Link-systems OmniLink II Press Automation Control Instrukcja Użytkownika

OmniLink IIOmniLink IIPress AutomationControlOPERATING MANUALVersion 1.0LINK ELECTRIC & SAFETY CONTROL COMPANY444 McNALLY DRIVE, NASHVILLE T

August 30, 2002 Manual Version 1.0 2.1Section 2 Installation Section 2.1 Preliminary Installation Considerations 1. Before you begin to install

August 30, 2002 Manual Version 1.0 5.17 StrokeModeSingle StrokeDriveSpeedStrokeSpeedSPMSPM2000OrderCounterPC STATUSCounter OFFQUICKACCESSEDITNOTES00

August 30, 2002 Manual Version 1.0 5.18 In order for the job notes to be saved after editing, the current job must be stored. Job storage is descri

August 30, 2002 Manual Version 1.0 5.19 The display provides the following information: 1. A list of all jobs presently in the internal file stora

August 30, 2002 Manual Version 1.0 5.20 Section 5.6.2 Recall Setup From the Jobs Menu, Figure 5.9, pressing the RECALL SETUP softkey will either tr

August 30, 2002 Manual Version 1.0 5.21 Section 5.6.3 Erase Setup From the Jobs Menu, Figure 5.9, pressing the RECALL SETUP softkey will either tra

August 30, 2002 Manual Version 1.0 6.1 Section 6 Digital Die Protection and Process Monitor The Digital Die Protection and Process Monitor Module

August 30, 2002 Manual Version 1.0 6.2 If the monitor detects a process fault, a stop signal will be sent to the press control. There are three typ

August 30, 2002 Manual Version 1.0 6.3 PARAMETER SPECIFICATION Enclosure Dimensions 11.9” (302 mm) High x 6.25” (159 mm) Wide x 4” (102 mm) Deep

August 30, 2002 Manual Version 1.0 6.4 17856234PROCESS MONITORDIE PROTECTION &12 43576891110 141312 1615MODEL 512xLINKERROR CODEMODULE NUMBER /

August 30, 2002 Manual Version 1.0 2.2It is also convenient to run the 115VAC power along with the high-speed serial bus cable to each module(s) enc

August 30, 2002 Manual Version 1.0 6.5 Section 6.4 Wiring The wiring diagram for Model 5020 units is shown in Figure 6.2. The wiring diagram for M

August 30, 2002 Manual Version 1.0 6.6 DIE PROTECTION &PROCESS MONITOR765123LINK14MODEL 51202365886442753178910151112131416 Figure 6.2 Model 51

August 30, 2002 Manual Version 1.0 6.7 DIE PROTECTION &PROCESS MONITOR765123LINK14MODEL 51212365886442753178 Figure 6.3 Model 5121 Wiring Diagr

August 30, 2002 Manual Version 1.0 6.8 Since there can be up to five Digital Die Protection and Process Monitors connected to each OmniLink II Press

August 30, 2002 Manual Version 1.0 6.9 mechanical sensors. For these sensors, it may be necessary to source more current through the sensors than r

August 30, 2002 Manual Version 1.0 6.10 V+SIGNALCOMV+SIGNALCOM24 VDC0 VDCTO INPUTNPN CONNECTIONSV+SIGNALCOMV+SIGNALCOM24 VDC0 VDCTO INPUTSERIESPARAL

August 30, 2002 Manual Version 1.0 6.11 Static Normally Off, the input should NOT be On under normal operation. In this case when the input switche

August 30, 2002 Manual Version 1.0 6.12 Section 6.5.2 Cyclic Cyclic inputs are derived from monitored events that occur once each machine cycle wh

August 30, 2002 Manual Version 1.0 6.13 Sensors that are used as inputs to cyclic channels can be either Normally On or Normally Off. The event is

August 30, 2002 Manual Version 1.0 6.14 Section 6.5.3 In Position In Position type channels are used to monitor whether material is fully fed int

August 30, 2002 Manual Version 1.0 2.34. NEVER use any cable other than that supplied by Link Systems for the high-speed serial bus that interconne

August 30, 2002 Manual Version 1.0 6.15 Figure 6.10 also shows some unacceptable conditions for In Position events. There are three unacceptable co

August 30, 2002 Manual Version 1.0 6.16 Section 6.5.4 One Part Detection Edge The One Part Detector Edge channel logic type is used to monitor eje

August 30, 2002 Manual Version 1.0 6.17 past the sensor. An example of One Part Detector Pass is shown in Figure 6.13. This example shows an exiti

