LINK Systems OmniLink 5000 User Manual

System 5000

Press Control

COLOR DISPLAY

OPERATING MANUAL

OmniLink 5000

LINK ELECTRIC & SAFETY CONTROL COMPANY

444 McNALLY DRIVE, NASHVILLE TN 37211

PH (615)-833-4168 FAX [phone]

TABLE OF CONTENTS

Section 1 Introduction ...........................................................1.1

Section 1.1 System Overview ................................................. 1.1

Section 2 Operator Terminal ......................................................2.1

Section 2.1 LCD Description .................................................2.1

Section 2.2 ACC Key.......................................................2.2

Section 2.3 CHG Key.......................................................2.2

Section 2.4 Arrow keys ..................................................... 2.2

Section 2.5 Program/Run Switch ..............................................2.2

Section 2.6 Numeric Data Entry...............................................2.2

Section 2.7 Alphanumeric Data Entry........................................... 2.3

Section 2.8 Automatic LCD Turn Off...........................................2.3

Section 3 Access Control .........................................................3.1

Section 3.1 Description ..................................................... 3.1

Section 3.1.1 Key Only Mode ........................................... 3.1

Section 3.1.2 Key or Password Mode .....................................3.1

Section 3.1.3 Password Only Mode.......................................3.2

Section 3.1.4 Key and Password Mode ....................................3.2

Section 3.2 Restricted Items ............................................3.3

Section 3.3 Access Control Operation .......................................... 3.4

Section 3.3.1 Program/Run Key Switch Operation ...........................3.4

Section 3.3.2 Password System Operation..................................3.5

Section 4 Operating Menus .......................................................4.1

Section 4.1 Main Menu .....................................................4.1

Section 4.2 Press Control Menu ...............................................4.2

Section 4.2.1 Brake Monitor............................................4.3

Section 4.2.2 Clutch Time..............................................4.3

Section 4.2.3 Automatic Single Stroke Time................................ 4.3

Section 4.2.4 Feed Complete Position.....................................4.4

Section 4.2.5 Continuous on Demand Time.................................4.4

Section 4.2.6 Au xiliary Equip ment M essage ................................4.4

Section 4.2.7 Reason For The Last Stop ...................................4.5

Section 4.2.8 Present Running Status .....................................4.5

Section 4.2.9 Diagnostics .............................................. 4.5

Section 4.2.9.1 Input Diagnostics ..................................4.5

Section 4.2.9.2 Output Diagnostics .................................4.6

Section 4.2.9.3 Press Control Memory Test...........................4.6

Section 4.2.9.4 Event Log........................................4.8

Section 4.2.9.5 Version Information ................................4.8

Section 4.2.10 RESET ERROR .........................................4.8

Section 4.2.11 Press Operator Station.....................................4.9

Section 4.3 Stroke Mode Selection .............................................4.9

i

Section 4.3.1 Setup/Stop Time Test ..................................... 4.10

Section 4.3.2 Timed Inch (When Provided) ...............................4.11

Section 4.3.3 Inch...................................................4.11

Section 4.3.4 Single Stroke............................................ 4.11

Section 4.3.5 Continuous ............................................. 4.11

Section 4.3.6 Automatic Single Stroke (When Provided) .....................4.12

Section 4.3.7 Continuous on Demand (When Provided) ...................... 4.12

Section 4.3.8 Maintain Continuous (When Provided) ........................ 4.13

Section 4.4 Programmable Limit Switch........................................ 4.13

Section 4.4.1 Bypass Output On/Off..................................... 4.14

Section 4.4.2 Change Output .......................................... 4.15

Section 4.4.3 Change Name ........................................... 4.15

Section 4.4.4 Restricted PLS Channels ................................... 4.17

Section 4.4.5 Counted Outputs......................................... 4.17

Section 4.5 Job Setups..................................................... 4.17

Section 4.5.1 Store Setup............................................. 4.18

Section 4.5.2 Recall Setup ............................................ 4.18

Section 4.5.3 Erase Setup............................................. 4.20

Section 4.6 Counters ...................................................... 4.20

Section 4.6.1 Production Counters ...................................... 4.21

Section 4.6.1.1 Production Counters On/OFF ........................ 4.22

Section 4.6.1.2 Production Counters Change Limit.................... 4.22

Section 4.6.1.3 Production Counters Reset .......................... 4.22

Section 4.6.1.4 Production Counters Increment/Decrement.............. 4.22

Section 4.6.1.5 Production Counters Change Count ................... 4.23

Section 4.6.2 Stroke Counter .......................................... 4.23

Section 4.6.3 Scrap Counter, Scrap Rate ................................. 4.23

Section 4.6.4 Configure Counters....................................... 4.24

Section 4.6.4. 1 Configur e Auxiliary Coun ter Names ................... 4.25

Section 4.6.4.2 Configure Counter Count By Value ................... 4.25

Section 4.6.4.3 Configure Counter Every How Many Stroke Value........ 4.25

Section 4.6.4.4 Configure Counter Reset When Order Counter Reset ...... 4.26

Section 4.6.4.5 Configure Counter Enable ..........................4.26

Section 4.6.4.6 Configure Reset Counters When Job Recalled............ 4.26

Section 4.7 Motor Speed Adjustment (When Provided)............................ 4.26

Section 4.8 Quick Access (ACC key).......................................... 4.27

Section 4.8.1 Machine Notes .......................................... 4.28

Section 4.8.2 Job Notes .............................................. 4.28

Section 4.8.3 Editing Machine Notes and Job Notes......................... 4.28

Section 4.8.4 Au xiliary Communications .................................. 4.29

Section 4.8.5 LOGOUT Softkey ........................................ 4.29

Section 5 Press Control Configuration Menus ........................................5.1

Section 5.1 Top Stop Calibration.............................................. 5.2

Section 5.1.1 Top Stop Calibration, Link Standard........................... 5.2

Section 5.1.1.1 Variable Speed Presses, Link Standard ..................5.4

ii

Section 5.1.1.2 Single Speed Presses, Link Standard ....................5.5

Section 5.1.2 Top Stop Calibration, Link High Speed .........................5.5

Section 5.1.2.1 Variable Speed Presses, Link High Speed................5.7

Section 5.1.2.2 Single Speed Presses, Link High Speed ..................5.8

Section 5.1.3 Stop Angle (Setup Mode) ...................................5.8

Section 5.2 Machine Parameters...............................................5.8

Section 5.2.1 Encoder Offset ...........................................5.9

Section 5.2.2 Automatic Carry Up Position.................................5.9

Section 5.2.3 Begin Timed Inch Position ...................................5.9

Section 5.2.4 Minimum Strokes/Minute ...................................5.9

Section 5.2.5 Maximum Strokes/Minute ..................................5.10

Section 5.2.6 Motion Filter ............................................5.10

Section 5.2.7 Clutch Engagement Time ...................................5.10

Section 5.2.8 Timed Inch Pulse.........................................5.10

Section 5.2.9 Automatic Turn Off.......................................5.10

Section 5.2.10 Maximum # Engagements per Minute ........................5.11

Section 5.2.11 Top Stroke Stop Time ....................................5.11

Section 5.2.12 Mid Stroke Stop Time ....................................5.11

Section 5.2.13 Machine Speeds.........................................5.11

Section 5.2.13.1 Maximum Strokes/Minute ..........................5.12

Section 5.2.13.2 Fixed Inch Spm..................................5.12

Section 5.2.13.3 Max Single Spm .................................5.12

Section 5.2.13.4 Flywheel Brake Tolerance ..........................5.13

Section 5.2.13.5 Minimum Entry..................................5.13

Section 5.2.13.6 Option Control ..................................5.13

Section 5.2.13.7 Continuous Modes Control .........................5.13

Section 5.2.13.8 Low Spm Input Offset.............................5.14

Section 5.2.13.9 Low Output Spm ................................5.14

Section 5.2.13.10 Low Output Calibration # .........................5.14

Section 5.2.13.11 Mid Output Spm ................................5.14

Section 5.2.13.12 Mid Output Calibration #..........................5.14

Section 5.2.13.13 High Output Spm ...............................5.15

Section 5.2.13.14 Output Calibration # .............................5.15

Section 5.3 Lube System ...................................................5.15

Section 5.3.1 Au xiliary Lube Systems ( option) .............................5.16

Section 5.4 Operator Terminal Configuration ....................................5.16

Section 5.4.1 Display Type ............................................5.16

Section 5.4.2 Time and Date...........................................5.17

Section 5.4.3 Rod Length and Stroke Length ..............................5.17

Section 5.4.4 Operator Terminal Type and Default Language ..................5.17

Section 5.4.5 Zero Stroke Count........................................5.17

Section 5.4.6 Access Configuration......................................5.18

Section 5.4.6.1 Access Mode Configuration .........................5.18

Section 5.4.6.2 Access Timeout...................................5.19

Section 5.4.6.3 Edit User........................................5.19

Section 5.4.6.4 Set Configuration Code.............................5.21

iii

Section 5.4.7 Conf igu re Au xiliary Communications ......................... 5.21

Section 5.6 Output Names/Messages .......................................... 5.22

Section 5.6.1 Input Names (option) ..................................... 5.22

Section 5.6.2 Aux. Equipment Messages ................................. 5.23

Section 6 Press Control I/O ....................................................... 6.1

Section 6.1 Press Control Inputs ..............................................6.1

Section 6.1.1 Run Buttons .............................................6.2

Section 6.1.2 Operator Station Selects .................................... 6.3

Section 6.1.3 Prior Action Setup Buttons .................................. 6.3

Section 6.1.4 Top Stops ............................................... 6.3

Section 6.1.5 Emergency Stops ......................................... 6.3

Section 6.1.6 Master Stops............................................. 6.3

Section 6.1.7 Forward/Reverse Motor Contacts .............................6.4

Section 6.1.8 Mode Selector Switch...................................... 6.4

Section 6.1.9 Press Line Interface........................................ 6.4

Section 6.1.10 Valve Monitor........................................... 6.4

Section 6.1.11 Lube System I/O ......................................... 6.7

Section 6.1.12 Hydraulic Overload I/O................................... 6.12

Section 6.1.13 Light Curtain........................................... 6.14

Section 6.2 Press Control Inputs (option)....................................... 6.15

Section 6.2.1 Aux. Lube System I/O..................................... 6.16

Section 6.2.2 Run Mode Interlocks...................................... 6.18

Section 6.2.3 Input Board #3 Select .....................................6.18

Section 6.2.4 Definable Top Stops ...................................... 6.18

Section 6.2.5 Definable Cycle Stops ..................................... 6.18

Section 6.2.6 Definable Master Stops ....................................6.19

Section 6.2.7 Continuous on Demand Run ................................ 6.19

Section 6.3 Press Control Outputs ............................................ 6.19

Section 6.3.1 Delayed Main Motor...................................... 6.20

Section 6.3.2 Flywheel Brake .......................................... 6.20

Section 6.3.3 Au xiliary Equip ment Sto p .................................. 6.20

Section 6.3.4 Slide Motion ............................................ 6.21

Section 6.3.5 Mode Outputs........................................... 6.21

Section 6.3.6 Stroking Enabled ......................................... 6.21

Section 6.3.7 Stop At Top Output ...................................... 6.22

Section 7 Installation ............................................................ 7.1

Section 7.1 Component Mounting .............................................7.1

Section 7.2 Field Wiring ..................................................... 7.5

Section 7.2.1 Operator Terminal/Card Rack ................................ 7.5

Section 7.2.2 Clutch/Brake Valve........................................ 7.6

Section 7.2.3 Resolver/Encoder ......................................... 7.6

Section 7.2.4 Inputs ..................................................7.7

Section 7.2.5 Outputs................................................. 7.8

Section 7.2.6 Flywheel Speed........................................... 7.9

iv

Section 7.2.7 Motor Current...........................................7.10

Section 7.3 Calibrating Flywheel Speed Interface .................................7.10

Section 7.3.1 Calibrating Flywheel Speed Display...........................7.12

Section 7.4 Communication Option ........................................... 7.13

Section 7.5 System Startup..................................................7.13

Section 7.6 Power Requirements/Fuses.........................................7.15

Section 8 Troubleshooting ........................................................8.1

Section 8.1 Error Messages ..................................................8.1

Section 8.2 External Faults...................................................8.3

Section 8.3 Internal Faults ...................................................8.4

Section 8.4 Diagnostic Leds ..................................................8.6

Section 9 ......................................................................9.1

Section 9.1 Software Version.................................................9.1

Section 9.2 Configuration Code and Clear Stroke Counter/Memory Code ...............9.1

v

Section 1 Introduc tion

The Sy stem 5000 Press Control i s design ed specif ical ly for use on part revolution mech anical power presses.
Two separately powered microprocessor systems each perf orm clutch/brake control logic i ndependen tly an d
cross communicate with each other to check control agreement. All inputs are isolated and read
independently by each channel. A combination resolver and encoder assembly is read and checked
indepen dentl y by each chann el . Power to the clutch/brake air valve(s) passes through three separate output
relays, whose co ntact s are checked by the two hardware independe nt logic systems. All safety critical
clutch/brake f un c ti on logic is stored in EPROM memory. In addition, the following features are provided:

The Operator Terminal includes a graphi c liquid crystal color displ a y with 7.3 in x 5.7 in viewing area, and
a sealed m em brane key board with tactile f eedback. Thi s Operator Termi nal di splay s in Engli sh and Spani sh.
The display language can be changed by one key stroke.

Eight programma bl e l imi t switch outputs standard, expandabl e to sixteen. Each output can be programm ed
with a 20 character description for easier operator interface.

Ten production counters ar e st andard.

Job storage for up t o 500 jobs is standard.

The keyed str o king selector allows selection of up to eight stro king modes thro ugh the operato r terminal.
Setup modes include Inch, Timed Inch, and Setup/St o p modes. Product ion modes include Single Stroke,
Continuous, Automatic Single Str oke, Continuous on Demand, and Maintain Continuous modes.

Automatically adjusted top st op for variable speed presses is standard.

Section 1.1 Sy st em Overview

Figure 1.1 shows the components that are contained in the System 5000, consisting of the following:

-OmniL ink LCD color oper ator ter minal.

-Press cont rol card rack.

-Relay or so lid state output modules (up to 4 banks of 8).

-Resolver/opt ical encoder assembly.

-Connections for field wiring necessary to oper ate machine.

-Optional expansion rack for additional cards.

1.1

Figure 1.1 System Components

1.2

Section 2 Operator Terminal

Section 2.1 LCD Description

Figure 2.1 shows the operator terminal front panel. This panel consi sts of a color LCD displ ay, key pad, and
key switch.

2P QL/LQN ,, /&'

23(5$725 7(50,1$/

MOTOR
SPEED

SPM
0

0

Stroke

Mode

% LOAD
0

Single Stroke Speed

Drive
Speed
Stroke

JOB NUMBER DESCRIPTION
100000 FRONT BRACKET

COUNTER LIMIT QUANTITY STATE
ORDER 2000 7 ON

BATCH 500 7 ON

SPM

0

Counter

SPM

0

STATUS :
ALL CONDITIONS OKAY

STATUS :
ALL CONDITIONS OKAY

STATUS :
ALL CONDITIONS OKAY

STATUS :
ALL CONDITIONS OKAY

Order

Counter OFF

PC STATUS

READ Y TO STROK E

MAIN
MENU

PRESS
CONTROL

AUTO
SETS

TONNAGE
MONITOR

DIE
PROTEC TI O N

LIMIT
SWITCH

JOB
SETUP S

COUNTERS

Figure 2.1 OmniLink Color LCD Operator Terminal

The color li quid crystal display (LCD) is divided into fixed areas. Cranks haft position and current stroking
mode o f the press are displayed in the upper left hand cor ner of the color LCD screen. The cra nkshaft
position information is updated 10 times a second. Thi s angular position is di s played in both graphical and
numeri cal f ormat. For speeds less than sixty strokes per minute, the pointer which is en closed i n a ci rcle wi ll
rotate to visual ly i n di cate the angular positi on of the crankshaf t and top and bottom of stroke indi cators will
appear. For eccentric driv e presses the top dead center of the stroke is equival ent to 0 degrees. The bottom
dead center of the stroke is always 180 degrees. In addition to the rotating pointer, there is a rectangular box
enclosed i n the ci rcle. Wh en the sli de i s stopped at the top of the stroke, within +/- 5 degrees of top, this box
will be g re e n w ith the let t e r s “T OP ” . When t he slide is st o p p ed at t he bot t om of t he s t r o k e, w it hin +/ - 5
degrees of bottom dead center, the box will b e y ellow wi th the l etters “BOT”. For speeds greater than sixty
strokes per mi nute, two rotating arrows will appear in the circle. These rotating arrows indicate crankshaf t
motion.

The remainder of the to p po rt ion of the screen displays four user selected items. These four user selected
items can be chosen by the user from a list of ten. These ten items are:

-Drive Speed

-Stroking Speed

-Auto Pr ess Speed (Drive speed when press is not st ro king and crankshaft speed when press is
stroking

-Press Control Status

2.1

-Press Control Reason for Last Stop

-Total Tonnage (If the control is equipped with a tonnage monitor)

-Counterbalance Pressure (If the control is equipped with automatic counterbalance adjust)

-Shut Height (If the control is equipped wit h automatic shut height adjust)

-Current Order Count

-Current Down Time Code
These four items are al so mode dependent. The user has the option to chose four items for setup modes, Inch
and Timed Inch modes, and four different items for pr oduction modes.

Areas along the right side of the display and the bot tom of the display provide legends for t he softkeys
located to the right of the LCD and botto m of the LCD, and a quick referenc e t o the menu selected. The
operat o r selects t he desired menu item by pressing the so ftkey next to it. T he largest area is available for
showing cont r ol and process information and is dependant on the present task being performed.

Section 2.2 ACC Key

This i s a qui ck access key . This key will supply direct access f rom any m enu to the Quick A ccess me nu. The
quick access menu contains mach ine notes, die notes, access to Down Time codes, nam e of current logged
in user, l og out softkey, and access to auxiliary communications. See Section 4.8 for a detailed description
of these functions.

Section 2.3 CHG Key

This chan ges the display l an guage f rom Engl i s h to a second language. For exam pl e, if the second language
is Spanis h, de pressing the CHG ke y will switch the displa y languag e from Eng lish to S pa nish. Depr essing
t he CHG key a ga in will re turn the display la n guage to English.

Section 2.4 Arrow keys

The up, down, left, and right a r r o w k eys are used to select items on a given display page. The LCD will
highligh t an area (called a cursor) in order to inform an operator which item is selected. The operator may
select another item by using the arrow keys to position the cursor .

Section 2.5 Program/Run Switch

This is a keyed selecto r switch read directly by the press contro l. The PROG position causes the press to
per form a Top Stop, and prevents str oke ini tiation unti l the switch is returne d to the RUN p osition . T here
are several user access modes that wil l require the operator to turn the keyed selector to PROG position in
order to modify parameters. This switch must be in the PROG position for co ntrol configuration, as
described in Section 5.

Section 2.6 Numeric Data Entry

Certain param eters m ay be entered into the operator termi nal in the program mode. An item to be changed
is highlighted. If the parameter contains a decimal point, it will be positioned automatically by the operator
terminal. The new number is entered with the numeric keypad and pressing ENT. The CLR key will clear

2.2

the present number being entered, and the entry process is aborted by pressing the EXIT softkey or one of
t he arrow ke ys. The numeric da ta will not change from the previous value if th e entry pro ce ss is ab orted.

Section 2.7 Alphanumeric Data Entry

It e ms t ha t re qu ir e t h e e nt r y o f bo t h let t e rs and nu mber s will a ut o mat ic ally p ro vid e th e T ex t E nt r y men u
shown i n Figure 2.2. Letters are selected by us i ng the l e f t and righ t arrow keys to position the letter pointer
under th e desi red l etter, then pressi ng the SELECT L ETTER softkey . If the l eft or ri ght a rrow key is presse d
and held, the pointer will automatically move to successive letters. Upper or lower case letters can be
selected by the LOWER CASE/UPPER CASE softkey. If upper case letters are curr ently being displayed
i n the tex t box , pre ss i ng th e L OW ER C AS E sof tke y wi l l ch an ge th e te xt b ox to l ow er c ase le tters . To cha ng e
a previous entered character, use the CURSOR LEFT and CURSOR RIGHT softkeys to position the data
entry line cursor over t he letter t o be changed and then select the new character. A space is inserted each
time the SPACE softkey i s pressed, and the CLR key cl ears all ch aracters that have been entered. Numbers
are entered directly from the numeric keypad. The entry process is aborted if the ABORT EDIT softkey is
pressed, leaving the previous data intact. The new description is accepted when the ENT key is pressed.

0

Stroke

Mode

0

Single Stroke

Use Keys to select let t er
Press ENT to save text

ABCDEFGHIJKLMNOPQRSTUVWXYZ.+-=()%<>/

Drive

Speed
Stroke

Speed

SPM

0
0

SPM

Order

Counter

Status:

Counter OFF

TEXT
ENTRY

ABORT
EDIT

CURSOR
LEFT

CURSOR
RIGHT

SPACE

SELECT
LETTER

EXIT

LOWER
CASE

UPPER
CASE

Figure 2.2 Alphanumeric Data Entry

Section 2.8 Aut omat ic LCD Tu rn Off

To i n cre a se the l i f e of th e L C D b ac kli gh t, th e b ac kl i g h t wi ll au tom a ti ca l l y tu rn of f ten m i n u tes af te r th e pre ss
main motor is turned off unless the Program/Run switch is in the PROG position or the mode selector is in
the MO DE SEL EC T pos i ti on . T he b ac kl igh t i s tur ne d b a ck on an d th e ten m i n u te ti mer res e t any ti m e a key
is pressed on the operator ter minal.

2.3

Section 3 Access Control

Section 3.1 Description

The Om ni Li n k control has sev eral param eters or operations that have lim ited access. The ability to perform
actions such as job recall, job storage, o r changing a tonnage monito r channel limits must be rest r ic t ed to
cer ta in personnel. The OmniLink control provides several means to limit access to these paramet er s o r
operations. A complete list of the parameters and operations that have li mi ted access is l isted in Section 3.2.
The items in Section 3.2 are called restricted items.

In addition to the restricted items listed in Section 3.2, there are other parameters that have l imited access.
These parameters, such as top stop angles and brake m onitor settings, are n ot li sted i n the tabl e of restricted
items. These ot her items are called configuration parameters. Access to the co nfiguration parameters is
protected by the Program/Run key and the Configuration code. Configuration parameters and their
programming are described in Section 5 of this manual. Access cont ro l will grant access only to the items
liste d in Section 3. 2.

The Omni Link control empl oys combin ations of two diff erent means to lim it access to restricted i tems. These
means are the Program/Run key switch and a user passwor d syst em. T he user password system assigns
names an d passwords to up to sixteen users. These two means can be used alone or in comb ination with each
other. When a user em pl oy s the proper means to gain access control, he will have the ability to perform the
actions and change the parameter s which have been designated to his access.

There are four possible m odes of operation for the restricted access system. They are the “Key Only” mode,
the “Key or Pa s sw ord” mode, the “Password Only ” mode, and the “Key and Password” mode. The control
can be configured to operate in any o ne of these four modes.

Section 3.1.1 Key Only Mode

The “Key Only” mode is the least complex of the four modes. This mode employs the Program/Run key as
the only means to limit access to restricted items. Any user with the Program/Run key can access all of the
restricted items. Without t he Pr ogram/Run key, user access to all of the restricted items is pro hibited.

Although the “Key Only” mode has the advantage of being easy to use, it does have a disadvantage. T his
mode cannot give a particul ar user access to only some of the restricted items. When operating i n thi s mode,
any us er with th e Progr am/Run key will ha ve access to all of the restricted items.

Section 3.1.2 Key or Password Mode

The key or password mode allows for either of two means to gain access to the restricted items. A user with
Pro g r am/ Ru n k ey can access all of the restricted items. A user wit h the cor rect passwo rd can access the
restricted items that have been designated for t he part icular user ’s access only. The system allows for
passwords to be assigned to sixteen users. Each user can be assigned access to any or all of the restricted
items.

The foll owi ng i s an ex am pl e of a “Key or Pa ss wor d” mode operation. The Program/Run key is given to the

3.1

die s et-up perso nnel. A press operato r is assigned a user name and password. With the passwor d t he
operator can reset tonnage moni tor faults, reset die protection faults, and reset counters. These are the onl y
thr ee items to which the operato r has access. In order t o load a die, the set-up per sonnel must use t he
Progr am/Run key to recall a job from job storage. The set-up personnel will also be able to make changes
to pr ogram m ab l e li m i t s wi tch se tti ng s, ton n age m oni tor s etti ng s, a nd di e pr otecti on se ttin gs . On ce the s et-up
personnel sets the die and verifies it s c orr ect operat ion, the operat or is left to run the die. If a tonnage
monito r fault occ u r s, t he operat o r can enter t he cor rect passwo rd and then reset t he fault. However, t he
o pe ra tor cannot ch ange a tonnag e monitor limit . This will allow t he operato r to ke ep runn ing t he job an d
reset faults that occur. However, if consi s tent stops occur because a tonnage m oni tor high setpoint is b ei ng
exceeded, the set-up personnel m ust be called to change the tonnage m onitor li mit, if i t has b een determi n ed
that t he limit should be increased.

The example above can be taken one additional step, if two press op er ators are given different user names
and differ ent pas swo rd s. O ne o per at or c an be assig ned the abilit y to chan ge t onn age monit or limits in
addit io n t o t he a b ility to rese t the t onnag e mo nit o r , w hile the o t he r o p er a t o r is no t as signed t he a bility t o
change the tonnage monitor limits. The control will allow for sixteen users each with a user nam e, password,
and access to selected or all rest ricted items.

Section 3.1.3 Password Only Mode

The “Password Only ” m ode all ows for six teen users. Each user can be assign ed access to some or all of the
restricted items. This mode does not use the Program/Run key.

The example listed above indicated that setup personnel required access to all restricted parameters. In the
“Key or Password” mode, the setup personnel used the Program/Run key to gain access to all of the
restricted parameters. In the “Password O nly” mode, the setup personnel can sti ll hav e access to all of the
restricted parameter s, but the system must be configured as such. The setup personnel must be assigned a
user name and password. In addition, all restricted items would be assigned access to t he set up perso nnel.

Since there is no access to all r est rict ed items with the Pro gram/Run key, every restr icted item must be
assigned to at least one user. I f any restricted item is not assigned to at least one o f the users, it cannot be
accessed. For example, i f Erase Jobs is n ot assigned to at least one user, it will be impossible to perform the
erase job function. Access to the Erase Jo bs must be assigned to at least o ne user, before t he erase job
funct ion can be performed .

Section 3.1.4 Key and Password Mode

The “Key and Password” mode requires the user to have the Program/Run key, user name, and user
password. Operation is basically the same as the Password only mode, except t hat in addition to entering
the password the user must switch the Program/Run key to the PROG position.

Since there is n o access to all restricted items wi th the Program/Run key onl y , every restricted item must be
assigned at least one user. If any restricted item is not assigned to at least one of the users, it can never be
accessed.

3.2

Section 3.2 Rest ricted It ems

The following table lists the restr icted items name and function.

RESTRICTED ITEMS

NUMBER NAME FUNCTION
1 PLS Bypass Bypass Prog rammable Limit Switch outputs
2 PLS Settings/N ames Change Programmable Limit Swit c h set points and

names
3 TM Bypass Bypass the Tonnage Monitor
4 TM Reset Reset the Tonnage Monitor
5 TM Peak High Limits Change the Tonnage Monitor high limits
6 TM Peak Low Limits Change the Tonnage Monitor low limits
7 TM Peak Reverse Limits Change the Tonnage Monitor reverse limits
8 TM Auto Setup Perform a Tonnage Monitor automatic limit setup
9 TM Dat a Windows Change the To nnage Monitor dat a window ang les and

limits
10 DP Bypass Bypass the Die Protect ion
11 DP Reset Reset the Die Protection
12 DP Settings Change the Die Protection settings
13 Auto Setup Reset Reset automatic air adjust and shut height adjust faults
14 Auto Set up S ettings Change the automatic air adjust and shut height adjust

settings
15 Counter Reset Reset counters that have reached their limit
16 Counter Settings Change counter limits. T ur n count ers off and on
17 Counter Change Change the current counter value. Increase current

count value by one (Increment). Decrease cur r ent

count value by one (Decrement). I ncrease scrap count

by one (Increment Scrap) . Decr ease scr ap count by one

(Decrement Scrap).
18 Feed Settings Change feed settings

3.3

19 PLC Screen 1 Sets Change parameters on Screen 1 of the Programmable

Logic Controller Interface

20 PLC Screen 2 Sets Change parameters on Screen 2 of the Programmable

Logic Controller Interface

21 PLC Screen 3 Sets Change parameters on Screen 3 of the Programmable

Logic Controller Interface

22 PLC Screen 4 Sets Change parameters on Screen 4 of the Programmable

Logic Controller Interface
23 Special Inter face Change parameters on the Special Interface Screen
24 Auto SS/COD T ime Change th e Automatic Sin gle Stroke max imum time

bet ween stroke s , t he Co ntinuous on Demand maximum

time between Run cycles, and the Feed Complete Angle
25 Reset Brake Mo nitor Reset Brake Monitor faults
26 Mot or Speed Adjust Adjust motor speed
27 Sto r e Jobs Sto r e jobs in memory, edit Machine Not es and Jo b

Notes
28 Re call Jobs Recall jobs fr om memory
29 Erase Jobs Erase jobs in memory
30 Reserved for future use
31 Reserved for future use
32 Reserved for future use

Section 3.3 Access Cont rol Operation

To gain access contro l the user must use one o f two means or a combinat io n o f these two means. These
means are the Program/Run key or the user password system.

