the shield to ground at any junction box or the transducer This will eliminate ground loops that could damage the PRESSPro Genesis and prevent ground shifts from damaging the cable or controller 38 ADVANCED MICRO CONTROLS INC INSTALLATION a Transducer Cable Installation continued CTL x Wiring Diagram CTL x CABLE Shields
42. cal noise but Low power digital AC I O lines are also less likely to carry electrical noise than Low power digital DC I O lines category 1 Communications Cables Corresponds to IEE levels 1 amp 2 Low power I O lines typically connect to devices such as proximity switches photo sensors and encoders Intra enclosure Similar characteristics to category Low voltage DC power cables 2 conductors these conductors interconnect Communications Cables system components within an enclosure Table 7 2 Conductor Categories Wiring Categories for PRESSPro Genesis DC Power Input Class 3 low voltage DC power cable Transducer cable Class 2 Analog I O line Die Monitor Input Wiring Class 2 Low Power DC I O line Stop Time Monitor Input Wiring Class 2 Low current AC DC I O line Relay Outputs Class 1 High Power digital AC DC I O line 20 Gear Drive Plymouth Ind Park Terryville CT 06786 29 Tel 860 585 1254 Fax 860 584 1973 http www amci com NA GENERAL INSTALLATION GUIDELINES System Layout Considerations continued Determine Proper Surge Suppression Devices After you have determined the category of each wire and cable you should next determine the proper surge suppression devices for all inductive loads DC loads require a flyback diode AC loads require R C net works or varistors AMCI supplies R C network surge suppressors that can be used with AC loads attached to Genesis controller in most
43. central grounding point for the enclosure and its equipment 20 ADVANCED MICRO CONTROLS INC GENERAL INSTALLATION GUIDELINES Ey fal Grounding continued Grounding Electrode Conductor Connection of the ground bus to the Grounding Electrode System is SOUND BUS made with the Grounding Electrode Conductor The Grounding sp Cate Groufiding Paini for GROUNDING nciosure an of Its ulpment Electrode Conductor should be the shortest length of stranded wire ani a ERI OR or braid possible The American NEC allows a length of up to six Se ee i feet but shorter is better A shorter length will help shunt high fre quency noise to the Grounding Electrode System RENES Just as a radio antenna is most sensitive to wavelengths that are mul tiples of its length a grounding wire has a higher impedance to noise frequencies whose wavelengths are multiples of its length Making the wire from the ground bus to the Grounding Electrode System as short as possible will raise the frequencies that it shows an increased 7 an OUND NG De Grounding Wire impedance to In extremely noisy environments it is sometimes Lei i he SYSTEM ro Genesis advisable to run two wires from the ground bus to the GES The Mounted to Enclosure Door length of these two wires should differ by 20 to 30 so they offer different impedances to the noise frequencies being shunted to earth ground Figure 7 1 Grounding Comp
44. crankshaft rotation programmed for a specific PLS output is shown below 0 Near top Zone Preset angle to E turn output ON 270 90 Up Stroke Zone Down Stroke Zone Preset angle or time to turn 180 output OFF Bottom Direction of Rotation Figure 1 5 Entering Angle and Time Presets for a PLS Output How Die Monitor Channels Operate You may also enter parameters for DM input channels to request the Genesis software to monitor the opera tion of your stamping press system based on crankshaft positions The DM input channels can detect the mis alignment absence or unwanted presence of parts moving through an automated stamping system If a deviant condition is detected the software will output a fault signal and an appropriate error message to the Genesis operator display You may select one of the following modes for a DM input channel gt Cyclic gt Single part SPART gt In position IN POS or gt Static For a detailed description of each DM input mode see Chapter 4 DIE MONITOR INPUT REQUIRE MENTS starting on page 13 10 ADVANCED MICRO CONTROLS INC AMEN CHAPTER 2 E Ie PLS OUTPUT REQUIREMENTS This chapter describes how you can enter setpoints advance data and timing parameters to pro gram each PLS output required to control your stamping press system It explains how PLS out puts operate and how you can set up each output channel Genesis PLS Outputs The Genesis PLS control fu
45. der to minimize the number of conduits connected to the control enclosure all wire running to one space on the machine was pulled through one conduit This included running AC outputs in the same conduit as low power DC inputs When the machine was built additional wire was pulled for each signal to make sure it could be easily terminated in the enclosure Instead of cutting wires to their proper lengths the additional wire lengths were left to accumulate in the bottom of the enclosure Not only did this installation potentially violate the NEC having inputs and outputs in close proximity allowed noise to be coupled into the inputs causing nuisance faults Solution Additional conduits were added to isolate the input and output cabling Wiring in the panel was shortened to appropriate lengths and the panel was re terminated The installer prioritized wiring layout in the enclosure and separated input and output wiring with as much physical space as possible When wiring had to cross it did so at right angles to minimize EMI coupling between the conductors 20 Gear Drive Plymouth Ind Park Terryville CT 06786 33 Tel 860 585 1254 Fax 860 584 1973 http www amci com NA GENERAL INSTALLATION GUIDELINES NOTES 34 ADVANCED MICRO CONTROLS INC CHAPTER 8 INSTALLING THE PRESSPro GENESIS Required Power Supply The PRESSPro Genesis draws its power from an external DC supply The output voltage of the supply must be between 18 and
46. detect time interval You may enter both parameters on the second configuration screen as follows 1 Press FUNCTION followed by CONFIG to request the first configuration screen 2 Press NEXT to page forward to the second configuration screen shown below CONFIGURE 2 OF 4 COUNTER MULTIPLIER 1 MOTI ON DETECT 500mS EDIT 2 P 357 SPM 0 Figure 10 3 Configuration Screen 2 3 When Configuration Screen 2 first appears the blinking cursor will be positioned on the Counter Multiplier value This parameter allows you to multiply the actual counter values reported on the Parts Counter screen and the Main Display screen if more than one part is stamped during each press stroke You may enter a Counter Multiplier of 1 2 3 or 4 the default value is 1 For example if you enter a value of 2 the actual part counters will be incremented by 2 after each transition of input 1 Key in the appropriate value and press ENTER to move the blinking cursor to the Motion Detect value 4 If you are supplying a brake input to the Genesis controller the Motion Detect parameter specifies the time it should take for the resolver to detect crankshaft motion after the brake is released input status goes from ON to OFF to resume normal operations If this time is exceeded a brake fault will be output and the error message MOTI ON TI ME EXCEEDED will appear on the operator display You may press the SELECT key to select a motion detect value of 125 250
47. e other channel and press ENTER 3 When the cursor is positioned on the correct channel number press the right arrow key gt to move the cursor to the ON field The maximum compensation value that may be entered on the Advances screen is 999 milliseconds ms Enter the correct value for your stamping press system and press ENTER to move the cursor to the OF F field 4 Enter the correct compensation value up to 999ms for your stamping press system and press ENTER to continue If you selected Normal N output for the current channel the Limit Switch screen will appear If you selected Timed T output for the current channel as indicated by a right arrow at the end of the Advances display line the Timed Output screen will appear NOTE Placing the cursor on either the ON setpoint or the OFF setpoint and pressing the INC or DEC key will increase or decrease the selected setpoint by one Placing the cursor on the dash between the ON or OFF setpoints and pressing the INC or DEC key will increase or decrease both setpoints by one ADVANCED MICRO CONTROLS INC CONTROLLER PROGRAMMING F4 amp A PLS Output Programming continued Timed Output Parameters You may use the Timed Output screen to enter duration parameters for each timed output channel as follows NOTE gt If the crankshaft is moving you cannot change any of the data displayed on the Timed Output screen 1 If the Timed Output screen is
48. ed parameter is displayed press ENTER to go to its present value Press SELECT to choose between YES or NO and press ENTER to store its value The value is accepted and the blinking cursor returns to the phrase position Parameter Default Description If set to YES a user with an Operator Level access is allowed to clear CLEAR FAULTS any faults that occur If set to YES a user with an Operator Level access is allowed to change SELECT TOOL which program is currently running INC DEC If set to YES a user with an Operator Level access is allowed to incre ment and decrement the limit switch on off setpoints If set to YES a user with an Operator Level access is allowed to clear the Actual Batch and Total counters This does not give an Operator tha CLEAR COUNTERS ability to clear the Tool or Stroke counters Only a user with Master or Setup level access can clear these counters This parameter enables or disables the Brake Monitoring function If set BRAKE MONITOR to YES any transition on the Brake Input will trigger a Brake Monitor cycle This parameter enables or disables the Motion Detect function If set to MOTION DETECT YES the PRESSPro Genesis will monitor the starting time of the press If set to YES the Genesis controller will remain in transducer fault LATCH TRANSD ERR until is is cleared by the user IF set to NO the transducer fault will clea
49. entered a tool setup number that already exists TOOL ALREADY IN USE will appear at the bottom of the screen After this message disappears and the blinking cursor returns to the current tool setup number repeat Steps 3 and 4 Delete an Existing Tool Setup If you are no longer using a tool setup you may delete it as follows 1 When the Select Tool screen is initially displayed the blinking cursor will be positioned on SELECT in the top left corner of the screen Press the SELECT key until DELETE appears 2 Press ENTER to move the blinking cursor to the current tool setup number in the top left corner of the screen If you want to delete the current setup skip to Step 4 3 Press the appropriate number keys to enter the number of the tool setup that you want to delete 4 When the number of the correct tool setup is displayed press ENTER 5 The following message will appear on the second line of the display ARE YOU SURE YES 6 To delete the tool setup identified at the top of the screen press ENTER again 7 If you are not sure that you want to delete the tool setup press SELECT to replace Y ES in the above message with N O then press ENTER 8 If you enter YES to delete a tool setup and the setup number that you keyed in does not exist TOOL NCORRECT will appear at the bottom of the screen After this message appears and the blinking cursor returns to the current tool setup number repeat Steps 3 through 6 NOTE g
