5100-8 Tonnage
and Analog
Signal Monitor
Installation and Operating
Manual
Doc # L-802-1110
Rev. 02
Link Electric & Safety Control Co.
444 McNally Drive
Nashville, TN 37211
Phone: (615) 833-4168
Fax: (615) 834-1984
© 2007
Table of Contents
1 INTRODUCTION .............................................................................................................................. 5
1.1 Features....................................................................................................................................... 5
1.2 Specifications.............................................................................................................................. 6
2 DEFINITIONS AND TERMINOLOGY............................................................................................ 7
2.1 Tonnage....................................................................................................................................... 7
2.1.1 Channel Tonnage................................................................................................................7
2.1.2 Total Tonnage..................................................................................................................... 7
2.1.3 Reverse Tonnage................................................................................................................. 9
2.2 Data Windows............................................................................................................................. 9
2.2.1 Data Window Start Angle................................................................................................. 10
2.2.2 Data Window End Angle.................................................................................................. 10
2.3 Limits........................................................................................................................................ 10
2.3.1 Machine Rating Limit....................................................................................................... 10
2.3.2 Low Limits........................................................................................................................ 10
2.3.3 High Limits....................................................................................................................... 10
2.3.4 Reverse Limits..................................................................................................................11
2.3.5 Total Tonnage Limit.........................................................................................................11
2.4 Stops.......................................................................................................................................... 11
2.4.1 Cycle Stop......................................................................................................................... 11
2.4.2 Top Stop............................................................................................................................ 11
2.4.3 Intelli-Stop ........................................................................................................................ 11
3 OPERATION.................................................................................................................................... 13
3.1 Main Operator Terminal Screen ............................................................................................... 13
3.2 The Tonnage Monitor Main Screen.......................................................................................... 14
3.2.1 Selecting a View...............................................................................................................18
3.2.1.1 Viewing the Peak and Data Window Tonnages and Settings....................................... 19
3.2.1.2 Showing Forward and Reverse Tonnage...................................................................... 19
3.2.2 Setting Limits.................................................................................................................... 19
3.2.2.1 Setting High Limits....................................................................................................... 19
3.2.2.2 Setting Low Limits ....................................................................................................... 20
3.2.2.3 Setting Reverse Limits..................................................................................................20
3.2.2.4 Automatically Setting Limits........................................................................................20
3.2.2.5 Turning Low Limits ON or OFF .................................................................................. 21
3.2.2.6 Turning Reverse Limits ON or OFF............................................................................. 21
3.2.3 Setting Additional Data Window Parameters................................................................... 21
3.2.3.1 Turning Data Windows ON or OFF ............................................................................. 21
3.2.3.2 Setting the Data Window “Start Angle”....................................................................... 21
3.2.3.3 Setting the Data Window “End Angle”........................................................................22
3.2.4 Bypassing the Tonnage Monitor....................................................................................... 22
3.2.5 Tonnage Alarms................................................................................................................22
3.2.5.1 Low Alarm.................................................................................................................... 23
3.2.5.2 High Alarm...................................................................................................................23
3.2.5.3 Reverse Alarm .............................................................................................................. 23
3.2.5.4 Machine Rating Alarm.................................................................................................. 23
3.2.5.5 Reverse Rating Alarm................................................................................................... 24
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3.2.5.6 Total Alarm/Stop Condition ......................................................................................... 24
3.2.5.7 Resetting Tonnage Alarms............................................................................................ 24
3.2.6 Error Conditions................................................................................................................ 24
3.2.6.1 Module Error Messages................................................................................................ 24
3.2.6.2 Channel Errors.............................................................................................................. 26
3.2.6.3 Resetting Errors ............................................................................................................ 26
3.3 The Tonnage Monitor Diagnostic Screen................................................................................. 27
3.4 The Tonnage Monitor Bypass Setup Screen............................................................................. 29
3.5 The Tonnage Monitor Graph Screen ........................................................................................ 30
3.5.1 Graph Start Angle............................................................................................................. 36
3.5.2 Graph End Angle .............................................................................................................. 36
3.5.3 Selecting the Channel to Graph ........................................................................................ 36
3.5.4 Graph Pan/Zoom Mode..................................................................................................... 36
3.5.5 Graphically Setting Values............................................................................................... 37
3.5.6 Sending the Graph............................................................................................................. 37
3.5.7 Reference Waveforms....................................................................................................... 39
3.6 The Tonnage Monitor Graph Settings Screen .......................................................................... 40
4 CONFIGURATION.......................................................................................................................... 42
4.1 Turning the Tonnage Monitor ON in Device Config ............................................................... 42
4.2 Setting the Number of Channels............................................................................................... 42
4.3 The Tonnage Monitor Configuration Screen............................................................................ 43
4.4 The Tonnage Monitor Machine Settings Screen ...................................................................... 44
4.4.1 Units.................................................................................................................................. 44
4.4.2 Machine Rating.................................................................................................................45
4.4.3 Machine Rating Alarm Level............................................................................................ 45
4.4.4 Max Forward Setpoint Level............................................................................................45
4.4.5 Max Reverse Setpoint Level............................................................................................. 45
4.4.6 Number of Data Windows................................................................................................ 45
4.4.7 Filter Frequency................................................................................................................ 45
4.4.8 Sample Window Start Angle ............................................................................................ 45
4.4.9 Sample Window End Angle.............................................................................................. 46
4.4.10 Auto-Zero Start Angle ...................................................................................................... 46
4.4.11 Auto-Zero End Angle ....................................................................................................... 46
4.4.12 Peak High Limit Stop Type .............................................................................................. 46
4.4.13 DW High Limit Stop Type ............................................................................................... 46
4.4.14 Auto Unbypass Leaving Setup Mode...............................................................................46
4.4.15 Bypass Low Limits in Setup Mode................................................................................... 46
4.4.16 Resetting Alarm Counters.................................................................................................47
4.5 The Tonnage Monitor Calibration Screen ................................................................................ 47
4.6 The Machine Rating De-rate Table Screen............................................................................... 48
5 JOB SETUPS.................................................................................................................................... 50
5.1 New Die Installation.................................................................................................................50
6 INSTALLATION ............................................................................................................................. 51
6.1 Mounting the Module ............................................................................................................... 51
6.2 Faceplate Connections and Indicators ...................................................................................... 52
6.3 Wiring Power for the Module................................................................................................... 52
6.4 Wiring High Speed Serial Bus Cable........................................................................................ 53
Doc #: L-802-1110 Page 2 Rev. 02
6.5 Setting the High Speed Serial Bus Termination Switch........................................................... 54
6.6 Strain Gage Locations............................................................................................................... 55
6.6.1 "C" Frame Machines.........................................................................................................55
6.6.2 Straight Side Machines.....................................................................................................55
6.7 Strain Gage Mounting............................................................................................................... 57
6.7.1 Direct Machine Mounting.................................................................................................57
6.7.2 Intermediate Weld Pad Mounting.....................................................................................58
6.8 Strain Gage Wiring...................................................................................................................59
6.9 Installation Procedure ............................................................................................................... 61