August 30, 2002 Manual Version 1.0 6.18 part is totally out of the die area. The Two Part Detector Edge input type functions much like the One Pa

August 30, 2002 Manual Version 1.0 6.19 The Two Part Detector Pass input type timing requires that the input sensor detect both parts during the tim

August 30, 2002 Manual Version 1.0 6.20 angle just before the part is released into the next stage of the die. The timing for Transfer is shown in F

August 30, 2002 Manual Version 1.0 6.21 Section 6.6 Configuration In order for the Digital Die Protection and Process Monitor to be recognized by

August 30, 2002 Manual Version 1.0 6.22 Section 6.6.1 Reset All Channels Configuration There are two options to Reset Configuration. These option

August 30, 2002 Manual Version 1.0 6.23 When bypassed, the system will halt all monitoring functions. See Section 6.7 for more information concerni

August 30, 2002 Manual Version 1.0 6.24 StrokeModeDriveSpeedStrokeSpeedSPMSPM00OrderCounterSYSTEM STATUSCounter OFFDieProtectionCHANGESETTINGEXIT00P

August 30, 2002 Manual Version 1.0 2.4Section 2.2 Mounting System Components Section 2.2.1 Mounting the Operator Terminal Enclosure The OmniLink I

August 30, 2002 Manual Version 1.0 6.25 Section 6.7.1 Channel Settings The channel settings define the monitoring type of the channel and the param

August 30, 2002 Manual Version 1.0 6.26 Channel Type Description Section for Additional Information Static Channel type used to monitor sensor

August 30, 2002 Manual Version 1.0 6.27 programmed names as required. It must be noted that when a job is stored in memory, only the number assigne

August 30, 2002 Manual Version 1.0 6.28 remains in the fault condition for the length of the delay time, a fault will be issued. If the channel ret

August 30, 2002 Manual Version 1.0 6.29 Diagnostics screen. A sample of the Die Protection Channel Diagnostics screen is shown in Figure 6.24. This

August 30, 2002 Manual Version 1.0 6.30 options range from bypassing individual channels to bypassing the entire system. Section 6.7.3.1 Channel By

August 30, 2002 Manual Version 1.0 6.31 Section 6.7.3.4 Bypass in Setup Mode and Bypass on Job Recall Individual channels can be automatically bypa

August 30, 2002 Manual Version 1.0 6.32 one time. The Reset can be configured to only reset the channels that are displayed on one Die Protection s

August 30, 2002 Manual Version 1.0 7.1 Section 7 Programmable Limit Switch (PLS) The Programmable Limit Switch is an optional addition to the Omni

August 30, 2002 Manual Version 1.0 7.2 PARAMETER SPECIFICATION 5100-5B Module Dimensions without Enclosure 10.4” (264 mm) High x 5.5” (138 mm) Wid

August 30, 2002 Manual Version 1.0 2.5 Figure 2.5 Dimensions for Mounting OmniLink II LCD Operator Terminal Section 2.2

August 30, 2002 Manual Version 1.0 7.3 Figure 7.1 PLS 5100-5B Open Frame Mounting

August 30, 2002 Manual Version 1.0 7.4 Figure 7.2 PLS Enclosure Mounting

August 30, 2002 Manual Version 1.0 7.5 Section 7.4 Wiring The wiring diagram for Programmable Limit Switch units is shown in Figure 7.3. The follo

August 30, 2002 Manual Version 1.0 7.6 Figure 7.3 PLS Wiring Diagram

August 30, 2002 Manual Version 1.0 7.7 Section 7.4.4.1 Electromechanical Relay Wiring Each electromechanical relay has both normally open and nor

August 30, 2002 Manual Version 1.0 7.8 In addition to being the desired setting for an unused channel, Always Off mode has another potential use.

August 30, 2002 Manual Version 1.0 7.9 programmed for counted outputs with a count of four, the channel will not turn on every stroke, but only turn

August 30, 2002 Manual Version 1.0 7.10 example, a feed roll pilot release is intended to release the feed rolls from the material, so that the die

August 30, 2002 Manual Version 1.0 7.11 The Programmable Limit Switch system should be configured before being put into operation. This configurati

August 30, 2002 Manual Version 1.0 7.12 Section 7.6.1 Reset All Channels Configuration There are two options to Reset Configuration. These option

August 30, 2002 Manual Version 1.0 2.6The standard resolver used with the OmniLink II press Automation Control is the 2500 Resolver. A 5000 Resolve

August 30, 2002 Manual Version 1.0 7.13 abcdbaeStrokeModeDriveSpeedStrokeSpeedSPMSPM00OrderCounterSYSTEM STATUSCounter OFFLimitSwitchCHANGECHANNELSE