50. epth of 4 00 for installation and removal of connectors and output relays All edges must be deburred before installing the unit Tel 860 585 1254 Fax 860 584 1973 http www amci com E 4 500 je 2 250 gt e 4 188 0 166 Dia e2094 4 places i l I I big SEA tk i ot TA I I I T I I I I I I I I I I I I E i I l 2 094 2 250 l o po j l l 4 188 fe ii l bo 4 500 I I I I I I I I I I I I I I I I I I rd bi I l l i l NU l l Y 10 ni TT ETTARI I I I Ic eM a A og eg Ng I E 0 125 max radius 4 Places Outline of PRESSPro Genesis 6 0 square area needed to a depth of 4 0 for installation and removal of relays and connectors Figure 8 1 Panel Cutout 20 Gear Drive Plymouth Ind Park Terryville CT 06786 35 E INSTALLATION Ground Bus A Ground Bus is required in each enclosure that houses electronic equipment The ground bus is directly tied to the grounding electrode system of the machine and becomes the central grounding point for the enclosure and all of its equipment Bonding wires are run from the enclosure and each piece of equipment to the ground bus and then a single grounding electrode conductor is run to the system s grounding electrode Each connection must be separate so a ground bus is sometimes fabricated in house or by the panel shop responsible for wiring the enclosure F
51. er is directly connected to the system ground or earth The installation of ungrounded systems is not covered by these instructions This chapter is presented as a tool in the hopes of avoiding common installation prob lems It is not a substitute for the safety practices called out in local electrical codes or in the United States the National Electrical Code published by the National Fire Protec tion Association If any conflicts exist local and national codes must be followed t is the responsibility of the user to determine what installation practices must be followed to conform to all local and national codes Safety is the single most important objective of any electrical installation The system must be safe to use and it must be able to detect unsafe conditions and remove power when these conditions occur The second important objective of an electrical installation is proper and consistent operation Proper opera tion can be achieved through Proper Grounding Suppression of electrical noise generated by the machine Suppression of electrical noise coming in from the environment Other machines power surges etc Grounding Proper grounding is the single most important consideration for a safe installation Proper grounding also ensures that unwanted electrical currents such as those induced by electromagnetic noise will be quickly shunted to ground instead of flowing through the machine Earth ground connect
52. es how Genesis software uses the optional brake input It covers basic brake input processing the brake monitor and motion detect functions driven by brake input and how to clear a brake fault Overview The Genesis controller has the ability to measure the time between when a 110Vac or 24Vdc braking signal is received and when the resolver stops turning If the measured time interval exceeds a user programmed value then the brake fault output is triggered The software will not only output a fault signal and halt controller operations if you remove the brake input it will also perform these actions if the brake input connection is severed or power is lost to the connection This safety feature is designed to add an additional safeguard to protect your stamping press machinery Another brake monitor feature is the Motion Detect feature Once the brake is released motion must begin within your programmed motion detect time or a motion detect fault will occur NOTE gt The two brake fault signals are used with external circuitry that you must design for your spe cific press control application For example when a brake fault signal is received you may want to stop press operation Since the brake monitoring functions are only triggered by transitions on the brake input you are not required to supply power to the input if you choose not to use the brake monitor functions Brake Input Functions The brake input controls both the brake monit
53. ess level Refer to Table 9 2 Access Level Privileges on page 44 for more information NOTE gt If the resolver is in motion i e the stamping press machinery is running you can only incre ment or decrement setpoints on the Limit Switch screen using the INC and DEC keys in Edit mode Note that you must be authorized to use these keys based on access data entered on Configuration Screen 4 To exit the Edit mode press the FUNCTION key followed by VIEW The software will also return to the View mode if no changes are made for 10 minutes while in the Edit mode Main Display Screen This screen will appear the first time that you power up the Genesis controller It will also appear during nor mal operations if no keys are pressed on the operator keypad for 10 minutes while in the Edit mode As illus trated below the Main Display screen has a different format than the typical Genesis data screen This screen provides updated status data in the following fields gt T Identifies the current tool setup gt STROKE Current number of strokes completed by the stamping press machinery gt P Reports the angular position of the crankshaft gt BATCH The actual number of parts processed in the current batch When the first input channel DM Input 1 transitions from LO to HI the part count value is multiplied by the Counter Multiplier value specified on Configuration Screen 2 gt SPM The current speed of the stamping
54. eters for the DM inputs Table 9 1 Genesis Data Screens 20 Gear Drive Plymouth Ind Park Terryville CT 06786 43 Tel 860 585 1254 Fax 860 584 1973 http www amci com PROGRAMMING OVERVIEW Password Access Levels The Genesis software provides Master Set Up and Operator password access levels When you initially begin to program the controller you may enable the Genesis password function on Configuration Screen 3 then enter a password for one user at the Master access level and another for users at the Set Up level A password is not required for users at the Operator level The following table lists the specific functions and data screens that may be accessed by users at each level Screens Functions Master Level Set Up Level Operator Level Main Display Screen View View View 1 1 Configuration Edit View View View Limit Switch Edit View Edit View Edit View Advances Edit View Edit View View Timed Output Edit View Edit View View Brake Monitor Edit View Edit View View Parts Counter Edit View Edit View Edit View Die Monitor Edit View Edit View View Select Tool Setups Create Edit Tool Setups Clear Error Messages 1 A user assigned to the Set Up or Operator access level cannot view Configuration Screen 3 Password Data the menu sequence will skip over this screen Only the Master user can view the password data displayed on this screen 2 The Master user can enable or disable a
55. f mounted correctly the body of the enclosure will be bonded to the ground bus through the mounting hard ware However you must install a bonding strap from the door of the enclosure to the ground bus Do not rely on the door s hinge to bond it to the rest of the enclosure The easiest way to ground the door is to run a bolt through the door as shown below and run a bonding wire to the ground bus Scrap Paint Away Both Sides of Enclosure Wall Star Washers Bolt ee Star Washer Tapped Hole Mi Bonding Wire To Ground Bus Stranded 8 AWG Wire Minimum Recommended Figure 8 3 Enclosure Door Bonding Once the ground bus is installed and the enclosure is bonded to it you can begin to install equipment in the enclosure and bond them to the ground bus as you go 36 ADVANCED MICRO CONTROLS INC INSTALLATION n Mounting the PRESSPro Genesis Figure 8 4 shows how to mount the unit in the door or panel Output Relays can be installed before or after the unit is mounted A closed cell neoprene gasket ships with the Genesis Before mounting the Genesis in the cutout install the gasket by removing its adhesive backing and adhering it to the back of the unit The top of the figure shows how three of the studs should be fastened to the panel or enclosure The bottom of the figure shows how to install the grounding lug on stud closest to the power connector Neoprene Gasket PRESSPro Genesis Adhesive Side Toward Unit
56. ghlights a key to be pressed on the PRESSPro Genesis When viewing the PDF version of the manual clicking on the Cross Reference cross reference text jumps you to referenced section 20 Gear Drive Plymouth Ind Park Terryville CT 06786 5 Tel 860 585 1254 Fax 860 584 1973 http www amci com ABOUT THIS MANUAL Trademark Notices PRESSPro and the AMCI logo are trademarks and AMCI is a registered trademark of Advanced Micro Controls Inc Adobe and Acrobat are registered trademarks of Adobe Systems Incorporated All other trademarks contained herein are the property of their respective holders Revision Record This manual 940 0P012 is the third release of the manual It was initially released Aug 28h 2008 It adds additional grounding and other installation material and updates the format of the manual Revision History 940 0G012 08 28 2008 Grounding information and manual format update 940 0G011 02 25 2005 Updated transducer cable drawings to CTL x 940 0G010 12 31 2001 Initial Release Where To Go From Here This manual contains information that is of interest to everyone from engineers to operators The table below gives a brief description of each chapter s contents to help you find the information you need to do your job Chapter Title INTRODUCING THE PRESSPro GENESIS Intended Audience Anyone new to the PRESSPro Genesis This chapter gives a basic over view of the
57. he operation of electronic con trols The entire grounding system even though conductive is not meant to carry current except under fault condi tions NOTE gt Under normal operating conditions the grounding system should carry no current at all Ground Fault Interrupt GFD circuits depend on this condition to work correctly Any ground current flowing through a GFI is considered a fault condition and the GFI immediately opens to remove power from the faulted circuit By this definition electrical noise and other transient currents such as inductive spikes are considered fault currents The fact that these currents are very short lived and of relatively small amperage allows them to be safely shunted without tripping a Ground Fault Interrupt circuit 20 Gear Drive Plymouth Ind Park Terryville CT 06786 21 Tel 860 585 1254 Fax 860 584 1973 http www amci com NA GENERAL INSTALLATION GUIDELINES Avoiding Grounding Problems continued Grounding problems occur when the grounding system carries currents during normal operation or when it cannot shunt high frequency electrical currents to earth AMCI generally encounters three types of grounding problems in systems that use AMCI equipment Ground Loops A ground loop occurs when AC or DC return currents can travel through the system ground path in addition to their normal return path This can cause damaging currents to electronics that share the power supply Grou
