LINK Systems 2500 PLS User Manual

System 2500

Programmable Limit Switch /Die Protection Unit

Operator Manual

WARNING!!

THIS UNIT IS NOT INTENDED FOR APPLICATIONS REQUIRING CONTROL RELIABILITY. DO NOT USE THE OUTPUT RELAYS OF THE SYSTEM 2500 AS PRIMARY INPUTS TO A PRESS CONTROL.

Manual LS-013

Revision 07

TABLE OF CONTENTS

Section 1 OVERVIEW OF THE SYSTEM 2500

1.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

1.2 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

1.3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Section 2	OPERATION
2.1 Using the Operator Interface Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .				2-1
	2.1.1	Keyboard Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-1
		2.1.1.1	ANGLE/RPM Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-1
		2.1.1.2	HELP Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-2
		2.1.1.3	CLEAR Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-2
		2.1.1.4	BRIGHT and DIM Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-2
		2.1.1.5	MAIN MENU Key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-2
	2.1.2	Mode Selector Keyswitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-2
2.2	Menu Selection Using the LCD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			2-3
	2.2.1	Main Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-3
2.3 Programmable Limit Switch (PLS) Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . .				2-4
2.4	OUTPUTS . . . . .		. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-4
	2.4.1	SETPOINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-5
		2.4.1.1	Adding Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-5
		2.4.1.2	Erasing Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-6
		2.4.1.3	Editing Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-6
		2.4.1.4	Timed Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-7
		2.4.1.5	Speed Advanced Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-7
		2.4.1.6	Incrementing Setpoints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-8
	2.4.2	VIEW STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-8
	2.4.3	COUNTED OUTPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-8
		2.4.3.1 Counted Outputs, VIEW SETUP . . . . . . . . . . . . . . . . . . . . . . .		2-9
		2.4.3.2 Counted Outputs, EDIT SETUP . . . . . . . . . . . . . . . . . . . . . . .		2-9
		2.4.3.3	CHANNELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-10
		2.4.3.4	COUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-11
		2.4.3.5	ACTIVE COUNT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-11
		2.4.3.6	COUNT ANGLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-11
2.5	CONFIGURE . . .		. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-12
	2.5.1 Configure Access Code Screen and Menu . . . . . . . . . . . . . . . . . . . . . .			2-12
	2.5.2	MOTION DETECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-13
	2.5.3	TOPSTOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-14
	2.5.4	TOPSTOP SPEED ADVANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-15

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	2.5.5	RESTRICTED CHANNELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-16
	2.5.6	OFFSET	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-17
	2.5.7 PLS OUTPUT SPEED ADVANCE . . . . . . . . . . . . . . . . . . . . . . . . . . .			2-17
2.6	COUNTERS . . .		. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-18
	2.6.1	PART Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-19
	2.6.2	BATCH Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-19
	2.6.3	QUALITY Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-20
	2.6.4	STROKE Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-20
2.7	STORE/RECALL		. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-20
	2.7.1	STORE	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-21
		2.7.1.1 Store Setup, USE THIS NAME . . . . . . . . . . . . . . . . . . . . . . .		2-22
		2.7.1.2 Store Setup, ENTER NEW NAME . . . . . . . . . . . . . . . . . . . .		2-22
		2.7.1.3	Memory Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-23
	2.7.2	RECALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-23
		2.7.2.1 Recall Setup, ENTER SETUP NAME . . . . . . . . . . . . . . . . .		2-24
		2.7.2.2 Recall Setup, VIEW NAMES . . . . . . . . . . . . . . . . . . . . . . . .		2-25
	2.7.3	REMOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-25
2.8	DIE-PROT (Die Protection) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .			2-26
	2.8.1	DIE-PRO INPUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-26
		2.8.1.1	EDIT INPUT MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-27
		2.8.1.2	VIEW STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-27
		2.8.1.3	VIEW CHANGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-27
	2.8.2	DIE-PRO ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-28
		2.8.2.1 Die Protection On/Off Status . . . . . . . . . . . . . . . . . . . . . . . . .		2-28
		2.8.2.2 Die Protection Lock Status . . . . . . . . . . . . . . . . . . . . . . . . . .		2-29
	2.8.3	TIMING CHANNELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-30
		2.8.3.1 SETPOINTS (for Timing Channels) . . . . . . . . . . . . . . . . . . .		2-30
		2.8.3.2 VIEW STATUS (for Timing Channels) . . . . . . . . . . . . . . . .		2-31
	2.8.4 AUTO SS (Automatic Single Stroke) . . . . . . . . . . . . . . . . . . . . . . . . . .			2-31
		2.8.4.1 Auto SS Programming Requirements . . . . . . . . . . . . . . . . . .		2-32
		2.8.4.2 Auto SS Hardware Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-33
		2.8.4.3 Auto SS Status Screen and Menu . . . . . . . . . . . . . . . . . . . . .		2-34
		2.8.4.4	AUTO SS ON/OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-35
		2.8.4.5	MIN DELAY TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-36
		2.8.4.6	1ST STROKE TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-36
		2.8.4.7	MAX DELAY TIME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-36
2.9 Die Protection Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .				2-37
	2.9.1	STATIC	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-37
	2.9.2	CYCLIC	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-39
	2.9.3	TRACK	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-41
	2.9.4	TRANSFER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-41
	2.9.5	IN POSITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .		2-42
	2.9.6	1 PART	. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	2-43

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2.9.7 2 PART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-45 2.10 STOPS/FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-46

Section 3	OUTPUTS
3.1	Relay Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-1
3.2	DC Solid State Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-1
3.3	AC Solid State Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	3-1

Section 4	INSTALLATION
4.1	Component Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-1
4.2	Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-4
4.3	Checkout and Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	4-8

Section 5	ERROR CODES
5.1	Error Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	5-1

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Section 1 OVERVIEW OF THE SYSTEM 2500

1.1 Features

The System 2500 has 8 or 16 channel output capability for Programmable Limit Switch functions.