7 CALIBRATION ............................................................................................................................... 63
7.1 Dynamic Calibration with Load Cells ...................................................................................... 64
7.2 Replacing System 1000/1100 Tonnage Monitors..................................................................... 67
7.3 Replacing System 5000 Tonnage Monitors..............................................................................67
7.4 Incorrect Tie Rod Tension........................................................................................................67
8 OPTIONAL COMPONENTS .......................................................................................................... 69
8.1 The 5100-8A Channel Expansion Option.................................................................................69
8.2 The 5100-8C Die Protection and Programmable Limit Switch Option.................................... 71
9 TROUBLESHOOTING.................................................................................................................... 74
9.1 Communication Errors.............................................................................................................. 74
9.1.1 “Communication Failure”................................................................................................. 75
9.1.2 “CTM F. Comm. Fail”...................................................................................................... 75
9.1.3 “No Resolver Info”...........................................................................................................76
9.2 “Press Running at Startup” ....................................................................................................... 76
10 PART TRACKING....................................................................................................................... 77
11 PARAMETER ENTRY AND ACCESS CONTROL .................................................................. 78
11.1 Parameter Entry ........................................................................................................................ 78
11.1.1 Numeric Entries................................................................................................................ 78
11.1.2 Text Entry ......................................................................................................................... 78
11.2 Configuration Code................................................................................................................... 79
11.3 Access Control Modes.............................................................................................................. 80
11.3.1 Key Only Mode................................................................................................................. 80
11.3.2 Key or Password Mode..................................................................................................... 80
11.3.3 Password Only Mode........................................................................................................ 81
11.3.4 Key and Password Mode .................................................................................................. 81
11.4 Access Control Operation......................................................................................................... 81
11.4.1 RUN/PROG Key Switch Operation.................................................................................. 81
11.4.2 Password System Operation ............................................................................................. 82
11.5 Restricted Items ........................................................................................................................ 83
11.6 Unrestricted Items..................................................................................................................... 83
Doc #: L-802-1110 Page 3 Rev. 02
Table of Figures
Figure 1: Example Die 1 with Signature..................................................................................................... 8
Figure 2: Example Die 2 with Signature..................................................................................................... 8
Figure 3: Example Data Window ............................................................................................................... 9
Figure 4: Operator Terminal Main Screen................................................................................................ 13
Figure 5: Tonnage Monitor Main Screen Showing Peak Forward Tonnage............................................ 14
Figure 6: Tonnage Monitor Main Screen Showing Data Window 1 Tonnage......................................... 17
Figure 7: Tonnage Monitor Main Screen Showing Reverse Tonnage ..................................................... 18
Figure 8: Tonnage Monitor Diagnostic Screen......................................................................................... 27
Figure 9: Tonnage Monitor Bypass Setup Screen .................................................................................... 29
Figure 10: Example Tonnage Waveform with Peak Settings Selected for View.....................................30
Figure 11: Example Waveform with Data Window 2 Settings Selected for View .................................. 33
Figure 12: Example Tonnage Waveform in Pan/Zoom Mode..................................................................35
Figure 13: Graph Settings Screen............................................................................................................. 40
Figure 14: Device Config Screen.............................................................................................................. 42
Figure 15: Tonnage Monitor Device Configuration Screen..................................................................... 43
Figure 16: Tonnage Configuration Screen................................................................................................ 43
Figure 17: Tonnage Monitor Machine Settings Screen............................................................................ 44
Figure 18: Tonnage Monitor Calibration Screen...................................................................................... 47
Figure 19: Example Tonnage De-rate Curve............................................................................................ 48
Figure 20: Tonnage Monitor Total Capacity De-rate Screen................................................................... 49
Figure 21: Unit Mounting Dimensions..................................................................................................... 51
Figure 22: Tonnage Monitor Faceplate..................................................................................................... 52
Figure 23: Power Connector..................................................................................................................... 53
Figure 24: System 5000 High Speed Bus Wiring..................................................................................... 53
Figure 25: Automation Control High Speed Bus Wiring......................................................................... 53
Figure 26: High Speed Serial Bus Connector........................................................................................... 54
Figure 27: Termination Switch................................................................................................................. 54
Figure 28: “C” Frame Machine Gage Locations...................................................................................... 55
Figure 29: Straight Side Machine Gage Locations................................................................................... 56
Figure 30: Upright Areas to Avoid........................................................................................................... 56
Figure 31: Solid Frame Machine Gage Locations.................................................................................... 57
Figure 32: Strain Gage Drill Fixture.........................................................................................................58
Figure 33: LST-1000 Strain Gage Mounting............................................................................................ 58
Figure 34: Weld Pad Mounting Fixture.................................................................................................... 59
Figure 35: Weld Pad Welding Technique................................................................................................. 59
Figure 36: Strain Gage Wiring.................................................................................................................. 60
Figure 37: Load Cell Hit with Bad Tie-Rod Tension...............................................................................68
Figure 38: Load Cell Hit with Good Tie-Rod Tension............................................................................. 68
Figure 39: 5100-8 Circuit Board Option Connectors ............................................................................... 69
Figure 40: 5100-8 Main Circuit Board With 5100-8A Option Board...................................................... 70
Figure 41: 5100-8 Main Circuit Board With 5100-8C Option Board ...................................................... 71
Figure 42: 802-5B Solid State Relay Board Dimensions ......................................................................... 72
Figure 43: 802-5B Solid State Relay Board Connections ........................................................................ 73
Figure 44: Example Text Entry................................................................................................................. 79
Figure 45: Example Password Entry Sequence........................................................................................ 82
Doc #: L-802-1110 Page 4 Rev. 02
1 INTRODUCTION
The Tonnage and Analog Signal Monitor module is available as optional module with both the
OmniLink II Press Automation Control and the System 5000 Press Control. Its primary purpose is to
measure and display the force being applied to the frame of a mechanical power press. The force
applied during the working portion of the stroke is compared with allowable limits based on the capacity
of the machine and correct operation of the die and material being used. Tonnages beyond these limits
cause various types of stop signals to be sent to the press control depending upon the importance of the
overload. Present tonnage readings, status messages, present tonnage limits, and detailed tonnage versus
angle graphs (signatures) can be examined or programmed through the same Operator Terminal as all
other OmniLink II or System 5000 settings. Additional options (detailed below) can be added to
provide even more capabilities.
1.1 Features
• The base Tonnage and Analog Signal Monitor module provides four strain link connections for use
on two or four channel machines.
• The 5100-8A option adds an additional four channels that work with strain gages, 4-20 milliamp
output sensors, and voltage output sensors. This option enables in-die on-the-fly analog part
measurement.
• In conjunction with the 5100-8A option, certain servo controllers can be tied in to the tonnage
monitor to allow in-die process adjustment based on the measurement of parts.
• The 5100-8C option adds four standard die protection inputs and four programmable limit switch
outputs.
• The crankshaft angle is supplied to the module via internal communication with the OmniLink II
Press Automation Control or the System 5000 Press Control. Position dependent parameters such as
the working portion of the stroke or data window settings are entered directly into the Tonnage and
Analog Signal Monitor module requiring no external cam switches.
• The same internal communication allows the module to instruct the control to Top Stop or Cycle
Stop depending on the type of tonnage alarm that has occurred.
• A graph of tonnage versus crankshaft angle (tonnage signature) can be displayed for each channel or
the total. This graph also shows the active areas of the data windows, if used.
• One reference signature per job can be stored and overlaid with the current signature for comparison.
• For each job, limits can be set for the maximum allowable forward tonnage (High Limit), minimum
required forward tonnage (Low Limit), and maximum allowable reverse tonnage (Reverse Limit) on
a channel by channel basis.
Doc #: L-802-1110 Page 5 Rev. 02
• Inside the monitoring region additional sets of high and low Limits (data windows) can be set to
become active at specific crankshaft angles. Up to four data windows can be programmed for each
job and can be used to monitor the tonnage of specific die features – for example, an individual
punch.
• A maximum allowable forward tonnage limit for the machine is established when the module is
installed, based on the capacity of the machine (Machine Rating) and cannot be turned off.
• If desired, additional limits can be placed on the total tonnage that reflects the maximum allowable
total tonnage at specific positions in the stroke.
• Limits can be programmed manually, automatically calculated by the Tonnage and Analog Signal
Monitor module, or recalled along with all other Link equipment settings through the use of job
setups.
• Status messages for each channel indicate the first alarm condition that occurred during the stroke.
