Link-systems OmniLink 5000 Manual do Utilizador Página 1

OmniLink 5000System 5000Press ControlCOLOR DISPLAYOPERATING MANUALLINK ELECTRIC & SAFETY CONTROL COMPANY444 McNALLY DRIVE, NASHVILLE TN 3721

2.2-Press Control Reason for Last Stop-Total Tonnage (If the control is equipped with a tonnage monitor)-Counterbalance Pressure (If the control is eq

7.8terminal along with its inputs. This terminal should be used to connect any permanent straps to inputs thatare not to be used in a particular inst

7.9Section 7.2.6 Flywheel SpeedThe R/D MODULE provides an isolated analog input in order for the press control to measure and displayflywheel speed (s

7.10Figure 7.13 Interface to Eddy Current with BridgeInput TachFigure 7.14 Interface DC to Variable Frequency DriveSection 7.2.7 Motor CurrentIf the p

7.11Step 1. In the Machine Speeds configuration screen turn off the speed limits and program all informationthat is known about the stroking speed of

7.122457 6.002252 5.502048 5.001843 4.501638 4.001433 3.501229 3.001024 2.500819 2.000614 1.500410 1.000205 0.500000 0.00Step 3. Once str

7.13Step 4. Run the press at the minimum speed and if necessary adjust the Low Spm Input Offset parameteruntil the Drive Speed reads correctly.Section

7.14Step 1 - Check for proper wiring.Before applying power to the press control check that the +24 volt terminal is not shorted to ground orto the L1

7.15the position of the resolver/encoder assembly. This assembly must be physically rotated until the displayindicates as close to 0 degrees as possi

7.16PLS/OR Relays,Solid State... 2 Amps at 120V, 60HzOutput Power Terminals:+24 vdc Supply... 250mA for

8.1Section 8 TroubleshootingThe system 5000 relies on serial communication between the operator terminal and the press control inorder to provide any

2.3the present number being entered, and the entry process is aborted by pressing the EXIT softkey or one ofthe arrow keys. The numeric data will not

8.2This message is generated by the brake monitor logic when the stopping time exceeds the allowable limit.An internal fault is also generated and mus

8.3valve in energized. This fault occurs only if configured for valve monitor type 002 (see section on ValveMonitor)."Mode Selected Error"T

8.4The Station #3 Right Run Button normally open contact closes without the normally closed path opening.This indicates a fault in the button or field

8.5The position read from the resolver does not agree with the position read from the optical encoder. Thiscould indicate misalignment within the res

8.6Section 8.4 Diagnostic LedsThe system 5000 card rack provides the following Led indicators:POWER CONNECTOR MODULE+24v This indicates the status of

9.1Section 9Section 9.1 Software VersionThe information in this manual is based on software version 2.90.Section 9.2 Configuration Code and Clear Stro

3.1Section 3 Access ControlSection 3.1 Description The OmniLink control has several parameters or operations that have limited access. The ability to

3.2die set-up personnel. A press operator is assigned a user name and password. With the password theoperator can reset tonnage monitor faults, res

3.3Section 3.2 Restricted ItemsThe following table lists the restricted items name and function.RESTRICTED ITEMSNUMBER NAME FUNCTION 1 PLS Bypass Bypa

3.419 PLC Screen 1 Sets Change parameters on Screen 1 of the ProgrammableLogic Controller Interface 20 PLC Screen 2 Sets Change parameters on Screen 2

3.5items. All restricted items are accessible when the Program/Run key switch is switched to the PROGposition.When operating in the “Key or Password”

3.6Step A: Select the restricted item. In the example shown in Figure 3.1 the restricted item is MotorSpeed. Once the parameter is selected then So

3.7

4.1Section 4 Operating MenusSection 4.1 Main Menu Figure 4.1 shows the Main Operating Menu. This screen provides an overall view of the functions ava

iTABLE OF CONTENTSSection 1 Introduction ...1.1Section 1.1 System Overview ...