Relay, solid state AC, and solid state DC outputs are available.

Multilevel programming security is provided so that fixed setpoints or special access can be provided on the first 8 output channels.

Timed outputs up to 2 seconds in duration and speed advanced outputs are programmed through the keyboard.

System 2500 PLS outputs 1 through 8 may be programmed so that they actuate only on certain machine strokes.

The Die Protection function of the System 2500 has 8 inputs available to the operator for use with die sensors and probes. These inputs may be used to monitor part ejection, stock in place, material in position, stock buckling, end of stock, or other factors.

Each die protection input can be programmed for any of the following modes: Static, Cyclic, Tracking, Transfer, In Position, Single Part detection or Two Part detection. A special option of Cyclic mode enables the operator to activate a PLS output in the event of die protection fault on this Cyclic input. This can be used for ejection of bad parts off an assembly line or similar applications.

Eight internal timing channels are provided so that the operator can create timing sequences for Cyclic, Transfer, In Position, and Part Detector modes.

The operator can select an output of either Emergency Stop (immediate stop) or Top Stop for each die protection input monitored.

The System 2500 includes outputs for providing power to external die protection sensors and also includes a separate power source for Link Model 3040 and 3080 parts detector units.

As an option, the unit can be programmed to use the die protection inputs and the PLS output relays in conjunction with an external control package to provide a complete system for implementing the Automatic Single Stroke function.

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A stroke counter and presettable batch counter, parts counter, and quality check counter are standard.

One hundred setups can be stored in nonvolatile memory and recalled by job number or name. Each setup can contain as many as 60 setpoints or dwell times for PLS outputs along with complete programming information for each die protection input.

A sturdy, compact single resolver unit is used by the System 2500 as position transducer.

Motion Detection to detect resolver de-coupling from the machine shaft is standard.

Programmable offset capability to align resolver zero with machine zero is standard.

The Operator Interface Terminal (OIT) includes user friendly keyboard programming with LCD display menus and prompting.

The System 2500 PLS displays angle and speed in 1 degree and 1 rpm increments.

The System 2500 PLS can operate at speeds up to 2000 rpm with solid state outputs.

1.2 Components

The System 2500 consists of three major components interconnected by cabling (see Figure 1). These components are:

CLogic Unit - This is the primary component of the system which contains the power supply and most of the electronic circuitry. Connections are provided on the Logic Unit for wiring both the outputs (such as limit switch relay contacts) and inputs (such as the die protection sensors).

COperator Interface Terminal (OIT) - This component is a panel mounted unit consisting of a keyboard and two displays. The OIT allows the operator to program the System 2500.

CResolver Unit - This is the position transducer for the system. It mounts on the machine and is coupled to the crankshaft. The Resolver Unit reads the crankshaft position and provides it to the Logic Unit.

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Figure 1

System 2500 Components

1.3 Specifications

Input Ratings
Primary Input Power Requirements:	115VAC ± 15VAC, 60Hz, 1 Ampere
Run Signal Input (Terminals 34 & 35):	115VAC @ 10mA nominal
	or 24VDC @ 2mA nominal
Die Protection Inputs and Auto SS Input:	Inputs are active low (ground); to activate,
	external circuit must sink 0.6mA (typical),
	1.2mA (maximum)
Output Ratings
28VAC Output:	450mA maximum
+12VDC Output (for sensors):	100mA maximum

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Switching Output Ratings
Electromechanical Relay Outputs:	5.0 Amperes @ 120VAC or 24VDC
AC Solid State Relay Outputs:	1.5 Amperes @ 240VAC
DC Solid State Relay Outputs:	3.0 Amperes @ 60VDC
General
Response Time, Die Protection
(static type, time from input change to E-Stop
relay contacts open):	25mS (typical), 33mS (maximum)
Response Time, Die Protection
(cycling type, time from window position
passed to E-Stop relay contacts open):	20mS (typical), 28mS (maximum)
Pulse width recognized by N.O. die protection
input (low pulse):	1mS minimum
Pulse width recognized by N.C. die protection
input (high pulse):	9mS minimum
Maximum Operating Speed:	2000 SPM
Maximum Ambient Temperature:	45°C (113F°)

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Section 2 OPERATION

2.1 Using the Operator Interface Terminal

The OIT is the means by which the operator can control the operation of the System 2500. The

following features should be noted on the terminal:

CA large LCD (liquid crystal display) for messages

CKeyboard consisting of 32 keys

CA four digit LED display (red characters in the upper right hand corner)

CMode Selector Keyswitch (lower right corner)

CSix individual status indicators: E-STOP, TOP-STOP, D/P BYPASS, FAULT, ANGLE, and RPM

The operator should familiarize himself with these features since they will be referred to frequently in the instructions following.

