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PRESSWATCH - Toledo Transducers

1. Analog Board 10 PW LS RV2 User s Manual Installation Conduit Hole Selection Follow Figure 1 3 to select the proper conduit hole for cabling The holes are for 74 conduit but they can be enlarged in the field if a larger fitting is required BOTTOM VIEW CONDUIT HOLES OO 1 2 3 4 AC Line e Shutdown e Resolver e Tonnage Sensor Relay e Serial Communication Analog Sensor Figure 1 3 Conduit Hole Selection DOC 16860 Page 11 T Toledo Integrated Systems PW LS RV2 User s Manual Installation AC Power Requirement With the proper jumper settings the PW LS can be powered by either 115 VAC or 230 VAC Factory set at 115 VAC The jumpers are located on the Power Board as shown in Figure 1 4 Figure 1 4 Power Board AC Power Jumper Settings 115 JumpersA amp B 230 VAC Jumper C Only DOC 16860 Page 12 Toledo Integrated Systems PW LS RV2 User s Manual Installation AC Power Connection AC power is connected to the PW LS as shown in Figure 1 5 Use Conduit Hole 1 see Figure 1 3 for the AC Power Wiring Use the proper fuse as indicated AC Power Connection L1 HOT L2 NEUTRAL e Fuse Slow Blow _ E ee 7 G GROUND e 50A 250V esee J7 Figure 1 5 Power Wiring DOC 16860 q Toledo Integrated Systems Page 13 PW LS RV2 User s Manual Installatio
2. sai 59 Calibration Information Label 63 Operator S G lden s susan Su ne pata n ad nosed ak aQ mana na aane au ma Da medet 65 APPENA Zaa ka ees 2 Ea V CUNG et I HC ua ut o ld 67 A Sensor Installation Doc 11080 erret 67 B Calibration Sheets 2 Form 1224 I 67 DOC 16860 Page qi Toledo Integrated Systems PW LS RV2 User s Manual Installation Table of Figures Figure 1 1 Figure 1 2 Figure 1 3 Figure 1 4 Figure 1 5 Figure 1 6 Figure 1 7 Figure 1 8 Figure 1 9 Figure 1 10 Figure 1 11 Figure 1 12 Figure 1 13 Figure 1 14 Figure 1 15 Figure 1 16 Figure 2 1 Figure 2 2 Figure 2 3 Figure 2 4 Figure 2 5 Figure 2 6 Figure 2 7 Figure 2 8 Figure 2 9 Figure 2 10 Figure 2 11 Figure 2 12 Figure 2 13 Figure 2 14 Figure 2 15 Figure 2 16 Figure 2 17 Figure 2 18 Figure 4 1 DOC 16860 Mounting qe PIE 9 epe u z u ta amana heads bead odes Len Cd qe eed bad 10 Conduit Hole Selection 2 2 22 rec nete reet coe 60 11 Power Board AC Power Jumper Settings 12 AC Power WIFInmQ uu nikon ud ven uit ien nente 13 Tonnage Sensor Input
3. Toledo Integrated Systems PW LS RV2 User s Manual Operation To load a new job manually click on the desired job the new job will become highlighted in the list and select Load Existing Job Notice the job number and name will update along with the historical text box If the loaded job is new or has not yet been learned a message will appear notifying the user that no available signature is available Once the job has been successfully learned a saved signature and folder will be created for the job To learn a job simply select Learn from the tonnage page once the new job is loaded This will automatically calculate setpoints based on 8 strokes The external job folder is located in the SlimWare installation directory Normally this path is C Program Files Toledo Integrated Systems SlimWare ExtData f the installation path is changed during installation the above path should be modified to show that change To view the INI file structure type view the External Configuration Files section on page 56 for all external file type structures Edit Existing Job e SlimWare allows for users to edit job parameters while the job is not loaded By selected the Edit Existing Job tab a list of all previously saved jobs excluding the currently loaded job will appear Click on the desired job and the setpoints standard and enveloping will load e Edit any of the job parameters and select Save Job Settings This
4. essen 15 Tonnage Sensor Cable Stripping 16 Tonnage Sensor Wiring uoce nee heme eee kee need 17 Resolver Input Descriptions 18 Resolver Master Mode Wiring 19 Resolver Slave Mode WiIriNG ccccccceccceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeess 19 Analog Output WING EROR 21 Shutdown Relay Wiring sts6ct 500 60 cence 22 Reset Te afro TE 23 Probe Input WINO iz denis fd eon Nadal ended 24 Probe Timing DIagralri oec ection adc ack 24 ue 25 Communication Error 22 2 26 Communication Error Historical Data 26 SlimWare Main Window ede tete o e on en on ol On 27 Tonnage SCO 29 Signature SCreeri soe ls cc Lt Loto Lt Lt dd dd dd du 32 Statistics OCT OG Mice u at cena m cee eto cess cevtcenecestcenecestcenecestcevecestceneceues 35 Selpoints Staridard SOreeri 2 erectio tessera ge eL DI Ora RE REO ERU I URDU 36 Setpoints Envelope Screen a 39 Conf
5. Signatures are not available when using a threshold trigger The threshold textbox is the tonnage value at which the PW LS unit will start to monitor If the threshold method is not selected this textbox is not editable e Resolver The standard method Use this method when a resolver is wired into the position input on the PW LS unit resolver position textbox is read only and displays the current resolver angle The maximum press speed with a resolver trigger is 1200 spm The resolver offset textbox allows users to enter the desired offset angle to obtain the correct resolver angle Valid offset angles range from 0 359 e Probe The probe method can be wired so that an input signal can trigger the monitor to start and stop monitoring maximum press speed with a probe trigger is 2000 spm Signatures are not available when using a probe trigger e Change Password Press the button to change the passwords for master setup or operator users Select the desired type of user from the top radio buttons and select Enter once a new password has been entered e Capacity The capacity settings for the unit should be set during initial startup and should not be changed thereafter Changing the capacity will affect all other setpoints DOC 16860 Page 46 T Toledo Integrated Systems PW LS RV2 User s Manual Operation Alarm Settings Alarm settings can be configured from the alarm settings page Belo
6. s in the upper right hand corner of the SlimWare window will not be flashing and a communications error will appear near the top of the screen as well as in the historical data box See Figure 2 2 and Figure 2 3 for examples of a communications error Communication Error Figure 2 2 Communication Error Alert Figure 2 3 Communication Error Historical Data Box See Comms Network Configuration on page 48 for a more detailed explanation of establishing communications between SlimWare and the PW LS monitor DOC 16860 Page 26 Toledo Integrated Systems PW LS RV2 User s Manual Operation Main Window Slimware Version 5 1 0 0 Signatures Statistics Setpoints Configure Figure 2 4 SlimWare Main Window The main window is always displayed regardless of what page a user is on The main window includes all of the navigation buttons resolver angle strokes per minute job number and name status bar and the historical data log Also displayed in the top left hand corner of the main window is the SlimWare version number and username if logged in e Status Bar A Displays the current status of the PW LS unit If an alarm is detected the status bar will flash red and white and display the highest level alarm To reset an alarm a user can simply click on this bar while alarmed e Indicator Lights B In the top right hand of the SlimWare windows are two 2 yellow LED s These LED s mirror th
7. Channel 0 High Channel 0 Low Channel 1 High Channel 1 Low Channel 2 High Channel 2 Low Channel 3 High Channel 3 Low Channel 4 High Channel 4 Low Position 20 20 20 20 20 20 20 20 20 20 14 170 190 220 284 p rp peces mj manj v Figure 2 9 Setpoints Envelope Screen Envelope Setpoints Tonnage Signatures Statistics Configure Enveloping allows for a form fitting curve through the entire press stroke Enveloping goes above and beyond a simple high and low setpoint by calculating different high and low limits throughout each degree of the press stroke With the PW LS unit five 5 envelope zones can be calculated allowing for different high and low tolerances throughout certain windows As seen in Figure 2 9 the enveloping setpoints for each zone are set by a degree based value Each window can be configured by entering the desired degrees To bypass a zone simply enter the same value as the previous zone For an eight 8 channel unit toggle between the slides by using the tabs near the top of the screen DOC 16860 T Toledo Integrated Systems Page 39 DOC 16860 PW LS RV2 User s Manual Operation Channel High and Low e These are the percentage values above and below the benchmark us
8. For a double action press this is the total capacity of the outer slide Capacity CH5 The total capacity associated with load sensors 6 9 For example in the case of a double action press where sensors 6 9 are used to measure the load for the inner slide the CH5 capacity is the total capacity for the inner slide For a single action press this will be blank Calibration Numbers Record each channel s Calibration Number from step 10 of the Calibration Procedure here DOC 16860 Page 63 Toledo Integrated Systems PW LS RV2 User s Manual Calibration Information Label 8 Time Mode If the monitor is configured to use one of the time modes B4 Mode First Level Second Level or Point in Time write the mode here If the standard setting of Normal Peak is used write Normal or simply leave this blank A Value If the monitor is configured to use one of the time modes B4 Mode First Level Second Level or Point in Time and is triggered by threshold or probe write the capture time value in milliseconds here B Position If the monitor is configured to use one of the time modes B4 Mode First Level Second Level or Point in Time and is triggered by resolver write the capture position in degrees here 9 Thres Value If the trigger method is set to Threshold record the Threshold value here If the trigger method is set to probe or resolver the threshold value is not applicable 10 Resolver If the trigger met
9. RUN SENSOR CABLE THROUGH CONDUIT PLACE SENSOR ON MOUNTING HOLES PLACE ANTI TORQUE WASHERS OVER SENSOR HOLES SCREW IN SENSORS BOLTS 4 EACH FINGER TIGHT USE ONLY THE 1 4 28 x 3 4 LOC WEL BOLTS THAT ARE IN THE SENSOR PACKAGE TORQUE EACH 1 4 28 3 4 SCREW TO 150 LB IN OR 12 5LB FT ASSEMBLE BOX COVER d KU NIRE n LOAD CSS MODEL T400 S N x 7 gt T400 INSTALLATION CONDUIT PAGE 7 TOLEDO TRANSDUCERS INC PRESS CALIBRATION TEST DATA HOLLAND OHIO U S A COMPANY DATE PRESS SERIAL No PRESS Type and amp No CONTACT PRESS CAPACITY PHONE LOAD MONITOR MODEL SERVICE ORDER CC MONITOR SERIAL No SLIDE ADJUST INDICATOR LINEARITY PLOT USING TONS SHOWN ON TOTAL DISPLAYS TOTAL LOAD DISPLAYED ON MONITOR L J _ Jl p e TOTAL TONNAGE APPLIED TO LOAD CELLS ON PRESS F1224 Rev A DRAW IN e CHANNEL NUMBER e SENSOR LOCATION e MONITOR LOCATION e LOAD CELL LOCATION e DIRECTION OF MATL FLOW SHUNT RESISTORS ONE MEG YES NO OTHER RESISTORS CHAN 1 ____ CHAN 2 CHAN 3 4 OF LOAD CELLS _ MATERIAL FLOW draw arrowhead FRONT OF PRESS BED TYPE OF LOAD CELL READOUT TONNAGE SENSORS CALIBRATION LOAD CELLS CAPACITY TONS SERIAL NO CCMOFFSET _ STI DEGRE
