Home

SMC Networks 5000 Switch User Manual

image

Contents

1. 9 mlll ccocoooocooc LE Ld 0 u u 0 0 t s 2 8 e SAT SAT 35 Sz EE c i33 5 aa 20 gt i E Ha B E a C LLLI Figure C 1 Logic Module Firmware Chip Locations April 17 2000 NOTCH ON IC Man ual Version 1 0 C 1 OTCH ON IC April 17 2000 Manual Versio n 1 0 C 2 AppendixD Lockout Procedure For Air Controlled Systems Section D 1 General Lockout Considerations The OmniLink 5000 auto setup card automatically controls pressures in cushions and counterbalances Because of this there are special considerations to keep in mind when locking an air system out at 0 pressure Note that cushions can be vented to zero pressure and the press will be allowed to run A counterbalance that has been vented to zero pressure however is considered a stop condition by the press control While a type A valve has only integrated Fill Dump valves th
2. 3 9 Section 3 6 4 Linear Transducer Slide Adjust Wiring 3 10 April 17 2000 Manual Version 1 0 1 Section 4 CONMOUTANON nats uh ee apa ated e waq aa m nah 4 1 Section 4 1 Setting up the OmniLink 5000 for the Auto Setup Module 4 1 Section 4 2 Configuring the Auto Setup board 4 2 Section 4 2 1 Configuring Counterbalance Cushion and Hydraulic Overload Modules 4 2 Section 4 2 2 Configuring Slide Adjust Modules 4 7 Section 4 2 2 1 Calibrating Linear Slide Adjust Systems 4 10 Section 4 2 2 2 Calibrating Rotary Slide Adjust Systems 4 11 Section 5 Operation L uec oes tory ed eeu seu wired epus dele ae ARNE DE 5 1 Section5 1 Slide Adjust Operations ne u RR ea Bed 5 3 Section 5 1 1 Slide On Manual and Off Settings 5 4 Section 5 1 2 Automatic Slide Movement 5 4 Section 5 1 3 Manual Slide Movement 5 6 Section 5 1 4 Slide Fault and Status arena wisi DI pay 5 6 Section 5 2 Air System Counterbalance Cushion and Hydraulic Overload Operation 5 6 Section 5 2 1 Air System On Manual and Off Settings 5 7 Section 5 2 2 Pressure and Force Setpoints
3. TYPICAL J ER TO SYSTEM 5000 CONTROL AUTO SLIDE ADJUST uh 3 en eG EA AUTO SLIDE ADJUST ROTARY POSITION TRANSDUCER CABLE ANCHOR AUTO SLIDE ADJUST CONNECTION BOX TRANSDUCER FIELD ENGINEERING EE Om CONTAINS CIRCULAR CONNECTORS MOUNT TO INSIDE OF RAM SLIDE REQUIRED FOR MOUNTING MOUNTED TO PRESS CROWN Figure B 3 Conceptual Dual Resolver Mounting April 17 2000 Manual Version 1 0 B 3 FUNCTION AQ COMMON REFERNCE r TERMINAL 1D2 AC COMMON GROUND REPLACES SLIDE ADJUST UP PUSHBUTTON Boma REPLACES SLIDE ADJUST DONAT PUSHBUTTON SLIDE 5UYILAPY DowTamaR INTERLDCK BELAY MO SLIDE ADJUST AUYILAFY CONTACTQR INTERLOCH RELAY CORMACT NO USED THIS APPLICATION ROTARY TRANSDUCER SEE ODL BEL 60000000073 NOTE JUUPER UST MOT HE MISLED ROTARY TRANSDUCER JUMCHOM BOY SCHERATIC CROULAR RORY TRANSDUCER 7 CONNOR ADVANCED MICRO CONTROLLERS MOLANEO OM PRESS SLOL SYSIEM 5000 CONTROL WOLANEN ON PRESS Figure B 4 Typical AMCI Dual Resolver Wiring Diagram April 17 2000 Manual Version 1 0 B 4 SLIDE DJUST MODULE 5000 4066
4. D 1 Section General Lockout Considerations D 1 Section 0 2 Valve Type Lockout Procedure D 1 Section D 3 Valve Type B Lockout Procedure D 2 section D4 Valve Type C Lockout Procedure D 2 Appendix Configuration Sheets ox wanner Oa AN XA XO dee c Section E 1 Air System Calibration 1 E 1 Section E 2 Shut height Calibration Sheets see NH Mira e E ace E 3 April 17 2000 Manual Version 1 0 11 Appendix Specifications Section 5000 10A Pressure Control Board Section F 2 5000 10B Linear Shut Height Control Board Section 5000 10 Rotary Shut Height Control Board April 17 2000 Manual Version 1 0 iii April 17 2000 Manual Versio n 1 0 iv Section 1 Introduction The 5000 10 Auto Setup Module ASM allows the OmniLink 5000 Press and Automation control to set up press shut height counterbalance air pressure cushion air pressures and hydraulic overload pressure settings automatically when jobs are recalled from memory It consists of a base 5000 10 microprocessor board that installs in the OmniLink extended card rack and additional modules that may be mounted
5. 5 7 Section 5 2 3 Air System Fault and 5 8 Section 9 3 Job Storage and Recall Issues 5 8 Section 6 Diagnostics Fault and Status Messages 6 1 Section6 1 Main Module Messages 6 1 Section 6 2 Counterbalance Cushion and Hydraulic Overload Fault Messages 6 1 Section 6 3 Counterbalance Cushion and Hydraulic Overload Status Messages 6 2 Section 6 4 Slide Adjust Fault Messages 6 3 Section 6 5 Slide Adjust Status Messages _ 6 4 Appendix A Configuration Examples A l Section Example Counterbalance Configuration 1 Section A 2 Example Cushion Configuration 2 Section A 3 Example Hydraulic Overload Configuration A 3 Section A 4 Example Linear Slide Adjust Configuration 5 Section A 5 Example Rotary Slide Adjust Configuration A 7 AppendixB Typical Wiring Diagrams B l Appendix C Installation Of OmniLink 5000 Firmware C 1 Appendix D Lockout Procedure For Air Controlled Systems
6. LABEL VLA COM ta oma 102 COMMON GROUND UP RELAY CONTACT MO Y own netur 5 METEEN Demer REALACES SLIDE ADJUST PUSHBLTION MARE MOT USED THIS APPLICATION RIGE AUS CUMTACTUN WIEMOCK RELAY CONTACT D ROTARY TRANSDUCER BILD te ce rer owo 16 5 slo NOTE 11 DULFER bassT MSTALLEC RDTSRY TRANSDUCER SCHEMAIC ROTARY OM PP S SLOL AN emu SX CONTROL fcumES Du PRESS Figure B 5 Typical GEMCO Dual Resolver Wiring Diagram April 17 2000 Manual Version 1 0 B 5 TYPICAL eG a 0 375 TO SYSTEM 5000 CONTROL AUTO SLIDE ADJUST CABLE ANCHOR PLATE DETAIL gt 1 625 4 HOLES 14 20 THREAD TRANSDUCER r 0 3195 0 875 AUTO SLIDE ADJUST LINEAR POSITION AUTO SLIDE ADJUST CONNECTION BOX 6X4X4 TRANSDUCER RING CONTAINS CIRCULAR CONNECTORS ol MOUNTED TO PRESS CROWN Figure B 6 Conceptual Linear Transducer Mounting April 17 2000 Manual Version 1 0 B 6 REQUIRED FOR MOUN PN TuMETIDM
7. a Make sure there 15 adequate clearance from the transducer to the crown or other possible interference points of the press A common mistake is mounting the transducer with the slide lowered and crushing the transducer when the slide is raised April 17 2000 Manual Version 1 0 3 10 b It may be necessary to order a transducer longer than the slide adjustment range because of mounting limitations c Ferromagnetic material a material readily magnetized such as iron or steel should be no closer than 25 from the magnet or the rod end This includes ferrous screws Non ferrous metals such as aluminum brass and non magnetic stainless can be in direct contact with the magnet or rod end d Transducers longer than 30 may need special supports and split magnets e The rod of the transducer is typically four to five inches longer than the specified length due to dead zone and null zone areas at the beginning and end of the rod f The cable from the transducer to the OmniLink 5000 should not be run with any high voltage wiring i e 120 240 VAC In fact the cable should be run in its own shielded conduit g Read the manufacturers instructions that came with the transducer for other possible issues and mounting considerations Section 3 6 4 Linear Transducer Slide Adjust Wiring A cable must go from the linear transducer mounted on the slide to the auto setup board in the 5000 extended card rack Since the slide goes up a
8. C valve will revert to the manual section and the pressure will be no lower than the regulator but may be higher because of the check valve To lock out a type valve 1 The air setpoint for the system to be locked out should be set to 0 psi OR the system must be turned OFF in the configuration menu 2 Use the LOX valve integrated into this type of valve to dump the system even if the pressure setpoint is set to 0 psi at the control This is necessary because if the control is powered down intentionally or unintentionally the valve will revert to the manual regulator setting and may attempt to fill the air system again Step 1 MUST be done even if a LOX valve is opened in step 2 since the control may try to pressurize the system using the Fill Dump valve if the power is on If the LOX valve is opened when the system is still turned on and the pressure setpoint is not 0 psi the system will think it has a leak and will attempt to fill so it is important to turn the system OFF in the configuration menu or set the pressure setpoint to 0 psi before the LOX valve 15 opened April 17 2000 Manual Version 1 0 D 2 Appendix E Configuration Sheets Section E 1 Air System Calibration Sheets Air Pressure Configuration Air Pressure Configuration Slot 1 Board Name Transducer Type Max Pressure Min Pressure Max Force Min Force Fault Time Tolerance Air Pressure Configuration Air Pressure Configuration
9. Resolver Turns Rotary Transducer Slide Configuration Slide Configuration Slot 2 Board Rotary Transducer Name Upper Limit Lower Limit Tolerance Pulse Distance Pulse Time Lock Time Resolver Turns April 17 2000 Manual Version 1 0 E 4 AppendixF Specifications Section F 1 5000 10 Pressure Control Board AC Output Relays Voltage 120VAC Current l Amp Continuous 20 Amp 16ms 5 Amp 75ms Fuse 2 Amp Fast Blow Picofuse Section F 2 5000 10 Linear Shut Height Control Board AC Output Relays Voltage 120VAC Current 1 Amp Continuous 20 Amp 16ms 5 Amp 75ms Fuse 2 Amp Fast Blow Picofuse Section 5000 10C Rotary Shut Height Control Board AC Output Relays Voltage 120VAC Current 1Amp Continuous 20 Amp 16ms 5 Amp 75ms Fuse 2 Amp Fast Blow Picofuse April 17 2000 Manual Version 1 0
10. adjust systems If the automatic slide adjust doesn t see slide adjust movement within two seconds of a command to move it will stop its command to move and generate the Fault message Slide Did Not Move IMPORTANT Automatic movement will be terminated if the ESTOP button JOG UP softkey JOG DN softkey or CANCEL AUTO ADJUST softkey is pressed while the slide is moving automatically Automatic movement will pause if the slide adjust switch is turned off It will resume when the slide adjust switch is turned back on April 17 2000 Manual Version 1 0 5 5 Section 5 1 3 Manual Slide Movement As noted in the section explaining the softkeys in the slide screen the slide may be manually moved by pressing the JOG UP and JOG DN softkeys Note that the jog keys will only appear when the editing cursor is on a slide adjust setpoint These keys will work regardless of whether the slide system is on off or in manual mode Note however that these keys will not override the mechanical up and down limit switches in the slide In addition these keys will not allow movement beyond the electronic limits entered in the configuration screen for the slide unless the slide system is OFF Section 5 1 4 Slide Fault and Status The last fault and current status of the slide system are displayed for diagnostic and informational purposes Under normal conditions Fault should be None If there is a problem with the
11. Hydraulic Overload Fault Messages None Transducer Fail Bad Module Fill Dump Reversed No error The pressure transducer gave a reading that is out of its normal range or gave no reading at all Check that the transducer cable is still plugged in If it is check for cable damage If the cable checks out the transducer may need to be replaced The unit did not sense an option module in the slot it was configured for Indicates that the option card is unplugged or has failed Indicates the fill output was connected to the dump valve and vice versa The system checks the air pressure when it is filling or dumping and if it goes the other direction assumes the lines have been connected incorrectly April 17 2000 Manual Version 1 0 6 1 Unable to Unable to Dump Max Press Exceeded Not at Min Pressure A D converter Fail Bad Config Data Pressure Switch Low The system was unable to make progress when trying to raise the air pressure This could be a bad connection to the fill valve a failed fill valve or no plant air pressure Probably the most common cause would be a bad air leak in the system The system was unable to make progress when trying to lower the air pressure Probably a bad connection to the dump valve or a failed dump valve The air pressure exceeded the maximum pressure programmed in the configuration menu Probably indicates a leaking fill valve or bad wiring causing the fill valve to
12. Repeat this process with the slide near the bottom of the adjustment range WARNING After calibration always check for proper operation of the slide adjust system as wiring or transducer faults could cause an invalid calibration Bad measurements could result in damage to the machine and tooling and can cause injury or death April 17 2000 Manual Version 1 0 4 13 April 17 2000 Manual Version 1 0 4 14 Section 5 Operation The purpose of the Auto Setup module 15 to allow automatic adjustment of such press systems as air counterbalances air cushions air operated hydraulic overloads and slide adjust systems to greatly reduce setup time for different Jobs and to help ensure that these systems are adjusted correctly for different Jobs All operation of auto setup functions other than automatic adjustments to previously stored values when the OmniLink 5000 recalls a Job start from the Auto Sets screen This screen is displayed when the AUTO SETS softkey on the Main Menu or Press Control screen is pressed The Auto Sets screen shows all configured functions and allows their settings to be adjusted Figure 5 1 shows an example Auto Sets screen Note that each configured function slide adjust counterbalance cushion or hydraulic overload has its own box with name settings position or pressure status and fault Order Counter Counter OFF PCSTATUS ProgramRun Switch 0 0 Speed Mode Si
13. Version 1 0 3 9 c The slide should travel no more than 1 inch per turn of the resolver d The cable from the resolver to the OmniLink 5000 should not be run with any high voltage wiring i e 120 240 VAC In fact this cable should be run in its own shielded conduit It is not necessary to know the exact gear ratio of slide travel to resolver turns only that conditions b and are met The resolver may rotate in either direction relative to slide travel i e the resolver may rotate clockwise or counter clockwise as the slide goes down Section 3 6 2 Rotary Slide Adjust Wiring A cable must go from the dual resolver mounted on the slide to the auto setup board in the OmniLink 5000 extended card rack Since the slide goes up and down relative to the machine some means of stress relief must be used on the cable between the slide and the machine frame The recommended method is to use a helical cable same principle as a telephone handset cord from the resolver to a junction box on the bottom of the crown This lets the wire run in a spring pattern to help it resist breaking Appendix B Figure B 3 shows a conceptual view of this type of resolver mounting The junction box should be grounded to the machine to help shield the connections inside The cable should remain unbroken except for the connector in this junction box to keep the shield integrity do not splice the cable Slide adjust motor starters with and without
14. auxiliary contactors are supported Solenoid air valves for air motors are also supported Refer to Appendix B for typical wiring diagrams Figures B 4 and B 5 show the wiring for two supported dual resolvers Figures B 9 and B 10 show the wiring of slide adjust motor starters with and without auxiliary contactors Figure B 11 shows the wiring of a slide adjust air motor If an OmniLink 5000 control is ordered with a slide adjust system then a wiring diagram will be provided as part of the documentation package Section 3 6 3 Linear Transducer Mounting Linear shut height control makes use of linear magnetostrictive transducers These transducers have a head that contains the electronics and a guide tube from 6 to 48 in length depending on the application The guide tube is mounted to pass through without touching a separately mounted annular doughnut shaped magnet The electronics sense the magnet location as the magnet moves up or down the guide tube when the slide is adjusted to provide shut height distance to the OmniLink 5000 control To install the linear transducer there must be some point on the slide assembly that moves up and down with respect to a fixed point on the slide assembly when the shut height is changed The transducer should be mounted to one point and the magnet to the other with strong rigid brackets The particulars of mounting a linear transducer may vary greatly from press to press but keep in mind the following points
15. be on too long The air pressure is not at the minimum pressure programmed in the configuration menu The A D converter failed so no pressure readings can be made Indicates a hardware error on the base board The configuration data for this system was corrupted The information in the configuration menu for this system must be reentered There is a pressure switch on the input air supply to the air valves Ifthe input air pressure is too low then the system could open the fill valve intending to raise the pressure but instead vent some air back into the air supply The system will not fill as long as the pressure switch is low Section 6 3 Counterbalance Cushion and Hydraulic Overload Status Messages At Pressure Filling Dumping Air Pressure High Air Pressure Low System is Off System Vented The air system is within tolerance of its target pressure The system is filling raising the air pressure The system is dumping lowering the air pressure The air pressure in the system is too high The air pressure in the system is too low The system has been turned off in the configuration menu The pressure will still be displayed if the transducer is working properly In addition if the system is equipped with a type C integrated valve see section 3 1 the air pressure may still be adjusted with the manual regulator A pressure setpoint of 0 psi was entered for a cushion system The dump valve is left op