2.1.1 Keyboard Use

The leftmost portion of the keyboard is a set of numerical keys for entering data when programming. The remaining keys are function keys which cause some action to occur when pressed in the proper sequence. Some of the function keys are for general use and their functions are always active. These are listed in the description following. The keyboard is illustrated on the foldout in the back of this manual. This foldout should be referred to during the description of keyboard use.

2.1.1.1 ANGLE/RPM Key

The four digit red display is intended to continuously display crankshaft angle or speed. The angle is being displayed if the ANGLE light above the four digit red display is lit. The speed in revolutions per minute (rpm) is being displayed if the RPM light above the four digit red display is lit. The operator may alternate between angle and rpm by pressing the ANGLE/RPM key.

NOTE: The four digit display is also used to display error codes. When an error code is being displayed, the angle and speed cannot be viewed. The error must first be cleared with the CLEAR key.

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2.1.1.2 HELP Key

The operator may request a Help screen from the System 2500 PLS by pressing the HELP key. The Help screens are intended to aid the operator by giving additional information and explanation of the current stage of the program sequence. Some Help screens may be more than two lines long. If the last character on the screen is a down arrow, more help information is available. The operator may press the down arrow key to view the additional lines. The operator may terminate a help screen and return to the program at any time by pressing the EXIT key. If no help screen is available for the present program sequence, a message will inform the operator that a help screen is not available.

2.1.1.3 CLEAR Key

The CLEAR key is used for two main functions. The first function is to remove any data input in progress. If the operator keys in the wrong data but has not yet pressed the ENTER key, he may press the CLEAR key to remove the entire data input. The correct data may then be keyed in. The CLEAR key cannot remove any data once it has been entered with the ENTER key.

The second function of the CLEAR key is to remove stops and faults. If a counter reaches its programmed limit and stops the machine, the CLEAR key may be pressed to reset the counter and allow the machine to be restarted. If a system fault occurs (such as a die protection fault), once the cause of the fault has been corrected the error condition can be removed by pressing the CLEAR key.

2.1.1.4 BRIGHT and DIM Keys

The intensity of the 80 character liquid crystal display can be varied by using the BRIGHT or DIM keys. Pressing the BRIGHT key will increase the intensity of the display. If additional brightness is required, the bright key must be released and pressed again. The DIM key is used to decrease the brightness of the display.

2.1.1.5 MAIN MENU Key

If at any time during the programming procedure the MAIN MENU key is pressed (lower right corner of keyboard) the Main Menu will be immediately displayed. This menu is the starting point for all programming of the unit. (See Section 2.2 for more information on the menu approach of the System 2500). NOTE: The MAIN MENU key will not cause the Main Menu to display if there is a communication failure between the OIT and Logic Unit.

2.1.2 Mode Selector Keyswitch

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The Mode Selector is a three position keyswitch. The key may only be removed in the RUN

position. The operating conditions for the three positions are as follows:

CRUN - This is the normal operating mode of the System 2500. When the key is in this position, the operator can only view limit switch setpoints or the die protection input modes. He cannot add, erase, or edit PLS setpoints in this position, nor can he edit the die protection setup. There is no E-Stop issued by the System 2500 in this mode unless an error condition is present.

CPROG - This is the program mode of the System 2500. When the key is in this position limit switch setpoints can be added, erased, or edited; Die-Protection can be edited; and setups can be stored to memory or recalled from memory. An E-Stop is always issued by the System 2500 in this mode to prevent machine motion while programming.

CINC - This is the increment mode of the System 2500. When the key is in this position, PLS setpoints can be increased or decreased by one degree at a time. An E-Stop is not issued by the System 2500. The increment mode allows the operator to fine tune PLS setpoints while the machine is in operation.

2.2Menu Selection Using the LCD

The LCD (liquid crystal display, in the center of the OIT) provides the operator with information needed to program the unit. This is done by displaying a menu (list of choices) and allowing the operator to select one of the menu items. On each menu one of the choices listed will be blinking. The blinking effect is called the cursor and is used to identify which item on the list the operator has selected. The cursor can be moved to a different choice on the menu using the arrow keys (see the figure on the foldout in the back of the manual). Once the cursor is on the item desired, the operator can press the ENTER key to get further information about that item. The operator is not required to memorize any function names or keyboard entry sequences.

2.2.1 Main Menu

The main menu is the first list of options offered to the operator during programming of the System 2500. There are five major functions from which to choose:

CPLS - (Programmable Limit Switch) This is the function of the unit wherein the output relays can be programmed to switch on or off at specified points of the machine cycle.

CCOUNTERS - There are three user presettable counters in the System 2500 which

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can be accessed by selecting this function. The total stroke count of the machine

as seen by the unit can also be displayed here.

CSTORE/RECALL - With the System 2500 a particular setup (which includes both limit switch and die protection settings) can be stored under a name or number and recalled at a later time. This saves the operator from having to re-enter different settings each time a die is changed.

CDIE-PROT - (Die Protection) In this function, inputs to the System 2500 which are wired to appropriate die sensors can be programmed to detect fault conditions related to the die and stop the machine before damage occurs.

CSTOPS/FAULTS - This function allows the operator to view explanations of Top Stop and Emergency Stop conditions when these conditions occur.

To select any of the above functions the operator must move the cursor to the desired function using the arrow keys, then press the ENTER key.

