LINK Systems OmniLink II User Manual

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Page 1

OmniLink II

Press Automation

Control

OPERATING MANUAL

OmniLink II

Version 1.0

LINK ELECTRIC & SAFETY CONTROL COMPANY

444 McNALLY DRIVE, NASHVILLE TN 37211

PH (615)-833-4168 FAX (615)-834-1984

Page 2

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

Section 1.1 Base System...................................................................................................................................................... 1.1

Section 1.1.1 Base System Standard Features.................................................................................................................1.1

Section 1.1.2 Base System Optional Features................................................................................................................. 1.2

Section 1.2 Optional Hardware Modules............................................................................................................................. 1.2

Section 1.3 System Overview..............................................................................................................................................1.3

Section 2 Installation....................................................................................2.1

Section 2.1 Preliminary Installation Considerations............................................................................................................ 2.1

Section 2.2 Mounting System Components......................................................................................................................... 2.4

Section 2.2.1 Mounting the Operator Terminal Enclosure..............................................................................................2.4

Section 2.2.2 Mounting the Resolver.............................................................................................................................. 2.5

Section 2.2.3 Mounting Optional Control and Monitoring Modules ..............................................................................2.6

Section 2.3 Wiring System Modules and Components........................................................................................................2.8

Section 2.3.1 Conduit Runs............................................................................................................................................. 2.8

Section 2.3.2 Wiring the Resolver to the R/D-Brake Monitor Module...........................................................................2.9

Section 2.3.3 Wiring 115VAC Power From Press Control to Operator Terminal ........................................................2.12

Section 2.3.4 Wiring the Valve Voltage Circuit ...........................................................................................................2.14

Section 2.3.5 Wiring the OmniLink Stop Circuit Output..............................................................................................2.14

Section 2.3.6 Wiring the Optional Setup Mode Input................................................................................................... 2.16

Section 2.3.7 Wiring Optional Analog Input/Output Board Circuits............................................................................ 2.17

Section 2.3.7.1 Wiring to Display Motor Load Current...........................................................................................2.17

Section 2.3.7.2 Wiring the Analog Speed Input and Output ....................................................................................2.17

Section 2.3.8 Optional Solid State Relay Outputs.........................................................................................................2.20

Section 2.4 Additional Mounting and Wiring if the Operator Terminal, R/D-Brake Monitor Module, and (Optionally)

Solid State Relay Module are Provided Without Enclosure for Customer Panel Mounting..............................................2.21

Section 2.4.1 Mounting the Base Components in the Customer Enclosure.................................................................. 2.21

Section 2.4.2 Wiring the Base Components in the Customer Enclosure.......................................................................2.22

Section 2.5 Wiring Serial Ports for Serial Feed Interface, PLC Interface, and LinkNet Information System Options .....2.22

Section 2.6 Wiring the Parallel Port for Messages from Auxiliary Equipment (Optional)................................................ 2.23

Section 3 Operator Terminal Basics...........................................................3.1

Section 3.1 OmniLink II Press Automation Control LCD Operator Terminal.................................................................... 3.1

Section 3.2 Operator Terminal Modes................................................................................................................................. 3.2

Section 3.3 Softkeys ............................................................................................................................................................3.3

Section 3.4 ACC Key ..........................................................................................................................................................3.3

Section 3.5 CHG Key ..........................................................................................................................................................3.4

Section 3.6 Arrow keys........................................................................................................................................................3.4

Section 3.7 Numeric Data Entry .......................................................................................................................................... 3.4

Section 3.8 Alphanumeric Data Entry .................................................................................................................................3.5

Section 3.9 Access Control Operation for Settings and Actions in Program Mode.............................................................3.8

Section 3.9.1 Program/Run Key Switch Operation.........................................................................................................3.8

Section 3.9.2 Using Key Only Access to Program Mode for Settings and Actions........................................................ 3.9

Section 3.9.3 Code (Password) System Operation........................................................................................................3.11

Section 3.9.4 Automatic Log Out .................................................................................................................................3.14

Section 4 Device and Main Configuration Menus....................................4.1

Section 4.1 Device Configuration Menu .............................................................................................................................4.1

Section 4.2 The Main Configuration Menu .........................................................................................................................4.4

