System 2500 Programmable Limit Switch /Die Protection Unit Operator Manual WARNING!! THIS UNIT IS NOT INTENDED FOR APPLICATIONS REQUIRING CONTROL RELIABILITY. DO NOT USE THE OUTPUT RELAYS OF THE SYSTEM 2500 AS PRIMARY INPUTS TO A PRESS CONTROL.
TABLE OF CONTENTS Section 1 OVERVIEW OF THE SYSTEM 2500 1.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1.2 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 1.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Section 2 OPERATION 2.1 Using the Operator Interface Terminal . . .
2.6 2.7 2.8 2.9 ii 2.5.5 RESTRICTED CHANNELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.6 OFFSET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5.7 PLS OUTPUT SPEED ADVANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . COUNTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6.1 PART Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.9.7 2 PART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45 2.10 STOPS/FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46 Section 3 3.1 3.2 3.3 OUTPUTS Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 DC Solid State Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Section 1 OVERVIEW OF THE SYSTEM 2500 1.1 Features The System 2500 has 8 or 16 channel output capability for Programmable Limit Switch functions. Relay, solid state AC, and solid state DC outputs are available. Multilevel programming security is provided so that fixed setpoints or special access can be provided on the first 8 output channels. Timed outputs up to 2 seconds in duration and speed advanced outputs are programmed through the keyboard.
A stroke counter and presettable batch counter, parts counter, and quality check counter are standard. One hundred setups can be stored in nonvolatile memory and recalled by job number or name. Each setup can contain as many as 60 setpoints or dwell times for PLS outputs along with complete programming information for each die protection input. A sturdy, compact single resolver unit is used by the System 2500 as position transducer.
Figure 1 System 2500 Components 1.3 Specifications Input Ratings Primary Input Power Requirements: 115VAC ± 15VAC, 60Hz, 1 Ampere Run Signal Input (Terminals 34 & 35): 115VAC @ 10mA nominal or 24VDC @ 2mA nominal Die Protection Inputs and Auto SS Input: Inputs are active low (ground); to activate, external circuit must sink 0.6mA (typical), 1.
Switching Output Ratings Electromechanical Relay Outputs: 5.0 Amperes @ 120VAC or 24VDC AC Solid State Relay Outputs: 1.5 Amperes @ 240VAC DC Solid State Relay Outputs: 3.0 Amperes @ 60VDC General Response Time, Die Protection (static type, time from input change to E-Stop relay contacts open): 25mS (typical), 33mS (maximum) Response Time, Die Protection (cycling type, time from window position passed to E-Stop relay contacts open): 20mS (typical), 28mS (maximum) Pulse width recognized by N.O.
Section 2 OPERATION 2.1 Using the Operator Interface Terminal The OIT is the means by which the operator can control the operation of the System 2500.
2.1.1.2 HELP Key The operator may request a Help screen from the System 2500 PLS by pressing the HELP key. The Help screens are intended to aid the operator by giving additional information and explanation of the current stage of the program sequence. Some Help screens may be more than two lines long. If the last character on the screen is a down arrow, more help information is available. The operator may press the down arrow key to view the additional lines.
The Mode Selector is a three position keyswitch. The key may only be removed in the RUN position. The operating conditions for the three positions are as follows: C RUN - This is the normal operating mode of the System 2500. When the key is in this position, the operator can only view limit switch setpoints or the die protection input modes. He cannot add, erase, or edit PLS setpoints in this position, nor can he edit the die protection setup.
can be accessed by selecting this function. The total stroke count of the machine as seen by the unit can also be displayed here. C STORE/RECALL - With the System 2500 a particular setup (which includes both limit switch and die protection settings) can be stored under a name or number and recalled at a later time. This saves the operator from having to re-enter different settings each time a die is changed.
the output relays on the System 2500. These choices are as follows: C SETPOINTS - This option allows the operator to program the output relays to turn on or off at different points in the machine stroke (referred to as the 'setpoints' of an output channel). This function is described in Section 2.4.1. C VIEW STATUS - Choosing this option will produce a display which indicates the on/off status of the output relays, in groups of 8. This function is described in Section 2.4.2.