2.3 Programmable Limit Switch (PLS) Functions

The Programmable Limit Switch functions are accessed by pressing the ENTER key while the cursor is on PLS in the Main Menu. After pressing the ENTER key, the LCD will display the PLS Menu. This menu has two options from which to choose:

COUTPUTS - This choice will allow the operator to program the relay outputs of the System 2500. Pressing the ENTER key with the cursor on OUTPUTS will cause the Outputs Menu to be displayed. The options available from the Outputs Menu are described in Section 2.4.

CCONFIGURE - This selection allows the operator to program certain information that enables the System 2500 to operate properly with the machine on which it is installed. This includes detecting motion of the machine crankshaft, setting the resolver zero point when the crankshaft is at zero position, etc. Further instructions for programming the configuration data are described in Section 2.5.

To select either of the above functions the operator must move the cursor to the desired function using the arrow keys, then press the ENTER key.

2.4 OUTPUTS

The Outputs Menu gives the operator three choices for programming or monitoring the status of

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the output relays on the System 2500. These choices are as follows:

CSETPOINTS - This option allows the operator to program the output relays to turn on or off at different points in the machine stroke (referred to as the 'setpoints' of an output channel). This function is described in Section 2.4.1.

CVIEW STATUS - Choosing this option will produce a display which indicates the on/off status of the output relays, in groups of 8. This function is described in Section 2.4.2.

CCOUNTED OUTPUTS - This menu option gives the operator an opportunity to program any of outputs 1 through 8 so that they are tied to a counter. This means that these outputs can be programmed to be active only on every other stroke, or every third stroke, or every fourth stroke, etc. This is useful for operations which should take place on a periodic basis but not on every stroke. The procedure for setting up outputs in this way is described in Section 2.4.3.

To select any of the above functions the operator must move the cursor to the desired function using the arrow keys, then press the ENTER key.

2.4.1 SETPOINTS

Selection of the SETPOINTS item from the Outputs Menu will allow the operator to view and modify the setpoints of the individual limit switch channels. These setpoints are the crankshaft angles at which the corresponding output relay will turn on or off. If the mode selector keyswitch is in the RUN position, the setpoints can only be viewed. If the keyswitch is in the PROG (Program) position, setpoints can be added, erased, or edited. If the keyswitch is in the INC (Increment) position, individual setpoints can be incremented or decremented in one degree increments.

The operator must enter the number of the channel he wishes to view by keying in a valid channel number and pressing the ENTER key. Valid channel numbers are 1 thru 16. Once a particular channel is displayed, the operator may view other channels by using the up and down arrow keys.

If the channel contains more than two setpoint pairs, the operator can use the left and right arrow keys to view the other setpoint pairs. When a channel contains no setpoints, a message stating that no setpoints are programmed will be displayed and the channel output will always be off.

2.4.1.1 Adding Setpoints

To add a setpoint pair the operator must select the desired channel and press the ADD key.

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Setpoints can only be added when the mode keyswitch is in the PROG (Program) position. The on and off points must then be entered as instructed. If incorrect data is keyed in, the CLEAR key will remove the entire line and the correct data can then be entered. The CLEAR key cannot be used once the ENTER key has been pressed to store the data. Once this has been done the setpoints must be erased or edited.

If a channel is restricted no setpoints can be added. An 'R' will appear in the display beside the channel number when this is the case. See Section 2.5.5 for more information on restricting channels.

If necessary, more than one setpoint pair can be added on any channel to turn the output on and off more than once in a machine stroke. When doing so, the setpoint pairs must be programmed so that they switch on and off in alternating sequence; that is, the angles entered cannot be in such an order so that two on points occur in succession followed by two off points. A warning message will occur if programming is attempted in this way.

Additionally, certain situations prevent the operator from programming more than one on/off pair on a channel. Only one setpoint pair is allowed on an output which is to be speed advanced (see Section 2.4.1.5). Attempting to add a second setpoint pair to a channel having advanced setpoints will produce an error message. Also, if an output channel is being used as the special assigned stop output for a Cyclic Die-Protection fault (see Section 2.9.2), or if the channel is tied to the counter (Section 2.4.3), then only one setpoint pair can be programmed. A message will be displayed signifying either of these last two conditions.

If the unit is programmed for Automatic Single Stroke operation, on/off setpoints cannot be programmed on channels 7 or 8. During Auto Single Stroke the unit takes control of these outputs and turns them on and off as required for proper operation (see Section 2.8.4).

WARNING: PLS OUTPUTS OF THE SYSTEM 2500 ARE NOT TO BE USED AS THE PRIMARY INPUTS TO A PRESS CONTROL.

2.4.1.2 Erasing Setpoints

With the keyswitch in the PROG mode, setpoint pairs can be erased with the ERASE key. The operator must select either the on or off setpoint of the pair to be erased. To select the setpoint the operator must use the right or left arrow keys. When either the on or off setpoint of the pair to be removed is blinking, the ERASE key must be pressed. A message will be displayed asking the operator to confirm the pair to be erased. If the correct pair has been selected the operator must again press the ERASE key. If the incorrect pair has been selected, the operator may press any key other than the ERASE key to abort the erase operation.

If a channel is restricted no setpoints can be erased. An 'R' will appear in the display beside the channel number when this is the case. See Section 2.5.5 for more information on restricting

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channels.