Section 4.2.1 Machine Parameters Menu........................................................................................................................ 4.7

Section 4.2.1.1 Configuring the Encoder (Resolver) Type.........................................................................................4.7

Section 4.2.1.2 Setting Top of Stroke Angle.............................................................................................................. 4.7

Section 4.2.1.3 Setting Minimum Press Speed and Loss Of Motion Time ................................................................4.8

Section 4.2.1.4 Temporarily Setting Other Items on the Machine Parameter Screen So that the Press Can be Stroked

Without Generating Brake Monitor or Motion Detector Faults ................................................................................. 4.9

Section 4.2.1.5 Setting Encoder Offset ......................................................................................................................4.9

Section 4.2.1.6 Use Mode Input Setting................................................................................................................... 4.12

Section 4.2.1.7 Setting Clutch Engagement Time Limit .......................................................................................... 4.12

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Section 4.2.1.8 Setting Brake Monitor Top Stop and Brake Monitor Mid Stroke Stop Limits................................4.13

Section 4.2.2 Speed/Load Configuration Menu Settings...............................................................................................4.14

Section 4.2.2.1 Setting Speed Mode.........................................................................................................................4.15

Section 4.2.2.2 Calibrating Variable Speed Drive Input SPM When “Input Only” is Selected ...............................4.16

Section 4.2.2.3 Calibrating Variable Speed Drive Input SPM When Output Without Recall or Output With Recall is

Selected for Speed Mode..........................................................................................................................................4.17

Section 4.2.2.4 Calibrating the Analog Output SPM Signal to Give Correct Drive Speed ......................................4.17

Section 4.2.2.5 Calibrating Percent Motor Load ......................................................................................................4.20

Section 4.2.2.6 Setting Speed Parameters.................................................................................................................4.20

Section 4.2.3 Top Stop Calibration Menu Settings .......................................................................................................4.20

Section 4.2.3.1 Top Stop Calibration for Fixed Speed Presses.................................................................................4.22

Section 4.2.3.2 Variable Speed Press Auto Top Stop Calibration............................................................................4.23

Section 4.2.4 Operator Terminal Configuration............................................................................................................4.26

Section 4.2.4.1 Top Area (Screen) Display Configuration.......................................................................................4.26

Section 4.2.4.2 Zeroing Stroke Count.......................................................................................................................4.27

Section 4.2.4.3 Key/Code Access Configuration......................................................................................................4.28

Section 4.2.4.4 Auxiliary Communications Setup....................................................................................................4.33

Section 4.2.5 Auxiliary Equipment Messages...............................................................................................................4.33

Section 5 Using the OmniLink II Press Automation Control Standard

Functions and Optional Speed Adjust Function .......................................5.1

Section 5.1 Main Menu (Screen) .........................................................................................................................................5.1

Section 5.2 Brake Monitor and Diagnostic Screen ..............................................................................................................5.2

Section 5.2.1 Brake Monitor ...........................................................................................................................................5.3

Section 5.2.2 Clutch Engagement Time Monitor............................................................................................................5.4

Section 5.2.3 Critical Angle and Intellistop ....................................................................................................................5.4

Section 5.2.4 Stopping Degrees.......................................................................................................................................5.6

Section 5.2.5 Auxiliary Equipment Messages.................................................................................................................5.7

Section 5.2.6 Reason for the Last Stop............................................................................................................................5.7

Section 5.2.7 Present Running Status..............................................................................................................................5.7

Section 5.2.8 Diagnostics ................................................................................................................................................5.7

Section 5.2.9 Module Limit Switch.................................................................................................................................5.8

Section 5.3 Counters ............................................................................................................................................................5.9

Section 5.3.1 Production Counters ..................................................................................................................................5.9

Section 5.3.1.1 Production Counters On/OFF..........................................................................................................5.10

Section 5.3.1.2 Production Counters Change Limit .................................................................................................5.11

Section 5.3.1.3 Production Counters Reset...............................................................................................................5.11

Section 5.3.1.4 Production Counters Increment/Decrement.....................................................................................5.11

Section 5.3.1.5 Production Counters Change Count.................................................................................................5.12

Section 5.3.2 Stroke Counter.........................................................................................................................................5.12