Setpoints can only be added when the mode keyswitch is in the PROG (Program) position. The on and off points must then be entered as instructed. If incorrect data is keyed in, the CLEAR key will remove the entire line and the correct data can then be entered. The CLEAR key cannot be used once the ENTER key has been pressed to store the data. Once this has been done the setpoints must be erased or edited. If a channel is restricted no setpoints can be added.
channels. 2.4.1.3 Editing Setpoints To edit an on or off setpoint, the operator must first place the mode selector keyswitch in the PROG mode. Then the setpoint to be modified must be selected with the right or left arrow keys. When the setpoint to be modified is blinking, the operator may key in the new setpoint value. If a mistake is made in keying in the data, the CLEAR key may be pressed to clear the data.
necessary for proper actuation of the output at maximum speed and at minimum speed (see Section 2.5.7 for a description of this procedure). The setpoint value should be left programmed at the correct setting for minimum speed. The setpoint should then be edited to 'Advanced' status, by pressing the ADVAN key while the cursor is on the setpoint. The screen will then ask the operator to confirm that the setpoint is to be advanced.
If the VIEW STATUS item is selected from the Outputs Menu, the OUTPUT STATUS screen will be displayed. This screen indicates for each of the first eight outputs whether the output is on or off. This information can be useful when first setting up the unit on the machine or when troubleshooting. On the far right of the display is the down arrow symbol, which indicates that by pressing the DOWN arrow key the status for outputs 9 through 16 will be displayed.
2.4.3.1 Counted Outputs, VIEW SETUP When VIEW SETUP is selected from the Counted Outputs Menu, the operator will see a list of the outputs which are tied to the counter. Also shown is the stroke count on which these outputs will be active and the current stroke count of the machine. (Remember that this is a special cycling counter and is NOT the same as the Part, Batch, Quality Check, or Total Stroke counters of the System 2500. See Section 2.6 for information regarding these counters).
2.4.3.3 CHANNELS If the operator wishes to tie a PLS output to the special counter, the ADD key must be pressed. After this key is pressed, the display will prompt for entry of the channel to be added. PLS channels 1 through 8 may be tied to the counter. Key in the desired channel number and press ENTER. The display will then return to the Counted Outputs setup information screen with the new PLS channel number added to the list.
change the ACTIVE COUNT, use the arrow keys to move the cursor to the ACTIVE COUNT value then key in a new value and press ENTER. For example, if the outputs tied to the counter should only be active every five strokes (make four strokes with these outputs OFF then one stroke where the outputs switch normally), enter the number 5 for ACTIVE COUNT. If the outputs should be active every eight strokes, enter the number 8 for ACTIVE COUNT. The maximum ACTIVE COUNT value that can be entered is 255.
2.5 CONFIGURE The Configure routines will allow the operator to program into the System 2500 important information relating to the machine on which it is installed. The configuration routines can only be entered with the mode selector keyswitch in the PROG position. Switching the keyswitch from the PROG position will terminate the configuration routine (except for the special case of setting TOPSTOP angle - see Section 2.5.3). To access these routines the operator must select CONFIGURE from the PLS Menu.
The motion detector is used as a check by the System 2500 PLS to insure that the resolver is properly wired, the input circuits are functioning, and the resolver is coupled to the machine crankshaft. The operator must enter three values into the motion detector configuration. These values are: C THRESHOLD - This is the crankshaft speed at which the System 2500 will recognize that the machine is in motion. The speed entered here should be 75% of the machine's slowest operating speed.
machine will come to a stop at the top. This is called the 'stopping angle' in further text of this manual. The Topstop selection from the Configure Menu (labeled TOPSTP) allows the operator to program this angle so that an accurate top stop will occur. The Topstop configuration display indicates on the top line the angle at which the E-Stop relay will open when a top stop signal is generated. The bottom line allows the operator to enter a new angle if required.