August 30, 2002 Manual Version 1.0 7.14 Section 7.7.1 Channel Settings The channel settings define the mode of the channel and the parameters assoc

August 30, 2002 Manual Version 1.0 7.15 Channel Type Description Section for Additional Information Always Off Channel output is always turned of

August 30, 2002 Manual Version 1.0 7.16 Section 7.7.1.4 Counted Outputs This parameter allows for the PLS channel to be programmed for counted outp

August 30, 2002 Manual Version 1.0 7.17 Section 7.7.3 Status Information Status information is available for the individual channel, the individua

August 30, 2002 Manual Version 1.0 2.7 Figure 2.8 Mounting Dimensions for 8 or 16 Channel Die Protection or Si

August 30, 2002 Manual Version 1.0 2.8Section 2.3 Wiring System Modules and Components Section 2.3.1 Conduit Runs Wiring between the enclosures fo

August 30, 2002 Manual Version 1.0 2.9The conduit runs that you will or may need, depending on the options you purchase and features that you wish t

August 30, 2002 Manual Version 1.0 2.10 Figure 2.10. Wiring Connections from 2500 Resolver to 802-5 R

August 30, 2002 Manual Version 1.0 iSection 1 Introduction...1.1 Sect

August 30, 2002 Manual Version 1.0 2.11 Figure 2.11. Wiring Connections from 5000 Resolver to 802-5 R

August 30, 2002 Manual Version 1.0 2.12Section 2.3.3 Wiring 115VAC Power From Press Control to Operator Terminal Pull red, white and green 16 gauge

August 30, 2002 Manual Version 1.0 2.13 Figure 2.13 115VAC Wiring Between Press Control and Operator

August 30, 2002 Manual Version 1.0 2.14Section 2.3.4 Wiring the Valve Voltage Circuit The OmniLink II Press Automation Control brake monitor and mo

August 30, 2002 Manual Version 1.0 2.15 Figure 2.14 Stop Circuit Connections from OmniLink II Automatio

August 30, 2002 Manual Version 1.0 2.16Section 2.3.6 Wiring the Optional Setup Mode Input The OmniLink II Press Automation Control provides an opti

August 30, 2002 Manual Version 1.0 2.17Section 2.3.7 Wiring Optional Analog Input/Output Board Circuits Section 2.3.7.1 Wiring to Display Motor Loa

August 30, 2002 Manual Version 1.0 2.18 Figure 2.16 Wiring the Analog Motor Load Current Input Tra

August 30, 2002 Manual Version 1.0 2.19 Figure 2.17 Wiring to Display and Set SPM Through OmniLink II O

August 30, 2002 Manual Version 1.0 2.20Section 2.3.8 Optional Solid State Relay Outputs The OmniLink II Press Automation Control provides an option

August 30, 2002 Manual Version 1.0 iiSection 4.2.1.8 Setting Brake Monitor Top Stop and Brake Monitor Mid Stroke Stop Limits ...

August 30, 2002 Manual Version 1.0 2.21Section 2.4 Additional Mounting and Wiring if the Operator Terminal, R/D-Brake Monitor Module, and (Optionall

August 30, 2002 Manual Version 1.0 2.22 Section 2.4.2 Wiring the Base Components in the Customer Enclosure The only wiring not

August 30, 2002 Manual Version 1.0 2.23in separate documents sent in addition to this manual when these options are purchased with your system. Sec

August 30, 2002 Manual Version 1.0 3.1Section 3 Operator Terminal Basics Section 3.1 OmniLink II Press Automation Control LCD Operator Terminal

August 30, 2002 Manual Version 1.0 3.2stopped within +/- 5 degrees of bottom dead center, the box will be yellow with the letters “BOT”. For speeds

August 30, 2002 Manual Version 1.0 3.3choose to configure the system to allow certain commonly used settings and actions to be done in Run Mode. Fin

August 30, 2002 Manual Version 1.0 3.4Section 3.5 CHG Key This changes the display language from English to Spanish. Depressing the CHG key again w

August 30, 2002 Manual Version 1.0 3.5keys on the keypad and pressing the ENT (Enter) key after you have changed the number to the desired value. T

August 30, 2002 Manual Version 1.0 3.6 Figure 3.3 The Die Protection Channel Settings Screen in Program Mode When the Channel T

August 30, 2002 Manual Version 1.0 iiiSection 5.6.2 Recall Setup ...