Section 5.3.3 Scrap Counter ..........................................................................................................................................5.12

Section 5.3.4 Configure Counters .................................................................................................................................5.13

Section 5.3.4.1 Configure Auxiliary Counter Names ...............................................................................................5.13

Section 5.3.4.2 Configure Counter Count By Value ................................................................................................5.14

Section 5.3.4.3 Configure Counter Every How Many Stroke Value ........................................................................5.14

Section 5.3.4.4 Configure Counter Reset When Order Counter Reset .....................................................................5.15

Section 5.3.4.5 Configure Counter Enable ...............................................................................................................5.15

Section 5.3.4.6 Configure Reset Counters When Job Recalled................................................................................5.15

Section 5.4 Motor Speed Adjustment (Option)..................................................................................................................5.15

Section 5.5 Quick Access (ACC key)................................................................................................................................5.16

Section 5.5.1 Machine Notes.........................................................................................................................................5.17

Section 5.5.2 Job Notes .................................................................................................................................................5.17

Section 5.5.3 Editing Machine Notes and Job Notes.....................................................................................................5.17

Section 5.5.4 Auxiliary Communications......................................................................................................................5.18

Section 5.5.5 LOGOUT Softkey ...................................................................................................................................5.18

Section 5.6 Job Setups (Storage and Recall)......................................................................................................................5.18

Section 5.6.1 Store Setup ..............................................................................................................................................5.19

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Section 5.6.2 Recall Setup ............................................................................................................................................5.20

Section 5.6.3 Erase Setup.............................................................................................................................................. 5.21

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Section 1 Introduction

The OmniLink II Press Automation Control for part revolution clutch mechanical power presses is a

flexible, intelligent, modular system that can be applied to presses with existing clutch brake and motor

controls to provide a wide variety of control; press, die, and process monitoring; and management

information functions. The system integrates setting and display of all functions through the OmniLink

II Color LCD Operator Terminal, which includes a 9.2” diagonal color TFT liquid crystal display (LCD)

with high brightness and large viewing angle, membrane keys for entry and navigation, and a

Program/Run keyswitch.

Section 1.1 Base System

The base system hardware package consists of the OmniLink II Color Operator Terminal and R/D-Brake

Monitor Module in an enclosure (panel mount versions are also available), and a resolver and its cable

with connector. The Operator Terminal is the central operator interface for display and settings of all

system functions and diagnostics. The easy to use large color TFT LCD display of the operator terminal

provides the screens and menus. The operator terminal keypad is used to program settings or store or

recall jobs. The resolver provides precise press crank or eccentric shaft angular position and speed to

sequence and monitor press automation functions.

Section 1.1.1 Base System Standard Features

• Control reliable time base brake monitor with dual limits for top and midstroke stopping.

• Clutch engagement time monitor that can aid in determining when clutch adjustment or disc

replacement should be done.

• Motion detection to detect resolver decoupling from the crankshaft.

• Powerful counting capability with 12 counters, 10 with flexible configuration.

• Six serial ports are provided, one of which is a high speed serial interface over which the operator

terminal and optional modules communicate. Others are used to communicate with intelligent controllers that control automation related to the press production system. One can be used provide Link’s optional Serial Feed Interface that sets up a feed for a job when recalled from storage on the OmniLink II Operator Terminal and displays feed settings on the operator terminal screen. Another can be used for Link’s optional PLC Interface to send job settings to a PLC programmed to perform automation and display status and diagnostic messages from the PLC.

• Auto top stop compensation for variable speed presses in the Continuous mode.

• Operator screens in English or Spanish at the touch of a key, intelligent diagnostics of the base

system and all system options in English and Spanish, “Help” in English and Spanish that automatically appears on the display screen for many data entry fields for settings.

• 500 job storage for all settings associated with standard and optional functions of the system.

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1.1

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Section 1.1.2 Base System Optional Features

• An optional analog input/output card allows stroking speed to be adjusted and displayed on the operator terminal even when not stroking for variable speed presses. It also allows motor load current to be displayed.

• Serial Feed Interface for most available electronic roll feeds.

• A flexible PLC interface that allows the OmniLink II Operator Terminal to send settings for jobs and

receive status and diagnostic messages from the PLC for display on the operator terminal screen.