16. can be set to be more restrictive than the actual minimum and maximum shut heights Next we go to the Mode line of the system and turn it ON by cycling through the choices with the CHANGE softkey The last thing we must do is verify that the Pulse Distance and Pulse Time settings work for our press These settings affect how automatic adjustment works We hit Exit twice to retum to the Auto Sets screen and hit the RESET ERROR softkey if necessary to clear errors in the slide adjust system The slide setpoint should also be set to some reasonable value In this example the slide should still be at our calibration point of 14 074 inches We set the slide setpoint to 14 000 inches After clearing errors if present we go back to the slide configuration screen With the slide adjust switch on we should see JOG UP JOG DOWN and AUTO ADJUST softkeys Again we check to make sure the slide is properly counterbalanced If it is not then the following tests will be meaningless An under or over counterbalanced slide will not move the same way that a properly counterbalanced slide will For fine adjustment purposes a momentary push of the JOG UP or JOG DOWN key will pulse the slide motor starter for Pulse Time seconds We hit a jog key to see how far the slide moves with one pulse Ideally it should take around 2 pulses to move 001 inch We hit the JOG DOWN key and find that it takes 5
17. gathered From the press manual or cushion information plate we find that the effective area of the cushion is 100 square inches and the maximum operating pressure is 90 psi This means that the cushion will exert 100 pounds of force for every 1 psi of cushion pressure 100 square inches 1 pound per square inch We also found out from experimentation that is takes about 3 psi to initially move the cushion and that the cushion just starts to fall at 2 psi This tells us that approximately 2 psi 15 required to overcome the weight of the cushion piston and pressure plate The pressure transducer installed on the system is a Setra model C206 that has a pressure range of 0 to 250 psi and an output of 4 to 20 ma A type integrated valve controls the pressure see section 3 1 for a discussion of valve types Now we go to the Auto Sets screen and with the RUN PROG switch in PROG hit the CONFIGURE softkey After typing the configuration code we press the CONFIGURE AIR softkey Since the cushion is wired in at AS2 if the slot reported on the screen in not already AS2 we hit the NEXT AIR SLOT softkey until it is The hardware detected should be Fill Dump The first thing we must configure is the Name of the system The cursor should already be on the Name line so we check to see if the name is already Cushion 1 If not the CHANGE NAME softkey allows us to cycle through the systems A
18. have access to the restricted items unless he repeats steps A through D In addition to the manual log out the system contains an automatic logout The intent of automatic log out is to reduce the possibility of users other than the intended user having access to restricted items If there were no provisions for automatic log out and a user forgot to manually log out all restricted items to which the user had been designated for access would be available from the log in time until power was removed from the OmniLink control This presents the possibility of users other than the intended user having access to restricted items Automatic log out is based upon both time and press strokes During system configuration automatic Access Timeout parameters are entered An automatic access timeout time and automatic access timeout strokes are entered The time entered is the amount of time after the last key stroke that will be allowed before the system will automatically log out the user For example if the automatic access timeout 1s set to 60 seconds the user will be logged out 60 seconds after the last key stroke If the user presses a key before the 60 seconds have elapsed a new 60 second cycle will be started The number of strokes that are entered is the number of press strokes after the last key stroke that will be allowed before the system automatically logs out the user For example if the automatic timeout 15 set to 10 strokes the user will be logg
19. is properly counterbalanced If it is not then the following tests will be meaningless An under or over counterbalanced slide will not move the same way that a properly counterbalanced slide will For fine adjustment purposes a momentary push of the JOG UP or JOG DOWN key will pulse the slide motor starter for Pulse Time seconds We hit a jog key to see how far the slide moves with one pulse Ideally it should take around 2 pulses to move 001 inch We hit the JOG DOWN key and find that it takes 5 pulses to move the slide 001 inch too many We change the Pulse Time value to April 17 2000 Manual Version 1 0 A 8 04 sec Repeating the test we find that it now takes 1 to 2 pulses to move 001 inch an acceptable value Now it is time to hit the AUTO ADJUST softkey The slide moves up past 14 000 the slide setpoint we entered in the operation screen and stops momentarily at 14 025 It then comes back down and stops at 13 996 The Pulse Distance value is set too high What should have happened is that the slide would go over 14 000 come back down to a position just over 14 000 say 14 003 and then pulse into position at 14 000 Since we went under our setpoint by 004 inches we change the Pulse Distance to 017 inches adding 004 for the undershoot plus 003 for good measure to the original value of 010 Now when we hit the AUTO ADJUST softkey the slide travels first to 14 039 stops momentaril
20. lock out type A valves 1 Set the air pressure setpoint for the system to 0 psi This will cause the control to open the dump valve and leave it open to vent the system Note that this valve will be open only as long as the control is powered If the system is set to 0 pressure but the control is turned off before the system can blow down it will still be pressurized 2 Use a LOX valve if present to dump the air system Step 1 MUST be done even if a LOX valve is opened in step 2 since the control may try to pressurize the system using the Fill Dump valve if the power is on April 17 2000 Manual Version 1 0 D 1 Section D 3 Valve Type B Lockout Procedure The type B valve has a manual regulator in parallel with the automatic section that prevents the pressure it is controlling from going below a minimum To lock this valve out 1 Set the pressure setpoint for the air system to 0 psi At this point the manual regulator will try to fill the system while the automatic section tries to dump 2 Use the LOX valve integrated into this type of valve to dump the system and lock out the manual section Step 1 MUST be done even if a LOX valve is opened in step 2 since the control may try to pressurize the system using the Fill Dump valve if the power is on Section D 4 Valve Type C Lockout Procedure When power is removed from the control or if the air system is turned OFF in the configuration menu a type
21. measurements could result in damage to the machine and tooling and can cause injury or death Section 4 2 2 2 Calibrating Rotary Slide Adjust Systems After setting the parameters in the previous section the rotary slide system must be calibrated before it can be used IMPORTANT Configuring calibrating the slide adjust module should only be done with no dies installed in the press and for presses equipped with slide counterbalance systems should proceed only after the counterbalance is properly adjusted to offset the weight of the slide If counterbalance pressure is too low bearing clearances will cause shut height measurements made during calibration to be too small WARNING Since the slide adjust configuration procedure requires measurement of the space between the press slide and bed or bolster this procedure must be performed with no dies or tooling in the press to prevent the possibility of a point of operation or pinch point injury to personnel making the measurement Failure to heed this warning may result in serious injury or death To calibrate a rotary slide adjust system a Make sure the upper and lower limit settings have been set correctly in the slide configuration April 17 2000 Manual Version 1 0 4 11 screen of Figure 4 3 It is absolutely critical to set the upper and lower limits correctly before calibrating a rotary slide adjust system The calibration process uses this Information to map the turns f
22. pulses to move the slide 001 inch too many We change the Pulse Time value to 04 sec Repeating the test we find that it now takes 1 to 2 pulses to move 001 inch an acceptable value April 17 2000 Manual Version 1 0 A 6 Now it is time to hit the AUTO ADJUST softkey The slide moves up past 14 000 the slide setpoint we entered in the operation screen and stops momentarily at 14 025 It then comes back down and stops at 13 996 The Pulse Distance value is set too high What should have happened is that the slide would go over 14 000 come back down to a position just over 14 000 say 14 003 and then pulse into position at 14 000 Since we went under our setpoint by 004 inches we change the Pulse Distance to 017 inches adding 004 for the undershoot plus 003 for good measure to the original value of 010 Now when we hit the AUTO ADJUST softkey the slide travels first to 14 039 stops momentarily travels down to 14 003 and pulses the slide into position at 14 000 perfect See section 5 1 for further details on slide adjust operation Section A 5 Example Rotary Slide Adjust Configuration This example assumes the rotary slide adjust system has been wired to the option board at SS1 First some information needs to be gathered A 100 turn AMCI series dual resolver is mounted on the press slide From the nameplate on the press or the press manual we find that the minimum shut height is 12 500 inches an
23. recommends a pressure no lower than 20 psi which represents a 100 ton trip point April 17 2000 Manual Version 1 0 The pressure transducer installed on the system is a Setra model C206 that has a pressure range of 0 to 250 psi and an output of 4 to 20 ma An SMC ITV2050 31T2S4 servo valve will be used to control the pressure This valve is 0 130 psi with a 0 10V input Now we go to the Auto Sets screen and with the RUN PROG switch in PROG hit the CONFIGURE softkey After typing the configuration code we press the CONFIGURE AIR softkey Since the hydraulic overload is wired in at AS7 if the slot reported on the screen in not already AS7 we hit the NEXT AIR SLOT softkey until it is The hardware detected should be 0 10 Volt Out The first thing we must configure is the Name of the system The cursor should already be on the Name line so we check to see if the name is already Hydraulic Overload If not the CHANGE NAME softkey allows us to cycle through the systems Using the arrow keys we move the cursor to the Transducer Type line Looking at table 4 1 we see that the transducer type for any model pressure transducer with a 250 psi pressure range and a 4 to 20 ma output is Type 3 We hit the CHANGE TYPE softkey select Type 3 from the list that appears When the proper type is selected the Air Pressure line should change to read the pressure currently in the h
24. servo valve used to control the system Table 4 2 Servo Valve Control Types Manufacturer Model Pressure Input Control Range Type Wilkerson ERI Series 0 125psi 0 10V April 17 2000 Manual Version 1 0 4 6 Table 4 2 Servo Valve Control Types Wilkerson ERI Series 0 90psi 0 10V SMC ITV2050 31T284 0 130psi 0 10V Section 4 2 2 Configuring Slide Adjust Modules To get to the configuration screen for slide adjust modules a Go to the Auto Sets screen This screen is reached by pressing the AUTO SETS softkey in the Main Menu or Press Control screen b With the RUN PROG key switch in the PROG position press the CONFIGURE softkey and enter the configuration code The code is provided separately from this manual for administrative control c Press the CONFIGURE SLIDE softkey d Turn the Slide Adjust OFF ON selector switch for your control to the ON position At this point the screen should look similar to Figure 3 3 Drive Order 0 Speed 0 SPM Counter Counter OFF Stro ke Stroke 0 STATUS _ Mode Single Stroke speed SPM Program Run Switch Slide System Configuration Slide Slot SS1 Hardware Detected Rotary Transducer Shutheight 20 000 in Name Slide Adjust 1 Mode ON uc NEXT SLIDE Shut Height Units in SLOT Upper Limit 22 000 in Lower Limit 12000 in JOG UP Tolerance 0 002in Pulse Distance 0 003 in Pulse Time 0 03 seconds JOG Lock Time 0 03 seconds DOWN Hel
25. should be set to at leastthe value that just barely supports the weight of the cushion cylinder This can be found by slowly increasing the pressure to the cushion until it just starts to rise Then back off the pressure until it just starts to fall The Min Pressure should be set to at least the average of the two pressures The Type B and C valve systems may be used to provide a minimum pressure through their manual regulator This keeps the cushion from falling due to air leakage when the control is powered off and prevents cushion pins from falling through the lower die shoe and bolster NOTE Cushions can always drift down when the plant air supply is off Also If a type B valve is used Min Pressure must be set above the manual regulator setting For hydraulic overloads the Min Pressure should generally not be set to less than 25 of the Max Pressure value This parameter only appears when a counter balance is being configured This should be set at the die weight the counterbalance handles at its maximum pressure Obtain this value from the press counterbalance table or press manual Note that the units to the right of this parameter are also configurable When the editing cursor is placed on these units softkey 1 will read CHANGE UNIT When pressed pounds kilograms tons or metric tons may be selected from a list Note that changing the unit here will also change the unit for Min Die Weight This parameter onl
26. the Minimum Pressure line we enter in 25 psi the value that balances only the slide Next Max Die Weight is entered as 7500 the weight counterbalanced at the maximum air pressure April 17 2000 Manual Version 1 0 Note that units to the right of the number are also an editable parameter When the editing cursor is placed on the Max Die Weight units we can press the CHANGE UNIT softkey to get a list of supported units The units can be pounds kilograms tons or metric tons We using pounds Note that the units for minimum and maximum die weight will always be the same but will not necessarily be the same as the Display Weight As units This allows us to enter the die weights in whatever units the name plate uses but operate the press in a different set of units Min Die Weight for a counterbalance should typically be 0 This represents no tooling on the upper die The Display Weight As units we setto pounds The Fault Time we leave at 20 seconds The Tolerance is left at the default 2 psi Finally we go back to the Mode line and use the CHANGE MODE key to toggle the mode to ON The Auto Sets operation screen can now be used to set the air pressure or die weight See section 5 2 for operation details Section A 2 Example Cushion Configuration This example assumes the cushion system has been wired to the option board at AS2 First some information needs to be
27. the steps necessary to change a slide adjust setpoint This is typical for password entry for all restricted items Order SPM Counter Counter OFF PC STATUS READY TO STROKE 0 SPM PRESS SUPPLY ACCESS CODE ERY T Slide Adjust 1 ON Setpoint in shutheight 20 000 In Fault None Sta tun Ponton STEP A SELECTINGPARAMETER TO BE CHARGED Order Counter Counter OFF PC STATUS READY TO STROKE USER NUMBER ONE USER NUMBER TAO USER NUMBER FIVE shutheight Fault None Status n Porton STEP E SELECTING US Ek NAME O sem 099 gt Counter OFF PC STATUS Counter 0 SPM READY TO STROKE USER NUMBER ONE CODE 20 000 n Fault None Status nm Ponton STEP C FR TE RING USER PASSWORD 0 sem gt Counter OFF Counter PC STATUS 0 SPM READY TO STROKE Slide Adjust 1 ON In shutheight 20 000 In Fault None Status In Ponton STEPO Figure 2 2 Example Password Entry Sequence April 17 2000 Manual Version 1 0 Step A Select the restricted item In the example shown in Figure 2 2 the restricted item is Slide Adjust 1 setpoint Once the parameter is selected then Softkey 1 the upper vertical softkey Softkey 1 is highlighted in Figure 2 2 will display the legend SELECT Step list of users that have acce
28. the user must use one of two means or a combination of these two means These means are the RUN PROG key or the user password system Section 2 2 6 1 RUN PROG Key Switch Operation The RUN PROG key switch is located on the lower right side of the operator terminal This is a two position switch The key is removable in the RUN position only If the RUN PROG key switch is being used as a means to access the restricted items the switch must be turned to the PROG position When the RUN PROG key switch is switched to the PROG position the press will Top Stop and stroking will be prohibited until the switch is returned to the RUN position April 17 2000 Manual Version 1 0 2 4 When operating in the Key Only mode the key switch is the only means available to access the restricted items restricted items are accessible when the RUN PROG key switch is switched to the PROG position When operating in the Key or Password mode the key switch is one of the means available to access the restricted items All restricted items are accessible when the RUN PROG key switch is switched to the PROG position When operating in the Key and Password mode the key switch and password must be used to access the restricted items In this mode the user will be granted access only to the restricted items that have been assigned to him Section 2 2 6 2 Password System Operation Figure 2 2 displays a typical password entry sequence This example shows