Section 3.3.1 Program/Run Key Switch Operation

The Program/Run key switch is located o n the lower right side of the operat or terminal. This is a two
pos ition s w itc h . T h e k e y is re mova b le in t h e RUN pos ition o nly. If th e P rog r am/ R u n k e y s w itc h is b e ing
used as a means to access the restricted items, the switch must be t u r ned t o the PROG po sition. When the
Pr o g r a m/R u n k e y sw it c h is sw it c he d t o th e P R O G p o s it io n , t he p r es s w ill T o p S t o p a nd str o k in g w ill be
prohibited until th e switch is retur ned to the RUN p ositio n.

When operating in the Key Only mode t he key switch is t he only means available to access the rest ricted

3.4

items. All restricted items are accessible when the Pro gram/ Run key switch is switched to the PROG
position.

When operating in the “Key or Pass word” mode, the key switch is one of the means availabl e to access the
restricted items. All restricted items are accessible when the Program/Run key switch is switched to the
PROG position.

When operating i n the “Key and Password” mode, the key switch and password must be used to access the
re s t r icte d it e ms. I n th is mo d e , t he u ser w ill be g r an t e d access o nly to t he restricted items that have been
assigned to him.

Section 3.3.2 Password System Operation

Figure 3.1 displays a typical password entry sequence. This example shows the steps necessary to change
the motor speed. This is typical for password ent r y for all restricted items.

SPM

0
0

SPM

MOTOR SPEED ……. 200 SPM MOTOR SPEED ……. 200 SPM

LEGEND FOR
SOFTKEY #1

STEP A: SELECTING PARAMETER TO BE CHANGED

SPM

0
0

SPM

MOTOR SPEED ……. 200 SPM

USER NUMBER ONE CODE _______

Order

Counter

PC STATUS

READY TO STROKE

Order

Counter

READY TO STROKE

Counter OFF

PC STATUS

Counter OFF

MOTOR
SPEED

SUPPLY
ACCESS
CODE

SPM
UP

SPM
DOWN

MOTOR
SPEED

CHANGE
NUMBER

SPM
UP

SPM

0
0

SPM

SELECT A USER NAME

USER NUMBER ONE
USER NUMBER TWO
USER NUMBER FIVE

STEP B: SELECTING USER NAME

SPM

0
0

SPM

MOTOR SPEED ……. SPM

Order

Counter

PC STATUS

READY TO STROKE

Order

Counter

READY TO STROKE

Counter OFF

PC STATUS

Counter OFF

MOTOR
SPEED

SELECT

SPM
UP

SPM
DOWN

MOTOR
SPEED

CHANGE
NUMBER

SPM
UP

SPM
DOWN

STEP C: ENTERING USER PASSWORD STEP D: CHANGING PARAMETER

Figure 3.1 Password Entry Sequence

3.5

SPM
DOWN

Step A: Select t he restr icted item. In the example shown in Figure 3.1 the restricted item is Motor

Speed. Once the parameter is selected then Softkey # 1 the upper vertical softkey (Softkey
# 1 is high lighted in Figure 3.1) , will display the legend “SUPPLY ACCESS CODE”. The
operator must press this softkey.

St e p B: A list of u s e rs t h at h a ve ac c e s s t o th is r e str ic t e d it em w ill a p pe a r . I n t he exa mp le

shown in Figure 3.1 only User Number One, User Number Two, and User Number
Five have access to t his restricted parameter. The system may have several more
users, but t he three user s listed on the screen are the only users t hat have access to
Moto r S peed. T he user must use the arrow keys to po sition the curso r o n his user
name. After placin g the cursor on the correct name, the user must press the SELECT
softkey. The SELECT softkey must be pr essed even if there is only one user name
displayed.

Step C: The display will show the selected user name and request the user password. The

user must enter the co r r ect password and t hen depress t he ENT key.

Step D: Upon e nt ry of the c orrect pa sswor d, the user will be allow access to the rest r icted item. In

t he exa mple show n in Figu re 3.1 , the u ser will have access to change motor speed.

After performing the steps listed above, the user will be logged in to the password system. The user will have
access to all restricted items that have been designated for his access. This access will remain until the user
performs a log o ut or until the user is automatically logged out .

The user can log out by u sing the A CC key. This ke y will d irectly switch the disp lay to the Qu ick Access
screen. The LOGOUT soft key legend will appea r a lon g the b ottom of t he screen. If the operator pre sses
t his ke y, h e w ill log ou t. H e w ill n o long er h a ve access t o t he rest ricted items, unless he r ep e a t s s tep s A
through D.

In a dd iti on to the man u al l og ou t, the s ystem contains a n a u tomatic l og ou t. T h e inte nt of a u tomatic log out
is to r e du c e t h e p o s s ib ility o f u s e r s oth e r th a n th e in te nd e d u s e r from ha v ing access to r est ricted items. If
there were no provisions for automatic log out and a user forgot to manually log out, all restricted items to
which the user had been designated for access wo uld be available from the log in time until power was
re mo ved fr om t he Omn iLink co nt r o l. T his pr es en ts t he p o ss ibilit y o f us er s o t h e r t han t he in te nd ed us er
having access to restricted items. Automatic log out is based upon both time and press strokes. During
system conf i guration automatic A ccess Tim eout parameters are entered. An automatic access timeout time
and automatic access timeout strokes are entered. The time en tered is the amount of time after the last key
st ro ke tha t will be allowed befo re t he system will automat ically lo g ou t t he user . Fo r example , if the
automatic access timeout is set to 60 seconds, the user will b e logged out 60 seconds after the last key stroke.
If the user depresses a key before the 60 seconds have elapsed, a new 60 second cy cle will be started. The
numb er of strokes that are entered is the num ber of press strokes after the last key stroke that wi ll b e al lowed
be f ore the s y ste m a utom a ti ca l l y l ogs out th e us er . For ex ampl e , i f th e au tom atic tim eou t i s se t to 10 str oke s,
the user will be logged out when the press completes ten str okes after the last key stroke. I f the user
depre sses a key befo re 10 strokes hav e been completed, a n ew 10 str oke cycle will be st art ed .

3.6

3.7

Secti on 4 Op erating M enus

Section 4.1 Main Menu

Figure 4.1 shows the Main Operating Men u. Thi s screen provi des an overal l vi ew of the f uncti ons avai l ab l e
along with pert inent infor mation for each. Fr om this menu the operato r may select the Press Contro l,
Pro gra mmable Limit S witch, Auto mat ic S et up s (wit h opt ional bo ard inst alled), Tonnag e Monit or ( with
optional board installed), Die Prot ection (with optional board installed), Job Setups, Count er s, and Mo tor
Speed Adjust. By depressin g the adjacent softkey, the screen will transfer to the Press Control, Automatic
Setups, Tonnage Monitor, Die Protection, Programmab le Li m it Switch, Counters, or Motor Speed screens.

6 5 4 3 2 1

8

7

SPM
0

MOTOR
SPEED

TOP

0

Stroke

Mode

% LOAD
161

0

Single Stroke

COUNTER LIMIT QUANTITY STATE

ORDER
BATCH

Drive

Speed
Stroke

Speed

STATUS:
READY TO RUN

STATUS:
ALL CONDITIONS OKAY

STATUS:
ALL CONDITIONS OKAY

STATUS:
ALL CONDITIONS OKAY

JOB NUMBER DESCRIPTION
100000 FRONT BRACKET

2000

500

0
0

SPM

SPM

Order

Counter

READY TO STROKE

7

ON

7

ON

Counter OFF

PC STATUS

MAIN
SCREEN

PRESS
CONTROL

AUTO
SETS

TONNAGE
MONITOR

DIE
PROTECTION

LIMIT
SWITCH

JOB
SETUPS

COUNTERS

Figure 4.1 Main Menu

Th e d isplay p rovides the following infor mation:

1. T he present r unning status o f the press co nt r ol.

2. T he curr ent status of the automatic slide adjust and air adjust module, if this module is installed.

3. The present status of the tonnage moni tor module, i f thi s m odule is in stalled. This i n cl udes se tpoint
alarms, faults, or a bypass condition.

4. The present status of the die protection module, if this module is ins tal led. This includes a top stop
or emergency stop due to sensor inputs, faults, or a bypassed condition.

5. T he present Job Number and its description.

4.1

6. The status of the o rder and batch counter. This includes the preset limit, the present quantity
produced, and the o n/o ff state o f the count er .

7. A bar graph which represents the current main motor speed.

8. A bar graph which represents the current main motor load.

Section 4.2 Press Control Menu

Figure 4.2 shows the Press Control Menu. This screen provides detailed information about t he press, the
press control, and auxiliary equipment. The softkeys shown active in the PROG mode indicate parameters
that can be changed.

0

0

Stroke

TOP

3

Brake Monitor Limit Stoptime

Top Stroke Stop 0200 183 mSec

1

Mid Stroke Stop 0250 0 mSec

2

Clutch time 0275 0250 mSec

4

Auto Single Stroke Time ……… 5 Sec

5

Feed Complete Position ……… 25 Degs

6

Cont. on Demand Time ……….10 Mins

7

Auxiliary Equipment Message

8

Option is not Installed

Reason for the Last Stop

9

Power Up

Present Running Status

10

Ready to Stroke

Mode

AUXILIARY
COMM.

Single Stroke

Limit Actual

Speed
Stroke

Speed

Figure 4.2 Press Control Menu

Th e d isplay p rovides the following infor mation:

Drive

0
0

DIAGNOS

SPM

SPM

SPM
0

Order

Counter

PC STATUS

READY TO STROKE

% LOAD
161

OPERATOR
STATON

Counter OFF

PRESS
CONTROL

CHANGE
NUMBER

MOTOR
SPEED

TONNAGE
MONITOR

AUTO
SETS

DIE
PROTECTION

EXIT

1. A brake monitor used when the press stops at t he t op of the str oke.

2. A brake monitor used when the press stops at any position other than to p.

3. T he act ual sto pping time of the press, measured by the brake monit or.

4. Clutch engagement time.

5. Auto Single Stroke Time

6. Feed Complete Position

4.2

7. Co ntinuous on Demand Time

8. Mess ages from auxiliary equip ment.

9. T he event t hat caused the press to stop.

10. The event that is keeping the press fro m running, if any exists.

If configured, t he Mo to r Speed Adjust screen can be accessed fro m this screen in order t o change the
stroking speed of the press (see Section 4.7). In addition the Tonnage Monitor, Auto Setups, and the Die
Protection can be accessed from this screen if so configured.

Section 4.2.1 Brake Monitor

Each time the press stops a time based b rake moni tor (2mS resolution) measures the time from deacti vation
of the clutch/brake v alv e until crankshaf t rotation is less than 1.8 rpm. An addi tional 8 m Sec is added to this
measured value to compensate for the reaction time of the control. If the actual time exceeds an al lowable
br ake mon ito r limit , th e pr es ent ru nn in g s t at u s will dis play “Stop Took Too Long” and the oper ator is
required to press a RESET ERROR so ftkey before any further st r okes can be initiated. The last measured
st o pp ing t ime is d isp laye d b es ide th e limit t ha t ap plie d. Se pa r at e limits a re pr o v id ed fo r mo nit o r ing t h e
stopp i n g ti me a t th e top of th e s troke ( Top Strok e Stop) or at a n y p ositi on oth e r th an top ( Mi d Strok e S top).
These limits can only be changed in the Machine Parameters configurat ion screen ( S ee Section 5.2. 11 and
Section 5.2.12).

WARNING! When your press is equipped with two-hand control devices and/or presence sensing
devices for point of oper ation protection, only qualified pers onnel with a knowl edge of ANSI (B11.1),
OSHA (CFR 1910.217), or other r egulations that govern the r el ationship between stopping time and
the distance at which two-hand control and/or presence sensing devices are to be located should set
or reset stop limits for the brake monitor. These limits must never be set for longer times than the
time the safety distance is based on.

Section 4.2.2 Clutch Time

The clutch engagem ent tim e is measured (4mS resoluti on) each time the clutch/brake val v e is engaged and
is the time from valve activation until crankshaft rotation exceeds the "minimum strokes/min" threshold. If
the act ual time exceeds a maximum limit, the stroke is aborted and the reason for the last sto p will display
“Motion Did Not Start”. Both the minimum speed threshold and the maximum engagement time can be set
only in the configuration menu (See Section 5.2.4 and Section 5.2.7).

Section 4.2.3 Automatic Single Stroke Time

This parameter i s the length of tim e that the pres s con trol w ill wait for the feed to initiate a str oke, after the
automatic single str oke mode has been selected and the first stroke manually activated. T he pr ess contro l
begins timing at the bott o m of the stroke, and requires that the Feed Complete input #42 go Low (0 volt)
and back High (24 volt) during the upstroke or while the press control pauses at the t op. The next stroke
is automatical l y initiated if the sign al f rom the f eed occurs bef ore the time l i mit is reached. If equipped wi th

4.3

a die protection module the press control wil l als o wait for all die protection inputs to become satisf i ed. The
maximum time allowed for successive automatic strokes initiated by the feed is configured by the facto ry,
and is set f or 10 seconds unless a speci fi c appl i cation requi res otherwise. An y stop input that causes a stroke
t o n ot b e initiat ed within th is time limit will r eq uire clearing th e fault a nd manually re-initiating t he stroke.

The Automatic Single Stroke Time parameter can be changed from this screen. To change this parameter
use the arrow keys to move the cursor to the Automatic Single Stroke time. If the CHANGE NUMBER
softkey appears, the user has access to change this param eter. Section 3 describes the mean s n ecessary for
the user to gain access.

Section 4.2.4 Feed Complete Position

This parameter specifies a posi ti on in the downstroke at which the Feed Complete Signal must be High (24
vol t) , or th e p r ess will be imme dia te ly s to pp e d . T h e in p u t is e x a min e d only at th e a n g le s pe c ifie d an d n o
further restrictions are placed on its activity. This f eature is acti ve only in the continuous mode, and only if
the press control has been configured to recognize the f eed line. If the press is stopped due to the feed not
being in place, the co nt inuous mode is aborted and must be manually setup and re-initiated.

The Feed Compl ete Position parameter can be ch an ged from this screen. To change this parameter use the
arro w keys to mov e th e c urs or to th e F e ed Com p l e te Pos i ti on . If th e C HA NG E NU MB ER sof tke y ap pea rs ,
the user has access to change this parameter. Section 3 describes the means necessary for the user to gain
access.

Section 4.2.5 Continuous on Demand Time

This parameter sets the length of time that the press control will wait for the Continuous on Demand Run
input to go high to initi ate contin uous stroking after the Continuous on Dem and stroke mode is acti vated by
manually depressing the set-up bu tt on and then the oper ato r cont ro l butto ns within 6 seconds. When the
au xiliar y e qu ipme nt re mo ve s t he ru n inp ut ( inp ut g oe s lo w ) t he p re ss c o n t r o l will s to p at the to p of t he
stroke, remain enabled, and wait for re-initiation. If continuous stroking is not initiated within this time limit
t he pr e s s c on tr ol w ill d is a b le the a u toma tic c yc l e, displa y the fa ult, a n d w ill re q u ire tha t th e s tr ok e b e r e­ini tiated by m anual m eans. The maxi mum tim e setting all owed for this parameter is confi gured by the factory,
and is set for 2 minutes unless otherwise specified. This parameter is used only if configured for Continuous
on Demand mode (see Section 4.3.7).

The Continuous on Deman d Tim e parameter can be ch anged from thi s screen. To chan ge thi s param eter use
the arrow keys to m ov e the cu rs or to th e C on ti n uou s on D em a n d Ti me. If th e C HA N GE NU MB ER sof tk ey
appears, the user has access to change this param eter. Section 3 describes the means n ecessary for the user
to gain access.

Section 4.2.6 Auxiliary Equipment Message

Status information from auxiliary equipment is provided through a parallel interface on the operator terminal.
If in stall ed, a 7 bit binary code is transl ated in to 1 of 127 messages (each up to 40 characters) held in ternall y
in the operator terminal. See Section 5.6.2 and Section 7.4.

4.4

Section 4.2.7 Reason For The Last Stop

Diagnostic information is provided to show the reaso n the press stops. Once a stroke is initiated, the first
stopp i n g a ction i s latc h ed an d d i s pl a y e d. Th i s i s don e to ca ptu re tr an s i en t c on di ti on s th at m ay re turn to th e i r
proper stat e after the press stops. This information remains latched until press stop s ag ain.

Additional information concerning press stops is archived in the Event Lo g. See Section 4.2.9. 4.

Section 4.2.8 Present Running Status

Diagnostic information is provided to show any reason why the stroke may not be initiated. This information
follows the present conditions of the inputs. Any input that prevents stroke initiation is displayed as long as
it exists. If no stop condition exists, a "Ready To Stroke" message i ndicates that only the correct run buttons
are required to initiate the stroke.

Since the press control contains two microprocessors that make independen t decisions about stop conditions,
the diagnostic area all ows room for messages f rom chan nel A and channel B. If both channel s report the same
eve nt, t h e mes sa g e is d isp la yed o n o ne line w it h no c ha nn el de s i g n a t i o n . I f d iffer e nt s t o p c o nd it io n s a r e
reported, each message is prefixed with "CH A" or "CH B".

Section 4.2.9 Diagnostics

Additiona l p r ess co ntro l diagnostics are available through the DIAGNOS softkey. Upon entry, the Input
Diagnostic menu is automatically selected.

Section 4.2.9.1 Input Diagnostics

Figure 4.3 shows the i n put diagn ostic screen. Each i n put is di spl ay e d wi th a n um b er, descripti on, and state.
The state indicates the voltage level (HI=+24 volts, LO=0 volts), and is shown fo r both channel A and
channel B separately . They are di s pl ay ed i n groups of eigh t and the operator can page through all i n puts by
using the NEXT GROUP softkey. The input number will start back at one after all groups have been shown
or if the VIEW INPUTS softkey is pressed. The total num ber of i nputs displ ayed i s forty-ei ght for a standard
control or seventy -two if conf i gured f or the third in put card. The third i n put card is availab l e onl y wh en the
extended card rack is provided.

4.5

0

y

0

Stroke

TOP

Num T

1 L. N.O. INCH BUTTON LO LO
2 R. N.O. INCH BUTTON LO LO
3 L. N.O. STATION # 1 LO LO
4 R. N.O. STATION # 1 LO LO
5 L. N.O. STATION # 2 LO LO
6 R. N.O. STATION # 2 LO LO
7 L. N.O. STATION # 3 LO LO
8 R. N.O. STATION # 3 LO LO
9 L. N.O. STATION # 4 LO LO
10 R. N.O. STATION # 4 LO LO
11 ALL N.C. RUN BUTTONS HI HI
12 T-STOP TOP STOP HI HI
13 E-STOP EMERGENCY STOP HI HI
14 E-STOP EMERGENCY STOP HI HI
15 E-STOP LIGHT CURTAIN 1 HI HI
16 E-STOP LIGHT CURTAIN 2 HI HI
17 STATION 1 SELECT HI HI
18 STATION 2 SELECT LO LO
19 STATION 3 SELECT LO LO
20 STATION 4 SELECT LO LO
21 MODE (RUN) HI HI
22 MODE (MODE SELECT) LO LO
23 AUTOMATIC SETUP LO LO
24 CONTINUOUS SETUP LO LO

pe Name CHA CHB

Figure 4.3 Input Diagnostics

Section 4.2.9.2 Output Diagnostics

Mode

Single Stroke

Drive

Speed
Stroke

Input Module 1

Speed

0
0

SPM

SPM

Order

Counter

PC STATUS

READY TO STROKE

VERSION
INFO

Counter OFF

INPUT
DIAGNOSTIC

VIEW
OUTPUTS

MEMORY
COMPARE

EVENT
LOG

NEXT
PAGE

EXIT

Th is s c re e n fu nc t io n s s imila r ly t o t he inp u t d ia gn o stic s . T his s c r ee n w ill s ho w t ha t s t a t u s o f th e ou t p u t s .
These are Output Relays 1-16. The state indicates the condition of the output, where HI=Output On and
LO=Output Off. The status of the programmable li mit swi tch outputs is shown on the programm able l imit
switch screen.

Section 4.2.9.3 Press Control Memory Test

This m enu compares the internal mem ory of both channel s of the press control and di splay s any locations that
do not agree. If any parameter of either chan nel becomes corrupt, an error message is di spl ay ed and stroke
initiation is inhibited. Either error message "MEMORY CHECK FAULT" o r "MEMORY COMPARE
FAULT" di spl ayed i n the press control' s present runni ng status indi cates that a system parameter is corrupt,
and this diagnostic menu should be used to determine which parameter is bad. All locations indicated as bad
must be reprogrammed bef ore the fault condition can be cleared. The me mory compari son is done i n groups,
and all are accessed with the NEXT GROUP softkey. The parameters programm ed by the factory (Group
4 and 5) are not accessible b y the user, but can viewed from this menu. The i tems tested are described b elow:

Group 1 Programmed in Press Control configuration and Auto Sets screens.

01 Stop time limit at the top of stroke
02 St op time limit at mid-str oke
03 Automatic Single Stroke Time
04 Feed Complete Position
05 Co ntinuous on Demand Time

4.6

Group 2 Programmed in Top Stop Calibration (configurat ion).

06 Sp eed Range (lowest )
07 Stop position (in single stroke)
08 St op position (in continuous)
09 Sp eed Range (1/3 r ange)
10 Stop position (in single stroke)
11 St op position (in continuous)
12 Sp eed Range (2/3 r ange)
13 Stop position (in single stroke)
14 St op position (in continuous)
15 Sp eed Range (highest)
16 Stop position (in single stroke)
17 St op position (in continuous)
18 St op position in setup/stop time mode

Group 3 Programmed in Machine Parameters (configuration).

19 Resolver/encoder offset
20 Automatic carry up position
21 Begin timed inch position
22 Minimum s trok es/min
23 Maximu m str okes/ min
24 Motion filte r
25 Clutch engagement time
26 Timed inch pulse durat ion
27 Automatic turn off time
28 Maximum # Engagements/Minute

Group 4 Programmed in Factory Configurat ion Machine Parameters.

29 Hydraulic Overload type (value)
30 Inch Butto n Co nfig (value)
31 Input configuration (value)
32 Output configuration (value)
33 Tonnage monitor type (value)
34 Die prot ection type (value)
35 Automatic Setups (value)
36 Light curtain mute type (value)
37 Feed line type (value)
38 Valve monito r type (value)
39 Valve monitor pull in time (value/10)
40 Valve monitor dr op out time (value/10)
41 Valve monito r track time (value/10)
42 Main motor delayed turn on time (value)
43 Main motor delayed turn off time (value)
44 Reser ved Factory parameter (value)

4.7

Group 5 Programmed in Factory Mode Configuration.

g

p

p

g

g

g

y

p

p

p

p

p

p

p

p

p

45 Allow Timed Inch (value)
46 Allow Auto Single Stroke ( value)
47 Allow Continuous o n Demand (value)
48 Allow Maint ain Continuous (value )
49 Maximu m Auto Single Str oke time (valu e)
50 Max. Continuous on Demand time (value)

Section 4.2.9.4 Event Log

The controls retain s a ev ent log. Thi s l og records the reason for the last 128 stops. All reasons f or last stop
are recorded, except automatic stop on top. Each entry i n the even t log contains the tim e, date, and the type
of stop. The event log is illustrated in Figure 4.4. Stops are displayed in chronological order with the most
recent stop displ ay ed f i rst. The “Next Page” and “Previ ous Page” sof tkeys can b e used to scroll through the
event log.

0

0

Stroke

TOP

Date TimeSubsystem

------------------ ------------------- ------------------------------------­ 3/21/2000 14:59:41 Event Lo
Reason: To

3/21/2000 14:59:02 E vent Log Subsystem
Reason: Li

3/21/2000 14:50:49 E vent Lo
Reason: Die Block

3/21/2000 14:49:22 E vent Lo
Reason: Auxiliar

3/21/2000 14:44:18 E vent Log Subsystem
Reason: To

3/21/2000 14:42:29 E vent Log Subsystem
Reason: To

3/21/2000 14:38:48 E vent Log Subsystem
Reason: To

3/21/2000 14:32:59 E vent Log Subsystem
Reason: To

Mode

Sto

ht Curtain # 1

Top Sto

Sto

Sto

Sto

Sto

Single Stroke

Subsystem

Subsystem

Drive

Speed

Stroke

Speed

Subsystem

Order

SPM

0

Counter

0

SPM

READY TO STROKE

Counter OFF

PC STATUS

EVENT
LOG

PREVIOUS
PAGE

NEXT
PAGE

EXIT

Figure 4.4 Event Log

Section 4.2.9.5 Version Information

The version information of the control hardware and software can be viewed by depressing the VERSION
INFO. softkey.

Section 4.2.10 RESET ERROR

The press contr ol screen alert s the o p er ator of an error condition by displaying a RESET ERROR softkey
as shown i n Fi gure 4.5. The reason for the error is shown under Present Runni n g Status. The press can not
be operated until the error is corr ected and an o perat or acknowledges the erro r by pressing the RESET
ERROR softkey. See the sect ion on Tr oubleshooting fo r conditions that require an operato r 's response.

4.8

0

0

Stroke

TOP

Brake Monitor Limit Stoptime
Top Stroke Stop 0200 208 mSec

Mid Stroke Stop 0250 0 mSec

Clutch time 0275 0250 mSec

Auto Single Str oke Time ……… 5Sec
Feed Compl et e Position ……… 25 Degs
Cont. on Demand Time ……….10 Mins

Auxiliary Equipment Message
Option is not Instal led

Reason for the Last Stop
Auto Stop on Top

Present Runni ng Status
Stop Took Too Long

Mode

AUXILIARY
COMM.

Single Stroke

Limit Actual

Drive
Speed
Stroke
Speed

0
0

DIAGNOS

SPM

SPM

SPM
0

Order

Counter

PC STATUS

READY TO STROKE

% LOAD
161

OPERATOR
STATON

Counter OFF

PRESS
CONTROL

MOTOR
SPEED

TONNAGE
MONITOR

AUTO
SETS

DIE
PROTECTION

RESET
ERROR

EXIT

Figure 4.5 Reset Error

Section 4.2.11 Press Operator Station

If an operator station select turns Off (i n put goes High), a stroke in progress is aborted and further stroking
prevented until acknowledged by the operator. The present running status will indicate “Press Oper. Station”
and the OPER. STATION softkey must be sel ected. The screen sh own in Figure 4.6 is provided to indi cate
which stat ion has been turned Off. If this station has been intentionally turned Off, t he VERIFY softkey
should be pressed to save thi s as the present combination of active operator stations. No error is generated
if a station is turned On (input goes Low), and the additional station is added to the present combinati on of
active operator stations. The OPER. STATION softkey can also be used to view the present station select
status. Verification is required only when one or more stations are tur ned Off.

0

0

Stroke

TOP

Any station (show n above) indicated wit h an ‘*’ has
changed from ON to OFF. Make certain that this is an
intended chan ge and that each opera to r has an act ive
station. Press th e VE RI FY key if deactivation of the
station is intended.

Warning! Failure to provide an active operator station
for each operator may result in serious injury or death
if two hand controls are used as safety devices

Single Stroke

Mode

Station Number Status

01 ON
02 OFF *
03 ON
04 ON

Drive
Speed
Stroke
Speed

Order

SPM

0

Counter

0

SPM

Press Oper. Station

Counter OFF

PC STATUS

OPERATOR
STATIONS

VERIFY

EXIT

Figure 4.6 Press Operator Station

Section 4.3 Stroke Mode Selection

The present stroking mode of the press control is di spl ay ed at the top of the LCD. The m ode is ch anged b y
placing the str oke mode selector switch in the MODE SELECT position, with the Pr ogram/Run switch in

4.9

the RUN position. The di spl ay automatical l y presents one of the m enus sh own i n F i gure 4.7 and al l ows the
oper ator to ch oose from one of the stroking modes shown or select the other page of modes . T he pr esent
mode is sho wn at t he t o p of the LCD, and a new mode is selected by pressing the desired softkey. The
display will re main in on e of the two menu s sho wn until the mode sele ctor is re turne d to the RU N or OFF
position. Stroking modes that have been turned off by the factory do not appear on the display and are not
available to the operator.