August 30, 2002 Manual Version 1.0 3.7 Figure 3.5 The Die Protection Channel Names Screen The first page of names for the Die Pr

August 30, 2002 Manual Version 1.0 3.8This illustration is for the Die Protection Channel Names Screen that will be present if one or more optional

August 30, 2002 Manual Version 1.0 3.9means available to access Program Mode. All settings and actions for the system are accessible to anyone when

August 30, 2002 Manual Version 1.0 3.10 Figure 3.7 Main Die Protection Screen in Run Mode for Module 1, Channels 1-8

August 30, 2002 Manual Version 1.0 3.11Section 3.9.3 Code (Password) System Operation If any of the access modes to Program Mode that use a code is

August 30, 2002 Manual Version 1.0 3.12module) and a group of eight channels for that module. One module may have up to 16 channels. The PREVIOUS PA

August 30, 2002 Manual Version 1.0 3.13 Figure 3.11 User Selection Box Appears on Die Protection Configuration Screen

August 30, 2002 Manual Version 1.0 3.14 Figure 3.13 Die Protection Channels Settings Program Mode Screen . To perform a reset

August 30, 2002 Manual Version 1.0 3.15new 60 second cycle will be started. The number of strokes that are entered is the number of press strokes a

August 30, 2002 Manual Version 1.0 4.1 Section 4 Device and Main Configuration Menus After your OmniLink II Press Automation Control is first ins

August 30, 2002 Manual Version 1.0 4.2 The Device Configuration menu is also used to update the software in the various modules used with the system

August 30, 2002 Manual Version 1.0 4.3 The left column of the Device Configuration screen lists hardware modules that can be used with the system.

August 30, 2002 Manual Version 1.0 4.4 Pressing the NEXT PAGE softkey causes the second page of the Device Configuration menu to be displayed, as sh

August 30, 2002 Manual Version 1.0 4.5 4. Configuring the Operator Terminal serial ports for any software options, such as serial feed interface an

August 30, 2002 Manual Version 1.0 4.6 If the CONFIGURE softkey is pressed, the display will ask for the configuration code. This user configuration

August 30, 2002 Manual Version 1.0 4.7 Section 4.2.1 Machine Parameters Menu Pressing the Machine Parameters softkey in the Main Configuration menu

August 30, 2002 Manual Version 1.0 4.8 top on the Machine Parameters menu. This setting comes from the factory as 00 since it is most likely that y

August 30, 2002 Manual Version 1.0 4.9 If the loss of motion time value calculated by the formula is not longer than the time that motion can dip be

August 30, 2002 Manual Version 1.0 4.10 Method 1. Slide at Top of Stroke 1. Inch the press to position the crankshaft within +/- 1 degrees of top

August 30, 2002 Manual Version 1.0 1.1Section 1 Introduction The OmniLink II Press Automation Control for part revolution clutch mechanical power

August 30, 2002 Manual Version 1.0 4.11 Thus, regardless of whether you have a negative or positive misalignment of encoder to crankshaft, the Encod

August 30, 2002 Manual Version 1.0 4.12 Section 4.2.1.6 Use Mode Input Setting The OmniLink II Press Automation Control provides an input that allo

August 30, 2002 Manual Version 1.0 4.13 be accommodated so that adjustment on a frequent basis is not necessary. A typical wear margin of 20% is us

August 30, 2002 Manual Version 1.0 4.14 3. Take the longest stop time recorded in step 2 and add a 10% to 20% margin for wear and other factors tha

August 30, 2002 Manual Version 1.0 4.15 Figure 4.10 Speed/Load Configuration Menu Section 4.2.2.1 Setting Speed Mode If you hav

August 30, 2002 Manual Version 1.0 4.16 Use the arrow keys to select your choice of 3 Speed Mode settings; Input Only, Output Without Recall, or Out

August 30, 2002 Manual Version 1.0 4.17 6. Select the CONTINUOUS stroking mode on the press stroking selector and initiate press stroking. 7. The

August 30, 2002 Manual Version 1.0 4.18 2. Return to the Speed/Load Configuration menu and set Speed Mode to Output Without Recall or Output With R

August 30, 2002 Manual Version 1.0 4.19 6. Observe the Stroke Speed indicator at the top of the operator terminal display. This is the true strokin

August 30, 2002 Manual Version 1.0 4.20 Section 4.2.2.5 Calibrating Percent Motor Load If an input signal is provided to the OmniLink Analog Input/

August 30, 2002 Manual Version 1.0 1.2Section 1.1.2 Base System Optional Features • An optional analog input/output card allows stroking speed to

August 30, 2002 Manual Version 1.0 4.21 Figure 4.12 Speed Adjusted Top Stop Calibration Menu There are 7 items indicated