• LinkNet Shopfloor Information System - networks your presses to computer(s) to gather information and provide comprehensive management information database and reporting system.

Section 1.2 Optional Hardware Modules

The system is designed to allow additional hardware modules to be added to the base system package to perform a wide variety of control and monitoring functions. The system uses distributed intelligence -each optional module has its own microprocessor to perform its logic functions. This provides increased computing power and superior performance, allowing more logic functions to be performed at greater speeds. All optional modules communicate to each other and to the OmniLink II Operator Terminal through a high speed serial bus cable with only four connections. This eliminates the need to individually wire all inputs and outputs back to the operator terminal. Adding modules is simple and quick, mount the module and wire the 3 wire and drain connection cable from the last module previously installed to the newly installed module.

Optional hardware modules that are currently available for the system are:

• The 5120 series Die Protection and Process Monitor modules available with 8 or 16 sensor inputs per module. Up to five 5120 series modules may be used with the system, giving a maximum of 80 total inputs for digital die protection and process monitoring.

• The 5105 series PLS/Logic Module available with 8 or 16 output relays (electromechanical, solid state ac, and solid state dc relays available) for programmable limit switch (PLS) or other output relay (OR) logic functions. Each module also has 16 inputs available for logic or sensing applications. Up to four 5105 series modules may be used with the system for a maximum of 32 PLS outputs, 32 OR outputs, and 64 sensing or logic inputs.

Optional hardware modules that are planned as additions to those currently available are:

• A 5108 series of Signature and Tonnage Monitor modules.

• A 5110 series of Auto Setup Modules that can automatically recall and set up shutheight,

counterbalance pressure, cushion pressure, etc., when a job is recalled.

• A 5130 series of Analog Die Protection and Process Monitoring modules to measure production process variables and part features during stamping. Gives capability for 100% “in process” parts quality inspection when used with appropriate input sensors.

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Section 1.3 System Overview

Figure 1.1 shows the base package hardware components for the OmniLink II Press Automation Control.

Crank or

Eccentric

Shaft

Figure 1.1 OmniLink II Press Automation Control Base System Package

Figure 1.2 (next page) shows the existing and planned components and features of the system with optional components.

RESOLVER

OMNILINK II PR ESS AUTOMATIO N CON TROL

RESOLVER CABLE

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Page 9

CRANK OR

ECCENTRIC

SHAFT

RESOLVE

OMNILINK II PRESS AUTOMATION CONTROL

HIGH SPEED SERAIL BUS CABLE (3 WIRES AND DRAIN)

RESOLVER CABLE

LINKNET

SERIAL PLC INTERFACE CABLE

FEED

PROGRAMMABLE

LOGIC

CONTROLLER

SERIAL FEED INTERFACE CABLE

UP TO 80 DIE PROTECTION & PROCESS

MONITORING INPUTS -- 8 OR 16 PER MODULE

MODEL 5120

MODEL

LINK

DIE PROTECTION &

MODULE NUMBER/

LINK

DIE PROTECTION &

MODULE NUMBER/

MODULES

UP TO 32 PROGRAMMABLE LIMIT SWITCH AND

32 LOGIC OUTPUTS - 8 OR 16 RELAYSPER MODULE

16 LOGIC & MONITORING INPUTS PER MODULE

MODEL

MODEL 5100-5

LINK

PROGRAMMABLE LIMIT SWITCH

DIE PROTECTION &

MODULE N

MBER/

LINK ELECTRIC & SAFETY CONTROL

444 McNally Drive Nashville, TN

37211

Phone: (615) 833-4168

MODEL

MODEL 5100-5

LINK

PROGRAMMABLE LIMIT SWITCH

DIE PROTECTION &

MODULE

LINK ELECTRIC & SAFETY CONTROL

444 McNally Drive Nashville, TN

37211

Phone: (615) 833-4168

OTHER MODULES TO BE

DEVELOPED

Analog Die & Process Monitor Module Tonnage & Signature Monitor Module AutoSets for Shut Height and

Figure 1.2. Existing and Planned System Components and Functions

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Section 2 Installation

Section 2.1 Preliminary Installation Considerations

1. Before you begin to install your OmniLink II Press Automation Control, you should read this entire manual carefully. This will help you to understand system functions and plan the installation to save time and the necessity to rework portions of the installation.