58. he version posted by Advanced Micro Controls Inc on our official website www amci com You may incorporate portions of this documents in other literature for your own personal use provided that you include the notice Portions of this document copyright 2008 by Advanced Micro Controls Inc You may not alter the contents of this document or charge a fee for reproducing or distributing it Standard Warranty ADVANCED MICRO CONTROLS INC warrants that all equipment manufactured by it will be free from defects under normal use in materials and workmanship for a period of 18 months Within this warranty period AMCI shall at its option repair or replace free of charge any equipment covered by this warranty which is returned shipping charges prepaid within eighteen months from date of invoice and which upon examination proves to be defective in material or workmanship and not caused by accident misuse neglect alteration improper installation or improper testing The provisions of the STANDARD WARRANTY are the sole obligations of AMCI and excludes all other warranties expressed or implied In no event shall AMCI be liable for incidental or consequential damages or for delay in performance of this warranty Returns Policy All equipment being returned to AMCI for repair or replacement regardless of warranty status must have a Return Merchandise Authorization number issued by AMCI Call 860 585 1254 with the model number and seria
59. hless resolver based transducer for position feedback and generates up to six PLS outputs based on the transducer s position programmed setpoints Figure 1 1 GN3B1 01A 00 PLS Controller and speed compensation advances If a deviant condition is detected on a DM input channel the controller will output a fault signal and a Top Stop or Die Fault warning to the operator display DM Input 1 can be used to provide part count data for each batch and job The brake monitor function checks and displays optional brake input data and will output a fault signal if appropriate NOTE gt In addition to controlling stamping press machinery you may use the Genesis unit as a mechanical cam switch replacement for other types of machinery such as packaging equip ment Genesis Software The PRESSPro Genesis software basically performs programmable limit switch and die monitoring func tions The software also allows you to Enter configuration data and detailed parameters for multiple tool setups Monitor batch and job duration with a parts counter Monitor misalignment absence or unwanted presence of parts with Die Monitor inputs Enter a resolver stopping time parameter that triggers a fault output if exceeded Enter a time interval when resolver motion should start after brake input is OFF Monitor error messages that appear on the operator display 20 Gear Drive Plymouth Ind Park Terryville CT 06786 7 Tel 860 58
60. how to use the display and keypad INITIAL TOOL SETUP Anyone that needs information on how to select a tool setup and enter configuration data including transducer setup parameters counter and motion parameters password data and operator access data CONTROLLER PROGRAMMING Anyone that needs information on how to program PLS output channels enter stop time monitor and counter data and program Die Monitor input channels SOFTWARE ERROR MESSAGES Anyone that needs information on error message that may be output by the PRESSPro Genesis software ADVANCED MICRO CONTROLS INC _ o n CHAPTER I i mt INTRODUCING THE PRESSPro GENESIS This chapter is written for anyone that wants to familiarize themselves with the features of the PRESSPro Genesis and the type of applications it was designed for Overview The PRESSPro Genesis PLS Controller includes an operator display keypad with software to control Programmable Limit Switch PLS outputs for crankshaft synchronization and Die Monitor DM inputs to protect press dies and machinery The software can also monitor an optional brake input and output a fault signal if unexpected condi tions occur You may use the display keypad to program a variety of software data screens creating custom tool setups for all your press control applications Six PLS outputs and four DM inputs are available for each tool setup The Genesis controller connects to a single turn brus
61. igure 8 2 shows various ways to mount the ground bus to an enclosure and how to connect a bonding wire to the bus Do not connect two or more lugs to the bus with a single bolt If you do the connection may loosen up over time Enclosure P aaa Stud Star Washer Ca 2 Places i SS lt Nut fa 2 Places 3 p Pett Scrap Paint Away From Stud Threads and Enclosure Wall 1 Flat smacco 2 Places oe is Thru Holes a Tapped e ea Star Washer Grounding Electrode Conductor Stranded 8 AWG Wire Minimum Recommended WELDED STUD Bolt 2 Places Star Washer Ca a 2 Places edi Washer 2 Places Scrap Paint Away Both Sides of Enclosure Wall DR gt Valli Star Washe Bey 2 Places Nut N Lu 0a 2 Places Tapped Holes m Q 2 ci Og Bolt Thru Holes a Tapped ee gt Star Washer Grounding Electrode Conductor Stranded 8 AWG Wire Minimum Recommended THRU WALL BOLT Figure 8 2 Ground Bus Installation The national electrical code specifies the minimum bonding wire size for equipment based on the rating of the overcurrent device in the circuit ahead of the equipment The code states that the size cannot be smaller than 14 AWG However the NEC is concerned with human safety not EMI protection For noise reduction pur poses the larger the bonding wire the better so AMCI strongly recommends stranded 8 AWG for all bond ing wires Bonding the Enclosure Door I
62. ions on electronic controls are one of two types Protective Earth Connection Point that must be tied to Earth for the safe operation of the device Protection against electric shock should the device be damaged Functional Earth Connection Point that must be tied to Earth to improve noise immunity of the device For the AMCI Genesis controller the Protective Earth Connection is any of the four mounting studs on the face of the unit The Functional Earth Connection of the AMCI Genesis Controller is the ground terminal L on the power connector 20 Gear Drive Plymouth Ind Park Terryville CT 06786 19 Tel 860 585 1254 Fax 860 584 1973 http www amci com NA GENERAL INSTALLATION GUIDELINES Grounding continued Grounding Electrode System The Grounding Electrode System is the common name for the building s earth ground infrastructure This system defines earth ground potential within a building and is the central ground for all electrical equipment The Grounding Electrode System of a building is typically made from the following components that are all bonded electrically tied together Metal Underground Water Pipes Must be electrically continuous and in direct contact with the earth for 10 feet or more Metal Frame of the Building The metal frame can be used when it is effectively grounded through a ground connection of suffi ciently low impedance Typically this is accomplished when the building frames
63. istance to high frequency sig nals than stranded wire or metal braid The suggestions for avoiding high impedance grounds are the same suggestions for a good Grounding Elec trode Conductor 1 Use 8 AWG stranded wire or 1 wire braid for all ground wires 2 Keep connections as short as possible This includes the metal conduit on the machine 20 Gear Drive Plymouth Ind Park Terryville CT 06786 25 Tel 860 585 1254 Fax 860 584 1973 http www amci com NA GENERAL INSTALLATION GUIDELINES Surge EMI Suppression Incoming Power In many systems three phase power is brought to the machine and the control system is powered from one of these phases In these cases good quality clean AC power can only be achieved by properly conditioning the three phase power not just the single phase used by the control system This is generally achieved by placing surge suppressors across each phase where the three phase enters the system and at all inductive loads that are on the three phase branch This includes inductive loads on any other machine that may be powered by the same feeder circuit u OO TE T 2FU B Suppressor 3 1 O_O T HE L2 3FU _ i Suppressor 3 Ls O O ro 3 L3 O Hi H3 _H2 H4Q Step Down Transformer GROUND BUS 1000000 Fuse To Control System Figure 7 6 Surge Suppression on Power Inputs NOTE gt 1
64. itched and noise will Suppressor not be coupled into the power supply Power Return Un Acceptable Connection 1 Inductive This connection protects the power supply and LS output but es Output ATT L Device allows noise to radiate through the load s wiring where it can Power In n o be coupled into other cables around it Suppressor Power Return Ui Ale pairs EONS Inductive This connection protects the power supply but nothing else Sat LS Output Device Noise can radiate through the load s wiring where it can be Li coupled into other cables around it and the LS Output relay Suppressor may eventually be damaged by high voltage inductive spikes Power Return o FIRE POP Inductive This connection protects the LS Output but nothing else Powerin Output Device Noise can radiate through the load s wiring where it can be n o coupled into other cables or into the power supply Noise in Suppressor the supply may affect any device powered by it Also ifthe Power Return suppressor shorts out the load will always receive power Figure 7 7 Installing Surge Suppression Devices Surge Suppression DC Outputs All inductive DC loads require a commutating or fly back diode across the load Inductive DC loads include relays solenoids and DC motors Unlike resistors diodes have a polarity and only conduct current in one direction Therefore care must be taken when i
65. l number if applicable along with a description of the problem A RMA number will be issued Equipment must be shipped to AMCI with transportation charges prepaid Title and risk of loss or damage remains with the customer until shipment is received by AMCI 24 Hour Technical Support Number 24 Hour technical support is available on this product For technical support call 860 583 7271 Your call will be answered by the factory during regular business hours Monday through Friday 8AM 5PM EST During non business hours an automated system will ask you to enter the telephone number you can be reached at Please remember to include your area code The system will page one of two engineers on call Please have your product model number and a description of the problem ready before you call We Want Your Feedback Manuals at AMCI are constantly evolving entities Your questions and comments on this manual are both welcomed and necessary if this manual is to be improved Please direct all comments to Technical Docu mentation AMCI 20 Gear Drive Terryville CT 06786 or fax us at 860 584 1973 You can also e mail your questions and comments to techsupport amci com ADVANCED MICRO CONTROLS INC i Se TABLE OF CONTENTS Inside Front Cover CHP 4 Die Monitor Input Important User Information IFC Requirements Standard Warranty iii IFC Die Monitor Input Modes 13 Returns Po