4.26. The status of the order and batch counter. This includes the preset limit, the present quantityproduced, and the on/off state of the counter. 7

4.37. Continuous on Demand Time8. Messages from auxiliary equipment.9. The event that caused the press to stop.10. The event that is keeping the press

4.4a die protection module the press control will also wait for all die protection inputs to become satisfied. Themaximum time allowed for successive

4.5Section 4.2.7 Reason For The Last StopDiagnostic information is provided to show the reason the press stops. Once a stroke is initiated, the first

4.6 1 L. N.O. INCH BUTTON LO LO 2 R. N.O. INCH BUTTON LO LO 3 L. N.O. STATION # 1 LO LO 4 R. N.O. STATION # 1 LO LO 5 L. N.O. STATION # 2 LO LO 6 R. N

4.7Group 2 Programmed in Top Stop Calibration (configuration).06 Speed Range (lowest)07 Stop position (in single stroke)08 Stop position (in continuou

4.8Group 5 Programmed in Factory Mode Configuration.45 Allow Timed Inch (value)46 Allow Auto Single Stroke (value)47 Allow Continuous on Demand (value

4.9StrokeModeSingle StrokeDriveSpeedStrokeSpeedSPMSPM00OrderCounterPC STATUSCounter OFFPRESSCONTROLMOTORSPEEDTONNAGEMONITORAUTOSETSDIEPROTECTIONEXIT00

4.10the RUN position. The display automatically presents one of the menus shown in Figure 4.7 and allows theoperator to choose from one of the strok

4.11Section 4.3.2 Timed Inch (When Provided)This mode selection functions like the Inch mode until a programmable downstroke slide position is reached

iiSection 4.3.1 Setup/Stop Time Test ... 4.10Section 4.3.2 Timed Inch (When Provided) ...

4.12emergency stop, or other stop input occurs. In the event of any stop condition, further strokes can beinitiated only after all operator run butto

4.13prevent further automatic stroking until the stop conditions are removed and automatic stroking is manuallyinitiated. Stroke initiation is preven

4.14StrokeModeSingle StrokeDriveSpeedStrokeSpeedSPMSPM00OrderCounterPC STATUSCounter OFFLIMITSWITCHCHANGENUMBERNEXTGROUPBYPASSON/OFFEXIT00READY TO STR

4.15To bypass an output:1. The operator must have access control. Access control is described in Section 3. If the user obtainsaccess control by usi

4.16descriptions to particular outputs of the current job. The menu in Figure 4.9 shows the output descriptionsavailable as two pages of fifteen name

4.17Section 4.4.4 Restricted PLS ChannelsAny programmable limit switch channel that has been restricted in the Press Control Configuration Menucannot

4.18The display provides the following information:1. A list of all jobs presently in the internal file storage. The jobs are identified by a 9 digit

4.19access control by using the password system, the user must be configured to have access to recall jobs frommemory. The Select Job menu is shown in

4.20From the Jobs Menu, Figure 4.10, depressing the ERASE SETUP softkey will transfer the screen to theSelect Job menu. The Select Job menu allows th

4.215. Current Scrap Count and Scrap RateSection 4.6.1 Production CountersThe OmniLink control has up to ten production counters. The first three pro

iiiSection 5.1.1.2 Single Speed Presses, Link Standard ...5.5Section 5.1.2 Top Stop Calibration, Link High Speed ...

4.22Production counters can be turned on or turned off. The user must obtain access control in order to turn thecounters on or off. Access control i

4.23must be configured to have access to change counter settings.To increase or decrease the current count value by one, select the counter and depres

4.24To change the value of the scrap count, position the cursor on the scrap counter and select the CHANGESCRAP softkey. Then enter the new count usi

4.25StrokeModeSingle StrokeDriveSpeedStrokeSpeedSPMSPM00OrderCounterPC STATUS1000COUNTERCONFIGEXIT00Program/Run SwitchTOPCHANGEINCREMENTCHANGESTROKESC

4.26CHANGE Strokes softkey, enter the new number, and press the ENT keySection 4.6.4.4 Configure Counter Reset When Order Counter ResetAll counters ot

4.27Spm. In this situation, the operator can enter a speed setting up to 400 in any mode but the command signalto the drive will go no higher than 25

4.28StrokeModeSingle StrokeDriveSpeedStrokeSpeedSPMSPM2000OrderCounterPC STATUSCounter OFFQUICKACCESSEDITNOTES00Ready to StrokeTOPEXITMACHINE NOTESNOT

4.29In order for the job notes to be saved after editing, the current job must be stored. Job storage is describedin Section 4.5.1.Section 4.8.4 Auxi

5.1Section 5 Press Control Configuration MenusThe System 5000 allows the user to configure the control and the operator terminal for specific machiner

5.2Section 5.1 Top Stop CalibrationThere are two versions of Top Stop Calibration. These are Link Standard and Link High Speed. The LinkStandard Top

ivSection 5.4.7 Configure Auxiliary Communications ... 5.21Section 5.6 Output Names/Messages ...