2. The high speed serial bus used to communicate between system modules begins with the OmniLink II LCD Operator Terminal and goes first to the R/D-Brake Monitor Module located in the back of the operator terminal enclosure, then on to each optional hardware module used with the system as shown in Figure 2.1. Every hardware module used with the system has a switch that can be closed to terminate the serial bus. The termination switch on the module installed at the far end of the serial bus should be thrown to the closed position. The switches on modules installed between the operator terminal and the last module should be in the open position. If only one optional module is used with the system, the termination switch on this module should be thrown to the closed position. If no optional modules are used with the system, the bus termination switch on the 802-5 R/D-Brake Monitor Module should be thrown to the closed position. The location of the termination switch for the 802-5 R/D-Brake Monitor Module is shown in Figure 2.1.

Analog Input/Output

Board Option

CON8

1 2 3 4 5

R 1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3

Figure 2.1 802-5 R/D-Brake Monitor Module

3. As shown in Figure 2.2, optional hardware modules may come with one module or multiple modules per enclosure, depending on the number and type of modules ordered. The modules do not have to be connected in any particular order on the serial bus, but the serial bus cable must connect to each module in the daisy chain fashion shown in Figure 2.2. It is desirable to run the cable for the serial bus to connect the optional hardware modules with the shortest total length of cable. The total length of serial bus cable used with the system must not exceed 300 feet.

802-5 R/D-Brake Monitor Module

Microprocessor 2

Microprocessor 1

Mi cr op ro c. 1 Prog . Memory

R/D

Can Termination

Bus

Switch

CON7

CON1

GN D

SHLD

C ANL

CAN H

CON2

1 2 3 4 5 6 7 8

CON5

L1 L2 G ND

Trans for mer

Output Relays

Fuse

CON4

1 2 3 4

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Page 11

It is also convenient to run the 115VAC power along with the high-speed serial bus cable to each module(s) enclosure in the same flexible liquid tight conduit with ground, as indicated in Figure 2.2.

OPER AT OR

TERMINAL

ENCLOSURE

USE THE SWITCH ON THE OPTION INSTALLED AT THE FAR END OF THE CABLE FROM THE OPERATOR TERMINAL TO TERMINATE THE SERIAL BUS CABLE.

SERIAL BUS CABLE AND POWER FOR MODULES RUN IN SAME CONDUIT

P T

I O N

O P T

I O N

P T

I O N

Figure 2.2 Serial Bus Connections

3. Dual connector plugs are used for each optional module shown in Figure 2.2 for both the high- speed serial bus and 115VAC power connection to the module. This allows both the serial bus and power connections to be strung from module to module as shown in Figure 2.3.

Cable Wire Color Connector

White CANL Orange CANH Blue GND Bare Shield

Terminal

SHIELD MUST BE CONNECTED TO PLUG

SERIAL BUS CABLE FROM LA ST MODULE

SERIAL BUS CABLE TO N EXT MODU LE

PLUGS INTO MODULE CONNECTOR HEADER FOR THIS MODULE

115 V AC TO NE XT MODULE

SERIAL BUS CONNECTOR PLUG FOR THIS MODULE

115 VAC FROM LAS T MODULE

16 GA RE D, WH ITE , GREEN WIRES

PLUGS INTO MODULE CONNECTOR HEADER

FOR THIS MODULE

16 GA RE D, WH I TE , GREEN WIRES

115 V AC CO NN E C T O R PLU G FOR THIS MODULE

Figure 2.3 Dual Connector Plugs for Modules for Serial Bus and Power

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4. NEVER use any cable other than that supplied by Link Systems for the high-speed serial

bus that interconnects the various components of the OmniLink II Press Automation Control. This cable has been chosen to optimize communication speed and distance for the serial bus. Use of other cables may result in communication faults that cause nuisance stops of your press production system. DO NOT splice sections of cable between OmniLink II modules. Use unbroken runs of cable between modules.

5. The wiring instructions for installation contained in this manual are necessarily generic since the OmniLink II Press Automation Control may be interfaced with a wide variety of control systems using multiple relay and electronic components. If the installer has questions related to the proper installation of the system, contact the service personnel at Link Systems. Always test each component of the system installation to see that proper function is obtained. In particular, make certain that all stop outputs from the OmniLink system to the press control are interfaced properly.