10. logged in Setting this option will override the operator personnel reset alarm option External Job Data and Management This allows for a third party program to be used with SlimWare For example if using a SCADA program this option would be checked By checking this option the Login Logout button becomes invisible and the external application button becomes visible Users must now login logout with INI files see the External Configuration Files section on page 56 for INI descriptions and instructions Data Alarm And Logging Checking this option will log all events from the event viewer window to a text file This file is stored in the program installation folder default location C Program Files Toledo Integrated Systems SlimWare If this log file becomes larger than 2GB the oldest record will be deleted and the most current records will be added e Signature Analysis Automatic Hard Hit Save This option allows for SlimWare to automatically save the current alarm signature to a file every time a hard hit occurs The file is stored in the C Program Files Toledo Integrated Systems SlimWare HardHit directory Automatic Signature Retrieval This option allows for SlimWare to automatically request a signature every 60 strokes if the signature page is loaded Show Setpoint Markers On Graph Checking this option will display the high and low setpoint markers on the signature s These markers are designated by yellow lines
11. 876 146 167 192 176 Sises Last High Alarm 676 19 Last Low Alarm 286 100 se Capacity Alarms 0 0 Figure 2 7 Statistics Screen Alarms 0 High Alarms Low Alarms Reverse Alarms Figure 2 7 shows a typical four 4 channel PW LS unit s historical statistics If the user is not logged in with a setup or master password these statistics are read only If logged in with a setup or master password these values can be cleared by pressing the button for the corresponding alarm row For an eight 8 channel unit toggle between the slides by using the tabs near the top of the screen e Highest Load Displays the highest recorded tonnage per channel e Lowest Load Displays the lowest recorded tonnage per channel e Last Alarm The last recorded alarm any type per channel e Last High Alarm The last recorded high alarm per channel e Last Low Alarm the last recorded low alarm per channel e fi Capacity Alarms The number of capacity alarms recorded per channel e CCM Alarms The number of CCM alarms recorded per channel e High Alarms The number of high alarms recorded per channel e Low Alarms The number of low alarms recorded per channel e Reverse Alarms The number of reverse alarms recorded per channel DOC 16860 Page 35 Toledo Integrated Systems PW
12. A Make sure the press is under no load B Navigate to the Configure Calibration screen C Press the Enter Track Mode button to display the balance for the tonnage sensors D Press the Initialize Auto Zero button The Gain Balance fields for each corner should read close to zero If not press the Initialize Auto Zero button once more If the corners still will not zero press the Reinitialize button to reset the internal Analog to Digital circuits then try the Initialize Auto Zero button again If one or more corners still will not zero check the sensor wiring page 14 and the mounting on the press see Appendix A for sensor installation instructions 3 Find the Shut Height of the Press A Jog the press until the ram is at bottom dead center BDC or 180 without any load cells or die in the press B Determine the amount of spacers needed with your load cells Cycle the press without load cells to insure correct height 4 Place the Load Cells in the Correct Position in the Press A All load cells should be equal distance from the sides and front and rear For example 12 from the sides 10 from front and rear Load cells are typically placed at each corner of the press s bed B Cycle the press without hitting the load cells first C Place cardboard on the top and bottom of the load cells DOC 16860 Page 59 q Toledo Integrated Systems PW LS RV2 User s Manual Calibration Procedure 5 Cycle the Pres
13. LS RV2 User s Manual Operation Setpoints Slimware Version 5 1 0 0 Logged in as Master Standard Setpoints Outer Envelope Setpoints Outer cm Tonnage Total Left Rear Left Front igh Setpoint 387 164 126 364 139 124 Statistics Benchmark 322 High f Configure Low Reverse Tonnage 4 Figure 2 8 Setpoints Standard Screen The setpoints page displays and configures the PW LS unit s alarm setpoint values From this page setpoints such as high and low setpoints high and low benchmark percentages and reverse setpoints can be altered Capacity settings are read only on this page and can only be changed from the configure screen Figure 8 1 shows a typical four 4 channel PW LS unit setpoint screen If the user is not logged in with a setup or master level password these setpoints are read only If a user is logged in with a setup or master password these values can be changed For an eight 8 channel unit toggle between the slides by using the tabs near the top of the screen DOC 16860 Page 36 Toledo Integrated Systems PW LS RV2 User s Manual Operation Standard Setpoints High Setpoint e The high setpoint value will stop the press when peak tonnage is above this value e The high setp
14. TO ONLY WELD THE WELD PADS ON THREE SIDES AS SHOWN A single pass is sufficient Do not remove the fixture until slag is removed and or assembly has cooled When welding cast iron use a dry nickel rod such as Lincoln Electric Soft Weld Hobart NI Cast 99 or MB Weld Prod MG 210 Strike arc on steel then puddle into the cast iron Remove the weld fixture DO NOT WELD AFTER FIXTURE IS REMOVED The 4 screws holding the pads to the fixture and the 1 center screw may be discarded DO NOT USE THE FOUR 1 INCH LONG SCREWS TO ASSEMBLE SENSOR The sensor kit contains four 34 inch long screws for assembling the sensor to the press member Weld pad surface must be clean no weld bumps scratches etc Be sure the weld pad tapped holes are clean and bottom of holes are free of weld flash Mount the sensor with the raised rib to the press The anti torque washers should go between the screw and the sensor body Torque each 4 28 x in long socket head screw to 150 LB IN or 12 5 LB FT PAGE 6 SENSOR ENCLOSURE MOUNTING USE 10 32 TAP IN THE TWO 3 8 DEEP HOLES THAT WERE DRILLED WITH THE FIXTURE IN THE PREVIOUS INSTRUCTIONS MOUNT THE ENCLOSURE TO THE PRESS MEMBER AND RUN 1 2 INCH CONDUIT TO THE LOAD MONITOR ENCLOSURE gem cc m E TAP THESE HOLES WITH 10 32 TAP E Uem Sue 10 32 x 3 8 PAN HEAD MACHINE SCREW 1 4 28 x 3 4 SOC HD SCREW SENSOR ENCLOSURE 24 Doc 11080 Rev A
15. be placed in setup for the beginning or end of runs Setup mode is not recommended for normal production use as several alarm modes are bypassed Learn Mode e Requires Setup or Master password e Press the Learn Mode button in the bottom left hand corner to place the PW LS unit into learn mode Learn mode will run for seven 8 strokes During these eight strokes the PW LS unit will calculate new high low and reverse setpoints as well as a new benchmark for each channel e When the learn mode button is pressed a dialogue box will appear prompting the user to confirm that learn mode is desired This is to prevent users from accidently entering learn mode and learning new benchmarks e The PW LS unit will come out of learn mode automatically after eight 8 strokes e The learn mode button is only available for users with a setup level password or higher Reverse Tonnage e Press the Reverse Tonnage button to display the reverse tonnage for each channel e Even with reverse tonnage displayed the monitor will function as in normal mode all alarms will be monitored This button is available for all users e To return to normal mode simply press the Reverse Tonnage button and the normal tonnage will be displayed Zero Display e Press the Zero Display button to clear the displayed tonnage e This is mostly used in the initial setup of the PW LS to make sure communications are correct and the tonnage values ar
16. e Point In Time With this mode enabled every stroke of the press will display the loading at the desired point in time value e Hardware Configuration e Channels The number of channels the PW LS unit is to monitor normally four 4 channels e Decimal Place Sets the digits to the right of the decimal point to be displayed e Capture Settings Position Used with modes other than normal peak this is the position resolver based that the load will be captured Time Used with modes other than normal peak this is the amount of time the peak hold circuit is monitored once the position has been crossed e Job Settings e Due to the fact that jobs can be stored under job numbers or job names SlimWare allows for users to select which method of storage is to be used To change any of the job settings listed below click on the drop down box and select the desired method The changes are automatically saved e Job Lookup ID If jobs are normally called by numbers select Number from the drop down box If job names are used select Name e Save When changing setpoints standard or enveloping to a loaded job the changes can be Always saved Prompted before saving Never saved dismissed e Level As an extra level of security a login level can be required to perform job changes Select the lowest level of user desired for job changes from this list All levels above the selected level will also be allo
17. on the graph e Slide Names Each slide can be configured for a specific name Type in the desired name and press Enter to save the name to the desired corner DOC 16860 Page 42 qi Toledo Integrated Systems DOC 16860 PW LS RV2 User s Manual Operation External Application Hotkey External App Checking this option will enable the external application button near the top right of the screen This button is used to call a third party program to the front Label input the name to be shown on the external application button App Name The name of the external application This name can be seen in the taskbar when the program is running Service This is the external applications service name The service name can be seen by right clicking on the taskbar and selecting Task Manager On the services tab of the task manager find the external applications service name Application Path This is the path to the exe of the external application Use the browse button to open a dialogue box to browse to the external program executable Page 43 m Toledo Integrated Systems PW LS RV2 User s Manual Operation Hardware Trigger The hardware trigger page contains the basic tonnage monitor features such as the monitor type number of channels corner capacity type of position instrument decimal place precision and enveloping mode Slimware Version 5 1 0 0 Logged in as Master Alarm Configuration Tonnag
18. to resolver Figure 1 10 Resolver Master Mode Wiring Slave Mode Wiring rss f MASTER ise SHIELD mm Do not connect SHIELD to PW LS PW LS AS TO SLAVE DEVICE RESOLVER Shielded Twisted Pair Cable e g BELDEN CABLE 8103 TT 2038 222 Note TTI labels 51 53 and 52 54 as stator pairs but some manufacturers label 51 52 and 53 54 as pairs Pay attention to this when connecting the PW LS as a slave system Figure 1 11 Resolver Slave Mode Wiring DOC 16860 Page 19 T Toledo Integrated Systems PW LS RV2 User s Manual Installation Resolver Input Setup 1 Set all DIP switches to the OFF right position 2 Determine whether the resolver input should be in MASTER mode or SLAVE mode and make the proper setting Master Mode Slave Mode 3 Make resolver connection 4 With the system on press can be either running or not running check to see if the LED turns on Scale down the rotor input voltage by 4X if the ROT LED does turn on No Scale Scale Down 4X 5 With the press running check to see if the STAT LED turns on If it turns