0

0

Stroke

TOP

TOP

Single Stroke

Mode

SETUP AND STOP TIME TEST

TIMED INCH

INCH

SINGLE STROKE

CONTINUOUS

NEXT GROUP OF MODES

0

0

Stroke

Single Stroke

Mode

AUTOMATIC SINGLE STROKE

CONTINUOUS ON DEMAND

OPERATOR MAINTAINED CONTINUOUS

Drive

Speed

Stroke

Speed

Drive

Speed

Stroke

Speed

Order

SPM

0

Counter

0

SPM

Ready to Stro ke

SPM

0

Counter

0

SPM

Ready to Stro ke

Order

Counter OFF

PC STATUS

STANDARD
MODES

SETUP
STOP TIME

TIMED
INCH

INCH

SINGLE
STROKE

CONTINUOUS

NEXT
GROUP

Counter OFF

PC STATUS

OPTIONAL
MODES

AUTO
S. S.

CONTINUOUS
DEMAND

MAINTAINED
CONTINUOUS

FIRST GROU P OF MODES

FIRST
GROUP

Figure 4.7 Stroke Mode Selection

Section 4.3.1 Setup/Stop Time Test

This m ode sel ection requires the use of the Inch b uttons to cause stroking. Wh en the buttons are depressed
and he ld, th e slid e a u toma tic a lly s top s in the do wns tr ok e a t a p r ogr a mma b le p os ition. T h is p e rmits q u ic k
setup of mechani cal feeds dri ven b y the press crankshaft or consistent measurement of downstroke stopping
time for det ermination of OSHA required safety distance for t wo hand cont rol and light cur tain safety
devices. Release of the Inch buttons or any stop input will cause slide stopping action to be initiated at any
t ime. Stroke initiatio n is allo we d only with the main motor r unn ing in the forwar d direction .

4.10

Section 4.3.2 Timed Inch (When Provided)

This m ode selection fun ctions li ke the Inch mode until a programm able downstroke slide position is reached.
After this poin t, holding the Inch buttons depressed re sults in a utomatica lly contro lled inch ing mov ement s
of the slide until the dies resist slide motion or until the botto m of the str oke is reached. When the bot tom
of the stroke is reached, the clutch action wil l stop. Releasin g the pal m buttons will then restore the normal
inch m ode f uncti on unti l the press cycl es back to the programmed downstroke position. Stroke ini tiation is
allowed only with the main motor running in the forward direction or OFF. This mode is optional and can
be configured ON or OFF by the fact ory.

Section 4.3.3 Inch

This m ode sel ection requires the use of the Inch b uttons to cause stroking. Wh en the buttons are depressed
and hel d, the sli de runs until the crankshaft angle reaches the top of the stroke, the Inch buttons are released,
or a stop input occurs. Each time the machine stops, further strokes can be m ade only after all run buttons
are released. Str oke initiation is allowed with the main moto r r u nning in the forward or r everse direction,
or OFF. Crankshaft motion after stroke ini tiation must exceed the min imum strokes/min threshold i f the mai n
motor is running in the forward direction.

Section 4.3.4 Single Stroke

This mode select ion requires the use of all active operat or stations to cause stroking. When all active
operator station run buttons are depressed and held, the sli de runs un til the cranksh af t angl e reaches the top
of the s tro ke o r any st op input occurs . The press will st op if a ny act ive run but to n is released in t he
downstroke, until the crankshaft reaches the angle of automatic carry up. After this angle is reached, the
press control wi l l keep the cl utch ai r val ve en ergi zed unti l the crankshaf t angl e reaches the top of the stroke
or any stop input occurs. Any or all active run butto ns may be released without causing the press to sto p
o n ce a utomatic ca rry up is in effe ct. Str oke s can be initiat ed in t he upstr oke, but the pre ss contr ol will not
enter auto matic carry up and will run to the to p of the stroke o nly as long as all active run buttons are
depressed. Each time the m ach i ne stops, further strokes can be made onl y af ter all run buttons are released.
The use of any inactive operator station run button before a stroke is initiated prevents stroke initiation. The
incorrect run butt o n is listed as the Reason For T he Last St o p, and a warning that an inactive station was
used is displayed until the RESET ERROR softkey is pressed. After this warning is acknowledged, further
stro kes can be made only after all run butto ns are r elea sed. The use of any inactive operato r st ation run
button after a stroke has been properly in itiated causes an imm ediate stop and requires all run b uttons to be
released before further strokes can be made. If station #4 is configured for a foot switch, stroke initiation
is allowed from eit her the active palm button st ations or the foot switch. The foot switch can not be used
in con jun c t io n w it h an y pa l m bu tt o n sta t io n . P re s s o p e r ation in t h is mo d e is a llo w e d on ly with t he ma in
motor running in the forward direction.

Section 4.3.5 Continuous

This mode selection requires the use of a Continuous Setup prior ac tion butt on and all active oper ator
stations to cause stroking. Six seconds are al l owed after the Setup button is depressed f or all active operator
stat ion r un but t o ns t o be depressed and held until slide mot ion begins. After stroke initiation, any or all
operator buttons may be released. The press control will keep the clutch air valve energized until a top stop,

4.11

emergency sto p, or ot her stop input occur s. In the event of any sto p condition, furt her s tr okes can be
initiated only after all operator run buttons and the Contin uous Setup button are released. Stroke in itiation
is prevented i f an in active station run button is depressed. If station #4 is confi gured f or a foot switch, stroke
initiation is prevented if the foo t switch is select ed. Only the act ive palm button stat ions may be used to
initiate a stroke in this mo de . Pr ess oper ation is allowed on ly with the main mot or runnin g in t he forw ard
direction.

Section 4.3.6 Automatic Single Stroke (When Provided)

This mode selection requires the use of an A utomatic Single Stroke Setup prior action button and all active
operator stations to cause strokin g. Six seconds are all owed after the Setup button is depressed for all active
operator station run buttons to be depressed and hel d until the crankshaf t angle reaches the point of automatic
carry up. Stroke initiat ion is a llowed only at the to p of the stro ke or in the downstroke and initiation is
prevented if an inactiv e station run button is depressed. If station #4 is configured for a foot switch, stroke
init ia t io n is p r ev en t e d if the fo ot s w it c h is se le ct e d . O nly t he a c t ive p alm b utt on st a t ion s ma y be u se d t o
ini tiate a stroke in this mode. After reachi ng the point of automatic carry up, any or all operator buttons may
be r eleased and t he press cont rol will automatically ret urn t he slide t o the top. Stro kes can then be
automatically initiated when material is in place and other prescribed conditions are met within a
programmabl e ti m e l i m i t (see section 4.2.3). In the event of any stop condition or if the condi tions requi red
t o automatically stroke the press fail to opera te with in the allowable time th e p re ss contro l will d isp lay the
condition as the reason for the last stop and further strokes can be i ni tiated only after all operator run buttons
and the Automatic Sin gle Stroke Setup button are released and re-depressed. An automatic stroke is i nitiated
when the auxiliary equipment cycles the Feed Complete input #42 low during the upstroke or while paused
at the to p a nd th en back high. If equip pe d with a die p rotection mod ule , the press contro l will w ait for all
die protection inputs to become satisfied before allowing initiation and will display “No Die Pro in Tim e ” as
the reason for stopping if not in position within the programmable time. Press operation is allowed only with
the main motor running in the forward direction. This m ode is optional and can be configured ON or OFF
by the factory. In some applications the auxiliary equipment or press line may not be ready for a part to be
made when the stroke is manually initiated. If configured for this type of interface, the press control will
initiate the first stroke if the auxiliary equipment is ready (Feed Complete input #42 is high). If not ready the
press control will enable the mode when manually setup and initiated, but will not make the stroke until the
auxilia ry equip ment is ready. In this situation the pr esent ru nning status will immed iately dis pla y “Waiting
for Feed” and the press control will initiate automatic strokes if they occur within the programmed Auto
Single Stroke Time.

Section 4.3.7 Continuous on Demand (When Provided)

Continuous on demand mode i s an automatic mode used when the press is part of a cell of machinery used
in a production process. The press is slaved to other mach in ery i n the cell whi ch provi des a sign al to instruct
the press to run co ntinuously for a period o f time to p r o d u ce needed part s and then to st o p and wait till
another continuous run i s needed to produce more parts for the process. This mode requires manual ini tiation
by pre s s in g the A u tomatic Se tu p button a n d th e n pre s s ing th e a c tive p a l m b u tton s w ithin 6 s e c onds in ord e r
t o enable automatic operat ion . Periods of c ont inuous s trok ing a re then automatically initiated b y au xiliary
equipm ent apply i ng a h igh si gnal to the Continuous on Demand Run Input. If a Continuous on Dem and Run
Signal is not received within the preset Continuous on Demand Time (see section 4.2.5), the mode will be
deactivated and must be manuall y reactivated. Any stop condition that occurs after the mode is en abl ed wil l

4.12

prevent further automatic stroking un til the stop conditions are rem oved and automatic stroking i s manual l y
init iate d. Stro ke initiat ion is pr evented if an inac tive st at io n r un button is dep ressed . If st atio n #4 is
confi gured for a foot switch, stroke ini tiation i s prevented if the foot switch is sel ected. Only the active pal m
button stations may be used to initiate a stroke in this mode. Stroking is allowed only when the main motor
is on and running in the forward direction. This mode is optional and can be configured On by the facto r y
only if the press control is equipped with a 3rd input bo ar d.

Section 4.3.8 Maintain Continuous (When Provided)

This mode selection requires the use of a Continuous Setup prior action button and maintained operation of
the selected operator stations to cause stroking. Six seconds are all owed after the Setup button is depressed
for all selected operator station run buttons to be depressed. After initiation, the press will stroke
continuously as long as the run buttons are depressed. If released while the press is in the downstroke, the
press will stop immedia tely. If released in t he up stroke , the pre ss will con tinue automatically to th e top of
the stroke. In the event of any stop conditi on, further strokes can be initiated only after all run buttons and
the Continuous Setup button are released. Str oke initiation is prevented if an inactive station run butt on is
depressed. If the press control is configured for a foot switch wired into station #4, initiation is allowed with
the foot switch only if all other o perat o r st at ions are tur ned Off. Press operat ion is allowed only with the
main motor running in the forward direction. This mode is optional and can be configured ON o r OFF by
the factory.

Section 4.4 Programmable Limit Switch

The menu i n Fi gure 4.8 allows the user to access the press control programmable li m i t switch outputs. The
present settings may be viewed in the RUN mode, but can only be altered in the PROG mode. All outputs
can accessed by pressing the NEXT GROUP softkey.

4.13

0

0

Stroke

TOP

1

Ch

On

01

180°

02

30°

03

40°

04

270°

05

90°

06

0°

07

0°

08
3
2

0°

Ch Description State

01 STOCK OILER LOW

R

02 ---------------------------- LOW

03 ---------------------------- LOW

04 AIR BLOW OFF LOW

05 ---------------------------- LOW

06 ---------------------------- LOW

07 ---------------------------- LOW

08 ---------------------------- LOW

Mode

Single Stroke

Off

.30 Sec

40°
50°

.50 Sec

180°

0°
0°
0°

On/Limit

003
002

180°

0°
0°
0°
0°
0°

Off/Cnt

Drive

Speed
Stroke

Speed

002 Cnt
001 Cnt
190°

0°
0°
0°
0°
0°

SPM

0
0

SPM

0

Order

Counter

PC STATUS

READY TO STROKE

180 359

Counter OFF

LIMIT
SWITCH

CHANGE
NUMBER

ENTER
ANGLE

ENTER
TIME

NEXT
GROUP

BYPASS
ON/OFF

CHANGE
NAME

RESET
COUNT

EXIT

Figure 4.8 Programmable Limit Switch

Th e information shown is as follows:

1. P LS out put channel numbers and their p re sent o n/off settings. Sett ings based on the angle of the
crankshaft are indicated with the ° sym b ol , and those based on time are indicated by Sec. Chan nels
1, 2, 9, and 10 are “counted outputs” that remain Off for a specified number of cycles before
activating. T wo on/off settings per channel ar e allowed for channels 3 to 8 and channels 11 to 16,
which can b e programm ed to cycl e twice f or each press stroke. For example, in Fi gure 4.8, chann el
3 will t ur n o n at 4 0 d egre es and off at 50 degre es, and tur n on again at 180 degrees a nd off at 19 0
degrees. If a channel i s to cycle onl y once per stroke the second on settin g and the second off setting
should be programmed to 000.

2. P LS output channel numbers, their descriptions, and their present output states. The output
information is updated four times a second.

3. Restricted channel status. An "R" designation after the channel number indicates that the channel
has been restricted and can n ot be changed by the operator. In Figure 4.8, Channel 2 is a restricted
channel.

Section 4.4.1 Bypass Output On/Off

When the user has access control, the BYPASS ON/OFF softkey can be used to override the programmed
setpoints and keeps the output turned off. The output state "BYPASS" is displ ay ed wh i l e i n thi s condi tion.
This state is maintained until the output is returned to normal by pressing the BYPASS ON/OFF softkey
again or the press contro l power is turned Off and back On. All outputs po wer up in the active state.

4.14

To bypass an output:

1. The operator must have access control. Access control is describ ed i n Section 3. If the user obtains

access control by using the passwor d system, the user must be configured to have access to bypass
t he pr ogr amma b le limit switch o utp uts.

2. Use the arrow keys to position the cursor onto the desired channel.

3. If the programmable limit switch channel is currently On, not Bypassed, press the BYPASS ON/OFF

softkey to Bypass the channel.

4. If the programmab le l i m it swi tch chann el is currently Bypas sed, press the B YPASS ON/OF F sof tkey

to turn the channel ON, not Bypassed.

Section 4.4.2 Change Output

When the user has access control, the CHANGE OUTPUT softkey is used to change the On or Off settings
of the output selected.

To change an output:

1. The operator must have access control. Access control is descri bed i n Section 3. If the user obtains

access control by using the password system, the user must be configured to have access to change
the progr ammable limit switch setpoints and names.

2. Use the arrow keys to position the cursor onto the setpoint that is to be changed.

3. P r ess t he CHANGE NUMBER softkey.

4. Use the numeric keypad to enter the new data and press ENT.

The softkey selecti ons change according to the setpoint sel ected. Outputs can be turned on onl y at a specifi c
crankshaft angle, but can be turned off either at an angle or after a programmed dwell time. If the cursor is
pos itioned to an Off setpont, t he ENTER A NGLE and ENTER T IME s oftkeys will appear .

The ENTER ANGLE softkey change s t he item to a degr ees format and allows an entry from 000 to 359
degrees.

The ENTER TIME softkey changes the i tem to a time f ormat and all ows an entry from 0.01 Sec to 9.99 Sec.
Only outputs 01-04 and 09-12 all ow tim ed off settings, and the second On/Of f pai r can not be used if the first
is timed off.

Section 4.4.3 Change Name

When the user has access control, the CHANGE NAME softkey allows the user to assign preprogrammed

4.15

descriptions to particular outputs of the current j ob. The men u in Figure 4.9 shows the output descriptions
available as two pages o f fifteen na mes. T he out put number to which the description is being assigned is
displayed at the bottom of the screen.

0

0

Stroke

TOP

Programmable Limit Swi tch Descriptions

Blow Off
Stock Oiler
Feed In iti a te
Pilot Release
Kicker
Elect ion Solenoi d
Default Mess age 6
Default Mess age 7
Default Mess age 8
Default Mess age 9
Default Mess age 10
Default Mess age 11
Default Mess age 12
Default Mess age 13
Default Mess age 14

Select Descr ipt i on f or PLS Channel # 03

Use

P

PR

R

Single Stroke

Mode

Keys to select name, press ENT to select

Drive

Speed

Stroke

Speed

Order

SPM

0

Counter

0

SPM

READY TO STROKE

Counter OFF

PC STATUS

PLS
NAMES

CHANGE
NAME

NEXT
GROUP

NO
NAME

EXIT

Figure 4.9 Selecting PLS Names

To change an output name:

1. The operator must have access control. Access control i s descri bed i n Section 3. If the user obtains
access control by using the password system, the user must be configured to have access to change
the progr ammable limit switch setpoints and names.

2. When vi ewing the Li mi t Switch menu, as shown i n Fi gure 4.8, position the cursor on the channel that
is to be ch an ged, press the CHANGE NAME s of tkey . The menu in Fi gure 4.9 is displ a yed, and the
cursor positioned to description 01.

3. Use t he arrow keys to position the cursor onto the desired description and press the ENT key. All
names in memory are available by pressing the NEXT GROUP softkey.

The NO NAME softkey removes the name assigned to that channel, and the descript ion pro cess can be
aborted by pressing the EXIT softkey.

To edit a name description:

1. Wh en vi e wi ng the PLS Nam e s m en u, us e th e a rrow k ey s to p osi ti on the cu rsor on the des cri p tion th at
is to be changed.

2. P r e s s t he CH ANG E N AM E s oft k ey. A t e xt ent r y sc re en will a pp ea r a nd t he d es cr ipt io n c a n be
edited. See Section 2.7.

4.16

Section 4.4.4 Restricted PLS Channels

Any prog rammable limit switch channel that has been res t r icted in the Press Contro l Configuration Menu
cannot be altered or bypassed by the operator. Only the first ei gh t chan nels, PLS 1 to 8, can be restricted.
A restricted channel is indicated as being restricted by an "R" aft er the channel number in the Description
section of the Li m i t Switch men u. The softkeys that all ow changes to be made to do not exist for restricted
channel s . Th e ch ann el m ust be confi gured Un-Restricted bef ore any ch ange can be m ade to the setpoints or
the description. See Section 5.5 for infor mation on rest r icting PLS channels.

Section 4.4.5 Counted Outputs

Channels 1, 2, 9 and 10 are programmable limit swi tch ch annels with counted outputs. These channels will
not cycle every stro ke but o nly cycle after the number o f str okes pr o grammed into the limit value for t he
channel. For exam ple, in Figure 4.8, the count li mit for chann e l 1 has been programmed to 3. Th is channel
will turn on every third stroke. On every third stroke, the channel will turn on at 180 degrees and rema i n on
for .30 seconds. The channel will remain off at all other times. If it is desired for a counted output channel
to cycle every stroke, the lim i t shoul d be s et to 000 or 001. The maximum val ue for the lim i t setting is 255.
The current count is shown in the CNT column. This is a count down counter . When this counter co unt s
down to 000, the output w ill cycle in relation t o the On and Off setting s tha t h ave been pr ogr ammed. The
RESET COUNT softkey will reset the present count values and set them equal to the limit setting. If both
channels on a group of 8 are programm ed as counted outputs this wi l l reset both channel s, b ut wil l n ot clear
the counters on t he other group of 8.

Section 4.5 Job Setups

From the Main Menu, Figure 4.1, pressing JOB SET UP S so ft key d isplays the menu in Figure 4.10 and
allows t he user t o access the internal file system of the oper ator t erminal. The parameters consisting of
programmable limit switch settings, automatic feed settings, tonnage monitor settings, and die protection
settings for the current job can b e saved f or later use. In addition, the settings f or a job previousl y stored can
be recalled into the current job.

0

0

Stroke

TOP

JOB NUMBER DESCRIP TI O N

1

000000001 FIRST EXAM PL E
000000002 SECOND EXAMPLE
000000003 THIRD EXAMP LE
000000004 FOURTH EXAMPLE
000000005 FIFTH EXAM PLE
000000006 SIXTH EXAMPLE
000000007 SEVENTH EXAM PLE
000000008 EIGHTH EXAMPLE
000000009 NINTH EXAMP LE
000000010 TENTH EXAMPLE
000000011 ELEVENTH EXAMPLE
000000012 TWELTH EXAMPLE
000000013 THIRTEENT H E XA M PLE
000000014 FOURTEENTH EXAMPLE
123456789 TWENTY CHARACTERS

Current Job:

2

Job Number Description
000000001 FIRST EXAMPLE

Mode

Single Stroke

Drive
Speed
Stroke
Speed

Order

SPM

0

Counter

0

SPM

READY TO STROKE

Counter OFF

PC STATUS

JOBS

NEXT
GROUP

LAST
GROUP

RECALL
SETUP

STORE
SETUP

ERASE
SETUP

EXIT

Figure 4.10 Jobs Setup Menu

4.17

Th e d isplay p rovides the following infor mation:

1. A list of al l j obs presentl y i n the internal f ile storage. The jobs are identi f i ed by a 9 digi t num ber, and
a 20 character description. A total of 500 jobs can be stored, and are shown in groups of up to 15.

2. T he current job being used by the press control.

Section 4.5.1 Store Setup

From th e J ob s M en u , Fi g ur e 4.1 0, s el e cti n g the STOR E SE TUP sof tk ey wi ll tra n sf e r th e sc ree n to th e Stor e
Jobs menu. The Sto r e Jo bs menu allows the user t o place all sett ings for the job currently in use into the
internal file storage area. The user must have access control to access the Store Jobs m en u. Access control
is descri b ed in Section 3. If the user obtains access control by using the password system, the user must be
confi gured to have access to store jobs in m em ory. The menu shown i n Fi gure 4.11 allows the user to enter
a new number under which the job will be stored. Po sition the cursor in the Job Number po sit io n . Then
press the CHANGE NUMBER softkey. A nine digit numeric number can be entered. This number must be
unique to this j ob. Entering a num b er al ready i n use al lows the current settings to replace the previ ous ones
for that numb er. After entering a job number, move the cursor to the Job Description position. Then press
t he CHA NG E TEXT softkey. The text ed it b ox will appear and the na me c an be entered. Press th e ENT
key to save the name and exit the text edito r . Finally, press the STORE SE TUP softkey. The curr ent job
inf ormation to be placed in the internal fi le sy stem under the job num ber and j ob name. The operator terminal
automatically returns to the Jobs menu.

0

0

Stroke

TOP

Job Number 000000001
Job Descr iption FIRST EXAM P LE

To Store a Job Setup:

1. Progr am all sett i ngs for th e Li m i t Switch ,
Tonnage Monitor, Die Pr ot ect ion, and Auto Setups

WARNING! Incorrect setups may cause damage and/or injury.

2. Enter the correct Job #.

3. Enter the Job descript ion.

STORE SETUP when ready

Mode

Single Stroke

Drive

Speed

Stroke

Speed

Order

SPM

0

Counter

0

SPM

PROGRAM/ R UN SW ITCH

Counter OFF

PC STATUS

STORE
JOBS

CHANGE
NUMBER

STORE
SETUP

EXIT

Figure 4.11 Storing a Job

NOTE:Changes made t o the current job are NOT automatically made to the internal file system. The user

must int e nt io na lly Sto r e t h e new se t t ing s o ve r t he o ld jo b number if t ho se se t tings ar e t o be sa ved
permanen tly.

Section 4.5.2 Recall Setup

From the J obs men u, Figure 4.10, pressing the RECA LL SETUP softkey wil l transfer the screen to the Sel ect
Job menu. The Select Job menu allows the user to select the job that is to be recalled. The user must have
access control to access the perform a job recall . Access control i s describ ed in Section 3. If the user obtains

4.18

access control by usi n g the password system, the user must be confi gured to have access to recall j obs from
memory. The Select Job menu is shown in Figure 4.12. There ar e two ways to select a job. The first way
is to enter the job numb er, if it is known. The ENTER NUMBER softkey all ows the user to enter the desired
job num ber di rectly i nto the operator terminal , whi ch automaticall y searches the fi l e system an d retrieves the
job i f l ocated. The second way is to select the job f rom the screen. Select a job by usin g the NEXT GROUP
key to locate the page that the job is on, and then using th e arrow keys to position the curs or on the correc t
job. With t he cursor on the co r r ect job, depress the SELECT softkey.

0

0

Stroke

TOP

JOB NUMBER DESCRIP TI O N

000000001 FIRST EXAM PL E
000000002 SECOND EXAMPLE
000000003 THIRD EXAMP LE
000000004 FOURTH EXAMPLE
000000005 FIFTH EXAM PLE
000000006 SIXTH EXAMPLE
000000007 SEVENTH EXAM PLE
000000008 EIGHTH EXAMPLE
000000009 NINTH EXAMP LE
000000010 TENTH EXAMPLE
000000011 ELEVENTH EXAMPLE
000000012 TWELTH EXAMPLE
000000013 THIRTEENT H E XA M PLE
000000014 FOURTEENTH EXAMPLE
123456789 TWENTY CHARACTERS

Mode

Single Stroke

Drive
Speed
Stroke
Speed

Order

SPM

0

Counter

0

SPM

PROGRAM/ R UN SW ITCH

Counter OFF

PC STATUS

SELECT
JOB

SELECT

NEXT
GROUP

ENTER
NUMBER

EXIT

Figure 4.12 Locating a job to recall

Eith er method of locatin g the desire d jo b results in a r eq ue st for fin al verifica tion as show n in Figure 4.1 3.
After verifying that the job number and description are correct, the RECALL SETUP softkey replaces the
information in the current job with that of the requested one. During the recall process, the message
"Loading the Job" is displayed. When complete, the operator terminal returns to the job setups menu and
the current job infor mation reflects the change.

Section 4.5.3 Erase Setup

0

0

Stroke

TOP

You Have Selected to RECALL:

Job Numb er Description
00000000 1 FIR ST EXAMPLE

WARNING! Alwa y s che ck to mak e cer ta in that you are
recalling th e cor rect setup. Recalling an incor r ect
setup for a pr oduction pr ocess can res ult in bodily
injury and/or damag e to m achine or tooli ng.

RECALL SETUP when ready.

Mode

Single Stroke

Drive
Speed

Stroke
Speed

SPM

0
0

SPM

Figure 4.13 Recall a Job

4.19

Order

Counter

PROGRAM/RUN SW I TC H

Counter OFF

PC STATU S

RECALL
JOB

RECALL
SETUP

EXIT

Fr o m th e Jo b s M en u , F ig ur e 4 . 10 , d ep r e ss ing t h e E R AS E S E TU P s o ft k ey w ill t r a ns fer th e s c re e n t o th e

g

g

y

Select Job menu. The Select Job menu allows the user to select the job that is to be erased. T he
user must have access control to perform a job erase. Access control is described in Section 3. If the user
obtains access control by usin g the password system, the user must be conf igured to have access to erase jobs
from memory.

Th e me thod for loc a tin g a job is the sa me a s t h os e for re c a lling one . O nc e t h e job to b e e r a s ed ha s b e e n
located, t he ERASE SETUP softkey can be used to erase the job.

Section 4.6 Counters

From the Mai n Menu, Fi gure 4.1, depressin g the COUNTER softkey displ ay s the menu sh own in F igure 4.14
and provides the operator certain production in formation. The present quantities of the order counter, batch
cou n te r , q u a lity c ou n te r, a uxilia ry c ou nte rs , s cr a p coun te r , a n d s tok e c ou n te r ca n b e v ie w e d . I n or de r to
make any changes to the co unt er s, the operato r must obtain contr ol access. Access control is described in
Section 3.

0

0

Stroke

TOP

Job Number Job Descript ion

1

1 FRONT BRACKET
Present Runnin

2

Pro

ram/Run Switch

3

COUNTER NAME COUNT LIMIT STATE PERCENT COMPLETE
Order Count

Batch Count

Count

Qualit
Aux 1 Count
Aux 2 Count
Aux 3 Count
Aux 4 Count
Aux 5 Count
Aux 6 Count
Aux 7 Count

Strok e Count 978776

4
5

Scrap Count 4 Scrap Rate 0.3984%

Mode

Single Stroke

Status

1000

50
90
50

DECREMENT
SCRAP

0
0
0
0
0
0

Drive

Speed
Stroke

Speed

2000

200
100

50

0
0
0
0
0
0

INCREMENT
SCRAP

ON
ON
OFF
TRIP
OFF
OFF
OFF
OFF
OFF
OFF

Figure 4.14 Counter Menu

Th e d isplay p rovides the following infor mation:

1. T he current Job Number and Description

50%
25%
90%

100%

SPM

0
0

SPM

Order

Counter

Program/Run Switch

CONFIG
COUNTER

1000

PC STATUS

LIMIT
SWITCH

DECREMENT
COUNT

COUNTER
OFF

RESET
COUNTER

EXIT

CHANGE
COUNT

CHANGE
LIMIT

CHANGE
SCRAP

INCREMENT
COUNT

ADD
TO SCRAP

DECREMENT
COUNT

SUBTRACT
FROM SCRAP

2. P r esent r u nning status of the press contro l

3. C u rr e n t C ou n t, L imit, S ta te , a nd Pe r ce nt C omp le te of th e O rd e r, B a tc h , Qu a lity, a nd all Au x ilia ry
Counters. T hese are called Production Counter s.

4. Current Stroke Count

4.20

5. Current Scr ap Co unt and Scrap Rate

Section 4.6.1 Production Counters

The Om niLi nk control has up to ten production counters. The fi rst three production counters have dedi cated
names. These ar e O rder, Batch and Qua lity. These three counte rs will always appea r on the scree n. The
o ther s ev e n c ou n te r s a re a u x ilia r y co unte rs. A u xiliar y c ou n te r s c a n b e e nable d o r d is a b le d in the c ounte r
configu r a tion . If a n a u x ilia r y c ou n te r is ena b le d in the co unte r conf ig u ra tio n , it will a p p ea r on th e s c re e n.
If an auxiliary counter is disabled in the counter configuration, it will not appear on the screen. Also during
counter confi guration, each of the auxiliary counters can be assigned a sixteen character name. This counter
co nfig ur at ion is on a jo b bas is. The co nfigu ra ti on in fo r mat i on w ill be s to re d w ith t he job . T he st o re d
info rma tio n in c lu d e s th e c ou n te r n a me . Wh e n a jo b is r ec a lle d , the c on fig u ra tion in f or ma tion w ill also b e
recalled. For example, if the first auxiliary counter is being used on job number one, it will be recall ed wh en
job number one is recalled. If it is not being used on job number two, it will not be recalled and not appear
on the screen when job number two is recalled.

