LinkNet
g
g
Pressroom
Monitorin
Software
Installation and Operatin
Manual
LinkNet
LinkNet
Table of Contents
1. Introduction.......................................................................1.1
1.1 Features ....................................................................1.1
1.2 System Requirements ..........................................................1.1
2. Installation........................................................................2.1
2.1 RS232-RS485 Converter Connections .............................................2.2
2.2 OmniLink 5000 Connections ....................................................2.2
2.3 System 1100 Connections ......................................................2.3
2.4 Drop Box Terminals...........................................................2.3
2.5 Software Installation ..........................................................2.4
3. Configuration .....................................................................3.1
3.1 Configuring the Comm Port .....................................................3.1
3.2 Configuring Shifts ............................................................3.1
3.3 Configuring Down Time Codes ..................................................3.2
3.3.1 Adding a Down Time Code ..................................................3.2
3.3.2 Editing a Down Time Code ..................................................3.3
3.3.3 Deleting a Down Time Code .................................................3.3
3.4 Configuring Machines .........................................................3.3
3.4.1 Adding a Machine to LinkNet.................................................3.3
3.4.2 Editing Machine Information .................................................3.4
3.4.3 Deleting a Machine from LinkNet ..............................................3.4
3.5 Configuring Dies .............................................................3.5
3.5.1 Adding Dies ..............................................................3.5
3.5.2 Editing Die Information .....................................................3.6
3.5.3 Deleting Dies .............................................................3.6
3.6 Configuring Tonnage Wave Capture............................................3.6
3.7 Configuring Preventive Maintenance ...........................................3.7
3.7.1 Adding a Preventive Maintenance Item..........................................3.7
3.7.2 Editing a Preventive Maintenance Item..........................................3.8
3.7.3 Resetting a Preventive Maintenance Item ........................................3.9
3.7.4 Deleting a Preventive Maintenance Item .........................................3.9
4. Using LinkNet .....................................................................4.1
4.1 The Overview Window ........................................................4.1
4.2 Detail Dialogs ...............................................................4.2
4.2.1 Counter Detail ............................................................4.2
4.2.2 Average Tonnage Detail.....................................................4.2
4.2.3 Production Rate Detail ......................................................4.3
4.2.4 Tonnage Detail............................................................4.4
4.3 The “Window” Menu ..........................................................4.4
4.4 The “View” Menu ............................................................4.4
4.5 The “Help” Menu.............................................................4.4
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manual rev 2.1 March 25, 1999
LinkNet
5. Reports ..........................................................................5.1
5.1 The Event Log Report .........................................................5.1
5.2 The Summary Report ..........................................................5.2
5.3 Press Performance Overview Report ..............................................5.3
5.4 Press Average Tonnage Graph ...................................................5.3
5.5 Press Production Rate Graph ....................................................5.4
5.6 Die Performance Overview Report ................................................ 5.4
5.7 Die Tonnage Alarms Report .....................................................5.5
5.8 Die High/Low/Average Tonnage Report ...........................................5.5
5.9 “Quick” Reports..............................................................5.5
6. Using the OmniLink 5000 with LinkNet ..................................................6.1
6.1 Configuring the OmniLink 5000 for LinkNet ........................................6.1
6.2 Using Down Time Codes on the OmniLink 5000 .....................................6.2
6.3 Network Job Storage on the OmniLink 5000 ........................................6.3
6.4 Network Job Recall on the OmniLink 5000 .........................................6.3
6.5 Sending Tonnage Graphs from the OmniLink 5000 ...................................6.4
6.6 Viewing Machine and Die Notes on the OmniLink 5000 ................................6.4
7. Using the System 1100 Tonnage Monitor with LinkNet ......................................7.1
7.1 Configuring the System 1100 Tonnage Monitor for LinkNet ............................7.1
7.2 Using Down Time Codes on the System 1100 Tonnage Monitor .........................7.1
7.3 Network Job Storage on the System 1100 ..........................................7.2
7.4 Network Job Recall on the System 1100 ............................................7.3
7.5 Sending a Tonnage Graph from the System 1100 .....................................7.3
7.6 The Network Clock on the System 1100 ...........................................7.3
Appendix A - Upgrading Link Equipment .............................................. A.1
A.1 General Chip Changing Rules ................................................... A.1
A.2 System 1100 Tonnage Monitor Upgrade Procedure .................................. A.1
A.2.1 System 1100 OIT Software Upgrade Procedure .................................. A.1
A.2.2 System 1100 Motherboard Software Upgrade Procedure ........................... A.2
A.3 OmniLink 5000 Upgrade Procedure .............................................. A.3
A.3.1 OmniLink OIT Communications Board Upgrade Procedure ......................... A.3
A.3.2 OmniLink OIT Software Upgrade Procedure .................................... A.4
A.3.3 OmniLink OIT Communications Card Software Upgrade Procedure................... A.5
A.3.4 OmniLink Logic Module Upgrade Procedure .................................... A.5
A.3.5 OmniLink Die Protection Module Software Upgrade Procedure...................... A.6
A.3.6 OmniLink Tonnage Monitor Module Software Upgrade Procedure ................... A.6
A.3.7 OmniLink Auto-Setup Module Software Upgrade Procedure ........................ A.7
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manual rev 2.1 March 25, 1999
LinkNet
1. Introduction
The Link Systems Network Application
(LinkNet) provides detailed monitoring of stamping
operations utilizing Link equipment. Supported
equipment includes the OmniLink 5000 press control
and associated option modules, and the System 1100
tonnage monitor. By using a simple to wire “daisy
chained” cable arrangement to attach these units to
an Intel based personal computer running Microsoft
Windows, a wealth of information can be gathered
automatically.