19. tonnage monitor that does more than protect your press and dies from hard hits The PW LS allows for 5 levels of alarms Capacity CCM High amp Low Setpoint High amp Low Envelope and Reverse Setpoint Each alarm type can be enabled bypassed and configured for top or immediate stop Another feature of the PW LS is to provide users with signature based tonnage analysis These signatures are extremely helpful in determining problems in the forming process Problems can include excessive tonnage through the stroke loose tie rods low nitrogen cylinders or reverse strike through tonnage SlimWare is able to monitor and control all features included with the PW LS unit DOC 16860 Page 25 T Toledo Integrated Systems PW LS RV2 User s Manual Operation Initial Startup The initial communications settings are as follows e Baud Rate 460800 e Serial Port Com5 e Address 0 If the Panel PC PW LS is set for different communication settings the settings must be manually configured from the Configure Comms Network screen see page 48 SlimWare will start automatically upon boot up It can also be manually started by either double clicking the shortcut on the desktop or by the following Start gt gt All Programs gt gt Toledo Integrated Systems gt gt SlimWare gt gt SlimWare To determine if communications have been established between SlimWare and the monitor start SlimWare If there is no communications the yellow LED
20. warranties of merchant ability or fitness for a particular purpose All such warranties are hereby disclaimed and excluded by the manufacturer Repair or replacement of defective products as provided above is the sole and exclusive remedy provided thereunder The manufacturer shall not be liable for any further loss damages or expenses including incidental or consequential damages directly or indirectly arising from the sale or use of this product Any unauthorized repair voids this warranty There are no warranties that extend beyond those expressly set forth herein DOC 16860 Page T Toledo Integrated Systems PW LS RV2 User s Manual Installation Features Overview The PressWatch LS Series is a press tonnage monitor with signatures It integrates tonnage monitoring and signatures with enveloping into ONE system It features a large 10 4 touch screen interface making the tonnage and signatures easy to read and access PRESSWATCH Production Monitor with Signatures LS Series Toledo Integrated Systems Holland OH Made in USA FEATURES e 20r4 channel tonnage monitoring e Hard Hit signature storage e Reverse tonnage e Job storage e Signatures each press corner and total e 3 password levels e 5 signature zones for enveloping e PressNet 5 compatibility e Critical Curve Monitoring OPTIONS e Additional 2 or 4 channels for tonnage e TR 1 Resolver monitoring or analog input DOC 16860 Page 5 T Toledo Integrated S
21. will save the setpoints to the desired job The changes will be reflected next time the job loads Create New Job DOC 16860 e To create a new job select the Create New Job tab The window below will load Load Existing Job Edit Existing Job Create New Job Dele Job Number Job Name Description Figure 2 16 Create New Job Page 54 Toledo Integrated Systems PW LS RV2 User s Manual Operation Enter the desired job number job name and description for the new job and select Create New Job The newly created job is not loaded just created It is created with the current setpoints that are stored in the PW LS unit the current job loaded To load the new job select the Load Existing Job tab The recently created job will be listed Click on the new job and select Load Existing Job The new job will be loaded If the setpoints of the currently loaded job are not suitable once created follow the steps above for editing an existing job Delete Existing Job DOC 16860 To remove an existing job select the Delete Existing Job tab and highlight the job that is to be removed Once highlighted select Delete Job A message box will appear asking for confirmation select Yes to permanently remove the job from SlimWare Page 55 qi Toledo Integrated Systems PW LS RV2 User s Manual Operation External Configuration Files There are two 2 configuration files that control
22. 60 Page 23 Toledo Integrated Systems PW LS RV2 User s Manual Installation Probe Input The PW LS can be triggered by an external probe signal The probe supply voltage 12VDC is provided by the PW LS The figure below illustrates the wiring for a variety of sensing devices ON PROBE CLOSED OFF PROBE OPEN SOURCING PROBE SINKING PROBE PNP N O BRN 12VDC pee re NORMALLY OPEN CONTACTS NORMALLY CLOSED CONTACTS 1500 OHM RESISTOR 1 2WATT MINIMUM Figure 1 15 Probe Input Wiring The timing of the probe should be such that it turns on just before the machine begins generating a load typically at 140 and remains on until the load is removed typically at 240 Load Signal Probe Closed Trigger Probe UU 740 240 140 240 Probe Open Figure 1 16 Probe Timing Diagram DOC 16860 Page 24 Toledo Integrated Systems PW LS RV2 User s Manual Operation Operation Overview Toledo Integrated Systems SlimWare Signature Tonnage Software Toledo Transducers 1 800 TTOLEDO Ethernet Remote PC View Live Signatures amp Alarms TE T400 Strain Gage Figure 2 1 System Overview The PW LS uses our exclusive SlimWare HMI Human Machine Interface software SlimWare can provide and monitor all information stored in the PW LS including tonnage setpoints alarm history and signatures tonnage curves The PW LS is a powerful
23. 7 749 WELD PAD METHOD FOR MOUNTING SENSORS BE SURE THE SENSOR LOCATION FOLLOWS THE BEST LOCATION DESCRIBED ON THE PREVIOUS PAGES STEP2 3 DRILL 4 4 28 TAP ROTATE FIXTURE STEP 3 90 DEGREES 54 XX CU Sc 4 4 28 X 1 1 4 SCREW 21 DRILL TWO SMALL CENTERED HOLES FOR ENCLOSURE STEP 4 144 28 X 1 SCREWS 114 28 X 1 1 4 SCREW rx Zu SS C WELD EACH PAD ON THREE SIDES ONLY STEP 5 ANTI TORQUE Ze WASHERS 114 28 x 3 4 LOC WEL BOLTS PUT RAISED RIB TO PRESS Doc 11080 Rev A STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7 T400 INSTALLATION Remove all paint grease and or rust from surface to be welded Surface should be flat T I R 1 32 of an inch Drill and tap the center hole for mounting the fixture to the press member This hole should be inch deep Optional Bolt the fixture to the press member using the 4 28 by 1 inch long socket head cap screw in the center of the fixture Orient the fixture as shown and drill out the 721 holes to a depth of 3 8 of an inch for the enclosure mounting The fixture is not used for tapping these holes Optional Remove the fixture from the press member Bolt the weld pads to the fixture with 4 28 by 1 inch long socket head cap screws provided Reattach the fixture with the weld pads bolted on using the center hole as in Step 3 Orient the fixture as shown Weld the weld pads to the press member BE SURE
24. Drill and Tap Method of Installing Sensors Page 5 Weld Method of Installing Sensors Page 6 T400 Enclosure Mounting Details Page 7 Doc 11080 Rev A T400 INSTALLATION PAGE 1 NOISN3 L SSANMOIHL LNO J NOISS3HdlNOO SSANMOIHL E Uoisue Jo pe su sBuipeaJ uoisseJduuoo JO uonoeuuoo jndui y aee y u Josues eu si SSAUYOIU JUOI OU JI sow y SI siu 3u0JJ eui ui sjosues yUNOW Us uey s sseuxolui 3u0JJ eui Jl INOHJ SSANMOIHL LNO4 AHL 33 SV3IN gt X AAYHL AP AIdILINW SSANMOIHL 3H L AYNSVAW x NOILVO2O T 1539 AHL ANIWYALAG OL MOH ease pepeus au Ul UMOUS sseJd eu JO JeeJ y JO UOJ y suoneoo peuiuuejep eq jsnuJ uoneoo Josuegs IN3IN3OV ld YOSNAS S310H LNO MOONM JHL NI SJ3IT3M NIVMLIS 2 1 9NISn LS3SSnS 3M aasn SI LINGNOO dl S3 10H LNO MOON ANIONI SAYNSOTONS 3S3HL SAONVD 5 00 1 IHL 1O31OMd SSSHL SAYNSOTONA HOSN3S 2 z qaasinoas SHOSNGS 2 L SALON PAGE 2 T400 INSTALLATION Rev A Doc 11080 31S O8 HO NMOSWO JHL WO H LGIM NWN109 1 NVH L H39S019 SHOSN3S SNI1VOO1 3181SSOd 41 S3SVO 11 NI 3AO8V Qdardosad SV Sd OH GIOAV NOILOAS 80049 1SV31 40 VAYV NV NI SHOSN3S TIVLSNI edssSdtd AAV3H AHSA HO
25. ERIAL FLOW draw arrowhead FRONT OF PRESS BED TYPE OF LOAD CELL READOUT TONNAGE SENSORS CALIBRATION LOAD CELLS CAPACITY TONS SERIAL NO CCMOFFSET _ STI DEGREES IN CHANNEL No 1 STI REFERENCE NUMBER LOW ____ TRIGGERED FROM PROBE YES NO TRIPPED ALARM RELAY STOPS PRESS YES _ ALL STICKERS AND DOCUMENTS FILLED OUT YES NO IF NOT EXPLAIN WHY __ No HIGH2 LOW 2 COMMENTS HIGH4 LOW 4____ Show threshold value if not triggered from probe HIGH NO EXPLAIN HGH6 ___ LOW6 HIGH8 LOW 8 TESTS MADE BY MAIL ADDRESS TOLEDO TRANSDUCERS INC P O BOX 10 HOLLAND OHIO 43528 TESTS ACCEPTED BY SHIPPING ADDRESS TOLEDO TRANSDUCERS INC PHONE 1 419 867 4170 6834 SPRING VALLEY DR FAX 1 419 867 4180 HOLLAND OHIO 43528
26. ES IN CHANNEL No 1 STI REFERENCE NUMBER LOW ____ TRIGGERED FROM PROBE YES NO TRIPPED ALARM RELAY STOPS PRESS YES _ ALL STICKERS AND DOCUMENTS FILLED OUT YES NO IF NOT EXPLAIN WHY __ No HIGH2 LOW 2 COMMENTS HIGH4 LOW 4____ Show threshold value if not triggered from probe HIGH NO EXPLAIN HGH6 ___ LOW6 HIGH8 LOW 8 TESTS MADE BY MAIL ADDRESS TOLEDO TRANSDUCERS INC P O BOX 10 HOLLAND OHIO 43528 TESTS ACCEPTED BY SHIPPING ADDRESS TOLEDO TRANSDUCERS INC PHONE 1 419 867 4170 6834 SPRING VALLEY DR FAX 1 419 867 4180 HOLLAND OHIO 43528 TOLEDO TRANSDUCERS INC PRESS CALIBRATION TEST DATA HOLLAND OHIO U S A COMPANY DATE PRESS SERIAL No PRESS Type and amp No CONTACT PRESS CAPACITY PHONE LOAD MONITOR MODEL SERVICE ORDER CC MONITOR SERIAL No SLIDE ADJUST INDICATOR LINEARITY PLOT USING TONS SHOWN ON TOTAL DISPLAYS TOTAL LOAD DISPLAYED ON MONITOR L J _ Jl p e TOTAL TONNAGE APPLIED TO LOAD CELLS ON PRESS F1224 Rev A DRAW IN e CHANNEL NUMBER e SENSOR LOCATION e MONITOR LOCATION e LOAD CELL LOCATION e DIRECTION OF MATL FLOW SHUNT RESISTORS ONE MEG YES NO OTHER RESISTORS CHAN 1 ____ CHAN 2 CHAN 3 4 OF LOAD CELLS _ MAT
27. NOSAL QI ZSZ 0FZ H3HSVM 30801 ANY 318VO 3n0HOL NO ALISOddO S33493G0 08 31001 GaYINDAY SHOSN3S OML HOSN3S GVO100r1 KINO 33H H3HSVM 3010801 318VO wA PAGE 4 T400 INSTALLATION Doc 11080 Rev A USING THE T400 SENSOR INSTALLATION FIXTURE KIT No 1977 749 METRIC INSTALLATION FIXTURE KIT No 1974 749 DRILL AND TAP METHOD FOR MOUNTING SENSORS BE SURE THE SENSOR LOCATION FOLLOWS THE BEST LOCATION DESCRIBED ON THE PREVIOUS PAGES 3 DRILL STEP 2 QM mm i 2 1 4 28 6 1 3 DRILL 5mm X DRILL THROUGH FOUR SMALL HOLES STEPS 34 1 4 28 X 1 1 4 SCREW METRIC 6 1 X 35 ROTATE FIXTURE 90 DEGREES 2041 STEP 5 O 21 DRILL C lt DRILL THROUGH THE TWO SMALL CENTERED HOLES ROTATE FIXTURE 90 DEGREES S1 4 28 STEPS 6 7 METRIC 6 1 TAP THROUGH FOUR LARGE HOLES _ ANT TORQUE lt WASHERS STEP 9 1 4 28 x 3 4 LOC WEL BOLTS PUT RAISED RIB TO PRESS Doc 11080 Rev A STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7 STEP 8 STEP 9 T400 INSTALLATION Remove all paint and grease from sensor mount area If the machine surface is flat total indicated reading of 002 and smooth 125 in the load sensor can be bolted directly to the surface Drill and tap the cent
28. PRESSWATCH Load Signature Series Production Monitor By Toledo Integrated Systems User s Manual 16913 PW LS RV2 User s Manual Installation PressWatch Load Signature Series RV2 Load Monitor User s Manual Revision A DOC 16860 Page 1 Toledo Integrated Systems PW LS RV2 User s Manual Installation Table of Contents Limited Warranty coop EUN NUN UN UNE NUN NND DN NUN UI 4 F at r S OVEIVIEW M 5 SDGOCIITGAHOFS mdi ndn d pU DU ADR ADU DU INI DM e DU Qul Pid oqa Din 7 2 m Sy Seb pa eode pd perito tort ed pu cpi Moo up ipod pi ton d pdt ice a smua ss 9 Mountndg the PASS set estet Gey ut cet cei cei cent cet cet cee tente te ttente ttm lente teretes 9 PW LS Componernts Des dtu es 10 Conduit Hole Selection aa a o REA de 11 AG Power Requirement u 2 12 AC Power COMMECHON pe roro t po Speo ec Mord puer to 13 Tonnage Sensor Connection 14 Resolver Connection a a EMI EN 18 Resolver uu c Sp oe hasa PP 20 PAG Output s M u ET 21 Shutdown Relays aed id nana Da id na na S nd aa na R
