LINK ELECTRIC & SAFETY CONTROL COMPANY System 5000 manual

Om niLink 5000 System 5000 Press Control AUTO SETUP MODULE COLOR DISPLAY OPERATING MANUAL LINK EL ECTRIC & SA FETY CONTROL CO MPANY 444 McNALLY DRIVE, NASHVILLE TN 37211 PH (615)-833-4168 FAX (615)-834-1984[...]

April 17, 2000 Man ual Versio n 1.0 i Table of Contents Section 1 Introduction .......................................................... 1.1 Section 1.1 Counterbalance Control .............................................. 1.1 Section 1.2 Cushion Control .................................................... 1.1 Section 1.3 Shut Height Control .....[...]

April 17, 2000 Man ual Versio n 1.0 ii Section 4. Configuration ......................................................... 4.1 Section 4.1 Setting up the OmniLin k 5000 for the Auto- Setup Module .................. 4.1 Section 4.2 Configuring the Auto-Setup board ........................................ 4.2 Section 4.2.1 Configuring Counterbalance, [...]

April 17, 2000 Man ual Versio n 1.0 iii Appendix F Specifications ......................................................... F.1 Section F.1 5000-10A Pressure Control Board ...................................... F.1 Section F.2 5000-10B Linear Shut Height Control Board ............................. F.1 Section F.3 5000-10C Rotary Shut Height Control[...]

April 17, 2000 Man ual Versio n 1.0 iv[...]

April 17, 2000 Man ual Versio n 1.0 1.1 Section 1 Introduction The 5000-10 Auto- Setup Module (ASM) a llows the OmniLink 50 00 Press and Automa tion 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[...]

April 17, 2000 Man ual Versio n 1.0 1.2 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 mechanica l condition, enhancing parts quality and reducing setup time. This system uses the existing slid[...]

April 17, 2000 Man ual Versio n 1.0 2.1 Section 2 Parameter Entry and Access Control Section 2.1 Parameter Entry Throughout the Omn iLink control, a fa irly standard for m of data entry is e mployed. When dat a entry is allowed, an “editing cursor” will appear on the screen. This cursor can typically be moved from parameter to parameter on the [...]

April 17, 2000 Man ual Versio n 1.0 2.2 Figure 2.1: Example Text Entry c) The fist character of the text is highlighted with the text cursor. The CURSOR LEFT and CURSOR RIGHT softkeys will move this cursor. d) Use the left and right arrow keys to point to the letter desired in the letter box next to the text being edited. This box will just appear [...]

April 17, 2000 Man ual Versio n 1.0 2.3 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 ce rtain personnel. The OmniLink contr ol provides sever al means t[...]

April 17, 2000 Man ual Versio n 1.0 2.4 The example above can be taken one additional step if two press operators are given differ ent user names and differ ent passwords. On e operator can be assigned the a bility to change au to setup limits in addition to the ability to reset faults, while the other operator is not assigned the ability to change[...]

April 17, 2000 Man ual Versio n 1.0 2.5 Figure 2.2: Example Password Entry Sequence 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 Passw ord” mode, the k[...]

April 17, 2000 Man ual Versio n 1.0 2.6 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 h [...]

April 17, 2000 Man ual Versio n 1.0 3.1 NOTE: NEVER remove or install any card in the OmniLink 5000 when the power to the control is on. Doing so can damage the control, the card, or both! Figure 3.1: OmniLink 5000 Extended Card Rack Section 3. Installation Section 3.1 Auto-Setup Module Installation The 5000-10 Auto-Setup Module (ASM) installs in t[...]

April 17, 2000 Man ual Versio n 1.0 3.2 or AS4. The plug in terminals on the modules should stick out of the faceplate of the base card.[...]

April 17, 2000 Man ual Versio n 1.0 3.3 Figure 3.2: Type “A” Valve Configuration Figure 3.3: Type “B” Valve Configuration 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[...]

April 17, 2000 Man ual Versio n 1.0 3.4 Figure 3.4: Type “C” Valve Configuration Figure 3.5: Typical Counterbalance System 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 Figur[...]