2.4.1.3 Editing Setpoints

To edit an on or off setpoint, the operator must first place the mode selector keyswitch in the PROG mode. Then the setpoint to be modified must be selected with the right or left arrow keys. When the setpoint to be modified is blinking, the operator may key in the new setpoint value. If a mistake is made in keying in the data, the CLEAR key may be pressed to clear the data. Also, to discontinue editing without making any changes, the EXIT key can be pressed which will redisplay the original setpoint value. Once the new setpoint is keyed in as desired the ENTER key must be pressed. The operator is then asked to confirm the change by pressing the YES key. If the operator does not want to confirm the change, he may press any key other than the YES key and the entire data entry sequence will be canceled.

If the operator desires to modify a setpoint that is not speed advanced so that it will be speed advanced, he must move the cursor to that setpoint and press the ADVAN key. Only one setpoint pair can be programmed on a channel if one of the setpoints is to be advanced (see Section 2.4.1.5 for information on Speed Advanced Outputs). A message will then be displayed asking the operator to confirm that the setpoint should be changed to a speed advanced setpoint. The YES key should be pressed to proceed with the change, or any other key to cancel the change.

If a channel is restricted its setpoints cannot be edited. An 'R' will appear in the display beside the channel number when this is the case. See Section 2.5.5 for more information on restricting channels.

2.4.1.4 Timed Outputs

Channels 1 thru 8 can be programmed as timed outputs. A timed output will come on at the angle of the on setpoint, and will turn off after the programmed dwell time. To add a timed output, the operator must follow the steps of section 2.4.1.1, except the TIME key must be pressed before entering the off setpoint. The dwell time must then be entered. Allowable dwell times are from 2 to 2046 milliseconds (a millisecond is 1/1000 of a second). The System 2500 PLS will only store even number dwell times. If an odd dwell time is entered, it will be rounded up to the next even number. A maximum of 5 timed outputs is allowed.

2.4.1.5 Speed Advanced Outputs

On PLS channels 1 thru 8, either the on or off setpoint or both setpoints of a setpoint pair can be speed advanced. If a setpoint is advanced, its value is decreased as the machine speed is increased. This means that the setpoint will occur earlier in the cycle to compensate for the increased speed. To speed advance an output the operator must first determine the setpoints

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necessary for proper actuation of the output at maximum speed and at minimum speed (see Section 2.5.7 for a description of this procedure). The setpoint value should be left programmed at the correct setting for minimum speed. The setpoint should then be edited to 'Advanced' status, by pressing the ADVAN key while the cursor is on the setpoint. The screen will then ask the operator to confirm that the setpoint is to be advanced. Pressing the YES key at this point will program that setpoint as advanced and the 'A' label will appear beside the setpoint as an indicator.

Configuration of the PLS Output Speed Advance is necessary for speed advanced outputs to function properly (see Section 2.5.7). The System 2500 PLS will calculate a speed advance constant from data entered for PLS Output Speed Advance in the configuration menu. The speed advance constant will then be used to adjust the setpoint angle of advanced setpoints as machine speed changes.

Note that once the data in the configuration menu is programmed, it should not be reprogrammed if the operator later chooses to advance another setpoint. All future setpoints programmed as advanced will use the speed advance constant already programmed. For later setpoints programmed as advanced it will not be necessary to test at maximum speed. For these setpoints it will only be necessary to enter the angle for proper operation at minimum speed and then edit the setpoint to advanced.

If a channel is to be programmed with advanced setpoints and the correct setpoints are already known, the setpoints can be directly programmed as advanced (rather than editing them to advanced status after they have been programmed). To program a setpoint angle to be speed advanced, the steps of section 2.4.1.1 must be followed to program the channel, except that the ADVAN key must be pressed after the angle is keyed in and before the ENTER key is pressed. Only one setpoint pair can be programmed on an output channel using Speed Advance.

2.4.1.6 Incrementing Setpoints

Individual on or off setpoints can be fine tuned by using the Increment mode. To use this mode the keyswitch must be in the INC position. When in the increment mode, the System 2500 does not generate an E-Stop. Since no E-Stop is generated, this mode allows adjustment of a setpoint while the machine is running. To adjust a setpoint the operator must first select the channel and then move the cursor to the on or off setpoint to be adjusted. When the desired setpoint is blinking, the operator must press the up or down arrow keys to increase or decrease the setpoint value, respectively. In many cases, the arrow key will have to be pressed more than once to change the setpoint by one degree (the setpoint changes by only a fraction of a degree each time the key is pressed).

2.4.2 VIEW STATUS

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If the VIEW STATUS item is selected from the Outputs Menu, the OUTPUT STATUS screen will be displayed. This screen indicates for each of the first eight outputs whether the output is on or off. This information can be useful when first setting up the unit on the machine or when troubleshooting. On the far right of the display is the down arrow symbol, which indicates that by pressing the DOWN arrow key the status for outputs 9 through 16 will be displayed.

Remember that outputs 9 through 16 can be programmed and the change in their on/off status observed on this screen at any time, but for any external action to occur there must be a second relay output board installed for relays 9 through 16.

2.4.3 COUNTED OUTPUTS

By pressing the ENTER key while the cursor is on COUNTED OUTPUTS in the Outputs Menu, the operator can access a special function for PLS outputs 1 through 8 which allows them to be tied to a counter. This is a separate counter for this function only and is not related to the Part, Batch, Quality Check, or Stroke counters of the System 2500 (see Section 2.6). The purpose of the Counted Outputs function is to allow a PLS output to be programmed in the following way:

1.The output is held off for a certain number of strokes regardless of its programmed setpoints.