29. S3SSdud 3I VH LSVO EWNHL dO JINN agg 315709 1 l AWVds 5544 AHL NI LNO LNO JVH L S31OH 3HL dO 3903 WOLLOS HO 3903 dOl JHL INO Z NVHL 3S0 19 SHOSN3S ONITIVLSNI GIOAV 55 dive TIVM 3 18no d V SI LI di AWVes TIVM SS3Md 3GISNI SHL NO SHOSN3S TIVLSNI 318ISSOd 31 18 1 LHOlddN 38 TIM 39NVIAHO Hd NIAN YTIOO AO SLI Y31139 COM SIL 1 OL SI HOSN3S V H3SO IO JHL 1 4 qou 311 3H1 dO ANIM Y3LN39 AHL NO 1 NAN109 dO H19N31 L AHL NI SI NOLIVOO I HOSN3S 1539 LH IYdN SS3ud JO gt s LL SYNSOTONA 8 SONIN3dO ONILVAH 211 YVAN LINGNOO LON OG NOILOVO AINO S38IM HOSN3S QVO LINGNOOD LAN GO JIL PAGE 3 T400 INSTALLATION Rev A Doc 11080 SHOSN3S HLO8 MOHS OL MIIA ONISNOH LN3ALLSRfGV JANS WVH 3Qri ONIAOW 3HL dO LNO NAHL Waal 1 LXAN OL LINGNOOD 2 JN3MWLSnfrav adris OL ANd SSAOW AHL N3HM Q3Q33N MOVIS d 18V9 SI dOO138n 1 AHL ALON 242 lt A y L817 HO KELLY NI 1 0S OL 1108 HOSNAS vIe x 8c vl HOV3 ANODOYOL H3WNO1Sn29 XO8 NOILWNINYAL SEN ZGZ SOPT 3d LAN HLIM HOLO3NNOO 43I NIVHIS C88 SLYC H ALON SAS ONIGNL
30. Send Gain Relnitailize Hardware Alarm Comms Trigger Settings Network a 3 Dea Figure 2 14 Configure Calibration Screen e Current Tonnage Displays the current tonnage from the PW LS unit e Load Cells User input of the displayed tonnage from the calibration load cells AutoCells e Current Balance Gain Depending on the mode and stage of calibration the monitor s balance zero or gain shunt e Desired Gain User input of the new desired gain values DOC 16860 Page 51 Toledo Integrated Systems DOC 16860 PW LS RV2 User s Manual Operation Enter Track Mode Puts the PW LS monitor in Track mode This mode is used for calibration purposes The monitor will not update its peak tonnage while in track mode To exit track mode simply press this button again Initialize Auto Zero This zero s the balance of the PW LS monitor Track mode must be enabled to auto zero the unit Display Gain Values Once the monitor is in track mode press this button to display the current gain values stored in the monitor These values will be displayed in the Current Balance Gain Values textboxes Calculate Used during the calibration process pressing this button will automatically calculate the desired gain values based on the current tonnage and load cell values Once calculated the values are automatically sent to the PW LS monitor Send Gain Values This button will send the desired gain
31. Settings There are 5 total configuration pages From these pages a user logged in with a master password can access such features as tonnage calibration user settings communication settings capacity values and alarm bypass settings Figure 2 10 shows the initial configure page settings Use the buttons near the bottom of the configuration window to navigate to the different configuration menus e Channel Names Each channel can be configured for a specific name Type in the desired name and press Enter to save the name to the desired corner DOC 16860 Page 41 T Toledo Integrated Systems PW LS RV2 User s Manual Operation e User Preferences Virtual Keypad Enabled by default this calls a keypad to the foreground when an alpha or numeric entry is required This is to be used when an external keyboard is not available touch screen applications If a keypad is not desired uncheck this option Setup Personnel Data Entry By checking this setup personnel are allowed to enter data including High Setpoints Low Setpoints Benchmark Percentage Setpoints Enveloping Setpoints Reverse Setpoints Operator Personnel Reset Alarms This option allows users logged in as an operator to reset alarms If operators should not be allowed to reset alarms uncheck this option Reset Alarms Without Password Checking this option will allow alarms to be reset regardless of the level of user logged in or when no one is
32. a SS 22 Reset Switch aa SERENA TT CAR EMEN SUE 23 Probe M Tv TU 24 E 25 OVO E 25 sans 2 E 26 VIG OW usse a un ato oben ipt nc nte S qam E asan a ano ied 27 IKINE e EAA Enc they beta hob ante 00 29 eni c M 32 Seis IF o MS 35 SPONS t ma Qa CEN 36 Standard Setpolliis scd u uma aa 37 Envelope uu Nd 39 Ren sic T EEE 41 SeffingSu pu c P 41 HardwarerTTiggel sd tun ete tn te tun tet tun tet rubet uut quouis 44 Alarm Settings cocotte diede od icd diced icd d cdd icd nd icd did d cdd d mue 47 COonms NelWOEG am code papel eei to ebd one 48 Penne nene 51 JOD Selle sooo itecto testem tecum cec Re et E 53 Load Exislirig MOD reote eto ondes 53 JOD eit et bt o Mt s t Mtt tte 54 Create 54 Delete Existing 2 2 26 ee as 55 External Configuration Files _ 56 u u
33. aded the overlay controls will become enabled Use overlays to compared previous good signatures to current signatures Open Selecting this control will load file dialogue box From here select either a SIG or SWS file to load as an overlay The overlay will be a light gray color in each channel Hide Once an overlay is loaded select the Hide control to hide the overlay View e The default view of the signatures page is all 4 corners shown in normal viewing mode Use the various buttons on the right hand side of the signature screen to enlarge one specific corner or view all corners laid on top of each other Corners This is the default viewing window This view displays all four channels DOC 16860 Page 33 q Toledo Integrated Systems PW LS RV2 User s Manual Operation All This view will overlay all four corners into one window This is best used to view differences between channels The remaining five 5 buttons are used to display channel s 0 to 4 The name used for each button is the user assigned corner name see the Configure Settings section on page 41 Detail and Scan DOC 16860 To view the details of each signature peak CCM envelope and capacity at each degree click anywhere in the signature window or use the four 4 buttons in the bottom left hand corner of the signature window A red line will appear through the signature viewing area To change the degree touch the s
34. assistance if needed Our Service Department can be reached at 419 867 4170 Monday through Friday 8 00 AM to 5 00 PM DOC 16860 Page 61 q Toledo Integrated Systems PW LS RV2 User s Manual Calibration Procedure DOC 16860 Page 62 T Toledo Integrated Systems PW LS RV2 User s Manual Calibration Information Label Calibration Information Label The Calibration Information Label is provided to document the Calibration Numbers press capacity and other important configuration data This label is located inside of the tonnage monitor on the door Below is an example of the information that should be documented 1 2 3 4 5 6 7 Model PW LS RESOLVER cal By JOHN DOE 9 28 10 Press vw 1O Add 0 Master Slave CAPACITIES CHO 2000 CH5 CALIBRATION NUMBERS CH1 1015 oo 1019 CH3 994 CH4 1006 CH9 TIME Mode NORMAL Value Pos _ T Toledo Integrated System Toledo Transducers Inc Holland OH 43528 Made in USA Figure 4 1 Calibration Information Label Offset 158 OOO OO PON Cal By The name of the person that performed the calibration procedure Date The date that the calibration was completed Press No The press on which the monitor is installed Address The network communication address for the monitor Capacity CH0 The total capacity of the press
35. ber can be configured independently DOC 16860 Page 47 m Toledo Integrated Systems PW LS RV2 User s Manual Operation Comms Network The comms communications network page contains all of the settings pertaining to the communication between SlimWare and the PW LS unit hard hit software connections and OPC server and client tag definitions Once configured during setup the communication and network settings should not be adjusted unless communications have been terminated Slimware Version 5 1 0 0 Logged in as Master Communication Network Slim Comport Settings OPC Tonnage Available Communication Ports Enable OPC Disabled Find Slim Available Com Ports Server Name CimQuestlnc IGOPCAB 1 Server IP 127 0 0 1 Signatures er Communication Must Be Stopped To Change Posts Bolster Tag Devicel Tag2 x Statistics Slim Baud Settings Network Port 1 Port 2 Port 3 Enable Network 38400 9600 38400 Server IP Setpoints 38400 57600 57600 Path 115200 76800 115200 DBUsemame 230400 115200 230400 DB Password 24 460800 230400 460800 SimAddress 0 i i i tage Settings Trigger Settings P 3 Dea om Figure 2 13 Configure Comms Network Screen Press Name e Comport Settings e This group box displays the available comports and whether communications are established and running e Availa
36. ble Com Ports Lists the available com ports on the PC e Communication Running Idle Indicates whether communications have been established and whether communications are running If the COM port is open this button will be green If no COM port is open this button is yellow e Find SLIM Select this button if the com port baud rate or address have been changed See more about this in the initial communication setup later in this section DOC 16860 Page 48 Toledo Integrated Systems PW LS RV2 User s Manual Operation e Baud Settings The PW LS unit comes standard with three 3 communication ports Each port can be configured for a different baud rate Baud Rate Port 1 and Panel PC This is the main communication port between the Panel PC SlimWare and the PW LS unit Select the correct baud rate and enter the address factory default is 0 of the PW LS unit Baud Rate Port 2 This is used for configuring the baud rate for PW LS port 2 This port is used for servicing the PW LS Baud Rate Port 3 This is used for configuring the baud rate for PW LS port Z3 This port is used as a possible second connection to the PW LS unit If communications has been lost or SlimWare is being installed on a new PC follow these steps to establish communication with the PW LS unit e Communication Setup DOC 16860 If communications are currently running press the green Communications Running button The butto
37. d part is formed then place the PW LS into Learn Mode by pressing the Learn Mode button After 8 strokes the PW LS establishes a new benchmark and calculates new high and low setpoints based on the percentage settings from the Setpoints screen e Ifthe PW LS is not configured to automatically generate high and low setpoints the setpoints be manually entered on the Setpoints screen e Once a benchmark and setpoints have been established for a particular die all settings can be saved in a job file by pressing the grey Job box at the bottom of the screen Select the Create New Job tab enter a unique job number name and description and press the Create New Job button to save e Toload a job file for an previously run die simply press the grey Job box at the bottom of the screen select the job file that you want to load and press the Load Existing Job button All stored setpoints will be sent to the PW LS e When an alarm occurs the shutdown relay opens to stop the press and the status bar at the top of the screen will flash red and display a message to indicate the type of alarm In the case of tonnage alarms the faulted channel s on the Tonnage screen will also flash red to indicate the location of the problem To reset the alarm first correct the situation that caused the alarm then press the red flashing status bar the faulted corner or the Reset Monitor button to clear the alarm and close the shutdown relay e To avoid nuisanc