1.1 Features
d
Average tonnage, highest good tonnage, and
lowest good tonnage is collected (from
equipment with tonnage monitors) in 10
minute intervals. This gives a good view of
the consistency of the production process.
d
Production Rate is collected in 10 minute
intervals. The production rate is also
factored into summary information for press
utilization calculations versus standard rate.
d
Down time codes may be defined. A
description for each down time code can be
typed in once at the computer and the
descriptions are downloaded to all Link
equipment on the network. The user may
choose from the descriptions, not just the
numeric code, at the press. Down time code
information is collected and stored by shift,
day, week, month, year, since last rework,
and over all time.
d
“Events” are recorded. Events are
automatically logged in the same databases
as down time codes. Examples of events
include tonnage alarms, bypass changes to
tonnage monitor and die protection, die
protection faults, part counter limit s, etc.
d
All data is stored in industry standard
Microsoft Access database files. These files
can be read from many common
spreadsheets, reporting tools, visual basic,
etc.
d
Jobs may be stored and recalled to and from
the host computer giving Link equipment
attached to the network essentially unlimited
job storage
d
Standard reports are provided by LinkNet to
make the information gathered by the system
more accessible and easier to interpret.
d
Reports are generated using Seagate
Software Crystal Reports. This allows the
end user to customize (with separate
purchase of Crystal Reports) LinkNet
reports for any special requirements, add a
company logo, etc.
d
Preventive Maintenance setpoints can be set
by elapsed time, press running time, and
strokes. OmniLink 5000 controls
additionally support setpoints by “Motor
On” time, Total feed length, and
Clutch/Brake engagements.
d
Tonnage signatures can be sent from
OmniLink 5000 and System 1100 tonnage
monitors to the network for analysis,
storage, or printing. Previous signatures can
be overlaid for direct comparison.
d
Notes for each machine and die can be
entered at the computer and viewed on
OmniLink 5000 operator terminals.
1.2 System Requirements
LinkNet has been designed to run on the
Windows 95 or Windows NT operating systems.
Minimum Hardware Requirements:
d
Pentium 166MHz CPU
d
16MB memory
d
1.2GB hard drive
d
VGA (640 by 480) display
d
Mouse
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d
At least one free RS232 serial port
Recommended Hardware:
d
Pentium II 333MHz CPU or better
d
32MB memory
d
4GB or larger hard drive
d
SVGA (800 by 600) display or better
d
Mouse
d
At least one free RS232 serial port
LinkNet
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2. Installation
LinkNet is connected to each piece of equipment
in a bussed arrangement commonly called “daisy
chaining”. The means that the communications
cable goes from the computer to the first machine,
from the first machine to the second, from the
second to the third, and so on as shown in Figure
2.1.
The “Drop Boxes” shown in the figure are small
boxes that contain plugable terminal strips. The
boxes are mounted on the press and serve as
junctions for the network wire to come in to the
machine, go out to the next machine, and drop to
Link equipment on the press. In addition, the boxes
can contain circuitry (called a repeater) to enable the
network to work with extremely long cable lengths
or with more than 32 machines.
