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