66. lays Additional relays can be ordered under the AMCI part number KM 3 20 Gear Drive Plymouth Ind Park Terryville CT 06786 9 Tel 860 585 1254 Fax 860 584 1973 http www amci com rs INTRODUCTION Surge Suppressors All inductive loads such as relays contactors and solenoids that are switched with mechanical relays require some form of surge suppression to reduce electrical noise EMI in the system DC loads require a commutat ing or fly back diode across their coils AC loads require a varistor or R C network as a surge suppressor with R C networks being the preferred devices The PRESSPro Genesis ships with eight R C network sup pressors that can be used in most applications For additional information see Surge EMI Suppression starting on page 26 How PLS Channels Operate After you enter parameters for a PLS channel the Genesis software will time or sequence outputs over the channel according to precise and repeatable positions of the crankshaft The Genesis controller interfaces to a resolver based transducer that monitors the crankshaft positions To program a PLS output you first enter the rotational position or preset angle where the PLS output should be turned ON You then enter the appropriate parameters to specify if you want the PLS output to turn OFF at a preset angle or a preset time Advance data can also be entered to compensate for fixed delays in the stamping press system A typical
67. licy i IFC Defining a Crankshaft 24 Hour Technical Support Number IFC Rotation Zone 13 We Want Your Feedback IFC Cyclic Modes 14 z Single Part SPART Mode 14 A t This MAnual pe 3 ae 5 In Position IN POS Mode 15 n Static Mode 15 a gt fi RR 5 Outputs for Die Monitor Channels 15 anua eyes MOUS siti gering Up Your Die Monitor Channels 15 Trademark Notices 6 Revision Record 6 CHP 5 Counters Revision History 6 Job Control Counters 16 Where To Go From Here 6 Batch Counter 16 CHP 1 Introduci the PRESSP Total Counter 16 mer n ri paint g tne 2 Machine Maintenance Counters 16 Tool Counter iii 16 OVETVIEW ici pri 7 celtica 16 Unit Description 8 on Operator Interface CHP 6 Specifications Display and Keyboard 8 Transducer Specifications 18 A sua RITRATTO ION I EE CHP 7 General Installation ransducer Input Connector Guidelines Fault Stop Output 9 Top Stop Output 9 Grounding AR RIT PARA TA 19 Limit Switch Outputs 9 Grounding Electrode System si 20 Die Monitor Inputs 9 Supplementary G
68. med by the channel 2 Type and location of the input switch or analog device that will supply the input signal for the channel 3 The appropriate input mode for the channel 4 The appropriate output response if a fault is detected on the channel 20 Gear Drive Plymouth Ind Park Terryville CT 06786 15 Tel 860 585 1254 Fax 860 584 1973 http www amci com AS CHAPTER 5S COUNTERS This chapter describes the four counters available on the PRESSPro Genesis Two of the counters Total and Batch are used to control jobs run on the machine The other two counters Tool and Stroke are used for machine maintenance Job Control Counters These counters are used to track the number of parts made by the press They are typically programmed to increment when the press position goes through zero but they can be programmed to increment when the position goes through zero only if Die Monitor Input 1 successfully completes a cycle Each counter has a programmable trip value that can be used to stop the machine when this value is reached or exceeded This is accomplished by dropping out the Top Stop Relay when either count is reached The status line of the display will read BATCH COMPLETED or TOTAL COMPLETED depending on which count was reached Batch Counter You may need to run a job in more than one batch For example a 50 000 piece job may need to be run as 10 batches of 5 000 This counter allows you to track the
69. minal to its chassis This type of installation is shown in figure 7 2 below As Controller 2 18Vdc to 30Vdc Isolated Power Supply rh O GROUND BUS Figure 7 2 Installation with Ground Loop There are three problems with this installation 1 The DC return wire for Controller 1 carries more that its intended current This may lead to heating and failure of the wire 2 The internal connection between chassis and DC Return on both controllers carries current during normal operation Depending in the magnitude of the current this could damage the units immediately or over time If either of the DC return wires were to fail both units would still operate with the combined return currents flowing through the remaining DC return wire 3 In the installation above the grounding system carries current during normal operation This means that any noise currents travelling on the Ground Bus can be injected into either of the controllers The installation may also present a shock hazard if the currents are large enough 22 ADVANCED MICRO CONTROLS INC GENERAL INSTALLATION GUIDELINES Ey All Avoiding Grounding Problems continued Ground Loops continued The only way to prevent these ground loop currents is to isolate the DC return paths of the two controllers This can be done by using two separate isolated DC supplies or by using isolated D
70. n all the data screens except for the password screen Configuration Screen 3 The Edit mode may be used to view and edit information displayed on specific data screens The operation mode that is currently active will be identified in the bottom left corner of the operator display NOTE gt If the Genesis password function is enabled on Configuration Screen 3 only users at the Master or Set Up level can access the Edit mode View Mode When power is applied to the Genesis controller the software will start up in this operation mode The soft ware will also return to this mode if the resolver is moving or if no changes are made for 10 minutes in the Edit mode To enter the View mode if the Edit mode is currently active press the FUNCTION key in the top right corner of the operator keypad followed by the VIEW key 46 ADVANCED MICRO CONTROLS INC PROGRAMMING OVERVIEW 19 Basic Operation Modes continued Edit Mode To enter this mode from the View mode press the FUNCTION key on the operator keypad followed by EDIT If the Genesis password function is enabled on Configuration Screen 3 the message ENTER PASS WORD will appear on the operator display Press the appropriate keys to enter your password followed by the ENTER key If you enter an invalid password the error message I NVALI D ACCESS will appear on the last line of the display If the password is valid you may edit the data on specific screens based on your acc
71. nction will turn outputs ON or OFF over each PLS channel according to precise and repeatable positions of a crankshaft monitored with a resolver based transducer For each channel you can program up to two pairs of ON OFF setpoints at counts from 0 999 enter advance data to compensate for fixed delays in the stamping press system and define an optional timing parameter to turn the output OFF You control when the output over each PLS channel turns ON or OFF by entering specific parameters on the Genesis data screens For example you turn a PLS output ON by defining a preset crankshaft angle i e an ON setpoint You turn a PLS output OFF by entering a crankshaft angle i e an OFF setpoint and an optional timing parameter to turn the signal OFF after a set time interval When you program a timed output the output will turn off after the programmed condition that occurs first That is the output will turn off if a the crankshaft passes through the OFF setpoint before the end of the programmed time interval or b the timer reaches its programmed value before the crankshaft rotates through the OFF setpoint 0 Near top Zone Preset angle to P turn output ON 270 90 Up Stroke Zone Down Stroke Zone Preset angle or time to turn 180 output OFF Bottom Direction of Rotation Figure 2 1 PLS Output Requirements Note that you may also enter advance data to compensate for fixed delays in the stamping press system For example an ad
72. nd Shift Remote machines or monitoring stations will usually be connected to a different point on the Grounding Electrode System than a local system A voltage potential can exist between these sta tions due to resistance between the grounding electrodes and earth A similar problem exists on machines that are not properly bonded together The resistance of a poor bond in the system will result in a voltage potential across the connection when current is forced through it Incorrectly installed sen sor or communications cables that run between these systems can be damaged by these Ground Shift potentials High Impedance Grounds The grounding system shows a high impedance to high frequency noise currents and these signals are not properly shunted to earth Ground Loops A ground loop occurs when AC or DC return currents can travel through the system ground path in addition to their normal return path This occurs in DC systems when the DC return often labeled DC is connected to earth ground at more than one point Sometimes these loops are hard to recognize because of electrical connections made within the pieces of equipment themselves Many products internally tie their DC return terminal to their chassis When the chassis is connected to the ground bus the DC return is also tied to the ground bus A ground loop is formed if a second piece of equip ment is powered from same power supply and this piece of equipment also ties its DC return ter
73. ndependent of the press stroke during the stamping process When the input signal on a static mode channel turns OFF the programmed out put for the channel will be turned ON For example you may use this mode to detect the end of stock Outputs for Die Monitor Channels If a fault is detected on any of the DM input channels the Genesis software will execute the output you requested on the Genesis data screens A fault is defined as any condition that deviates from the expected con ditions defined for a DM channel You may request the software to generate a Stop Fault output and display the STOP FAULT error message on the operator display or a Top Stop output and the TOP STOP FAULT error message The CONTROLLER PROGRAMMING chapter starting on page 55 describes how to request either type of fault output for a DM input channel using the Die Monitor data screens Setting Up Your Die Monitor Channels Before you begin to program the Genesis software you should determine the number of DM input channels required for your specific press control application The controller supports a total of four DM channels NOTE The first DM channel i e DM Input 1 can be used for counting parts Gather the information described in the following list to decide how to use each DM channel to meet the needs of your press control application This list will also help you determine how to set up each channel 1 The function that will be perfor