LinkNet
Figure 2.1:
Daisy Chained Network Example
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At the computer, an RS232 to RS485 converter
is necessary. This converts the standard serial port
on the host computer to a differential serial port
suitable for electrically noisy industrial
environments. Link makes an RS232 to RS485
converter specifically for this purpose with
termination resistors built in that provide for reliable
communications.
The computer that runs the network should be
capable of running Windows 95, Windows 98, or
Windows NT 4.0 (service pack 4 or higher).
Suggested computer is at least a Pentium II
333MHz with 32 MB of memory, 4GB of hard disk
space, Super VGA with resolution of 800 by 600 or
better, mouse, and at least one spare RS-232 port.
The network wiring should be Belden 8103 or
equivalent (three twisted pairs and a shield) and
should not exceed 4000 ft (unless using a repeater).
LinkNet
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manual rev 2.1 March 25, 1999
Belden 8103 cable and many similar cables
organized as twisted pairs use a special color code
scheme. Instead of each wire using a different color,
each pair uses a color. One wire in the pair is
predominately white with a thin color stripe, and the
other wire in the pair is predominately the color with
a thin white stripe. When referring to these wires a
common convention is to name the predominate
color first. For example, a blue wire with a thin
whit e stripe is called blue with white (shortened to
blue/white). A white wire with a thin blue stripe is
called white with blue (shortened to white/blue).
This convention will be used in this document.
Other wire types can be used, but assuming
Belden 8103 cable and the Link RS232 to RS485
converter, the network should be wired as shown in
the following sections.
2.1 RS232-RS485 Converter Connections
The Link converter is labeled the same way as
network drop boxes on the RS485 side. The RS232
side is equipped with a 6' cable that plugs into any
standard 9 pin serial port connector on the host
computer. A power cord is also provided. The six
terminal RS485 connector should be wired as
follows:
GND - Green/White and White/Green
RXD+ - Orange/White
RXD- - White/Orange
TXD+ - Blue/White
TXD- - White/Blue
SHLD - Shield (bare) Wire of Cable
LinkNet
5) RX- should connect to TXD- on the drop
box (White/Blue wire).
Note that “RX” and “TX” can be called different
things depending on the manufacturer of the
converter, but will almost always reflect some
variation of “transmit” and “receive” (such as TXD
and RXD).
2.2 OmniLink 5000 Connections
There should be 5 connectors on the back of the
OmniLink 5000 operator interface terminal as shown
in Figure 2.2. If only 4 connectors are present, then
an older communications board is installed. If this is
the case, contact Link for pricing to upgrade the unit
to the new communications board with network
support. Appendix “A” has complete instruct ions for
updating OmniLink 5000 software and retrofitting
the new communications board. Port 5 is the
network port and should be wired as follows:
REF - Green/White and White/Green
RXD+ - Orange/White
RXD- - White/Orange
TXD+ - Blue/White
TXD- - White/Blue
If another kind of RS-232 to RS-485 converter
is used, it should be set up in the following manner:
1) If configurable, transmit should always be
on.
2) TX+ should connect to RXD+ on the drop
box (Orange/White wire).
3) TX- should connect to RXD- on the drop
box (White/Orange wire).
4) RX+ should connect to TXD+ on the drop
box (Blue/White wire).
Figure 2.2:
2.3
OmniLink 5000 OIT Backpanel
manual rev 2.1 March 25, 1999
2.3 System 1100 Connections
System 1100 tonnage monitors with software
versions older than version 3.2 in the operator
interface board (the circuit board that is mounted on
the door of the 1100) will need to have a software
upgrade in order to function with LinkNet. Contact
Link for the appropriate software. Appendix “A”
has complete instructions for upgrading the
software. The System 1100 has 3 terminal strips on
the circuit board mounted to the door of the unit,
two of which should already be wired. The
“NETWORK” port (see Figure 2.3) should be
wired as follows:
Terminal A - Green/White and White/Green
Terminal B - White/Blue
Terminal C - Blue/White
Terminal D - White/Orange
Terminal E - Orange/White
LinkNet
box has. This circuitry allows the network to extend
over 4000ft and can allow more than 32 units to be
attached to the line.
