AMETEK 2110 Shut Height Monitor User Manual
Shut Height Monitor with Resolver/LDT Interface
Installation and Programming Manual
Series 2110
GEMCO
Shut Height Monitor
®
ii
1080 North Crooks Road
Clawson, MI 48017-1097
Phone: (248) 435-0700
FAX: (248) 435-8120
Internet: www.ametekapt.com
www.ametek.com
This manual is divided into three parts. Part 1 provides an introduction and installation
instructions for Series 2110 Shut Height Monitor. Part 2 contains instructions for the basic
operation and programming of the monitor. Part 3 contains four appendixes: Error Messages,
Function Summary Chart, Catalog Numbering System, and Specications. A glossary and index
are also provided at the back of this manual.
Disconnect power before servicing. The Gemco Series 2110 contains no servicable components
other than the power supply fuse. Consult factory for repair or replacement.
Copyright 1997, 1998, 1999 by AMETEK, Inc.
All Rights Reserved - Made in the U.S.A.
Version 0.3
Ametek has checked the accuracy of this manual at the time it was printed. Any comments you
may have for the improvement of this manual are welcomed.
Ametek reserves the right to revise and redistribute the entire contents or selected pages of this
manual. All rights to the contents of this manual are reserved by Ametek.
Preface
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iiiInstallation, Maintenance, and Programming Manual
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Contents
Chapter 1: Theory of Operation ..........................................................................1
Chapter 2: Hardware Overview
2.1: Standard Modules ........................................................................................................... 2
Controller (FMMP01) ..................................................................................................... 3
Relay Output (FMOR01) ............................................................................................... 3
Digital Output ................................................................................................................. 3
Power Supply (FMPS01) ............................................................................................... 3
2.2 Input Module................................................................................................................... 4
Resolver (FMIR01) ........................................................................................................ 4
Variable Pulse (FMIP01) ............................................................................................... 4
LDT Input (FMIP02) ...................................................................................................... 4
2.3 Status LED's/Programming Keys ................................................................................... 5
Chapter 3: Mounting and Wiring ........................................................................7
Things to Consider ......................................................................................................... 7
3.1: Mounting & Section ...................................................................................................... 7
Controller ........................................................................................................................ 7
Resolver .......................................................................................................................... 8
LDT ................................................................................................................................ 8
Cabling V1 Option .......................................................................................................... 8
3.2: Wiring.............................................................................................................................. 11
Controller Module (FMMP01) ....................................................................................... 11
Relay Output Module (FMMP01) .................................................................................. 11
Power Supply Module (FMPS01)................................................................................... 12
Resolver Module (FMIR01) ........................................................................................... 13
Variable Pulse LDT Module (FMIP01) Input Option V1............................................... 13
LDT Input (FM1P02) Input Option L1 ......................................................................... 14
Chapter 4: Programming ..................................................................................... 18
Before Getting Started ....................................................................................................18
Programming Keys Dened ........................................................................................... 19
4.1: Resolver Conguration Functions .................................................................................. 20
Scale Factor (300) ...........................................................................................................20
Turns Counting (301) ..................................................................................................... 21
Position Offset (302) ......................................................................................................21
Conguring the Resolver ...............................................................................................21
Enter Scale Factor for the Conguration Process ..........................................................22
Set Turns Counting to 1 .................................................................................................22
Set the Position Offset to 0 .............................................................................................23
Enter Newly Determined Scale Factor ...........................................................................23
iiiInstallation, Maintenance, and Programming Manualiii
Adjust the Turns Counting Factor ..................................................................................23
4.2: LDT Conguration Function .......................................................................................... 24
Wire Speed (300) ...........................................................................................................24
Count Direction (301) ....................................................................................................26
Position Offset (302) ......................................................................................................27
Zero Pulse Time (305) ....................................................................................................27
Fault Pulse Time (306) ...................................................................................................28
LDT Output Type (307) .................................................................................................28
4.3: Monitor Setup Functions ................................................................................................29
Unit of Measurement (14) .............................................................................................. 29