29. used for hydraulic overload control and is built in to the base card PRESS CONTROL CARD RACK POWER CONNECTOR YODU OPTIONAL EXPANSION RACK Figure 3 1 OmniLink 5000 Extended Card Rack Each module is held on to the base card by four 46 32 screws If not already assembled install each module on the base card putting slide adjust cards 551 or 552 and air adjust cards in ASI AS2 AS3 April 17 2000 Manual Version 1 0 3 1 or AS4 The plug in terminals on the modules should stick out of the faceplate of the base card April 17 2000 Manual Version 1 0 3 2 Section 3 2 Valve Systems Counterbalance and cushion systems are very similar in the way they are controlled Three basic integrated valve configurations are available from Link to be used with the OmniLink 5000 ASM For clarity in the following sections these valve configurations are defined here Type An integrated Fill Dump Valve as shown in Figure 3 2 This valve has the advantage of simple straight through piping with all pilot pressures run internally and is easily mounted It may be used for air cushion and air counterbalance control This is the least expensive of the three valves Leaks in cushion and counterbalance systems will cause loss of pressure in these systems when either control power is off or supply pressure is absent However the control must be turned back on and pressure re established before the press will stroke PRESSURE GAGE INTEGRATE
30. 100 SOL CONT ON SH 6 en 5 126 SLIDE ADJUST DOWN LINE 179 OIG Det 521 SEE as 121 163 s STA Ges SLIDE ADJUST AIR ONSOL VALVE ORD ih OR SLIDE LOCK SOL VALVE d T IPERED IF IAD OPTI Figure B 11 Typical Slide Air Motor Solenoid Wiring April 17 2000 Manual Version 1 0 B 9 April 17 2000 Manual Versio n 1 0 B 10 Appendix C Installation Of OmniLink 5000 Firmware Firmware for the OmniLink 5000 press control is contained on two integrated circuits Please follow the instructions listed below for replacing the OmniLink 5000 firmware 1 Remove all power from the OmniLink 5000 press control Insure that the power to the OmniLink card rack and the OmniLink Operator Interface terminal has been removed 2 3 4 circuits are as shown in Figure C 1 5 6 Insert the logic board in the card rack Remove the logic board from the card rack Apply power to the control and verify operation Note the location of the notches on integrated circuits 5000 A and 5000 B Remove integrated circuits 5000 A and 5000 B See Figure C 1 Insert the new 5000 A and 5000 B integrated circuits Verify that the notches on the integrated
31. 15 set by the automatic system or the manual regulator as shown in Figure 3 4 for cushion and counterbalance adjustment Unlike the type B valve the manual regulator can be set to any allowable pressure without interfering with automatic pressure adjustment it does not have to be a minimum pressure This system is ideal for press counterbalance systems as the manual regulator can be set to balance the heaviest die used on the press When the OmniLink 5000 control is powered off the valve automatically reverts to at least the pressure set by the manual regulator If there 15 an air leak in the counterbalance system the manual regulator keeps the system charged to support the weight of the die SHOP AIR INLET 10 SURAE Figure 3 4 Type C Valve Configuration Section 3 3 Counterbalance Control Installation The automatic counterbalance control system consists of an air control module mounted on the ASM a control valve or valves and a pressure transducer The typical manually controlled press counterbalance system looks something like Figure 3 5 SAFETY POP OFF VALVE COUNTER BALANCE CYLINDER PRESSURE GAGE PRESSURE REGULATOR AA SHOP Al INLET BLOW DOWN VALVE ON ROD ATTAC PRESS SLIDE Figure 3 5 Typical Counterbalance System April 17 2000 Manual Version 1 0 3 4 For automatic control the pressure regulator and check valve are replace
32. 5 will be flawed because clearances will not be taken up by the counterbalance Now we press the CALIBRATE SLIDE softkey to perform the actual slide calibration as described in section 4 2 2 1 using the wire speed from the transducer nameplate 9 219 in this example and an orientation of 0 After calibration the Present Position field in the slide configuration screen should display the number we just entered for the calibration position to the nearest thousandth In other words if we had entered 14 074 inches for our calibration position the present position should read 14 073 to 14 075 inches Now we take the press back to the top of the stroke With the slide adjust switch on JOG UP and JOG DOWN softkeys should be displayed in the slide configuration screen Using the jog keys we raise the slide to verify that the upper mechanical limit switch works correctly Be very careful as the slide approaches the true maximum shut height 16 000 inches in this example as the upper limit switch may be inoperative or misadjusted Replace or adjust the limit switch as necessary In the same way we verify that the lower mechanical limit switch works correctly Again for emphasis be very careful as the slide approaches the true minimum shut height 12 500 inches in this example as the lower limit switch may be inoperative or misadjusted Replace or adjust the limit switch as necessary If desired the Upper Limit and Lower Limit
33. D FILLZOLIMP VALVE SHOP AIR TO SURGE INLET TANK Figure 3 2 Type A Valve Configuration ED Type B An integrated Fill Dump valve with a manual regulator check valve and LOX valve in parallel as shown in Figure 3 3 for cushion but not counterbalance adjustment This valve adds a parallel manual regulator system to the Type A valve which may be set to prevent the air pressure in the cushion from going below a minimum value set by the manual regulator as long as there is shop air pressure This prevents cushion drift down when control power is off with its associated lost die pins below the press bolster and lost time while they are recovered This valve also allows the cushions to be adjusted using the manual regulator path if the automatic system fails allowing the press to be operated until the automatic system is restored When the automatic system is on the manual regulator on this valve system must not be set higher than the lowest pressure that the automatic system is to provide because the automatic valves will try to dump while the manual regulator fills if the automatic setpoint is lower than the manual regulator pressure SHOP AIR 10 SURGE INLET TANK L PRESSURE REGULATOR INTEGRATED Figure 3 3 Type B Valve Configuration April 17 An Integrated Fill Dump valve with a manual regulator check valve and LOX valve and a four way valve that selects whether the pressure
34. G Key Switch 2 4 Section 2 2 6 2 Password System Operation 2 5 Section 3 Installation ayy sem uta aaa dete seat d Dr 3 1 Section 3 1 5 Module Installation 3 1 Section 32 Svstems 2 25 u has is a las iste fece ue DES 32 Section 3 3 Counterbalance Control Installation 3 3 Section 3 3 1 Counterbalance Pressure Transducer Mounting 3 5 Section 3 3 2 Counterbalance Air Valve System Mounting 3 6 Section 3 3 3 Counterbalance System Wiring 3 6 Section 3 4 Cushion System Installation 3 6 Section 3 4 1 Cushion Pressure Transducer Mounting 3 7 Section 3 4 2 Cushion Air Valve System Mounting 3 7 Section 3 4 3 Cushion System Wiring 3 7 Section 3 5 Hydraulic Overload System Installation 3 8 Section 3 6 Slide Adjust System Installation 3 8 Section 3 6 1 Rotary Transducer Mounting 3 8 Section 3 6 2 Rotary Slide Adjust Wiring 3 9 Section 3 6 3 Linear Transducer Mounting
35. If the slide adjust system detects an error it will be reported on this line A fault occurs when a hardware or firmware problem is diagnosed by the system See section 6 for fault messages and their meanings Status The current status of the slide adjust system Status messages indicate what the system is doing in the normal course of its operation See section 6 for status messages and their meanings Section 5 1 1 Slide On Manual and Off Settings The Auto Setup module allows three modes of operation to be chosen in the configuration menu for each slide adjust system ON MAN manual or OFF ON is the proper mode for the normal intended use of the system The operator or setup person cannot change the mode in the operation screen but the setting is reported at the top of the slide adjust box after the slide name Slide Adjust 1 or Slide Adjust 2 for convenience The mode setting affects the operation of the slide system in the following ways ON Jobs that are recalled will automatically move the slide to the position stored in the job subject to the conditions described in section 5 1 2 The AUTO ADJUST softkey can be used to initiate automatic movement of the slide to the currently programmed setpoint The JOG UP and JOG DN softkeys can be used to manually move the slide MAN manual This mode can be chosen if there is some reason the employer does not want to allow recall of previously st
36. Slot 2 Board Name Transducer Type Max Pressure Min Pressure Max Force Min Force Fault Time Tolerance Air Pressure Configuration Air Pressure Configuration Slot 3 Board Name Transducer Type Max Pressure Min Pressure Max Force Min Force Fault Time Tolerance April 17 2000 Manual Version 1 0 Air Pressure Configuration Air Pressure Configuration Slot 4 Board Name Transducer Type Max Pressure Min Pressure Max Force Min Force Fault Time Tolerance Air Pressure Configuration Air Pressure Configuration Slot 7 Board 0 10 Volt Out Name Transducer Type Valve Type Max Pressure Min Pressure Max Force Min Force Fault Time Tolerance E 2 April 17 2000 Manual Version 1 0 Section E 2 Shut height Calibration Sheets Linear Transducer Slide Configuration Slide Configuration Slot 1 Board Linear Transducer Name Wire Speed Upper Limit Lower Limit Tolerance Pulse Distance Pulse Time Lock Time Orientation Linear Transducer Slide Configuration Slide Configuration Slot 2 Board Linear Transducer Name Wire Speed Upper Limit Lower Limit Tolerance Pulse Distance Pulse Time Lock Time Orientation April 17 2000 Manual Version 1 0 E 3 Rotary Transducer Slide Configuration Slide Configuration Slot 1 Board Rotary Transducer Name Upper Limit Lower Limit Tolerance Pulse Distance Pulse Time Lock Time
37. System 5000 Press Control AUTO SETUP MODULE COLOR DISPLAY OPERATING MANUAL LINK ELECTRIC amp SAFETY CONTROL COMPANY 444 McNALLY DRIVE NASHVILLE TN 37211 000 Ur UWG Table of Contents Section 1 o EL DA Er nas E supe ue 1 1 Section 1 1 Counterbalance Control 1 1 Section 1 2 Cushion Control 1 1 Section 1 3 Shut Height Control 1 2 Section 1 4 Hydraulic Overload Control 1 2 Section 2 Parameter Entry and Access Control 2 1 Section 2 1 Parameter 8 5 2 1 Section 2 1 1 Numeric Entries ee Dr 2 1 Section 2 1 2 Text anc errasse OA REN ns XX Sa RE WS 2 1 Sectioii2 Access control Coe e ME EA S LEER cole 2 3 Section 2 2 T Key Only a ta eR ev a a 2 3 Section 2 2 2 Key or Password Mode tar RAPI 2 3 Section 2 2 3 Password Only Mode ac sa eraser leren ia 2 4 Section 2 2 4 Key and Password Mode 2 4 Section 2 2 5 Restricted Items o esee b e Ces d NER UT Ce RR a 2 4 Section 2 2 6 Access Control Operation 2 4 Section 2 2 6 1 RUN PRO
38. When the editing cursor is placed on these units softkey 1 will read CHANGE UNIT When pressed pounds kilograms tons or metric tons may be selected from a list Note that changing the unit here will also change the unit for Min Cushion Force This parameter only appears when a cushion is being configured Set this value to the force generated at the Min Pressure you have selected Note that the units to the right of this parameter are also configurable When the editing cursor is placed on these units softkey 1 will read CHANGE UNIT When pressed pounds kilograms tons or metric tons may be selected from a list Note that changing the unit here will also change the unit for Max Cushion Force This parameter only appears when a cushion is being configured Set this parameter to the units that cushion force should be displayed in When the CHANGE UNIT softkey is pressed the choices listed will be pounds lbs kilograms Kgs tons and metric tons Mtons Note that the display unit can be changed at any time and is independent of the units used for minimum and maximum cushion force If a job was stored in tons and this unit is changed to pounds the stored job will still be correct For example 1f 2 tons were stored for a job and the display unit is changed to pounds when the job is recalled it will be set to 4000 pounds This parameter only appears when a hydraulic overload is being configured This should be set to the t
39. andths into position This is to ensure consistent setups by taking up gear lash from the same direction every time Note that a slide setpoint of 00 000 used to store a job that will not overwrite the previous slide setpoint on recall will prohibit automatic adjustment Automatic movement is subject to the following conditions a The slide adjust switch must be on b The press must be stopped c The press must be at the top of the stroke d The hydraulic overload on the press if present must not be tripped e The Link Master Control LMC relay must be engaged f There must be no faults in the slide system and the counterbalance system if present g The auto adjust sequence for the slide will not start until the counterbalance system if present is at least up to its pressure setpoint If the correct pressure setpoint for the counterbalance has been entered this will ensure that the counterbalance has taken up any clearances in the slide connection system to increase accuracy of shut height adjustment When the slide adjust system waits for the counterbalance system to finish adjusting to its pressure setpoint the status message of the slide adjust system will be Waiting for Cntr Bal A counterbalance pressure that 15 far too low or far too high during any shut height adjustment may place excessive load on the shut height adjust motor and may even stall the motor This condition can also occur with non automatic motorized slide
40. cal failures Slide adjust switch failure If the main 5000 control reports to the auto setup card that the slide adjust switch is ON but no AC voltage is detected at the slide adjust relays this error will be generated It is also generated 1f the 5000 reports slide adjust switch OFF but the auto setup module does see AC voltage at the relays The Up solid state relay on the slide adjust module failed open Indicates a hardware failure of the relay The Up solid state relay on the slide adjust module failed shorted Indicates a hardware failure of the relay The Down solid state relay on the slide adjust module failed open Indicates a hardware failure of the relay The Down solid state relay on the slide adjust module failed shorted Indicates a hardware failure of the relay The Lock solid state relay on the slide adjust module failed open Indicates April 17 2000 Manual Version 1 0 6 3 Lock Relay Shorted Transducer Fail Coarse Resolver Fail Res Moved in Check Resolver Misaligned Res Gearing Wrong Bad Module Bad Config Data a hardware failure of the relay The Lock solid state relay on the slide adjust module failed shorted Indicates a hardware failure of the relay For linear slide systems indicates that the linear transducer is not sending information to the slide adjust module This may be a cable problem unplugged connector failed power supply failed transducer or opti
41. ct the tooling on each job April 17 2000 Manual Version 1 0 1 2 Section 2 Parameter Entry and Access Control Section 2 1 Parameter Entry Throughout the OmniLink control a fairly standard form of data entry is employed When data entry is allowed an editing cursor will appear on the screen This cursor can typically be moved from parameter to parameter on the screen with the up down left and right arrow keys The topmost softkey is used to select the parameter for editing and can change description depending on the parameter selected Section 2 1 1 Numeric Entries Assuming access has been achieved by one of the means listed in the following sections to change a numeric value a Place the editing cursor on the parameter to be changed by using the up down left and right arrow keys as appropriate Note that the editing cursor will only appear on the screen when editing is allowed For instance editing is usually not allowed when the press is running b The topmost softkey will usually say something along the lines of CHANGE XXXXXX where XXXXXX is the name of the value to be changed It may also simply say CHANGE NUMBER In any case hit this softkey to enter numeric input mode The editing cursor will change to a rectangle around the parameter to be edited c Use the numeric keypad to input the new number desired for the parameter d Press the ENT key to finish Note that moving off the parameter with the arrow ke