Drop boxes have three sets of plugable terminal
strips labeled “DATA IN”, “DATA OUT”, and
“UNIT”. The terminal strip labeled “DATA IN”
should be connected to the wire coming from the
host computer side, “DATA OUT” should go to the
next drop box, and “UNIT” should go to the Link
equipment on the press. All three connectors should
be wired as follows:
GND - Green/White and White/Green
RXD+ - Orange/White
RXD- - White/Orange
TXD+ - Blue/White
TXD- - White/Blue
SHLD - Shield (bare) Wire of Cable
For Repeaters Only:
Figure 2.3:
System 1100 Door Circuit Board
2.4 Drop Box Terminals
There are two kinds of drop boxes, regular and
repeater.
Regular drop boxes (Figure 2.4) simply have
connectors for field wiring to pass the
communication signals through.
Repeater drop boxes (Figure 2.5) have active
circuitry in addition to the terminals the regular drop
L1 - “Hot” side of 110V AC
L2 - “Neutral” side of 110V AC
M. GND - Machine Ground
Some older versions of the drop box do not
have the “SHLD” terminal. In this case, tie the
shields of all the cables together with a wire
nut.
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manual rev 2.1 March 25, 1999
Figure 2.4:
Regular Drop Box Connectors
LinkNet
2.5 Software Installation
Once the wiring is completed, the software on
the host computer must be installed. Insert the
LinkNet compact disk (CD) in the computers CDROM drive. If “Auto Insert Notification” is enabled
for the drive (it is by default), then the LinkNet
installation program will automatically start when
the CD is inserted. If for some reason “Auto Insert
Notification” is not enabled, hit the “Start” button
on the desktop, select “Run...”, and when prompted
for the name of the program to run type
“D:\SETUP” (without the quotes) and hit the “OK”
button. Note that the “D” in “D:\SETUP” should be
the drive letter of your CD-ROM drive.
The installation program will ask where to put
the LinkNet files. It is strongly recommended that
the default directory be accepted. Program and data
files will then be installed.
Figure 2.5:
Repeater Drop Box Connections
Whenever possible, the drop boxes should be
mounted on the press in easy reach for
troubleshooting purposes. In addition, the length of
the line from the drop box to the Link equipment
should be kept as short as is reasonably possible.
The drop boxes have knockouts sized for ½”
conduit or cord grips.
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The installation program will create a new
program group called “LinkNet” and will put a
LinkNet icon on the windows desktop. To start
LinkNet, double click on the icon on the desktop, or
select it from the programs menu by hitting the
Windows “Start” button, then “Programs”, then the
“LinkNet” group, and then the “LinkNet” selection
in that group.
LinkNet
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3. Configuration
After the software is installed, it must be
configured. This consists of the following steps:
d
Select a communications port for LinkNet to use
to “talk” to the presses.
d
Set the number, days, and starting times of
shifts.
d
Enter down time codes and their descriptions.
d
Tell LinkNet what machines are present.
d
Tell LinkNet what dies are present.
d
Configure Preventive maintenance.
LinkNet
Figure 3.1: Configuration Menu
3.1 Configuring the Comm Port
LinkNet uses a standard RS-232 serial port
(commonly called a “comm port”) to communicate
with the machines on the factory floor via an
external RS-232 to RS-485 converter. No boards
have t o be installed or configured on the host
computer. There are typically two comm ports
installed in most computers, “COM1" and “COM2".
A spare comm port must be available for LinkNet to
use.
Select “Configure” and then “Comm Port” from
the menu in LinkNet as shown in Figure 3.1 and a
dialog box similar to Figure 3.2 should appear. Note
that only comm ports that are not currently in use
(by anything other than LinkNet itself) show up in
the list. Pick the comm port that will be used by
LinkNet from the list and click on the “OK” button.
Figure 3.2: Comm Port Selection Dialog
3.2 Configuring Shifts
LinkNet collects information only while in a
shift. This keeps the system from needlessly filling
up the hard drive with information not related to
production and lets many types of information be
tracked by shift. The relative performance of
different shifts can then be compared and analyzed.
To configure shifts, select “Configure” and then
“Shifts” from the LinkNet menu as shown in Figure
3.1. A dialog similar to Figure 3.3 should appear.
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manual rev 2.1 March 25, 1999
Figure 3.3:
Shift Configuration Dialog
Each day may have up to three shifts
configured. The “Use This Shift” checkbox by each
shift determines whether or not the shift will be used
for that day. Note that a shift can be used some
days and not others - each day is individually
configurable. Also note that each starting time can
be on the day before the current day, and that each
ending time can be on the day following the current
day. This allows the flexibilit y to assign a shift to a
day on which it does not necessarily start or end.