Decimal Location (13) ...................................................................................................30
Position Hold (15) ..........................................................................................................30
Auxiliary LED (16) ........................................................................................................31
4.4: Press Setup Functions ....................................................................................................32
Move Detection Time-Out (12) ......................................................................................32
Bolster Offset (303) ........................................................................................................33
Negative Over Travel Limit (304) .................................................................................33
Upper End Limit (400) ...................................................................................................34
Lower End Limit (401) ..................................................................................................34
Relay State (402) ............................................................................................................35
Relay Override (403) ......................................................................................................35
4.5: Digitial Outputs .............................................................................................................. 36
Output Type (200) ..........................................................................................................36
Latch/Synchronize Handshake (201) .............................................................................37
Logic Level (202) ...........................................................................................................37
Error Condition Output State (203) ................................................................................38
4.6: Program and Supervisory Mode Functions ....................................................................41
Program Mode Access (10) ............................................................................................41
Program Mode TIme-Out (11) .......................................................................................42
Appendix A: Error Messages.............................................................................. 43
Error Conditions (306) ...................................................................................................48
Appendix B: Function Summary Chart ........................................................... 49
Appendix C: Catalog Numbering System ......................................................... 51
Appendix D: Specications ................................................................................. 52
Glossary ..........................................................................................................................53
Index ...............................................................................................................................55
1
Installation and Programming Manual
Chapter 1: Theory of Operation
Chapter 1: Theory of Operation
The Series 2110 shut height monitor accurately indicates shut height positions to quickly and
accurately assist setup personnel in changing a die on a mechanical stamping press. Positions
can be monitored within a thousandth of an inch. During a die change, the monitor displays the
position of the press’s shut height on a large LED display. If the shut height is moved beyond
its programmed end limits, the monitor de-energizes a limit switch. (This will only occur if the
optional relay module is installed.) This limit switch can work in conjunction with the safety
interlock of the press. For example, when wired properly, power will be removed from the
press’s ram adjust motor(s).
The monitor can also stop updating the shut height during a press’s stamping cycle while
retaining the last shut height read. This is used to lter out press movement and deection
during the stamping cycles. When power is applied to the input, the monitor holds the displayed
shut height on the read out. When this input is released, the monitor continuously updates the
display with the current shut height position.
A built-in timer is also included which is used to detect a possible jam or drive component
failure. The timer starts when power is applied to the ram adjust motor(s) and stops when the
monitor senses motion from the input device. If the ram does not move within a programmed
value, the monitor de-energizes limit switches and displays an error message. When properly
wired to the safety interlock of the press, the limit switches de-energizing will take power away
from the press’s ram adjust motor(s).
Other features of the shut height monitor include the following:
n Measures in inches or millimeters.
n Program mode access code protects against unauthorized access.
n Separate bolster plate offset speeds setup.
n States of the limit switches can be changed for N.O. and N.C.
operations.
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Chapter 2: Hardware Overview
The shut height monitor contains a heavy-duty case which can hold up to ve modules:
n Power Supply
n Controller (CPU)
n Digital Output (optional)
n Analog Output (optional)
n Resolver Input (optional)
n Linear Displacement Transducer L1 (optional)
n Linear Displacement Transducer V1 (optional)
n Relay Output (optional)
The shut height monitor’s faceplate contains a 6-digit, seven-segment LED display and four
programming keys. The LED display is used to indicate the shut height position as well as to
enter parameters when programming. The programming keys are used to program the monitor.
Ten small status LEDs are also provided. These LEDs are used to indicate the state of the
monitor during machine operation.
Figure 2-1 Shut Height Monitor
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Chapter 2: Hardware Overview
This section provides descriptions of the shut height monitor’s standard modules. See also Section
2.2: Input Modules. For wiring instructions, see Section 3.2: Mounting & Wiring.
Controller (FMMP01)
This module contains the Central Processing Unit (CPU) which is used to process data it receives
from the resolver or LDT (depending on which input device is used). It then shows the position
of the shut height on the monitor’s display. The controller is also responsible for continuously
monitoring all programmed setpoints and timing functions. To store programmed functions,
including calibrated settings, the controller contains battery-backed memory. This battery requires
no maintenance and is non-replaceable. The controller is located in slot 1 of the enclosure.
Relay Output (FMOR01)
This is an optional module. It contains an upper and lower limit relay. These relays can be
programmed to either energize or de-energize when the press’s shut height reaches either of the
relay’s programmed limits. When these relays are programmed to de-energize and are wired
properly, power will be taken away from the press’s ram adjust motor(s). For a listing of errors
which will cause the upper and lower limit relays to de-energize, see Chart A-5 in Appendix A:
Error Messages. The relay output module is located in slot 4 of the enclosure.