April 17, 2000 Man ual Versio n 1.0 3.5 Figure 3.6: Auto-Counterbalance with Type “A” Integrated Valve. Figure 3.7: Auto-Counterbalance with Type “C” Integrated Valve. For automatic control, the pressure regulator and check valve are replaced with an a ir valve system. Figures 3.6 and 3.7 illustrate systems using the Type “A” and Type ?[...]

April 17, 2000 Man ual Versio n 1.0 3.6 Figure 3.8: Acceptable Locations for Mounting Counterbalance Pressure Transducer. Section 3.3.1 Counterbalance Pr essure Transducer Mounting The system uses an automatic method o f control in which t he fill valve or du mp valve is energi zed to raise or lower the pressure of the system and a pressure transdu[...]

April 17, 2000 Man ual Versio n 1.0 3.7 Figure 3.9: Typical Standard Cushion System Figure 3.10: Cushion System with Type “B” Integrated Valve. Section 3.3.2 Counterbalance Air Valve System Mount ing The mounting locati on of the valve sys tem is not critical. Consideration shou ld be given, howev er, to ease of maintenance, plumbing, and wirin[...]

April 17, 2000 Man ual Versio n 1.0 3.8 Figure 3.11: Acceptable Locations for Mounting Cushion Pressure Transducer. Section 3.4.1 Cushion Pressure Tr ansducer 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 [...]

April 17, 2000 Man ual Versio n 1.0 3.9 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 pum[...]

April 17, 2000 Man ual Versio n 1.0 3.10 NOTE: The cable should r emain unbroken e xcept for the con nector in this junc tion box to keep the shield integrity - do not splice the cable! c) The slide should tra vel no more than 1 inch per turn of the resolver. d) The cable from the resolver to the OmniLink 5000 should not be run with any high voltag[...]

April 17, 2000 Man ual Versio n 1.0 3.11 NOTE: The cable should r emain unbroken e xcept for the con nector in this junc tion box to keep the shield integrity - do not splice the cable! b) It may be necessary to order a transducer longer than the slide adjustment range because of mounting limitations. c) Ferromagnetic material (a material readily m[...]

April 17, 2000 Man ual Versio n 1.0 4.1 NOTE! An access code is required to reach the configuration menus of the OmniLink 5000 press control. The code is provided separ ately from this manual for administrative control. WARNING! Only qualified employe es who are authoriz ed by the user should configure the automatic set-up module. Failure to proper[...]

April 17, 2000 Man ual Versio n 1.0 4.2 Figure 4.2: Example Air Configuration Screen 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, an[...]

April 17, 2000 Man ual Versio n 1.0 4.3 There are several parameters that must be configured in this screen. The editing cursor indica tes which parameter is currently selected. Softkey 1 (the uppermost vertical softkey) will change its description based on the parameter and, when pressed, allows the currently selected paramete r to be changed. The[...]

April 17, 2000 Man ual Versio n 1.0 4.4 For cushions this should be the maximum operating pressure specified by the cushion manufacturer. For hydraulic ove rloads this value s hould be the press ure specified by the press manufacturer for rated tonnage operation. Min. Pressure This value should be set to the minimum ope rating pressure at which you[...]

April 17, 2000 Man ual Versio n 1.0 4.5 are pounds (lbs), kilograms (Kgs), tons, and metric tons (Mtons). Note that the display unit can be changed at any time and is independent of the units that the maximum and minimum die weight are using. If a job was store d in tons, and this unit is changed to pounds, the stored job will still be correct. For[...]

April 17, 2000 Man ual Versio n 1.0 4.6 choices are pou nds (lbs), kilogra ms (Kgs), tons, and metric tons (Mtons) . Note that the display uni t can be changed at any time and is ind ependent of the u nits used for minimum and maximum trip point. I f a job was stored in tons, and this unit is changed to pounds, the stored job will still be correct.[...]

Table 4.2: Servo-Valve Control Types April 17, 2000 Man ual Versio n 1.0 4.7 Wilkerson ER1 Series 0-90psi 0-10V 5 SMC ITV2050-31T2S4 0-130psi 0-10V 6 Section 4.2.2 Configuring Slide Adjust Modules To get to the config uration screen f or slide adjust modu les: a) Go to the “Auto Sets” screen. This scr een is reached by pressing the “A UTO SET[...]