2.5.4 TOPSTOP SPEED ADVANCE For variable speed machines the operator may program the stopping angle to advance (occur earlier in the stroke) as the speed increases. For functions which result in a top stop this will insure that the machine will continue to stop on top as the machine speed increases. In order for a speed advanced stopping angle to operate properly, the Topstop Speed Advance configuration data must be programmed (found under the TOPSTP ADVAN selection of the Configuration Menu).
while the cursor is on the top line. Using the arrow keys the operator can 'scroll' through all the lines of data that must be entered. (The only exception to data entry is the MAX SPEED shown on the first screen. MAX SPEED is for display only and cannot be entered on the Topstop Speed Advance screen. To change the value of MAX SPEED the operator must go to the MOTION DETECTOR data screen, Section 2.5.2). All speed advance data must be entered for proper operation.
To remove a PLS channel from the list the operator must press the REMOVE key, then move the cursor to the channel number desired using the arrow keys. The CLEAR key must then be pressed to remove the restriction from the chosen channel. 2.5.6 OFFSET The offset is a value that the System 2500 PLS will add to its resolver reading to make up for the difference between machine zero position and resolver zero position. The offset value is limited to + or - 10 degrees.
The operator can use the cursor to select a data value, then key in the proper value and press ENTER. When a 'down arrow' symbol is displayed as the last character on the bottom line of the display, this indicates that another data line is available to the operator by pressing the down arrow key while the cursor is on the bottom line.
Part) and Die Protection is active (not bypassed) then the count will increment whenever a part is seen by this input. (Remember that the part counter must still be set active for counting to take place as noted earlier). If an input is programmed as a Part Detector but Die Protection is bypassed, no counting will take place. 2. If no Die Protection input is programmed as a Part Detector then the part counter will increment at 270 degrees just as the stroke counter.
quality count limit are performed by the operator in the same way as for the part counter. If the quality counter is not being used, it should be deactivated. 2.6.4 STROKE Counter The stroke counter is used to record the total number of machine strokes since the System 2500 was connected to the machine. The stroke counter is incremented each time the machine passes 270 degrees. The stroke counter is always active. It cannot be reset by the user. 2.
backup memory to be the current setup, the setup name will immediately appear on the Store/Recall Menu. Similarly, if the current setup is stored into backup memory, the setup name which the operator assigned will immediately appear on the Store/Recall Menu. In either case, the name signifies that the current setup matches one stored in backup memory under that name. If the current setup does not match one that is stored in backup memory, the message 'New data' will be displayed.
the current setup is edited. Note that the current setup is not changed after the store; only a copy of it has been saved in backup memory. When STORE is selected from the Store/Recall Menu, the display will change to show the Store Menu and will also show the last name used by the operator in a Store or Recall operation. The STORE menu gives the operator two choices for entering the setup name: C USE THIS NAME - Use the name which appears on the top line of the Store Menu to store the current setup.
After the name has been keyed in, the operator must press the ENTER key. The System 2500 will then ask the operator to verify that he wishes to store the current setup using the name displayed. By pressing the STORE key, a copy of the current setup will then be stored in backup memory. Note that the current setup is not affected by the store operation, and that the PLS and die protection information previously entered will still be in effect.
Figure 4 Recalling a Setup When the operator chooses RECALL from the Store/Recall Menu, the Recall Menu is displayed. This menu gives the operator two options for choosing the setup name to be recalled. These are listed on the display as follows: C ENTER SETUP NAME - The name of the setup to be recalled can be entered directly using this option. C VIEW NAMES - The operator may view a listing of all the stored setups in backup memory, and choose one to recall. 2.7.2.
After the name has been keyed in, the operator must press the ENTER key. The System 2500 will then ask the operator to verify that he wishes to recall the setup whose name is displayed. By pressing the RECALL key, the setup by this name in backup memory will be copied over the current setup. The PLS and die protection information now in effect will be that of the recalled setup. WARNING! Unexpected machine operation may take place when the new setup is recalled.
If a stored setup is no longer needed it may be removed from the System 2500 PLS backup memory. If the operator desires to remove a stored setup, he must select REMOVE from the Store/Recall Menu. The options for choosing the setup name to remove from memory are the same as those for recalling a setup from memory (see Section 2.7.2). The operator can remove a setup by entering the setup name, or by viewing a listing of the current setups and choosing one.
