System 5000 Press Control AUTO SETUP MODULE COLOR DISPLAY OPERATING MANUAL VERSION 1.
Table of Contents Section 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1.1 Counterbalance Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1.2 Cushion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 1.3 Shut Height Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5.1 Slide Adjust Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5.1.1 Slide On, Manual, and Off Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 5.1.2 Automatic Slide Movement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 on the base board to provide pressure or shut height adjustment functions.
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.
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.
TEXT ENTRY ABORT EDIT CURSOR LEFT T his is text to edit CURSOR RIGHT Use Keys to select letter Press ENT to save text ABCDEFGHIJKLMNOPQRSTUVWXYZ.+-=()%<>/ SPACE SELECT LETTER LOWER CASE UPPER CASE EXIT 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.
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 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 reset 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.
When operating in the Key Only mode the key switch is the only 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 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.
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 B: A list of users that have access 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.
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.
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 “A” 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.
Type “C” An integrated Fill/Dump valve with a manual regulator, check valve, and LOX valve, and a four-way valve that selects whether the pressure is 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.
For automatic control, the pressure regulator and check valve are replaced 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. April 12, 2012 Figure 3.6: Auto-Counterbalance with Type “A” Integrated Valve. Figure 3.7: Auto-Counterbalance with Type “C” Integrated Valve. Manual Version 1.1 3.
Section 3.3.1 Counterbalance Pressure Transducer Mounting The system uses an automatic method of control in 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.
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.
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.
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 pressure through an air pump to control the trip point (tonnage) at which the hydraulic overload cylinder will dump.
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 “c” 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.
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.
Section 4. Configuration After the ASM is installed (see section 3.1), it must be configured to work with the press. Configuration consists of several steps that depend on the options selected for the ASM. NOTE! An access code is required to reach the configuration menus of the OmniLink 5000 press control. The code is 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.
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.
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 The “Help” box at the bottom of the screen changes depending on the parameter that the editing cursor is currently on.
For hydraulic overloads this value should be the pressure specified by the press manufacturer for rated tonnage operation. Min. Pressure 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.
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. Max. Cushion Force 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. When the editing cursor is placed on these units, softkey 1 will read “CHANGE UNIT”.
is recalled it will be set to 4000 pounds. Fault Time 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.
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.
Slide Slot Corresponds to the physical slot number (SS1 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. Hardware Detected 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”. Shutheight The current slide position reported by the transducer.
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 tolerance (measured at the top of the stroke) after stamping begins, the tolerance must be set to a higher value.
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.
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. 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.
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.
h) 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. 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.
Section 5 Operation The purpose of the Auto-Setup module is 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.
various sub-systems. c) 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. d) Air pressure controlled sub-systems (counterbalances, cushions, and hydraulic overload) display the current actual pressure for that system in large numbers for easy visibility. e) Cushions allow the setpoint pressure to be entered directly in psi or to be set in force.
will 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. “JOG UP” 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 ½ 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 cursor is on the slide setpoint.
Fault 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.
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.
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 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.
Fault 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. Status 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.
The RUN/PROG key, a user code, or both may be required to change them. If a force setpoint is entered, the proper pressure in psi will be calculated and applied to the system. Likewise if pressure is entered, the force 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”.
Section 6 Diagnostics - Fault and Status Messages When the press control screen reports a stop condition that indicates the auto-setup board asserted or is asserting a stop signal, the “Auto-Sets” screen module status and the individual sub-systems status line will give additional information. Section 6.1 Main Module Messages All Conditions OK 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.
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. Unable to Dump 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. Max. Press. Exceeded The air pressure exceeded the maximum pressure programmed in the configuration menu.
Hyd Overload Tripped The hydraulic overload operation screen will display this message when the press hydraulic overload system is tripped. Waiting for Top The hydraulic overload system is waiting for the press to reach the top of the stroke before it adjusts the hydraulic overload setting. LMC is Out 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.
unplugged connector, failed power supply, failed transducer, or option 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. Coarse Resolver Fail 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. Res.
shown if the position transducer is still functioning correctly. Waiting for Cntr-Bal The slide adjust system is waiting for the counterbalance, if present, to come to its correct pressure before automatically moving the slide. Slide Too High The slide is higher than the slide setpoint plus tolerance. Slide Too Low The slide is lower than the slide setpoint minus tolerance. Hyd Overload Tripped The hydraulic overload has tripped. The slide will not move down in this condition.
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 A.
supported units. The units can be pounds, kilograms, tons, or metric tons. We are 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.
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.
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.
some information needs to be gathered. A GEMCO 952 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.
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.
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 and the maximum shut height is 16.000 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.
Appendix B Typical Wiring Diagrams Figure B.1: Typical Counterbalance Wiring Diagram. April 12, 2012 Manual Version 1.1 B.
Figure B.2: Typical Cushion Wiring Diagram. April 12, 2012 Manual Version 1.1 B.
Figure B.3: Conceptual Dual Resolver Mounting. April 12, 2012 Manual Version 1.1 B.
Figure B.4: Typical AMCI Dual Resolver Wiring Diagram. April 12, 2012 Manual Version 1.1 B.
Figure B.5: Typical GEMCO Dual Resolver Wiring Diagram April 12, 2012 Manual Version 1.1 B.
Figure B.6: Conceptual Linear Transducer Mounting April 12, 2012 Manual Version 1.1 B.
Figure B.7: Typical GEMCO Linear Transducer Wiring April 12, 2012 Manual Version 1.1 B.
Figure B.8: Typical MTS Temposonics II Linear Transducer Wiring April 12, 2012 Manual Version 1.1 B.
Figure B.8A: Typical Balluff Linear Transducer Wiring April 12, 2012 Manual Version 1.1 B.
Figure B.9: Typical Slide Motor Starter Wiring With Auxiliary Contactor Figure B.10: Typical Slide Motor Starter Wiring Without Auxiliary Contactor Figure B.11: Typical Slide Air Motor Solenoid Wiring April 12, 2012 Manual Version 1.1 B.
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) Remove the logic board from the card rack.
Appendix D 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.
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.
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.
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.
Section E.
Rotary Transducer Slide Configuration Slide Configuration Slot #1 Board Rotary Transducer Name ___________________ Upper Limit __________ Lower Limit __________ Tolerance __________ Pulse Distance __________ Pulse Time __________ Lock Time __________ Resolver Turns __________ Rotary Transducer Slide Configuration Slide Configuration Slot #2 Board Rotary Transducer Name ___________________ Upper Limit __________ Lower Limit __________ Tolerance __________ Pulse Distance __________ Pulse Time __________ Lock
Appendix F Specifications Section F.1 5000-10A Pressure Control Board AC Output Relays: Voltage: Current: Fuse: Section F.2 5000-10B Linear Shut Height Control Board AC Output Relays: Voltage: Current: Fuse: Section F.3 120VAC 1Amp Continuous 20 Amp 16ms 5 Amp 75ms 2 Amp Fast-Blow Picofuse 5000-10C Rotary Shut Height Control Board AC Output Relays: Voltage: Current: Fuse: April 12, 2012 120VAC 1Amp Continuous 20 Amp 16ms 5 Amp 75ms 2 Amp Fast-Blow Picofuse Manual Version 1.