All production coun ters that are turned on will incremen t as th e p re ss stroke s, when the press is oper ating
in a production mode. Production modes are Single Stroke, Continuous, Automatic Single Stroke,
Continuous on Demand, and Maintained Continuous modes. Normally each counter will increment by one
counter per press stroke. However, all of the counters have the option to confi gured to increase by mul tipl e
counts every press stroke or by mul tipl e counts every programmed num ber of press strokes. The val ues of
the increment and the number of press strokes before a co unt changes are pro grammed in t he counter
configurat ion menu. For example, an operat ion that runs a three out blanking die would have the counter
increase by three every press stroke. Another example, an operation that runs a one part out lam i n ation di e
that requires ten laminations per part would hav e the counter increase by one every ten press strokes. As a
final example, an operation that ru ns a four pa rt o ut lamination die that requires ten laminations per part
would have the counter increase by four every ten press strokes.

When the current count reaches the programm ed li m it, a top stop will be i ssued. This stop will remain active
until the counter is reset or is turned off.

All counters can be conf igured so that the current count val ue i s l oaded with the l ast count from the previous
run of a job. For example, Job A was runn ing on a machi n e and i t was decided that Job B should be run on
the machine. The Order Counter for Job A was at 1020. When Job B was loaded from memory with a Job
Recall, t he curr ent count for Job A’s Order Counter, 1020, was st ored in memory. The next time that Job
A i s loaded with a Recall, the count for the Order Counter will be set to 1020. If this feature is being used,
it is imperative that the current job be terminated by recalling another job. The current counts are stored only
when a job recall is performed.

The three dedicated counters are Or der, Bat ch, and Quality. T he Order count er usually recor ds t he t ot a l
parts made for a given process setup. The Batch counter usually records a small group of a process run, such
as the number of parts that can be put into one container. The Quality counter is used to record the number
of parts t hat can be made between quality inspections.

Section 4.6.1.1 Production Counters On/OFF

4.21

Production counters can be turned on or turned off. The user must obtain access control in order to turn the
counters on or off. Access control is described i n Section 3. If the user obtains access control by using the
password system, the user must be configured to have access to change counter settings. When a counter
is turned off, it does not increase. In addition, a counter that is turned off cannot issue a st op t o the pr ess
control.

A production counter is tu r ned on or off by first selecting the counter and then depressing the COUNTER
OFF/ON softkey. To select a counter, use the arrow keys to position the cursor on the counter that is to be
chang ed . The cursor can be either in the COUNT column or in the LIMIT column. Once the cur so r is
positioned over the proper counter, depressing the COUNTER OFF/ON softkey will turn the counter off if
it is cur rently on a nd will turn th e counte r on if it is cur re nt ly off.

Section 4.6.1.2 Production Counters Change Limit

Each production counter has a l imi t setting. When this li mit is reached, a top stop will be issued. The slide
will s top at the top of the s tr oke and further stroking will be pr evented until the counter is reset or until the
counter is turned off . The user must obtain access control i n order to change a counter li mi t. Access control
is described in Section 3. If the user obtains access control by using the password system, the user must be
configured to have access to change counter set tings.

A production counter limit is changed by first selecting the counter limit and then entering the new value.
To change a counter limit, use the arrow keys to positioned the cursor over the counter limit that is to be
changed, press the CHANGE LIMIT softkey, enter the new li mit using the n umeric key pad. After the correct
limit is entered, press the EN T key.

Section 4.6.1.3 Production Counters Reset

A counter reset will set a production counter’s current count to zero. The user must obtain access control
in order to r eset a counter . Access co nt r ol is described in Sect ion 3. If the user obtains access contr ol by
using the password system, the user must be configured to have access to reset a counter.

A counter is reset by first selectin g the counter and depressing the COUNTER RESET softkey. To reset a
counter, u s e th e a rr ow ke ys to p os iti on the c ur s or on the c ou n te r that is to be r e s e t. Th e c ur s or c a n b e e ithe r
in the COUNT column or in the LIMIT column. Once the cursor is positioned on the counter t o be reset,
press the COUNTER RESET softkey.

The counters can be configured so that resetting the Order Counter will also reset other counters. Each of
the production counters can be configured to be reset when the Order Count is reset. This option is
programmed in the counter configuration screen. Any or all of the production counter s can be configured
to reset when the Order Count is reset.

Section 4.6. 1. 4 Production Cou nt ers Increment/Decrement

Product ion counters can be manually increased by one count or decr eased by one count The user must
obtain access control in order to increase a counter value by one or decrease a counter value b y one. Access
control is described in Section 3. If the user obtains access control by using the password system, the user

4.22

must be configured to have access to change counter settings.

To increase or decrease the current count value by one, select the counter and depress either the
INCREMENT or DECREMENT softkey. To select a counter, use the arrow keys to position the cursor on
the counter that is to be changed. The cursor can be either in the COUNT colum n or in the LIMIT colum n .
Once the cursor is positioned on the counter to be changed, depress the INCREMENT key to increase the
count by one or the DECREME NT key to decrease the count by one.

Section 4.6.1.5 Production Counters Change Count

The current count value of a production counter by be changed. The user m ust obtain access control in order
to change a current count value. Access control is described in Section 3. If the user obtains access control
by using the password system, the user must be configured to have access to change counter settings.

To change a current count value, select the counter, depress the CHANGE COUNT softkey, and enter the
new value. To select a co unter, use the arro w keys to position the cursor on t he count value that is to be
changed. Once the cursor is positioned on the co unt value t o be changed, press the CHANGE COUNT
softkey. Then enter the new count using the numeric keypad. After t he cor rect limit is entered, press the
ENT key.

Section 4.6.2 Stroke Counter

The strok e c oun te r i n cr em e n ts a n y ti m e th e c ran k sh a f t tra ve l s f rom th e top of th e s troke to the b ottom of the
stroke. This counter increm ents i n all press operating modes, unl i ke the production counters that in cremen t
in production modes; Single Stroke, Continuous, Automatic Single Stroke, Continuous on Demand or
Main tained Conti nuous modes, only . The stroke counter is reset f rom the press control confi guration m enu.

Section 4.6.3 Scrap Counter, Scrap Rate

The scrap counter is used to keep track of the numb er of scrap parts that have been produced. This counter
is automaticall y increased when the tonnage m oni tor registers an out of li m i t hi t. It may be changed, added
to, subt r acted from, increased by one, or decr eased by one manually. When the scrap count er is manually
increased b y a count, all production counters are automaticall y decreased by the same count. When the scrap
counter is manually decreased by a count , all production counters ar e automatically increased by the same
count.

Note:
The total num b er of parts in the system i s constant. If there are 1000 parts in the order count and 100 parts
in the sc rap count, there is a total of 1100 parts i n the system. Changing the scrap count to 500, will result
in the order count being changed to 600. Since there are only 1100 part s in the system, the scrap count
cannot be changed to a value greater than 1100.

The user must obtain access control i n order to change the val ue of the scrap counter, add to or subtract from
the scrap counter. Access control is n ot required to increm ent the scrap count by one or decrement the scrap
count by one. Access control is described in Section 3. If the user o btains access control by using the
password system, the user must be configured to have access to change counter settings.

4.23

To change the value of the scrap count, position the cursor on the scr ap counter and select the CHANGE
SCRAP softkey. Then enter the new count using the numeric keypad. After the correct value is entered,
press t he E NT key. If the scrap count is increased, t he amount by which it is increased is subtracted from
the production counters. If the scrap count is decreased, the amount by whi ch it i s decreased is added to the
production counters.

To ad d a num ber of s cr a p pa r ts to the sc ra p cou n te r, pos iti on the cu r s or on the s c ra p cou nter a n d s e lect the
ADD TO SCRAP softkey. Then enter the numb er to be added using the numeric key pad and press the ENT
key. The number entered is added to the scrap count and subtracted from the production counters.

To subtr act a number of scrap parts from the scr ap coun ter , po sition the cursor on t he scrap count er and
select the SUBTRACT FROM SCRAP softkey. Then enter the number to be subtracted using the num eric
keypad and press the ENT key. The number entered is subtracted from the scrap count and added t o t he
production counters.

To increase the scrap count er count, press t he INCREMEN T SC RAP softkey. The value of the scrap
counter will i ncrease by one. The current count value of al l production counters with a current value greater
t han zero a nd which a re turne d on, will de crease by one.

To decrease the scrap counter press the DECREMENT SCRAP softkey. The val ue of the scrap count will
decrease by one. The current count value of all production counters with a current value less that its limit
will increase by one.

The scrap rate is also displ ayed on the counter screen. The scrap rate is the cal cul ated by di viding the scrap
count by th e su m of the s crap count and the curr ent ord er count. If the Orde r Counter is turned off, “N/A”
will be displayed for the scrap rate. This indicates that the scrap rate is not applicable, since a true value of
the order count is not avail ab l e. It should be noted that if the user ignores the decimal poi nt and the percent
symbol, the number displayed is the scrap rate in parts per million, ppm. For example, a scrap rate of .3984%
is equivalent to 3984 ppm.

Section 4.6.4 Configure Counters

As described in Section 4.6.1 counters can be configured on a job basis. The counter configuration menu
must be access with the key switch and by use of the current Configurat ion code. The Configurat ion code
is described in Section 5. The counter configuration information is stored with other job related information.
Whe n a jo b is r ec a lle d th is co unte r infor ma tion is a ls o r e c a lled . It mu s t be noted tha t othe r c onfigu r a tion
param eters as descri bed in Secti on 5 and not job rel ated param eters, b ut are ma chi ne re lated p aram eters. The
configurat ion parameters in Section 5 related to all jobs and are not changed when the job is changed.

Depressin g th e CONFIG C OUNTER softkey from the Coun ter s men u, Figure 4.14, will display the Enter
Configuration code box. Enter the correct code and depress the ENT (Enter) key. The Counter
Configu rat ion men u, Figure 4.15, will b e d isplaye d.

4.24

0

0

Stroke

TOP

COUNTER NAME

Order Counter 1 1
Batch Counter 1 1 YES
Quality Counter 1 1 YES
Aux 1. Counter 1 1 NO YES
Aux 2. Counter 1 1 NO YES
Aux 3. Counter 1 1 NO YES
Aux 4. Counter 1 1 NO YES
Aux 5. Counter 1 1 NO YES
Aux 6. Counter 1 1 NO YES
Aux 7. Counter 1 1 NO YES

Single Stroke

Mode

COUNTS
BY

Set Counts to Zero When J ob R ec alled: YES

Drive

Speed
Stroke

Speed

EVERY
HOW
MANY
STROKES

SPM

0
0

SPM

RESET
WHEN
ORDER
COUNTER
RESET

Figure 4.15 Counter Configuration Menu

Section 4.6.4.1 Configure Auxiliary Counter Names

Order

Counter

PC STATUS

Program/Run Sw itc h

ENABLE
COUNTER

1000

COUNTER
CONFIG

EXIT

CHANGE
INCREMENT

CHANGE
STROKES

CHANGE
SETTING

CHANGE
NAME

The names of the seven auxiliary counters can be programmed by the user. The names of the Order, Batch,
and Quality counters are fixed and cannot be programmed.

To cha nge an a uxiliar y counter name position th e c ursor on the counte r name to b e c h anged a nd pr ess the
CHANGE NAME softkey. The text edit box will appear and the name can be entered. Press the ENT key
to save t he name and exit the t ext edito r .

Section 4.6.4.2 Configure Counter Count By Value

The Count By value of all counters can be programmed. Nor mally this value is one. However, on certain
applications, such as multi part out dies, this value can be a number other than one. A counter will increase
its value by the programmed Count By v alue. If a die produced two parts each stroke, the Count By v alue
o f the Or der Co unter shou ld be two. The counter will inc rease its value by t wo e v ery time it increases.

To change the increment value position the cursor on the Counts By value to be changed, press the
CHANGE INCREMENT softkey, enter the new number, and press t he ENT key

Section 4.6.4.3 Configure Counter Every How Many Stroke Value

The number o f press strokes between counter increments can be programmed. Normally this value is one.
However, on certain applications, such as lamination dies, this value can be a number other than one. If a
die produces a part every ten strokes, the Counter Every How Many Stroke value sh ould b e set to ten. The
counter will inc rease its cou nt ever y ten pr ess strokes.

To change the numb er of strokes value posi tion the cursor on the Counts By value to be changed, press the

4.25

CHANGE Stro kes softkey, enter the new number, and press the ENT key

Section 4.6.4.4 Configure Counter Reset When Order Counter Reset

All counters other than the Order counter can be reset in two ways. The counters can be individually reset
or t he co unter can be reset when the Order counter is reset.

To chan ge the Reset When Order Counter Rese t setting of a c ounter positi on the cursor on the value to be
changed, press the CHANGE SETTING softkey.

Section 4.6.4.5 Configure Counter Enable

Each o f th e seven a uxiliar y counters can be enable d or disabled. When a counter is enable d, it will appe ar
o n t he c o u nt e r s c r e e n . W hen a c o u nte r is dis a ble d it w ill not a p p ea r o n th e c o u nte r sc r e en . T he Ba t c h,
Order, and Qualit y counters are always enabled.

To change the Enab l e Counter setting of a counter position the cursor on the value to be chan ged, an d press
the CHANGE SETTING softkey.

Section 4.6.4.6 Configure Reset Counters When Job Recalled

This configuration provides the user with the option to restore the counters’ previous count when a job is
rec alled. If s et to “No”, all counters will be loaded with the previous counts that were registered when the
las t jo b r u n w a s te r mina t e d . A jo b is t e r mina t e d w h en an o t he r jo b is r e ca lle d. F o r e x a mp le , J o b A w a s
running on a machine and it was decided that Jo b B should be run on the machine. The Order Counter for
Job A was at 1020. When Job B was loaded from memory with a Job Recall, the current count for Job A’s
Order Counter, 1020, was stored in mem ory. The nex t time that Job A is l oaded with a Recall , the count for
t he Or der Co unter will be set to 1020.

If a job is not ter minated by a recall of another jo b, the current counter information will be lo st . In t he
exampl e above, if Job B was not loaded from m emory wi th a Recall , but instead was set-up by changi ng some
of the settings that were already l oaded for Job A, the current counter information at the end of Job A would
be lost.

A “Yes” configu ra tion will set the cu rren t count for a ll count ers to 0 when the job is recalled.

To c hange the Reset Counter When Job Recalled setting of a counter position the cu r sor on the value to be
changed, and press the CHANGE SETTING softkey.

Section 4.7 Motor Speed Adjustment (When Provided)

The System 5000 all ows the operator to enter stroking speed from the keyboard as shown in Fi gure 4.16 and
automatically sends this command (as an analog signal) to the motor dr ive. The stroking speed can be set
over the entire speed range of the press (determined by the configuration), but the press control can
automaticall y l i m i t the output in certain m odes. For exampl e, a press that has a maxi m um stroking speed of
400 Spm may be configured to limit single stroke mode to less than 250

4.26

Spm. In thi s si tuation, the operator can enter a speed settin g up to 400 in any mode but the comm an d signal
t o t h e d rive w ill g o no h ig h e r th a n 2 5 0 s pm w he n S in g le S tr ok e mode is se l ected (i .e . it w ill c lamp a t the
configured limit). In addition, t he pr ess co ntr o l can be configured to co mmand a fixed speed in Inch and
Tim ed Inch m odes in whi ch case the operator’s speed setting wi ll not take place unti l the appropriate stroking
mode is selected. T he operato r should be aware of how the press is intended (has been configured) t o
funct ion in all stro king modes. Messages are displayed on t he screen to indicate if the press contro l is
configured for fixed inching speed or if a limit has been placed on single stroke modes.

As shown in Fi gure 4.16, both drive speed (Spm ) and m otor current (% Load) are displayed in num eri c an d
bar graph f ormats. The Spm b ar graph ranges f rom 0 Spm to the maxi m um strokes/min ute of the press (see
Section 5.2.5). The % Load bar graph ranges from 0 to 200 %.

0

0

Stroke

TOP

Motor Speed . . . . . . . 200 SPM

Inch Mode Speed is Fix ed at . . . . . . 50 SPM

Maximum Sin gle Str oke Speed is . . 250 SPM

SPM
200

Mode

% LOAD
161

Single Stroke

Drive

Speed
Stroke

Speed

200

Order

SPM

Counter

0

SPM

Ready to Stro ke

Counter OFF

PC STATUS

MOTOR
SPEEC

CHANGE
NUMBER

SPM
UP

SPM
DOWN

EXIT

Figure 4.16 Motor Speed Adjustment

The user must obtain access control in order to change the motor speed value. Access control is describ ed
in Section 3. If the user obtains access control by using the password system, the user must be configured
to have access to change motor speed.

Moto r speed can be changed by either enter ing a new value or by using the SPM UP and SPM DOWN
softkeys. To enter a new Motor speed value, depress the CHANGE NUMBER softkey and enter the new
value from the numeric keypad. After the corr ect motor speed value is entered, press the ENT key.

Section 4.8 Quick Access (ACC key)

The upper right hand key, ACC, can be us ed from any screen v iew the Quick Access screen. Thi s s creen is
shown in Figure 4.17.

4.27

0

0

Stroke

TOP

1

CURRENT LOGIN IN: OPERATOR # 1

2

Press lube should be type xyz. Check level dai ly
Flywheel belt def lection should be no t more that 1” at midpoi nt .

Mode

Single Stroke

Drive

Speed

Stroke

Speed

MACHINE NOTES

200

Order

SPM

Counter

0

SPM

Ready to Stro ke

Counter OFF

PC STATUS

QUICK
ACCESS

EDIT
NOTES

3

Use material lube abc for this part
Material shoul d have a maximum thickness of .161

NOTES FOR JOB # 1

LOGOUT

AUXILIARY
COMM.

EXIT

Figure 4.17 Quick Access Screen

Th is disp lay provides the following info rmat ion :

1. T he name of the current user who has access contr ol. If the user logged in using a password.

2. Machine notes. These are notes that per tain to the machine.

3. Jo b notes. Th ese are notes tha t pertain to the job . These notes will be sav ed and recalled with the
job setup.

Section 4.8.1 Machine Notes

The Machine Not es area allows info rmation concerning the machine to be entered and displayed. This
inf ormation i n not change as the current job is ch anged. This area al l ows for eight li nes of text with each li ne
containing up to 59 characters.

Section 4.8.2 Job Notes

The Job Notes area allows information concerning the job to be entered and displayed. This information is
stored and recalled with the other job related information. This area allows for eigh t lines of text with each
line containing up to 59 characters.

Section 4.8.3 Editing Machine Notes and Job Notes

The machi ne n otes and job n otes can be changed b y f i rst selecting the EDIT NOTES softkey. The user must
have access control to edit these notes. Access control is describ ed in Section 3. If the user obtains access
control by usi ng the password system, the user must be configured to have access to store jobs. Position the
cursor to the line that is to be changed. Select the CHANGE TEXT softkey. The text edit box will appear
and the line can be edited. Press t he ENT key to save the text o n the line. If another line is to be edited,
po s it io n th e c u r so r t o th at lin e a nd r e p ea t t h e s t e ps a bo ve . T he a rro w ke y s w ill mo ve t h e c u r so r fo r t h e
Machine N otes box to the Job No tes box.

4.28

In order for the job notes to be saved after editing, the current job must be stored. Job storage is described
in Section 4.5.1.

Section 4.8.4 Auxiliary Communications

The AUXILIARY COMM softkey will pro vide access to co mmunication opt ions. These opt ions include
co mmunica tion with elect ronic ser vo fe eds, auxilia ry equip ment (such a s PLCs) , a lapt op int erface for
downloading messages, and a network interface. See the manual pertaining to the particular device that is
connected for communication.

Section 4.8.5 LOGOUT Softkey

Selecting the LOGOUT so ftkey will remove access contr ol from the current user. If a user has logged in
using th e p assword sys tem, this user will retain access cont r ol until the user is logged out. Log out can be
either m an ual or automatic. A user can b e m an ual l y l ogged out by usi n g the LOGOUT Softkey . Automatic
lo g out is describe d in Section 3.

4.29

Secti on 5 Press Control C onfiguration Menus

The System 5000 allows the user to configure the contro l and the operat or terminal for specific machine
requirement s . T his rest r icted menu section is accessed from the Press Cont ro l menu. The Configuration
softkey is available only in the Program/Run switch is in the PROG position. The Press Control menu with
the Program/Run switch in the PROG position is shown in Figure 5.1.

0

0

Stroke

TOP

Brake Monitor Limit Stoptime
Top Stroke Stop 0200 183 mSec

Mid Stroke Stop 0250 0 mSec

Clutch time 0275 0250 mSec

Auto Single Str oke Time ……… 5Sec
Feed Compl et e Position ……… 25 Degs
Cont. on Demand Time ……….10 Mins

Auxiliary Equipment Message
Option is not Instal led

Reason for the La st Sto p
Power Up

Present Runni ng Status
Ready to Stroke

CONFIGURE

Mode

AUXILIARY
COMM.

Single Stroke

Limit Actual

Drive

Speed
Stroke

Speed

0
0

DIAGNOS

SPM

SPM

SPM
0

OPERATOR
STATON

Order

Counter

Program/Run Switch

% LOAD
161

Counter OFF

PC STATUS

PRESS
CONTROL

CHANGE
NUMBER

MOTOR
SPEED

TONNAGE
MONITOR

AUTO
SETS

DIE
PROTECTION

EXIT

Figure: 5.1 Press control menu

If the CONFIGURE softkey is selected, the display will ask for the Configuration code. This Configuration
code is user programmable. The original code is sent from the factory to a perso n so designated when the
contro l is ordered. See Section 9.2. T he user has the opt ion of keeping the orig inal code o r changing to
another. The user must reco rd a nd pr ot ect t he current code. This code must be provided to qualified
personnel only. If entered correct ly, a selection of configuration menus shown in Figure 5. 2 is p r es e nt ed.
Once access to the confi guration menu has been granted, the Program/Run switch may b e switched back an d
fort h between PROG and R UN. The configurat ion mode will remain in effect until manually Exited,
returning the display to the press control menu.

0

0

Stroke

TOP

Single Stroke

Mode

Top Stop Cal ib ration

Machine Parameters

Lubricatio n System

Operator Ter m in al

Restricted Pr ogrammable Lim i t S wit ch

Names and Messages

Exit Calibration

Drive
Speed
Stroke
Speed

Order

SPM

0

Counter

0

SPM

Program/Run Switch

Counter OFF

PC STATUS

P/C
CONFIG.

TOP STOP
CALIBRATE

MACHINE
PARAMETERS

LUBE

OPERATOR
TERMINAL

RESTRICTED
PLS

NAMES

Figure 5.2 Configurations Menu

5.1

EXIT

Section 5.1 Top Stop Calibration

There are two versions of Top Stop Calibration. Th ese are Link Standard and Link High Speed. The Link
Standard Top Stop calibrat ion is for Link controls that supports the standard st op on top algorithm. Link
standard controls are intended to be used on presses that can stop in 180 degrees or less when stro king at
their maximum speed. The screen for this standard to p st o p ca libra t ion is shown in Figure 5.3. Sections

5.1.1, 5.1.1. 1, and 5.1.1.2 describe the stand ard t op stop calibration. The Link High Speed Top Stop
cali b ration i s f or Li nk controls that supports the hi gh s peed stop on top algorithm . Li n k h i gh s peed controls
are intended to be used on presses t hat cannot st op within 180 d egr e es when stro king at their maximum
speed. The screen for this top sto p calibration is shown in Figure 5.4. Section 5.1.2, 5.1.2. 1, and 5.1.2. 2
describe the high speed top st op calibrat ion.

All OmniLink controls are capabl e of adjusting the stop on top angle. The angl e at which the press control
begin s to stop is automatically adjusted to compensate for the speed of the press in order to come to rest at
top dead center over the operating speed range of the mach ine. The stopping angl e calculated by the press
contro l is based on information programmed in a calibrat ion menu . The stopping characteristics can be
programmed separ at ely for st ro king modes t hat st op after each st roke (I nch, Timed Inch, Single Stroke,
Automatic Single Stroke, and Trip Mode) and for stroking modes that run several strokes before stopping
(Continuous).

Section 5.1.1 Top Stop Calibration, Link Standard

The menu shown in Figure 5.3 allows the press control's top stop angle to be cal ibrated at four speeds that
describe the operating range of the m ach ine. It should be noted that speed adv an ce is b ased on the speed of
the crankshaft and not the flywheel.

5.2

Stroke

TOP

Speed Advance Top Stop

Stroking
Mode

Single

5

Continuous

6

0

Mode

1

0

Single Stroke

Speed and Stopping Angle

50

340
338

2 3 4

Drive

Speed
Stroke

Speed

100

330
328

200

150

320
318

0

200

310
308

SPM

SPM

Order

Counter

Program/Run Switch

RPM

Counter OFF

PC STATUS

TOP STOP
CALIBRATE

CHANGE
NUMBER

[ Calculated }

Speed Top Ang

Ch A 050 340 340

7

Ch B 050 340 340

8

Stop Pos (Setup Mode) = 090

Measured
Stop Ang

MOTOR
SPEED

EXIT

Figure 5.3 Top Stop Configuration Menu Link
Standard Firmware

Th e d isplay sh ows th e following information :

1. T he programmed lowest operating speed of the machine.

2. T he programmed speed approximately 1/3 of the way between lowest and highest programmed
speeds.

3. T he programmed speed approximately 2/3 of the way between lowest and highest pro grammed
speeds.

4. T he pro g r ammed highest operating speed of the machine

5. The programmed angle at which the press will begin to stop when running at each speed shown.
These four angles are used when the press is in a single stroke mode, and will automatically stop at
the end of each stroke.

6. T he programmed angle at which the pr es s w ill begin to stop when running at each speed shown.
These four angles are used when the press is in continuous running mode.

7. The actual speed of the crankshaf t and computed top stop position recorded by the press control each
t ime a str oke is made .

8. T he programmed angle at which the press will begin to st op in the downstro k e when operat ed in
Setup/Sto p Time Test mode. See Section 5.1.3.

5.3

If configured, t he Mot or Speed Adjust screen can be accessed fro m this screen in order to change the
stro king speed of the press (see Section 4.7).

Section 5.1.1.1 Variable Speed Presses, Link Standard

Variabl e speed presses require a cali bration procedure be performed when the press control is in stalled. This
process uses the to p st op characteristics of the press at four programmed speeds. The suggested top sto p
calibration procedure is as follows:

1. S witc h to the PROG position and ent er t he four spee ds at which t he to p st op p os itio n will be
calibrated. These speeds, shown left to right, cor r espond to the following formulas:

Left Lowest operating speed of the machine.
Next Lowest speed + (1/3 (highest-lowest)).
Next Lowest speed + (2/3 (highest-lowest)).
Right Highest oper ating speed of the machine.

A cursor appears in the PROG mode to indi cate whi ch param eter is to be chan ged, an d is positioned
with the arrow keys.

2. Select Single Stroke mode. In this mode the four top stop angles shown on the line labeled Single
(li ne 5 ab ove) aff ect the stopping characteristics of the press. These parameters are used during thi s
port ion of the calibration process.

3. S et the flywheel speed to the lowest range.

4. S witch to the RUN position and operate the press.

5. Ad just t he t op st op angle until the press comes to r est at to p dead center. Changes are made by
selectin g the PROG mode and posi ti oning the cursor onto the stop angle for this speed and present
stroking mode.

NOT E:The ne w va l ues do n ot be com e w ri tten i nto th e pre ss control ' s m em ory un ti l the Prog ram /R un sw itc h

is returned to the RUN position.

NOTE:A top stop angle MUST be equal to or greater than the stop angle for the next higher speed range,

or it will be rej ected when returned to the RUN position. To program a new angle, the high er speed's
angle may have to be changed also.

6. S et the flywheel speed to the next speed range approximately 1/3 of the way between lowest and
highest pro gr ammed speeds. Repeat Steps 4 and 5.

7. S et the flywheel speed to the next speed range approximately 2/3 of the way between lowest and
highest pro gr ammed speeds. Repeat Steps 4 and 5.

5.4

8. S et the flywheel speed to the highest speed r ange. Repeat Steps 4 and 5.

9. Repeat steps 3, 4, 5, 6, 7, and 8 wi th the press in Continuous mode. In thi s mode the four top stop

angles shown on the line labeled Contin uous (line 6 above) affect the stopping characteristics of the
press. These parameters are used during this portion of the cali bration process. The Top Stop button
should be used to cause the press control to initiate a st op on top.