Selection of this menu item will allow the operator to program the die protection inputs to perform a monitoring function or to see when a change in status has occurred on a die-prot input. These choices are shown on the DP INPUT MENU: C EDIT INPUT MODE - Allows the operator to view or edit the mode of operation of each die protection input. C VIEW STATUS - Allows the operator to see if a die protection input is closed (grounded) or opened.
By choosing VIEW CHANGE from the DP INPUT MENU, the operator can view the crankshaft angle at which a particular die protection input changes. For example, if a part detector is being used that causes a die protection input to change from open (ungrounded) to closed (grounded) when the part passes, then the crankshaft angle where the part passes can be displayed using the VIEW CHANGE option.
BYPASS’ indicator on the OIT will flash to alert the operator. In order to change the status from ON to OFF and vice versa, the keyswitch must first be in the PROGRAM position. (When in the RUN position, a message is displayed on the right side of the screen and no changes are allowed.) The upper right portion of the screen will then display a message directing the operator to press the YES key to bypass the die protection (as seen in Figure 5.
When the lock function is to be used, input #32 cannot be programmed for any of the active die protection modes (static, cyclic, etc.) Attempting to activate the lock feature with this input programmed for die protection will result in a warning message. Conversely, once the lock feature has been activated any attempt to program this input for die protection monitoring will be disallowed. Once a switch has been wired to Input #32, the lock feature must be activated.
an event is expected to occur on a die protection input. The timing channels are internal only; that is, there are no relay outputs associated with these channels that will turn on or off. By choosing TIMING CHANLS from the Die-Prot Menu, the operator will be able to view or edit the timing channel information. The Timing Menu offers these options: C SETPOINTS - Allows operator to view or edit the on/off setpoints of each timing channel.
2.8.3.2 VIEW STATUS (for Timing Channels) The VIEW STATUS option of the Timing Menu will display the current on or off status of all eight timing channels. The status on any timing channel will change as the machine crankshaft rotates provided that the channel has had on/off setpoints programmed (see Section 2.8.3.1). 2.8.4 AUTO SS (Automatic Single Stroke) (NOTE: This choice may not appear on the Die-Prot Menu if the System 2500 was not ordered from the factory with the Automatic Single Stroke option.
external control logic. These connections to the System 2500 should be wired according to the drawings provided by Link Systems to insure proper operation. 2.8.4.1 Auto SS Programming Requirements The System 2500 has several requirements for internal programming by the operator before correct operation of Auto Single Stroke can be achieved. First are the data values directly related to Auto Single Stroke which are listed as follows: 1.
the 'ON' position. 3. There can be no E-Stop condition present, and the Top Stop button cannot be depressed. 4. The Auto Single Stroke Setup button must be pressed and released. Once the setup button has been pressed, the operator must manually make the first stroke to begin Automatic Single Stroke operation. This must be done within the time limit programmed for First Stroke Time (see Section 2.8.4.6 below). During the first (manual) stroke the automatic function will be latched in.
2.8.4.3 Auto SS Status Screen and Menu When AUTO SS is chosen from the Die-Prot Menu, a screen will appear indicating Auto Single Stroke status on the left half of the screen, and providing access code input information on the right half of the screen. There are two lines of status information on the left. The top line is labeled 'AUTO SS' followed by an indication of 'OFF' or 'ON'. This indicates whether or not the Auto Single Stroke capability has been internally enabled.
2.8.4.4 AUTO SS ON/OFF When this choice is made, the information which was present on the Auto SS status and access code screen will be redisplayed on the left side of this screen. On the right side will be the menu for turning Auto Single Stroke 'ON' or 'OFF'. In order for the Automatic Single Stroke option to be functional, the operator MUST turn Auto SS 'ON' in this screen. This is done by using the arrow keys to move the cursor to the 'ON' label, then pressing the ENTER key.