38. e Display Gain Values button to view the gain numbers again The values in the Gain Balance fields should closely match the values in the Desired Gain fields K Repeat steps H J until the actual gain numbers match the desired gain values In most cases the process will not need to be repeated 7 Verify Results and Repeat A From the Calibration screen turn off Track Mode if it is on B Cycle the press C Verify that the load cell values and the peak tonnage values from the Channel Tonnage fields are the same If not repeat step 6 until the values are the same 8 Make Linearity Check A Raise the shut height in 020 to 030 inch increments to decrease tonnage B Cycle the press and impact the load cells C Compare the tonnage applied to the load cells to the tonnage displayed on the monitor These values should be documented 9 Document calibration details on the Calibration Sheet Form 1224 provided and file it for future reference 10 Record Gain Numbers A On the Calibration screen turn on Track Mode then press the Display Gain Values button to view the values in the Desired Gain fields These are the Calibration Numbers B Record these values on the calibration label located on the door inside of the unit See the Calibration Information Label section on page 63 for details on the calibration label 11 Calibration Complete The calibration procedure is now complete Contact Toledo Integrated Systems Service Department for
39. e Mode Hardware Configuration Tonnage Channels Autoset Enable Autoset B4 Mode O Capacity Signatures Benchmark First Level Capture Settings TFP Enveloping Second Level Position 0 Time 0 Enable Enveloping Statistics Point In Time Job Settings Lookup ID v Save Prompt v Level Setup u v z Setpoints Trigger Capacity Threshold Resolver Probe iss Threshold Resolver _ Left Rear Threshold 1200 Angle 184 Right Rear Offset 158 Left Front Change Password Right Front Figure 2 11 Configure Hardware Trigger Screen e Tonnage Mode e Normal Peak The normal mode of operation For most applications this is the desired mode Unless otherwise noted use this tonnage mode e B4 Mode This mode is a combination of the normal peak mode and first level mode When selected B4 mode displays the distribution forces at the first level time in channels 1 thru 4 Then when the punch finishes the stroke the total load is displayed in channel O DOC 16860 Page 44 Toledo Integrated Systems PW LS RV2 User s Manual Operation e First Level In first level mode the load is the peak loading which occurs during the portion of the stroke from the initial threshold crossing until the time point is reached e Second Level The second level loading is the peak load which occurs in each channel between the time point and the end of the stroke
40. e alarms and shutdowns while adjusting the press put the PW LS in Setup Mode The press will still be protected from an over capacity hit but high and low setpoint violations will be ignored DOC 16860 Page 65 qi Toledo Integrated Systems PW LS RV2 User s Manual Operator s Guide DOC 16860 Page 66 T Toledo Integrated Systems PW LS RV2 User s Manual Appendix Appendix A Sensor Installation Doc 11080 B Calibration Sheets 2 Form 1224 DOC 16860 Page 67 q Toledo Integrated Systems PW LS RV2 User s Manual Appendix DOC 16860 Page 68 T Toledo Integrated Systems INSTALLING T400 LOAD SENSORS FIVE HOLES DRILLED AND TAPPED IN PRESS MEMBER 400 LOAD SENSOR TWO ANTI TORQUE WASHERS FOUR LOC WEL BOLTS 3 4 INCH LONG TORQUE EACH 1 4 28 x 3 4 IN LONG SOCKET HEAD SCREW TO 150 LB IN OR 12 5 LB FT WELD PADS ARE WELDED ON THREE SIDES ONLY T400 LOAD SENSOR TWO ANTI TORQUE WASHERS FOUR LOC WEL BOLTS 3 4 INCH LONG TORQUE EACH 1 4 28 x 3 4 IN LONG SOCKET HEAD SCREW TO 150 LB IN OR 12 5 LB FT The above illustrations represent the proper arrangement of Model T400 Load Sensor kit parts using either the Drill and Tap method or the Weld method A proper installation is necessary to produce good results Before installing the sensors please read the appropriate instructions listed below Sensor Placement Page 2 Press Frame Page 3 Pitman Mount Page 4
41. e transmit and receive LED s status located on the PW LS unit If these LED s are idle this is due to a communication error DOC 16860 Page 27 Toledo Integrated Systems PW LS RV2 User s Manual Operation e Navigation C These buttons allow the user to navigate to the various pages throughout SlimWare o Tonnage Pressing this button will load the tonnage page From the tonnage page the current peak or reverse tonnage can be viewed easily Personnel with a setup or master password can also enable setup or learn modes from this page o Signatures This button will load the signature page From the signature page users can recall current signatures from the PW LS monitor or recall previously saved signatures o Statistics Pressing this button will load the statistics page This page displays information such as the highest load number of high alarms and last alarm Personnel logged in with a setup or master password can clear the alarm history from this page o Setpoints Clicking the setpoints button will load the setpoints page If the user is not logged in with a setup or master password this page is read only and no setpoints can be changed If a user is logged in with a setup or master password setpoints such as high and low alarms and reverse tonnage setpoints can be modified o Configure Only a master password can access the configure page From this configure page all personnel and hardware settings ca
42. e updating properly DOC 16860 Page 30 T Toledo Integrated Systems PW LS RV2 User s Manual Operation Reset Monitor e Requires Setup or Master password Operator option available e Press the Reset Monitor to reset any alarms e The Reset Monitor button by default is only available to setup or higher level passwords however it can be enabled for Operators if Operator Personnel Reset Alarms is enabled on the configure page See page 41 e Alarms can also be reset by pressing the channel which is alarmed or pressing the flashing status bar at the top of the screen subject to password authorization Bar Graphs e bar graphs next to each channel display the relationship between the current tonnage and the high and low setpoint window e This graph can be changed to display either the current tonnage with regards to the high and low setpoint window or the benchmark with regards to the percentage variation of each hit The display is determined by which autoset mode Capacity or Benchmark is selected in the configuration page Mode Display e Just above the total tonnage is the mode display box This displays what type of mode the monitor is in These modes can be any of the following e Normal Peak Shown in Figure 2 5 e B4 e First Level e Second Level e Point In Time e The tonnage modes can only be changed from the configuration page To learn more about each type of mode refer to the configuration section o
43. ed to calculate the high and low enveloping limits in each specified zone These values are used during learn mode Position e The PW LS allow for up to five 5 zones to be calculated throughout the press stroke Enter the desired windows in these textboxes Page m Toledo Integrated Systems 40 PW LS RV2 User s Manual Operation Configure Settings Configuration User Preference Channel Names Tonnage Channel D Total Total Virtual Keypad v Setup Personnel Data Entry perator Personnel Reset Alarms Channel 2 RR Right Rear Reset Alarms Without Password Channel 3 LF Left Front C Extemal Job And Data Management Channel 1 LR Left Rear Signatures C Data and Alarm Logging Channel 4 RF Right Front Statistics Signature Analysis C Automatic HardHit Save Channel 6 LR CHE C Automatic Signature Retrieval Channel 7 CH7 C Show Setpoint Markers On Graph Channel 5 Total CH5 Setpoints Channel 8 LF CH8 Slide Names x Outer Outer Channel 9 CH9 Inner Inner External Application Hotkey C ExtemalApp Label Maximizer App Name Maximizer Service Maximizer _PC Application Path C Program Files T oledo Integrated Systems Maximizer Maximizer_PC exe Hardware 7 Alarm Comms Calibrati Trigger Settings Network aan v Defaut 0 Figure 2 10 Configure Settings Screen
44. er hole for mounting the fixture to the press member This hole should be 1 2 inch 13mm deep Bolt the fixture to the press member using the 4 28 by 1 inch M6 1 x 35 long socket head cap screw in the center of the fixture Insert the number 3 drill Smm into the smaller corner hole and drill out all four holes to a depth of 4 of an inch 19mm Loosen the fixture Rotate the fixture 90 degrees clockwise Tighten the center screw of the fixture Insert the number 21 drill into the small centered hole and drill out both holes to a depth of 3 8 of an inch These holes are for mounting the sensor enclosure The fixture does not allow for tapping these holes They are tapped without the fixture Enclosure mounting is not done in metric Loosen the fixture Rotate the fixture another 90 degrees clockwise such that the larger corner holes line up with the holes drilled in Step 4 Insert a tap to be sure the holes line up Lock the fixture in place by tightening the center screw Insert the tap into the larger tap guide holes and tap each hole BE SURE TO USE PLENTY OF TAPPING FLUID Remove the fixture and repeat Steps 1 7 for each additional sensor mounting position Mount the sensor with the raised rib to the press The anti torque washers should go between the screw and the sensor body Torque each 4 28 x in long socket head cap screw to 150 LB IN or 12 5 LB FT PAGE 5 USING THE T400 SENSOR INSTALLATION FIXTURE KIT No 197
45. ge value The difference is then added to the benchmark value and the high setpoint value is established e The high percentage value is stored with each job so each job can have a different high percentage value Low Percent e The low percentage value is used in conjunction with learn mode This value is used to determine the new low setpoint value e While in learn mode the PW LS unit will multiply either the capacity or new benchmark value configurable by the low percentage value The difference is then deducted from the benchmark value and the low setpoint value is established e The low percentage value is stored with each job so each job can have a different low percentage value Reverse Tonnage e Reverse tonnage is current reverse tonnage that the SLIM has recorded e Also called Snap Thru tonnage this is tonnage that is applied to the press once the punch stamps through the part e Reverse tonnage is read only and cannot be changed Reverse Setpoint e The reverse setpoint value will stop the press when reverse tonnage is beyond this value e The reverse setpoint value is stored with each job so each job can have different reverse setpoint value e Areverse setpoint alarm can be configured for an immediate or top stop See Configure Alarm Settings section on page 47 DOC 16860 Page 38 T Toledo Integrated Systems PW LS RV2 User s Manual Operation Slimware Version 5 1 0 0 Logged in as Master