74. ndicate that the transducer cable may be severed or compro mised in some way Clearing a Brake Fault When either the brake monitor or the motion detect function outputs a fault the normal operations of the Gen esis controller will cease and the software will trigger a stop fault After the condition that caused the fault is corrected you must press the FUNCTION key on the operator keypad followed by the CLEAR key to clear the fault output 20 Gear Drive Plymouth Ind Park Terryville CT 06786 12 Tel 860 585 1254 Fax 860 584 1973 http www amci com CHAPTER 4 DIE MONITOR INPUT REQUIREMENTS This chapter describes how to select the parameters for each Die Monitor input channel required to protect your stamping press machinery lt covers the Die Monitor input modes the available outputs and how to set up each of input channel Die Monitor Input Modes Each DM channel is set up to verify if an expected condition took place during your stamping press opera tions When a deviant condition i e a fault condition occurs the software executes the specific output you requested on the Genesis data screens The software provides a total of four DM input modes You may use any of the first three modes listed below when input signals are synchronized with the rotation of a crankshaft and detectable within a specific zone of rotation or window Use the Static mode if the input signals are inde pendent of the press stroke The
75. not displayed press FUNCTION followed by TIMED to request this screen CH TI MED OUTPUT 1 2 DURATI ON 0 mS EDIT 2 P 357 SPM 0 Figure 11 3 Timed Output Screen 2 When the Timed Output screen first appears the blinking cursor will be positioned on the number 1 for the first channel or the number of the channel that you were editing viewing on the previous screen To move to another channel press the up or down arrow keys A or w or enter the number of the other channel and press ENTER If a line for a specific channel is blank see Channel 1 line above indicating that Normal output has been selected for the channel move the cursor to a line displaying the DURATI ON parameter This parameter indicates that Timed output has been selected for the channel 3 When the cursor is positioned on a line with the Duration parameter press ENTER to move the cursor to the number field 4 The maximum duration value that may be entered on the Timed Output screen is 9999 milliseconds This parameter sets the amount of time that the output will be ON for the current channel Key in the correct value for your stamping press system and press ENTER to record the duration value in the setup data The cursor will then return to the Limit Switch screen to allow you to enter setup data for another PLS output channel NOTE gt If the Limit Switch OFF setpoint is reached before the programmed duration value expires the output will tu
76. nsducer Position Resolution Programmable from 2 to 1 000 counts per turn Position can be preset to any value within its range from the keyboard Tachometer Range 0 to 2 000 RPM Limit Switch Update Time 100 microseconds Limit Switch On Off Resolution 1 part in 1 000 counts per turn 0 36 indepen dent of programmed position resolution Program Input Built in keyboard and display Program Storage EEPROM memory 100 000 write cycles mini mum Number of Available Programs Tools 50 Number of available programs is indepen dent of the size of the programs Programs can be assigned any number between 1 and 99 Available Output Type Position on Position off Up to 2 on off dwells per output Position on Position off OR time off Single on off dwell and on time programmable from 1 to 9 999 milliseconds Automatic Advances Separate On Off Advances available for each output Advance can be programmed from 0 to 999 milliseconds Number of Outputs Eight Six PLS and two warning outputs Each output is a SPDT mechanical relay included with the PRESSPro Genesis Compatible Output Relays DC AMCI KM 3 Omron G2R 1 S or equ Number of Inputs Five Total Four DM Die Monitor Inputs and one Brake input DM Inputs DC only Each requires 10 to 30Vdc 10mA to activate Brake Input AC DC Requires 110Vac 8 mA ms OR 10 to 30Vdc 10mA to activate Environmental Conditions Operating Temperature 0 t
77. nstalling diodes As shown in the figure below the cathode of the diode which is denoted by the white or black band on one end of the diode must be installed on the positive side of the load If you install the diode backwards it will most likely destroy itself as soon as you apply power to the load DC Load Connection _ Inductive Device LS Output Power In ue n o COLORED BAND Power Return Figure 7 8 DC Output Surge Suppression 20 Gear Drive Plymouth Ind Park Terryville CT 06786 27 Tel 860 585 1254 Fax 860 584 1973 http www amci com NA GENERAL INSTALLATION GUIDELINES Surge EMI Suppression continued Surge Suppression DC Outputs continued The diode must be sized to handle the inductive surge of the load when it turns off Some devices can be ordered with built in fly back diodes or the device manufacturer will offer suppres sors designed specifically for the device These types of devices are strongly recommended The fly back diode will slightly increase the device s turn off time by maintaining the magnetic field while it shunts energy back into the device If needed this additional delay can be compensated for by adjusting the LS OFF Advance parameter available on the PRESSPro Genesis Surge Suppression AC Outputs Switching AC loads with hard contacts such as mechanical relays or contactors can generate a large amount of electrical noise Suppression networks m
78. o 60 C Relative Humidity 5 to 95 without condensation Storage Temperature 40 to 85 C 20 Gear Drive Plymouth Ind Park Terryville CT 06786 Tel 860 585 1254 Fax 860 584 1973 http www amci com 17 6O SPECIFICATIONS Transducer Specifications The following table contains mechanical and environmental specifications for all of AMCI s single resolver transducers that are compatible with the PRESSPro Genesis All HT 20 C s All other Redundant HTT All Specification HT 20K s amp HT 20 s All HT 400 s 20 1 5 8 Shaft HT 20L s amp HTT 400 1 H 25 s Shaft Diameter 0 625 0 625 0 625 0 625 0 625 Radial Shaft Loading 100 lbs max 100 Ibs max 100 Ibs max 100 Ibs max 100 Ibs max Axial Shaft Loading 50 Ibs max 50 Ibs max 50 Ibs max 50 Ibs max 50 Ib max Starting Torque 8oz in 25 C 8oz in 25 C 80z in 25 C 8oz in 25 C 6oz in 25 C Moment of Inertia oz in sec Weight 7 Ibs 4 Ibs 4 8 lbs 4 8 lbs max 1 8 Ibs Enclosure IP67 NEMA 4X IP64 IP64 IP64 IP67 6 25X 104 6 25X 104 8 75X104 8 75X10 8 75X10 Specification All ee All 0 1200 All 0 1875 All Sealed Shaft R11 s Shaft R11 s R11 s Shaft Diameter 0 375 0 1875 0 375 0 1875 0 250 or 0 188 Radial Shaft Loading 40 Ibs max 6 lbs max 2 lbs max 6 lbs max 6 lbs max Axial Shaft Loading 20 Ibs max 3 Ibs max 1 Ib max 3 Ibs max 3 Ibs max Starting Torque 20z in 25
79. ocations of the output relays and I O wir ing connectors PRESSPro Genesis BACK c c 1g TS g FS VERRI n O Bowl Bue ea ink toate O g OUTPUT CONNECTOR TD oDDDDDDD DDD DIE MONITOR INPUTS Inputs 1 4 and Input Common a ee O O OUTPUT CONNECTOR D SDDDDDODDDOOOD LS2 through LS6 Sa A STOP TIME MONITOR INPUT SHD Differential Input and Shield Ground NO NC E NONC C NONC C NONC C NONE O aaa O Figure 8 9 I O Connector Placement Die Monitor Input Wiring dpr ban dal Sei up Figure 8 10 shows a simplified schematic of the Die Monitor Inputs The S7 4 m inputs are designed to accept 10 30 Vdc and require 10 mA to activate i i gt i 14 14 14 4 Note that the Input Common Pin is attached to one side of the power supply that powers the sensors connected to the inputs If your sensors have sourcing outputs then attach the Common pin to i ower supply ground Pp pply 8 n DDD gt If your sensors have sinking outputs attach the Common pin to Vdc or of the supply NNN NO All of your sensors must be sourcing or sinking You cannot attach both types to the PRESSPro Genesis at the same time INP UT COMMON Figure 8 10 DM Input Schematic 40 ADVANCED MICRO CONTROLS
80. odes and the Main Display screen Genesis Data Screens You may use the data screens displayed by the Genesis software to program custom tool setups and monitor the operation of your stamping press system Each screen is listed below along with the operations commonly performed on each screen Note that the Main Display screen is described in this chapter the Select Tool and Configuration screens are described in the INITIAL TOOL SETUP chapter starting on page 49 and all the other screens are covered under CONTROLLER PROGRAMMING starting on page 55 Data Screen Commonly Used to Main Display Screen View current status data Select Tool Select create copy and edit tool setups Configuration Screen 1 Define transducer setup parameters Configuration Screen 2 Enter counter multiplier and motion detect parameters Configuration Screen 3 Modify password data Configuration Screen 4 Enter operator access data Limit Switch Select the type of output for each PLS channel and enter ON OFF setpoints Advances Enter speed compensation data for PLS outputs Timed Output Enter duration parameters for timed PLS output channels Brake Monitor E input status and enter a stopping time parameter for the Parts Counter Enter desired batch and job part counts and view actual part count data Machine Maintenance View tool or stamping press and stroke counter data Die Monitor Screen Enter param
81. onents The minimum sizes for the Grounding Electrode Conductor are 8 AWG stranded wire or 1 braid but larger sizes may be needed depending on the total ground fault current your system can generate The actual size is determined by the size of the largest conductor in the system The American NEC allows the use of a solid wire for the Grounding Electrode Conductor but this should be avoided High frequency currents electrical noise travel along the surface of a conductor Heavy gauge stranded wire and braid both have large surface areas solid conductors do not Therefore stranded wire and braid have a much lower effective resistance to electrical noise Grounding Wires Grounding wires are used to connect the pieces of equipment to your ground bus AMCI strongly suggests using 8 AWG stranded wire or 1 wire braid for all grounding connections The American NEC allows the use of solid wire for grounding wires but this should be avoided for the same reasons they should not be used for the Grounding Electrode Conductor Avoiding Grounding Problems As stated before there are two reasons to properly ground a system The first reason is to protect human life A properly designed grounding system will be able to detect potential shock currents and remove power from the system The second reason is to improve system reliability by shunting electrical noise currents to earth instead of allowing them to flow through the system where they can disrupt t