WARNING! Improper system installation or improper interface of

6. Installation of this system should be done in accordance with OSHA’s lockout/tagout regulations

stop outputs from the OmniLink system to the press control may result in damage to press, dies or other equipment and increase the possibility of injury to operators and others. Use qualified installers.

(see CFR 1910.147). You will be mounting OmniLink components on the press, and may be exposed to mechanical hazards if press movement should occur during mounting activities. You will also be wiring electrical circuits that will use 115VAC (nominal) voltages. Unless these circuits are de-energized during wiring activities, a serious or even fatal shock may occur. Depending on the options purchased with your OmniLink system, you may also be installing air valves or pressure sensors for air counterbalance or air cushion systems. These air systems could cause serious injury if not depressurized before installation is started. Remove hazardous energy during OmniLink system installation in accordance with CFR 1910.147.

WARNING! Failure to comply with CFR 1910.147 regulations and remove hazardous energy during installation of the OmniLink II Press Automation Control may result in serious injury or death! Use only qualified installers trained in lockout procedures for installation.

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Section 2.2 Mounting System Components

Section 2.2.1 Mounting the Operator Terminal Enclosure

The OmniLink II LCD Operator Terminal must be mounted in a position that is easily seen and accessed by the operator. The liquid crystal display is designed for optimum viewing from the bottom of the display. If the operator terminal is mounted in a vertical plane, it should be mounted slightly above the operator's eye level for best visibility. If mounted in a sloped position, 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

2.4.

Figure 2.4 LCD Mounting Orientations

The OmniLink II Press Automation Control operator terminal is usually furnished mounted on the front of an enclosure, which also contains the R/D-Brake Monitor Module mounted in the back of the enclosure and pre-wired to the operator terminal. Figure 2.5 gives the dimensions of the operator terminal enclosure, including mounting dimensions.

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11.00 ( 27.74)

0.312 (.792) Diameter

(4 Places)

11.65

(29.59)

10.4

(26.42)

SPM 0

MOTOR SPE E D

TOP

Strok e

Mode

% LO AD 1 61

OmniLink II LCD

OPERATOR TERMINAL

Drive

Spee d

Strok e Spee d

JOB NUMBER DESCRIPTION 100 000 FRONT BRACKE T

COUNTER LIMIT QUANTI TY STATE

ORDER BAT CH

0 0

STATUS: OK

STATUS: ALL C ON DI TI ONS OKAY

STATUS: ALL C ONDI TIONS O KAY

STATUS: ALL CONDITIONS OKAY

2000

500

SP M

77ON

Or der

Counter

SYS TEM STATUS

READ Y TO STROKE

Co un t e r OF F

MAIN SCREEN

BRAKE

PRES S

MONITOR

CONTROL

AUTO SETS

TONNAGE MON ITOR

DIE PROTECTION

LIM IT SWIT CH

JOB SETUPS

COUNTERS

CHG

789

456

123

CLR

ACC

ENT

11.125 (28.26)

OmniLink II Press Automation Control

LINK ELECTRIC & SAFETY CONTROL CO.

444 McN ALLY DR. NASHVILLE, TN 37211 PHONE (615) 833-4168

Enclosure Depth: 6 (15.24)

PROG RUN

13.50 (34.29)

Figure 2.5 Dimensions for Mounting OmniLink II LCD Operator Terminal

Section 2.2.2 Mounting the Resolver

Mounting the resolver to be driven in a one to one ratio by the crank or eccentric shaft. The resolver may be direct driven by a coupling off the center of the shaft or driven by a chain and sprockets as shown in Figure 2.6.

NOTE! A CHAIN GUARD IS NECESSARY TO MEET OSHA 1910.219 STANDARDS

CHAIN

CRANK OR ECCENTRIC

CROWN

SHAF T

Figure 2.6 Mounting the 2500 or 5000 Resolver

RESOLVER

PRESS

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The standard resolver used with the OmniLink II press Automation Control is the 2500 Resolver. A 5000 Resolver can optionally be used with the system. In either case, a spring loaded mounting base, as shown in Figure 2.7, will be supplied with the resolver to maintain chain tension if the resolver is chain and sprocket driven. Mount the resolver on the spring base. Mount the spring base to accommodate alignment of chain and sprockets so that they may be driven by crank or eccentric shaft.