42. d Corresponds to the physical slot number ASI in the example of Figure 4 2 selected for configuration on the auto setup card ASS and AS6 do not exist but are reserved for future expansion The NEXT AIR SLOT softkey will cycle through the available slots in the system Note that AS7 is built in to the base auto setup board and is always installed For counterbalances and cushions this should be Fill Dump referring to the control method for the board For hydraulic overloads this should be 0 10Volt Out If there is no board installed in that slot the board will be None Detected Gives a readout of the current pressure detected by the pressure transducer based on the transducer type selected Note that when the transducer type is changed this pressure will also change even though the actual air pressure stays the same This value can not be changed by the user It is reported in this screen for convenience Press the CHANGE soft key repetitively to cycle through and select the available names for the module in the slot which you are configuring Counter Balance 1 Counter Balance 2 Cushion 1 Cushion 2 Cushion 3 Cushion 4 Hydraulic Overload Not Configured Stop when the desired name appears Use the CHANGE MODE soft key to cycle the status from ON to MAN to OFF and back to ON ON means the OmniLink 5000 will automatically adjust the air pressure when a job is recalled to the air pressur
43. d the maximum shut height is 16 000 inches Now we go to the Auto Sets screen and with the RUN PROG switch in PROG hit the CONFIGURE softkey After typing the configuration code we press the CONFIGURE SLIDE softkey Since the slide adjust system is wired in at SS1 if the slot reported on the screen in not already AST we hit the NEXT SLIDE SLOT softkey until it is The hardware detected should be Rotary Transducer The first thing we must configure is the Name of the system The cursor should already be on the Name line so we check to see if the name is already Slide Adjust 1 If not the CHANGE NAME softkey allows us to cycle through the systems During initial slide setup the Mode of the slide needs to be set to OFF Moving the editing cursor to the mode parameter we hit the CHANGE MODE softkey until the mode reads OFF Before we set anything further we need to choose the units for the slide system Moving the editing cursor to the Shut Height Units parameter we use the CHANGE UNIT softkey to set the units to inches for this example Note that this sets the units for all other shut height position or distance parameters on this screen and during calibration After calibration the units can be changed if desired The Upper Limit and Lower Limit we set to 16 000 inches and 12 500 inches respectively When the mode if the system is OFF these limits ar
44. d with an air valve system Figures 3 6 and 3 7 illustrate systems using the Type A and Type C valves described in section 3 2 In all cases a pressure transducer is used to monitor the air pressure COUNTER BALANCE AUTES PRESSURE TRANSDUCER LOW PRESSURE SWITCH PRESSURE GAGE INTEGRATED FILL DUMP VALVE SHOP AIR INLET PISTON ROD ATTACHES TO PRESS SLIDE SAFETY L POP OFF VALVE COUNTER BALANCE CYLINDER PRESSURE RANSDUCER SHOP AIP INLET PISTON FOO PRESSURE ATTACHES TQ A WAT RAIN PRESS SLIDE N REGULATOR A A T x INTEGRATED VALVE Figure 3 7 Auto Counterbalance with Type Integrated Valve April 17 2000 Manual Version 1 0 3 2 Section 3 3 1 Counterbalance Pressure Transducer Mounting The system uses an automatic method of control tn which the fill valve or dump valve is energized to raise or lower the pressure of the system and a pressure transducer is used to tell the ASM what pressure is in the system The pressure transducer is constantly monitored to verify that the system is at the proper pressure When filling or dumping air into or out of the counterbalance the transducer tells the system when to stop Because air pressure drops occur across air lines when filling or dumping proper placement of the pressure transducer is very important for correct operation of the system Possible pressure transducer mounting locations from best to worst are refer to Fi
45. de will be engaged and pressure can be adjusted through a manual regulator Section 5 2 2 Pressure and Force Setpoints April 17 2000 Manual Version 1 0 5 7 Pressure can be set in one of two ways First if the air system was correctly configured the desired force which the pressure is to create can be entered in the Force Setpoint row on the air pressure screen Second if preferred the desired air pressure in psi may be entered into the pressure setpoint row For counterbalances the Die Weight Set is the weight of the upper die that attaches to the slide The counterbalance must also offset the weight of the press slide but since this is a constant accounted for when the system 1s configured only the upper die weight need be entered The upper die weight which is required by OSHA to be stamped on the die can be entered in the force setpoint row For cushions the Cush Force Set is the amount of push that is exerted by the air pressure times the cylinder area For hydraulic overloads the Press Trip Set is the value usually in tons at which you wish the hydraulic overload system to trip Note that pressure die weight cushion force and trip points are restricted items as defined in section 2 The RUN PROG key a user code or both may be required to change them Ifa force setpoint is entered the proper pressure in psi will be calculated and applied to the system Likewise if pressure is entered the forc
46. downstroke before material is contacted by the dies By setting the pressure automatically when a job is recalled the OmniLink 5000 assures that the pressure is correct for the tooling used This not only reduces machine maintenance but increases safety and speeds up job setup tremendously In addition the Auto Setup module sets the correct pressure for each die rather than an approximate pressure for a range of die weights from tables provided with manually adjustable counterbalance systems Section 1 2 Cushion Control Quick die change is becoming increasingly important to maintaining a competitive edge By controlling up to four cushions automatically the OmniLink 5000 can shorten die change and assure a correct setup in the least amount of time April 17 2000 Manual Version 1 0 1 1 Section 1 3 Shut Height Control When a linear or rotary shut height control module is provided the OmniLink 5000 can provide accurate repeatable shut height adjustment on presses that are in reasonable mechanical condition enhancing parts quality and reducing setup time This system uses the existing slide motor starter Section 1 4 Hydraulic Overload Control Most presses use hydraulic overload system in which an air pressure sets up a much greater hydraulic pressure to control the trip point tonnage at which the overload cylinder collapses On these presses the OmniLink 5000 can control the trip point to not only protect the machine but also prote
47. e associated with that job MAN means the OmniLink 5000 will automatically adjust the air pressure but the pressure can only be changed from the Auto Setup screen by entering the desired air pressure A recalled job will NOT change the pressure if you configure the module to MAN OFF means the OmniLink 5000 will not control the air pressure This value should typically be set to ON This value should be set to the maximum operating air pressure at which the counterbalance cushion or hydraulic overload is designed to operate For counterbalances this 1s the pressure which counterbalances the heaviest upper die the press is designed to accommodate The press counterbalance table typically mounted on the press or the press manual should give this value April 17 2000 Manual Version 1 0 4 3 Min Pressure Max Die Weight Min Die Weight Display Weight As For cushions this should be the maximum operating pressure specified by the cushion manufacturer For hydraulic overloads this value should be the pressure specified by the press manufacturer for rated tonnage operation This value should be set to the minimum operating pressure at which you will operate your counterbalance cushion or hydraulic overload For counterbalances this value is the pressure that balances the slide with no tooling and cannot be set below 5 psi Obtain this value from the press counterbalance table or press manual For cushion s the Min Pressure
48. e is provided separately from this manual for administrative control c Press the CONFIGURE AIR softkey At this point the screen should look similar to Figure 4 2 Stroke 0 Drive 0 Order PC STATUS Stroke Mode Single Stroke Shen 0 SPM ProgramRun Switch Air System Configuration Air Slot 51 Hardware Detected Fill D ump Air Pressure 56 psi Name Counter B alance 1 Mode OH Maxirrurn Pressure 90 psi Minimum Pressure 5 psi Max Die Weight 1000 Ibs Min Die Weight 0 Ibs Display Weight As Ibs Fault Time 30 seconds Tolerance 2 psi Transducer Type 4 200psi 4 20ma Figure 4 2 Example Air Configuration Screen April 17 2000 Manual Version 1 0 4 2 There are several parameters that must be configured in this screen The editing cursor indicates which parameter is currently selected Softkey 1 the uppermost vertical softkey will change its description based on the parameter and when pressed allows the currently selected parameter to be changed The up and down arrow keys move the editing cursor from one parameter to another See Appendix A for examples of setting up each kind of system The features of this screen are Help Air Slot Hardware Detected Air Pressure Name Max Pressure The Help box at the bottom of the screen changes depending on the parameter that the editing cursor is currently on It gives a short version of how the parameter is use
49. e not enforced This allows us to check the operation of the mechanical limit switches The Tolerance Pulse Distance Pulse Time and Lock Time are left at 004 010 03 and 0 respectively the default values We may find these have to be changed later on April 17 2000 Manual Version 1 0 A 7 Before calibrating the slide we MUST make sure the slide is properly counterbalanced if counterbalance is used on our press If the slide is not properly counterbalanced the slide calibration will be flawed because clearances will not be taken up by the counterbalance Now we press the CALIBRATE SLIDE softkey to perform the actual slide calibration as described in section 4 2 2 2 We need to know the resolver turns 100 for calibration After calibration the Present Position field in the slide configuration screen should display the number we just entered for the lower calibration point In this example assume we had entered 14 074 inches for our lower calibration point Now we take the press back to the top of the stroke With the slide adjust switch on JOG UP and JOG DOWN softkeys should be displayed in the slide configuration screen Using the jog keys we raise the slide to verify that the upper mechanical limit switch works correctly Be very careful as the slide approaches the true maximum shut height 16 000 inches in this example as the upper limit switch may be inoperative or misadjusted Replace or ad
50. e setpoint will be calculated and displayed Section 5 2 3 Air System Fault and Status The last fault and current status of the air system are displayed for diagnostic and informational purposes Under normal conditions the Fault message should be None If there is a problem with an air system it will be reported on the Fault line Status gives the current state of the system such as At Pressure Filling Dumping etc For the most part these messages will be self explanatory See section 6 for acomplete list of fault and status messages with explanations Section 5 3 Job Storage and Recall Issues There are a few things to keep in mind for job storage and recall a A store operation must be done for the current air pressure and slide adjust setpoints to be stored in the job number If you recall a job and then change one or more of the recalled setpoints the changed setpoints will not be stored for later recall unless you store the job again while the setpoints are set at the new value b Since one or more cushions may or may not be used with any given die the On Off status of each cushion system is stored with the job For example Job 1 is stored with Cushion 1 turned off Next Job 2 is stored with Cushion 1 turned on Every time Job 1 is recalled Cushion 1 will be turned off Every time Job 2 is recalled Cushion 1 will be turned on Note that if the cushion system is in ma
51. e tank fromthe Fill Dump valves e Ifthere is no surge tank the pressure transducer should be mounted right at the inlet on the cushion Figure 3 11 Acceptable Locations for Mounting Cushion Pressure Transducer Section 3 4 2 Cushion Air Valve System Mounting The mounting location of the cushion air valve system is not critical Consideration should be given however to ease of maintenance plumbing and wiring when choosing the mounting location Also note that sometimes the check valve in the original system may be up at the surge tank itself The check valve must be removed for the automatic system to work Section 3 4 3 Cushion System Wiring Refer to Appendix B Figure B 2 for typical wiring of the cushion valve and pressure transducer Note that the auto select connection is only connected if a type C integrated valve is used For type A and B valves the auto select connection from pin 2 of the cushion module is not required If your April 17 2000 Manual Version 1 0 3 8 control came configured for a cushion adjust system then a wiring diagram should have been provided as part of the documentation package Section 3 5 Hydraulic Overload System Installation Some press hydraulic overload systems use an air pressure to set up a much greater hydraulic pres
52. e type B and C integrated air valves See Section 3 1 for a discussion of valve types that Link uses to control air pressure on cushions and counterbalances has a manual as well as an automatic section The manual section for these valves looks like a typical manual air pressure control with a regulator followed by a check valve There is a pressure gauge G1 after the regulator but before the check valve and a gauge G2 at the output air port after the check valve When raising the pressure by turning the manual regulator up the pressure forces the check valve open and gauge G1 will be approximately equal to gauge G2 However when lowering the pressure at the manual regulator the check valve will prevent the actual output pressure from going down assuming there are no leaks A LOX valve on the output is used to blow down the system to lower the pressure In either case gauge G2 shows the true pressure in the counterbalance or cushion The automatic section of type B and valves and the only section of type A valves consists of a fill valve and a dump valve A transducer mounted on the counterbalance surge tank or cushion electronically reports the pressure of the system to the auto setup board If the pressure is too low the fill valve puts more air in the system If the pressure is too high the dump valve vents air to atmosphere Section D 2 Valve Type A Lockout Procedure To
53. ed out when the press completes ten strokes after the last key stroke If the user presses a key before 10 strokes have been completed a new 10 stroke cycle will be started April 17 2000 Manual Version 1 0 2 6 Section 3 Installation Section 3 1 Auto Setup Module Installation The 5000 10 Auto Setup Module ASM installs in the OmniLink 5000 extended card rack Figure 3 1 shows the location of the ASM in the last slot of the extended card rack To remove the module loosen the knurled screws at the top and bottom of the board and use them to pull the board straight out of the rack To install start the module in the card guide slots on the rack push straight into the rack to firmly seat the module and tighten the knurled screws NEVER remove or install any card in the OmniLink 5000 when the power to the control is on Doing so can damage the control the card or both The face plate of the ASM is partitioned with labels such as SS1 AS1 etc These labels represent the type of module that can be installed on the card at that location SS1 and SS2 can have slide adjust modules installed AS1 through AS4 can have air adjust modules counterbalance and cushion use the same control module installed Slide adjust cards are twice the width of air adjust cards Note that SS2 overlaps with AS1 and AS2 to allow a second slide adjust card to be installed in a double action press at the expense of two air slots AS7 is
54. el AUTO AD JUST CALIBRATE SLIDE Figure 4 3 Example Slide Configuration Screen There are several parameters that must be configured in this screen The editing cursor indicates which April 17 2000 Manual Version 1 0 4 7 parameter is currently selected Softkey 1 the uppermost vertical softkey will change its description based on the parameter and when pressed allows the currently selected parameter to be changed The up and down arrow keys move the editing cursor from one parameter to another See Appendix A for examples of setting up each kind of system The features of this screen are Help Slide Slot Hardware Detected Shutheight Name Shut Height Units The Help box at the bottom of the screen changes depending on the parameter that the editing cursor is currently on It gives a short version of how the parameter is used Corresponds to the physical slot number 551 in the example of Figure 4 3 selected for configuration on the auto setup card The NEXT SLIDE SLOT softkey will cycle between SS1 and SS2 This will be Linear Transducer for 5000 10B option boards or Rotary Transducer for 5000 10C option boards If there is no option board installed in that slot this should read None Detected The current slide position reported by the transducer NOTE This number will be incorrect until Cal Position and Orientation are entered during configuration This is reported as a convenience in thi