82. or and motion detect software functions described in this sec tion A separate Genesis data screen is provided for each function to allow you to enter the parameters required to control both functions Brake Monitor Function A Brake Monitor screen displays the current status of the brake input and the time required for the resolver to stop the last time the brake input status turned from OFF to ON generating a brake cycle You may also enter a parameter on this screen to specify the longest acceptable stopping time for the resolver When the resolver stopping time exceeds this parameter value the software will output a brake fault and the error mes sage STOP TI ME EXCEEDED to the operator display NOTE gt For a detailed description of the Brake Monitor screen refer to the Brake Monitor Program ming section of chapter 11 starting on page 58 Motion Detect Function You may enter a motion detect parameter to specify the time it should take for the resolver to detect crank shaft motion after the brake input status goes from ON to OFF If this time is exceeded the software will out put a brake fault and the error message MOTI ON TI ME EXCEEDED on the operator display The software will also perform these actions if the crankshaft motion begins after the brake input status goes from ON to OFF and the motion stops without the input status turning ON which would normally generate a brake fault The second error condition may i
83. ow within the window then The end of the current window Input Active ON Setpoint OFF Setpoint CASE A Input Active ON Setpoint OFF Setpoint CASE B Figure 4 3 Valid Single Part Transitions If a problem is detected the fault output is set after The beginning of the next window FF at int bef A Ci lA mies 2 Remains OFF for the cycle The end of the current window 14 ADVANCED MICRO CONTROLS INC DIE MONITOR INPUTS 4 Di In Position IN POS Mode This input mode will detect if ejector and other automation parts Input Active are retracted to the correct home position during the stamping process You may use this mode to determine if the input signal ON Setpoint OFF Setpoint remained ON within the entire rotation window once during each press stroke Note that the signal must turn OFF outside the window The conditions that apply to this input mode are listed Figure 4 4 Valid In Position Transitions below For this Expected A problem is detected when If a problem is detected the Condition the Input Signal fault output is set after Input signal turns ON 1 Turns OFF before the end of the window The input signal turns OFF before and OFF 2 Does not turn OFF outside the window The next window begins after the window 3 Does not turn ON before window goes ON The current window begins Static Mode This input mode may be used to output a warning message if an event occurs i
84. played press ENTER to move the cursor forward to the password 5 You may then change the password for the selected access level i e the password that must be entered by each user at either the Master or the Set Up level After you key in any four digit number for the password press ENTER The value is accepted and the blinking cursor returns to the DI SABLE ENABLE position NOTE All the Genesis controllers are shipped with a default Master password of 1234 20 Gear Drive Plymouth Ind Park Terryville CT 06786 53 Tel 860 585 1254 Fax 860 584 1973 http www amci com 10 INITIAL TOOL SETUP Entering Configuration Data continued Additional Config Programming Screen 4 Use the last configuration screen to define which features operators will have access to and to turn on or off some of the controller s functionality 1 Press FUNCTION followed by CONFIG to request the first configuration screen 2 Press NEXT three times to page forward to the final configuration screen illustrated below CONFI GURE 4 OF 4 CLEAR FAULTS YES EDIT 2 P2357 SPM 0 Figure 10 5 Configuration Screen 4 3 When Configuration Screen 4 first appears the blinking cursor will be positioned on the CLEAR FAULTS phrase displayed on the second line shown above At this point pressing the SELECT key will cycle you through the parameters available on this screen These parameters are given in the table below 4 When the desir
85. power and a third as the Functional Earth Connection The Functional Earth Connec tion must be tied to ground to improve the noise immunity of the Genesis More on proper grounding tech niques in Chapter 6 GENERAL INSTALLATION GUIDELINES starting on page 17 Transducer Input Connector When looking at the display the eight pin Transducer Input Connector is located on the right side of the unit The mating connector AMCI part number MS 8P ships with the unit The PRESSPro Genesis accepts a single resolver transducer for position feedback Fault Stop Output This output signals a problem with the stopping time of the press by triggering when the stopping time of the press exceeds the programmed Brake Fault Timer Top Stop Output This output signals that the press should be brought to a Top Stop This output triggers when there is a Die Monitor fault or when the programmed value for the Parts Counter is reached Limit Switch Outputs Connectors for the limit switch outputs are on the back of the unit Output one comes off the top connector while outputs two through six come off the bottom Die Monitor Inputs There are a total of four Die Monitor inputs These inputs are used to verify the flow of stock through the press is synchronized with the stroke of the press These inputs can also be used to verify that ejectors or other automation parts are also synchronized Compatible Relays The PRESSPro Genesis ships with eight SPDT mechanical re
86. r Input Wiring 40 Error Messages 61 Stop Time Monitor Input 42 Programming Error Messages 61 Output Wiring iii 42 Machine and Hardware Error Messages 62 CHP 9 Software Introduction Genesis Data Screens 43 Password Access Levels 44 Using the Operator Display Keypad 44 Display Layout 44 Using the Operator Keypad 45 Basic Operation Modes 46 View Mode in 46 Edit Mode n 47 Main Display Screen 47 4 ADVANCED MICRO CONTROLS INC ABOUT THIS MANUAL Read this chapter to learn how to navigate through the manual and familiarize yourself with the conventions used in it The last section of this chapter highlights the manual s remaining chapters and their targeted audience Audience This manual explains the operation installation and programming of AMCI s PRESSPro Genesis standalone programmable limit switch PLS model number GN3B1 01A 00 It is written for the engineer responsible for incorporating the PRESSPro Genesis into a design as well as the engineer or technician responsible for its actual installation Navigating this Manual This manual is designed to be used in both printed and on line formats Its on line form is a PDF document which requires Adobe Acrobat Reader version 4
87. r an ON setpoint greater than Scale Factor 1 on the Die Monitor screen INPUT POSIT OFF ERR Programming Attempted to enter an OFF setpoint greater than Scale Factor 1 on the Die Monitor screen INPUT ERROR Programming Value lt 0 or gt 4 1 If the resolver is in motion i e the stamping press machinery is running you can only increment or decrement setpoints on the Limit Switch screen using the INC and DEC keys in the Edit mode Note that you must be authorized to use these keys based on access data entered on Configuration Screen 4 Table 12 1 Programming Error Messages 20 Gear Drive Plymouth Ind Park Terryville CT 06786 Tel 860 585 1254 Fax 860 584 1973 http www amci com 61 EPA ERROR MESSAGES Error Messages continued Machine and Hardware Error Messages ERROR MESSAGE CAUSE Parameters defined for a DM input channel STOP FAULT Machine triggered this message and a Fault Stop signal Possible causes 1 Parameters defined for a DM input channel TOP STOP FAULT Machine triggered this message and a Top Stop signal 2 TOTAL DESIRED part count values specified on the Parts Counter screen was reached BRAKE FAULT value was exceeded on the Brake BRAKE MONITOR ERROR Machine Monitor screen defining the longest acceptable stopping time for the resolver MOTION DETECT value was exceeded on Con MOTION DETE figuration Screen 2 specifying the time it should
88. r as soon as the resolver signals become valid If set to YES the batch counter will increase whenever Input 1 transi COUNT INPUT 1 tions If set to NO the batch counter will increase when the resolver s position Table 10 1 Additional Parameters 54 ADVANCED MICRO CONTROLS INC _ i A 1I A o e CONTROLLER PROGRAMMING This chapter describes how to program PLS output channels enter stop time monitor and counter data and program Die Monitor input channels PLS Output Programming Each PLS output channel may be programmed by entering basic limit switch information advance data and any required timing parameters as described in the following sections The Limit Switch screen can also be used to monitor the status of the outputs Limit Switch On Off Setpoints You may use the Limit Switch screen to select a specific type of limit switch for each output channel and up to two pairs of ON OFF setpoints for each channel as follows 1 If the Limit Switch screen is not displayed press FUNCTION followed by LIM SW to request this screen Note that the columns on the top line identify an output channel CH the STATUS of the channel and the first ON setpoint FROM and OFF setpoint TO entered for the channel The arrow on the right side of the second line below indicates that additional setpoints have been entered for Channel 1 CH STATUS FROM1 TO1 1 N OFF 0 2 T OFF 270 90 EDIT 2 P 357 SPM
89. rformance from a supplementary grounding electrode Soil resistance is extremely dependant on moisture content For example top soil with a moisture content of 30 has a resis tance of 6400 ohms per centimeter The same soil with a moisture content of 2 5 has a resistance of 250 000 ohms per centimeter Unless there is ground water beneath the building to keep the soil moist a sup plementary grounding electrode may have little effect It is possible to treat the soil to lower its resistance typically with sodium chloride table salt or a metal salt These treatments are not permanent and must be renewed periodically It is possible to install two or more supplementary grounding electrodes for the system These electrodes must be at least six feet apart but eight to ten feet apart will yield a lower effective resistance These elec trodes must be bonded together as well as bonded to the buildings Grounding Electrode System Stranded conductors should be used The size of the bonding jumper depends on the size of the largest conductor in the system but in no case can it be smaller than 8 AWG Ground Bus AMCI strongly suggests the use of a ground bus in each system enclosure The ground bus is simply a metal bar with studs or tapped holes for accepting grounding connections in the enclosure The ground bus is the only component in the enclosure that is directly connected to your Grounding Electrode System Therefore the ground bus is becomes the