Section 5.1.1.2 Single Speed Presses, Link Standard

Singl e speed presses requi re a cali b ration procedure sim i l ar to that of variab l e speed m ach i n es b e performed
when the press control is install ed. Since the press operates at only one speed, the four program speeds and
top stop positions m ust be programmed to the same v al ue. The suggested top stop cali b ration procedure is
as follows:

1. S witch to t he PROG position and enter the speed at which the press is to be operat ed into all four

speed settings.

A cursor appears in the PROG mode to indi cate whi ch param eter is to be changed, and i s positioned
with the arrow keys (see section on Operator Terminal).

2. Select Single Str oke mode. In this mode the four top st op angles shown on the line labeled Single

(li ne 5 ab ove) aff ect the stopping characteristics of the press. These parameters are used during thi s
port ion of the calibration process.

3. S witch to the RUN position and operate the press.

4. Adjust the top stop angle until the press comes to rest at to p dead cent er . All four to p stop angles

for this stroking m ode must be set to the same value. Changes can be m ade only in the PROG mode.

NOT E:The new val ue s do n ot be com e w ri tten i nto th e p res s con trol ' s m em ory u nti l the Progra m/ Run sw itc h

is returned to the RUN position.

5. R epea t steps 3 and 4 with the press in Continuous mode. In this mode the four to p stop angles

shown on the li n e labeled Continuous (line 6 above) af fect the stopping characteristics of the press.
These parameters are used during this portion of the cal ibration process. The Top Stop button should
be used to cause t he press control to initiate a st op on top.

Section 5.1.2 Top Stop Calibration, Link High Speed

The menu shown in Figure 5.4 allows the press control's top stop angl e to be calibrated at two speeds (low
and high) that descr ibe the operat ing range of the mac hine. These calibrat ion parameters are used to
calculate t he coefficients to a nonlinear equation that models the stopping characteristics of the press and
entries that do not yi el d a valid equation are rejected. It should be noted that speed advance is b ased on the
speed of the crankshaft and not the flywheel.

5.5

0

0

Stroke

TOP

Manual Stroking Modes

Speed Low-High 0020 0100 RPM

1

Top Stop . . . . . . 0010 0050 BTDC

Continuous Stroking Modes

Speed Low-High 0020 0300 RPM

2

Top Stop . . . . . . 0010 0200 BTDC

[ Calculated }

Speed Stop Ang

Ch A 100 340

3

Ch B 100 340

4

Stop Pos (Setup Mode) = 090

Single Stroke

Mode

Speed Adjusted Top Stop

Drive

Speed
Stroke

Speed

200

0

SPM

SPM

Order

Counter

Program/Run Switch

Counter OFF

PC STATUS

TOP STOP
CALIBRATE

CHANGE
NUMBER

MOTOR
SPEED

EXIT

Figure 5.4 Top Stop Configuration Menu Link High
Speed

Th e d isplay sh ows th e following information :

1. T he prog ram sett ings for modes that sto p after each st ro ke (I nch, Timed Inch, Single S tro ke, and
Automatic Singl e Stroke). These settings incl ude a low speed (in Rpm) and associated top stop angle
(in Degrees Bef ore Top Dead Center) along with a hi gh speed an d top stop angle. These two speeds
define the minimum and maximum oper ating speed for t hese stroking modes. T he two to p sto p
angles should be set to stop the press at the top of the stroke at the speed limits. The press control
uses these settings to calcul ate coeff icients that describe the stopping characteristics over the entire
speed range.

2. The program settin gs for modes that run several strokes before stopping (Contin uous and Contin uous
on Demand). The settings include a low speed (in Rpm) and associated top stop angle (in Degrees
Before Top Dead Center) along with a hi gh speed and top stop angle. These two speeds define the
minim um and max imum operating speed for these stroking modes. The two top stop angles should
be set to sto p the press at the t op o f the stro ke at t he speed limit s. Th e p ress co ntro l uses these
settings to calculate coeff icients that describe the stopping characteristics over the entire speed range.

3. The actual speed of the crankshaf t and computed top stop position recorded by the press control each
t ime a str oke is made .

4. T h e p r o g r amme d a ng le a t w h ic h t h e p r e ss will b e gin t o s t o p in t h e d o w ns t r o k e wh en o p er a t e d in
Setup/Sto p Time Test mode. See Section 5.1.3.

Section 5.1.2.1 Variable Speed Presses, Link High Speed

5.6

Variabl e speed presses require a cali bration procedure be performed when the press control is i nstall ed. This
process involves running the press at both a low and high speed and adjusting the top stop position
(programm ed i n Degrees Before Top Dead Center) to stop the press at the top of the stroke at both speeds.
This procedure must be performed for bot h manual stroking modes and continuous stro king modes. The
suggested top stop calibrat ion procedur e is as follows:

1. With the Prog r am/Run switch in the RUN position, select Single Stroke mode.

2. Switch to the PROG position, use the cursor keys to move to the speed settings for manual stroke

modes, and enter the low and high operating speeds (shown as left and right columns respectively)
for the press (see a r ea 1 in Fig. 5.4). Move the cursor down to t he to p sto p po sitions for manual
stroke modes and enter the degrees before to p at which the clutch/brake o utputs should be de­energized i n order to stop the press at the top of the stroke for both the low and hi gh speeds. If these
parameters are not known, t hey can be determined by the following procedure:

Program the top sto p po sitions for both low and high speed to 0000. Switch to t he RUN position,
set the machine speed to the low stroking speed and make one str oke using the appropriate run
buttons. With both top stop positions set to the same value, the press control will NOT calculate a
stopping angle based on speed but will use the programmed setting at all stroking speeds. Examine
the calculated speed and stop angle (area 3 in Fig. 5.4) and verify that the actual speed is
approximately equal to the progr ammed low speed and that the calculated stop angle shows 000
degrees. Since the stop signal is generated at zero degr ees, the present crankshaft angle (shown in
the top left of the LCD) indicates the number of degrees that the press took to stop. Enter this
number into the top stop position settings for both low and high speed. Make one stroke using the
appropriate run buttons and verif y that the calcul ated stop angle i s the same as the programmed val ue.
Since the stopping characteristics of the press may be different in the downstroke than in the
upstroke, this first programmed top stop position may need to be adjusted to stop the press at the
des i red top of the stroke . If ad ju stm en t i s n ee ded, the ne w va l ue MU ST b e en tered i nto b oth top stop
parameters in order to pr event the press control fro m attempting to calculate a stop angle.

Once adjusted to stop at top at the low speed, set the machine speed to the high stroking speed and
make one stroke using the appropriate run buttons. Examine the c a lcula t ed speed and stop angle
(area 3 in Fig. 5.4) and verify that the actual speed is approximately equal to t he programmed high
spe ed and that t he calculated st op angle is the same as the value programmed into bot h t op s to p
positions. The present crankshaft angle (shown in the top left of the LCD display) indicat es t he
numb er of degrees past zero that the press traveled at this speed. Si nce the stop was ini ti ated some
number of degrees before top (shown as calculated stop angle), add the present crankshaft angle to
the calcul ated stop angle an d enter this val ue i nto the top stop position for high speed (do not change
the programmed top stop position for low speed). When the Program/Run key is switched to the
RUN position, the press control wil l use the two speed parameters and their associated stop positions
to calculate coefficients used in an equation that describes the stopping charact er istics of the press.
Fro m this poin t o n the press co ntrol will calcula te a stopping angle ba sed on speed throughout the
entire speed range of the press. Since the stopping characteristics of the press may be di ff erent in the
downstroke than in the upstroke, it may be necessary to adjust the high speed top stop position in
order to stop the press at the desired top of stroke. Once programmed f or operation at high speed,
the press can be operated at any intermediate speed to verify t hat t he calibration procedure has

5.7

generated the cor r ect sto pping curve.

3. With the Program/Run switch in the RUN position, select Continuous mode.

4. The sam e top stop calib ration procedure as described above can be performed f or Continuous stroke
modes (area 2 i n Fig. 5.4). It should be possi bl e to use the man ual stroke mode settings as a starting
point and then make adjustments at the low and high sp e ed s to co mpensate for different sto pping
characteristics in cont inuous str oking modes. If Continuous mode allows the flywheel speed to be
set higher than Single Stroke, after calibrating at t he first two speeds, set the speed pot to the
maximum stroking speed. Since the press control is operating with a calibrated stopping curve, the
calculated speed and to p stop angle (area 3 of Fig. 5.4) should indicate the actual values for t his
speed. Press the top stop button and enter the calculated speed and stop angle from the last stroke
into the high speed column f or Continuous stroke modes. It may then b e necessary to adjust this hi gh
speed top st op position in order to achieve the desired to p of stroke.

Section 5.1.2.2 Single Speed Presses, Link High Speed

Single speed presses can be calibrated by setting the top stop position for both low and high speed to the
same value. This prevents the press contro l from calculating a stopping angle based on press speed, and
instructs the control to initiate a top stop at the angl e programmed regardless of speed. Thi s stopping angl e
can be set differently for manual stroking modes and continuous stro king modes (see Figure 5.4).

Section 5.1.3 Stop Angle (Setup Mode)

This programmed angle is used ONLY in the Setup/Stop Tim e Test m ode, and is limited to between 2 and
358 degrees. It is used at all speeds, and is intended to provide a repeatable sto p signal with which to
measure the stopping tim e of the press and to aid in the setup of mechan ically driv en feeds. This angle can
be changed only in the PROG mode by positioning the cursor onto this parameter and using the numeric
keypad. As indicated above t his angle is used only in the Setup/St op T ime Test mode, and is limited t o
between 2 and 358 degrees.

Section 5.2 M ach in e Parameters

The m enu shown i n F i gure 5.5 shows the machi n e parameters that can be chan ged b y the user. Chan ges can
be made onl y i n the PROG m ode. The arrow keys are used to position the cursor onto the parameter which
is to be change.

5.8

0

0

Stroke

TOP

Parameter Setting

Encoder Offset ……………………..
Auto Carry Up ……………………..
Begin Timed Inch………………….
Minimum Strokes / Min …………..
Maximum Strokes / Min ………….
Motion Filter ……………………….
Clut ch Engage me nt ……………...
Timed Inch Pulse …………………
Automatic Turn Off ……………….
Max. # Engage/Min ………………..
Top Stroke Stop Time …………….
Mid Stro k e Stop Time …………….

Mode

Single Stroke

Drive
Speed
Stroke
Speed

180
100

200

200

200
240

1

50

1

50

0
0

deg
deg
deg
Spm
Spm

mS
mS
Min

mS
mS

200

Order

SPM

Counter

0

SPM

Program/Run Switch

Counter OFF

PC STATUS

MACHINE
PARAMETERS

CHANGE
NUMBER

SET
ZERO

FACTORY
CONFIG

SPEED
CONFIG

EXIT

Figure 5.5 Machine Parameters
Configuration

Section 5.2.1 En cod er Offset

The offset is to compensate for mi salignment between the resolver/encoder zero and the mach ine zero. To
enter, the user must position the crankshaf t at top dead center and press the SET ZERO softkey . The off set
value displayed is the number that must be added t o t he actual resolver reading to get 0°. If the present
re s olv e r a ngle is w ithin t h e allow a b le limit, the a n g u lar d is pla y va lue w ill indic a te 0°. This value is limited
to ± 10° from reso lver zer o. If the position is beyond t he limit, the limit is used as the offset. Co arse
adjustmen t is provide d by allowin g ma nual en try of 0°-9° or 350°-359°.

Section 5.2.2 Automatic Carry Up Position

This param eter is the angl e at which the press control wi l l automatical ly keep the cl utch/brake val ve engaged
until the machi ne reaches the top of the stroke. It is used only i n Si ngl e Stroke and Automatic Singl e Stroke
modes. Once this angl e is reached, an operator may release the run buttons wi thout causing the press to stop.
Th is value is limited to b etwee n 120° and 180°, and an entry beyond the limit is rejected.

Section 5.2.3 Begin Timed Inch Position

This parameter is the angle in the downstroke at which the press control will enter timed inch. It is used only
if the Timed Inch mode is selected. The timed inch function will continue until the crankshaft angle reaches
180°, o r a n o t he r s tr o kin g mo d e is s ele ct e d. T his v alu e is limit e d t o be t we en 0 ° and 135°, and an entry
beyond th e limit is re jected .

Section 5.2.4 Minimum Strokes/Minute

This parameter is the minimum speed threshold for the motion detector. It is used to verify clutch
engagement and t o det ect loss of resolver/encoder mot ion due to a failure in mechanism (chain etc.) that
connects the resolver/encoder to the crankshaft. The threshold is used to indi cate the start of motion or the
loss of motion and sh ould therefore be set well b elow the actual mi ni m um operating speed of the press. This
value is lim ited to between 2 and 100 rpm , and an entry bey ond the limit is rejected. Entries are rounded to

5.9

the nearest accept able rpm.

Section 5.2.5 Maximum Strokes/Minute

This param eter also appears in the Conf i gure Speed screen and can al so be programmed in that screen. See
Section 5.2.13.1. This parameter is used to scale the analog input of flywheel speed to t he R/D board for
variab le speed presses. A full scale i nput (+5 volt on the A/D converter) is considered to be this speed and
all other inputs are scaled accordin gly. Thi s parameter is also used in com bination with the m otion filter to
dete rm i n e th e l e n gth of ti m e th at l os s of m oti on ca n ex i s t du ri n g th e str oke wi th ou t ca us i n g a stop con diti on .
This v alue is limited to between 10 and 920 rpm. The resolution of the press control veloci ty calculation is

1.83 rpm for mach ines below 460 rpm and 3.66 rpm for machines equal to or greater than 460 rpm. Speed
parameters are rounded t o the nearest resolvable number when entered into the press co nt r ol.

Section 5.2.6 Motion Filter

This parameter defines a limit on the amount o f time after clutch engagement that motion can drop below
the minimum strokes/ min se tting before being c onside red a s top condition. This “loss of motion” mo nito r
is i n tended to detect conditions such as a breakage in the connection f rom the crankshaf t to the resolver and
if motion re mains belo w t he min imum limit for mo re than the p rogr ammed time an immed iate sto p is
gene ra ted a nd the reason for t he last s top will dis play “Motion Stopped”. T his valu e is limited to be tween
0 and 2, and an entry beyond t he limit is rejected. The table below describes the effects of this parameter.
For example, a press with the maximum strokes/minute set at 20 and a motion filter o f 000 will g enerate a
loss of motion time of 3/20=.150 seconds.

Number Time (in Sec) motion can fall below threshold.

-------------------------------------------------------------------------------------------­00 3.0 divided by (maximum strokes/min) (minimum filter)
01 5.0 divided by (maximum stro kes/min) (medium filter)
02 7.5 divided by (maximum stro kes/min) (maximum filter)

Section 5.2.7 Clutch Engagement Time

This parameter is the maximum length of time allowed after the clutch/brake valve is engaged until motion
becomes greater than the minimum speed threshold. The al l owabl e l i m i t and actual clutch engagemen t tim e
are displayed in the press control menu. This value is limited to between 4 and 996 milliseconds, and an entry
beyond th e limit is re jected .

Section 5.2.8 Timed Inch Pulse

This parameter i s the l ength of ti me that the clutch/b rake val ve i s kept engaged in the Tim ed Inch m ode. The
press control will automatically turn the valve off after this time period has elapsed. This value is limited to
between 16 and 500 millisecon ds , and an entry be yond th e limit is re jec ted.

Section 5.2.9 Automatic Turn Off

This parameter is the length of time that the main motor can be left on without operating the press and is

5.10

provided as an energy conservation feature. After this time has elapsed, the press control will turn its LMC
relay off until the main motor t ur ns off. This value is limited to between 0 and 250 minutes, and an entry
beyond the limit is rejected. An entry of 0 disables this feature.

Section 5.2.10 Maximum # Engagements per Minute

This p ara meter sets the maximum number of times that the clutch/brake valve can be energized and de­energized in any 1 minute interval. This opt ion is typically used to pr event excessive heating of the clutch.
A 1 minute timer is started upon the first activation of the clutch valve and the number of re-activations is
moni tored. If the operator attempts to dis-engage an d then re-engage the v al ve m ore than thi s programm ed
number of settings within the time interval, the press control will automatically inhibit further stroking for
the remainde r o f the 1 minut e, and t he p re sent ru nning st at us w ill dis play “Max. # Engage Delay”. This
m on itor also a p p li e s to Tim e d Inch m od e in w h ich cas e the n u mbe r of au tomati c p u lse s at the b ottom of th e
stroke can not exceed this programmed limit. This option is turned Off by setting the parameter to 000.

Section 5.2.11 Top Stroke Stop Time

This parameter sets the maximum tim e all owed for the press to come to re st when a utomatic ally stopped at
the top of the stroke. If the measured stop time exceeds this limit the operator must acknowledge the fault
by pressing the RESET ERROR softkey before any further st r okes can be initiated (see S ection 4.2. 1 and
Section 4.2.10). Since this limit applies only when the press is being automatically stopped at the top of the
stroke, it can be set close to the actual tim e requi red an d can b e used to detect early wear i n the brake. This
limit can be set from 20 milliseconds t o 998 milliseconds.

Section 5.2.12 Mid Stroke Stop Time

This par am e ter se ts the m a x i m u m ti me al lowe d f or the p re ss to com e to re st w he n stop pe d d urin g th e s trok e.
If the measured stop time exceeds thi s li m it the operator must acknowledge the faul t by pressi ng the RESET
ERROR softkey before any further strokes can be i niti ated (see Section 4.2.1 and Section 4.2.10). Since this
limit applies when the press is stopped in the downstroke it establishes the maximum allowable stopping time
of the press and can be used to determine the m in im um safety di stance f or two hand control and li ght curtain
safety devices. The Setup/Stop Time Test stroking mode can be used to determine the maximum stopping
t ime of the press (see Se ction 4 .3. 1). This limit can be set fr om 20 millisecond s to 998 milliseconds.
.

WARNING! When your press is equipped with two-hand control devices and/or presence sensing
devices for point of oper ation protection, only qualified personnel with a knowledge of ANSI (B11.1),
OSHA (CFR 1910.217), or other regul ations that gover n the re lationship between s topping time and
the distance at which two-hand control and/or presence sensing devices are to be located should set
or reset stop limits for the brake monitor. These limits must never be set for longer times than the
time the safety distance is based on.

Section 5.2.13 Machine Speeds

The Confi gure Speed screen is accessed by pressing the SPEED CONFIG softkey i n the Machi ne Parameters
configurat ion screen. The Configure Speed screen is shown in Figure 5.6. The speeds associated with
particular stroking modes shown in this screen are speed “limits” for the maximum number of s trok es/min

5.11

at which the press will stroke in that mode. On variable speed presses that have high maximum stroking
speeds for the Continuous mode, the st ro king speeds in Inch and Single Stro ke may be limited to prevent
excessive clutch and brake wear.

0

0

Stroke

TOP

Press Functio n Setting

Maximum Stro kes/ Min ………………..
Fixed Inch Spm…………………………
Max Single Spm………………………..
Flywheel To lerance……………………
Minimum Entry………………………...
Option Control………………………….
Cont.Modes Control…………………..
Low Spm Input Offset………………...
Low Output Spm……………………….
Low Output Cal #……………………...
Mid Ou t put Spm……………………….
Mid Ou t put Cal #……………………….
High Output Spm……………………...
Output Cali br at i on #…………………..

Mode

Single Stroke

Drive

Speed

Stroke

Speed

Order

SPM

200

405

50

100

0
0
0
0
0
0
0
0
0

400

Counter

0

SPM

Program/Run Switch

Counter OFF

PC STATUS

CONFIGURE
SPEED

CHANGE
NUMBER

ENTER
CAL. MODE

MOTOR
SPEED

EXIT

Figure 5.6 Machine Speed
Configuration

Section 5.2.13.1 Maximum Strokes/Minute

This parameter also appears in the Machine Parameters scr een and can also be pro g r ammed in that screen.
See Section 5.2.5. This parameter is used to scale the analog input of fly wheel speed to the R/D board for
variable speed presses and i ts value equals a full scal e input to the A/D converter. The mini mum resolution
of f lywheel speed is equal to this s peed divided b y 255. The parameter is also used in combination with the
m otion filter to determ in e the length of time that loss of motion c an exi st during the stroke without causing
a stop condition (see Section 5.2.6). This value is limited to bet ween 10 and 920 rpm. Speed par ameters
are rounded to the nearest resolvable number when entered into the press control. The maximum
strokes/mi nute value entered should be set slightly greater than the actual high speed for which the vari ab le
speed drive is adjusted.

Section 5.2.13.2 Fixed Inch Spm

This parameter is used to co nfigure the pr ess co ntr ol to str oke at a fixed speed in Inch and Timed Inch
modes. The example shown in Figure 5.6 describ es a press that has a maximum stroking speed of 400 s pm
but has been conf i gured to Inch at a fix ed speed of 50 spm. Each time Inch or Time d Inch m ode i s sel ected,
the anal og output of the press control wi ll command the drive to run at 50 spm. If a fixed Inch speed is n ot
desired, a programm ed se tting of 0000 wi l l turn this feature off an d the press control wi l l b ase i n ch speed on
the maxi m um sin gle s troke spm (Section 5.2.13.3). If turned off i n the ex ampl e (Fi gure 5.6), the press could
inched at any speed setting up to the maximum single str oke limit (100 spm).

Section 5.2.13.3 Max Single Spm

This parameter is used to set a maximum stroking speed for single stroking modes (any mode that
automaticall y stops at the end of each stroke). These modes include Single Stroke, Setup/Stop Time Test,

5.12

Automatic Singl e Stroke, and can in clude Inch and Tim ed Inch i f a f ixed Inch speed has been turned off. The
example shown in Figure 5.6 describes a press that has a maximum continuous stroking speed of 400 spm
but has b een conf igured to run no greater than 100 spm i n si ngl e stroking modes. Note that this i s not a fi xed
speed and that the motor speeds screen allows the speed to be set over the entire range. If the programmed
speed is greater than the maxi m um single stroke spm the anal og output to the driv e wi l l “clamp” at the limit.
For exampl e, i f the press descri b ed i n Fi gure 5.6 was stroking at 200 spm i n Contin uous m ode and was then
switched to Singl e Stroke mode the press control would comm and the driv e to run at 100 spm (the m axim um
single stro ke limit). If the progr ammed spee d s ett ing were t hen manually decreased no change would be
made to the analog output until the setting went below 100 spm. The drive is commanded to stroke at the
programmed setting if below the limit. If a maximum speed is not desired, a programmed sett ing of 0000
will turn this feature off and the press control can be initiated in single strokes modes over the entire speed
range.

Section 5.2.13.4 Flywheel Brake Tolerance

This parameter is not used in this version of software and should be set to 000.

Section 5.2.13.5 Minimum Entry

This param eter allows the press control to be conf igured to reject an operators attempt to run the press below
a defined point in production modes. In the example shown in Figure 5.6 a minimum entry setting of 075
would mean that t he press could not be operated in any product ion mode (Single Stroke o r Continuous)
below 75 spm. Note t hat the p re ss would still Inch a t 50 spm for d ie setting .

Section 5.2.13.6 Option Control

This parameter allo ws t he press contro l to be configured to sto re the speed sett ings for Co ntinuous and
Single Stro king modes along with the other job settings for each job. If this parameter is set to 001 these
se tt ings a re r ec alled w ith the job and th e mot or will au to mat ically d rive to the des ired spe ed w hen t he
production mode is sel ected. If this param eter is set to 000 the speed settings are not recall ed for job. If this
par ameter is s et to 002 the motor spee d control op tion is turne d Of f and th e press control will n ot generate
analog command signals to the drive. If turned Off the operator will not be given access to the Motor Speed
Adjust screen described in Section 4.7.

Section 5.2.13.7 Continuous Modes Control

This parameter allows the press control to be configured to ramp the press speed to the programmed
continuous speed setting after the clutch is engaged, in Continuous or Continuous On Demand modes. If
this parameter is set t o 001 and a maximum single stroke spm is programmed, when Continuous mode is
selected the drive is commanded to the maximum single str oke speed before t he str oke is initiated. When
the clutch is engaged the drive is commanded to t he cont inuous speed sett ing and remains there while
stro king. When the press sto ps the drive is commanded to the maximum sing le st ro ke speed and if the
stroking speed was greater than this “at rest” speed plus the flywheel brake tolerance, the flywheel brake is
app li e d to b rin g th e motor sp e e d to th e fi x e d at r e s t s e tting . T h is fea tur e is tur n e d off if thi s p ar a mete r is s e t
to 000.

5.13

Section 5.2.13.8 Low Spm Input Offset

This parameter is used in the calibrat ion pro cedure of the flywheel speed input t o the press cont rol. If
needed, this parameter can be used to adjust the spm reading at low speed (see Section 7.3).

Section 5.2.13.9 Low Output Spm

This p ar am e ter i s u se d to c ali b ra te th e a n al og outp ut f rom th e p res s con trol to th e m otor dri v e , an d to d ef i n e
the low end of the speed rang e for this press. Operat ing speeds or configuration speeds (i.e. fixed Inch
speed) can not be set bel ow thi s va l ue. See section 7.3 for more in f ormation ab out calib rating m otor speed.

Section 5.2.13.10 Low Output Calibration #

This parameter se ts the analog ou tput voltage req uir ed to dri ve the flywheel spee d to the Low Ou tput Spm
(see Section 5.2.13.9) . T he calibration number is scaled as:

Analog Out put (vdc) = Calibration # x 10.00 (4095=10.00 vdc)

4095

Cal. # Analog Out put Voltage
0000 0.0 vdc
1024 2.5 vdc
2048 5.0 vdc
3072 7.5 vdc
4095 10.0 vdc

An example of how this is used would be to set the minimum stroking speed of a press (high speed of 400
spm) to 50 spm. After the drive has been calibrated to o perat e at maximum rated speed with a 10.00 vdc
comman d si gn al , it i s f ound that 2.5 vdc is requi red to operate the press at 50 spm. Setting the Low Output
Spm to 50 spm and the Low Output Cali bration # to 1024 wil l conf i gure the press control to all ow operation
o nly fro m th e c onf ig u red L o w S p m to H ig h S p m. Th e an alog out pu t w ill be s c ale d to va ry line a rly fr om

2.5vdc at 50 spm to 10.00vdc at 400 spm.

Section 5.2.13.11 Mid Output Spm

This parameter sets the mid range speed of the press and can be used to compensate for non-linear
characteristics of the mot o r dr ive. If needed, it is used a long with the Mid Output Calibration # (Section

5.2.13.12) t o adjust the analog output command signal over the speed range of the pr ess. If not used it
should be set to 0000. See sect ion 7.3 for more information on calibrating motor speed.

Section 5.2.13.12 Mid Output Calibration #

This parameter sets the a nalog output voltage r equired to dri ve the f lywh eel spe ed to the Mid Ou tput Spm.
The calibration number is scaled as described in Sect ion 5.2.13. 10. An example of how this is used would
be after cal ib rated for low to high speed (as descri bed i n Secti on 5.2.13.10) the press control is programmed
to command 225 spm (1/2 of 50-400 spm) and outputs 6.25 vdc (1/2 of 2.5-10.0 vdc). However, with thi s

5.14

comman d si gnal the motor drive only strokes the press at 220 spm . In thi s si tuation the Mi d Output Spm can

g

(

(

p

p

p

yp

(

(

p

yp

(

(

p

be set to 225 spm and the Mid Output Calibrati on # can be set to whatever output voltage i s required to drive
the press to 225 spm. For example, if 6.30 vdc is required to drive the motor to 225 the cal. # is set to (4095
x 6.30)/10.00=2580. If no adjustment at mid range is required this parameter along with the Mid Output
Spm should be set to 0000.

Section 5.2.13.13 High Output Spm

This parameter sets the high speed of the press. The drive m ust be calib rated so that the press strokes at this
speed when the analog output o f t he pr ess control is at 10.00 vdc (cal. # of 4095). In the example shown
on Figure 5.6 the high output spm (maximum rat ed speed) of the press is 400 spm (see section 6.3).

Section 5.2.13.14 Output Calibration #

This parameter is used to initially calibrate speed of the motor drive to the 0.00 vdc to 10.00 vdc command
signal f rom the press control. When a num b er i s entered in to this f i el d, the press control enters a cali b ration
mode and converts the number entered into an anal og output command to the motor drive. The num ber can
range from 0000 (0.00 vdc) to 4095 ( 10. 00 vdc). This calibration mode can be used to slowly ramp the
comman d sign al to 10.00 vdc (cal # 4095) and cali brate the motor drive to the correct maxim um (hi gh output
spm) stroking speed of the press (see Section 7.3 of more information on the calibration procedure).