46. ges or alarms that occur This log can be saved to a log file located in the installation folder if Data and Alarm Logging is enabled from the configure page DOC 16860 Page 28 T Toledo Integrated Systems PW LS RV2 User s Manual Operation Tonnage Slimware Version 5 1 0 0 Logged in as Master Left Rear NORMAL PEAK Right Rear Signatures Total Statistics Setpoints Left Front Right Front Configure _ alo mm Figure 2 5 Tonnage Screen The tonnage page displays all relevant tonnage information This information includes current tonnage alarm status of each channel the monitor mode setup learn or normal and a graphical representation of each corners high low setpoint windows with regards to current tonnage Figure 2 5 shows a typical four 4 channel PW LS monitor Each corner displays the current tonnage and will turn red if an alarm is flagged for that channel DOC 16860 Page 29 qi Toledo Integrated Systems PW LS RV2 User s Manual Operation Setup Mode e Requires Setup or Master password e Press the Setup Mode button in the bottom left hand corner to place the PW LS unit into setup mode While in setup mode the press will be able to run and the following alarms will be bypassed High and Low Envelope Alarms High and Low Setpoint Alarms Reverse Alarms The setup mode button is only available for users with a setup level password or higher The monitor should only
47. he sensor cable as shown in Figure 1 7 below Be sure not to knick any of the signal conductors or cut the braid shield m approx 2 inches e CABLE JACKET k IGNALWIRES BRAIDSHIELD Figure 1 7 Tonnage Sensor Cable Stripping 2 Strip approximately 74 of insulation from each of the four signal conductors Note If your sensor cable is not double shielded with both foil and a braid electrical noise may affect your output readings DOC 16860 Page T Toledo Integrated Systems 16 PW LS RV2 User s Manual Installation Illustration B Sensors Connection The PW LS accepts the signals from Toledo Transducers T 400 sensors as well as other strain gage sensors Figure 1 8 illustrates the sensor connections T400 Sensor ees Tension Force o Tension connection shown For compression connections switch the red and white wires If two sensors share the same connector the black wires from both sensors are wired to the black terminal Wire the shield and green wires from both sensors in a similar DOC 16860 T400 Sensor o 9 Compression Force CONNECTION FOR 2 OR 4 CHANNEL UNITS w WHITE Figure 1 8 Tonnage Sensor Wiring CONNECTION FOR 6 OR 8 CHANNEL UNITS OUTER SLIDE TONNAGE SENSOR INNER SLIDE TONNAGE SENSOR Page 17 Toledo Integrated Systems PW LS RV2 User s Manual Installation Resolver Connection The PW LS
48. hod is set to Resolver fill out the following information A Resolver Configuration Record the resolver dip switch settings from the Resolver Board here B Offset Value Enter the offset value that is required to zero the press angle 11 STI TFP If the monitor is configured for the special STI or TFP modes mark the appropriate mode and enter the STI or TFP calibration numbers in this section DOC 16860 Page T Toledo Integrated Systems 64 PW LS RV2 User s Manual Operator s Guide Operator s Guide Slimware Version 5 1 0 0 Logged in as Master Left Rear NORMAL PEAK Right Rear Signatures Total Statistics Setpoints Left Front Right Front Configure Learn Mode Zero Display Reset Monitor A m De mm e The PW LS tonnage monitor reads the force generated as a stamping press produces parts By comparing this force to a known good benchmark tonnage the PW LS can generate high and low limits setpoints and check the force from each stroke to ensure that it falls within this acceptable range The PW LS can generate alarms and stop the press when the tonnage gets too high or too low which protects the quality of the parts produced as well as protecting the press and die from dangerous over capacity tonnage Setup Mode e When setting a new die in the press place the PW LS into Setup Mode by pressing the Setup Mode button on the Tonnage screen Run material through the press until a goo
49. ignature viewing window or use the four 4 navigation buttons mentioned above The details display is updated if the view or angle is changed When all four corners are displayed the details include e Degree e Channel 1 Signal Value e Channel 2 Signal Value e Channel 3 Signal Value e Channel 4 Signal Value If the total or any corner is displayed the values include e Degree e Load Value e CCM Value e High Envelope Value e Low Envelope Value To remove the red line detail scan click the Clear Detail Scan button located in the bottom left hand corner of the signature window The current loaded signature filename or timestamp is shown in the bottom right hand corner of the signature window If the signature has been downloaded from the press this path will include the timestamp and press name from which the signature was downloaded If the signature has been recalled from a file the file path will be shown All signatures and overlays are saved as SWSX files Page 34 Toledo Integrated Systems PW LS RV2 User s Manual Operation Statistics The statistics page is used to detail the number and types of alarms that have been recorded by the PW LS unit From this page any user can view the various alarms for each channel Slimware Version 5 1 0 0 Logged in as Master ht R Total Left Rear Rear Left Front Front Highest Load 954 290 237 284 232 Lowest Load o 0 0 Last Alarm
50. igure Settings Screen 41 Configure Hardware Trigger Screen 44 Configure Alarm Settings Screen a ccce 47 Configure Comms Network Screen 48 Configure Calibration Screen a r rr 51 Load Existing JOD u M D 53 Create New puak quaua sau qua desastre 54 Wc 56 Slimware_ Stat ini bead len dg Cod qucd quad 57 Calibration Information Label 63 Page 3 qi Toledo Integrated Systems PW LS RV2 User s Manual Installation Limited Warranty This unit is warranted by the manufacturer Toledo Transducers Inc to be free of defects in workmanship and materials for one year from date of manufacturer s shipment This warranty is limited to repairing or replacing products which manufacturer s investigation shows were defective at the time of shipment by the manufacturer All products subject to this warranty must be returned for examination repair or replacement F O B to Toledo Transducers Inc 6834 Spring Valley Drive Holland Ohio 43528 The express warranty set forth herein is in lieu of all other warranties expressed or implied including without limitation any
51. job login and setpoint features These two configuration files are named Ext Job ini and Slimware Stat ini These files are to be written to the following location C Program Files Toledo Integrated Systems SlimWare ExtData The above path reflects the default installation path If this path was changed during SlimWare installation the path will reflect these changes Ext Job ini e Ext Job ini controls all features related to job changes A sample Ext Job ini is shown below in Figure 2 17 Ext Job ini Notepad File Edit Format View I 305 Lookupsznewjob Figure 2 17 Ext Job ini File e Job This is a static value and cannot be changed When writing the Ext Job ini this value must be included e Lookup Depending on the type of lookup value defined under the Job Settings tab this is the value that SlimWare will use to lookup or create the job e In Figure 2 17 SlimWare is searching for the job labeled newjob According to this lookup SlimWare will be searching by the job name not job number If this job can be found the job and corresponding setpoints will be loaded If newjob is not found the job will be created with the current setpoints and the user will be alerted that the job could not be found in the historical data window DOC 16860 Page 56 Toledo Integrated Systems PW LS RV2 User s Manual Operation Slimware Stat ini e Slimware Stat ini controls all features
52. n Tonnage Sensor Connection Refer to Figure 1 6 for the procedures below to connect tonnage sensors properly 1 Power down the unit Open the door of the PW LS enclosure 2 Run Tonnage Sensor Cables through the Conduit Hole 4 see Figure 1 3 and route cables upward to the right of the Analog Board lt Prepare the sensor cable for termination as described in Illustration on page 16 4 Remove the four 7 pin Phoenix plugs from the Analog Board and wire each sensor cable as described in Illustration B on page 17 2 The 7 pin phoenix plugs can then be inserted into the corresponding sockets The tonnage sensor cable connections are now complete DOC 16860 Page 14 T Toledo Integrated Systems PW LS RV2 User s Manual Installation Channel 1 Left Rear Sensor Channel 6 LR Inner Slide or Analog Input 1 COM1 Connector Channel 2 Right Rear Sensor Channel 7 RR Inner Slide or Analog Input 2 COM2 Connector pe EUR Channel 3 Left Front Sensor Channel 8 LF Inner Slide or Analog Input 3 COM3 Connector Channel 4 Right Front Sensor Channel 9 RF Inner Slide or Resolver Analog Input 4 Track Output Probe Shutdown Relay Connector l DC Power Figure 1 6 Tonnage Sensor Input DOC 16860 Page 15 q Toledo Integrated Systems PW LS RV2 User s Manual Installation Illustration A Sensor Cable Termination 1 Strip t
53. n be modified alarms can be disabled and a tonnage calibration can be performed o External Application shown only when enabled This button will call an external program which is declared on the configuration page This will be hidden if the External Application feature is disabled on the configure page o Login Logout Pressing this button will load the login keypad if no user is currently logged in Enter the correct password and the button will change to a green background indicating that a user is logged in While logged in if the user selects this button again the current user will be logged out The Login Logout pushbutton will be hidden if SlimWare is configured to use external data management The PW LS comes shipped with the default passwords set to Master m Setup s Operator o The passwords can be changed from the Configure gt Hardware Trigger screen e Resolver Angle D Displays the current angle of the press if a resolver is used e SPM Strokes Per Minute D Displays the speed at which the press is running e Job Number E Displays the current job number loaded If enabled a user can click on the job number box and load or create a new job e Job Name E Displays the current job name loaded If enabled a user can click on the job name box and load or create a new job e Historical Data Log F This displays all pertinent information regarding the PW LS unit and any chan
54. n page 44 Alarms e Ifthe PW LS unit detects an alarm the status bar will begin flashing red and white and the alarmed channel will turn red To reset any of these alarms first find the cause for the alarm Once the cause has been corrected press either the alarmed corner the status box or the reset monitor pushbutton in the bottom right hand corner of the tonnage page subject to password authorization DOC 16860 Page 31 q Toledo Integrated Systems PW LS RV2 User s Manual Operation Signatures Slimware Version 5 1 0 0 Logged in as Master Right Rear Tonnage Inner Views All Total m Statistics ignature Monitor Left Front Right Front Alarm Setpoints File S Configure Figure 2 6 Signature Screen The signature page is used to display historical or live signatures from the PW LS monitor To navigate to the signature page simply press the Signatures button on the right side of the main screen Figure 2 6 shows a typical four 4 channel signature with enveloping Operators can analyze the signatures from each stroke and determine if there are problems such as excessive tonnage early or late in the stroke Slide e slide is to determine whether to poll the PW LS unit for the inner or outside slide If the number of channels is set to 2 or 4 the inner slide option is disabled Outer Polls the PW LS for the outer slide signature Channels 0 4 Inner Poll