April 17, 2000 Man ual Versio n 1.0 4.8 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 paramete r to be changed. The up and down arrow keys move the editing cursor from one parameter to another. See Appendix A for example[...]

April 17, 2000 Man ual Versio n 1.0 4.9 Upper Limit This value is an ele ctronic upper limi t for the slide adju st system that acts a s a backup for the me chanical up limit sw itch. The automati c shut height system will not adjust the shut height above this value, which should be set just below where the mechanical up limit switch open up. Lower[...]

April 17, 2000 Man ual Versio n 1.0 4.10 Lock Time Most slide adjust syst ems now use an inte grated brake bu ilt in to the slide adju st motor that automatically locks the system down when the slide adjust motor is not on. “Lock Time” is used only for slide adjust systems that have a separate locking system that must be disengaged before the s[...]

April 17, 2000 Man ual Versio n 1.0 4.11 WARNING: After calibrat ion always check for proper operation o f 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. transducer is used) must now be set. This value is li[...]

April 17, 2000 Man ual Versio n 1.0 4.12 NOTE: It is absolutely critical to set the upper and lower limits correctly before calibrating a ro tary slide adjust sy stem. The calibra tion process uses t his information to map the turns from the dual resolver into the measurement space of the slide. If the upper and lower limits are not set correctly, [...]

April 17, 2000 Man ual Versio n 1.0 4.13 NOTE: It is very important to make as accurate a measurement as possible for the Upper and Lower Calibration Points. If these measurements are wrong, then the slide position reported by the system will also be wrong! WARNING: After calibrat ion always check for proper operation o f the slide adjust system as[...]

April 17, 2000 Man ual Versio n 1.0 4.14[...]

April 17, 2000 Man ual Versio n 1.0 5.1 Figure 5.1: Example Auto-Sets Screen Section 5 Operation The purpose of the Auto-Setup module i s to allow automatic adjustment of such press systems as a ir counterbalances, air cushions, air operated hydraulic overloads, and slide adjust systems to greatly reduce setup time for different jobs, and to help e[...]

April 17, 2000 Man ual Versio n 1.0 5.2 for the shut height setpoint. See section 6 for an explanation of all status messages for the various sub-syste ms. c) Each configured sub-system has a fault message. Under normal conditions, this fault should read “None”. See sec tion 6 for an expla nation of all fault messages for the various sub-syste [...]

April 17, 2000 Man ual Versio n 1.0 5.3 “CONFIGURE” Allows the individual options such as counterbalance, cushion, and slide adjust modules to be configured during initial installation of the system and will not be used for production opera tion setup. Note tha t this key is only available when the RUN/PROG keyed switch is in the PROG position.[...]

April 17, 2000 Man ual Versio n 1.0 5.4 rotary transducer mounted on the slide system of the press. The units for the position can be in inches or millimeters depending on the configuration. See section 4.2.2 for details. Fault If the slide adjust system detects an error it will be re ported on this line. A fault occurs when a hardware or firmware [...]

April 17, 2000 Man ual Versio n 1.0 5.5 NOTE! A counterbalance pressure that is far too low or far too high during any shut height adjustment may place excessive load on the shut height adjust motor and may even stall the motor. This condition can also occur with non-automatic motorized slide adjust systems. If t he automatic slide adjust doesn’t[...]

April 17, 2000 Man ual Versio n 1.0 5.6 Section 5.1.3 Manual Slide Moveme nt As noted in the section explaining the softkeys in the slide screen, the slide may be manually moved by pressing the “JOG UP” and “JOG DN” softkeys. Note that the jog keys will only appear when the editing cursor is on a slide adjust setpoint. These keys will work [...]

April 17, 2000 Man ual Versio n 1.0 5.7 setpoint for a previously stored job when that job setup is recalled from memory and the air system is “ON”. This numbe r can be set in pou nds, kilograms, tons , or metric tons depending on the configuration as detailed in section 4.2.1. Press Trip Set For hydraulic overloads only, the desired trip point[...]

April 17, 2000 Man ual Versio n 1.0 5.8 Pressure can be set in one of two ways. First, if the air system was correctly configured, the desired force which the pressure is to create can be entered in the “Force Setpoint” row on the air pressure screen. Second, if preferred, the desired air p ressure in psi may be entered into th e “pressure se[...]