To change the time, simply type in the new desired delay and press the ENTER key. The delay time entered can be from 4 to 2000 milliseconds (ms) in 1 ms increments. The minimum delay time entered here (in milliseconds) must be less than the maximum delay time entered in Section 2.8.4.7 (in seconds) or an error will be generated. In other words, if 1 second is entered as the maximum time in Section 2.8.4.7, the minimum time entered here must be less than 1000 milliseconds. 2.8.4.
CAUTION! THIS IS AN AUTOMATICALLY STARTING POWER PRESS AND SHALL BE PROPERLY GUARDED PER OSHA 1910.217 INCLUDING TABLE 0-10. SERIOUS INJURY CAN BE CAUSED TO THE MACHINE OPERATOR OR TO OTHER PERSONNEL IF THIS WARNING IS NOT HEEDED. 2.9 Die Protection Modes of Operation Each of the eight DIE-PROT inputs can be programmed for one of seven different modes of die protection: STATIC, CYCLIC, TRACK, TRANSFER, IN POSITION, 1 PART or 2 PART parts detection. 2.9.
An example of the use of a normally closed input is an end of stock sensor, as shown in Figure 9. A probe is mounted so that it is grounded by the stock being fed into the production machine. When the end of stock is reached, the probe will no longer contact the stock, opening the input and causing a fault.
2.9.2 CYCLIC Cyclic inputs are derived from monitored events that occur once each machine cycle when the production process is functioning normally. An example of a cyclic event is shut height monitoring as shown in Figure 10. In normal operation, when the die closes, a switch or probe will be closed, then, when the die opens again, the switch will open. If parts should stack up in the die, the switch will not close and a fault will be detected.
the operator enter one of these output channel numbers to be used as the fault output. The channel selected cannot have been previously restricted nor can it be tied to the counter. If the unit is programmed for Automatic Single Stroke, channels 7 and 8 are reserved and cannot be assigned as the cyclic fault output. Once a channel is selected, the system will ask for the number of strokes to delay before activation of this PLS output.
2.9.3 TRACK Tracking inputs are used to monitor events that should closely follow (track) a System 2500 PLS output. A die protection input can be programmed to track a PLS output within a specified period of time. When programming an input for Track Mode the operator will first be asked to enter the PLS channel to be tracked and then the tracking time (the amount of time that the die protection input is allowed to 'lag' behind the PLS output).
When programming an input for transfer mode, the operator is asked to enter a timing channel number. This is the internal timing channel of the System 2500 that will be used for checking the transfer input (see Section 2.8.3 for more information on timing channels). The timing channel should be set to turn on just after the part is gripped, and turn off just before the part is released into the next stage of the die (see Figure 13). 2.9.
die closes. An illustration of the In Position timing sequence is shown in Figure 15. Figure 15 In Position mode timing 2.9.6 1 PART The One Part mode is used to monitor parts ejection for dies producing one part per stroke. This mode functions much like the cyclic mode, the difference being that the timing channel must turn on before, not while, the part is being ejected (activating the sensor). The operator will be prompted for a timing channel number when 1 Part mode is selected.
Figure 17 Probes used with Part Detector inputs.
the die protection input erroneously. If a Die Protection input is programmed as a Part Detector, the user presettable counters of the System 2500 (Part Counter, Batch Counter, and Quality Check Counter) will then be tied to that input. In other words, when any one of those counters is turned on (active), the counter will increment each time a part is seen by the Part Detector input. See Section 2.6 for additional information on the Counter functions.
window, as might be the case for a very long part. Note: If the input is programmed for ‘Part Must Pass’, the sensor is not allowed to become active outside the window or a fault will be generated. This provides protection against a part ‘bouncing’ on a probe-type detector and satisfying the die protection input erroneously.
Section 3 OUTPUTS The PLS-2500 system is available with a minimum of 8 outputs and a maximum of 16 outputs. These are provided in groups of eight on circuit boards which are mounted on the cover of the Logic Unit. Each group of eight outputs can be relays, DC solid state modules, or AC solid state modules. 3.1 Relay Outputs Each relay output board provides eight relays for the user. The first two relays on any board (i.e.
restriction on which terminal is connected to the power source and which is connected to the load. The outputs for the AC solid state relay board are rated to carry 1.5 amps RMS at 240 VAC.