2.The output becomes active for one stroke so that its on/off setpoints cause the output relay to switch.

3.The cycle of steps 1 and 2 is repeated.

The effect is that the output becomes active for one stroke every five strokes, or every eight strokes, etc. depending on the count that the operator programs. This is useful for programming some special action such as a scrap chopper which only becomes active after several machine strokes have been made.

The first screen displayed for this function is the Counted Outputs Menu. It offers the following choices:

CVIEW SETUP - Allows the operator to see which channels are tied to the counter and the present stroke count.

CEDIT SETUP - Allows the operator to tie a PLS channel to the counter or remove a channel from being tied to the counter. Also allows change of the present counter value and which stroke count will activate the outputs.

To select either of the above functions the operator must move the cursor to the desired function using the arrow keys, then press the ENTER key.

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2.4.3.1 Counted Outputs, VIEW SETUP

When VIEW SETUP is selected from the Counted Outputs Menu, the operator will see a list of the outputs which are tied to the counter. Also shown is the stroke count on which these outputs will be active and the current stroke count of the machine. (Remember that this is a special cycling counter and is NOT the same as the Part, Batch, Quality Check, or Total Stroke counters of the System 2500. See Section 2.6 for information regarding these counters). This information is important since outputs tied to the counter will NOT be active on every stroke. The operator or maintenance personnel may need to know why a certain PLS output is not on during its programmed on portion of the stroke. By viewing this screen the operator will know when the counter-tied outputs will be active.

2.4.3.2 Counted Outputs, EDIT SETUP

In order to program the necessary information to use the Counted Outputs function, the operator must select EDIT SETUP from the Counted Outputs Menu. Prior to doing this, the keyswitch must be placed in the PROG position. If EDIT SETUP is selected with the keyswitch in another position an error message will appear. After EDIT SETUP is selected, the operator will be asked to enter a special access code to proceed. This is the same code that is required to enter the Configure Menu (see Section 2.5). The code is printed on the back page of this manual. It is suggested that this code be given to qualified users only. If the keyswitch is turned to a position other than PROG while the Counted Outputs setup is being edited, the error message will appear and the operator will have to re-enter the access code. Through the keyswitch and access code protection any undesired changes to this special function of the PLS outputs are prevented.

Once the access code has been properly entered the display will contain all the information required for the Counted Outputs function. The following will be displayed:

CCHANNELS - A list of the PLS output channels which are presently tied to the counter.

CCOUNT - The present stroke count of the machine (as pertains to this function). When this count is the same as the ACTIVE COUNT, the PLS outputs listed beside CHANNELS will be active for one stroke.

CACTIVE COUNT - The stroke count at which the PLS outputs tied to the counter will become active. On this stroke count the PLS outputs listed beside CHANNELS will follow the on/off setpoints that have been programmed for each output. Until the count is reached, these outputs will always be off.

CCOUNT ANGLE - The crankshaft angle at which the counter will count up, i.e. the place in the stroke where the COUNT value on this screen will change.

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2.4.3.3 CHANNELS

If the operator wishes to tie a PLS output to the special counter, the ADD key must be pressed. After this key is pressed, the display will prompt for entry of the channel to be added. PLS channels 1 through 8 may be tied to the counter. Key in the desired channel number and press ENTER. The display will then return to the Counted Outputs setup information screen with the new PLS channel number added to the list.

Any channel to be tied to the counter can have only one setpoint pair programmed (one 'on' setpoint and one 'off' setpoint). Additionally, the channel cannot be one that is already used as the assigned output for a Die-Prot Cyclic fault. If the unit is set up for Auto Single Stroke operation, outputs 7 and 8 cannot be tied to the counter. Attempting to add any channel previously programmed as described here will cause an error message to appear.

To remove a PLS output from being tied to the counter, the operator must first press the REMOVE key. The LCD will then request the number of the channel to be removed. Key in the channel number and press ENTER. The display will then return to the Counted Outputs setup information screen with this channel number deleted from the list. Remember that removing an output from being tied to the counter means that the output will no longer be held off until the active stroke, but will now be active on every stroke. If this is not desirable the operator may turn the output off by erasing its setpoints (see Section 2.4.1.2).

Any channel that has been restricted previously cannot be tied to the counter nor removed from being tied to the counter. Any unrestricted channel that has been tied to the counter can then be restricted to prevent any further changes.

2.4.3.4 COUNT

When setting up outputs that are tied to the counter, the operator may find it necessary to adjust the count that the machine is presently on to make the outputs become active on the proper stroke. To do so the operator must use the arrow keys to move the cursor to the current count value (upper right corner), then key in new value and press ENTER. For example, suppose the press has a repeating five stroke sequence where certain PLS outputs are to become active on the fifth stroke. If during setup of this function the press is mechanically two strokes away from the stroke where the PLS outputs are to be active, then the operator should enter the number 3 for the present COUNT.

2.4.3.5 ACTIVE COUNT

The ACTIVE COUNT is, as the name implies, the stroke count on which the PLS outputs tied to the counter are to become active for one stroke. The ACTIVE COUNT is the maximum value that the counter will reach; in other words, as the press strokes the COUNT will increase until the ACTIVE COUNT value is reached and on the next stroke the COUNT will start over at 1. To

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change the ACTIVE COUNT, use the arrow keys to move the cursor to the ACTIVE COUNT value then key in a new value and press ENTER. For example, if the outputs tied to the counter should only be active every five strokes (make four strokes with these outputs OFF then one stroke where the outputs switch normally), enter the number 5 for ACTIVE COUNT. If the outputs should be active every eight strokes, enter the number 8 for ACTIVE COUNT. The maximum ACTIVE COUNT value that can be entered is 255.