55. en in this condition April 17 2000 Manual Version 1 0 6 2 Ctr Bal Vented Stop Hyd Overload Tripped Waiting for Top LMC is Out A pressure setpoint of 0 was entered for a counterbalance The dump valve is left open in this condition Unlike a cushion this is considered a stop condition The hydraulic overload operation screen will display this message when the press hydraulic overload system is tripped The hydraulic overload system is waiting for the press to reach the top of the stroke before it adjusts the hydraulic overload setting The Link Master Control relay is disengaged for some reason possibly an error at the control No air adjustment may be made while the LMC is tripped Section 6 4 Slide Adjust Fault Messages None No errors present Up and Down Reversed The Up relay has been connected to the Down side of the motor starter Slide Did Not Move Slide Adj Sw Fail Up Relay Open Up Relay Shorted Down Relay Open Down Relay Shorted Lock Relay Open and vice versa The system checks position when moving the slide and generates this message if it goes in the opposite direction from that intended If the slide does not move within approximately 2 sec this error will be generated Possible causes are counterbalance pressure so far off that the slide adjust motor cannot overcome it wiring problems starter overloads a picofuse blown on the slide adjust module or other mechani
56. eset faults while the other operator is not assigned the ability to change the limits Section 2 2 3 Password Only Mode The Password Only mode allows for sixteen users Each user can be assigned access to some or all of the restricted items This mode does not use the RUN PROG key The example listed above indicated that setup personnel required access to all restricted items In the Key or Password mode the setup personnel used the RUN PROG key to gain access to all of the restricted items In the Password Only mode the setup personnel can still have access to all of the restricted items but the system must be configured as such The setup personnel must be assigned a user name and password In addition all restricted items would be assigned access to the setup personnel Section 2 2 4 Key and Password Mode The Key and Password mode requires the user to have the RUN PROG key user name and user password Operation is basically the same as the Password only mode except that in addition to entering the password the user must switch the RUN PROG key to the PROG position Section 2 2 5 Restricted Items The following table lists the auto setup module restricted items name and function AUTO SETUP MODULE RESTRICTED ITEMS NAME FUNCTION Auto Setup Reset Reset Auto Setup Faults Auto Setup Settings Change Auto Setup Settings Pressures Slide Setpoints etc Section 2 2 6 Access Control Operation To gain access control
57. ey to toggle the mode to ON The Auto Sets operation screen can now be used to set the air pressure or trip tonnage See section 5 2 for operation details Section 4 Example Linear Slide Adjust Configuration This example assumes the linear slide adjust system has been wired to the option board at SS1 First some information needs to be gathered A GEMCO 932 series linear transducer is mounted on the press slide From the name plate on the transducer we find that the wire speed is 9 219 microseconds per inch Remember that some transducer manufacturers may call this gradient but the value must always represent microseconds per inch From the nameplate on the press or the press manual we find that the minimum shut height is 12 500 inches and the maximum shut height is 16 000 inches Now we go to the Auto Sets screen and with the RUN PROG switch in PROG hit the CONFIGURE softkey After typing the configuration code we press the CONFIGURE SLIDE softkey Since the slide adjust system is wired in at SS1 if the slot reported on the screen in not already ASI we hit the NEXT SLIDE SLOT softkey until it is The hardware detected should be Linear Transducer The first thing we must configure is the Name of the system The cursor should already be on the Name line so we check to see if the name is already Slide Adjust 1 If not the CHANGE NAME softkey allows us to cycle th
58. gure 3 8 a A spare port on the counterbalance surge tank b The same port that the safety pop off valve is mounted on if it has its own port on the surge tank c Right at the outlet on the surge tank that goes to the counterbalance cylinder d Right at the inlet on the surge tank from the Fill Dump valves If there is no surge tank the pressure transducer should be mounted right at the inlet on the counterbalance cylinder April 17 2000 COUNTER BALANCE CYLINDER PRESSURE TRANSDUCER PISTON ROD 5 TO PRESS SLIDE WATER DRAIN VALVE Figure 3 8 Acceptable Locations for Mounting Counterbalance Pressure Transducer Man ual Version 1 0 3 6 Section 3 3 2 Counterbalance Air Valve System Mounting The mounting location of the valve system is not critical Consideration should be given however to ease of maintenance plumbing and wiring when choosing the mounting location Also note that sometimes the check valve in the original system may be up at the surge tank itself The check valve in the original system must be removed for the automatic system to work properly Section 3 3 3 Counterbalance System Wiring Refer to Appendix B Figure B 1 for typical wiring of the counterbalance valve and pressure transducer Note that the auto select connection is used only for a type C valve For type A valves the auto select connection from pin 2 of the counterbalance module is not required If you o
59. ide has gone as high as the max position programmed in the configurations menu and will not be allowed to go higher April 17 2000 Manual Version 1 0 6 4 Min Position Reached Maoving Up Moving Down System Off Waiting for Cntr Bal Slide Too High Slide Too Low Hyd Overload Tripped Auto Adjusting Waiting for Top E Stop Button Waiting S A Switch LMC is Out The slide has gone as low as the min position programmed in the configuration menu and will not be allowed to go lower The slide is moving up The slide is moving down The slide adjust system is turned off The slide can still be manually moved by using the jog up and jog down buttons The slide position will still be shown if the position transducer is still functioning correctly The slide adjust system is waiting for the counterbalance if present to come to its correct pressure before automatically moving the slide The slide is higher than the slide setpoint plus tolerance The slide is lower than the slide setpoint minus tolerance The hydraulic overload has tripped The slide will not move down in this condition The slide is automatically going to the programmed slide setpoint The slide must be at the top of the stroke for automatic positioning to occur If a job is recalled at the bottom of the stroke this message will be displayed until the press is at the top Emergency stop button is depressed The slide will not automatically move
60. in this condition Waiting for the slide adjust switch to be turned on The slide cannot move while the slide adjust switch is in the off position The Link Master Control relay is disengaged for some reason possibly an error at the control No slide movement may be made while the LMC is tripped April 17 2000 Manual Version 1 0 6 5 Appendix A Configuration Examples This section of the manual will go though an example setup of each kind of system on a typical press Each example assumes that the hardware installation has been completed and the system is ready for configuration The following examples assume the access system is using Key Only mode as described in section 2 Other modes may require entering a user code to change certain parameters Section 1 Example Counterbalance Configuration This example assumes the counterbalance system has been wired to the option board at AS1 First some information needs to be gathered From the press counterbalance table mounted on the frame of the machine or found in the press manual we find that at zero die weight the counterbalance pressure should be 25 psi The maximum upper die weight for our example press is 7500 pounds At that weight the table says the pressure should be 78 psi The pressure transducer installed on the system is a Setra model C206 that has a pressure range of 0 to 250 psi and an output of 4 to 20 ma A type C integrated valve controls the
61. is going up Use 1 if the magnet travels toward the control head when the slide is going down Press the CONTINUE SLIDE CAL softkey to continue the calibration process or EXIT to return to slide configuration e The wire speed if a GEMCO linear transducer is used or the gradient if an MTS linear April 17 2000 Manual Version 1 0 4 10 transducer is used must now be set This value is listed on the transducer model plate Press the CONTINUE SLIDE CAL softkey to continue the calibration process or EXIT to return to slide configuration f Finally the Calibration Point must be set The slide should be taken to bottom dead center 180 degrees and the shut height should be measured Without moving the slide that measurement should be entered here This tells the system what the current shut height 1s Press the CONTINUE SLIDE CAL softkey g The slide system should now be calibrated Check for proper operation by running the slide up near the top of the adjustment range and checking the slide position reported Note that linear transducers are repeatable but not absolutely accurate This means the reported slide position may differ from the measured position by as much as 030 Repeat this process with the slide near the bottom of the adjustment range WARNING After calibration always check for proper operation of the slide adjust system as wiring or transducer faults could cause an invalid calibration Bad
62. just the limit switch as necessary In the same way we verify that the lower mechanical limit switch works correctly Again for emphasis be very careful as the slide approaches the true minimum shut height 12 500 inches in this example as the lower limit switch may be inoperative or misadjusted Replace or adjust the limit switch as necessary If desired the Upper Limit and Lower Limit can be set to be more restrictive than the actual minimum and maximum shut heights For rotary transducers the upper and lower limits should never be set outside the actual minimum and maximum shut heights Next we go to the Mode line of the system and turn it ON by cycling through the choices with the CHANGE softkey The last thing we must do is verify that the Pulse Distance and Pulse Time settings work for our press These settings affect how automatic adjustment works We hit Exit twice to retum to the Auto Sets screen and hit the RESET ERROR softkey if necessary to clear errors in the slide adjust system The slide setpoint should also be set to some reasonable value In this example the slide should still be at our calibration point of 14 074 inches We set the slide setpoint to 14 000 inches After clearing errors if present we go back to the slide configuration screen With the slide adjust switch on we should see JOG UP JOG DOWN and AUTO ADJUST softkeys Again we check to make sure the slide
63. l just appear above or just below the text to be edited depending on where it is in the screen Hit the SELECT LETTER softkey to place that letter at the text cursor In the example above the text cursor is on the in This and would be replaced with an A The text cursor will automatically move to the right when a letter is selected Note that numerals can be entered directly with the numeric keypad e The SPACE softkey can be used to enter a space character in the text f The softkey immediately above the EXIT softkey is used to select between uppercase and lowercase letters g The EXIT or ABORT EDIT softkeys can be used to abort the editing operation The text will revert to what it was before the editing operation started h After the text has been changed as desired press the ENT key to accept the changes April 17 2000 Manual Version 1 0 2 2 Section 2 2 Access Control The OmniLink control has several parameters or operations that have limited access In regards to the auto setup module the ability to perform the actions of resetting faults or changing limits must be restricted to certain personnel The OmniLink control provides several means to limit access to these parameters or operations These parameters and operations are called restricted items The OmniLink control employs combinations of two different means to limit access to restricted items These means are the RUN PROG key switch on the operator termi
64. ll not be used for production operation setup Note that this key is only available when the RUN PROG keyed switch is in the PROG position Press this softkey to move the slide up A momentary push will pulse the slide up once for fine control If the key is held down for more than about a second the slide will move up continuously until the key is released This key is only available when the keyed slide adjust switch is in the ON position and the editing cursoris on the slide setpoint Press this softkey to move the slide down A momentary push will pulse the slide down once for fine control If the key is held down for more than about a second the slide will move down continuously until the key is released This key is only available when the keyed slide adjust switch is in the ON position and the editing cursoris on the slide setpoint Press this softkey to automatically move the slide to the setpoint An auto adjust sequence always goes above the setpoint and then comes down to it for consistency This key 1s only available when the keyed slide adjust switch 18 in the ON position and the editing cursor is on the slide setpoint Note that when an auto adjust sequence is in progress this key will change to CANCEL AUTO ADJUST When pressed under this circumstance it will cancel the auto adjust sequence and cause slide motion to stop Certain errors will cause the auto setup module to generate a top stop or cycle stop to the
65. memo TERI 07 u ur aman Wa qi REPLACES SLIDE ADJUST UP PUSHBL TION cu ane wam erri WAT RENN ae en Em ETE ra m y REPLACES ADJ OOM PUSHELNTON MUG Copco MD RLOCK BELAY COMET MUG ULUR VELA CUD Y M4BLES SLICE 40JUST POWER a DE P no meen mung 78 E eee mm mine Hs LINDAR TRA MSDUDLR STELT 19 MTL CM SIU 5000 CONT MOUNTED DM Figure B 7 Typical GEMCO Linear Transducer Wiring April 17 2000 Manual Version 1 0 B 7 AUTO SETUP u TEPUIMAL 102 COMMON CROLNO o HOC SOD PELL poenam REPLACES SLIDE 50347 PUSHBLTION REPLACES SLIDE AOLA COUN PUSAELTICH ADN COMTACT P MITA CO m01 COMTACTOP DELAY fp MO USO APPLIDATICH SEE 6 5 1111807 ICE AR 1544 TPkNS0UDCEP 0044 BEL 19 MIJ TEUPZSDMCS SPA PAGES 5878 VLC AT RCHT MLD 5 LINEAR i un v Du PRESS LECT In ez cua Cowo
66. n M PREFS Figure B 8 Typical MTS Temposonics II Linear Transducer Wiring April 17 2000 Manual Version 1 0 B 8 LI EAR OR ROTARY SHUTHEIGHT ADJU TYPICAL WIRING SCHEMATIC SYSTEM 5000 WIRING NUMBERS MAY VARY FROM CONTROL TO CONTROL gt SLIDE ADJUST Le 105 OFF ON i 109 20L 2 2N po pl pg 3 ps 161 P4 hye SLIDE ADJUST UP SG p 3 e ME OME SLIDE ADJUS 5000 10B OR 2M 2MU DOWN LIMIT 125 5000 10C 126 127 CONT ON SH 6 9 5 Oe 5 I 162 198 SLIDE ADJUST DOWN LINE 179 29 sort 2N 155 2MU 2MD F e 6 N 164 N 165 2 SLIDE ADJUST ON CARD POS SSD 5 IPERED IF HYD 2 LOAD OPTION EAR OR ROTARY SHUTHEIGHT ADJUS TYPICAL WIRING SCHEMATIC 2 SLIDE ADJUST 102 105 ore oN OL 2MD 20L 2 120 m Ben pe 124 1 SLIDE ADJUST UP N De 5000 108 N ra OR DOWN LIMIT 195 5000 100 127 19 CONT ON SIL 6 28 D SLIDE ADJUST DOWN LINE 179 TE p Figure B 10 Typical Slide Motor Starter Wiring Without Auxiliary Contactor LINEAR OR ROTARY TRANSDUCER SHUTHEIGHT ADJUST TYPICAL WIRING SCHEMATIC SYSTEM 5000 WIRING NUMBERS MAY VARY FROM CONTROL TO CONTROL 102 SLIDE ADJUST 1e 102 OFF ON ke 120 191 UP LIMIT 122 123 SoL Gr De on 2 911 SLIDE ADJUST UP SOL VALVE MM 5000
67. nal and a user password system The user password system assigns names and passwords to up to sixteen users These two means can be used alone or in combination with each other When a user employs the proper means to gain access he will have the ability to perform the actions and change the parameters which have been designated to his control There are four possible modes of operation for the restricted access system They are the Key Only mode the Key or Password mode the Password Only mode and the Key and Password mode The control can be configured to operate in any one of these four modes Section 2 2 1 Key Only Mode The Key Only mode is the least complex of the four modes This mode employs the RUN PROG key as the only means to limit access to restricted items Any user with the RUN PROG key can access all of the restricted items Without the RUN PROG key user access to all of the restricted items is prohibited Although the Key Only mode has the advantage of being easy to use it does have a disadvantage This mode cannot give a particular user access to only some of the restricted items When operating in this mode any user with the RUN PROG key will have access to all of the restricted items Section 2 2 2 Key or Password Mode The key or password mode allows for either of two means to gain access to the restricted items A user with RUN PROG key can access all of the restricted items A user with the correct pass