Section 4 INSTALLATION 4.1 Component Mounting The System 2500 PLS consists of three major components; the Operator Interface Terminal (OIT), the Logic Unit, and the Resolver Unit. These components are identified in Figure 1. In order for the System 2500 to function correctly, these major components must be properly installed and connected. Please read this entire section before attempting installation. The OIT must be mounted in a position that is easily accessible and viewable by the operator.
Figure 21 Operator Interface Terminal Mounting Dimensions speed shafts other then the crankshaft. However, the resolver must be driven by the high speed shaft in the inverse ratio by which the shaft motion is related to the crankshaft (that is if the high speed shaft turns in a 3:1 ratio to the crank, the resolver must turn in a 1:3 ratio to the high speed shaft.) Coupling of the resolver to the crankshaft is usually accomplished by a chain drive.
Figure 22 Logic Unit Mounting Dimensions of the legend, the resolver is at zero. The System 2500 PLS allows the user to program an offset value to make up for minor differences from machine top dead center and resolver zero. Since the System 2500 PLS will allow the user to program a +/- 10 degree offset value, the mechanical alignment from the machine shaft and the resolver assembly must be within +/-10 degrees.
Figure 23 Resolver Mounting Dimensions 4.2 Wiring After the three major components of the System 2500 PLS have been mounted, the wiring of these components may proceed. It is the responsibility of the installer to insure that the wiring conforms to all applicable local codes. Wiring may be accomplished in the following order: 1. 4-4 Wire the OIT to the plug-in terminal strip provided for this purpose (terminals #1 through #8) as shown in Figure 24.
isolated. Figure 24 Operator Interface Terminal Wiring 2. Before connecting the resolver to the Logic Unit, proper direction of rotation of the resolver shaft must be ascertained. The direction of resolver rotation must be observed by looking at the resolver shaft from the shaft end of the resolver unit. If the resolver shaft is to rotate clockwise when the machine shaft to which it is connected is rotating in the desired direction, wire the resolver for clockwise rotation.
Figure 25 Resolver Wiring 4. 4-6 Wire the System 2500 PLS E-Stop contacts to the emergency stop circuit of the machine control. The System 2500 PLS has two sets of E-Stop contacts. One set of these contacts must be connected to the emergency stop of the machine control. The other set of contacts may be used to stop any auxiliary equipment.
open. The E-Stop contact connections are located on the terminal block of the relay output board for outputs 1 through 8. This board is mounted on the top of the Logic Unit. Figure 26 Wiring of RUN Input 5. The RUN input must be wired across one solenoid of the dual air valve. Machine motion occurs when the dual air valve is energized. The RUN input connections are terminals #34 and #35 located on the large 20 circuit plug-in terminal block of the Logic Unit. These connections are shown in Figure 26.
For each relay output card present (1 card standard, a second card optional for a total of 16 outputs), the terminal block on the card provides connections to the contacts of the output relays. These terminals are labeled to specify which relay output and which contact arrangement (NC or NO) is provided at each connection. 7. Wire the connections for the Die Protection system as required. Die Protection probes, sensors, and switches should be wired to terminals #25 through #32 as needed. 8.
Figure 27 Wiring of LINK 3040 Infrared Parts Detector 5. Run the machine in the proper direction. Verify that the angle is increasing as the machine rotates. If the angle is decreasing, the resolver must be wired for the opposite rotation. 6. Set the machine offset. This procedure is described in Section 2.5.6. 7. Set the machine Topstop angle. This procedure is described in Section 2.5.3. If the machine is a variable speed machine, it may be desirable to set up the Topstop angle to be speed advanced.
4-10 8. Program all PLS outputs that are to be used. 9. Set the PLS Output Speed Advance parameters. This procedure is described in Section 2.5.7. If speed advanced outputs are not used, this step may be omitted.