Remember also that the correct stroke in the cycle that the machine is presently on should be entered beside COUNT on this screen (see Section 2.4.3.4). This must be done to insure that the sequencing is correct.

2.4.3.6 COUNT ANGLE

The count angle is the crankshaft angle where the counter will change. To change the count angle move the cursor to COUNT ANGLE using the arrow keys then key in a new angle (0 to 359 degrees) and press ENTER. In most cases this angle can be set at zero degrees (top of stroke). However, if the die setup is such that a PLS output must be ON through zero degrees during the active stroke, the count angle can be set to another value. The reason for this is that it is not desirable to have the count angle change while the PLS outputs are programmed to be ON. If this occurs, as soon as the count changes to the active count all PLS outputs tied to the counter will immediately turn on. Likewise, when the count changes from the active count back to 1, all PLS outputs tied to the counter will immediately turn off. It is more desirable to have the counter change at a point in the stroke where all PLS outputs tied to the counter are programmed to be off so that the change in count will not immediately affect those outputs.

Example: (See Figure 2) PLS output

channels 1 and 5 are tied to the counter. During the active stroke, channel 1 is to turn on at 350 degrees and turn off at 10 degrees.

Channel 5 is to turn on at 160 degrees and

turn off at 270 degrees. In this case it would

be better to change the COUNT ANGLE from 0 degrees to 300 degrees, since at this

point in the stroke channels 1 and 5 are both

off. In this way, the count will change to the active count at 300 degrees; both output

channels can turn on and off properly at their

programmed setpoints; then when 300

Figure 2

degrees is reached again the counter will

Desired Location of Count Angle

recycle to 1 and the outputs will become inactive.

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2.5 CONFIGURE

The Configure routines will allow the operator to program into the System 2500 important information relating to the machine on which it is installed. The configuration routines can only be entered with the mode selector keyswitch in the PROG position. Switching the keyswitch from the PROG position will terminate the configuration routine (except for the special case of setting TOPSTOP angle - see Section 2.5.3). To access these routines the operator must select CONFIGURE from the PLS Menu.

2.5.1 Configure Access Code Screen and Menu

Selection of CONFIGURE will display a screen which will ask the operator to enter the configuration access code. Failure to enter this code correctly will prohibit the operator from entering the Configure Menu. The access code is printed on the last page of this manual. It is suggested that the code be given to qualified users only. The Configure Menu allows the operator to make modifications to the System 2500 PLS setup which can alter the operation of the unit. Once the Configure Menu has been attained one of the following functions may be selected:

CMOTION DETECTOR - Provides for entry of data for the internal motion detector function which verifies that resolver is connected and operating properly.

CTOPSTOP - Allows entry of the crankshaft angle where a stop signal to the machine should occur in order for the machine to come to a stop at the top of the stroke.

CTOPSTOP ADVANCE - Allows entry of the information needed by the System 2500 to advance the TOPSTOP setpoint angle as the crankshaft speed increases.

CRESTRICTED CHANNELS - Allows the operator to add or remove restricted channels.

COFFSET - Selection of resolver zero point.

CPLS OUTPUT ADVANCE - Allows entry of the information needed by the System 2500 to advance PLS setpoints as the crankshaft speed increases.

To select any of the above functions the operator must move the cursor to the desired function using the arrow keys, then press the ENTER key.

2.5.2 MOTION DETECTOR

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The motion detector is used as a check by the System 2500 PLS to insure that the resolver is properly wired, the input circuits are functioning, and the resolver is coupled to the machine crankshaft. The operator must enter three values into the motion detector configuration. These values are:

CTHRESHOLD - This is the crankshaft speed at which the System 2500 will recognize that the machine is in motion. The speed entered here should be 75% of the machine's slowest operating speed.

CCLUTCH TIME - This is the time required after the machine control gives the run signal before crankshaft motion begins (i.e., clutch engagement time). The range of values that can be entered is 2 to 998 milliseconds. This time should be set to as small a value as possible.

CMAX SPM - This the maximum machine speed in strokes per minute (SPM).

All data requested by the motion configuration must be entered for the unit to operate properly. To enter or change any value move the cursor to the desired value, key in the new data and press ENTER. The System 2500 will accept only even numbers for this data; entry of odd values will be rounded up to the next even value. Note that if the value entered for MAX SPM is less than the value entered for THRESHOLD, an error will be generated. To clear the error correct values must first be entered and then the CLEAR key pressed. Additionally, an error will be generated if the value entered for MAX SPM is less than the value entered for MINIMUM PRESS SPEED in the Speed Advance data screen. In this case either the MAX SPM or MINIMUM PRESS SPEED must be corrected to its proper value before pressing the CLEAR key.

The Motion Detector data is used in the following way: When the machine 'RUN' signal becomes active (terminals 34 and 35) the System 2500 is alerted that the machine has been commanded to stroke. The unit then expects machine motion (i.e., resolver motion) to occur within the time limit programmed in CLUTCH TIME. Machine motion is recognized when the machine crankshaft is turning faster than the speed programmed as THRESHOLD. If the System 2500 PLS does not detect motion at a speed greater than THRESHOLD within the time limit programmed as CLUTCH TIME, it assumes that a fault has occurred and de-energizes the E- Stop relay. The MAX SPM data entered is used in other resolver related checks and also in calculating Speed Advance constants (see Sections 2.5.4 and 2.5.7).