90. rge an Existing Setup 50 Suppression Devices 30 Delete an Existing Tool Setup 50 Minimize Voltages in the Entering Configuration Data 51 System Enclosure 30 Transducer Setup Parameters Power Supply Sizing 30 Screen 1 51 Component Placement 31 Counter amp Motion Parameters Conduits to Enclosure 32 Screen 2 ecen 52 CHP 8 Installing the PRESSPro Password PEDRALS Genesis Screen c sedescs eee e 53 Additional Config Programming Required Power Supply 35 Screen 4 Li 54 Mine eras mess canon S CWP 11 Controller Programming utput Programming Bonding the Enclosure Door Sa 36 ai Ioff T Di 55 Mounting the PRESSPro Genesis 37 Advance Data in 56 Connecting Power in 37 Timed Output Parameters 57 Transducer Input Connector 38 Brake Monitor Programming 58 Transducer Connector Pinouts 38 Brake Monitor Data 58 Transducer Cable Installation STE 38 Counter Programming iii 59 CTL x Wiring Diagram 39 Counter Data ii 59 AMCI Transducer Outline Drawings 39 Die Monitor Input Programming 60 AMCI Transducer Mounting 40 VO Wiring li 40 CHP 12 Software Error Messages Die Monito
91. rn off when the programmed OFF setpoint is reached 20 Gear Drive Plymouth Ind Park Terryville CT 06786 57 Tel 860 585 1254 Fax 860 584 1973 http www amci com K Ki CONTROLLER PROGRAMMING Brake Monitor Programming This section describes how to enter a stopping time or brake fault parameter on the Brake Monitor screen Brake Monitor Data You may use the Brake Monitor screen to check the current status of the brake input and to enter a stopping time parameter for the resolver NOTE The Genesis controller does not require a brake input The BRAKE INPUT PROCESSING chapter starting on page 12 describes how the controller handles this input 1 If the Brake Monitor screen is not displayed press FUNCTION followed by BRAKE to request this screen The second line displays the current status of the brake input ON or OFF and the total time it took for the resolver to stop during the last braking cycle The default status for the brake input is ON BRAKE MONI TOR STATUS ON TI ME 0 mS BRAKE FAULT 500mS EDIT 2 P 357 SPM 0 Figure 11 4 Stop Time Monitor Screen 2 When this screen first appears the blinking cursor will be positioned on the value specified for the BRAKE FAULT parameter Key in a value to define the longest acceptable stopping time allowed for the resolver When the resolver stopping time exceeds the programmed value a brake fault will be output and the error message STOP TI ME EXCEEDED will appear on
92. rounding BISCO sisi 20 Compatible Relays 9 Cane 20 Surge Suppressors ninni 10 Grounding Electrode Conductor 21 How PLS Channels Operate 10 Grounding Wires ences 21 How Die Monitor Channels Operate 10 Avoiding Grounding Problems 21 CHP 2 PLS Output Requirements Ground Loops ubi 22 G is PLS Output i1 Ground Shifts 23 onesie UtPUtS i High Impedance Grounds sui 25 Setting Up Your PLS Channels 11 Surge EMI Suppression 26 CHP 3 Brake Input Processing Incoming Powers 26 OVVIO lle 12 Inductive Loads siii 27 Brake Input Functions 12 Surge Suppression DC Outputs 27 Brake Monitor Function 12 Surge Suppression AC Outputs 28 Motion Detect Function 12 System Environment 29 Clearing a Brake Fault eee 12 20 Gear Drive Plymouth Ind Park Terryville CT 06786 3 ao Tel 860 585 1254 Fax 860 584 1973 http www amci com TABLE OF CONTENTS CHP7 General Installation CHP 10 Initial Tool Setup Guidelines continued Selecting a Tool Setup 49 System Layout Considerations 29 Select an Existing Tool Setup 49 Wiring Categories for Create a New Tool Setup 50 PRESSPro Genesis 29 Create a Tool Setup from Determine Proper Su
93. rrosion then ground cur rents will begin to flow through the cable shield Please remember that some of the ground current will always flow through the cable shield because the two resistances are in parallel It s only the percentage of current flowing through the cable that increases as the resistance of the conduit connections go up If the cur rent flowing through the shield is electrical noise it can then be coupled into the cable signals perhaps caus ing a signal fault If it is a large current such as a ground fault or a lightning strike induced pulse then the cable and controller may be physically damaged Two steps can be taken to minimize and prevent ground shift problems Do not ground sensor and communication cables at both ends Grounding the cable at one end is suffi cient The end of the cable that should be grounded is the one closest to where the sensor is powered Generally this means that cables will be grounded in the control enclosure Every transducer cable made by AMCI has the cable shields isolated from the transducer connector Properly install and verify all bonding wires on your system Bonding wires should be installed in con duits when there is a possibility of them being damaged Even though it s not applicable to the Genesis controller the same type of problem exists on communications ports that are not isolated Think of a machine controller that communicates with a supervisor display several hundred feet
94. s Figure 7 4 on the following page shows the ground shift problem on a large machine with two driven rods that are not properly bonded together 20 Gear Drive Plymouth Ind Park Terryville CT 06786 23 Tel 860 585 1254 Fax 860 584 1973 http www amci com NA GENERAL INSTALLATION GUIDELINES Avoiding Grounding Problems continued Ground Shifts continued O D Shields Transducer Cable Incorrectly Bonded Bonded to Earth at Controller to Transducer dia i Transducer Bonded to Machine Damaged Corroded or Missing Bonding Wire Induced Current Pulse Transducer Cable Damaged Corroded Electrode to Earth Missing Bonding Wire Electrode to Earth Resistance Resistance Figure 7 4 Ground Shift Example Large Machine When the cable shield is connected at both ends there are two paths to the Grounding Electrode System One is through the damaged corroded or missing bonding wire and one is through the transducer cable The effective circuit is shown below the diagram When a surge current occurs on one end of the machine a large percentage of the total current flow can be through the cable shield If the current is electrical noise it can then be coupled into the cable signals perhaps causing a signal fault If the current is a large fault current such as a ground fault or a lightning strike ind
95. s of conductors as possible gt Minimize the distance that conductors run in parallel with each other to minimize capacitive coupling gt If conductors must cross they should do so at right angles to minimize inductive coupling If you have a PLC in you system be sure to consider the spacing of the modules within the rack Do not place an AC output module next to low level DC input module unless absolutely necessary For example consider placing low level input modules on the left side of the rack high power AC output modules on the right side and medium power I O in the center This should help you maximize the spacing of I O wiring within the enclosure More often that not only one control enclosure is used in a project because of space or budgetary constraints If your application falls into this category it is imperative that you keep as much physical space as possible between the high voltage AC supply and the rest of the system The following figure shows an example of a problem installation and its fix This example is based on a real life implementation A m CONTROL ENCLOSURE A CONTROL ENCLOSURE a AC INPUTS CONDUIT N Sensor and Control Inputs AC phase voltage levels 2 AC INPUTS CONDUIT Sensor and Control Inputs AC phase voltage levels DO DC INPUTS CONDUIT DC INPUTS CONDUI
96. st be aware of when specifying R C networks When Contacts Close When Contacts Open Low Resistance Higher surge current through relay contacts 1 ower transient volta ge spike Positive High Capacitance to charge capacitor Negative High Resistance Lower surge current through relay contacts Low Capacitance to charge capacitor Positive Table 7 1 R C Network Trade offs Higher transient voltage spike Negative 28 ADVANCED MICRO CONTROLS INC GENERAL INSTALLATION GUIDELINES Ey Al Surge EMI Suppression continued Surge Suppression AC Outputs continued In general capacitor values range from 0 1 to 1 0 uF and resistor values range from 150 to 680 ohms AMCI supplies R C network surge suppressors that can be used with the controller in most cases They have a capacitance of 0 5 uF and a resistance of 220 ohms The easiest way to accurately specify a R C network is by following the recommendations of the load s manufacturer Most manufacturers have tested and specify standard R C networks and many sell networks that are designed to integrate with their products If you can not get help from your load s manufacturer feel free to contact AMCI for assistance System Environment When designing the physical layout of your system it is important to review the environment your control sys tem will be placed in This should include reviews of both the physical and electrical environments Check the quality
97. t s mounting studs See figure 8 4 Mounting the PRESSPro Genesis on page 37 for instructions on bonding a wire to a stud DO NOT UNDER ANY CIRCUMSTANCES ground both ends of the cable shield Doing so can from a ground loop that can damage the sensor or PRESSPro Genesis This will also prevent a ground shift from damaging the sensor cable or PRESSPro Genesis 20 Gear Drive Plymouth Ind Park Terryville CT 06786 41 Tel 860 585 1254 Fax 860 584 1973 http www amci com m INSTALLATION I O Wiring continued Stop Time Monitor Input Figure 8 12 shows a simplified schematic of the Stop Time Moni tor Input This AC DC input operates at either 110Vac 8 MA ng or 10 30Vdc 10 mA NOTE The PRESSPro Genesis does not require an input on the Stop Time Monitor to function correctly If you are not using this functionality do not connect anything to this input PIN ATTACHED TO CHASSIS OF UNIT Pin is an effective ground only if unit is grounded correctly Q z40 S vorm tr Wiring to the Stop Time Monitor Input is very similar to wiring the Die Monitor Inputs See figure 8 11 on the previous page for information on wiring a DC sensor to the input Note that Vdc or ground can be attached to either input pin and the input will still Zs work correctly E WwW e401 va ml LS Enable oe A Opt l When wiring the input to accept 110Vac the neutral conduc