CHAIN

CRANK OR ECCENTRIC SHAFT

Figure 2.7 Resolver Mounted on Spring Base to Maintain Chain Tension for Chain Drive

Chain and sprockets may have been purchased from Link Systems. If so, the sprockets will be 35B28 (28 teeth) and chains will be size 35 roller chain. Link suggests that, if the customer provides chain and sprocket, the same type be used. This resolver electronic offset during calibration can only correct +/10o of mechanical misalignment, and 28 teeth make it easier to be within the offset that can be corrected.. If you have a press that only provides access to an intermediate shaft or back shaft for connection of the resolver, you will have to determine how many turns this shaft makes for each turn of the crank or eccentric shaft. You must then use sprockets of different size, chosen to provide one turn of the resolver for one turn of the crank or eccentric shaft.

Section 2.2.3 Mounting Optional Control and Monitoring Modules

If you have purchased Die Protection & Process Monitoring, PLS/Logic, Auto Sets, Tonnage & Signature Monitoring, or other optional modules, these may be packaged in separate or combined enclosures, depending on how they were ordered. Figure 2.8 shows the mounting dimensions for the 8 or 16 channel Die Protection and Process Monitor Module enclosure and the enclosure for a single PLS/Logic Module. Mount the enclosures for these modules in locations where the enclosure doors can be easily opened for module access and wiring. Multiple module enclosures will be shipped with mounting dimensions inside the enclosure.

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.312 (.7925) 4 Places

8 OR 16 CHANNEL

DIE PROTECTION AND

PROCESS MONITOR

MODULE ENCLOSURE

ENCLOSURE FOR SINGLE

PLS/LOGIC MODULE

11.125

(28.258)

10.5

(26.67)

13.75

(34.925)

13.3

(33.782)

6.6

(16.76)

4” DEEP

4.25

(10.795)

(17.78)

4.75” DEEP

4.75

(12.065)

Figure 2.8 Mounting Dimensions for 8 or 16 Channel Die Protection or Single PLS/Logic Units

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Section 2.3 Wiring System Modules and Components

Section 2.3.1 Conduit Runs

Wiring between the enclosures for OmniLink II Press Automation Control components should be run in conduit. The use of flexible liquid tight conduit with ground is suggested, but hard conduit can also be used. Figure 2.9 shows some of the typical conduit runs that may be required.

CHAIN

CRANK OR E CCENT RIC

RESOLVER

PRESS

1/2’ Flexible liquid tight conduit with ground for 2500 Resolver cable. (3/4” for 5000 Resolver.)

1/2” Fle x ible liqu id tig ht conduit with ground for high speed serial bus cable and power to OmniLink II Press Automation Control option al modu les

OmniLink II LCD

OPERATOR TERMINAL

Drive

Order

SPM

Counter OFF

Speed

Counter

Stroke

SYSTEM STATUS

Stroke

TOP

SPM

Mode

READY TO STROKE

Speed

MAIN SCREEN

BRAKE

PRESS

STATUS:

ACC

CHG

MONITOR

CONTROL

STATUS:

AUTO

ALL CONDITIONS OKAY

SETS

STATUS:

TONNAGE

789

ALL CONDITIONS OKAY

MONITOR

% LOAD

STATUS:

SPM

456

DIE

161

ALL CONDITIONS OKAY

PROTECTION

LIMIT

JOB NUMBER DESCRIPTION

123

SWITCH

100000 FRONT BRACKET

COUNTER LIMIT QUANTITY STATE

JOB

CLRENT

2000

ORDER

SETUPS

50077ONON

BATCH

COUNTERS MOTOR SPEED

LINK ELECTRIC & SAFETY CONTROL CO.

PROG RUN

444 McNALLY DR. NASHVILLE, TN 37211 PHONE (615) 833-4168

OmniLink II Press Automation Control

Omni Link I I LCD

OPE RAT OR T E RMI N AL

Drive

Or de r

Stroke

TOP

Mode

% LO AD

SPM

161

MOTO R SPEED

LIN K E LEC TRI C & S AFE T Y CO N TROL CO.