• Low limits can be set to automatically bypass when in a setup mode, if desired. These limits are
then automatically restored when switching back to a production mode. This feature typically
eliminates the need to manually bypass all limits on the tonnage monitor and the associated risk of
forgetting to un-bypass it.
• If manually bypassing all limits on the tonnage monitor is needed, a setting is available that will
automatically un-bypass the tonnage monitor when switching back to a production mode.
• For each job, low limits can be set to automatically bypass when a bad or empty part is in the part
tracking registers.
• For each job, low limits can be set to automatically bypass for the first few strokes (user selected
number) to accommodate presses that “ramp up” to speed causing false low limit alarms on startup.
This setting also works in conjunction with the auto-setup feature to allow accurate setpoints in these
cases.
1.2 Specifications
Size: 2.25” wide, 10.50” high, 7” deep
Input Power: 88-264VAC, 47-63Hz, 50 Watt
Fuse: 5mm X 20mm, 2 Amp, 250 Volt, Fast Blow
Output Power: 24VDC, 0.8 Amps max (for optional Die Protection sensors)
Gain Range: 189 to 14164
Press Speed Capability: Up to 2000 strokes per minute
Doc #: L-802-1110 Page 6 Rev. 02
2 DEFINITIONS AND TERMINOLOGY
This section will give some background and explain the meaning of various settings and readings in the
tonnage monitor. It is strongly recommended that this section be read in order to use the tonnage
monitor effectively!
2.1 Tonnage
The tonnage monitor reads forming forces (“tonnage”) from strain gages mounted on the machine
frame. Each strain gage is a “channel”. Tonnage monitors typically have two or four strain gages
depending on the type of machine. For example, OBI presses typically use two strain gages (one on
each side), while straight side presses typically use four strain gages (one on each corner). Sections 6.6
and 6.7 starting on page 55 covers strain gage location considerations and mounting procedures.
2.1.1 Channel Tonnage
A channel tonnage is the tonnage read from a single strain gage. A numerical channel tonnage reading
shown by the tonnage monitor is the highest tonnage exerted on that channel through the stroke or data
window (data windows are discussed in section 3.2). In addition, the tonnage monitor can show the
tonnage waveform for a channel. This waveform shows how the tonnage varies with press crankshaft
angle.
2.1.2 Total Tonnage
In addition to recording the maximum tonnage measured for each channel, the tonnage monitor module
calculates and records the instantaneous summation of all channels. It performs the same peak
measurement on this value as is performed on the individual channels. This value is displayed as the
total tonnage exerted on the machine frame at any single position in the stroke.
When forces occur on all channels at the same time, the maximum total tonnage is the summation of the
maximum channel tonnages. For example, the die shown in Figure 1contains two equally sharp punches
of equal cross-sectional area and equal length. This die is located in the center of an OBI press bed
equipped with a two channel tonnage monitor with strain gages mounted on both sides of the press
frame. If the tonnage required for each punch is 100 tons and both punches impact the material at the
same position in the stroke (at the same time) the graph in
Figure 1 shows the forces applied to the left
and right sides of the machine frame along with the resulting total force. This process would result in
the tonnage monitor displaying 100 tons for the left channel, 100 tons for the right channel, and 200 tons
for the total.
Doc #: L-802-1110 Page 7 Rev. 02
200 TONS
200 TONS
200 TONS
200 TONS
TOTAL
TOTAL
TOTAL
TOTAL
t
t1t
t
SLIDE
SLIDE
SLIDE
SLIDE
UPPER DIE
UPPER DIE
UPPER DIE
UPPER DIE
BOLSTER
BOLSTER
BOLSTER
BOLSTER
Punches
Punches
Punches
Punches
hit at the
hit at the
hit at the
hit at the
same time
same time
same time
same time
LEFT
LEFT
LEFT
LEFT
CHANNEL
CHANNEL
CHANNEL
CHANNEL
RIGHT
RIGHT
RIGHT
RIGHT
CHANNEL
CHANNEL
CHANNEL
CHANNEL
t1t
1
1
1
1
100 TONS
100 TONS
100 TONS
100 TONS
t
t1t
t
t1t
1
1
1
1
100 TONS
100 TONS
100 TONS
100 TONS
t
t1t
t
t1t
1
1
1
1
Figure 1: Example Die 1 with Signature
When forces occur on the individual channels at different positions in the stroke (at different times), the
total force depends on the amount of force exerted at any specific position. If the die described in the
previous example had punches of different lengths as shown in Figure 2, the punches would not impact
the material at the same position in the stroke.
100 TONS
100 TONS
100 TONS
100 TONS
40 TONS
40 TONS
40 TONS
40 TONS
60 TONS
60 TONS
60 TONS
60 TONS
SLIDE
SLIDE
SLIDE
SLIDE
UPPER DIE
UPPER DIE
UPPER DIE
UPPER DIE
BOLSTER
BOLSTER
BOLSTER
BOLSTER
Punches
Punches
Punches
Punches
hit at
hit at
hit at
hit at
different
different
different
different
times
times
times
times
TOTAL
TOTAL
TOTAL
TOTAL
LEFT
LEFT
LEFT
LEFT
CHANNEL
CHANNEL
CHANNEL
CHANNEL
RIGHT
RIGHT
RIGHT
RIGHT
CHANNEL
CHANNEL
CHANNEL
CHANNEL
100 TONS
100 TONS
100 TONS
100 TONS
t
t1t
t
t1t
1
1
1
1
60 TONS
60 TONS
60 TONS
60 TONS
t
t1t
t
t1t
1
1
1
1
40 TONS
40 TONS
40 TONS
40 TONS
t
t1t
t
t1t
1
1
1
1
t
t2t
t
t2t
2
2
2
2
t
t2t
t
t2t
2
2
2
2
t
t2t
t
t2t
2
2
2
2
Figure 2: Example Die 2 with Signature
The graph in
Figure 2 shows that the punch on the left contacts the material first and exerts a total force
of 100 tons at time t1, with 60 tons distributed to left side of the machine frame and 40 tons distributed
to the right. After the left punch breaks through the material, and at a different position in the stroke, the
punch on the right contacts the material and exerts a total force of 100 tons at time t2, with 60 tons
distributed to the right side of the machine frame and 40 tons distributed to the left. This process would
result in the tonnage monitor displaying that the maximum tonnage measured on the left side of the
Doc #: L-802-1110 Page 8 Rev. 02
machine frame was 60 tons, that the maximum tonnage measured on the right side of the machine frame
was 60 tons, and that the maximum total tonnage exerted on the machine frame was 100 tons.
2.1.3 Reverse Tonnage
In addition to monitoring the “forward” tonnages for a press, the tonnage monitor also measures and
monitors the “reverse” tonnage. A press frame acts as a kind of stiff spring. When exerting tonnage in
the down part of the cycle, portions of the press frame stretch proportionally to the tonnage exerted. In
the case of a punch, for example, the tooling comes down and contacts the material. The press frame
starts stretching, and this generates tonnage exerted on the material. Finally the tonnage exerted is
sufficient for the punch to “break through” the material, and when it does the press frame tries to “spring
back” to its original shape. Just like a regular spring, the press will overshoot its original resting
position due to inertia and will actually compress instead of stretch. The tonnage registered on the frame
during this “rebound” is the reverse tonnage. Reverse tonnages are typically much harder on the press
than forward tonnages. As a result, press manufactures usually allow much less reverse tonnage on a
machine than forward tonnage. For instance, a 500 ton machine may only be rated for 50 tons of reverse
load.