Power Supply (FMPS01)
This module supplies power to the shut height monitor. It also contains a fault check relay and an
auxiliary input. The fault check relay is designed to take power away from the press’s ram when
a fault occurs during machine operation, or when power is taken away from the monitor. In order
for this to work, the fault check relay must be properly wired to the press’s safety interlock. For a
listing of errors which will cause the fault check relay to open, see Chart A-4 in Appendix A: Error
Messages. The auxiliary input is used with the press’s ram adjust motor(s). When used with the
Move Detection Time-out function, this input can detect a possible jam or drive component failure
when power is applied from the motor(s) but no movement occurs. When used with the Position
Hold function, this input can be used to stop the monitor from updating the shut height during a
press’s stamping cycle. The auxiliary input accepts 85-265 VAC. The power supply is located in
slot 5 of the enclosure.
Digital Output (FMOD01) Output Option D1, D2 or D3
This module is used to transmit parallel digital output data to a PLC or personal computer. The
digital output is eld congurable for position or velocity data in a binary, BCD or grey code
format. This data is updated every 50 microseconds for resolver input and 40 milliseconds for
LDT input. The electrical characteristics of this output data can be current sinking, current
sourcing or TTL, which must be specied in the module’s part number.
2.1: Standard Modules
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This module also provides two input pins for use as a eld congured latch or synchronized
handshake input. The latch input freezes the digital output data while the PLC reads it. The
data is updated when the input is released. When congured for synchronized handshake, the
PLC must provide a clocked square wave input into these input pins. Digital data is updated
on each transition of the square wave and the PLC is synchronized to read the updated position
data after a 100 microsecond settling time.
This input accepts a 5 to 24 VDC source from the PLC to perform the latch or synchronized
handshake function described above. For details on wiring to the digital output board, see
pages 16 & 17.
Analog Output (FMOA01) Output Option A1
This module is used to transmit position or velocity data to a PLC in an analog format. The
module provides two separate analog output channels that can be independently congured for
position or velocity data.
These analog outputs can be eld scaled over any range and congured for 0 - 10 VDC, 10 - 0
VDC, -10 VDC to +10 VDC, 4 - 20 mA, 20 - 4mA, 0 - 20 mA or 20 - 0 mA.
For applications that require remote indication it is recommended to use an aftermarket analog
input display or a digital input display. When using one of these displays the optional analog or
digital output board must be specied in the part number.
The shut height monitor can be used with a resolver or Linear Displacement Transducer (LDT).
Both input devices’ input modules are located in slot 3 of the enclosure. You can identify the
module type by the name found on the back of the module.
Resolver (FMIR01) Input Option R1
This module is used with a Gemco resolver. The resolver assembly consists of a highly
accurate and repeatable brushless resolver, housed in an industrial-grade enclosure. The shaft
position is calculated from two analog signals that vary as a function of the angular rotation of
the input shaft.
The brushless resolver works on the same principle as a rotary transformer to couple power into
the rotor. The construction of the brushless resolver consists of a two-phase stator and a singlephase rotor. Each stator is positioned 90° apart from each other. The two stators continually
provide two different output voltages. Using these two outputs, the module performs a
ratiometric conversion and provides an absolute position. This results in a highly accurate
and repeatable transducer having excellent reliability with an innite resolution which can be
converted by a resolver-to-digital converter into digital position data.
2.2: Input Modules
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Variable Pulse (FMIP01) Input Option V1
This module is used with an LDT that provides its output in the form of a pulse width modulated
RS-422 signal. The module only works with Gemco 951VP2110 LDT’s.
LDT Input (FMIP02) Input Option L1
This module will accept an output from a controlled pulse, start stop pulse or variable pulse
magnetostructive LDT. This card accepts a wide range of LDT inputs and faster updates than
the variable pulse described above.
It allows the shut height monitor to receive the signals from the LDT. The pulse width signal
is converted to position data which the monitor displays and uses for shut height position. The
module also provides +24 VDC to supply power to the LDT. The monitor was designed to
work with the Gemco Series 951 or 952 LDT. However, other LDTs can be used with the shut
height monitor. If you are using a different type of LDT, contact the factory for wiring and
programming instructions.
