DIE PROTECTION MODULE COLOR DISPLAY OPERATING MANUAL LINK ELECTRIC & SAFETY CONTROL COMPANY 444 McNALLY DRIVE, NASHVILLE TN 37211 PH (615)-833-4168 FAX (615)-834-1984 OmniLink 5000 System 5000 Press Control
System 5000 Die Protection Module Operator Manual Manual LS-001 Revision 07
TABLE OF CONTENTS Section 1 Introduction to the System 5000 Die Protection Module . . . . . . . . . . . . . . . . . . 1-1 Section 1.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Section 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Section 2.1 Main Menu Status Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Section 2.
Section 3.6 2 Part Detector-Edge and 2 Part Detector-Pass . . . . . . . . . . . . . . . . . . . . . 3-6 Section 3.7 Track PLS and Track PLS Invert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7 Section 4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 4.1 Extended Card Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Section 4.2 Module Installation . . . . . . . . . .
Section 1 Introduction to the System 5000 Die Protection Module The Die Protection Module is an optional addition to the integrated System 5000 Press Control which is designed for use in monitoring various die conditions that are important to the correct operation of the die. This is accomplished by installing appropriate sensors and probes in or near the die and connecting these sensors to inputs on the Die Protection Module.
Section 2 Operation Section 2.1 Main Menu Status Block When the Main Menu is displayed on the System 5000 Operator Terminal, one of the softkeys on the right side of the screen is labeled DIE PROTECTION. To the left of this key is a status block indicating the current operating status of the die protection module. Under normal operating conditions the status message will read "All Conditions OK".
Figure 2.1 Die Protection Menu Section 2.3 Access Control The OmniLink control has several parameters or operations that have limited access. In regards to die protection the ability to perform actions of turning bypass off and on, resetting faults, or changing die protection settings 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.
in this mode, any user with the Program/Run key will have access to all of the restricted items. Section 2.3.2 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 Program/Run key can access all of the restricted items. A user with the correct password can access the restricted items that have been designated for the particular user’s access only. The system allows for passwords to be assigned to sixteen users.
entering the password the user must switch the Program/Run key to the PROG position. Section 2.3.5 Die Protection Restricted Items The following table lists the die protection restricted items name and function. DIE PROTECTION RESTRICTED ITEMS NAME FUNCTION DP Bypass Bypass the Die Protection DP Reset Reset the Die Protection DP Settings Change the Die Protection type, settings, and name. Section 2.3.
appear and will be active. Section 2.3.6.2 Password System Operation Figure 2.2 displays a typical password entry sequence. This example shows the steps necessary to change a die protection channel setting. This is typical for password entry for all restricted items. Figure 2.2 Password Entry Sequence Step A: Select the restricted item. In the example shown in Figure 2.2 the restricted item is die protection Change Type.
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 a die protection 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 Die Protection Menu displays the programmed types for the die protection input channels. The channel numbers under the "CH" column on the left correspond to the input terminal numbers on the connector card assembly for the die protection module. For each of the inputs, the information under the "Type of Sensor" column describes how the input is programmed to operate. This is determined in advance by the operator according to what condition in the die the input is to monitor.
control must be obtained as described in Section 2.3. A selection box will appear. This box will list all of the channel types. Move the cursor to the channel type that is required, and press the SELECT softkey. Section 2.5 Input Description Input descriptions are helpful labels which aid the operator in identifying which sensor is tied to a particular input and what that input is monitoring. This is of particular value if many die protection inputs are used.
2.3 contains 15 names. The other names can be accessed by pressing the NEXT GROUP softkey or using the arrow keys and moving the cursor past the first or last name. To select a name fro the list of 45 names, position the cursor to the name that is to be selected and press the ENT key. If the desired name does not appear, either one of the existing names can be changed or a unused location programmed with the desired name.
Section 2.6 Input Status In the Die Protection menu display, the column on the right labeled "Status" indicates the present status of each individual input. If the die condition which the input is monitoring is satisfactory (sensor is seeing the proper inputs within the desired timing restrictions) then the message for the input will be "OK". If the sensor input is not satisfactory, the message "ERROR" will be displayed for the input.