Section 5 ERROR CODES 5.1 Error Listing The following is a listing of error codes generated by the PLS-2500 unit and suggested action for correction of the errors. These codes apply to software version 1.8 and above. Error No. 001 Message / Action OIT UNABLE TO COMMUNICATE WITH LOGIC BOARD 1) Verify that Operator Interface Terminal cable is properly wired to the plug-in terminal strip for Logic Unit. 2) Verify that plug-in terminal strip is securely installed into header (receptacle) on Logic Unit.
3) Verify that 6 pin plug-in terminal strip is securely installed into header (receptacle) on Logic Unit. 4) Notify factory. 040 PROCESSOR INTERNAL DATA ERROR 1) Notify factory. 041 LOSS OF RESOLVER SIGNAL 1) Verify that resolver cable round connector is securely installed to its mate on rear of resolver package. 2) Verify that resolver cable is properly wired to 6-pin plug-in terminal strip for Logic Unit.
3) Verify that resolver cable is properly wired to 6-pin plug-in terminal strip for Logic Unit. 4) Verify that 6-pin plug-in terminal strip is securely installed into header (receptacle) on Logic Unit. 5) Notify factory. 061 SETUP IN BACKUP MEMORY HAS BAD DATA - SETUP NOT RECALLED 1) The setup that you attempted to recall contains invalid data. You may choose to remove the setup from backup memory to eliminate it.
found to be corrupt. Before this error can be cleared, certain information in the Configure Menu (see Section 2.5) and Counter Menu (see Section 2.6) must be entered. In the Configure Menu all MOTION DETECTOR values, all SPEED ADVANCE information, the Topstop angle, and the machine OFFSET must be entered. In the Counter Menu each counter must first be turned on, then each can be left on or turned off if desired. Error 063 can be cleared when this data is programmed.
operator has entered a THRESHOLD value which is greater than the value entered for the Max Speed of the machine, which cannot be allowed. To clear this error the operator must go to the MOTION DETECTOR choice of the Configure Menu and enter the proper motion values. 069 PLS OUTPUT SPEED ADVANCE DATA INVALID, RE-ENTER IN CONFIGURE MENU 1) The data stored to make the PLS Output Speed Advance feature work properly is invalid.
2) Verify that resolver cable is properly wired to 6-pin plug-in terminal strip for Logic Unit. 3) Verify that 6-pin plug-in terminal strip is securely installed into header (receptacle) on Logic Unit. 4) Check wiring of 'AC RUN' input on 20-terminal plug-in strip. 5) Verify that 20-terminal plug-in strip is securely installed into its header (receptacle) on Logic Unit. 6) Check machine brake. Verify that braking time does not exceed 2 seconds. 7) Notify factory.
present go to step 2. 2) Go to the DP Inputs menu and choose EDIT INPUT MODE (see Section 2.8.1.1). Scroll through the die protection input screens which show the mode for each input. For every input which is listed as having an INVALID mode, reprogram the input as UNUSED or program it for the correct mode for its function.
Time in the AUTO SS menu). If at the end of this time there are one or more die protection inputs still unsatisfied, this error will be generated and the unsatisfied die protection inputs will be listed so the operator can investigate the problem. 215 AUTO SS INFORMATION LOST - MUST RE-ENTER ALL AUTO SS TIME LIMITS A check of the internal memory of the System 2500 has indicated invalid information for the Automatic Single Stroke delay times.
internal ON/OFF software switch MUST first be turned ON. If the AUTO SS ENABLE input is activated (i.e., setup button pressed) before turning the Auto Single Stroke feature ON, this error will be generated (see Section 2.8.4.2 above). 222 MACHINE DID NOT STOP WITHIN 20 DEGREES OF TOP - AUTO SS UNLATCHED When using the Automatic Single Stroke feature, the machine must ALWAYS stop between 340 degrees and 20 degrees (i.e.
timing channels that are used so that die protection can be performed. 2) Recall a setup which was previously stored containing the proper PLS and die protection data for this die. 3) If die protection is not required for this application, the operator may bypass the die protection function (see Section 2.8.2). Then Error 243 may be cleared by pressing the CLEAR key.
ACCESS CODE FOR EDITING PROTECTED INFORMATION 1984