5.3StrokeModeSingle StrokeDriveSpeedStrokeSpeedSPMSPM2000OrderCounterPC STATUSCounter OFFTOP STOPCALIBRATECHANGENUMBER00Program/Run SwitchTOPEXITMOTOR

5.4If configured, the Motor Speed Adjust screen can be accessed from this screen in order to change thestroking speed of the press (see Section 4.7).S

5.58. Set the flywheel speed to the highest speed range. Repeat Steps 4 and 5.9. Repeat steps 3, 4, 5, 6, 7, and 8 with the press in Continuous mode.

5.6StrokeModeSingle StrokeDriveSpeedStrokeSpeedSPMSPM2000OrderCounterPC STATUSCounter OFFTOP STOPCALIBRATECHANGENUMBER00Program/Run SwitchTOPEXITMOTOR

5.7Variable speed presses require a calibration procedure be performed when the press control is installed. Thisprocess involves running the press at

5.8generated the correct stopping curve. 3. With the Program/Run switch in the RUN position, select Continuous mode. 4. The same top stop calibratio

5.9 StrokeModeSingle StrokeDriveSpeedStrokeSpeedSPMSPM2000OrderCounterPC STATUSCounter OFFMACHINEPARAMETERSCHANGENUMBER00Program/Run SwitchTOPEXITSETZ

5.10the nearest acceptable rpm.Section 5.2.5 Maximum Strokes/MinuteThis parameter also appears in the Configure Speed screen and can also be programme

5.11provided as an energy conservation feature. After this time has elapsed, the press control will turn its LMCrelay off until the main motor turns

5.12at which the press will stroke in that mode. On variable speed presses that have high maximum strokingspeeds for the Continuous mode, the strokin

vSection 7.2.7 Motor Current ...7.10Section 7.3 Calibrating Flywheel Speed Interface ...

5.13Automatic Single Stroke, and can include Inch and Timed Inch if a fixed Inch speed has been turned off. Theexample shown in Figure 5.6 describes

5.14Section 5.2.13.8 Low Spm Input OffsetThis parameter is used in the calibration procedure of the flywheel speed input to the press control. Ifneed

5.15command signal the motor drive only strokes the press at 220 spm. In this situation the Mid Output Spm canbe set to 225 spm and the Mid Output Ca

5.16Section 5.3.1 Auxiliary Lube Systems (option)If the optional expansion card rack and third input board are provided, two auxiliary lube systems ar

5.17The displayed item can change when the press stroking mode is changed. The user can chose four items thatare to be displayed in Setup modes, such

5.18To zero the stroke count, authorized personnel must enter a specific number and press ENT. The numberthat must be entered is the second code numb

5.19To change the current access mode position the cursor on the current access mode, press the CHANGESETTING sofkey, position the cursor to the desir

5.20StrokeModeSingle StrokeDriveSpeedStrokeSpeedSPMSPM00OrderCounterPC STATUSCounter OFFUSERCONFIGEXIT00Program/Run SwitchTOPCHANGETEXTCHANGENUMBERUSE

5.21Section 5.4.6.4 Set Configuration CodeSelecting the SET CONFIG. CODE softkey in the Access Configuration Menu, Figure 5.9, will displaythe Configu

5.22servo feeds, auxiliary equipment (such as PLCs), a laptop interface for downloading messages, and anetwork interface. See the manual pertaining t

1.1Section 1 IntroductionThe System 5000 Press Control is designed specifically for use on part revolution mechanical power presses.Two separately po

5.23StrokeModeSingle StrokeDriveSpeedStrokeSpeedSPMSPM2000OrderCounterPC STATUSCounter OFFINPUTNAMESCHANGENAMEAUXILIARYEQUIPMENT00Program/Run SwitchTO

6.1Section 6 Press Control I/OThe System 5000 provides 48 inputs (expandable to 72), 8 programmable limit switch outputs (expandableto 16), and up to

6.2Input Card 2Input #Description Section----------------------------------------------------------------------------------------------------- 25 Slid