(Note: If a Memory Data Loss error occurs on any input, the RESET ERRORS softkey will not clear the error until the data for that input has been reprogrammed.) Section 2.9 BYPASS ON/OFF key The monitoring function of the die protection module can be ‘turned off’ if desired, by placing the module in Bypass mode. In this mode, it is not necessary for the die protection inputs to respond properly according to their programmed input types. This is very useful when setting up or making adjustments to the die.
In the example Die Protection Screen shown in Figure 2.1, the information shown is for Channel 01 and includes Type of Stop Output, Window ON, and Window OFF, Number of Stroke Delay, and a bar graph showing the timing window. Section 2.10.1 Changing Channel Information To edit die protection channel information, the user must first obtain access control. Access control is described in Section 2.3.
To change the delay time, gain access to the Channel Information Area (see Section 2.10.1), use the arrow keys to the current Delay time then press the CHANGE NUMBER softkey. The operator must then enter a value for the time (0 to 65.500 seconds) and press the ENT key on the keyboard. Section 2.10.
monitoring is described in the “Track PLS and Track PLS Invert” topic of Section 3. When an input is defined as a Track type input, the Channel Information Area will display the PLS channel to be tracked (labeled Track PLS Ch #). The operator must specify which PLS output channel is to be tracked for proper operation. The system is capable of tracking PLS outputs 1 through 8. To change the PLS channel to be tracked, gain access to the Channel Information Area (see Section 2.10.
bottom rather than beginning at top dead center since in many applications parts are ejected near the top of the stroke. When the press moves through 170 degrees the monitoring begins, and until 170 degrees is passed again the die protection input will be monitored for any change. The first time that the input closes (is connected to machine ground) the angle at which this occurs will be displayed in the status block beside the message reading "Closed at".
The Die Protection screen has a LIMIT SWITCH softkey. This key will allow direct access to the programmable limit switch screen. During setup of Die Protection it may be necessary to adjust programmable limit switch channels. This softkey will allow that direct access. If the Limit Switch screen is entered from the Die Protection screen, pressing the EXIT softkey in the Limit Switch Screen will return the display to the Die Protection screen. Section 2.
Section 3 Die Protection Input Types and Their Uses Each of the sixteen die protection inputs can be programmed for any one of eleven different die protection types: Static Normally Open, Static Normally Closed, Cyclic, Transfer, In Position, 1 Part Detection (Edge Only or Pass Completely), 2 Part Detection (Edge Only or Pass Completely), Track PLS, and Track PLS Invert. In addition, any input can be programmed as Unused if desired. Section 3.1 Static N.O. and Static N.C.
above, i.e., if the input is not in the 'normal' state, a fault will occur immediately. However, if a value other than zero is programmed the input is allowed to change from the normal state for the length of time programmed without a fault occurring. If the input does not return to the normal state before the time expires, a fault is generated. This allows the operator to avoid nuisance faults from sensors that 'bounce' open or closed momentarily. The delay time can range from 0 to 65.500 seconds in 0.
Figure 3.4 Cyclic input timing monitor events in the production process that may not occur every stroke, but must occur within some number of strokes. An example of such an application is slug detection, where under normal operation slugs are allowed to build up and be ejected after several strokes. In such a scenario, a slug would not be detected by the sensor on every stroke, and this would produce a fault were the stroke delay counter not used.
as Transfer type to monitor the mechanism for dropped parts during the transfer. When programming an input for transfer type, the operator must enter crankshaft angles to mark ON and OFF points for a timing 'window' during which the transfer will occur (see “Programming Window Setpoints” in Section 2). The Window ON setpoint should be set to an angle just after the part is gripped.