August 30, 2002 Manual Version 1.0 4.22 6. Calculated Degrees Before Top Dead Center. For variable speed presses, the OmniLink II Press Automation

August 30, 2002 Manual Version 1.0 4.23 to Program so that you can change the settings made in step 3. If the press has stopped X degrees beyond Top

August 30, 2002 Manual Version 1.0 4.24 It is IMPORTANT TO NOTE that the OmniLink II cannot provide Auto Top Stop Compensation for top stop signals

August 30, 2002 Manual Version 1.0 4.25 5. The stopping time and distance (angle) for the press may be different depending on the angular region ov

August 30, 2002 Manual Version 1.0 4.26 Continuous mode at various speeds between the low and high speeds. For each speed, press the Top Stop key a

August 30, 2002 Manual Version 1.0 4.27 7. Counterbalance Pressure. If the control is equipped with optional automatic counterbalance adjust 8. Shut

August 30, 2002 Manual Version 1.0 4.28 Figure 4.14 Code Entry Screen to Zero Stroke Count Entering the two digit code sent for

August 30, 2002 Manual Version 1.0 4.29 4. Those settings and operations that the system always requires Key/Code access to Program Mode to make.

August 30, 2002 Manual Version 1.0 4.30 the Access Configuration screen shown in Figure 4.15. The Restrict/Unrestrict configuration screen shown in

August 30, 2002 Manual Version 1.0 1.3Section 1.3 System Overview Figure 1.1 shows the base package hardware components for the OmniLink II Press Au

August 30, 2002 Manual Version 1.0 4.31 The stroke log out is based upon a number of press strokes between keyboard activity. If the user does not

August 30, 2002 Manual Version 1.0 4.32 Note! The list of permissions shown on the screen is shown as an example. New software versions and hardware

August 30, 2002 Manual Version 1.0 4.33 Section 4.2.4.4 Auxiliary Communications Setup The AUXILIARY COMM. SETUP softkey provides access to the con

August 30, 2002 Manual Version 1.0 4.34 To enter the alpha-numeric messages associated with each input message code (number) go to the Auxiliary Nam

August 30, 2002 Manual Version 1.0 5.1 Section 5 Using the OmniLink II Press Automation Control Standard Functions and Optional Speed Adjust Functi

August 30, 2002 Manual Version 1.0 5.2 Figure 5.1 Main Menu of the Operator Terminal Section 5.2 Brake Monitor and Diagn

August 30, 2002 Manual Version 1.0 5.3 The central portion of the display provides the following information: 1. A brake monitor used when the pre

August 30, 2002 Manual Version 1.0 5.4 WARNING! When your press is equipped with two-hand control devices and/or presence sensing device

August 30, 2002 Manual Version 1.0 5.5 on where in the stroking cycle the fault occurs and how many degrees the press crankshaft will travel after t

August 30, 2002 Manual Version 1.0 5.6 The Intellistop angle is automatically computed by the OmniLink based on the angle of travel during top stopp

August 30, 2002 Manual Version 1.0 1.4 Figure 1.2. Existing and Planned System Components and Functi

August 30, 2002 Manual Version 1.0 5.7 Section 5.2.5 Auxiliary Equipment Messages The OmniLink II Press Automation Control makes optional provision

August 30, 2002 Manual Version 1.0 5.8 Figure 5.4 Diagnostics Screen The softkeys along the bottom of the screen navigate to ot

August 30, 2002 Manual Version 1.0 5.9 Section 5.3 Counters From the Main Menu, Figure 5.1, depressing the COUNTER softkey displays the menu shown

August 30, 2002 Manual Version 1.0 5.10 in the counter configuration. If an auxiliary counter is enabled in the counter configuration, it will appe

August 30, 2002 Manual Version 1.0 5.11 access Program Mode in order to turn the counters on or off. If the user accesses Program Mode by using the

August 30, 2002 Manual Version 1.0 5.12 have permission to change counter settings. To increase or decrease the current count value by one, select

August 30, 2002 Manual Version 1.0 5.13 To change the value of the scrap count, position the cursor on the scrap counter and select the CHANGE SCRAP

August 30, 2002 Manual Version 1.0 5.14 Batch, and Quality counters are fixed and cannot be programmed. To change an auxiliary counter name, posi

August 30, 2002 Manual Version 1.0 5.15 Section 5.3.4.4 Configure Counter Reset When Order Counter Reset All counters other than the Order counter

August 30, 2002 Manual Version 1.0 5.16 higher than 80 SPM when INCH mode is selected. If the press control is configured for fixed setup (INCH) mo