2.2 Data Windows
Peak tonnage monitors capture the maximum tonnage seen by each strain gage over the stroke. This
maximum tonnage is compared to setpoints to determine if an alarm should be generated to stop the
production process. While this is adequate for most applications, complex tooling can produce multiple
peaks resulting in only the highest peak being checked against setpoints. Where closer monitoring is
desired in these applications, the tonnage monitor provides up to four “Data Windows” to monitor
additional peaks other than the absolute maximum peak tonnage. These additional peaks are referred to
as “local” peaks. Each data window consists of a separate high and low limit that are used from a given
start angle to a given end angle.
The tonnage graph in Figure 3A is for a two station
die. The first station (between 165 and 170 degrees)
LOCAL
LOCAL
PEAK
PEAK
ABSOLUTE
ABSOLUTE
PEAK
PEAK
cuts out the part (local peak), and the second station
(at 180 degrees) stamps a logo onto the part (absolute
peak).
A.
A.
Since the tonnage required to coin the logo is greater
than the tonnage required to cut the part, the local
peak is not checked using a normal peak tonnage
B.
B.
monitor. The local peak could completely disappear
DW1
and a normal peak tonnage monitor would not detect
any anomaly in the process since the absolute peak
limits are still being satisfied. This is exactly what
DW1
165 170 180
165 170 180
Figure 3: Example Data Window
would happen if the material did not feed between
strokes as shown in Figure 3B. Using a single data window, however, places a separate high and low
limit on the local peak.
Doc #: L-802-1110 Page 9 Rev. 02
2.2.1 Data Window Start Angle
The Start Angle for a data window is the angle at which the setpoints for that data window start to be
enforced. For example, in Figure 3 data window 1 has a start angle of 165 degrees.
2.2.2 Data Window End Angle
The End Angle for a data window is the angle at which the setpoints for that data window stop being
enforced. For example, in Figure 3 data window 1 has an end angle of 170 degrees.
2.3 Limits
The tonnage monitor can compare the tonnages it reads to limits set for each job. The following
sections detail these limits.
2.3.1 Machine Rating Limit
The machine rating limit, unlike low and high limits, is intended to protect the machine rather than the
tooling. This limit can be configured to be between 100% and 125% of the tonnage rating for each
channel with a typical value of 125%. For instance, on a 400 ton machine with a four channel tonnage
monitor module, each channel is rated at 100 tons (400 ton machine divided by four channels). The
machine rating limit for each channel in this case would be 125% of 100 tons which is 125 tons. Note
that it is possible to get a machine rating alarm even though the total tonnage does not exceed the
machine rating. Suppose the tonnages for the above machine read 80 for channel 1, 90 for channel 2,
130 for channel 3, 80 for channel 4, and 380 for the total. A machine rating alarm would be indicated on
channel 3 even though the total tonnage was less than 400 tons. A machine rating alarm results in a
Cycle Stop to the press. Unlike high, low, and reverse limits, this limit can NOT be bypassed.
2.3.2 Low Limits
A low limit is the minimum tonnage required to properly produce a particular part. There are separate
low limits for each channel of the tonnage monitor for both the peak tonnages and data window
tonnages. If something in the process changes during normal operation that causes any channel to not
reach its’ minimum limits, a Top Stop is issued. In setup modes (Inch and Timed Inch for the 5000
press control, setup mode input active on the automation control) it is common to operate the press
without material in the die during the setup operation. In order to prevent unintended stops, the tonnage
monitor can be configured to automatically turn OFF the Low Limits during these modes. The Low
Limit for a particular channel can not be set greater than or equal to that channels' high limit.
2.3.3 High Limits
High Limits should be set above the maximum tonnage required to properly produce a particular part
and is set for each channel of the tonnage monitor for both peak and data window tonnages. If
something in the process changes during normal operation that causes the tonnage developed to exceed
this maximum limit, a stop (configurable as Cycle Stop, Top Stop, or Intelli-Stop) is issued.
Doc #: L-802-1110 Page 10 Rev. 02
2.3.4 Reverse Limits
A Reverse Limit should be set more negative than the maximum reverse tonnage developed when
properly producing a particular part and is set for each channel of the tonnage monitor for the peak
tonnage only. Data windows do NOT have reverse limits associated with them. If something in the
process changes during normal operation that causes the tonnage developed to exceed this maximum
reverse limit, a Top Stop is issued. Excessive reverse tonnages are damaging to the machine frame and
reverse tonnage limits are active during the entire working portion of the stroke.
2.3.5 Total Tonnage Limit
There is only one limit that can be applied to the total tonnage. If so configured (see section 4.6 on page
48 for details), the machine rating de-rate table will apply a limit to the total tonnage that varies with the
crank angle (related to height off the bottom of the stroke). The machine rating is specified by the press
manufacturer at a specific height off the bottom of the stroke. Above this height the total tonnage
available is limited by the torque of the crankshaft and clutch and will decrease as the height off the
bottom increases. The machine rating de-rate table tells the tonnage monitor how to limit the total
tonnage. A Cycle Stop will be issued if this limit is exceeded.
2.4 Stops
There are three different kinds of stops that the tonnage monitor can generate. Some conditions always
generate a particular kind of stop, while others are programmable by the user.
2.4.1 Cycle Stop
A “Cycle Stop” sends a signal to the control to immediately stop the press, regardless of where it is in
the cycle. Note that this does NOT mean that the press will actually stop at the point where the stop was
generated, as all presses take some amount of time to drop out the clutch, apply the brake, and come to a
stop. For instance, if an over-tonnage occurs at 175 degrees, the press may end up stopped at 200
degrees. The number of degrees a press requires to actually stop depends (among other things) on the
design of the press and on stroking speed. All other conditions being equal, the faster the press is
stroking, the longer it requires to stop.
2.4.2 Top Stop
A “Top Stop” sends a signal to the control to stop the press at the top of the stroke. Note that all presses
take some amount of time to stop. If the control determines that it can not stop at top in the time left
when it receives the stop command, it will make an additional stroke. Many high speed presses take
more than 1 full stroke to stop regardless of where the stop occurs.
2.4.3 Intelli-Stop
An “Intelli-Stop” sends a signal to the control to “Cycle Stop” if the stop can be accomplished by a
certain “critical angle”, otherwise it will “Top Stop”. This stop type is used to attempt to prevent
sticking the slide on bottom under load. For instance, the critical angle might be set to 170 degrees. If
the control determines that the press can stop before this angle is reached, it will issue a “Cycle Stop” to
attempt to prevent further damage to the machine and/or tooling. If, however, the control determines
Doc #: L-802-1110 Page 11 Rev. 02
that the press will not be able to stop before 170 degrees, it will issue a “Top Stop” to minimize the
chance of sticking the slide, since the press was going to go through the bottom anyway.
Doc #: L-802-1110 Page 12 Rev. 02
3 OPERATION
3.1 Main Operator Terminal Screen
The operator terminal main screen shown in Figure 4 provides the current status of the tonnage monitor
module directly beside the TONNAGE MONITOR softkey and indicates if attention is required by the
module.
0
0
0
0
Stroke
Stroke
TOP
TOP
Mode
Mode
Job Num. Description
Job Num. Description
10012 Left Support Bracket
10012 Left Support Bracket
Counter Limit Quantity
Counter Limit Quantity
ORDER
ORDER
BATCH
BATCH
Single Stroke
Single Stroke
Off
Off
Off
Off
Speed
Speed
Stroke
Stroke
Speed
Speed
Drive
Drive
SPM
SPM
0
0
0
0
SPM
SPM
Status:
Status:
Program/Run Switch
Program/Run Switch
Status:
Status:
All Conditions OK
All Conditions OK
Status:
Status:
All Conditions OK
All Conditions OK
Order
Order
Counter
Counter
Program/Run Switch
Program/Run Switch
Counter OFF
Counter OFF
Current Status
Current Status
MAIN
MAIN
SCREEN
SCREEN
PRESS
PRESS
CONTROL
CONTROL
AUTO
AUTO
SETS
SETS
TONNAGE
TONNAGE
MONITOR
MONITOR
DIE
SPM60%Load
SPM60%Load
SPEED
SPEED
ADJUST
ADJUST
90
90
Status:
Status:
All Conditions OK
All Conditions OK
Status:
Status:
All Conditions OK
All Conditions OK
Status:
Status:
All Conditions OK
All Conditions OK
JOB
JOB
SETUPS
SETUPS
DIE
PROTECTION
PROTECTION
LIMIT
LIMIT
SWITCH
SWITCH
ANALOG
ANALOG
MONITOR
MONITOR
COUNTERS
COUNTERS
Figure 4: Operator Terminal Main Screen
The status of the tonnage monitor module could indicate any of the following conditions:
"All Conditions OK" No alarms exist and no stop signals are being given by the module.