68. nches or millimeters depending on how the system is configured See section 4 2 2 for details The slide setpoint is the desired shut height for a slide in inches or millimeters depending on how the system is configured see section 4 2 2 for details Each configured sub system has an indicator that tells what mode the system is in ON OFF or MANUAL See section 4 for details on the mode Each configured sub system is named at the top of the box in which its parameters and settings are shown Hydraulic overloads allow the setpoint pressure to be entered directly in psi or to be set in terms of press trip point This point can be pounds kilograms tons or metric tons depending on how the system is configured The configuration parameters see section 4 2 1 allow the system to convert from trip point to psi automatically There are a number of softkeys in this screen CHANGE NUMBER This key allows the parameter that the editing cursor is currently on to be changed The editing cursor may be placed on a parameter using the up down left and right arrow keys This key is not always available depending on the access code configuration as defined in section 2 April 17 2000 Manual Version 1 0 5 2 CONFIGURE JOG UP JOG DOWN AUTO ADJUST RESET ERROR Allows the individual options such as counterbalance cushion and slide adjust modules to be configured during initial installation of the system and wi
69. nd down relative to the machine some means of stress relief must be used on the cable between the slide and the machine frame The recommended method is to use a helical cable same principle as a telephone handset cord from the transducer to a junction box on the bottom of the crown This lets the wire run in a spring pattern to help it resist breaking Appendix B Figure B 6 shows a conceptual view of this type of mounting The junction box should be grounded to the machine to help shield the connections inside The cable should remain unbroken except for the connector in this junction box to keep the shield integrity do not splice the cable Slide adjust motor starters with and without auxiliary contactors are supported by the OmniLink shut height system as are solenoid operated valves for air motor operation Refer to appendix B for typical wiring diagrams Figures B 7 and B 8 show the wiring for two supported linear transducers Figures B 9 and B 10 show the wiring of slide adjust motor starters with and without auxiliary contactors Figure B 11 shows the wiring of a slide adjust air motor If you order an OmniLink 5000 control with a slide adjust system a wiring diagram will be provided as part of the documentation package April 17 2000 Manual Version 1 0 3 11 Section 4 Configuration After the ASM 15 installed see section 3 1 it must be configured to work with the press Configuration consists of several steps that de
70. ngle Stroke Slide Adjust 1 OH Hydraulic Overload OH J Pressure Set 65 psi i i Setpoint 20 000 in Press Tons Set 320 Tons 4 l Sfutheignt 20 000 in 65 psi Fault Hone Fault Hone Status In Position Counter Balance 1 OH Pressure Set 72 psi Pressure Set 32 psi g Die Weight Set 722 Ibs CushForce Set 2 Tons Actual Actual 72 psi 32 psi Hone Faut Hone Status At Pressure Status At Pressure Cushion 2 OH Cushion 3 OFF f m Pressure Set 54 psi Pressure Set e Cush Force Set 627 Ibs Cush Force Set 0 lbs d Actual Actual 1 54 psi Pressure 0 psi c Fault Hone b L Status At Pressure Status At Pressure Cushion 1 OH Module Status All Conditions OK Figure 5 1 Example Auto Sets Screen The main features of this screen are a The module status gives the overall status of the auto setup module as a whole instead of the status of a single sub system such as a counterbalance When the module is functioning properly thus should read All Conditions OK See section 6 1 for other diagnostic messages b Each configured sub system has a status Under normal conditions this status will read At Pressure for air based sub systems such as counterbalances that are within the tolerance setting of the set pressure Slide sub systems will read In Position when within the tolerance setting April 17 2000 Manual Versi
71. nual mode then the above does not apply c Ifa job is recalled when the press is not at the top the slide adjust system will display a status of April 17 2000 Manual Version 1 0 5 8 Walting for Top When the press does reach the top and all other necessary conditions are satisfied the slide will go to the slide setpoint d Ifajob is recalled when the slide adjust switch is not on the slide adjust system will display a status of Waiting S A Switch When the slide adjust switch is turned on and all other necessary conditions are satisfied the slide will go to the slide setpoint e When job is recalled the slide will not complete the auto adjust sequence until the counterbalance system if present has at least reached operating pressure Whilethe slide is waiting it will display a status of Waiting for Cntr Bal This allows the counterbalance to take up any clearances in the system for a consistent setup f Ifaslide adjust system is stored in a job with a slide setpoint of 0 then when that job is recalled the current setpoint will not be replaced and the slide will not move This is to accommodate intermediate jobs in a setup that may need to cycle cushion pressures before the slide moves April 17 2000 Manual Version 1 0 5 9 Section 6 Diagnostics Fault and Status Messages When the press control screen reports a stop condition that indicates the auto setup board asserted or 15 asserting a stop signal the A
72. olerance measured at the top of the stroke after stamping begins the tolerance must be set to a higher value It may also be possible to set this value lower on some presses The automatic slide adjust is always accomplished by going above the desired shut height setpoint value and descending to the setpoint value The pulse distance value must be set to cause the slide adjust system to make a preliminary stop slightly above the desired setpoint The system will then incrementally pulse the slide adjust motor to achieve the desired slide setpoint position The pulse distance value must be set by trial and error A good starting point is 010 25mm This value would turn off the slide adjust motor 010 25mm above any setpoint entered before the pulse sequence would begin The final stopping point will be less than 010 25mm above the setpoint value and may end up below the desired setpoint since electrical reaction times and mechanical inertia will cause the slide to travel slightly further after the signal to stop is given The pulse distance selected is too large if the system has to pulse more than a few times to get into final position after the preliminary stop and should be decreased The pulse distance selected is too small if the system overshoots the desired slide setpoint position and should be increased No pulses will occur if this happens because the shut height will already be below the intended setpoint The system p
73. on 1 0 5 1 d e g h k for the shut height setpoint See section 6 for an explanation of all status messages for the various sub systems Each configured sub system has a fault message Under normal conditions this fault should read None See section 6 for an explanation of all fault messages for the various sub systems Air pressure controlled sub systems counterbalances cushions and hydraulic overload display the current actual pressure for that system in large numbers for easy visibility Cushions allow the setpoint pressure to be entered directly in psi or to be set in force This force can be pounds kilograms tons or metric tons depending on how the system is configured The configuration parameters see section 4 2 1 allow the system to convert from force to psi automatically Air pressure controlled sub systems counterbalances cushions and hydraulic overload have a pressure setpoint in psi This number is the intended pressure for that system Counterbalances allow the setpoint pressure to be entered directly in psi or to be set in terms of die weight This weight can be pounds kilograms tons or metric tons depending on how the system is configured The configuration parameters see section 4 2 1 allow the system to convert from weight to psi automatically Slide adjust system show the shut height reported by the transducer in large numbers for easy visibility This number will be in i
74. on board 5000 10B problem For rotary slide systems indicates that the fine resolver is not being read correctly This could be a cable problem unplugged connector failed transducer or option board 5000 10C problem The coarse resolver on a rotary system could not be read correctly This could be a cable problem unplugged connector failed resolver or option board 5000 10C problem The fine resolver moved while the coarse resolver was being read Indicates the resolver may be mounted too loosely or that the slide adjust motor brake is not holding The fine and coarse resolvers are no longer in proper alignment Indicates that one of the resolvers is loose internally The resolver may need to be checked or replaced The system will need to be recalibrated The resolver is geared too high or too low Refer to section 3 6 1 for resolver gearing requirements The unit did not sense a slide adjust module in the slot it was configured for Indicates that the card has become unplugged or that the card has failed The configuration data for this system was corrupted The system must be reconfigured Section 6 5 Slide Adjust Status Messages In Position Up Limit Switch Open Down Limit Sw Open Max Position Reached The slide 15 within tolerance of the slide setpoint The slide has hit the mechanical up limit switch and can go no higher The slide has hit the mechanical down limit switch and can go no lower The sl
75. on the base board to provide pressure or shut height adjustment functions When one slide adjust is provided up to four air systems and a hydraulic overload can be adjusted For double action or banjo presses with two slide adjust systems up to two air systems and a hydraulic overload can be adjusted Section 1 1 Counterbalance Control The proper setup of the air counterbalance system in a press is often thought of as a relatively unimportant detail In fact the counterbalance performs a very critical function By countering the weight of the slide and its associated tooling a properly adjusted counterbalance Takes up bearing clearances before the die closes at the bottom of the stroke reducing bearing load and impact Helps reduce gear tooth impact in geared machines by maintaining drive edge gear tooth contact in the press downstroke Decreases the downstroke stopping time of the press since less load is seen by the brake in the downstroke Enhances safety by reducing the possibility that the slide will free fall if the brake is released and the clutch is not engaged Causes less total energy to be used by the press Increases drive motor life by reducing peak motor currents None of the foregoing advantages will be realized if the counterbalance pressure is set too low But a counterbalance pressure that is set too high is also detrimental to the press causing excessive clutch wear and loss of flywheel energy in the
76. orce will always be the same but will not necessarily be the same as the Display Force As units This allows us to enter the maximum and minimum cushion forces in whatever units the name plate uses but operate the press in a different set of units Min Cushion Force for the cushion should be 0 This is because the minimum pressure 2 psi is only sufficient to balance the cushion itself The Display Force As units we set to pounds The Fault Time we leave at 20 seconds The Tolerance is left at the default 2 psi Finally we go back to the Mode line and use the CHANGE MODE softkey to toggle the mode to ON The Auto Sets operation screen can now be used to set the air pressure or cushion force See section 5 2 for operation details Section A 3 Example Hydraulic Overload Configuration This example assumes the hydraulic overload system has been wired to the base auto setup board at AST First some information needs to be gathered From the press manual or the press manufacturer find the minimum air pressure at which the hydraulic overload system will reliably operate and the tonnage trip point that corresponds to that pressure Also find the maximum pressure at which the hydraulic overload is intended to operate and the tonnage trip point that corresponds to that pressure Assume we find that the maximum pressure is 80 psi and corresponds to a 400 ton trip point We also find that the press manufacturer
77. ored job setups from memory The slide position will not automatically change when a job is recalled The slide setpoint can still be changed by manual entry of the desired setpoint and by pressing the AUTO ADJUST softkey to initiate an auto adjust sequence The JOG UP and JOG DN softkeys can be used to manually move the slide OFF The slide position will not automatically change when a job is recalled No automatic movement will occur even if the AUTO ADJUST softkey is pressed The JOG UP and JOG DN softkeys will still move the slide This mode is provided to allow temporary reversion to completely manual adjustment of shut height by use of the JOG UP and JOG DN softkeys if the slide mounted transducer fails Section 5 1 2 Automatic Slide Movement Automatic movement of the slide can be initiated by either pressing the AUTO ADJUST softkey in April 17 2000 Manual Version 1 0 5 4 the slide adjust screen or when a stored job is recalled and the system is ON Note that the AUTO ADJUST key will only appear when the slide adjust switch is ON and the editing cursor is on the slide adjust setpoint of a slide adjust system An auto adjust sequence always approaches the slide setpoint from above For instance if the current position is 10 000 and the slide setpoint is 12 000 the auto adjust sequence might take the slide first to 12 015 then back to 12 004 and then pulse the slide the last four thous
78. pend on the options selected for the ASM An access code 15 required to reach the configuration menus of the OmniLink 5000 press control The code 15 provided separately from this manual for administrative control WARNING Only qualified employees who are authorized by the user should configure the automatic set up module Failure to properly configure and calibrate the module can result in machine damage which in turn may result in injury or death to persons Section 4 1 Setting up the OmniLink 5000 for the Auto Setup Module The OmniLink 5000 press control must be told that the 5000 10 ASM is installed in the card rack If the module was installed at Link as part of an OmniLink 5000 package this step will already be done and configuration should proceed with section 4 2 a Go to the Press Control P C screen b With the RUN PROG key switch in the PROG position press the CONFIGURE softkey and enter the configuration access code d Press the FACTORY CONFIG softkey The screen should now be similar to Figure 4 1 Order SPM Counter Counter OFF c Press the MACHINE PARAMETERS softkey 0 LLL PCSTATUS _ SPM i Speed Orn Mode Single Stroke a Program Run Switch FA CTORY Option j PARA METERS auic Overload CHANGE NUMBER e Use the up and down arrow heh Buton Corfig keys on the operator Torrage terminal to put the cursor on the Automatic Setup ro
79. pounds when the job is recalled it will be set to 4000 pounds If the pressure in a counterbalance cushion or hydraulic overload system goes out of tolerance due to a leak or any other reason a countdown starts The control will try to bring the pressure back into tolerance before the countdown expires If it can not correct the pressure the press will be stopped The fault time is the countdown in seconds Suggested value Is 20 seconds This is the amount by which the system will allow the pressure to vary and still be considered good For instance if tolerance is 2 then a setting of 30 psi will be considered At Pressure from 28 to 32 psi Suggested setting 15 2 This value depends on the kind of pressure transducer used on the system Table 4 gives the transducer type number to use with various transducers Contact Link for others Note that the used pressure range is typically half the actual pressure range of the transducer This allows the transducers to better survive pressure shocks that may occur in operation Table 4 1 Transducer Types Manufacturer Transducer Used Output Trans Model Pressure Pressure Type Range Range 4 20ma 4 20ma 4 20ma 4 20ma 0 300psi SS QQ S 0 400psi This parameter only appears when a hydraulic overload is being configured For hydraulic overloads controlled with 0 10Volt Out proportional voltage refer to table 4 2 for the proper control type based on the