The shut height monitor has 10 status LEDs and four programming keys. The LEDs provide
information on the monitor’s state during machine operation. The programming keys are used
to program functions and perform basic operations.
2.3: Status LED's/Programming Keys
Figure 2-2: Monitor's Status LED's and Programming Keys
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PROGRAM The program LED turns on when the controller is in program mode and
turns off when the controller is not in program mode. Functions cannot be
programmed when this LED is off.
FAULT OK The fault check OK LED turns on when the power supply’s fault check
relay is closed, indicating the system is OK. This LED will turn off when
a fault is detected, indicating that the fault check relay is open.
MVT FLT The movement fault LED turns on when a movement fault is detected.
(For more information, see Move Detection Time-Out in Section 4.4:
Press Setup Functions.)
BOLSTER This LED indicates that the current shut height position is referenced from
a bolster plate. The bolster LED turns on when a value is programmed
into the Bolster Offset function. (For more information, see Bolster Offset
in Section 4.4: Press Setup Functions.)
BED This LED indicates that the shut height position displayed on the monitor
is referenced from the press’s bed. The bed LED turns on when the
Bolster Offset function contains a 0 value. (For more information, see
Bolster Offset in Section 4.4: Press Setup Functions.)
UPR LIM The upper limit LED turns on when the press’s shut height reaches
the value programmed in the Upper End Limit function. (For more
information, see Upper End Limit in Section 4.4: Press Setup Functions.)
LWR LIM The lower limit LED turns on when the press’s shut height reaches
the value programmed in the Lower End Limit function. (For more
information, see Lower End Limit in Section 4.4: Press Setup Functions.)
INCH The inch LED turns on when the unit of measurement is in inches.
MM The millimeter LED turns on when the unit of measurement is in
millimeters.
AUX The auxiliary LED is programmable and can be used with the Position
Hold function. When enabled, this LED indicates when the shut height
position is being held. (For more information, see Position Hold and
Auxiliary LED in Section 4.3: Monitor Setup Functions.)
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The function key is used to begin a process for programming a function.
When this key is pressed, the monitor prepares itself for the entry of a
specic function number.
The scroll key is used to scroll through the monitor’s list of function
numbers, as well as other lists. This key is also used to increment selected
digits shown on the monitor’s LED display.
The shift key is used to move to (select) a specic digit shown on the
monitor’s LED display from right to left.
The enter key is selected after a function number has been entered. This
begins the programming process for the selected function. The enter key
is also used to program a value in a function.
NOTE: For more information on how to use the programming keys, see Chapter 4: Programming.
(F)
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Chapter 3: Mounting and Wiring
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Chapter 3: Mounting and Wiring
Chapter 3: Mounting and Wiring
This chapter provides instructions for mounting and wiring the shut height monitor. These
instructions have been divided into two sections: Section 3.1: Mounting and Section 3.2:
Wiring.
Things to Consider
It is recommended that you consider the following before installing the shut height monitor:
To minimize the effects of electromagnetic interference (EMI), the monitor
should be mounted as far away as possible from motor starters and control
relays.
The monitor should be mounted in an area free of water spray, corrosive gases,
ying chips, or any other foreign matter that could cause damage to the unit.
If the monitor is mounted directly on the press, it should be installed in an area
where shock and vibration will be minimized.
The monitor should be located in an area that is within the temperature and
humidity specications. (See Appendix D: Specications.)
Controller
To assist you in mounting the shut height monitor, refer to Figure 3-1. Perform the following
steps:
1. According to the dimensions as shown in Figure 3-1, cut out a section of the
panel you wish to mount the monitor to.
2. Remove the mounting rails on the left and right side of the unit by removing
the #6-32 UNC screws located on the rear of the unit.
3. Place the monitor in the newly cutout section of the panel.
4. From behind the panel, insert the two mounting rails into the monitor’s side
grooves. The feet of the rails must be inserted rst. See Figure 3-1 for the
location of the mounting rails.
The mounting rails secure the monitor by their feet being pressed against the
back of the panel.
3.1: Mounting
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Chapter 3: Mounting and Wiring
5. Insert each #6-32 UNC screw into each of the monitor’s screw holes.
6. Using a 7/64" Allen wrench, secure the screws into position. This will secure
the mounting rails. Eight to 10 inch pounds of torque is required.