98. t You cannot delete the tool that is currently being edited or viewed Trying to delete the current tool will cause the TOOL ALREADY IN USE message to be displayed 50 ADVANCED MICRO CONTROLS INC INITIAL TOOL SETUP Co Entering Configuration Data The Genesis software provides four screens that allow you to enter a variety of configuration data All the configuration screens are described in the following sections NOTE gt You cannot change the values displayed on any configuration screen in the View operation mode If V E W appears in the bottom left corner of a screen press FUNCTION followed by EDIT to enter the Edit mode Transducer Setup Parameters Screen 1 These parameters affect the position data reported at the bottom of each data screen You may enter trans ducer setup parameters on the first configuration screen as follows 1 Press FUNCTION followed by CONFIG to request the first configuration screen illustrated below CONFI GURE 1 OF 4 SF 1000 PRESET 0 DIR CW BI DI RECTION EDIT 2 P2357 SPM 0 Figure 10 2 Configuration Screen 1 2 When Configuration Screen 1 first appears the blinking cursor will be positioned on the value entered for the Scale Factor SF This parameter which defaults to 360 sets the position resolution for the Genesis controller Key in any value between 2 and 1000 counts per turn and press ENTER to move the blinking cursor to the PRESET value 3 The Preset Val
99. tor is ic typically attached to one of the pins and the hot conductor is Figure 8 12 STM Input Schematic switched through the load to the other If you cannot ground the shield of the cable at the sensor ground it at the Shield Ground pin of the connector DO NOT ground both ends of the shield Output Wiring Figure 8 9 I O Connector Placement found on page 40 shows the placement of the relays and the pinout of the output connectors The connectors are also labeled on the unit The relays support AC and DC loads When installing the cabling for the outputs all local and national codes must be followed Additionally Keep as much physical space as possible between output wiring and input wiring within the enclosure Do not place output wiring in a conduit with input wiring If you are using inputs you should have at least two conduits connected to the enclosure One conduit for the inputs and a second for power and the outputs Of course additional conduits may be necessary for your application Finally all inductive loads on the machine require surge suppressors especially those that are switched with mechanical relays Refer to Surge EMI Suppression starting on page 26 for additional information 42 ADVANCED MICRO CONTROLS INC CHAPTER 9 SOFTWARE INTRODUCTION This chapter lists the Genesis data screens and password access levels explains how to use the operator display and keypad describes the basic operating m
100. transducers are available on our website http www amci com If you do not have internet access contact AMCI and we will fax the informa tion to you 20 Gear Drive Plymouth Ind Park Terryville CT 06786 39 Tel 860 585 1254 Fax 860 584 1973 http www amci com gg INSTALLATION AMCI Transducer Mounting All AMCI resolver based transducers are designed to operate in the industrial environment and therefore require little attention However there are some general guidelines that should be observed to ensure long life gt Limit transducer shaft loading to the following maximums Bearing life is rated for a minimum of 2X10 rotations at these loads However loading should always be minimized The effect of shaft load ing on bearing life is roughly exponential Halving the load on a shaft will effectively quadruple the life of its bearings Radial Load Axial Load All 0 625 Shafts 100 Ibs 445 N 50 lbs 222 N All 0 375 Shafts 40 Ibs 133 N 20 lbs 66 7 N All Other Shafts 2 Ib 4 45 N 1 1b 2 22 N Table 8 1 Transducer Bearing Loads gt Minimize shaft misalignment when direct coupling shafts Even small misalignments produce large loading effects on front bearings Itis recommended that you use a flexible coupler whenever possible A flexible coupler is required for all HT 6 transducers and R11 resolvers IO Wiring Figure 8 9 is the rear view of the PRESSPro Genesis and shows the l
101. ts to Enclosure When designing the layout of you system be sure to include enough conduits to house the different categories of cabling To guard against coupling noise from one conductor to another follow the spacing guidelines in table 7 3 below These spacing values should be followed for routing cables both inside and outside of an enclosure Of course sometimes these guidelines cannot be followed such as when the connection points on a controller are spaced closer together than these guidelines recommend Category Guidelines 1 These conductors can be routed in the same cable tray raceway or conduit as machine power conductors of up to 600Vac Power conductors cannot feed larger than 100HP devices If they must cross power feeds they must do so at right angles Route in a raceway or conduit separate from all category 1 conductors and properly shield where applicable Any metal wireway or conduit that houses the conductor must be bonded along its entire length and bonded to the enclosure at its entry point If in a continuous metal wireway or conduit route at least 3 from category 1 conductors of less than 20A 6 from category 1 conductors of greater than 20A and 12 from any cate gory 1 conductor of any amperage of the circuit is greater than 100 kVA If not in a continuous metal wireway or conduit route at least 6 from category 1 conduc tors of less than 20A 12 from category 1 conductors of greater than 20A and
102. uced pulse then the cable may be physically damaged The figure below shows how the problem can occur on a smaller machine with a single grounding point Transducer Cable Bonded to Earth at Controller Conduit Bonding Machine to Enclosure Shields Incorrectly OCIA ET Bonded to Transducer Transducer Bonded oa Transducer Cable to Machine Pulse Damaged or Corroded Bond Electrode to Earth Between Machine and Enclosure Resistance Figure 7 5 Ground Shift Example Small Machine In this example the system is tied to the Grounding Electrode System at the control enclosure and the metal frame of the machine is grounded through conduits to the control enclosure The shields of a transducer cable are tied to ground at the control enclosure They are also tied to ground at the machine by being connected to the metal body of the sensor which is tied to the machine s metal frame The effective circuit is shown below the diagram 24 ADVANCED MICRO CONTROLS INC GENERAL INSTALLATION GUIDELINES Ey Al Avoiding Grounding Problems continued Ground Shifts continued The resistance of the conduit is the sum of the resistance of the conduit itself which is very low and the resis tance of the connections made between the conduit pieces such as those made at junction boxes and enclosure walls If one of these junctions is poorly made or begins to fail over time due to co
103. ue P RESET sets the initial value for the Machine Position This position is the angular position of the crankshaft reported at the bottom of each screen The Preset Value defaults to zero You may enter any value between zero and Scale Factor 1 and press ENTER Pressing ENTER on the Preset Value parameter changes the resolver position to the Preset Value 4 The Count Direction parameter DI R sets the direction the transducer shaft must rotate to increment the position count Press SELECT to toggle between the clockwise i W and counterclockwise C C W direction When the correct value is displayed press ENTER to move the cursor forward 5 When the blinking cursor is on BI DI RECT ON or UNI DI RECT ON press SELECT to toggle between these two values If setto BI DI RECTI ON the outputs will fire regardless of the direction of rotation of the crankshaft If set to UNI DI RECTI ON the output will only fire when the position value is incrementing provided that the crankshaft does not complete 180 of travel in the reverse direction 20 Gear Drive Plymouth Ind Park Terryville CT 06786 51 Tel 860 585 1254 Fax 860 584 1973 http www amci com 10 INITIAL TOOL SETUP Entering Configuration Data continued Counter amp Motion Parameters Screen 2 These parameters include a Counter Multiplier that allows you to multiply the part counter input and a Motion Detect parameter that may be used to select a motion
104. ust be installed on all AC loads that are switched by hard con tacts not just the loads driven by the PRESSPro Genesis relays The two most common suppressors for AC loads are varistors and R C networks AMCI strongly suggests R C networks for all AC applications A varistor is a solid state device that turns on and conducts when the voltage across its terminals exceeds its rated value Herein lies the problem with using a varistor as an AC suppressor The voltage problem must be generated before the varistor responds In our testing we have found that hard contacts will still arc when a varistor is placed across the AC load This arcing is due to the fact that the breakdown voltage of the air between the contacts when they first open can be less than the rated voltage of the varistor If the instanta neous AC voltage applied to the contacts is above the breakdown voltage of air but less than the rated voltage of the varistor the contacts will arc On the other hand an R C network acts as a low pass filter instantaneously dampening fast transients when they occur The main drawback of R C networks is that they are harder to correctly specify than varistors Varistors only require you to specify breakdown voltage and power dissipation ratings R C networks require you to balance the need of suppression when the contacts open against the amount of surge current the relay can tolerate when the contacts close Table 7 1 shows the trade offs you mu
105. vance value will force the output to turn on and off earlier in the cycle as a function of speed The CONTROLLER PROGRAMMING chapter starting on page page 55 provides detailed instructions describing how to enter the appropriate parameter values on Genesis data screens to control all of your PLS output channels Setting Up Your PLS Channels Before you begin to enter the appropriate PLS output parameters on Genesis data screens you should deter mine the number of channels required for your specific press control application The Genesis controller sup ports a total of six PLS channels Gather the information described in the following list to decide how to use each PLS channel to meet the needs of your application This list will also help you determine how to set up each channel 1 The function that will be performed by the PLS channel 2 Angular location of the ON and OFF setpoints 3 The type of limit switch output appropriate for the channel i e Normal if the output should be turned ON and OFF at pre programmed crankshaft positions or Timed to set up a timed output channel 4 Any advance data required to compensate for fixed delays in the system 5 If the output is Timed the correct time parameter to enter for the channel 20 Gear Drive Plymouth Ind Park Terryville CT 06786 11 Tel 860 585 1254 Fax 860 584 1973 http www amci com E n n CHAPTER z uao DOO BRAKE INPUT PROCESSING This chapter describ

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