80. press When this occurs the RESET ERROR softkey will appear Before the press can be started again the fault must be corrected and this key must be pressed to clear the error condition Note that this is a restricted operation and an access code may be required depending on system configuration as detailed in section 2 Section 5 1 Slide Adjust Operation Each configured slide system has its own box on the screen Figure 5 1 shows a setup with only one slide adjust system The title of the box has the shut height system name and the mode the system is in ON OFF or MANUAL This box contains Setpoint Actual Position The desired position of the slide shut height adjustment This number may be changed by manual operator entry when the operator has access via key or user code depending on the configuration of the system as detailed in section 2 The setpoint will also be changed to the required slide setpoint for a previously stored job when that job setup is recalled from memory and the system is ON The units for this setpoint can be in inches or millimeters depending on the configuration See section 4 2 2 for details The actual position of the slide shut height adjustment as indicated by a linear or April 17 2000 Manual Version 1 0 53 rotary transducer mounted on the slide system of the press The units for the position can be in inches or millimeters depending on the configuration See section 4 2 2 for details Fault
81. pressure see section 3 1 for a discussion of valve types Now we go to the Auto Sets screen and with the RUN PROG switch in PROG hit the CONFIGURE softkey After typing the configuration code we press the CONFIGURE AIR softkey Since the counterbalance is wired in at AS1 if the slot reported on the screen in not already AS1 we hit the NEXT AIR SLOT softkey until it is The hardware detected should be Fill Dump The first thing we must configure is the Name of the system The cursor should already be on the Name line so we check to see if the name is already Counter Balance 1 If not place the editing cursor on the name and press the CHANGE NAME softkey to cycle through the systems Using the arrow keys we move the editing cursor to the Transducer Type line Looking at table 4 1 we see that the transducer type for any model pressure transducer with a 250 psi pressure range and a 4 to 20 ma output is Type 3 We hit the CHANGE TYPE softkey and select Type 3 from the list that appears When the proper type 15 selected the Air Pressure line should change to read the pressure currently in the counterbalance system Next we use the arrow keys to move the editing cursor to the Maximum Pressure line Since we found earlier that the pressure used to balance the heaviest die the press supports is 78 psi we hit the CHANGE MAX PRES softkey and key in this value Going to
82. pril 17 2000 Manual Version 1 0 A 2 Using the arrow keys we move the cursor to the Transducer Type line Looking at table 4 1 we see that the transducer type for any model pressure transducer with a 250 psi pressure range and a 4 to 20 ma output is 3 We hit the CHANGE softkey and select Type 3 from the list that appears When the proper type is selected the Air Pressure line should change to read the pressure currently in the cushion system Next we move the editing cursor to the Maximum Pressure line Since we found earlier that the maximum pressure allowed on the cushion is 90 psi we hit the CHANGE MAX PRES softkey and key in this value Going to the Minimum Pressure line we enter in 2 psi the value that just supports the weight of the cushion piston and pressure plate Next we have to calculate Max Cushion Force We know that for every psi the cushion will generate 100 pounds of force Since the maximum pressure is 90 psi and 2 psi is used to overcome the cushion weight the max force will be 90 psi 2 psi 100 square inches or 8800 pounds Note that units to the right of the number are also an editable parameter When the editing cursor is placed on the Max Die Weight units we can press the CHANGE UNIT softkey to get a list of supported units The units can be pounds kilograms tons or metric tons We are using pounds Note that the units for minimum and maximum cushion f
83. psi as measured by a pressure transducer that is an input to the system If the air system detects an error it will be reported on this line A fault occurs when a hardware or firmware problem is diagnosed by the system See section 6 for a list of fault messages and their meanings The current status of the air system Status messages indicate what the system is doing in the normal course of its operation See section 6 for a list of status messages and their meanings Section 5 2 1 Air System On Manual and Off Settings An air system can be set in the configuration menu to modes of ON MAN manual or OFF The operator can not change this mode setting in the operation screen but the setting is reported on the top line after the air system name for operator information The ON setting is the normal setting for each air system The mode setting affects the air system in the following ways ON MAN manual OFF Jobs that are recalled from memory will automatically take the air system to the pressure stored in the job The air pressure will not automatically change when a job is recalled The pressure or force setpoint can stillbe changed by manually entering a desired pressure setpoint The air pressure will not automatically change when a job is recalled The OmniLink 5000 will not control the air pressure in any way For units equipped with an integrated valve with manual fallback the manual si
84. ration procedure requires measurement of the space between the press slide and bed or bolster this procedure must be performed with no dies or tooling in the press to prevent the possibility of a point of operation or pinch point injury to personnel making the measurement Failure to heed this warning may result in serious injury or death IMPORTANT Configuring calibrating the slide adjust module should only be done with no dies installed in the press and for presses equipped with slide counterbalance systems should proceed only after the counterbalance is properly adjusted to offset the weight of the slide If counterbalance pressure is too low bearing clearances will cause shut height measurements made during calibration to be too small To calibrate a linear slide adjust system a Make sure the upper and lower limit settings have been set correctly in the slide configuration screen of Figure 4 3 b Press the CALIBRATE SLIDE softkey in the slide configuration screen of Figure 4 3 c Ascreen will appear with a warning that calibrating the slide should not be undertaken without first reading this manual Press the CONTINUE SLIDE CAL softkey to continue the calibration process or EXIT to return to slide configuration d The orientation of the linear transducer must now be set This should be set to 0 if the magnet moves toward the control head where the transducer cable plugs in of the transducer when the slide
85. rder an OmniLink control with a counterbalance adjust system then a wiring diagram will be provided as part of the documentation package Section 3 4 Cushion System Installation The typical manually adjustable press cushion system looks something like Figure 3 9 SAFETY PRESSURE Gate PRESSURE REGULATOR For automatic control the pressure regulator and check valve are replaced with an air valve system Figure 3 10 shows asystem using a Type B valve as described in section 32 Type A and C valves may also be used A pressure transducer is used to monitor the air pressure Figure 3 10 Cushion System with Type B Integrated Valve Section 3 4 1 Cushion Pressure Transducer Mounting The system uses a method of control in which the fill valve or dump valve is energized to raise or lower the pressure of the system The pressure transducer tells the system when it has reached the proper pressure Because air pressure drops occur across air lines when filling or dumping proper placement of the pressure transducer is very important for correct operation of the system Possible pressure transducer mounting locations from best to worst are refer to Figure 3 11 a A spare port on the cushion surge tank b The same port that the safety pop off valve is mounted on if it has its own port on the surge tank c Right at the outlet on the surge tank that goes to the cushion d Right at the inlet on the surg
86. rip tonnage at the maximum pressure Note that the units to the right of this parameter are also configurable When the editing cursor is placed on these units softkey 1 will read CHANGE UNIT When pressed pounds kilograms tons or metric tons may be selected from a list Note that changing the unit here will also change the unit for Min Trip Point This parameter only appears when a hydraulic overload is being configured Set this value to the force generated at the Min Pressure you have selected Note that the units to the right of this parameter are also configurable When the editing cursor is placed on these units softkey 1 will read CHANGE UNIT When pressed pounds kilograms tons or metric tons may be selected from a list Note that changing the unit here will also change the unit for Max Trip Point This parameter only appears when a hydraulic overload is being configured Set this parameter to the units that the trip point should be displayed in The April 17 2000 Manual Version 1 0 4 5 Fault Time Tolerance Transducer Type Valve Type choices are pounds lbs kilograms Kgs tons and metric tons Mtons Note that the display unit can be changed at any time and is independent of the units used for minimum and maximum trip point If a job was stored in tons and this unit is changed to pounds the stored job will still be correct For example if 2 tons were stored for a job and the display unit is changed to
87. rom the dual resolver into the measurement space of the slide If the upper and lower limits are not set correctly the system may fail to calibrate b Press the CALIBRATE SLIDE softkey in the slide configuration screen of Figure 4 3 c A screen will appear with a warning that calibrating the slide should not be undertaken without first reading this manual Press the CONTINUE SLIDE CAL softkey to continue the calibration process or EXIT to return to slide configuration d Now the screen should warn that the upper and lower limits must be set correctly before continuing slide calibration See step a above Press the CONTINUE SLIDE CAL softkey to continue the calibration process or EXIT to return to slide configuration e The number of resolver turns must now be set Use table 4 3 to find the correct number of turns for the resolver used in the system Table 4 3 Resolver Turns Manufacturer Turns 128 Patriot GEMCO SD 0410901 Press the CONTINUE SLIDE CAL softkey to continue the calibration process or EXIT to return to slide configuration f The system now needs an upper calibration point With the press as near as possible to bottom dead center 180 degrees use the JOG UP and JOG DOWN softkeys to take the slide near the top of the adjustment range The slide should be slightly lower than the upper limit that was entered on the slide configurationscreen Take the measurement ofthe shu
88. rough the systems During initial slide setup the Mode of the slide needs to be set to OFF Moving the editing cursor to the mode parameter we hit the CHANGE MODE softkey until the mode reads OFF Before we set anything further we need to choose the units for the slide system Moving the editing cursor to the Shut Height Units parameter we use the CHANGE UNIT softkey to set the units to inches for this example Note that this sets the units for all other shut height position or distance parameters on this screen and during calibration After calibration the units can be changed if desired The Upper Limit and Lower Limit we set to 16 000 inches and 12 500 inches respectively When the mode if the system is OFF these limits are not enforced This allows us to check the operation of the mechanical limit switches The Tolerance Pulse Distance Pulse Time and Lock Time are left at 004 010 03 and 0 respectively the default values We may find these have to be changed later on We find that the magnet on the linear transducer travels toward the control head where the cable comes out as the press is going up We need to know this for calibration Before calibrating the slide we MUST make sure the slide is properly counterbalanced if a counterbalance is used on our press If the slide is not properly counterbalanced the slide calibration April 17 2000 Manual Version 1 0 A
89. rs must be used if no rotating shaft is accessible but the linear transducer can only be used on presses with barrel screw type adjustment mechanisms Section 3 6 1 Rotary Transducer Mounting The Link software supports two different types of rotary transducers for the slide adjust system Both are based on dual resolvers to provide an absolute position indication Resolvers are a tough accurate rotary position sensor By using two resolvers mounted in an enclosure with one resolver geared down relative to the other a multi turn resolver typically around 100 turns is created As mentioned earlier just about every slide adjust system is different Some point must be found that rotates when the slide is adjusted Some obvious points are the slide adjust motor shaft and the shaft that drives a dial counter if present that indicates slide position Depending on the press there may be other points that can be used The resolver should be tied in to one of these points and may need to be geared up or down Requirements are a As much as possible the resolver should be mounted where it will not be submerged in oil grease or other contaminants b The total slide travel from maximum shut height to minimum shut height must not exceed the number of turns of the resolver for example 100 turn resolver is used the total slide travel from maximum to minimum must not result in more than 100 turns at the resolver April 17 2000 Manual
90. s screen cannot be changed by the user Use the CHANGE NAME soft key repetitively to cycle through the available names for this system Slide Adjust 1 Slide Adjust 2 Not Configured Stop when the desired name appears This name will appear on the Auto Sets screen Use the CHANGE MODE soft key to cycle the status from ON to MAN to OFF and back to ON ON means the OmniLink 5000 automatically adjusts to the new shut height associated with a job when that job is recalled from memory but only if the Slide Adjust OFF ON selector switch is turned to the ON position MAN means the OmniLink 5000 can control the shut height but the shut height can only be changed from the Slide Adjust screen A RECALLED job will NOT change the shut height although an operator can cause the system to automatically adjust to a new shut height by turning the Slide Adjust OFF ON switch to the ON position entering the desired shut height value in the Slide Setpoint row and pressing the AUTO ADJUST softkey OFF means the 5000 will not automatically adjust the shut height and will ignore any errors from the system Operators can always manually jog the slide into position through the use of the JOG UP and JOG DOWN softkeys These keys appear when the Slide Adjust OFF ON switch is in the ON position regardless of whether ON MAN or OFF is configured This value should typically be set to ON All shutheight parameters and the shut height ac
91. slide system it will be reported here Status gives the current state of the system such as In Position Slide Low Moving Up etc For the most part these messages will be self explanatory See section 6 for a complete list of fault and status messages with explanations Section 5 2 Air System Counterbalance Cushion and Hydraulic Overload Operation Counterbalances cushions and hydraulic overloads at least the overloads the ASM supports are all controlled by air pressure and as such are grouped as air systems Each configured air system has its own box on the screen see Figure 5 1 The title of the box has the air system name and the mode the system is in ON OFF or MANUAL This box contains Pressure Set The desired pressure of the air system in psi This number may be changed by manual operator entry when the operator has access via key or user code depending on the configuration of the system as detailed in section 2 It may also be automatically changed to the required pressure setpoint for a previously stored job when that job setup is recalled from memory and the air system is ON Die Weight Set For counterbalances only the desired die weight to be counterbalanced by the air system This number may be changed by manual operator entry when the operator has access via key or user code depending on the configuration of the system as detailed in section 2 It will also be changed to the required die weigh
92. ss to this restricted item will appear In the example shown in Figure 2 2 only User Number One User Number Two and User Number Five have access to this restricted parameter The system may have several more users but the three users listed on the screen are the only users that have access to change an Auto Setup Setting The user must use the arrow keys to position the cursor on his user name After placing the cursor on the correct name the user must press the SELECT softkey The SELECT softkey must be pressed even if there is only one user name displayed Step C display will show the selected user name and request the user password The user must enter the correct password and then press the ENT key Step D Upon entry of the correct password the user will be allowed access to the restricted item In the example shown in Figure 2 2 the user will have access to change the Slide Adjust 1 setpoint After performing the steps listed above the user will be logged in to the password system The user will have access to all restricted items that have been designated for his access This access will remain until the user performs a log out or until the user is automatically logged out The user can log out by using the ACC key This key will directly switch the display to the Quick Access screen The LOGOUT soft key legend will appear along the bottom of the screen If the operator presses this key he will log out He will no longer