"Error Condition Exists" An alarm or an error has been detected and must be reset before the
control will allow stroking.
"System Bypassed” The module is bypassed and will not supply a stop signal to the control if
an alarm occurs.
"Option is NOT Installed" The control has not been configured to recognize the module.
"Communication Failure" A problem exists in the communication link between the operator terminal
and the module (see section
9.1 on page 74 for details).
Doc #: L-802-1110 Page 13 Rev. 02
3.2 The Tonnage Monitor Main Screen
The TONNAGE MONITOR softkey in the Main Menu provides access to the tonnage monitor module.
This screen shows the maximum forward tonnages recorded during the last stroke, the description and
status of each channel, the overall status of the tonnage monitor module, and limits that apply to the
current view.
Peak forward tonnage, peak reverse tonnage, and data window forward tonnages can be selected for
viewing. Figure 5 is an example of a peak forward tonnage view, Figure 6 shows a data window
forward tonnage view, and Figure 7 shows a peak reverse tonnage view. Two channel screens look
much the same but have no channel three or channel four information sections.
There are several softkeys on the main tonnage monitor screen that come into play at various times. The
softkeys and other functions of this screen are discussed in the following sections. In the following
screens, softkeys that are shaded may say different things depending on the data input field selected. In
addition, some softkeys may not be shown at times depending on the RUN/PROG key position,
whether the press is running, and other factors.
ij
ij
0
TOP
TOP
h
h
Peak
Peak
g
g
Forward Tonnage
Forward Tonnage
CH1 - Left Rear
CH1 - Left Rear
High Limit:
High Limit:
f
f
e
e
d
d
c
c
b
b
a
a
18.7
18.7
Low Limit: 16.0
Low Limit: 16.0
Status OK
Status OK
CH3 - Left Front
CH3 - Left Front
High Limit: 20.0
High Limit: 20.0
19.5
19.5
Low Limit: 12.0
Low Limit: 12.0
Status OK
Status OK
CONFIGURE
CONFIGURE
0
0
0
Stroke
Stroke
Mode
Mode
View
View
Module Status: OK
Module Status: OK
Single Stroke
Single Stroke
25.0
25.0
Tons
Tons
Tons
Tons
DIAGNOS
DIAGNOS
HIGH 150%
HIGH 150%
LOW 0%
LOW 0%
HIGH 150%
HIGH 150%
LOW 0%
LOW 0%
Drive
Drive
Speed
Speed
Stroke
Stroke
Speed
Speed
Total
Total
82.8
82.8
BYPASS
BYPASS
SETP
SETP
SPM
SPM
0
0
SPM
SPM
0
0
Tons
Tons
CH2 - Right Rear
CH2 - Right Rear
High Limit: 25.0
High Limit: 25.0
20.4
20.4
Low Limit: 16.0
Low Limit: 16.0
Status OK
Status OK
CH4 – Right Front
CH4 – Right Front
High Limit: 30.0
High Limit: 30.0
27.9
27.9
Low Limit: 20.0
Low Limit: 20.0
Status OK
Status OK
GRAPH
GRAPH
Tons
Tons
Tons
Tons
Order
Order
Counter
Counter
Program/Run Switch
Program/Run Switch
HIGH 150%
HIGH 150%
LOW 0%
LOW 0%
HIGH 150%
HIGH 150%
LOW 0%
LOW 0%
AUTO-SETUP
AUTO-SETUP
Counter OFF
Counter OFF
Current Status
Current Status
Tonnage
Tonnage
Monitor
Monitor
CHANGE
CHANGE
VIEW
VIEW
LOW LIMITS
LOW LIMITS
ON/OFF
ON/OFF
BYPASS
BYPASS
ON/OFF
ON/OFF
REVERSE
REVERSE
TONNAGE
TONNAGE
RESET
RESET
FAULT
FAULT
EXIT
EXIT
CHANGE
CHANGE
HIGH LIMIT
HIGH LIMIT
CHANGE
CHANGE
LOW LIMIT
LOW LIMIT
Figure 5: Tonnage Monitor Main Screen Showing Peak Forward Tonnage
Doc #: L-802-1110 Page 14 Rev. 02
In Figure 5, the various parts of the screen are:
a) Module Status
The overall status of the tonnage monitor.
b) Channel Status
c) Low Limit Value
d) Graphical Limit
Bar
e) Tonnage Reading
f) High Limit Value
Each channel also has a status that indicates any alarms conditions or other
problems related to just that channel.
The low tonnage limit setting for this channel and view (peak, data window 1,
data window 2, etc).
This is a floating bar graph that graphically indicates where the tonnage for the
channel is relative to the low and high setpoints for that channel. The bottom
of the graph is the low limit and the top of the graph is the high limit. A
tonnage that is halfway between the low and high limits will show a green bar
in the middle of the graph. If the tonnage were to start going up towards the
high limit (perhaps due to material thickness variation), the bar would also go
up and would first turn yellow, and then red as it approached the high limit.
Likewise, if the tonnage started to go down towards the low limit, the bar
would go down and first turn yellow, and then red as it approached the low
limit.
The numeric tonnage reading for this channel and view. In the example
screen of Figure 5, this is the peak forward tonnage for channel 1.
The high tonnage limit setting for this channel and view (peak, data window 1,
data window 2, etc).
g) Tonnage Direction
This indicates whether forward or reverse tonnage is being viewed (Note that
data windows do not have reverse tonnage associated with them).
h) View
This line indicates which tonnages and settings are being viewed - Peak, Data
Window 1, Data Window 2, Data Window 3, or Data Window 4.
i) Channel Rating
Graph
This bar graph shows the percent of channel rating that the tonnage represents.
It will be green to 100% channel rating, yellow from 100% to 125% channel
rating, and red from 125% to 150% channel rating. For example, a 400 ton 4
channel machine would have a 100 ton channel rating. For this case, if a
channel read 100 tons then the graph would be all green up to about 2/3 of the
graph. If the channel read 110 tons, then a little yellow would show above the
green. If the channel read 130 tons, there would be red above the yellow. In
general, this graph should always be kept in the green.
j) Total Tonnage
This is the numeric value for the total tonnage.
Reading
Doc #: L-802-1110 Page 15 Rev. 02
CHANGE VIEW
Softkey
This softkey is used to change the tonnage view between peak, data window 1,
data window 2, data window 3, and data window 4 as explained in section
3.2.1 on page 18.
LOW LIMITS
ON/OFF Softkey
BYPASS ON/OFF
Softkey
REVERSE
TONNAGE Softkey
RESET FAULT
Softkey
AUTO-SETUP
Softkey
GRAPH Softkey
This softkey toggles the low limits between ON and OFF. See section
on page
19 for more information on limits.
3.2.2
This softkey turns the tonnage monitor bypass mode ON and OFF. See
section 3.2.4 on page 22 for more information on bypassing the tonnage
monitor.