Section 5.3 Lube System

The lube system menu shown in Figure 5.7 allows the user to select one of several preprogrammed
lubrication systems. The type chosen automatically set s up the proper input co nfiguration, and allows the
user to enter any additional ti m i ng informati on i f required. To accomm odate recircul atin g oi l or grease l ube
systems with flow rat e sensors, t he system 5000 provides two inte rnal "Flow Rate" t imers that set the
maximum ti me for the lubri cati on cycle. The two timers all ow di fferent conditions to exist between power
up an d no r mal o p er at io n. I n ap plic at io ns wh er e t he "L ube Sys t em O ut p ut " ( O R- 5 ) is co nt r o lling a lu be
pump, additional timers are pro vided to control t he time between gr ease pulses (Output Off), the time the
output is kept on after proper flow has been verified (Output On), and the frequency at which the output is
pulsed duri n g the l ube cy cl e (Output Pulse). See Section 6.1.11 Lube System I/O for a detail ed descri pti on
of each type available.

0

0

Stroke

TOP

Lube Parameter Settin

Lube System Type ……………...
Flow Rate
Flow Rate
Out
Out
Out
Minimum # of Pul ses …………...

Aux. Lube 1 T
# of Strokes Off………………….
Flow Rate
Flow Rate
Out

Aux. Lu be 2 T
# of Strokes Off………………….
Flow Rate
Flow Rate
Out

Single Stroke

Mode

Running) …………...

Power Up)…………..
ut Off (Type 4)………...
ut On (Type 4)………...
ut Pulse (Type 4)………..

e………………..

Running)…………….

Power Up)…………..
ut P ulse……………………..

e………………..

Running)…………….

Power Up)…………..
ut P ulse……………………..

Drive
Speed
Stroke
Speed

10000

50000

Order

SPM

200

0

SPM

1
0

Sec

0

Sec

0

Mins

0

Sec

0

Sec

0

1

Sec

2

Sec

30

Sec

2

2

Sec

30

Sec

45

Sec

1

Counter OFF

Counter

PC STATUS

Program/R un Sw itch

LUBE
SYSTEM

CHANGE
NUMBER

EXIT

Figure 5.7 Lube System
Configuration

5.15

Section 5.3.1 Auxiliary Lube Systems (option)

If the optional expansion card rack and third input board are provided, two auxiliary lube systems are added
to the lube system menu as shown in Figure 5.7. These auxiliary lubes function independently, and allow for
metered systems only. Each allows the time betw een lubrication cycles to be set in terms of the number of
press strokes, variabl e f rom 10-99,990. A lube cy cl e duration tim e can be s et for both normal operation and
power up situations. See Sect ion 6.2.1 Aux. Lube System I /O fo r a detailed description o f each type
available.

Section 5.4 Operator Terminal Configuration

The operat or terminal configuration menu is shown in Figure 5.8

0

0

Stroke

Single
Stroke

Mode

TOP DISPLAY AREA CONFIGURATION

When in a Setup M ode
(Inch, Timed I nc h, Etc.)

Area 1: Drive Speed
Area 2: Stroking Speed
Area 3: Distance to Bottom
Area 4: Current Status

Rod/Strok e Units:

Rod Length:

Stroke Lengt h:

Operator Te rm inal Type:

Default Language:

Drive

Speed

Stroke

Speed

Area 1: Drive Speed
Area 2: Stroking Speed
Area 3: Order Count
Area 4: Current Status

Date: 03/18/2000
Time: 12:38:25 PM

In

30.000 in

7.500 in

Link Standard
English

200

When in a Produ ction Mode

(Single Stroke , Con t. . . . Etc .)

Counter

0

SPM

Program/Run Switch

Order

SPM

Counter OFF

PC STATUS

TOP DISP.
CONFIG.

CHANGE
SETTING

ZERO
STROKE
COUNT

ACCESS
CONFIG

AUXILIARY
COMM SETUP

EXIT

Figure 5.8 Operator Terminal
Configuration

Section 5.4.1 Display Type

The center sect ion and the right side section of the top display area can be configured t o show four items.
The choice of items are:

-Drive Speed

-Stroking Speed

-Auto Press Speed (Drive speed with press is not stroking and crankshaft speed when press is
stroking

-Press Control Status

-Press Control Reason for Last Stop

-Total Tonnage (If the control is equipped with a tonnage monitor)

-Counterbalance Pressure (If the control is equipped with automatic counterbalance adjust)

-Shut Height (If the control is equipped wit h automatic shut height adjust)

-Current Order Count

-Current Down Time Code

5.16

The displ ay ed item can change wh en the press stroking mode is ch anged. The user can chose f our items that
are to be di splayed in Setup modes, such as Inch and Timed Inch, and four items that are to be displayed i n
Production modes, such as Single Stroke and Continuous.

The displayed items can be selected by positioning the cursor into the area t hat is to be changed and
depressing the CHANGE SETTING softkey. A menu of items will app ea r on th e scr ee n. Only items that
are no t cu rrently selected will ap pe ar. Select the item to be displayed a nd th en pr ess the ENT key.

Section 5.4.2 Time and Date

This control contains a real time clock. To set the time and date, po sition the cursor o ver the value that
requires chan ge, depress the CHANGE NUMBER softkey, enter the new v alue usin g the n umeric key pad,
and press the ENT key.

Section 5.4.3 Rod Length and Stroke Length

The rod length and stro ke length are used to calculate the distance fro m the bott o m of the stro ke. T hese
it ems ca n be displa yed and entered in either inch es of millimeters .

To c han ge th e u nit s fo r inch es to millime t er s o r fr o m millimet e rs t o in che s, po s it ion th e cu r s o r o ve r t he
Rod/Stroke Units and the depress the CHANGE SETTING softkey.

The rod length is the len gth of the connection between the center of the crankshaf t and the slide connection
point. Val ues between 000.000 and 384.000 in ches (0.00 and 9753.60 millimeters) may be entered. To enter
the rod l e n gth , pos i ti on th e c urs or ov e r th e R od L en g th, de pre ss th e C HA N GE N UM B ER s of tk ey , e n ter th e
new value using the numeric keypad, and press the ENT key.

The stroke length is the total linear travel of the press slide from top to bottom. The stroke length of the
press must be en tered when the Om niLin k 5000 control is i n stal l ed on the press. Val ues between 0.000 and

384.000 inches (0.00 and 9753.60 millimet e rs ) ma y be e nt e re d. T o e nt e r t he st r o ke leng t h, po s itio n th e
cursor o ver the Str oke Length, depress t he CH ANG E NU MBER so ftkey, enter the new value using the
numeric keypad, and press the ENT key.

Section 5.4.4 Operator Terminal Type and Default Language

The Operator Termin al Ty pe f or the control described in thi s m anual sh ould read, “Link Standard” or “Link
High Speed.” Lat e r ve r sio n s o f t he Omn iLi nk c o nt r o l w ill a u t o ma t ic ally d e t e ct th e c o n t r o l t yp e. E a r lie r
versions of the Om n i Li n k control wil l requi re that the correct type be en tered. The Operator Termin al Ty pe
is ent er ed by pressing the CHANGE TYPE softkey and selecting the correct type.

The Defaul t Language settin g sel ects the screen l anguage that wi l l appear when the sy stem powers up. The
Default Language can be changed by pressing the CHANGE TYPE softkey and selecting the desired
lan guage.

Section 5.4.5 Zero Stroke Count

5.17

To zero the stroke count, aut ho r ized personnel must enter a specific number and press ENT. The number

y

q

y

y

y

g

y

y

q

y

y

y

y

y

that must be entered is the second code number listed in the Section 9.2. The present stro ke count is
displayed in the counter menu.

Section 5.4.6 Access Configuration

As described in Section 3 the user must gain Access Control in or der to per form certain operations and
change certain parameters. As described in Section 3, this access contro l can be obt a ined by two means,
Progr am/Run key or a user password system. These two means can be used alone or in combination with
each other.

Depressing the ACCESS CONFIG softkey from the Operat o r Ter minal Configuration screen, Figure 5.8,
will display the Access Configurat ion screen, Figure 5.9.

0

0

Stroke

TOP

1
2
3

4

Access Mode:
Access Timeout:
Access Timeout:

User Des c r iption Used
Operator Level # 1 Yes
Operator Level # 1 Yes
Setup Yes

Single Stroke

Mode

ACCES S CODE CONFIG URATION

Ke

or Code
20 Seconds
10 Strokes

Drive

Speed
Stroke

Speed

No
No
No
No
No
No
No
No
No
No
No
No
No

Figure 5.9 Access Code Configuration

Th is disp lay provides the following info rmat ion :

1. Access Mode

SPM

0
0

SPM

Order

Counter

PC STATUS

Program/Run Switch

HELP

Access Mode:
“Ke

and Code ”

re

uires access
code and
RUN/PR OG Ke
for an
changes. “Code
Onl

” requires
access code and
i

nores
RUN/PR OG Ke
“Ke

or Code”

re

uires an
access code or
the RUN/PROG
Ke

but not

both. “Ke

” requires

Onl
RUN/PR OG Ke
and does not
use access code.

Counter OFF

ACCESS
CONFIG

SET
CONFIG.

.

CODE

EXIT

CHANGE
SETTING

CHANGE
NUMBER

EDIT
USER

2. Access Timeout, timed based

3. Access Timeout, St r oke based

4. A listing of all user names and their current On/Off stat us

Section 5.4.6.1 Access Mode Configuration

There are four access modes. These are Key an d Code, Code Only, Key or Code, and Key Only. These
modes are explained in Sect ion 3. The curr ent access code applies to all users.

5.18

To change the current access mode position the cursor on the current access mode, press the CHANGE
SETTING sofkey, position the cursor to the desired access mode, press the ENT key.

Section 5.4.6.2 Access Timeout

When a user gains cont r ol access by using a password, he will lo gg ed in un til he manually logs out or is
automaticall y logged out. See Section 3.3.2. Automatic l og out can be either tim e b ased or stroke based.
The log out time and the log out numb er of strokes are programm ed in the Access Configuration menu.

The timed log out is based upon the time between key board activity. If the user does not press any key
on th e op er a tor te rmi nal w ithin the tim e pr ogr a mm e d, th e c on tr ol wi ll a u tomatica ll y l og ou t th e u s e r. To
program the Access Timeout t ime move the curso r t o Access Timeout time, press the Change Number
softkey, enter the desired time, and p r ess the ENT key. This time can be programmed from 0 to 999
se conds . A tim e ou t tim e of 0 se c onds tu r n s off th e tim e d log ou t. I f the tim e out tim e is s e t to 0 s e c on d s ,
there is no time based automatic log out.

The stroke log out is based upon a number of press strokes between key board activity. If the user does
not pre ss a ny k e y o n t he o perat o r t erminal within the number of strokes pro gr ammed, the control will
automatically log out t he user . To pr ogram the Access Timeout number of strokes move the cur sor t o
the Access Ti meout strokes, press the Chan ge Numb er softkey, enter the desired time, and press the ENT
key. The number of strokes can be programmed f rom 0 to 999. A tim eout num ber of s troke of 0 strokes
turns off the stoke based automatic log out. If the log out number of strokes is set to 0 strokes, there is
no stroke based auto matic log out.

Section 5.4.6.3 Edit User

The control allows for up to sixteen users to have the ability to gain access control. Each user is assigned
a name an d a password. The Access Confi guration men u is used to select a user and to enter the user edit
menu. To edit a user position the cursor on the user name that is to be edited and press the EDIT USER
softk ey. The User Configura tion menu, Figure 5. 10 , will be dis played .

5.19

0

y

g

y

g

y

g

g

g

g

0

Stroke

TOP

1
2
3

4

PLS Settin

TM Peak Hi

TM Peak Lo w Limits:

TM Reverse Limits:

Auto Setup Settin

Single Stroke

Mode

USER CONFIGURATION

User: Operator Level # 1
Code: 1234
Used: Yes

PLS B

pass:

s/Names:

TM B

pass:

TM Reset:

h Limits:

TM Data Wi nd ows:

DP B

pass:

DP Reset:

DP Settin

Auto Setup Reset:

Counter Reset:

Counter Settings:

s:

s:

Drive

Speed
Stroke

Speed

PERMISSIONS

Yes
Yes
No
Yes
No
Yes
No
No
No
Yes
No
Yes
No
Yes
Yes

Counter Chan

Feed Settin
PLC Screen 1 Sets:
PLC Screen 2 Sets:
PLC Screen 3 Sets:
PLC Screen 4 Sets:

Special Interface :

Auto SS/COD Time:

Reset Brak e Monitor :

Figure 5.10 User Configuration Menu

Th is disp lay provides the following info rmat ion :

1. User name

SPM

0
0

SPM

Store Jobs:

Recall Jobs:

Erase Jobs:

Order

Counter

Program/Run Switch

Yes

e:

No

s:

No
No
No
No
No
No
No
No
Yes
No

Counter OFF

PC STATUS

USER
CONFIG

EXIT

CHANGE
TEXT

CHANGE
NUMBER

CHANGE
SETTING

2. User’s cur r e nt p a ssword

3. The Yes/No status of the user. If Yes, this user is enabled. If No, this user is disabled

4. A listing of pe rmissions for this user .

To edit the user’s name position the cursor over t he current user name and press the CHANGE TE XT
softkey. The text editor box will appear and the name can be entered. Depressing the ENT key will exit
the editor and save the name enter ed.

To edit the user’s code position the cursor over the current user password, press the CHANGE NUMBER
softkey, enter the new number, and depress the ENT key.

The user can be enabled or disabl ed. W hen a user is enab led (Yes), the user’s name will appear on a list
of possibl e users that may obtain access control. Wh en a user is disab led (NO), the user’s name will not
appear on a list of possible user that may obtain access control. To change the user st at us position the
cursor on the User position, and press the CHANGE SETTING sofkey.

Each user can be granted permission to access certain restricted items. These items are listed i n Section

3. If a restricted item is configured with a YES, the user can obtain access to that item. If the restricted
item i s confi gured with a NO, the user cannot obtain access to that item. To change the permission status
of a particular item position the cursor to the item and press the CHANGE SETTING softkey.

5.20

Section 5.4.6.4 Set Configuration Code

Selecting t he SET CONFIG . CODE softkey in the Ac cess Configura tion M enu, F igu re 5.9, will display
the Confi guration Code screen, Figure 5.11. Thi s screen allows the Configuration Code to be changed.
This is the configuration code that prot ects Top Stop Calibration, Machine Parameters, Lubrication
Systems Conf iguration, Operator Termin al Configuration, Restricted Programm able Lim it Switch Se tting,
Names and Messages, Counter Configuration, Tonnage Monitor Configuration, Die Protection
Configu rat ion, an d Au t o S et up s Co nfigu rat ion. It is imperat ive that this co de be give to autho rized
personnel who are familiar with t he contr ol and with the co nsequences of incor re ct p ar ameter settin gs.

0

0

Stroke

TOP

This Configuration Code is used to gain access to the
configuration area of the Press Control. Tonnage
Monitor, and other systems. This code should ONLY be
known to authorized setup personnel trained in the
meaning and use of the screens it protects. Make sure you
keep the code in a safe place. If it is lost, you will
have to contact the factory to restore access to the
system!

Mode

Single Stroke

Configuration Code: ***

Drive

Speed
Stroke

Speed

200

0

SPM

SPM

Order

Counter

Program/Run Switch

Counter OFF

PC STATUS

CONFIG.
CODE

CHANGE
NUMBER

EXIT

Figure 5.11 Setting Configuration Code

The configurat ion code is set at the factory. It is suggested that t his code not be changed unless the
security of the configuration code has been jeo p ar d ize d . If a configuration code has been obtained by
personnel who do not r equire access to t he co nfiguration parameters, it must be c hang e d . When t his
code is changed, the previo us code will no longer be valid. The value of the new code should be
documented and stored in a secure place.

If a current code value is lost, the factory must be consulted.

To change the configuration code press the Change Number softkey , enter the new code, and press the
ENT key.

Section 5.4.7 Configure Auxiliary Communications

The AUXILIARY COMM. SETUP softkey provides access to the configuration screens for the
communication opt ions These o p t io ns include serial communication ports for interfacing to electronic

5.21

se rvo fe ed s, au xilia ry e qu ipme nt (s uc h a s PL Cs ), a la pt o p inte r fa ce fo r d o wnlo a ding mes sa ge s, an d a
network interface. See the manual pertaini ng to the particular dev ice that is connected for communi cation.

Section 5.5 Restricting PLS Outputs

This selection provides the menu shown in Figure 5.12 and allows the user to restrict operator access to
specific pr o gr ammable limit switch outputs. The arrow keys are used to position the cursor o nto the
desired chann el an d the CHANGE STATUS softkey i s used to restrict or un-restrict the selected channel .
Changing the status of a PLS channel to Restricted secures the present setpoint and description
info rma t io n. The ab ilit y to c han ge o r byp as s t he ch ann el w ill be r e mov ed fr o m t he dis pla y se lec t ion s
normally available in the programmable limit switch menu. No changes will occur to a restricted channel
if a different job is recalled. Channels that are bypassed before being restricted will automatically return
to no r mal operation. Only PLS o utputs 1-8 can be restr icted.

0

0

Stroke

TOP

Ch Status

1 Restricted
2 un-Restrict ed
3 un-Restrict ed
4 un-Restrict ed
5 un-Restrict ed
6 un-Restrict ed
7 un-Restrict ed
8 un-Restrict ed

Single Stroke

Mode

Rest r icted PLS Output s

Use

P

R

P

R

Keys to select Channel

Drive
Speed
Stroke
Speed

200

Order

SPM

Counter

0

SPM

Program/Run Switch

Counter OFF

PC STATUS

RESTRICTED
PLS

CHANGE
STATUS

LIMIT
SWITCH

EXIT

Figure 5.12 Restricting PLS Outputs

Section 5.6 Output Names/Messages

Th is con f igu rat ion menu allows descript ive in forma tion to b e p rog rammed into the o pe ra tor terminal.

Section 5.6.1 Input Names (option)

If the optional expansion card rack and third input card are pr o vided, this menu selection displays t he
screen in Figure 5.13. To edit a description position the cursor over the description and press the
CHANGE NAME softkey. The text edit box will appear. After the correct description is entered press
the ENT key. Fif teen inputs (I58-I72) can be assign ed a twenty character appli cation specif i c description
by the user. The type of stop condition and terminal number is shown for each input.

5.22

0

0

Stroke

TOP

Num Type Stop Descri pt ion

In58 T-Stop MATERIAL LUBE LOW
In59 T-Stop -------------------------------­In60 T-Stop -------------------------------­In61 T-Stop -------------------------------­In62 T-Stop -------------------------------­In63 T-Stop -------------------------------­In64 T-Stop -------------------------------­In65 E-Stop PLC Stop
In66 E-Stop -------------------------------­In67 E-Stop -------------------------------­In68 E-Stop -------------------------------­In69 M-Stop -------------------------------­In70 M-Stop -------------------------------­In71 M-Stop -------------------------------­In72 M-Stop --------------------------------

Single Stroke

Mode

Press Control Input Descriptions

Drive
Speed
Stroke
Speed

200

Order

SPM

Counter

0

SPM

Program/Run Switch

Counter OFF

PC STATUS

INPUT
NAMES

CHANGE
NAME

AUXILIARY
EQUIPMENT

EXIT

Figure 5.13 Editing the Third Input
Board Descriptions

Section 5.6.2 Aux. Equipment Messages

Depressin g the AUXILIA RY EQUIPMENT softkey on the Input Nam es menu, Fi gure 5.13, wil l display
t he A uxilia ry N ame s me nu , F igu re 5. 14 . Th is me nu a llo ws th e u se r t o en te r mess ag es fo r e qu ipme nt
external to the press control. Each message is f orty characters in l ength, and is assi gned a m essage number
from 000 to 127. The message number corresponds to t he binary patter n that must be provided to the
operat or terminal's parallel input por t. The NEXT GROUP softkey can be used to display additional
messages.

0

0

Stroke

TOP

Number Description

000 Tr ansfer Okay
001 Tr ansfer Part Sen sor # 1 Faul t
002 Tr ansfer Part Sen sor # 2 Faul t
003 Tr ansfer Part Sen sor # 3 Faul t
004 Tr ansfer Part Sen sor # 4 Faul t
005 Tr ansfer Stopped W aiting on Material
007 ------------------------------------------------------------------­008 ------------------------------------------------------------------­009 ------------------------------------------------------------------­010 ------------------------------------------------------------------­011 ------------------------------------------------------------------­012 ------------------------------------------------------------------­013 ------------------------------------------------------------------­014 ------------------------------------------------------------------­015 -------------------------------------------------------------------

Single Stroke

Mode

Auxiliary Equipment Message ON

Drive
Speed
Stroke
Speed

200

Order

SPM

Counter

0

SPM

Program/Run Switch

Counter OFF

PC STATUS

AUXILIARY
NAMES

CHANGE
NAME

NEXT
GROUP

OPTION
ON/OFF

ERASE
NAME

EXIT

Figure 5.14 Edit Auxiliary Equipment
Names

This option can be turned On or OFF. To change the On/Off status, press the OPTION ON/OFF softkey.

To edit a description position the cursor on t he description and depress the CHANGE NAME softkey.
The text edit box will appear. Af ter the corre ct d escription is entered p ress t he EN T key.

5.23

Section 6 Press Control I/O

The System 5000 provides 48 in puts (expandabl e to 72), 8 programmabl e li mit swi tch outputs (expandabl e
to 16), and up to 16 predefined output relays for use on mechanical power presses.

Section 6.1 Press Control Inputs

The standard system 5000 provides 48 inputs arr anged as two cards o f 24 inputs. Most of these inputs
are dedicated to specific functions that must be permanently st r apped if not used. Inputs for the lube
system, h ydraulic overload system, and val ve monitor allow for different types of systems. These inputs
may be changed and/or disabled through the configuration menus (see sections on lube, hydraulic
overload, and valve monitor). All input s require a +24 volt source to provide a "HI" signal, and will
default t o a 0 volt "LO " signal if the source is removed. The system 5000 provides a +24 volt po wer
supply f or connections to the these in puts. The in puts and thei r appropriate sections are describ ed bel ow:

Input Card 1

Input #Description Section

---------------------------------------------------------------------------------------------------­ 01 Left Normally Open Inch Button 6.1.1
02 Right Normally Open Inch Button 6.1.1
03 Left Normally Open Sta. #1 Run Button 6.1.1
04 Right Normally Open Sta. #1 Run Button 6.1.1
05 Left Normally Open Sta. #2 Run Button 6.1.1
06 Right Normally Open Sta. #2 Run Button 6.1.1
07 Left Normally Open Sta. #3 Run Button 6.1.1
08 Right Normally Open Sta. #3 Run Button 6.1.1
09 Left Normally Open Sta. #4 Run Button 6.1.1
10 Right Normally Open Sta. #4 Run Button 6.1.1
11 All Normally Closed Inch/Run Buttons 6.1.1
12 Top Stop Button 6.1.4
13 Emergency Stop Button Contact 1 6.1.5
14 Emergency Stop Button Contact 2 6.1.5
15 Light Curtain 1 6.1.13
16 Light Curtain 2 6.1.13
17 Operato r Station #1 Select 6.1. 2
18 Operato r Station #2 Select 6.1. 2
19 Operato r Station #3 Select 6.1. 2
20 Operato r Station #4 Select 6.1. 2
21 Mode Selector Switch in Run Position 6.1.8
22 Mode Selector Switch in Mode Select 6. 1. 8
23 Automatic Single Stroke/Cont. On Demand Setup Button 6.1.3
24 Continuous Setup Button 6.1.3

6.1

Input Card 2

Input #Description Section

----------------------------------------------------------------------------------------------------­ 25 Slide A dju st On /O ff Sw itch 6.1 .5
26 Run Mode Interlock 1 6.2.2
27 Feed Fault 6.1.5
28 Au x iliary Cycle Stop 6.1 .5
29 Operato r Station #4 Control Type 6.1. 2
30 Clutch/Brake Pressure Switch 6.1.4
31 Counter- balance Pressure Switch 6.1.4
32 Au x iliary Top S top 6.1 .4
33 See Lube System 6.1.11
34 See Lube System 6.1.11
35 See Lube System 6.1.11
36 See Hydraulic Overload System 6.1.12
37 See Hydraulic Overload System 6.1.12
38 Die Blocks 6.1.6
39 Au x iliary Maste r Stop 6.1 .6
40 Barrier Interlocks 6.1.6
41 Press Line Manual/Auto Switch 6.1.9
42 Feed Complete Signal 6.1.9
43 Feed Line Manual/Auto 6.1.9
44 Valve Monitor 1 6.1.10
45 Valve Monitor 2 6.1.10
46 Motor Forward 6.1.7
47 Motor Reverse 6.1.7
48 Master Stop Button 6.1.5

Section 6.1.1 Run Buttons

The press control is ty pically configured so that Inch, Timed Inch, and Setup/Stop Time Test m odes use
the Inc h Bu ttons . A fi x ed ti m e of 1 sec ond is al l owe d f rom the ti me one bu tton i s pre ss ed (N orm al l y O pen
Contact = +24 volts) until the other button is pressed, or the attempted stroke initiation is aborted. All
run butto ns mu s t then be r eleased before any fur ther st rokes can be attempted.

The Single Stroke, Continuous, Automatic Single Stroke, Continuous on Demand, and Maintain
Continuous modes use the active operator st ations for st ro ke initiation. I n some applicat ions the press
control can b e confi gured so that Inch, Timed Inch, and Setup/Stop Tim e Test modes also use the active
operat o r st at ions. A fixed time of 1 second is allowed independently for each station. This means that
there can be no greater t han a 1 second delay from the time one butt on on a given operat o r st a t ion is
pressed until the ot her button is pressed. Ther e is no t ime requirement from one operato r station to
another. See t he section on Operator Station Selects and the specific stroking mode for additional
information.

6.2

Section 6.1.2 Operator Station Selects

These in puts def i ne the activ e operator stations for Singl e Stroke, Continuous, Automatic Si ngle Stroke,
Continuous on Deman d, and Mai n tain Contin uous m odes. They may defi n e the stations f or Inch, Tim ed
Inch, and Setup/Stop Time Test modes if the control has been conf i gured to use these stations. An open
input (0 volts) selects the station to be act ive, and an input of +24 volts de-selects the station. A stroke
may not be initiated unt il all active operato r station butto ns are pressed, and all inactive stat ions de­energized. The press control generates an immediate stop if any inactive statio n is pressed. The input
labeled "Operator St at ion #4 Control Type" configures operato r stat ion #4 as either Palm Buttons or a
Foot Switch. An input of +24 volts indicates that stat ion #4 is being operat ed with palm buttons, and 0
volts indicates a foot switch. This input must be a permanent strap on t he input card installed when the
press control is configured. Appropriate Warnings must alert the operators as to how this station
functions. If configured as a Foot S w it c h and the st ation #4 select line is +24 volts, all ot her op erat o r
st at io ns mus t be in ac tiv e. T he F oo t S wit c h fun ct io ns o nly in Sin gle St r o ke and Ma int a in C on tin uo u s
modes.

Section 6.1.3 Prior Action Setup Buttons

The Continuous, Auto matic Single Stroke, Continuous on Demand, and Maintain Continuous modes
require the correct setup button be pressed before stroking can be initiated. The setup button must be held
closed (+24 volts) for approximately 1/2 second, at whi ch time the press control will al l ow 6 seconds for
stro ke initiation to t ake place. If all active oper ator station run buttons are not pressed in the allocated
time, the press control will automatical ly tim e out the setup action. The m ode can not be setup again until
all oper ator buttons and setup butt ons are released.

Section 6.1.4 Top Stops

A low level (input o pen) o n thes e inputs cause the press co ntro l to st op the next t ime crankshaft angle
reaches the top o f the str o ke, if any occur while the press is stroking. They prevent the mac hine fr o m
being started anywhere in the stro ke, unt il they are cleared (returned to +24 vo lt).

Section 6.1.5 Emergency Stops

A low l evel (in put open) on these inputs cause the press control to stop immediately, and prevent stroke
initiation until they are cleared (ret urned to +24 volt). E mergency stop butto n contact 1 and cont act 2
inputs are intended to be wired to the same switch. T hese inputs must track each other within an
allowable time or a fault is generated. Master Stop input #48 is shown as an emergency stop because it
causes the press control to ini tiate an i m m edi ate stop but not open the LMC relay . A separate contact on
the master stop button is used to remove 120 vac power to the motor star t circuit .

Section 6.1.6 Master Stops

A low level (input o pen) o n these inputs cause the press cont ro l to st o p immediately. In additio n t hey
cause the press contr ol to turn o ff the LMC Relay out put and prevent stroke initiation until they are
cleared (returned to +24 volt).

6.3

Section 6.1.7 Forward/Reverse Motor Contacts

These inputs report the state of the mai n m otors, where +24 volts indicates that the motor is on. The press
control al lows stroke initiation in Inch and Tim ed Inch modes in ei ther direction or if b oth motors are off.
All oth e r mo d e s w ill immed iat ely stop , and n o a d dit ion a l s tr ok es a llow e d u n le s s th e moto r is t u rnin g in
the forward direction. A fault occur s if the inputs r eport that both moto r s are on.

Section 6.1.8 Mode Selector Switch

These inputs report the state of the mode selector key swi tch. The press control allows stroke initiation
in onl y the RUN position. The MODE SELECT position allows the present stroking mode of the press
to be selected from the operator terminal. The OFF state is assumed if both inputs are open (0 volts).