55. n should turn yellow and the text will change to Communication Not Running From the available comport list box select the desired comport SlimWare will automatically try to connect to the desired comport If needed change the baud rate and address for port 1 to the desired values This group box contains the OPC server address and OPC client tag names used for job changes bolster ID etc Enable OPC If checked SlimWare will attempt to read the OPC tags defined from the tag names and server address Server Name This is the OPC server name By default this is CimQuestInc IGOPCAB 1 Server IP The IP address of the PC where the OPC server is located Job Tag The OPC client tag name This value is defined by the job name number tag in the PLC Page 49 m Toledo Integrated Systems DOC 16860 PW LS RV2 User s Manual Operation Network This group box contains the network settings for using the optional PressNet and Hard Hit Report software Enable Network If checked SlimWare will attempt to write any alarm values to the remote database and save hard hit signatures alarms to the remote PC If the remote PC is unavailable SlimWare will attempt to store the alarm information in a local database Once the remote PC becomes available the alarm data stored in the local PC will be transferred to the remote PC database Server Name The name of the remote PC ex John Smith Server IP The IP address of
56. oint value is stored with each job so each job can have a different high setpoint value e Ahigh setpoint alarm can be configured for an immediate stop or top stop See Configure Alarm Settings section on page 47 Peak Tonnage e Peak tonnage is the current tonnage that the PW LS has recorded This value is specific to the monitor mode Normal Peak B4 First Level Etc e Peak tonnage is read only and cannot be changed Benchmark e The benchmark value is the desired peak tonnage per corner The benchmark value is created by putting the monitor into learn mode e The benchmark tonnage is read only and can only be changed by putting the PW LS into learn mode e The benchmark tonnage is stored with each job so each job can have a different benchmark tonnage Low Setpoint e The low setpoint value will stop the press when peak tonnage is below this value e The low setpoint value is stored with each job so each job can have a different low setpoint value e A low setpoint alarm can only be configured for top stop See Configure Alarm Settings section on page 47 DOC 16860 Page 37 q Toledo Integrated Systems PW LS RV2 User s Manual Operation High Percentage e The high percentage value is used in conjunction with learn mode This value is used to determine the new high setpoint value e While in learn mode the PW LS unit will multiply either the capacity or new benchmark value configurable by the high percenta
57. on scale down both stator input voltages first by 2X If it still turns on scale it down further by 3X and then by 5X until the STAT LED is not turned on Perform the test in this order to give our unit the highest workable voltage and therefore more accurate results NOTE Two stator inputs must have the same scale down factor Therefore the setting of STAT1 must be the same as STAT2 No Scale Scale Down 2X Scale Down 3X Scale Down 5X 6 Record all DIP switch settings on the calibration label 7 Setup is basically completed Refer to the Operation section of this manual for resolver offset adjustment DOC 16860 Page 20 T Toledo Integrated Systems PW LS RV2 User s Manual Installation Analog Output The analog outputs are provided on an 11 pin connector for easy access and for interfacing with other peripherals Use Conduit Hole 4 see Figure 1 3 for the Analog Output wiring Analog Voltage Output e Swing between 5VDC e 1 25V Capacity Com Common CHO Channel 0 Tonnage CH1 Channel 1 Tonnage CH2 Channel 2 Tonnage CH3 Channel 3 Tonnage CH4 Channel 4 Tonnage CH5 Channel 5 Tonnage or Channel 0 Analog CH6 Channel 6 Tonnage
58. or Channel 1 Analog CH7 Channel 7 Tonnage or Channel 2 Analog CH8 Channel 8 Tonnage or Channel 3 Analog CH9 Channel 9 Tonnage or Channel 4 Analog Figure 1 12 Analog Output Wiring DOC 16860 Page 21 q Toledo Integrated Systems PW LS RV2 User s Manual Installation Shutdown Relay An internal relay is provided for press shutdown The relay terminals are located on the Control Board as shown below Relay rating is 8 Amps 250VAC or 30VDC Relay contact provides standard Normally Open operation Normally Closed operation is also available as an option NORMALLY CLOSED RELAY CONTACT FOR PRESS SHUT DOWN CIRCUITRY EXTERNAL BYPASS SWITCH OPTIONAL Figure 1 13 Shutdown Relay Wiring DOC 16860 Page 22 T Toledo Integrated Systems PW LS RV2 User s Manual Installation Reset Switch Two terminals are provided for connecting an external reset switch optional The reset terminals are located on the Control Board as shown below The rating of the switch and wiring can be minimal since it only interfaces with a small signal similar to a TTL signal Note In order to reduce noise that may trigger false reset e Use twisted pair wires for the connection e Donotrun this pair of wires along with any high voltage or high current cables e Keep the wiring no longer than 12 feet 12VDC PNP NORMALLY OPEN MOMENTARY SWITCH Figure 1 14 Reset Switch Wiring DOC 168
59. r For die setter For general operation 10 4 diagonal TFT LCD display Full color SVGA graphics Touch screen standard USB ports available for keyboard and or mouse Windows XP Embedded 4GB Compact Flash for operating system and data storage Integrated Ethernet NIC Page 7 Toledo Integrated Systems Shutdown Relay General DOC 16860 Resolver Computer Interface Power requirements Operating temperature Dimensions PW LS RV2 User s Manual Installation Mechanical relay with N O contacts N C optional 8 250VAC 8 AMP 30VDC Built in excitation supports standard 5000Hz rotor excited positional resolver 10 100 1000 Mbps Ethernet 95 Watts max 85 132VAC 50 60Hz or 170 264VAC 50 60Hz 0 50 degrees Celsius 12 5 W x 14 5 H x 7 53 D or 318mm W x 368mm H x 191mm D Page T Toledo Integrated Systems 8 PW LS RV2 User s Manual Installation Installation Mounting the PW LS The PW LS is an electronic instrument and must therefore be protected from physical stresses such as shock and vibration Shock mounts are provided with every PW LS for this purpose Failure to use these shock mounts may result in premature failure of the instrument and possibly void your warranty The PW LS may be mounted directly to the press or to an adjacent structure It should be positioned so that the display is easily read and the instrument is readily accessible Figure 1 1 below provide
60. r will enable enveloping mode Enveloping is disabled by writing a false to this variable e Reset The only value that can be written to this variable is true By writing true the monitor will issue the reset command to reset any alarms e Loginlevel By writing a 3 2 1 or 0 users can be logged in or out Below are the login levels and equivalent values o Master 3 Setup 2 Operator 1 Log Out 0 O DOC 16860 57 qi Toledo Integrated Systems PW LS RV2 User s Manual Operation DOC 16860 Page 58 T Toledo Integrated Systems PW LS RV2 User s Manual Calibration Procedure Calibration Procedure In order for the PW LS to accurately report the correct tonnage and protect the press the unit must first be calibrated The following section explains the procedure for performing a new calibration 1 Set Press Capacity and Place Monitor in Setup Mode A If not already logged in press the Login button and enter the master password B Navigate to the Configure Hardware Trigger screen C Enter the press capacity for the total and each corner Refer to the Configure Hardware Trigger section on page 44 for more detail D Navigate to the Tonnage screen and press the Setup Mode button Setup mode will eliminate nuisance alarms during the calibration procedure while still providing over capacity protection 2 Balance the Tonnage Sensors
61. related to setpoints login and other functions with the PW LS unit 9 Stimware_Stat ini Notepad File Edit Format View Help tonnage monitor delay 8 activemode setup on envelope true reset true loginlevels 3 Figure 2 18 Slimware Stat ini File For all items defined below only one variable is required when writing the Slimware Stat ini For example to reset the monitor only the reset command needs to be sent The delay activemode envelope and loginlevel are not required to be written along with the reset command e tonnage monitor This is a static value and cannot be changed When writing the Slimware Stat ini this value must be included e Delay This value is used in conjunction with the activemode feature described below When the delay value is set the monitor will remain in setup mode for the declared amount of cycles before switching to learn mode In Figure 2 18 the monitor will remain in setup mode of eight 8 cycles before automatically moving to learn mode e Activemode There are four possible declarations for this variable o Setup on This will place the monitor in setup mode o Setup off This will take the monitor out of the setup mode o learn on This will place the monitor into learn mode o learn off This will take the monitor out of the learn mode Activemode is optional and is only required when the delay value is declared e Envelope By setting this value to true the monito
62. resolver input has a built in excitation which supports standard 5 000 Hz rotor excited positional resolvers The input can be configured in Master Mode or Slave Mode In Master Mode the PW LS supplies excitation voltage to the resolver and is wired directly to the resolver In Slave Mode the PW LS does not supply excitation voltage to the resolver and is wired to the resolver input terminal of a Master device where the resolver signal is shared Use Conduit Hole 3 see Figure 1 3 for the Resolver Cable The resolver input consists of the following components Wstat Turns on if the 2 STATOR voltages are too high Turns on if ROTOR voltage is too high Master Mode Connect to resolver See Figure 14 plu Slave Mode Connect to Master device See Figure 15 9 SLAVE Master and Slave Selections 14 ROT R1 R2 Voltage Scaling Q I2 13 15 Ce STAT1 S1 S3 Voltage Scaling 2 3 5 e SIAT2 52 S4 Voltage e Scaling Figure 1 9 Resolver Input Descriptions DOC 16860 Page 18 Toledo Integrated Systems PW LS RV2 User s Manual Installation Master Mode Wiring 51 N cant smaoRPAR P 2 S4 ORG WHT R1 BLU WHT R2 HIELD SHL SHIELD Shielded Twisted Pair Cable PW LS AS e g BELDEN CABLE 8103 Do not connect SHIELD MASTER DEVICE 2038 222