April 17, 2000 Man ual Versio n 1.0 5.9 “Waiting for Top”. When the press does reach the top and all other necessary conditions are satisfied, the slid e will go to the slide setpoint. d) If a job is recalled when the slide adjust switch is not on, the slide adjust system will display a status of “Waiting S/A Switch”. When the slide adjust [...]

April 17, 2000 Man ual Versio n 1.0 6.1 Section 6 Diagnostics - Fault and Status Messages When the press c ontrol screen re ports a stop conditi on that indicates th e auto-setup boa rd asserted or is asserting a stop signal, the “Auto-Sets” screen module status and the individual sub-systems status line will give additional information. Sectio[...]

April 17, 2000 Man ual Versio n 1.0 6.2 Unable to Fill The system was unable to make progress when trying to raise the air pressure. This could be a bad connection to the fill valve, a failed fill valve, or no plant air pressure. Probably the most common cause would be a bad air leak in the system. Unable to Dump The system was una ble to make prog[...]

April 17, 2000 Man ual Versio n 1.0 6.3 Ctr-Bal Vented -Stop A pressure setpo int of 0 was entere d for a counterb alance. The dump valve is left open in this condition. Unlike a cushion, this is considered a stop condition. Hyd Overload Tripped The hydraulic overload operation screen will display this message when the press hydraulic overload syst[...]

April 17, 2000 Man ual Versio n 1.0 6.4 a hardware failure of the relay. Lock Relay Shorted The “Lock” solid state relay on the slide adjust module failed shorted. Indicates a hardware failure of the relay. Transducer Fail For linear slide systems, indicates that the linear transducer is not sending information to the s lide adjust module. This[...]

April 17, 2000 Man ual Versio n 1.0 6.5 Min Position Reached The slide has gone as low as the min position programmed in the configuration menu and will not be allowed to go lower. Moving Up The slide is moving up. Moving Down The slide is moving down. System Off The slide adjust system is turned off. The slide can still be manually moved by using [...]

April 17, 2000 Man ual Versio n 1.0 A.1 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 usi[...]

April 17, 2000 Man ual Versio n 1.0 A.2 Note that units to the right of the number are also an edita ble parameter. When the editing c ursor is placed on the Max Die Weight units, we can press the “CHANGE UNIT” softkey to get a list of supported units. Th e units can be poun ds, kilograms, tons, or metric tons. We are using pounds. N ote that t[...]

April 17, 2000 Man ual Versio n 1.0 A.3 Using the arrow keys, we move the cursor to the “Transducer Type” line. Looking at table 4.1, we see that the transduc er type for any mo del pressure tra nsducer with a 250 psi pressure ran ge and a 4 to 20 ma output is “Type 3”. We hit the “CHANGE TYPE” softkey and select Type 3 from the list th[...]

April 17, 2000 Man ual Versio n 1.0 A.4 The pressure tra nsducer installe d on the system is a Se tra model C206 that h as a pressure ra nge of 0 to 250 psi and an output of 4 to 20 ma. An SMC ITV2050-31T 2S4 servo-valve w ill be used to contr ol the pressure. T his valve is 0-130 ps i with a 0-10V input. Now we go to the “Auto Sets” screen and[...]

April 17, 2000 Man ual Versio n 1.0 A.5 Finally, we go back to the “Mode” line and use the “CHAN GE MODE” softkey to toggle the mode to “ON”. The “Auto Sets” operation screen can now be used to set the air pressure or trip tonnage . See section 5.2 for op eration details. Section A.4 Example Linear Slide Adjust Configuration This ex[...]

April 17, 2000 Man ual Versio n 1.0 A.6 will be flawed because clearances will not be taken up by the counterbalance. Now we press the “ CALIBRATE SLIDE” s oftkey to perfor m the actual slide c alibration as des cribed in section 4.2.2.1 using the wire speed from the transducer nameplate (9.219 in this example) and an orientation of 0. After ca[...]

April 17, 2000 Man ual Versio n 1.0 A.7 Now it is time to hit the “AUTO ADJUST” softkey. The slide moves up past 14.000 (the slide setpoint we entered in the operation screen) and stops momentarily at 14.025. It then comes back down and stops at 13.996. The “Pulse Distance” value is set too high. What should have happened is that the slide [...]