This softkey changes the tonnages displayed to reverse peak tonnages (see
Figure 7). This key is only present when viewing forward peak tonnage. See
section 3.2.1 on page 18 for more information.
This softkey is used to reset tonnage alarms and fault conditions. See section
3.2.5.7 on page 24 and section 3.2.6.3 on page 26 for more information on
resetting alarm and error conditions.
This softkey is used to initiate an auto-setup sequence. See section 3.2.2.4 on
page 20 for more information.
This softkey brings up the tonnage graph screen. See section 3.5 on page 30
for information about the graph screen.
BYPASS SETUP
Softkey
DIAGNOS Softkey
CONFIGURE Softkey
This softkey brings up the bypass setup screen. See section 3.4 on page 29 for
more information on this screen.
This softkey brings up the tonnage monitor diagnostics screen. See section
3.3 on page 27 for more information on this screen.
This softkey brings up the tonnage monitor configuration screen. Note that it
is only present when the RUN/PROG key switch is in the PROG position. In
addition, the system configuration code is required to gain access to these
screens. See section
4.3 on page 43 for more information on this screen.
Doc #: L-802-1110 Page 16 Rev. 02
Figure 6 shows a four channel screen when viewing data window 1 tonnages. Notice that the major
difference between this screen and that of Figure 5 is the addition of three new parameters and the lack
of a REVERSE TONNAGE softkey.
k
k
0
0
0
0
Stroke
Stroke
TOP
TOP
Data Win 1
Data Win 1
Forward Tonnage
Forward Tonnage
High Limit: 13.2
High Limit: 13.2
Low Limit: 9.1
Low Limit: 9.1
Status OK
Status OK
High Limit: 12.2
High Limit: 12.2
Mode
Mode
View Total
View Total
CH1 - Left Rear CH2 - Right Rear
CH1 - Left Rear CH2 - Right Rear
9.8
9.8
CH3 - Left Front
CH3 - Left Front
Tons
Tons
(ON)
(ON)
Single Stroke
Single Stroke
HIGH 150%
HIGH 150%
LOW 0%
LOW 0%
HIGH 150%
HIGH 150%
Drive
Drive
Speed
Speed
Stroke
Stroke
Speed
Speed
39.5
39.5
Tons
Tons
High Limit: 11.5
High Limit: 11.5
10.3
10.3
Low Limit: 8.5
Low Limit: 8.5
Status OK
Status OK
CH4 – Right Front
CH4 – Right Front
High Limit: 14.8
High Limit: 14.8
SPM
SPM
0
0
SPM
SPM
Angles
Angles
Start Ang: 166.0
Start Ang: 166.0
End Ang: 177.0
End Ang: 177.0
Tons
Tons
Order
Order
Counter
Counter
Program/Run Switch
Program/Run Switch
HIGH 150%
HIGH 150%
LOW 0%
LOW 0%
HIGH 150%
HIGH 150%
lm
lm
Counter OFF
Counter OFF
Current Status
Current Status
Tonnage
Tonnage
Monitor
Monitor
CHANGE
CHANGE
VIEW
VIEW
LOW LIMITS
LOW LIMITS
ON/OFF
ON/OFF
BYPASS
BYPASS
ON/OFF
ON/OFF
DATA WIN
DATA WIN
ON/OFF
ON/OFF
CHANGE
CHANGE
ON ANGLE
ON ANGLE
CHANGE
CHANGE
OFF ANGLE
OFF ANGLE
CHANGE
CHANGE
LOW LIMIT
LOW LIMIT
CHANGE
CHANGE
HIGH LIMIT
HIGH LIMIT
11.4
11.4
Low Limit: 8.1
Low Limit: 8.1
Status OK
Status OK
CONFIGURE
CONFIGURE
Tons
Tons
LOW 0%
LOW 0%
Module Status: OK
Module Status: OK
DIAGNOS
DIAGNOS
BYPASS
BYPASS
SETP
SETP
13.7
13.7
Low Limit: 12.0
Low Limit: 12.0
Status OK
Status OK
GRAPH
GRAPH
Tons
Tons
LOW 0%
LOW 0%
AUTO-SETUP
AUTO-SETUP
Figure 6: Tonnage Monitor Main Screen Showing Data Window 1 Tonnage
In Figure 6, some additional settings in a data window view are:
k) Data Window
On/Off
This determines whether the data window is active. When “On”, the data
window setpoints are enforced from the “Start Angle” to the “End Angle”.
When “Off”, these settings are not used at all and will NOT stop the press.
l) Data Window
The angle at which the data window setpoints will start to be enforced.
Start Angle
m) Data Window End
The angle at which data window setpoints stop being enforced.
Angle
RESET
RESET
FAULT
FAULT
EXIT
EXIT
Doc #: L-802-1110 Page 17 Rev. 02
Figure 7 shows a four channel screen when viewing reverse tonnages. Notice that there are no limit bars
when viewing reverse tonnage as there is only one reverse limit for each channel.
n
n
0
0
0
0
Stroke
Stroke
TOP
TOP
Peak
Peak
Reverse Tonnage
Reverse Tonnage
Status OK
Status OK
Mode
Mode
View
View
CH1 - Left Rear
CH1 - Left Rear
Rev Limit: -
Rev Limit: -
1.9
1.9
CH3 - Left Front
CH3 - Left Front
Rev Limit: - 2.0 Rev Limit: - 2 .0
Rev Limit: - 2.0 Rev Limit: - 2 .0
Single Stroke
Single Stroke
2.4
2.4
Tons
Tons
150%
150%
0%
0%
150%
150%
Drive
Drive
Speed
Speed
Stroke
Stroke
Speed
Speed
Total
Total
7.3
7.3
Tons
Tons
CH2 - Right Rear
CH2 - Right Rear
Rev Limit: - 2.5
Rev Limit: - 2.5
2.3
2.3
Status OK
Status OK
CH4 – Right Front
CH4 – Right Front
0
0
0
0
SPM
SPM
SPM
SPM
Tons
Tons
Order
Order
Counter
Counter
Program/Run Switch
Program/Run Switch
Counter OFF
Counter OFF
Current Status
Current Status
Tonnage
Tonnage
Monitor
Monitor
CHANGE
CHANGE
REV LIMIT
150%
150%
0%
0%
150%
150%
REV LIMIT
CHANGE
CHANGE
VIEW
VIEW
REV LIMITS
REV LIMITS
ON/OFF
ON/OFF
BYPASS
BYPASS
ON/OFF
ON/OFF
1.5
1.5
Status OK
Status OK
CONFIGURE
CONFIGURE
Tons
Tons
Module Status: OK
Module Status: OK
DIAGNOS
DIAGNOS
0%
0%
BYPASS
BYPASS
SETP
SETP
Status OK
Status OK
1.7
1.7
GRAPH
GRAPH
Tons
Tons
Figure 7: Tonnage Monitor Main Screen Showing Reverse Tonnage
In Figure 7, an additional setting in the reverse tonnage view is:
n) Reverse Limit
Value
REV LIMITS
ON/OFF Softkey
FORWARD
TONNAGE Softkey
The reverse tonnage limit setting for this channel. Note that only peak tonnage
has a reverse limit.
This softkey toggles the reverse limits between ON and OFF. See section
3.2.2 on page 19 for more information on limits.
This softkey will change the tonnages displayed back to peak forward tonnage.
See section
3.2.1 on page 18 for more information.