63. s A From the Calibration screen turn off Track Mode if it is on B Further adjust the shut height so that the press impacts the load cells and generates a load at 10096 of press capacity See warning below C If an alarm is generated on the tonnage monitor press the flashing banner at the top of the screen to reset it WARNING Depending on the press capacity and the size of the load cells being used loading the press at capacity with load cells could indent the ram or bolster To prevent this situation from happening do one of the following a Calibrate the press only up to 8096 of capacity or b Use larger load cells to increase the loading surface For instance to calibrate a 400 Ton press at capacity use 4 250 Ton load cells instead of 4 100 Ton load cells 6 Gather Record and Enter Data Automatic Method A Record the load cell readings for each of the corners on the calibration sheet These are the load values of the press corners Also enter these values in the corresponding Load Cell fields on the Calibration screen B Record the peak tonnage values from the Channel Tonnage fields for each of the corners C Press the Enter Track Mode button to turn on Track Mode D Press the Display Gain Values button to view the current gain E Press the Calculate and Send button The correct Calibration Numbers will automatically be calculated and loaded into the tonnage monitor F Press the Gain Values Displayed button to t
64. s the PW LS for the inner slide signature Channels 5 9 DOC 16860 Page 32 Toledo Integrated Systems PW LS RV2 User s Manual Operation Signature e The signature group box contains the controls for polling retrieving from file or saving to file a signature Monitor Select this button to poll the PW LS for the most up to date signature If the SLIM unit is alarmed use this control to poll the alarmed signature File Selecting this button will load a file dialogue box From here select either a SIG or SWS file to open and view in the signature viewing window When a signature is loaded the file path will be shown below the viewing window Save Select this control to save the loaded signature to a file Print Use the print function to print out any signatures or overlays shown in the viewing window The default print setting is landscape mode When printing a signature the current signature view will be printed Note Before you can print one of the following must be true gt The PW LS Panel PC must be connected to and configured for the network and a network printer must be properly setup gt The PW LS Panel PC must be connected to a local USB printer and the printer s drivers must be properly installed Envelope e This option enables an operator to hide or display envelope and benchmark signatures This option is only available if enveloping is enabled Overlay e Once a signature is lo
65. s the mounting dimensions and demonstrates the proper attachment of the provided shock mounts A ground wire is also provided for proper instrument grounding and should be installed across one of the shock mounts GROUND f 5 HH p 5 16 18 STUD SHOCK MOUNT ASSEMBLY 1 25 D 10 00 ERN 32mm 254mm sr L1 5 625 1 397mm 38 12 50 7 53 9 5mm 318mm 191mm Figure 1 1 Mounting Dimensions DOC 16860 Page 9 Toledo Integrated Systems PW LS Components PW LS RV2 User s Manual Installation NUS XX SQA TX NN NN ANAA DAAN SNNN TON X SX S Model RESOLVER Ar SS CAPACITIES SS CALIBRATION NUMBERS ZZ OSTINo O TFP No 7 l m Iz 7 7777777 7777 7 VPE 7 NAA S 77 Z SS Control Board OO Power 7 Board N X Calibration Label Figure 1 2 DOC 16860 PW LS Components qi Toledo Integrated Systems __ m E co m o ipt Er m EJ T Em co EXT L w Ha BU Im m E En E L TE m E a leo m eu dB B m B re IS L8 J oc jas Ca LE H
66. the remote PC DB Username The MySQL database username Default root DB Password The MySQL database password Default 1234 Press Name The name of the press This is stored in the remote database and used for reporting purposes Test DB Connection This button can be used to verify the connection between SlimWare and the remote database By clicking this button SlimWare will attempt to connect to the remote database A message box will appear indicating the connection status m Page Toledo Integrated Systems 50 PW LS RV2 User s Manual Operation Calibration This section details the features of the tonnage Calibration screen The steps for calibrating the PW LS can be found in the Calibration Procedure section which can be found later in this manual Calibration should only be done by a trained Toledo Integrated Systems technician or someone else with tonnage monitor calibration knowledge Warning Improper calibration of the PW LS unit can result in physical damage to the press Please contact Toledo Integrated Systems if you have any questions about the tonnage calibration procedure Slimware Version 5 1 0 0 Logged in as Master Calibration Calibration Tonnage Channel Tonnage Load Cells Gain Balance Desired Gain Mode Left Rear 136 100 Right Rear 116 100 Signatures Left Front 100 Values Statistics Calculate Right Front 100 And Send Setpoints
67. urn off the gain and view the sensor balance Use the Initialize Auto Zero button to zero the corners again if needed G Press the Display Gain Values button to view the gain numbers again The values in the Gain Balance fields should closely match the values in the Desired Gain fields H Repeat steps E G until the actual gain numbers match the desired gain values In most cases the process will not need to be repeated Manual Method A Record the load cell readings for each of the corners on the calibration sheet These are the load values of the press corners B Record the peak tonnage values from the Channel Tonnage fields for each of the corners C Press the Enter Track Mode button to turn on Track Mode D Press the Display Gain Values button to view the current gain E Use the following formula to determine the new gain number New Gain Number Load Cell reading Peak Tonnage reading x Current Gain Number F Repeat the calculation for each corner DOC 16860 Page 60 T Toledo Integrated Systems PW LS RV2 User s Manual Calibration Procedure G Enter the new calculated gain number for each corner into their corresponding Desired Gain fields H Press the Send Gain Values button to load the new gain numbers into the tonnage monitor l Press the Gain Values Displayed button to turn off the gain and view the sensor balance Use the Initialize Auto Zero button to zero the corners again if needed J Press th
68. values to the PW LS unit Reinitialize Pressing this button will reinitialize the calibration data in the PW LS unit This is used if the PW LS balance and or gain becomes unresponsive i e the Auto Zero fails to balance one or more channels or sending the Gain Values fails m Page Toledo Integrated Systems 52 PW LS RV2 User s Manual Operation Job Settings The job settings can be controlled through SlimWare itself or externally through INI configuration files see page 56 From SlimWare users can add edit or delete job setpoints To access the job settings page click anywhere in the job group box near the bottom of the screen see Figure 2 4 point E If the password is at or above the required level to access the job settings page the screen in Figure 2 15 will load Slimware Version 5 1 0 0 Logged in as Master Load Create Jobs Load Existing Job Edi Exist Load Existing Job Edit Existing Job Create New Job Delete Existing Job Default dat New Job dat Signatures Statistics Setpoints Configure Load Existing Job A Figure 2 15 Load Existing Job Load Existing Job As mentioned above SlimWare is able to manually or externally load a new job If External Job Data and Management is checked on the configuration page third party programs need to create an INI file in SlimWare s external file directory and a new job will load DOC 16860 Page 53
69. w is a sample screen of the alarm settings page Each type of alarm can be configured for a specific type of stop including top or immediate stop Alarms can also be bypassed on a channel by channel basis Slimware Version 5 1 0 0 Logged in as Master Bypass Channel 0 4 Tonnage Right i Right Total Left Rear Rear Left Front Front Stop Type Signatures Capacity g CCM Active Statistics High Setpoint Active Setpoints Low Setpoint Active Reverse Bypassed High Envelope Active Active ee E A ETT EG ae Figure 2 12 Configure Alarm Settings Screen For example in the above screen shot the reverse alarms are bypassed while capacity CCM High and Low setpoint and High and Low enveloping alarms are active Immediate stops are declared for Capacity and CCM alarms while top stops are declared for the remaining alarms To bypass and or change the alarm type click on the button to scroll through the available options When any type of alarm or stop is changed an Apply and Cancel button will appear in the bottom right hand corner of the configuration screen To save the alarm setting changes press the Apply button For an eight 8 channel unit toggle between the slides by using the two tabs near the top of the screen As with the four 4 channel unit each slide and channel num
70. wed to perform job changes e Press Type e Standard The factory default and most common setting this is the normal mode of operation for a standard press e STI Designed for double action stamping presses This type allows for the inner and outer slide tonnage to be monitored with only mounting four 4 sensors e TFP Designed for a specific type of transfer press system with six 6 columns where center columns are shared by two slides DOC 16860 Page 45 q Toledo Integrated Systems PW LS RV2 User s Manual Operation e Autoset e Enable Autoset Capacity When enabled the monitor will calculate all percentages based on press capacity The percentages can be configured from the setpoints page e Enable Autoset Benchmark When enabled the monitor will calculate all percentages based on the obtained benchmark value calculated during learn mode The percentages can be configured from the setpoints page e Enveloping e Enable Enveloping Check this to enable enveloping mode Enveloping provides a window throughout the press stroke that monitors tonnage from 35 to 284 degrees Trigger e Threshold Setting the trigger to threshold will allow a user to enter a desired tonnage value at which the monitor should start monitoring For example if 100 tons is entered the monitor will not begin its peak hold circuit until 100 tons has been obtained The maximum press speed is 400 spm with a threshold trigger
71. ystems DOC 16860 T Toledo Integrated Systems PW LS RV2 User s Manual Installation Page 6 Specifications Tonnage Counters Job Storage Password Speed Limit Human Machine Interface HMI Unit DOC 16860 No of Channels Sensor Inputs Sensor Excitation Sensor Input Connections Automatic Zero Balance Balance Range Gain Range Analog Output Analog Output Connection Inaccuracy Non linearity Frequency Response Resolution Calibration Shunts Stroke counter Part counter Good part counter 2 Batch counters Yes Master level Setup level Operator level Up to 1200 SPM Display Input Operating System Flash Disk Network PW LS RV2 User s Manual Installation Two or Four Six or Eight optional Full bridge strain gage sensors 120 to 1 000 ohms Up to 8 350 ohm sensors Built in 10VDC 500mA max Short circuit protected 7 pin 2 pitch Phoenix connector Yes 1mV V of offset digitally controlled 100 to 11 000x digitally controlled 1 25VDC Press Capacity 15 pitch Phoenix connector 196 of full scale max 1 of full scale max Flat DC to 6 KHz Each channel provides a 4 digit load value in 1024 count resolution Calculation based on 1 Meg Ohm shunt resistor 9 digit for Press Preventive Maintenance 8 digit 1 to 255 parts stroke programmable 8 digit 8 digit Top stop Limited only by available PC storage capacity For superviso

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