6.3Section 6.1.2 Operator Station SelectsThese inputs define the active operator stations for Single Stroke, Continuous, Automatic Single Stroke,Conti

6.4Section 6.1.7 Forward/Reverse Motor ContactsThese inputs report the state of the main motors, where +24 volts indicates that the motor is on. The

6.5alters the function of the valve monitor inputs in the following manner:Valve Monitor type 000: Air Valve With Internal MonitorInput #44 Input from

6.6the line is pressurized. Since the valve has some physical reaction time, two factory programmedparameters are provided. The parameter ‘V/M Turn

6.7and the LMC turned Off if the press travels beyond 20 degs into the downstrokeduring a soft brake stop on top.Factory Configured Parameter definiti

6.8Lube Type 002: Recirculating Oil with Static InputsInput #33 Low Lube Level/Press(stop if input = 0 volts)Input #34 High Lube Pressure (stop if inp

6.9Lube System Type...004Flow Rate (Running)...030 SecFlow Rate (Power Up)...060 SecOutput Off (type 004)...010 MinOutput On (type 004

1.2Figure 1.1 System Components

6.10necessary to pulse this output during the lubrication cycle. The "Output Pulse" timer sets the rate at whichthe output turns on and off

6.11Lube System Type...006Flow Rate (Running)...010 SecFlow Rate (Power Up)...030 SecOutput Off (type 004)...060 MinOutput On (type 004)..

6.12The duration of the time interval is equal to the time set by the Flow Rate configuration parameter. Thereare two flow rate configuration paramete

6.13pump is energized.7. The hydraulic pump output (OR-3) is turned On and the present running status will indicate thestatus of the pressure switch u

6.14stroke initiation until this is done.3. If the press has stopped in the downstroke the present running status will display “MotorDirection” and th

6.15Forward On Muted from 180 degs to 346 degsReverse On Muted from 0 degs to 180 degsBoth Off Never MutedIn Single Stroke, Continuous, Trip Mode, and

6.16Aux. Lube 2 Type...001# of Strokes Off...01000Flow Rate (Running)...010 SecFlow Rate (Power Up)...000 SecOutput Pulse...000 S

6.17Aux. Lube 1 Type...002# of Strokes Off...10000Flow Rate (Running)...010 SecFlow Rate (Power Up)...030 SecOutput Pulse...000 Secene

6.18high) the system has been programmed to generate an initial lube cycle. Output OR-13 energizes a motordriven lube pump until the flow sensor input

6.19altered, the name that is displayed for diagnostic purposes can be defined by the user. The programmablename (up to twenty characters), along wit

2.1Section 2 Operator TerminalSection 2.1 LCD DescriptionFigure 2.1 shows the operator terminal front panel. This panel consists of a color LCD displ

6.20 17 (OR-1) 2 Delayed Main Motor 6.3.1 18 (OR-2) 2 Hydraulic Overload Cylinder 6.1.12 19 (OR-3) 2 Hydraulic Overload Pump 6.1.12 20 (OR-4) 2 Flywhe

6.21Section 6.3.4 Slide MotionThis output (OR-8) turns on when the crankshaft rpm exceeds the minimum strokes/minute threshold.Section 6.3.5 Mode Outp

6.22the stroke. In Automatic Single Stroke the output will remain on while the press is stopped at the top andthe press control is waiting for the pr

7.1Section 7 InstallationSection 7.1 Component MountingThe Operator Terminal must be mounted in a position that is easily seen and accessed by the ope

7.2The physical layout dimensions for basic card rack are shown in Figure 7.3.Figure 7.3 Card Rack Dimensions

7.3The physical layout and mounting dimensions for the relay module are shown in Figure 7.4.Figure 7.4 Output Power Supply and Relay ModulesDimensions

7.4The mounting dimensions for all available assemblies are shown in Figure 7.5.Figure 7.5 Card Rack and Output Power SupplyMounting DimensionsThe mou

7.5Figure 7.7 Dimensions for Resolver/EncoderMounted on Spring BaseAnother sprocket must be attached to the machine shaft. The proper size hole must

7.6Figure 7.8 Operator Terminal and Card Rack Power and InterconnectWiringSection 7.2.2 Clutch/Brake ValveThe connections for the clutch/brake dual va

7.7possible. Allow sufficient wire length so that the R/D CONNECTOR can be removed from the card rackand positioned so the R/D BOARD can be removed f