3.2.1 Selecting a View
0%
0%
AUTO-SETUP
AUTO-SETUP
FORWARD
FORWARD
TONNAGE
TONNAGE
RESET
RESET
FAULT
FAULT
EXIT
EXIT
As explained in Section 2.2, data windows can monitor “local” peaks with a separate set of setpoints
from the “absolute” peak. Each set of tonnages and limits makes up a “view” in this screen and is
indicated by the box in the upper left of the screen as shown by “h” and “g” in
Figure 5. The absolute
peak tonnages and associated limits are called the “peak view”. In all, there are six different “views” of
tonnages and settings - peak forward, peak reverse, data window 1 forward, data window 2 forward, data
Doc #: L-802-1110 Page 18 Rev. 02
window 3 forward, and data window 4 forward. The default view on entering the screen is peak forward
tonnages and settings.
3.2.1.1 Viewing the Peak and Data Window Tonnages and Settings
The CHANGE VIEW softkey allows the operator to select which set of tonnages and settings are shown
on the tonnage monitor screen. The view can be the maximum forward tonnage that occurred anywhere
during the last stroke (Peak) or the maximum tonnage that occurred during a particular data window
(Data Window 1 through Data Window 4). Each time the CHANGE VIEW softkey is hit the view will
change. The order is Peak, Data Window 1, Data Window 2, Data Window 3, Data Window 4, and then
back to Peak.
3.2.1.2 Showing Forward and Reverse Tonnage
When viewing peak forward tonnage, press the REVERSE TONNAGE softkey to change the view to
peak reverse tonnage and settings. This key is only available in the peak forward view (as seen in
Figure 5) as data windows do not have reverse tonnage associated with them.
When viewing peak reverse tonnage, press the FORWARD TONNAGE softkey to change the view to
peak forward tonnage and settings. This key is only available in the peak reverse view as shown in
Figure 7.
3.2.2 Setting Limits
As can be seen in Figure 5, Figure 6, and Figure 7, there are several limits that must be set in the
tonnage monitor for it to perform its function. Each channel in the peak view has a low, high, and
reverse limit. Each channel in a data window has a low and high limit as well as a data window start
and end angle.
NOTE: These limits are restricted items and access to them is controlled by the
RUN/PROG key, access code, or both as described in section 11 on page 78.
In addition, these items are only allowed to be changed when the editing
cursor is present. For most items, the editing cursor will NOT be available
when the press is running. Also, when the access mode is “Key Only” or
“Key AND Code”, the editing cursor will only appear when the RUN/PROG
key switch is in the PROG position. The following subsections assume that
access to the parameters has been obtained and that the editing cursor is
present.
3.2.2.1 Setting High Limits
To set a high limit, first choose the view and channel to change. Place the data entry cursor on a high
limit setpoint (see “f” in
Figure 5) using the up, down, left, and right arrow keys. Softkey 1 (The
uppermost vertical softkey) should read CHANGE HIGH LIMIT. Press this softkey to enter numeric
entry mode (or simply start entering numbers after the field is selected). Enter the new limit with the
numeric keypad and press the ENT key to set the limit. The high limit MUST be greater than the low
limit for that channel and view but less than “Max Forward Setpoint Level” (see section 4.4.4 on page
45 for details).
Doc #: L-802-1110 Page 19 Rev. 02
3.2.2.2 Setting Low Limits
To set a low limit, first choose the view and channel to change. Place the data entry cursor on a low
limit setpoint (see “c” in Figure 5) using the up, down, left, and right arrow keys. Softkey 1 (The
uppermost vertical softkey) should read CHANGE LOW LIMIT. Press this softkey to enter numeric
entry mode (or simply start entering numbers after the field is selected). Enter the new limit with the
numeric keypad and press the ENT key to set the limit. The low limit MUST be less than the high limit
for that channel and view! Note that setting this value to zero effectively disables it.
3.2.2.3 Setting Reverse Limits
To set a reverse limit, first set the view to “peak reverse” as shown in Figure 7. Place the data entry
cursor on a reverse limit setpoint (see “n” in Figure 7) using the up, down, left, and right arrow keys.
Softkey 1 (The uppermost vertical softkey) should read CHANGE REV LIMIT. Press this softkey to
enter numeric entry mode (or simply start entering numbers after the field is selected). Enter the new
limit with the numeric keypad and press the ENT key to set the limit.
3.2.2.4 Automatically Setting Limits
The AUTO SETUP softkey initiates an automatic calculation of tonnage limits based on the tonnages
that the tool is currently reading. Like manually setting limits, this is a restricted function. The operator
must have access via RUN/PROG Key or access code depending on how the system has been
configured (See section 11 on page 78 for access configuration details). When this key is pressed, a box
will appear which allows the operator to enter a Percent Tolerance (percent of machine rating of each
channel) which is applied to the peak tonnage recorded during the automatic setup process. A tolerance
from 1% to 10% of the channel rating is added to the highest tonnage recorded in the 16 successive
strokes made in the auto setup mode in order to calculate the High Limit. The tolerance is subtracted
from the lowest peak tonnage recorded during the procedure in order to calculate the Low Limit. The
tolerance is subtracted from the most negative peak tonnage recorded in order to calculate the Reverse
Limit. The 16 strokes of the automatic setup process will not begin until after the number of strokes set
in the “Low Limit Bypass Strokes” parameter (see Section 3.4 on page 29 for details) have elapsed.
WARNING:
While in auto setup mode, the tonnage monitor module will ignore any
high, low, or reverse alarm. Only machine rating alarms are active.
For progressive dies, material should complete its progression through
all stations before beginning auto setup.
To begin the automatic setup procedure the operator must remain in the tonnage monitor screen, switch
the RUN/PROG keyed selector switch to the RUN position, and stroke the press in order to allow the
tonnage monitor to measure the typical variation of the process. The actual tonnages and number of
strokes remaining are automatically updated each stroke. A maximum of 60 seconds is allowed between
strokes or the setup procedure will automatically abort and leave the present limits unchanged. After the
last stroke, the tonnage monitor module will automatically exit the automatic setup mode and calculate
the tonnage limits. Normal operation will continue with the new limits. Low limits and reverse limits
are updated even if turned OFF. Data window limits are not updated if the data window is turned OFF.
Once started, the AUTO SETUP softkey changes to CANCEL AUTO SETUP. The automatic setup
Doc #: L-802-1110 Page 20 Rev. 02
procedure can be aborted at any time before the sixteenth stroke by pressing this softkey. The
previously entered limits will then remain in effect.
3.2.2.5 Turning Low Limits ON or OFF
Pressing the LOW LIMITS ON/OFF softkey will toggle all low limits (including those in all data
windows) ON or OFF. This key is only available when viewing forward tonnage (as in Figure 5 and
Figure 6). Like changing setpoints, this is a restricted operation. The operator must have access to this
operation via RUN/PROG Key or access code depending on how the system has been configured (See
section 11 on page 78 for access configuration details). When low limits are turned off, “Low Lim
OFF” will be displayed with a yellow background just below the tonnage reading on each channel.
NOTE: Individual low limits can be effectively turned OFF by setting the limit to
zero.
3.2.2.6 Turning Reverse Limits ON or OFF
Pressing the REV LIMITS ON/OFF softkey will toggle all reverse limits ON or OFF. This key is only
available when viewing reverse tonnages (as in Figure 7). Like changing setpoints, this is a restricted
operation. The operator must have access to this operation via RUN/PROG Key or access code
depending on how the system has been configured (See section 11 on page 78 for access configuration
details). When reverse limits are turned off, “Rev Lim OFF” will be displayed with a yellow
background just below the tonnage reading on each channel.
3.2.3 Setting Additional Data Window Parameters
In addition to high and low setpoints, data windows have three other parameters associated with them.
3.2.3.1 Turning Data Windows ON or OFF
Each data window can be individually turned ON or OFF. When OFF, the limits associated with the
data window are NOT enforced. To set the data window ON/OFF state, change the view to the data
window desired. The screen should look something like
Figure 6. Place the data entry cursor on the
ON/OFF parameter in the View box as pointed to by “k” in Figure 6. Softkey 1 (The uppermost vertical
softkey) should read DATA WIN ON/OFF. This softkey toggles the data window setting between ON
and OFF.