Section 6.1.9 Press Line Interface

These in puts are provided for in terfacin g to a press line. If the system 5000 is confi gured to recogni ze the
press line (configuration type 001 or 002), the "Press Line Manual/Auto" selector switch input informs
the press contr ol and the press line of the intended mode of operation. In the manual mode ( input at 0
volts), the press control will allow stroke initiation in only the manual stroking modes (Inch, Timed Inch,
Setup/Stop Time Test, Single Stroke, Trip Mode, and Operator Maintain Continuous) and only if the feed
line re p or ts th a t it is in th e ma n u a l mod e (" Fee d L ine Manu a l/Au to in p u t a t 0 v olts ) . In the automa tic
mo de , t h e p r e ss con t r o l w ill allo w s t r o k e init ia t io n in o nly a u t o ma t ic str o ki ng mo d es ( Con t inu o u s an d
Automatic Single Stroke) and only if the feed line is fully setup for aut omatic ("Feed Line Manual/Auto
input at +24 volts). A confi guration ty pe 002 rel eases these requirem ents in Singl e Stroke and Trip Mode,
and al lows the press li ne to operate manuall y or automaticall y. A configuration ty pe 000 releases the press
line interface requirements in all modes.

The "Feed Complete Signal" allows the press line to initiate strokes in the Automatic Single Stroke mode
(see section on Automatic Feed Settings for more inf ormation). If confi gured to recognize the press lin e,
this input is monitored in Continuous to verify that the feed is complete by a programmed position in the
downstroke. In Automatic Single Stroke, the function of thi s input does not depend on Press/Feed Lin e
confi guration of the system 5000. The in put m us t cy cle low in the upstroke or while the press is paused
at the t op and back high in order to initiate aut omatic strokes. The factory configuration allows the
following interfaces:

Feed Line Type Interface to Press/Feed Line

------------------------------------------------------------------------------------­000 P r ess is separate from press line.
001 P ress Line is slaved to pr ess.
002 Press Line is slaved in all modes except

Single Stroke and Trip Mode.

Section 6.1.10 Valve Monitor

These in puts are provided f or monitoring the clutch/brake dual air valve. Sin ce there are dif ferent valve
mechanisms , the i nternal monitor can be configured b y the factory f or different types. The type selected

6.4

alters the function of the valve monitor inputs in the following manner:

Valve Monitor type 000: Air Valve With Internal Monitor

Input #44 Input from valve monitor 1 (0 volts = valve fault)
Input #45 Input from valve monitor 2 (0 volts = valve fault)

This is a "static" valve monitor. If either valve monitor input goes low the press control will immediately
stop and further stroke initiation is prevented until the inputs are in the RUN condition (+24 volts). This
is intended to be used with a clutch/brake valve that internally monitors for a fault condition, provides an
output that indicates a malfunction, and remains locked out unt il an external reset solenoid is energized
by an operator pressing a valve reset button. None of the factory programm ed ti mers are used with this
monitor.

Valve Monitor type 001: Air Valve with Proximity Sensors Only

Input #44 Input from proximity sensor 1
Input #45 Input from proximity sensor 2

This is a "timed" valve monito r. When t he press control's clutch/brake o utput is de-energized, both
proximity senso rs must repor t t hat the valve is in the Off position (inputs at 0 volts). When the press
control's output is energized, both proximity sensors must report that the valve is in the On position (both
inputs at +24 volts). Since the valv e has some physi cal reaction time, two factory programmed param eters
are provided. The parameter ‘V/M Turn On Ti me” sets the maximum amount of time (in mSec) that both
inputs #44 an d #45 must swi tch hi gh when the clutch i s en gaged. If both inputs do not switch hi gh wi thin
this am ount of tim e the cl utch/brake val v e i s turned Of f and “V/M Pull In F aul t” is reported as the reason
fo r th e s top. T he pa ra m ete r “V/ M Turn O f f Tim e” sets the maximum amount of time (in mSec) that both
input s # 44 and #45 must switch low when the clutch is dis-engaged. If bot h inputs do not switch low
withi n thi s amount of tim e the present runni ng status wil l i n di cate a “V/M Drop Out Fault”. A fault from
this type valve monito r generates an immediate stop and requires tha t the o perato r press the RESE T
ERR OR so ftkey in the press control menu before any further stro kes can be initiated. The parameter
“V/M Track Time” is not used and should be set to 100.

Valve Monitor type 002: Valve with Internal Monitor and

Clutch Line Pressure Switch

Input #44 Input from valve monitor (0 volts = valve fault)
Input #45 Input from Clutch Line Pressure Switch

This is a "static and timed" valve monitor. If the static input #44 goes low the press control will
immed iate ly s t o p an d fur t h er s t r o k e init ia t io n is p r ev en t e d u n t il t he va lve moni t or in pu t is in t h e R U N
condition (+24 volts). This static input is intended to be used in conjunction with a clutch/brake valve that
internally latches the fault condition until a valve reset solenoid is energized. In addition, when the press
control's cl utch/b rake output is de-energized, the clutch li ne pressure switch m ust report that there is n o
pressure on the output of the clutch val ve (i nput at 0 volts). When the press control' s output is energi zed,
the clutch li ne pressure switch m ust turn On (i nput at +24 volts) within a programm ed time to indi cate that

6.5

the line is pressurized. Since the valve has some physical reaction time, t wo factory programmed
parameters are provided. The parameter ‘V/M Turn On Time” se t s t he ma ximu m amou nt of time ( in
mSec) that input #45 must switch high when the clutch is engaged. If the input do es not switch high
wi thi n thi s amount of tim e the clutch/b ra k e va lv e is tu rn e d O ff a nd “V/M Pul l In F aul t” i s reported as the
reason for t he st op. The parameter “V/M Turn Off Time” sets th e maximum amoun t of time ( in mSec)
that input #45 must switch low when the clutch is dis-engaged. If the input does not switch low within
this amount o f time the present running stat us will indicate a “V/M Drop Out Fault”. A fa u l t fro m the
clutch l ine pressure switch generates an immediate stop and requires that the operator press the RESET
ERROR softkey in the press contro l menu befo re any further strokes can be initiated. The parameter
“V/M Track Time” is not used and should be set to 100.

Valve Monitor type 003: Air Valve With Internal Monitor (Reset Error Required)

Input #44 Input from valve monitor 1 (0 volts = valve fault)
Input #45 Input from valve monitor 2 (0 volts = valve fault)

Th is is a "s t at ic " va lve mo n ito r . If e it he r inpu t go e s lo w , t he pr es s c o nt ro l w ill immed iat e ly st o p a nd
fu rthe r s tr ok e in itia tion pr e v e nte d u ntil th e v a lve mon itor in p u ts a re in th e R U N c on d ition (+ 2 4 volts).
In addition, the operato r must acknowledge the fault by pressing the RESET E RROR so ftkey. This is
intended to be used with clutch/brake valves t hat pr ovide indication of a fault condition but “self reset ”
when power is removed. None o f the factory programmed timers are used with this monitor.

Valve Monitor type 004: Hydraulic Clutch/Brake control with soft brake

This valve mo nitor type allow s for t he co ntro l and monit oring o f press es with hydr aulic clut ch/brak e
systems and soft brake. The soft brake will be active only when the press control automatically stops the
press at the top of the stroke, in all modes of operation. Any stop other than a st op o n top will use the
full brake and not the soft brake.

Output relay OR-16 will control the soft brake. When OR-16 is turned On, the soft brake will be active.
A sensor which monito rs the po sition of the soft br ake valve must be employed. This sensor must be
connected to input # 45.

Input # 44 Clutch/Brake pressure switch. This input will monitor the output port pressure of

the clutch/brake valv e and will switch hi gh when there is suf f i cient pressure in the
output port of valve. The control will monitor this input for proper tracking of the
clu tc h / b rake driv e ou tp u t. T h e c on tr ol w ill is s u e a “Valve Monito r 1" fault and
turn off the clutch/brake driv e output if this in put does not track the clutch/brake
drive output when energized. The control will issue a “Valve Moni tor 1" faul t and
drop out the LMC if this input go es high while the clutch/brake output is Off.

Input # 45 Soft brake proximity sensor. This input should be high (+24 vdc) when the soft

brake valve is not in the soft brake position and should switch low when the soft
brake output OR-16 turns On. A “Valve Monitor 2" fault is genera te d and the
LMC is turned Off if this input go es high anytime except during a soft brake. A
“V/M Drop Out” fault is g e n e rate d an d th e LM C tu r n e d O ff if th is in p u t fa ils to
track the soft brake valve activation. A “Soft Brake OverRun” fa ult is generated

6.6

and the LMC turned Off if the press travels beyond 20 degs into the downst r oke
during a soft brake stop on to p.

Factory Configured Parameter definitions:

V/M Pull In Tim e (mSec). This parameter sets the tim e duration that the soft brake output OR-16
i s On when the press is stopping at the top of the stroke. The maximum setting of this parameter
is 1000 milliseconds. The minimum setting of this parameter is 40 milliseconds. This parameter
can be set in 2 0 millis econ d incr ements.

V/M Drop Out Time (mSec). This parameter sets the tracking time for the soft brake proximity
senso r wired into inpu t 45 (Va lve Mo nito r 2) . This p aramet er c an be set in 20 milliseco nd
increments. The input must track output, OR-16, within the time set by this parameter. This
means that when OR-16 turns On input #45 must switch low within this time and when OR-16
turns Off input #45 must switch back high within this time limit.

V/M Track Time (mSec). This parameter sets the tracking time for the clutch/brake valve
feedback wi red i n to input 44 (Valv e Moni tor 1). Under normal operation the in put is l ow (0vdc)
when the cl utch/brake val v e i s Of f , no pressure in the output port of the val v e, and swi tches hi gh
(+24vdc) when clutch/brake drive is On, pressure in the out put po rt o f the valve. The time can
be set from 000 to 900 mSec in increment s of 20 milliseconds. The input must track the
clutch/brake output within the time set by this parameter.

Section 6.1.11 Lube System I/O

The system 5000 all ows the user to configure certain inputs and outputs for specifi c l ubri cati on system s.
The fun ction of Inputs #33, #34, #35 and output #21 (OR-5) are determi ned by the l ube confi guration type
(see Section 5.3 for a description of the lube).

Lube Type 000: Lube System Monitor is Disabled

Input #33 Not used
Input #34 Not used
Input #35 Not used
Output #21 (OR-5) Not used (always off)

Lube Type 001: Recirculating Oil with Static Inputs

Input #33 Low Lube Pressure (stop if input = 0 volts)
Input #34 High Lube Pressure (sto p if input = 0 volts)
Input #35 Low Lube Level (stop if input = 0 volts)
Output #21 (OR-5) Lube Fault (opens if fault occurs)

This is a "static" l ubricati on system. If any i nput goes to a stop condition, the press top stops. If the i nput
remains in a stop condition after the press stops, the lube system output (OR-5) will turn off. This output
will remain off and further stroke initiation is prevented until all inputs return to the run state. The output
is i ntended to be used to turn off the mai n m otor in the event of a l ube sy stem faul t. The tim ers associated
with the lube system are not used and should be set to zero.

6.7

Lube Type 002: Recirculating Oil with Static Inputs

Input #33 Low Lube Level/Press(stop if input = 0 volts)
Input #34 High Lube Pressure (sto p if input = 0 volts)
Input #35 Held closed flow sensor (stop if input = 0 volts)
Output #21 (OR-5) Lube Fault (opens if fault occurs)

This is a "static" lubrication system. If any input goes to a stop condition, the press top stops. If the input
re ma in s in a stop c on d ition a fte r the pr e s s s top s , th e lu b e s ys te m o utp u t w ill tu rn off. This ou tpu t w ill
remai n off and f urther stroke initi ati on is prevented until all i nputs return to the run state. The output is
intended to be used to turn off the main motor in the ev en t of a l ube system fault. The tim ers associated
with the lube system are not used and should be set to zero.

Lube Type 003: Recirculating Oil with Flow Rate Sensor

Input #33 Low Lube Level/Press(stop if input = 0 volts)
Input #34 High Lube Pressure (sto p if input = 0 volts)
Input #35 Pulsing Flow Rate Sensor (cycles)
Output #21 (OR-5) Lube Fault (opens if fault occurs)

Th is is a co n t inu o u s ru n ning lu br ic ation sys t e m with a flow r a t e s e ns o r that mu s t p er io d ic a lly cyc le t o
indicate pr oper lube flow. When power is turned on, the press control starts an inter nal flow r ate timer
set by the “Flow Rate (Running)” parameter. If the flow rate sensor input changes state (goes from low
to hi g h or high to lo w), b efore the timer exp i re s the in ter va l i s re se t. If th e i n pu t f ai ls to c h an g e w i th i n the
programmed time a lube system fault is generat ed and the message “No Lube Flow” is displa yed . This
err or c on dition will automatically clear and t he pr esent running status will ret urn to “Ready To Stroke”
when proper flow is sensed. In situations where the lube pum p must be man uall y started, the press control
will d isp la y “No Lube Flow” aft er p o w e r is a p plie d u nt il t h e lu be s yst e m is st a r t e d an d p r ope r fl o w is
detected.

In s o m e a p p li ca tion s th e c ycle ti me of th e fl ow ra te inp u t is too s h or t or too e rr a tic to eff e c tive ly mon i tor
one interval . The “Minimum # of Pulses” parameter can be used to tim e a specif i c n um ber of transi tions.
A typical example would be a press that when the lube pump is On, input #35 stays low for o ne second
and high for one second (10 transitions in 10 seconds). If the “Minimum # Pulses”=010 and “Flow Rate
(Running) time”=015 seconds, the press control wil l consi der the lube system to be functioning correctly
as long as at least 10 tr ansitions are detected within 15 seconds. These are the only timing paramet ers
used by this lube system and all others should be set to 000.

If lube flow malfunctions or o ne of the static inputs (#33, #34) indicate a stop condition, a lube system
fault is generated and the press top st ops. If the static input remains in a stop condition or t he flow rate
sensor co nt inues to remain unchanged after the press st ops, t he lube system output OR-5 will turn Off.
This output is intended to stop the main motor and will remain Off and further stroke initiation prevented
until all static inputs return to the run stat e and t he flow rate sensor begins to cycle correctly.

Lube Type 004: Pulsed Lube with Flow Rate Sensor

Input #33 Low Lube Level (stop if input = 0 volts)
Input #34 Lube Pressure Fault (sto p if input = 0 volts)
Input #35 Lube Cycle Limit Switch (cycles)

6.8

Output #21 (OR-5) Lube System Output

This i s a closed loop lubrication sy stem wh ere the Lube System Output (OR-5) is used to drive the Lube
Pump. It is in tended to be used on machi n es that require occasional l ub ri cation to crankshaft bearin gs or
slide gibs (i.e. portions of the press that move only when t he clutch is engaged). When the main motor
is turned on, an inter nal timing system is started. The Lube Pu mp out put is tur ned on until flow is
rep ort ed by the lube cycle limit switch making a complete cycle (low to high to low, or high to low t o
high ). W hen o per at ing co rr ect ly, t his in put will cyc le befo re the "Flo w Ra te " t ime e xp ire s and will
complete the lub rication cycl e. A fter the cycle is complete the output can be programmed to remai n On
a fixe d t ime (O ut pu t On t ime in se co nd s) b efo re t ur ning off. The ou tp ut the n re mains off fo r so me
programmed tim e (Output Off ti m e i n m i n utes). The Off tim e i s accum ul ated onl y whi l e the cl utch/b rake
is en ergized. The entire cycl e then repeats. If the lub e cycle input f ails to switch within the “Flow Rate”
time, a lube sy stem f ault is generated. The press top stops if thi s occurs whi le runn in g, and further stroke
initiation is prevent ed until an operator presses t he RESET ERROR so ftkey in the press cont ro l menu.
The operator's recognition of the condition resets the in ternal time r and the lube cy cle wi ll start again. The
length of time allowed for the flow rate sensor to activate can be set differently for a machine power up
condition “Fl ow Ra te ( Powe r U p)” an d the normal operating condition “Flow Rate (Running)”. A “Flow
Rate (Po wer Up )” time set to 000 secs causes no lubrication to take place when power to the press is
appli ed. It should be understood that when operating correctly, the f l ow rate tim e f or both power up and
normal running conditions does Not de ter mi n e the l e ngth of ti me th a t th e lub e p u mp i s On . The pu mp i s
turned Off as soon as the lube cycle limit switch makes one complete cycle as described above.

Thi s typ e lub e sy stem requi res the p aram eters shown bel ow (an y other pa rame ters are not us ed an d sh ould
be set to 000). The Figure below describes a typical example of a press with a motor dr iven lube pump
connected to OR-5 that requires lubrication ev ery 10 m i nutes and b y observation i t is f ound that the lube
cycle limit switch no r mally makes a complete cycle in 20 secs but may take longer when power is first
applied. When power is first applied and the
m ain m otor turned On , output OR-5 will tu rn
On to provide lubrication and input #35 will be
monitored. If this input cycles within 60 secs
the first lube cycle is complete and OR-5 will
turn Off. It will remain Off for 10 minutes of
continuous stroking. The output will then turn
On for the next lube cycle and input #35 is
again monitored, but this time with a
maximum limit of 30 secs. The no rmal lub e cycle will be complete and th e outpu t tur ned Off when th e
input cy cl es (20 secs). A “No Lube F l ow” fault is gen erated i f the i n put does not cycle wi thi n 30 secs f or
this and al l additional l ub e cy cl es. Note: If a p a ra mete r is chan g e d , th e new s e ttin g w il l Not be used un til
the present t iming port ion of the lube cycle is complete. For example, if the p r es s co ntro l is presently
ti mi n g the 1 0 min Off tim e s hown above a n d a n e w s e tting of 001 mi n is e ntere d , th e new s e ttin g w il l Not
be used until t he present 10 min interval is complete. The 1 min settin g w ill b e u sed for th e next a nd all
futu re Off times. To “force” the new setting to be used immediately you can turn power to t he contro l
Off and back On or change the Lube Sy stem Ty pe to 000 an d back to 004. Thi s will reset the lube system.

Lube System Type..........004

Flow Rate (Running).......030 Sec

Flow Rate (Power Up)......060 Sec

Output Off (type 004).....010 Min

Output On (type 004)......000 Sec

Output Pulse (type 004)...000 Sec

I n ap p lic a tion s w he re the Lube Syste m O u tp u t (O R - 5) is c on tr olling a s ole noid dr iv e n pu mp it may b e

6.9

necessary to pulse thi s output during the lub rication cycl e. The "Output Pulse" timer sets the rate at which
the o u t p u t tur ns on and off. When the lube cycle start s, OR-5 is turned on for the durat ion set by the
output pulse time and is then tu rned off for t he same period. An Output P ulse=005 secs in the above
example would cause OR-5 to turn On 5 secs/Off 5 secs during the lube cycle. An output pulse time set
to 000 secs or a time set greater than the flow rate time will result in the lube output remaining on
constan tly du ring the lube cycle ( as would typ ically be used when c on trolling a motor d riven pump).

In addition to the closed loop operation, two static inputs are moni tored. A top stop is gen erated if ei ther
input goes to a stop co ndition and further strokes are pr evented until the fault is corrected.

Lube Type 005: External Lubrication System

Input #33 Lube Fault 1 (stop if input = 0 volts)
Input #34 Lube Fault 2 (stop if input = 0 volts)
Input #35 Lube Fault 3 (stop if input = 0 volts)
Output #21 (OR-5) Lube Fault (opens if fault occurs)

This is a lubrication system that is performed external to the system 5000. If an y l ube fault input goes to
a stop conditi on, the press top stops and displ ays the specif ic i nput (i.e. Lube Fault 1). If the input remai ns
in a s t op c on dit io n af te r th e p re ss st o ps , t he lub e sys t em o ut p ut O R- 5 w ill t ur n o ff. T h is o ut p ut w ill
rem a in off and further stroke initiation is prevented until a ll inputs re turn to the run state. The output is
intended to be used to turn off the main motor in the ev en t of a l ube system fault. The tim ers associated
with the lube system are not used and should be set to zero.

Lube Type 006: Pulsed Lube without Flow Rate Sensor

Input #33 Low Lube Level (stop if input = 0 volts)
Input #34 Lube Pressure Fault (stop if input = 0 volts)
Input #35 Not-Used
Output #21 (OR-5) Lube System Output

This is an open loop lubrication system where the system 5000 Lube System Output (OR-5) is used to
dr ive a Lu be P u mp. W he n p o w er is fir st a p plie d a nd t he ma in mo t o r is t u rn e d O n , a n inte r na l t iming
system is start ed. The lube syst em output OR-5 is turned On for the duration set by the "Flow Rate
(Power Up)" time (in seconds). After the cycle is complete the output can be programmed to remain on
an additional "Outpu t On" time (in seconds) before turning off. The output t hen remains off for the
"Output Off" time (in minutes). Unlike type 004, the Off t ime is Not conditioned with the clutch/brake
signal and tim es as long as the main motor is turned On. When the "Output Off" time expires, the entire
cycle repeats. The lube system will "pause" its present timing function and turn OR-5 Off when the main
motor is turned Off, and resume timing when the motor is turned back On. The length of time that the
lube system i s turned On can be set dif ferentl y f or a machi ne power up condition and the normal operating
condition. A flow rate time (power up) set to 000 secs causes no lubrication to take place when power
to the press is applied.

6.10

Thi s ty pe l ube sys tem req uires the param eters s hown b el ow (any other param eters are not used an d sh ould
be set to 000). The Figure below describes a typical example of a press with a motor dr iven lube pump
connected to OR-5 that requires lubri cati on every 60 minutes if the main motor is running and does not
have a flow rate sensor. When power is first
applied and the main motor turned On, output
OR-5 will turn On for 30 secs to provide
lubr ic at io n. OR -5 will t u r n O ff an d r ema in Off
for 60 minut es (timed only while the mo tor is
On). The output will then turn On for 10 secs to
complete the next lube cycle. This 60 min Off
and 10 se cs On lube per iod will continue as long
as the main motor is running. Note: If a
par am e ter i s ch an g ed , th e n e w s etti n g wi ll Not be
used until the present timing por tion of the lube cycle is complete. For example, if the press contro l is
pre se n tl y ti m in g th e 6 0 m in Of f ti me s h own a b ove an d a n ew s etti n g of 0 01 m i n i s en te red , th e n e w s ettin g
will Not be used until the present 60 min interval is complete. The 1 min setting will be used for the next
and all future Off times. To “force” the new setting to be used immediately you can turn power to the
control Of f an d back On or change the Lube Sy stem Ty pe to 000 and back to 006. This will reset the lube
system.

In a p pl ications w h e re the L u b e Syste m Ou tp u t (O R - 5 ) is c ontrolling a s ole n oid d riven p ump it ma y be
necessary to pulse thi s output during the l ubrication cy cle. The "Output Pulse" tim er sets the rate at which
the out put tur ns on and off. When the lube cycle s t a r ts, OR - 5 is t ur ned on for the durat ion set by the
output pulse time and is then turned off for the same period. The output continues with this "50% dut y
cycl e" operation until the lube cy cl e i s compl ete as described above. An output pulse time set to 000 secs
or a time set greater than the flow rate time will result in the lube output remaining on constantly during
t he lube cycle (a s would typic ally be used w h en contro lling a motor drive n pump).

Lube System Type.........006

Flow Rate (Running)......010 Sec

Flow Rate (Power Up).....030 Sec

Output Off (type 004)....060 Min

Output On (type 004).....000 Sec

Output Pulse (type 004)..000 Sec

As indi cated, this lube sy stem does not monitor the lube fl ow. Two static inputs are moni tored, and a top
stop is generated if ei ther input goes to a stop condition. F urther strokes are prevented until the condition
is corrected.

Lube Type 007: Recirculating Oil with Two Flow Rate Sensor s (Special Firmwar e Required)

Input # 33 Low Lube Level/Press(stop if input=0 volts)
Input # 34 Pulsing Flow Rate Sensor # 1
Input # 35 Pulsing Flow Rate Sensor # 2
Output #21(OR- 5) Lube Fault ( opens if fault occurs)

This is an internally "timed" and "counted" lubrication system. This lube monitor is designed to count the
numb er of cycles of two pulsin g flow rate sensors during a ti me interval . If the num b er of cycles of each
sensor during a time interval equals or exceeds the number assigned to the Min # Pulses configuration
parameter, the l ube system i s considered to be operating properly . If the num ber of cycl es of either sensor
dur in g the time inte r val i s le ss than the num ber assigned to the Min # of Pulses configuration parameter,
a lube sy stem faul t is gen erated and the press will top stop. After slide m otion has ceased, the lube output
(O R- 5) w ill be t u rn ed off. T he s t op co nd it io n will r e main u nt il t he n um be r o f p uls es fo r each sensor
during a tim e interval equals or exceeds the num ber assigned to the Min # Pulses confi guration parameter.

6.11

The d ur a tion of th e tim e inte rval i s eq u a l to the tim e s e t b y th e F low R a te c onfigu ra tion p a ra mete r . Th e r e
are two flow ra te configurati on p a ra meters. Th e Flow Rate (At Power Up) is the param eter that is used
fo r the fi rs t tim e i n terv al af ter p ower i s app l ie d to th e Om n i Li n k con trol . A l l othe r ti me i nte rva l s a re b as ed
upon t he Flow Rate (When Running) parameter.

If only one flow rate sensor is being used, it will be necessary to jump Input # 34 to Input # 35. The single
flow rate sensor can be connected to either Input # 34 or Input # 35.

The special firmware is required to run this lube type. The special firmware t hat contains lube type 007
does not co nt ain lube type 003.

Section 6.1.12 Hydraulic Overload I/O

The inputs and outputs provided are intended to interface to an external hydraulic overload mechanism ,
and the in ternal m oni tor can be confi gured b y the factory for diff erent types. The type sel ected alters the
function o f the hydraulic overload inputs and outputs in the following manner:

Hydraulic Overload type 000: No Hydraulic Overload Monitored

Input #36 Not used
Input #37 Not used.
Output #18 (OR-2) Not used.
Output #19 (OR-3) Not used.

Hydraulic Overload type 001: Limit switch/Pressure switch

Input #36 Hydraulic Overload Limit Switch
Input #37 Hydraulic Overload Pressure Switch
Output #18 (OR- 2) Hydraulic Overload Cylinder
Output #19 (OR-3) Hydraulic Overload Pump

Under normal operating condi ti ons, both outputs are On and b oth i n puts are in the run state (+24 volts).
If either i nput opens (0 volts) a hydrauli c overload faul t is generated, and both outputs turn Off . The press
stops immediately if this occurs while running and the input that caused the overload is displayed as the
reason for t he st op. The op er ator must then reset by following the steps described below:

Step

1. Acknowledge the overload by pressing the RESET ERROR softkey.

2. Switch to Inch Mode. The present running status will display “Run Onl y In Inc h” and will prevent
stro ke initiation until this is done .

3. If n e c e s s a ry, s witch the main motor to R evers e to “back off” the l oad (if the press i s equi pped f or
this).

4. Use the correct run buttons to Inch the press to the top of the stroke. The press control will
automatically stop the press inside the hydraulic overload reset ar ea at the top of the stroke.

5. The press control will inhibit further stroking at the top of the stroke and automatically reset the
hydraulic overload system by first tur ning the Cylinder Output (OR-2) On. The present running
sta tus will indicate th e status of the limit switch until inpu t #36 switches high.

6. T he present running status will then indicate that fixed 20 second delay is perfor med before the

6.12

pump is energized.

7. T he hydraulic pump output ( OR-3) is turned On and the present running status will indicate the

status of the pressure switch until input #37 switches high.

8. The running status will displ ay “Ready To Stroke” to i n d ica te th a t the r e s e t s e qu e n c e is c omplete

and stroking may be resumed in any mode.

Hydraulic Overload type 002: Proximity Switch

In put #36 H ydraulic Over load Proximity Switch
Input #37 Not used
Output #18 (OR- 2) Not used (functions the same as OR-3)
Output #19 (OR-3) Hydraulic Overload Pump

Unde r n or ma l op er a tin g c onditio n s , the p ump ou tp u t is O n a n d th e p r ox imity s w itc h inp ut is in the r u n
state (+24 volts). If the i nput opens (0 volts) a hy drauli c overload faul t is generated, and both outputs turn
Off . The press stops immedi ately if this occurs whil e running and display s that an overload i s the reason
for the stop. The op er ator must then reset by following the steps described below:

Step

1. Acknowledge the overload by pressing the RESET ERROR softkey.

2. Switch to Inch Mode. The present running status will display “Run On ly In In ch” and will prevent

stro ke initiation until this is done .

3. If n e c e s s a ry, s witch the main motor to R evers e to “back off” the l oad (if the press i s equi pped f or

this).

4. Use the correct run buttons to Inch the press to the top of the stroke. The press control will

automatically stop the press inside the hydraulic overload reset ar ea at the top of the stroke.

5. The pres s contr ol will in hi bi t fur ther stroking at the top of the str oke an d automaticall y reset the

hydraulic ove rloa d system by t urning both outputs On. The present runn ing sta tus will indicate
the status o f the pro ximity switch until input #36 switches high.