April 17, 2000 Man ual Versio n 1.0 A.8 Before calibrating the slide, we MUST make sure the slide is properly counterbalanced, if a counterbalance is used on our press. If the slide is not properly counterbalanced, the slide calibration will be flawed because clearances will not be taken up by the counterbalance. Now we press the “ CALIBRATE SLID[...]

April 17, 2000 Man ual Versio n 1.0 A.9 “.04" sec. Repea ting the test, we fi nd that it now takes 1 to 2 pulses to move .00 1 inch - an acce ptable value. Now it is time to hit the “AUTO ADJUST” softkey. The slide moves up past 14.000 (the slide setpoint we entered in the operation screen) and stops momentarily at 14.025. It then comes [...]

April 17, 2000 Man ual Versio n 1.0 B.1 Figure B.1: Typical Counterba lance Wiring Dia gram. Appendix B Typical Wiring Diagrams[...]

April 17, 2000 Man ual Versio n 1.0 B.2 Figure B.2: Typical Cushion Wir ing Diagram.[...]

April 17, 2000 Man ual Versio n 1.0 B.3 Figure B.3: Conceptual Dual Resolver Mounting.[...]

April 17, 2000 Man ual Versio n 1.0 B.4 Figure B.4: Typical AMCI Dual Resolver Wiring D iagram.[...]

April 17, 2000 Man ual Versio n 1.0 B.5 Figure B.5: Typical GEMCO Dual Resolver Wiring Diagram[...]

April 17, 2000 Man ual Versio n 1.0 B.6 Figure B.6: Conceptual Linear Transducer Mounting[...]

April 17, 2000 Man ual Versio n 1.0 B.7 Figure B.7: Typical GEMCO Linear Transducer Wiring[...]

April 17, 2000 Man ual Versio n 1.0 B.8 Figure B.8: Typical MTS Temposonics II Linear Transducer Wiring[...]

April 17, 2000 Man ual Versio n 1.0 B.9 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 17, 2000 Man ual Versio n 1.0 B.10[...]

April 17, 2000 Man ual Versio n 1.0 C.1 Figure C.1: Logic Module Firmware Chip Locations 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 5[...]

April 17, 2000 Man ual Versio n 1.0 C.2[...]

April 17, 2000 Man ual Versio n 1.0 D.1 Note! Step 1 MUST be done even if a LOX va lve is opened in step 2 s ince the control may try t o pressurize the s ystem using the Fill/ Dump valve if the power is on! Appendix D Lockout Procedure For Air Controlled Systems Section D.1 General Lockout Cons iderations The OmniLink 5000 auto-setup card automati[...]

April 17, 2000 Man ual Versio n 1.0 D.2 Note! Step 1 MUST be done even if a LOX va lve is opened in step 2 s ince the control may try t o pressurize the s ystem using the Fill/ Dump valve if the power is on! Note! Step 1 MUST be done even if a LOX va lve is opened in step 2 s ince the control may try t o pressurize the s ystem using the Fill/ Dump [...]

April 17, 2000 Man ual Versio n 1.0 E.1 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. For[...]

April 17, 2000 Man ual Versio n 1.0 E.2 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 Conf[...]

April 17, 2000 Man ual Versio n 1.0 E.3 Section E.2 Shut height Calibration Sheets Linear Transducer Slide Configuration Slide Configuration Slot #1 Board Linear Transducer Name _________________ Wire Speed __________ Upper Limit __________ Lower Limit __________ Tolerance __________ Pulse Distance __________ Pulse Time __________ Lock Time _______[...]

April 17, 2000 Man ual Versio n 1.0 E.4 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 Configura[...]

April 17, 2000 Man ual Versio n 1.0 F.1 Appendix F Specifications Section F.1 5000-10A Pressure Control Board AC Output Relays: Voltage: 120VAC Current: 1Amp Continuous 20 Amp 16ms 5 Amp 75ms Fuse: 2 Amp Fast-Blow Picof use Section F.2 5000-10B Linear Shut Height Control Board AC Output Relays: Voltage: 120VAC Current: 1Amp Continuous 20 Amp 16ms 5[...]