3.2.3.2 Setting the Data Window “Start Angle”
The “Start Angle” for the data window is the crankshaft angle at which the setpoints associated with the
window start to be enforced. To change the start angle, change the view to the data window desired.
The screen should look something like Figure 6. Place the data entry cursor on the “Start Ang”
parameter (“l” in
Figure 6). Softkey 1 (The uppermost vertical softkey) should read CHANGE START
ANGLE. Enter the new value with the numeric keypad and press the ENT key to set the angle. The
start angle MUST be less than the end angle for that data window (you may have to change the end
angle first)!
Doc #: L-802-1110 Page 21 Rev. 02
3.2.3.3 Setting the Data Window “End Angle”
The “End Angle” for the data window is the crankshaft angle at which the setpoints associated with the
window stop being enforced. To change the end angle, change the view to the data window desired.
The screen should look something like
parameter (“m” in
Figure 6). Softkey 1 (The uppermost vertical softkey) should read CHANGE END
Figure 6. Place the data entry cursor on the “End Ang”
ANGLE. Enter the new value with the numeric keypad and press the ENT key to set the angle. The end
angle MUST be greater than the start angle for that data window (you may have to change the start angle
first)!
3.2.4 Bypassing the Tonnage Monitor
The BYPASS ON/OFF softkey toggles the tonnage monitor bypass between ON and OFF. Like
changing setpoints, this is a restricted operation. The operator must have access to this operation via
RUN/PROG Key or access code depending on how the system has been configured (See section 11 on
page 78 for access configuration details). When bypassed, all tonnage monitor limits are ignored with
the exception of machine rating alarms. In addition, the tonnage monitor status will say “System
Bypassed” with a yellow background and “Bypassed” will be displayed with a yellow background just
below the tonnage reading on each channel. The module will always power up with Bypass turned OFF.
3.2.5 Tonnage Alarms
The Main Tonnage Monitor screen provides a status indication for each channel. This message indicates
any tonnage alarm or error condition that has occurred and under normal operating conditions should
show "Status OK".
If a tonnage alarm occurs, the message will change to reflect the first alarm detected on that channel
during the stroke. In addition the module status at the bottom of the Main Tonnage Monitor screen will
indicate "One or More Channel Errors".
If the tonnage monitor was the first system that stopped the press, then the Present Running Status in the
Press Control or Brake Monitor screen will show “Tonnage Monitor Stop”. If, for example, a die
protection channel issued a stop at 100 degrees and then a tonnage alarms occurred at 170 degrees, then
the Present Status would read “Die Protection Stop” even though there is also a tonnage alarm.
Any tonnage alarm stop will remain in effect and further stroking prevented until the alarm is reset by
pressing the RESET FAULT softkey.
WARNING:
Tonnage alarms can generate a stop before the bottom of the stroke.
When the RESET FAULT softkey is pressed, the tonnage monitor is
effectively BYPASSED until the top of the stroke. Make sure to clear
the fault condition before reengaging the press.
Doc #: L-802-1110 Page 22 Rev. 02
3.2.5.1 Low Alarm
One of the messages listed below in the Channel Status indicates that the maximum tonnage recorded
during the last stroke did not reach the Low Limit setting.
“Low Peak Alarm” Tonnage did not reach the Low Lim it set in Peak Tonnage.
“Low Dw1 Alarm” Tonnage did not reach the Low Limit set in Data Window #1.
“Low Dw2 Alarm” Tonnage did not reach the Low Limit set in Data Window #2.
“Low Dw3 Alarm” Tonnage did not reach the Low Limit set in Data Window #3.
“Low Dw4 Alarm” Tonnage did not reach the Low Limit set in Data Window #4.
This limit is not checked and the message will not appear until the press reaches the end of the working
portion of the stroke for the peak low limit – or the end of the data window for a data window low limit.
When the condition is detected on any channel, a Top Stop is issued.
3.2.5.2 High Alarm
One of the messages listed below in the Channel Status indicates that the maximum tonnage recorded
during the last stroke exceeded a High Limit setting.
“High Peak Alarm” Tonnage exceeded the High Limit set in Peak Tonnage.
“High Dw1 Alarm” Tonnage exceeded the High Limit set in Data Window #1.
“High Dw2 Alarm” Tonnage exceeded the High Limit set in Data Window #2.
“High Dw3 Alarm” Tonnage exceeded the High Limit set in Data Window #3.
“High Dw4 Alarm” Tonnage exceeded the High Limit set in Data Window #4.
When the condition is detected on any channel, a stop is issued. The type of stop issued depends on
whether the high setpoint is a peak high setpoint or a data window high setpoint. A peak high alarm will
issue a stop as configured by the “Peak High Limit Stop Type” setting. A data window high alarm will
issue a stop as configured by the “DW High Limit Stop Type” setting. See section 4.4.13 on page 46 for
details on these settings.
3.2.5.3 Reverse Alarm
A Channel Status message "Reverse Alarm" indicates that the maximum reverse tonnage recorded
during the last stroke exceeded the Reverse Limit setting in Peak Tonnage. When the condition is
detected on any channel, a Top Stop is issued.
3.2.5.4 Machine Rating Alarm
A Channel Status message "Machine Rating" indicates that the maximum forward tonnage recorded
during the last stroke exceeded the channel rating as set by the “Machine Rating Alarm Level” (see
section 4.4.3 on page 45 for details). When the condition is detected on any channel, a Cycle Stop is
issued.
Doc #: L-802-1110 Page 23 Rev. 02
3.2.5.5 Reverse Rating Alarm
A Channel Status message "Reverse Rating" indicates that the maximum reverse tonnage recorded
during the last stroke exceeded the reverse channel rating as set by the “Max Reverse Setpoint Level”
(see section
4.4.5 on page 45 for details). When this condition is detected on any channel, a Top Stop is
issued.
3.2.5.6 Total Alarm/Stop Condition
This alarm condition indicates that the maximum total tonnage exceeded the capacity of the machine at
the height in the stroke at which it occurred. It is the only limit applied to the total tonnage and may or
may not coincide with any channel alarm. When the condition is detected on the total tonnage, a Cycle
Stop is issued.
This alarm will only occur if the tonnage monitor is configu red to de-rate the total tonnage capacity.
The machine rating is specified by the press manufacturer at a specific height off the bottom of the
stroke (for example .25 inches). Above this height the total tonnage available is limited by the torque of
the crankshaft and will decrease as the height off the bottom at which the tonnage occurs increases (see
section
4.6 on page 48 for how this de-rate curve is programmed).
3.2.5.7 Resetting Tonnage Alarms
When a tonnage alarm occurs, the tonnage monitor will issue a stop (the type of stop depends on the
alarm type and configuration). This stop will remain in effect and further stroking p revented until the
alarm is reset by pressing the RESET FAULT softkey in the main tonnage monitor screen.
WARNING:
Tonnage alarms can generate a stop before the bottom of the stroke.
When the RESET FAULT softkey is pressed, the tonnage monitor is
effectively BYPASSED until the top of the stroke. Make sure to clear
the fault condition before reengaging the press.
3.2.6 Error Conditions
A number of error conditions can be reported by the tonnage monitor. Some of these conditions are
reported in the “Module Status” area (see “a” in
Figure 5) and some are reported for a particular channel
in the channel status area (see “b” in Figure 5).
3.2.6.1 Module Error Messages
The following is a list of errors that can appear in the “Module Status” area:
“Boot Info Corrupt”
The boot information block failed its’ validity check. If this is not cleared by
turning the unit off and back on, then the unit needs to be sent to Link for
repair.
Doc #: L-802-1110 Page 24 Rev. 02
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