93. sure through an air pump to control the trip point tonnage at which the hydraulic overload cylinder will dump On these presses the auto setup card can use an E P valve also known as a servo valve to actually set the trip point for the hydraulic overload These systems vary widely and it will be necessary for Link to obtain prints of the press hydraulic overload system in order to determine where to mount control components If your control came configured for a hydraulic overload adjust system then a wiring diagram should have been provided as part of the documentation package Section 3 6 Slide Adjust System Installation Standard slide adjust systems that set shut height on presses vary widely depending on manufacturer and age In general slide adjust systems are either manually turned by wrenches or levers or use electric or air motors to adjust the shut height The OmniLink automatic slide adjust system can only be used on presses with motorized slide adjust Slide adjust motor s must be wired to the automatic shut height adjust module s in the OmniLink extended card rack In addition either a linear magnetostrictive or a rotary resolver based transducer must be mounted in such a way as to detect slide adjust position and wired to the automatic shut height module Rotary transducers may be used when shafts that turn when shut height is adjusted are accessible such as a shaft that drives a mechanical shut height indicator Linear transduce
94. t setpoint for a previously stored job when that job setup is recalled from memory and the air system is ON This number can be set in pounds kilograms tons or metric tons depending on the configuration as detailed in section 4 2 1 Cush Force Set For cushions only the desired cushion force to be generated by the air system This number may be changed by manual operator entry when the operator has access via key or user code depending on the configuration of the system as detailed in section 2 It will also be changed to the required cushion force April 17 2000 Manual Version 1 0 5 6 Press Trip Set Actual Pressure Status setpoint for a previously stored job when that job setup is recalled from memory and the air system is ON This number can be set in pounds kilograms tons or metric tons depending on the configuration as detailed in section 4 2 1 For hydraulic overloads only the desired trip point to be set by the air system This number may be changed by manual operator entry when the operator has access via key or user code depending on the configuration of the system as detailed in section 2 It will also be changed to the required trip point for a previously stored job when that job setup is recalled from memory and the air system is ON This number can be set in pounds kilograms tons or metric tons depending on the configuration as detailed in section 4 2 1 The actual air pressure of the air system in
95. t height in this position as carefully and accurately as possible and without moving the slide enter the number as requested on the screen It is very important to make as accurate a measurement as possible for the Upper and Lower Calibration Points If these measurements are wrong then the slide position reported by the system will also be wrong April 17 2000 Manual Version 1 0 4 12 Press the CONTINUE SLIDE CAL softkey to continue the calibration process or EXIT to return to slide configuration g Finally the lower calibration point must be set Use the JOG UP and JOG DOWN softkeys to take the slide near the bottom of the adjustment range The slide should be slightly higher than the lower limit entered on the slide configuration screen Take the measurement of the shut height in this position as carefully and accurately as possible and without moving the slide enter the number as requested on the screen It is very important to make as accurate a measurement as possible for the Upper and Lower Calibration Points If these measurements are wrong then the slide position reported by the system will also be wrong Press the CONTINUE SLIDE CAL softkey to continue the calibration process or EXIT to return to slide configuration h The slide system should now be calibrated Check for proper operation by running the slide up near the top of theadjustment range and checking the slide position reported
96. tual position can be displayed and entered in inches or millimeters Use the CHANGE UNIT softkey to toggle this setting between inches and millimeters Note that values already entered will be converted to the new unit April 17 2000 Manual Version 1 0 4 8 Upper Limit Lower Limit Tolerance Pulse Distance Pulse Time This value is an electronic upper limit for the slide adjust system that acts as a backup for the mechanical up limit switch The automatic shut height system will not adjust the shut height above this value which should be set just below where the mechanical up limit switch open up This value is an electronic lower limit for the slide adjust system that acts as a backup for the mechanical down limit switch The automatic shut height system will not adjust the shut height below this value which should be set just above where the mechanical down limit switch opens up This value determines how far offthe slide can be from the slide setpoint and still be considered In Position Recommended initial value is 004 10mm While the automatic slide adjust system will normally make its initial adjustment to within 001 02mm of the selected setpoint value the impact created by the stamping operation may cause the shut height to change slightly as clearances in gears and threads of the slide adjustment mechanism shift If the design or condition of the press causes the shut height to change by more than the t
97. ulses the slide adjust motor starter when it gets close to where it wants to go in order to do fine positioning i e after making the preliminary stop determined by the pulse distance The pulse time must be set by trial and error A good starting value for this parameter is 03 sec If the system cannot pulse into position during an auto adjust sequence then this value should be increased A pulse time that produces an average change of about a half a thousandth of an inch in shutheight for each pulse is desirable Too long a pulse time will result in overshooting the setpoint limit by an unacceptable amount Reduce the pulse time if significant overshoot occurs April 17 2000 Manual Version 1 0 4 9 Lock Time Most slide adjust systems now use an integrated brake built in to the slide adjust motor that automatically locks the system down when the slide adjust motor is not on Lock Time is used only for slide adjust systems that have a separate locking system that must be disengaged before the slide adjust motor is engaged The lock time is the amount of time the system will wait before energizing the slide adjust motor after unlocking the system to prevent the slide adjust motor from trying to run before the lock fully releases Section 4 2 2 1 Calibrating Linear Slide Adjust Systems After setting the parameters in the previous section the linear slide system must be calibrated before it can be used WARNING Since the slide adjust configu
98. uto Sets screen module status and the individual sub systems status line will give additional information Section 6 1 Main Module Messages All Conditions OK Communication Fault A D Converter Fail Bad Config Data Bad NV Ram Interrupt Timeout General Module status is ok This does not mean that the individual sub systems such as shut height control counterbalance and cushion control are ok The OmniLink 5000 OIT cannot communicate with the auto setup card This may indicate a total failure of the base card or a blown communications chip The A D converter on the base card of the auto setup module is not responding correctly This will prevent operation ofall air controlled systems such as counterbalances cushions and hydraulic overload If the air system is using a type C valve see section 3 1 it can be turned OFF in the configurations screen and will revert to manual control The configuration data stored in non volatile ram was corrupted The auto setup card will need to be reconfigured after pressing the reset error key in the Auto Sets screen The non volatile ram cannot be read or written to correctly This indicates a hardware problem with either the microprocessor or the ram The OmniLink 5000 control should send an interrupt to the auto setup module every so often This error is generated if that does not happen and indicates some kind of hardware problem Section 6 2 Counterbalance Cushion and
99. w and enter 001 If this parameter is 000 the OmniLink 5000 won t recognize and respond to the ASM f Press the EXIT softkey until the Press Control screen reappears April 17 2000 Manual Version 1 0 Protection Automatic Setup CONFIGURE MODES VAM Pul In Time 5255 VM Drop Out Time Sec WM Track Time M M Tum On Delay rn Sec M M Tum Off Delay Sec Reserved Factory Parameter Figure 4 1 Factory Configuration Parameters 4 1 Section 4 2 Configuring the Auto Setup board The ASM must be configured for the each shut height and pressure module that is installed on it The configuration necessary depends on the particular kind of module Section 4 2 1 Configuring Counterbalance Cushion and Hydraulic Overload Modules Counterbalances and cushions are conceptually very similar and use essentially the same control techniques Hydraulic overloads are somewhat different but are usually air controlled systems there are some non air controlled hydraulic overloads but the auto setup board does not support them at this time To get to the configuration screen for cushion counterbalance and hydraulic overload modules a Go to the Auto Sets screen This screen is reached by pressing the AUTO SETS softkey in the Main Menu or Press Control screen b With the RUN PROG key switch in the PROG position press the CONFIGURE softkey and enter the configuration code Note that the cod
100. word can access the restricted items that have been designated for that particular user only The system allows for passwords to be assigned to sixteen users Each user can be assigned access to any or all of the restricted items The following is an example of a Key or Password mode operation The RUN PROG key is given to the die set up personnel A press operator is assigned a user name and password With the password the operator can reset auto setup faults This is the only auto setup related item to which the operator has access In order to load a die the set up personnel uses the RUN PROG key to recall a job from job storage The set up personnel will also be able to make changes to auto setup limits Once the set up personnel sets the die and verifies its correct operation the operator is left to run the die If an auto setup fault occurs the operator can enter the correct password and then reset the fault However the operator cannot change auto setup limits This will allow the operator to keep running the job and reset faults that occur However if consistent stops occur because an auto setup limit needs changing the set up personnel must be called to change the limit April 17 2000 Manual Version 1 0 2 3 The example above can be taken one additional step if two press operators are given different user names and different passwords One operator can be assigned the ability to change auto setup limits in addition to the ability to r
101. y travels down to 14 003 and pulses the slide into position at 14 000 perfect See section 5 1 for further details on slide adjust operation April 17 2000 Manual Version 1 0 A 9 Appendix B Typical Wiring Diagrams AUTO SETUP PRESSURE JRANSUUCLR WPNE SCHEMATIC 451 fWOUNTED X SURGE TANK ae 120 sec FU3EDI un sf amo seien VE so on 2 ouer vuv stan SCC DETAIL BELOW warm ENS SEE DESL LANE HELD JE PONT SETTINGS APPLY PPCSIURE TRAUICLCER 203 9 200 Bst COUNTERBALANGE 4030571 NMOOULE WEL SDXEMORK VALUE VAR COTE PRLS ILL ar wer AIME i CALPE Oum Figure 1 Typical Counterbalance Wiring Diagram April 17 2000 Manual Version 1 0 B 1 AUTO SETUP PRESSURE TRANSDUCER 157 00490 AT SURGE 0 i us ese sus er 2 ou 1 SELECT VAE SEND PRESSJRE CRAUSQUDLR GETAL LDU WOOL 3 sf vue saut uon 0 Jan 3 spa PRESSURE TRANSDUCER PSEC ABE DIE CUSHION ADJUST MODULE TECH SOLL WILT UNE ee E I Za sg Ft prog GNEM Figure B 2 Typical Cushion Winng Diagram April 17 2000 Manual Version 1 0 B 2
102. y appears when a counter balance is being configured Set this value to 0 die weight This represents no tooling on the upper slide at the minimum counterbalance pressure Note that the units to the right of this parameter are also configurable When the editing cursor is placed on these units softkey 1 will read CHANGE UNIT When pressed pounds kilograms tons or metric tons may be selected froma list Note that changing the unit here will also change the unit for Max Die Weight This parameter only appears when a counter balance is being configured Set this parameter to the units that die weight should be displayed in The choices April 17 2000 Manual Version 1 0 4 4 Max Cushion Force Min Cushion Force Display Force As Max Trip Point Min Trip Point Display Trip As are pounds lbs kilograms Kgs tons and metric tons Mtons Note that the display unit can be changed at any time and is independent of the units that the maximum and minimum die weight are using If a job was stored in tons and this unit is changed to pounds the stored job will still be correct For example if 2 tons were stored for a job and the display unit is changed to pounds when the job is recalled it will be set to 4000 pounds This parameter only appears when a cushion is being configured This should be set to the cushion force generated at its maximum pressure Note that the units to the right of this parameter are also configurable
103. ydraulic overload system Next we use the arrow keys to move the editing cursor to the Maximum Pressure line From the information we already gathered we enter 80 psi Going to the Minimum Pressure line we enter 20 psi Max Trip Point should be the tonnage trip point at the Max Pressure 80 psi in this case so we enter 400 tons Note that units to the right of the number are also an editable parameter When the editing cursor is placed on the Max Trip Point units we can press the CHANGE UNIT softkey to get a list of supported units The units can be pounds kilograms tons or metric tons A hydraulic overload will typically use tons and that is what we select Note that the units for minimum and maximum trip point will always be the same but will not necessarily be the same as the Display Trip As units This allows us to enter the minimum and maximum trip points in whatever units the name plate uses but operate the press in a different set of units Min Trip Point should be the tonnage trip point at the Min Pressure 20 psi in this case so we enter 100 tons The Display Trip As units we set to tons The Fault Time we leave at 20 seconds The Valve Type is set to 6 This value comes from table 4 2 for the type of servo valve we have The Tolerance is left at the default 2 psi April 17 2000 Manual Version 1 0 A 4 Finally we go back to the Mode line and use the CHANGE MODE softk
104. ys or hitting the EXIT key will abort the edit and leave the parameter at the value it had before the editing process began Section 2 1 2 Text Entry For text entry a Place the editing cursor on the text to be changed by using the up down left and right arrow keys as appropriate Note that the editing cursor will only appear on the screen when editing is allowed For instance editing is usually not allowed when the press is running b The topmost softkey will usually say something along the lines of CHANGE XXXXXX where XXXXXX is the name of the value to be changed It may also simply say CHANGE TEXT or CHANGE DESC In any case hit this softkey to enter text entry mode The right hand softkeys will change a letter selection box will appear and the editing cursor will change to a rectangle around the text to be edited Figure 2 1 shows the softkeys and an example text parameter April 17 2000 Manual Version 1 0 2 1 TEXT ENTRY ABORT EDIT CURSOR LEFT CURSOR RIGHT SPACE SELECT LETTER is text to edit Use same Keys to select letter Press ENT to save text ABCDEFGHIJKLMNOPGR STUWW faz Figure 2 1 Example Text Entry c The fist character of the text is highlighted with the text cursor The CURSOR LEFT and CURSOR RIGHT softkeys will move this cursor d Use the left and right arrow keys to point to the letter desired in the letter box next to the text being edited This box wil

Download Pdf Manuals

image

Related Search

Related Contents

Tripp Lite SmartOnline 200-240V 10kVA 9kW UPS Spare / Redundant Power Module, 3U Rack/Tower  Emerson Grommets Brochures and Data Sheets  ELLIPTICAL TRAINER USER'S MANUAL  BETRIEBSANLEITUNG  AN119 Converting an Equinox FS2003 programmer to run FS2000A  Owner`s Manual - Electric Car Parts Company    Manual de Usuario  For Dummies HTML, XHTML and CSS, 7th Edition  1.3 / 2 / 3 MEGA PIXEL EYEBALL DOME IP CAMERAS User`s Manual  

Copyright © All rights reserved.
DMCA: DMCA_mwitty#outlook.com.