6. The runni n g status will displ ay “Ready To Stroke” to in dica te th a t the re s e t s e qu e n c e is c omplete

and stroking may be resumed in any mode.

Hydraulic Overload type 003: Overload w/manual reset

Input #36 Hydraulic Overload Sensor
Input #37 Test-Nor mal-Reset key switch
Output #18 (OR- 2) Hydraulic Overload Valve
Output #19 (OR- 3) Hydraulic Overload Indicator

Under normal operating conditions, both outputs are On, the overload sensor input #36 is in the run state
(+24 volts) and key switch is i n the Normal posi tion (+24 vol ts). If i nput #36 opens (0 volts) a hy draul i c
overload fault is generated, both outputs turn Off, and the hydraulic overload Tripped indicator will light.
The press stops immediatel y if this occurs while runn ing and di splays that the overload as the reason for
the sto p . The operat or must then reset by following the steps described below:

Step

1. P lace the Test-Normal-Reset key switch in the Reset position.

2. Switch to Inch Mode. The present running status will display “Run O nl y In Inch ” and will prevent

6.13

stro ke initiation until this is done .

3. If the press has stopped in the downstroke the present running status will display “Mot o r
Direction” and the main motor must be switched to Reverse to “back off” the load. If the press
stops after the bottom of the stroke, the press can be Inched only with the motor running in the
Forward direction.

4. Use the correct run buttons to Inch the press to the top of the stroke. The press control will
automatically stop the press inside the hydraulic overload reset ar ea at the top of the stroke.

5. The press control will inhibit further stroking at the top of the stroke and automatically reset the
hydraulic overload system by first turning the Cylinder Output (OR-2) On. T he present running
sta tus will indicate th e status of the o verload senso r until inpu t #36 switches high.

6. Output (OR-3) is turned On (hydraulic overload Reset indicator will light) and the present running
status will indicate that the key switch must be placed in the Normal position until input #37
switches lo w.

7. The runni n g status will displ ay “Ready To Stroke” to in dica te th a t the re s e t s e qu e n c e is c omplete
and stroking may be resumed in any mode.

If the Test-Normal-Reset key swi tch i s pl aced i n the Reset position at any time except during a hydrauli c
o ve rlo ad fa ult , t he p res s co ntr ol w ill issu e a t op sto p a nd inhibit fur the r st ro king unt il the swit ch is
returned to the Normal position. If switched to the Test position, input #36 will open and both outputs
will turn Off. The h ydr au lic ove rloa d system must then be r eset as descr ib ed above.

Section 6.1.13 Light Curtain

The li ght curtain i nputs provide emergency stop signal s to the press control, unl ess m uted (ignored) in the
upstro ke by the light curtain configur at io n. These inputs can be configured by the factory to provide
several methods of muting. This pro g r ammed information affects the light curtain only in the upstr oke,
and an emergency stop is always performed if the inputs open (0 volts) in the downstroke. The
information below de s cribes how the light c urtain may be co nfigu red:

Light Cur tain Type Condit ions when the light curtain is muted

-----------------------------------------------------------------------------------------­000 Muted in the upstroke in Inch, Timed Inch
001 Muted in Inch, Timed Inch, and Manual modes
002 Muted in Inch, Timed Inch, and Automatic modes
003 Muted in all modes
004 Light curtain is never muted
005 Muted in al l m odes. Li gh t curtain inputs are checked in upstroke (requires

a PLS out put also be used).

In the Inch and Timed Inch modes, t he u pstro ke and downstroke are det ermined by the for ward and
reverse motor inputs. This affects how the light curtain is muted in the following manner:

Motor Contacts Conditions when the light curtain is muted

------------------------------------------------------------------------------------------

6.14

Forward On Muted from 180 degs to 346 degs
Reverse On Muted from 0 degs to 180 degs
Both Off Never Muted

In Single Stroke, Continuous, Trip Mode, and Maintain Continuous modes, the light curtain is muted from
180 degs to 346 degs if the press i s stopped. Once the stroke is i ni tiated and motion has been establi sh ed,
t he ligh t c ur t a in is mu t e d fr o m 1 8 0 deg s t o 0 de g s to a llo w a ux iliar y e q uip me nt th e e ntir e u ps t r o k e in
which to p erfo rm its funct ion .

In Automatic Single Stroke mode the light curtain is muted from 180 degs to 346 degs. After stroke
initiation the light curtain is muted from 180 degs to 0 degs while the press is moving. If the press stops
in the regi on f rom 346 degs to 0 degs, the press control wi ll wai t until motion stops before checki ng i f the
li ght curtain is stil l i n terrupted. If the l i ght curtain i s interrupted after this time, further automatic strokes
are prevented and the mode must be manually re-initiated.

Section 6.2 Press Control Inputs (option)

If the optional expansion card rack and third input board are provided, an additional 24 inputs are
available. The inputs and their appropriate sections are described below:

Input Card 3 (4 operator station version)

Input #Description Section

-------------------------------------------------------------------------------------------­ 49 Valve Monitor 3 -----­ 50 Valve Monitor 4 -----­ 51 Aux. Lube Fault 1 6.2.1
52 Aux. Lube Fault 2 6.2.1
53 Die Clamp Pressure 6. 2. 2
54 Run Mode Interlock 2 6.2. 2
55 Continuous On Demand Run 6.2.7
56 Input Board 3 Installed 6.2. 3
57 Aux. Lube Enable 6.2. 1
58 Definable To p Stop 6.2.4
59 Definable To p Stop 6.2.4
60 Definable To p Stop 6.2.4
61 Definable To p Stop 6.2.4
62 Definable To p Stop 6.2.4
63 Definable To p Stop 6.2.4
64 Definable To p Stop 6.2.4
65 Definable Cycle Stop 6.2.5
66 Definable Cycle Stop 6.2.5
67 Definable Cycle Stop 6.2.5
68 Definable Cycle Stop 6.2.5
69 Definable Master Stop 6.2.6
70 Definable Master Stop 6.2.6

6.15

71 Definable Master Stop 6.2.6
72 Definable Master Stop 6.2.6

Section 6.2.1 Aux. Lube System I/O

If the optional expansion card rack, third input card, and fourth output gr oup ar e pro vided, the system
5000 allows two auxiliary lubric atio n syst ems. Only met ered lubricat ion c ont rol is availa ble, whe re
controlled pulses of grease or oil are provided at preset intervals. The lube systems function
independently, as described by the configuration type (see Section 5.3.1 for a description of the
configuration screen).

Auxiliary Lube System 1 uses output #29 (OR-13) to control its metered lube pump and input number 51
as a flow r ate sensor if configured to monitor flow.

Auxiliary Lube System 2 uses output #30 (OR-14) to control its metered lube pump and input number 52
as a flow r ate sensor if configured to monitor flow.

Both auxiliary lube systems use input #57 as an enable signal to indicate that lubrication is t o be
performed.

Th e followin g c on figu ra tion types are available for bo th au x iliary lube systems 1 and 2:

Aux. Lube Type 000: Aux. Lube System Monitor is Disabled.

Input #51/52 Not Used
Input #57 Not Used
Output #29/#30 (OR-13/14) Not Used

Aux. Lube Type 001: Pulsed Output w/o Flow Rate Feedback.

Input #51/52 Not Used
Input #57 Aux Lube Enable
Output #29/#30 (OR-13/14) Lube Pump

This lubrication system waits for the Aux Lube Enable input to be switched to +24 volts before beginning
t he de s ig n a te d timing. T h e lub e p u mp ou tp u t w ill be t u rne d Off if the e n a b le s ig n a l is r emo v e d . Wh e n
power is applied to the press and the enable input is turned On, the auxiliary lube pump is turned On for
the time specified as "Flow Rate (Power Up) " (in secs). If this time has been programmed for 000 Sec,
no lub ri cation pul se i s gi v en at power up. After the pulse tim e i s com pl ete, the pump output is turned Of f
until the press m akes the specifi ed "Num b er of Strokes Off ". The pump output is then turned On for the
time specified as "Flow Rate ( Running)" (in secs). This lubrication cycle repeats as long as t he en able
signal is turned On. This lube type does not
monitor the flow of grease or o il.

Aux. Lube 2 Type........001

The Figure below describes a typical example of
au xiliar y lube syst em # 2 be ing u se d t o lu bric at e a
cushi on. Ty pe 001 is used because the lube sy s tem
does not have a flow rate sensor. Out put OR-14

# of Strokes Off.......01000

Flow Rate (Running).....010 Sec

Flow Rate (Power Up)....000 Sec

Output Pulse............000 Sec

6.16

energizes a m otor driven l ube pum p f or 10 seconds every 1000 strokes. When power is f i rst appl i ed an d
the auxiliary Lubes are enabled (input #57 switches high) the lube has been programmed Not to generate
an initial lube cycle and instead proceeds to count 1000 strokes with output OR-14 Off . The output wi ll
then turn On for 10 seconds to complete one l ubricati on cycl e. This 1000 strokes Off and 10 secs On l ube
period wil l contin ue as l ong as the enabl e si gn al i s h i gh . Note: If a p a ra mete r is chan g e d, th e n e w se ttin g
will Not be used until the present tim ing portion of the lube cycle is complete. For example, if the press
contro l is presently count ing 1000 stro kes shown above and a new sett ing o f 20 is entered, the new
se tting w il l Not be used until the present interval is complete. The 20 strokes setting will be used for the
next and al l future Off cycles. To “force” the new settin g to be used immediately y ou can turn power to
the control Of f and b ack On or change the Aux . Lube 2 Type to 000 and back to 001. This will reset the
lube system.

In applications where the Aux. Lube Output (OR-13/14) is controlling a solenoid driven pump it may be
necessary to pulse this output during the lubrication cycle. An additional "Output Pulse" timer sets the
rate at which the output turns On and Off. If “Output Pulse”=001 in the example above, when the lube
cycle starts OR-14 would turn On for 1 second and Off f or 1 second during the 10 second l ube interval.
An output pulse time set to 000 secs or a time set greater than the flow rate time will result in the lube
output remaining On constantly during the lube cycle (as would typically be used when controlling a motor
driven pump).

Aux. Lube Type 002: Pulsed Output with Flow Rate Feedback.

Input #51/52 Pulsing Flow Rate Sensor
Input #57 Aux Lube Enable
Output #29/#30 (OR-13/14) Lube Pump

This lubrication system waits for the Aux Lube Enable input to be switched to +24 volts before beginning
t he de signa te d timin g . T h e lu b e p u mp ou tp ut will be tu r n e d Off if t h e en a ble sig nal is r e move d . Wh e n
power is applied to the press and the enable input is turned On, the auxiliary lube pump is turned On and
the "Lube Faul t Input" is m oni tored for flow. The output remai ns On until thi s i nput makes one compl ete
cycle (low to high to low) or (high to low to high), at which time the output is turned Off and the
lubrication pulse is complete. If the flow rate sensor fails to make a cycle in the time specified as "Flow
Rate (Power Up)" (in secs ) the output is turned Off and the error message "A ux. Lube Faul t" i s di spl ay ed.
Further str o kes are prevented unt il an operator pr esses the RES ET ERROR so ftkey, at which time the
lubri cation pul se wi ll agai n b e attempted. If the fl ow rate time at power up has been programm ed for 000
Sec, no lubrication pulse is given. After t he lube pulse is successfully completed, the pump output is
turned Off un til the press makes the specif i ed " Num b er of Strokes Off". The pum p output is then turned
On an d th e f l ow rate se n sor m on i tored f or the ti m e spe cified as " Flow Rate (Run n ing)" (in se cs ). Fa i lure
of the flow rate senso r t o make a complete cycle generates t he same fault as described above. T his
lubrication cycle repeats as long as the enable signal is turned On.

The Figure below describes a typical example of
au xiliar y lu be s yst e m #1 be ing u se d t o lu br ica te a
cushi on. Type 002 i s used because the cushi on h as
a flow r a te sensor that nor mally makes a complete
cycl e i n 7 seconds. When power is f irst appl ied an d
the auxiliary Lubes are enabled (input #57 switches

Aux. Lube 1 Type.......002

# of Strokes Off......10000

Flow Rate (Running)....010 Sec

Flow Rate (Power Up)...030 Sec

Output Pulse...........000 Sec

6.17

high ) the system has b een programm ed to generate an ini tial lub e cy cl e. Output OR-13 energi zes a m otor
driven lube pump until the flow sensor input #51 indicates pro per flow. The sensor is given 30 seconds
to cycle for this first lube interval. As soon as the input cycles, output OR-13 is turned Off for 10, 000
strokes. The output will then turn On until proper flow is detected, allowing 10 seconds before an “Aux.
Lube 1 Fault” is g e ner a te d . Th is pe r iod ic lu b r ic a tion will c ontin u e a s lon g a s the e na b le s ig n a l is h ig h .
Note: If a parameter is changed, the new settin g w ill Not be used until the present tim ing portion of the
lube cy cle i s compl ete. For example, if the press control is presently countin g 10000 strokes shown above
and a new setting of 20 is entered, the new setting will Not be used until the present in terval i s compl ete.
Th e 20 stro kes sett in g w ill b e u sed for th e ne xt and all future Off cycles. To “force” the new setting to
be used immedi atel y y ou can turn power to the control Off an d back On or change the Aux . Lube 1 Ty pe
to 000 and back to 002. T his will reset the lube system.

In applications where the Aux. Lube Output (OR-13/14) is controlling a solenoid driven pump it may be
necessary to pulse this output during the lubrication cycle. An additional "Output Pulse" timer sets the
rate at which the output turns On and Off. If “Output Pulse”=001 in the example above, when the lube
cycl e starts OR-13 would turn On for 1 second and Off for 1 second until the fl ow sensor input #51 makes
a complete cycle. An output pulse time set to 000 secs or a time set greater than the flow rate time will
result in the lube output remaining On constantly during the lube cycle (as would typically be used when
controlling a motor driven pump).

Section 6.2.2 Run Mode Interlocks

A low level (input open) on these inputs cause the press control to stop im mediately, and prevent stroke
initiation until they are cleared (returned to +24 volt). The inputs function in all stro king modes except
Inch and Timed Inch.

Section 6.2.3 Input Board #3 Select

If the optional expansion card rack and third input board are pr o vided , this input must be permanently
strapped to +24 volt on the input connector card and the press control must be confi gured by the factory
to r ecognize the third input card. A fault is generated if all conditions are not correct .

Section 6.2.4 Definable Top Stops

A low level (input o pen) on these seven input s cause the press co ntr o l to st o p t he next time crankshaft
angle reaches t he to p of the stro ke, if any occur while the press is stro king. They prevent the machine
from b eing started any where in the stroke, until they are cleared (returned to +24 volt). Whil e the f unction
of the inputs can not be altered, the name that is displayed for diagnostic purposes can be defined by the
user. The programmab l e nam e (up to twenty characters), along wi th the type of stop (TS) and the in put
numb er (I58-I64) are displayed in the Press Control menu as a reason for the press stopping or a reason
why the pr ess w ill n ot str oke.

Section 6.2.5 Definab le Cycle Stops

A low level (input o pen) o n these four inputs cause the press cont ro l to st o p immediately, and pr event
stroke i nitiation un ti l they are cleared (returned to +24 volt). While the fun cti on of the inputs can not be

6.18

altered, the name that is displ ay ed for diagn ostic purposes can be def in ed by the user. The programmab l e
name (up to twenty characters), along with the type of stop (E S) and the input number (I65-I68) are
displayed in the Press Control menu as a reason for the press stopping or a reason why the press wi ll not
stroke.

Section 6.2.6 Definable Master Stops

A low l evel (i nput open) on these four in puts cause the press control to stop immedi ately . In addition they
cause the press contr ol to turn o ff the LMC Relay out put and prevent stroke initiation until they are
cleared (ret urned to +24 volt). While the function of the inputs can not be altered, t he name that is
displayed for diagno st ic p urposes can be defined by the user. The programmable name (up to twenty
characters), along with the type of stop (MS) and t he input number (I69-I72) are displayed in the Press
Control men u a s a re ason for the pre ss stopping o r a reason w hy the press will not stroke.

Section 6.2.7 Continuous on Demand Run

This input must be high (24 volts) before stroking in Continuous on Demand mode can begin. Continuous
str ok in g w ill c on tinu e a s long a s th is inpu t r e mains h ig h ( 24 volt s ). Whe n t h is inp u t g oe s low (0 v olts)
while the press is running in Continuous on Demand mode, the press will top stop. Continuous stroking
will resume if this input goes h igh (2 4 volts ) before the Contin uou s on D emand timer times out.

Section 6.3 Press Control Outputs

The sys tem 5000 output driv e modul e all ows up to four groups of ei ght outputs each (relay or soli d state)
to be connected. Two o f these groups (1 and 3) are pro grammable limit switch output s, and two ar e
assigned to specific machine functions. The o utputs are listed below:

Output # Group # Description Sect ion

-----------------------------------------------------------------------------------------------------------------------­ 01 1 Prog rammable limit switch
02 1 Prog rammable limit switch
03 1 Prog rammable limit switch
04 1 Prog rammable limit switch
05 1 Prog rammable limit switch
06 1 Prog rammable limit switch
07 1 Prog rammable limit switch
08 1 Prog rammable limit switch

09 3 Prog rammable limit switch
10 3 Prog rammable limit switch
11 3 Prog rammable limit switch
12 3 Prog rammable limit switch
13 3 Prog rammable limit switch
14 3 Prog rammable limit switch
15 3 Prog rammable limit switch
16 3 Prog rammable limit switch

6.19

17 (OR-1) 2 Delayed Main Motor 6.3.1
18 ( OR-2) 2 Hydra ulic Over load Cylinder 6 .1. 12
19 (OR-3) 2 Hydraulic Overload Pump 6.1. 12
20 (OR-4) 2 Flywheel Brake 6.3.2
21 (OR-5) 2 Lube System Output 6.1.11
22 ( OR-6) 2 Auxiliary Equipme n t Stop 6.3.3
23 ( OR-7) 2 Auxiliary Equipme n t Stop 6.3.3
24 (OR-8) 2 Slide Motion 6.3.4

25 (OR-9) 4 Press in Inch/Timed Inch 6.3.5
26 (OR-10) 4 Press in Manual Stroke Modes 6.3.5
27 (OR-11) 4 Press in Continuous Mode 6.3.5
28 (OR-12) 4 Pr ess in Auto Single Stroke 6.3.5
29 (OR-13) 4 Aux. Lube 1 Output 6.2.1
30 (OR-14) 4 Aux. Lube 2 Output 6.2.1
31 (OR-15) 4 Stroking Enabled 6.3.6
32 (OR-16) 4 Stop At To p Output 6.3.7

Section 6.3.1 Delayed Main Motor

This output (OR-1) tracks the state of the main motor. If the main motor turns ON, this output will delay
a specified time before tur ning ON. When the main motor turns OFF, t his out put will delay a specified
time before t u r ning OFF. T he time for t urn ON and turn OFF can be individually programmed by the
factory within the range of 0 seconds to 120 seconds.

Section 6.3.2 Flywheel Brake

Thi s output (OR-4) turns on (f ly wh eel brake i s rel ease d) an y ti me th e forward or reverse m otor in put turns
ON (+24v). It turns OFF when both motor inputs turn OFF unless the press mode is in Inch or Timed
Inch. This feature allows the press to be "dead motor inched".

Section 6.3.3 Auxiliary Equipment Stop

Output (OR-6) provides a stop signal to equipmen t external to the press control. A stop signal is issued
(Output is turned Off) if the emergency stop button is pressed, auxiliary cycle stop input opens, die block
input opens, auxiliary master stop input opens, master stop switch opens, or the main motor is in reverse.
If the optional third input card exists, a stop sign al is issued if any cycl e stop input, except Input # 68, or
master stop input opens, or if either run mode interlock op ens while in a stroking mode other than Inch
or Tim ed Inch. A stop signal i s i ssued if the li ght curtain causes the press to stop (i.e. is not being m uted),
exce pt in t h e Inch mod e. If configu re d to mute in Inch, the lig ht cur tain will not issue an auxiliary stop.
This is done so that t he light curt ain can be blocked w hile setting up the feed in Inch. If configured to
never mute the light curtain (type 004), this output turns off anytime light curtain is blocked.
Output (OR-7) turns Off if either the Tonnage Monitor or the Die Protection Module generat es a cycle
stop o r a t op sto p . If a to p st op is ge ne ra t e d th is ou tp u t w ill t u r n Off as soo n as t he co nd it ion occ ur s
while the press may continue to run to the top of the stroke.

6.20

Section 6.3.4 Slide Motion

This output (OR-8) tur ns on when the crankshaft rpm exceeds the minimum strokes/minute threshold.

Section 6.3.5 Mode Outputs

These four outputs provide the present stroking mode of the press control. They f unction in the foll owing
manner:

Output ( OR-9) I nch and Timed Inch Modes
This output t ur ns o n when the press control is in Inch or Timed Inch mode.

Output (OR-10) Setup/Stop T ime Test, Single Stroke, and Maintain Continuous Modes
T his o u tp u t t ur ns on w hen th e pr es s co nt ro l is in S et up /S to p T ime T es t, Sing le S tr ok e, or Ma int ain
Continuous mode.

Output (OR-11) Co nt inuous, Maintain Continuous and Continuous on Demand Mode
This output turns on when the press contro l is in Continuous, Maintain Continuous or Continuous on
Deman d mod e.

Output (OR-12) Auto Single Stroke and Continuous on Demand Mode
This out put t urns on when the press control is in Automatic Single Stroke and Continuous on Demand
mode.

The table below show t hat stat us of the stroking mode o utput s. The “X” indicates that the out put is
energized in the listed mode.

Stroke Mode OR9 OR10 OR11 OR12

Inch X
Timed Inch X
Stop Time Test X
Single Stroke X
Continuous X
Auto Single Stroke X
Ma intain Cont. X X
Cont. on De mand X X

Section 6.3.6 Stroking Enabled

This output (OR-15) turns on when no stop conditi on ex ists and the press control is prepared to engage
the clutch/brake air valve wh en the proper run buttons are depressed. This output will remain on un til a
st op con dit ion o ccu rs o r u ntil t he p res s au t oma t ica lly s to ps o n to p. It will re main o ff unt il all st op
conditions are removed and all o pe r a t o r ru n butto ns are released. Stro king modes that require a prior
action setup button such as Continuous, Automatic Single Stroke, and Maintain Continuous will keep this
o utput off unt il the mo de has bee n prop er ly setup. The output will turn on when the prior action setup
button is pre ssed for a t least 1/2 second and w ill remain on if the prope r run buttons are used to initiate

6.21

the stroke. In Automatic Single Stroke the output will remain on while the press is stopped at the top and
the press contr ol is waiting for the proper automatic initiation signal from the feed.

Section 6.3.7 Stop At Top Output

This output (OR-16) turns On when the press de-energizes the clutch/brake output in order to
automatically stop the press at t he t op of t he stroke. I t remains On until the press comes to a complete
stop . This can be used by external equipment such as transfer systems as an indication that the press is
stopping at the top and to complete a f eed operation. Thi s output is al so used in appl i cations where a soft
brake is being controlled (see section on valve monitor).

6.22

Section 7 Installation

Section 7.1 Component Mounting

The Operato r Ter minal must be mounted in a position that is easily seen and accessed by the operat o r.
The li quid crystal displ ay i s design ed to be vi ewed from the bottom of the display. If the operator terminal
is mounted in a vertical plane, it must be mounted slightly above the operator's eye level. If mounted on
a sloped surface, it should be mounted so that the operator's line of sight is from the bottom of the LCD.
The desirable orientations are shown in Figure 7.1.

Figure 7.1 LCD Mounting Orientations

The required cutout dimensions for the operat or ter minal are shown in Figure 7.2.

Figure 7.2 Operator Terminal Mounting Dimensions

7.1

The physical layout dimensions for basic card rack are shown in Figure 7.3.

Figure 7.3 Card Rack Dimensions

7.2

The physical layout and mounting dimensions for the relay module are shown in Figure 7.4.

Figure 7.4 Output Power Supply and Relay Modules
Dimensions

7.3

The mounting dimensions for all available assemblies are shown in Figure 7.5.

Figure 7.5 Card Rack and Output Power Supply
Mounting Dimensions

The mounting dimensions for the resolver/encoder assembly are shown in Figure 7.6. When the
res o lver/encoder is driven by a chain, the spring base should be used. The resolver/encoder assembly
mounted on the spring base i s sh own i n F i gure 7.7. The shaft of the resolver/encoder is 3/4 " in diameter
with a 3/16 " wide keyway. The sprocket attached to the resolver/encoder must be bored and keyed to
fit. Do not install the sprocket without a proper size key. After installing sprocket and key, the clip ring
must be installed in the groove on the end of the reso lver shaft.

Figure 7.6 Resolver/Encoder Mounting
Dimensions

7.4

Figure 7.7 Dimensions for Resolver/Encoder
Mounted on Spring Base

Another sprocket must be attached to the machine shaft. The proper size hole must be drilled and tapped
in t he static center of the machine shaft. After att aching the spro cket to the shaft, an additio nal hole
sho u ld b e d rille d a pp r ox imat ely 3 / 4 " off of t h e st a t ic c ent e r. T his h o le s ho uld be dr illed t hr ou g h t he
sprocket and into the machine shaft . The spr ocket should be removed and the off center hole in the
machine shaft tapped for a 1/4 " bolt or larger. The off center hole in the sprocket must provide proper
clearance for t he bolt. Att ach the spro cket to t he machine shaft with the center bolt and the off cent er
bolt. When attaching the chai n to the sprockets, the zero position of the resolver/encoder must be ali gned
with the top dead center of the machine shaft. The zero position of the resolver/encod er is indicated by
the l e g e n d on th e fron t of th e a s s e mbly . Whe n the k eywa y i s a li g n e d with th e z e ro p os iti on of th e leg e n d ,
the assemb ly i s at zero. The sy stem 5000 al lows the user to program an of fset val ue to make up for mi nor
dif ferences from the m achine top dead center and resolv er/en coder zero. The offset value is l imi ted to ±
10 degrees of resolver zero.

Section 7.2 Field Wiring

Section 7.2.1 Operator Terminal/Card Rack

Figure 7.8 shows the field connectio ns bet ween the operat or terminal and the card rack. T he shield
should not be connected at the operator termi nal si de, but should b e cut and taped so as not to acciden tly
short.

7.5

Figure 7.8 Operator Terminal and Card Rack Power and Interconnect
Wiring

Section 7.2.2 Clutch/Brake Valve

The connections for the clutch/b rake dual valve are provided on the POWER CONNECTOR MODULE
(labeled V1-V5). A typical wiring diagram for an air valve with internal monitor is shown in Figure 7.9.
This interface is 120 VAC (wire labeled 103 is hot and wire labeled 102 is neutral). Additional
co nne ctions for monitor ing the va lve mus t remain +24 volt D C .

Figure 7.9 Clutch/Brake Valve Connections

Section 7.2.3 Resolver/Encoder

Figure 7.10 shows the fi eld connecti ons between the resolver/encoder assembl y and the system 5000 card
rack. A shielded cable with 6 twisted pairs must be used. This cable must be run in a dedicated condui t
from the encl osure housing the card rack assembl y to a junction box m ounted behin d the resolv er/encoder
unit. The exposed cable from the junction box to the reso lver/encoder as se mbly sho u ld be as short as

7.6

possibl e. All ow suffi cien t wire length so that the R/D CONNECTOR can be removed f rom the card rack
and positioned so the R/D BOARD can be removed from and inserted into the card rack.

Figure 7.10 Resolver/Encoder Wiring

Section 7.2.4 Inputs

The fi el d conn ections f or the sy stem 5000's i nputs are +24 vol t DC. The connections to inputs 1-24, 25­48, and optionall y 49-72 MUST NEVER be connected to 120 VAC. Each input card provides a +24 v olt

7.7

terminal along wi th its inputs. This termi nal should be used to connect any perm anent straps to inputs that
are not to be used in a particular installation. The +24 volt power supply is fused and provided for field
connections on the POWER CONNECTOR MODULE.

Each input board has two four po sition Address Switches, one for each press cont rol channel. The
switches m ust be positioned in the man ner shown below for each i nput board. The switches on each b oard
must be in the same po sition.

INPUTS SWITCH POSITION

1234

------------------------------------------------------------------­1-24 OFF ON ON ON
25-48 ON OFF ON ON
49-72 OFF OFF ON ON

Section 7.2.5 Outputs

The OUTPUT DRIVE MODULE provides ri bbon cabl e connections f or up to four groups of ei ght relay s.
Each cable is polarized for co nnection to a par ticular group as defined below:

GROUP RELAY MODULE

----------------------------------­1PLS 1-8
2OR 1-8
3 PLS 9-16
4 OR 9-16

An Output Power Module accommodates up to two Relay Modules, and requires 120 VAC in order to
supply the +12 vol t DC relay power. Each relay output provides a n ormal ly open contact fused at 7 amps
and a second contact that may be selected as either normally open or normally closed. This selection is
made by locating the 7 amp pico fuse in the proper orientation. Figure 7.11 shows the configurations
allowed on a ny rela y outp ut.

Figure 7.11 Relay Output Selections

7.8