For example, it may be desired to have a shift that
starts at 10PM on Monday and runs until 6AM on
Tuesday to be considered a Tuesday shift. Likewise,
a shift that starts a 6PM on Monday and runs until
2AM on Tuesday can be considered a Monday shift.
LinkNet
same day or across days. If any shifts overlap in
time, a message will be displayed indicating which
days have a problem.
3.3 Configuring Down Time Codes
Down time codes (DTCs) are numeric values
that have a user assigned meaning attached to them.
These codes allow the user to track the uptime,
downtime, and usage of each press. Each DTC has
a user entered description that is downloaded to the
Link equipment on the presses. When a machine has
to be stopped (or is stopped by monitoring
equipment such as tonnage monitors, die protection,
and so on) the operator can enter the reason for the
stop by selecting one of the DTC descriptions that
were downloaded to the press.
The time spent in a DTC is logged by LinkNet
into a database that can be viewed and analyzed.
Problem spots (such as repeated problems with a
feed, material, lubrication, etc.) can be easily
identified by the percentage of down time that they
cause. This enables supervisors to target limited
time, money, and other resources at the areas that
will do the most good in terms of production.
To configure down time codes, select
“Configure” and then “Down Time Codes” as shown
in Figure 3.1. A dialog box similar to Figure 3.4
should appear.
NOTE: Each day except Monday has a “Set
Same as Monday” button. Since the typical
case is for Monday through Friday to have the
same shift times, set the shift times for Monday
first, and then go to each day that should be the
same as Monday and hit the “Set Same as
Monday” button to copy the shift times over to
that day. Any other days can be set according
to need.
The starting and ending time of each shift can be
configured in 10 minute intervals. Use the up and
down arrows next to the hour, minute, and AM/PM
boxes to change each setting. When the shifts are
configured as desired, click on the “OK” button.
No two shifts may overlap in time either on the
Figure 3.4:
DTC Configuration List
This dialog allows DTCs to be added, edited, or
deleted.
After all additions and changes have been made,
click the “OK” button. The DTC descriptions will
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manual rev 2.1 March 25, 1999
LinkNet
then be sent to each press on the network
automatically.
3.3.1 Adding a Down Time Code
To Add a DTC, click on the “Add DTC” button.
A dialog box similar to Figure 3.5 should appear.
Figure 3.5:
Add/Edit DTC Dialog Box
By default the DTC number is the next available
number, but may be changed to any unused number
between 1 and 250 if desired. Up to 25 characters
can be entered for the DTC description, but note
that the System 1100 can only display the first 19
characters. In addition, a down time category can be
assigned. Available categories are Miscellaneous,
Die Change Related, Press Related, Die Related,
Feed Related, Straightener Related, Material
Related, and Scheduled Maintenance. When
viewing a down time report, the down time
percentages will be shown by individual down time
code and by category.
information in the database has been stored. If the
DTC needs to be changed, delete the old DTC and
add a new one with the desired number.
3.3.3 Deleting a Down Time Code
To delete a DTC, select a DTC from the list (see
Figure 3.4) and click on the “Delete DTC” button.
A message will appear indicating that the select ed
DTC is about to be deleted and will ask for
confirmation. Click the “Yes” button to delete the
DTC or the “No” button to keep the DTC.
3.4 Configuring Machines
Since the same network cable is shared by each
machine on the network, LinkNet uses a machine
number to identify the particular press that it wants
to “talk” to. Each machine on the network must
therefore be assigned a unique non-zero number.
Before a piece of Link equipment can “talk” to
LinkNet, it must be assigned a machine number.
Refer to section 6.1 for details on how to set the
machine number for OmniLink 5000 press
automation controls, and section 7.1 for System
1100 tonnage monitors.
3.4.1 Adding a Machine to LinkNet
When the machine numbers of each unit
connected to the network have been entered,
LinkNet must be told what they are. Select
“Configure” from the main LinkNet menu as shown
in Figure 3.1, then select “Machine” and a dialog
box similar to Figure 3.6 should appear.
3.3.2 Editing a Down Time Code
To Edit a DTC, select a DTC from the list (see
Figure 3.4) and click on the “Edit DTC” button.
The dialog box of Figure 3.5 will appear but will not
allow the DTC number to be changed - only the
description and category. This is to prevent
accidental changes that would affect the way
3.3
manual rev 2.1 March 25, 1999
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