Resolver
The resolver is mounted and coupled to the main ram adjust drive motor, or another shaft that
rotates when the shut height is adjusted.
NOTE: Backlash and slop in the shaft will affect shut height accuracy.
LDT
The LDT is mounted on the upper pitman arm of the press with the sensing rod facing down and
next to the upper ram. The magnet assembly is mounted off the upper ram per the drawing - see
Figure 3-2. Universal mounting kit (SD0441300) will simplify mounting of LDT to the upper
pitman arm. See Figure 3-2A for a typical mounting example.
Cabling
Since the LDT rides with the upper ram, a method must be found to control the cable during a
press cycle.
AMETEK manufactures several cable termination kits which provide a junction box mounted
to the crown of the press and a coiled cord set that protects the cable and its connection to the
junction box and the LDT or resolver. (See Figure 3-2B for general mounting details).
Select the appropriate cable termination kit from the variations listed below.
1) Magnetostrictive LDT used with type V1 input on series 2110 module.
Catalog No. SD0482700L25
2) Magnetostrictive LDT used with type L1 input on series 2110 module.
Catalog No. SD0443800L25
3) Resolver used with type R1 input on series 2110 module.
Catalog No. SD0439600L25
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Figure 3-1 Dimensional Drawing
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Chapter 3: Mounting and Wiring
Figure 3-2 Transducer Mounting
Figure 3-2B Termination Kit
Figure 3-2A Universal Mounting Kit
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This section contains pinout diagrams for each module. System wiring diagrams follow.
Controller Module (FMMP01)
The controller has two connectors: a D9 connector (J1) for RS-232 and RS-485 serial
communications, and a program lockout connector (J2) intended for a keyswitch. (See Figure
3-3). Making connections to both connectors is optional. However, the program lockout
connector must be jumpered to allow the unit to enter program mode. J2’s input rating is +5
VDC maximum dry contact or open collector (drain) only. Actuation voltage must be less than
+1.0 VDC at 0.2 mA. The terminal wire size is No. 22-12 AWG.
Figure 3-3 Controller Pinout Diagram
NOTE: (J2) program lockout connector.
NOTE: The controller’s program lockout connector (J2) must be jumpered to allow the unit
to enter program mode.
Relay Output Module (FMOR01)
The relay output module contains an upper and lower limit relay. Each relay contains a N.O.
contact pair and a separate N.C. contact pair. (See Figure 3-4). Each relay contact rating is 8
amps, 250 VAC, 30 VDC, 1/4 HP 125, 250 VAC. It is recommended that you connect these
relays to the ram adjust motor control circuit to prevent movement beyond the programmed
upper and lower limits. The terminal wire size is No. 22-12 AWG.
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Figure 3-4 Relay Output Pinout Diagram
Figure 3-5 Power Supply Pinout Diagram
Power Supply Module (FMPS01)
The power supply module has a main power input, an auxiliary input, and a fault check output.
(See Figure 3-5). Power input: 85-265 VAC at 450 mA maximum. Fault check output: 8 amps
250 VAC, 30 VDC, 1/4 HP 125, 250 VAC. It is recommended that the fault check contacts be
connected to the required safety interlock for the press. Auxiliary input: 85-265 VAC at 12 mA
maximum. The terminal wire size for all connectors is No. 22-12 AWG. See page 3, 35, 36 and
37 for use of this special purpose input, concerning position hold and move detection.
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Resolver Module (FMIR01)
The resolver module has an eight-position connector. (See Figure 3-6). The terminal wire size
for all positions is No. 22-12 AWG. Terminal 7 and 8 are not used.
Figure 3-6 Resolver Pinout Diagram
Variable Pulse LDT Module (FMIP01) Input Option V1
The variable pulse LDT module has an eight-position connector. It is only necessary to connect
your LDT to positions 1 through 4. (See Figure 3-7). Positions 1 and 2 provide +24 VDC to
power the LDT. Positions 3 and 4 are used for the LDT’s pulse-width output signals. These
signals comprise an RS-422 differential input. Positions 5-8 are provided for future expansion.
The terminal wire size for all positions is No. 22-12 AWG. This module should only be used
with Gemco LDT model 951VP-2110 tranducers.
Figure 3-7 Variable Pulse LDT Pinout Diagram Input Option V1
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