2.5.3 TOPSTOP

Certain functions of the System 2500 can be programmed so that stop conditions will allow the machine to stop at the top of its stroke rather than cause an immediate stop. The System 2500 accomplishes this by opening the E-Stop relay at the proper angle in the stroke so that the

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machine will come to a stop at the top. This is called the 'stopping angle' in further text of this manual. The Topstop selection from the Configure Menu (labeled TOPSTP) allows the operator to program this angle so that an accurate top stop will occur.

The Topstop configuration display indicates on the top line the angle at which the E-Stop relay will open when a top stop signal is generated. The bottom line allows the operator to enter a new angle if required. This configuration step is unique in that the operator may move the keyswitch to the RUN position so that the top stop accuracy can be tested. When the keyswitch is moved to the RUN position, E-STOP can be cleared (if no errors exist) and the System 2500 will allow the machine to run. In addition, the YES key on the OIT will become active as a way to initiate the top stop. The operator can then make several strokes, press the YES key to cause a top stop, and note where the machine stops. If the machine does not stop on top, the operator should return the keyswitch to the PROG position whereupon the display will allow entry of a new stopping angle (in RUN mode no configuration data can be entered). If the machine went over top, the operator should enter a smaller angle value (earlier in stroke). If the machine stopped short of top, the operator should enter a larger angle (later in stroke). After entering a new angle the keyswitch can be returned to the RUN position to test the stopping point again. (Note that after switching back to RUN mode it will be necessary to clear the E-Stop condition by pressing the CLEAR key). By switching between Run and Program modes and entering data, the stopping angle can be fine tuned to stop the machine on top.

On variable speed machines it will often be desirable to use the speed advance capability of the System 2500 to automatically adjust the stopping angle as the speed changes. In order for the Topstop Speed Advance function to work properly its configuration data must be programmed (see Section 2.5.4). The top stop fine tuning procedure just described can be used to find the stopping angle of the machine at various speeds so this information can be entered into the Topstop Speed Advance configuration. Once the Topstop Speed Advance data has been recorded, the stopping angle itself can then be programmed as 'Advanced' so that the stop signal will automatically occur earlier in the stroke as the speed increases. If the stopping angle is to be programmed as advanced, the angle should be left at the setting that was found while the machine was set for its LOWEST operating speed. This angle should be keyed in on the Topstop display as before except that the ADVAN key should be pressed before pressing the ENTER key. The letter 'A' will appear beside the stopping angle to designate that the angle will be advanced. The ADVAN key should NOT be pressed while different angles are being entered during the fine tuning process (in other words, the 'A' should not be displayed during the fine tuning process).

If it is desired to return to the Configure Menu for additional programming, be sure that the keyswitch is in the PROG position before pressing the EXIT key. If the keyswitch is in any position other than PROG at any step of the Configure routines other than Topstop an error message will appear. The operator will then have to move the selector switch back to PROG and re-enter the access code to resume the configuration functions.

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2.5.4 TOPSTOP SPEED ADVANCE

For variable speed machines the operator may program the stopping angle to advance (occur earlier in the stroke) as the speed increases. For functions which result in a top stop this will insure that the machine will continue to stop on top as the machine speed increases. In order for a speed advanced stopping angle to operate properly, the Topstop Speed Advance configuration data must be programmed (found under the TOPSTP ADVAN selection of the Configuration Menu). The data values required are the minimum press speed and the stopping angle of the machine at four different machine speeds. (The stopping angle is the crankshaft angle where a stop signal must be given in order for the machine to stop at the top of the stroke). This information must be determined beforehand by the operator using the procedure to be described, and then entered in the TOPSTP ADVAN selection of the Configure Menu. If the stopping angle is not to be speed advanced, the operator may skip programming of the Topstop Speed Advance data.

The stopping angles for the machine can be found using the Topstop function of the Configure Menu (see Section 2.5.3 for instructions on using Topstop). The System 2500 performs the top stop function by opening the E-Stop relay at the proper point in the stroke to top stop the press.

By adjusting the angle entered in the TOPSTOP data screen, the machine can be made to stop on top at the particular press speed chosen. For determining the speed advance constants, the machine must be run at four different speeds and the correct angle for initiating a top stop must be found for each speed and then recorded. The four speeds are:

1.Minimum machine speed.

2.Minimum speed plus one-third of the difference between maximum speed and minimum speed.

3.Minimum speed plus two-thirds of the difference between maximum speed and minimum speed.

4.Maximum machine speed.

Once the correct angles for initiating a stop at these four speeds have been recorded, the operator can return to the TOPSTP ADVAN selection of the Configuration Menu to enter the angles.

Choosing TOPSTP ADVAN from the Configure Menu gives the operator access to several data screens on which the minimum press speed and stopping angles can be entered. The operator can use the cursor to select a data value, then key in the proper value and press ENTER. When a 'down arrow' symbol is displayed as the last character on the bottom line of the display, this indicates that another data line is available to the operator by pressing the down arrow key while the cursor is on the bottom line. In the same way, an 'up arrow' symbol displayed as the last character on the top line indicates that another data line is available by pressing the up arrow key

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