“Programming Window Setpoints” in Section 2). The Window ON angle should be set to a point well before the feed takes place. The Window OFF angle should be set to a point after the material has been fed into place and is making contact with the sensor. If the material is not in contact with the sensor when the timing window turns off, a fault will be generated. The OFF angle must also be set so that the fault will stop the press before the die closes.
sensor used to detect the part will see only one part, causing nuisance production stops. Parts with holes or irregular shapes can look like two parts to probes and infrared sensors, giving false signals. When programming an input as a 2 Part Detector type, the operator must choose whether it will be required for the second part to completely pass the detector during the timing window. If it is desired that the second part completely pass (i.e.
Figure 3.10 3040 Infrared Parts Detector Light Screen with Part Detector inputs are shown in Figure 3.11. Section 3.7 Track PLS and Track PLS Invert Tracking type inputs are used to monitor events that should closely follow (track) a System 5000 PLS output. On the die protection module, any input channel can be programmed to track a PLS output within a specified length of time. If the input fails to follow the on/off switching of the PLS output within the specified time, a stop is generated.
Figure 3.
An example of the use of a Track PLS Invert type on an input is the monitoring of an air cylinder used for parts ejection, as shown in Figure 14. Suppose a PLS output on the System 5000 is used to activate the cylinder, with the power source for the cylinder switched through the N.O. contacts of the PLS relay. A probe type switch is located such that it will close and ground the die protection input when the air cylinder is retracted (at the home position).
Section 4 Installation Section 4.1 Extended Card Rack The Die Protection Module is designed for use in the Extended Card Rack of the System 5000. To field install the Extended Card Rack (in systems which are not already equipped) first remove the right end cover plate on the standard card rack, keeping the mounting screws and nuts for use in securing the extended rack.
On the Factory Parameters screen, one of the parameters displayed is Die Protection. Use the down arrow key to move the cursor to the Die Protection parameter and enter one of the following values: Value Description 001 Die Protection enabled; Bypass of die protection is allowed in all stroking modes (if operator has access control for this feature) 002 Die Protection enabled; Bypass mode allowed in all stroking modes except Continuous (e.g.
Section 5 Troubleshooting Section 5.1 Status Messages The following sections are listings of status messages generated by the System 5000 Die Protection Module, firmware version 2.2. For each message an explanation of the cause is given. Section 5.1.1 Main Menu Status Messages One of the messages below will always be present in the status block beside the softkey labeled DIE PROTECT on the Main Menu.
Section 5.1.2 View Channel Status Messages The Status block of the View Channel screen for any input (see Figure 2) will display information regarding the present condition of that input and of the module in general. If the sensor wired to the input is operating properly and the module has no error conditions present, the status block will read "OK". If an error has been detected in the operation of the sensor wired to this input, an error message will appear describing the failure that was detected.
a failed or stuck sensor. “Input failed to close throughout stroke delay” This error message occurs only when the stroke delay counter is set to some number other than zero. When this is true, the input is not required to close (to ground) within the timing window on every stroke, but it must close within the window on at least one stroke before the number of strokes entered in the counter has passed.
The In Position type requires that the input be closed (grounded) at the end of the timing window (the OFF setpoint) and then be open at some other point in the stroke. This message indicates that the input never opened at any point in the stroke, thus indicating a possible failed or stuck sensor. Section 5.1.2.
thereby signifying that the second part was not detected. "First part did not pass completely during Timing Window" This input is programmed as a "2 Part Detector-Pass" which is identical to the "2 Part DetectorEdge" type except that the second part seen must completely pass the detector (i.e., the input must finish open or ungrounded when the timing window ends).
tracking time being set for too small a value for this operation. "Input did not close in time after PLS turn On" This input is programmed as a Track PLS type so that the input must follow the PLS channel programmed under "Track PLS Channel". This message indicates that the PLS output turned on and the tracking time expired before the input closed (to ground) in response.
"At Least One Die Protect Input Must be Used" If the die protection system is not bypassed, then at least one of the sixteen inputs must be programmed as some type other than "Unused". The operator must program at least one input to one of the eleven active types. "Memory Data Loss, Must Re-Program Input" This message indicates that the programming information for this input has become corrupt and cannot be used.