444 McNALLY DR. NASHVILLE, TN 37 2 11 PH O NE (615) 833-4168

JOB NUMBER DES CRIPTION 100000 FRON T BRA CKE T

COU NTER LIMIT QUANTITY STATE

ORDER BATCH

Speed

Stroke Speed

STATUS: OK

STATUS: ALL CONDIT ION S OKAY

STATUS: ALL CONDITIONS OKAY

2000

50077ONON

SPM

0 0

SPM

Co unter

SYSTEM STATUS

READY TO STROKE

Cou nt er OF F

MAIN SCREEN

BRA KE

PRESS

MONITOR

CONTROL

AUTO SETS

TONNAGE MON ITOR

DIE PROT ECTION

LIMIT SWITCH

JOB SETUPS

COUN TERS

CH G

789

456

123

CLR

PROG RUN

OmniLink II Press Au tomation Control

AC C

ENT

PR ESS CONT ROL

1/2” Flexible conduit with ground for 115VAC from press control transformer, connections to control dual va lve out pu t, stop o utputs from Om niLink t o press control

1/2” Fle x ib le liqu id ti g ht condu it (s ) w ith grou nd fo r other OmniLink system options

1/2” Fl e x ib le liqu id ti g ht condu it with groun d if any op ti o nal

low voltage connections: setup mode input, analog speed or motor current signals are used.

Figure 2.9. General View of Components and Wiring Runs for Installation.

August 30, 2002 Manual Version 1.0

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The conduit runs that you will or may need, depending on the options you purchase and features that you wish to use on your OmniLink II, are:

• Conduit from resolver to R/D-Brake Monitor Module in OmniLink Operator Terminal enclosure.

• Conduit for 115VAC connections between OmniLink Operator Terminal and Press Control.

• Conduit for low voltage connections between OmniLink Operator Terminal and Press Control (only

if options or press control circuits require low voltage as set forth in following sections).

• Conduit for 115VAC power and high speed serial bus cable from Operator Terminal to any remote enclosure containing optional module(s) ,such as Die Protection, PLS, etc., selected to be connected as the first module on the serial bus.

• Conduit runs from the enclosure containing the first optional module on the serial bus to successive enclosures containing optional module(s) to be connected on the serial bus.

• If optional Serial Feed Interface is purchased, conduit from the OmniLink II Operator Terminal enclosure to the feed control enclosure.

• If optional PLC Interface is purchased, conduit from the OmniLink II Operator Terminal enclosure to the enclosure housing the PLC.

NOTE! Do not run both 115VAC and lower voltage circuits in the same conduit from the OmniLink II Operator Terminal to the press control. If you have both 115VAC circuits and low voltage circuits, run them in separate conduits as shown in Figure 2.9. It is permissible to run 115VAC power wires and the high speed serial bus cable from the Operator Terminal to the first optional module and any successive modules used in the same conduit(s).

Section 2.3.2 Wiring the Resolver to the R/D-Brake Monitor Module

The standard resolver used with the OmniLink II Press Automation Control is Link’s 2500 Resolver. Link’s 5000 Resolver may be optionally provided. The resolver provides crankshaft angle to the OmniLink II and its cable must be wired to the 802-5 R/D-Brake Monitor Module, located on the inside back of the Operator Terminal enclosure (the module may be located elsewhere if the Operator Terminal is furnished without enclosure).

The 2500 Resolver comes with a cable with 3 pairs with a drain for each pair and a 6-pin MS connector to plug into the resolver. Run a ½” conduit from the 2500 Resolver to the knockout on the bottom left of the Operator Terminal enclosure. Pull the cable through the conduit and wire to the 802-5 R/D-Brake Monitor Module as shown in Figure 2.10.

The 5000 Resolver comes with a cable with 6 pairs with a drain for each pair and a 14-pin MS connector to plug into the resolver. Run a 3/4” conduit from the 5000 Resolver to the knockout on the bottom left of the Operator Terminal enclosure. Pull the cable through the conduit and wire as shown in Figure

2.11.

August 30, 2002 Manual Version 1.0

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Analog Input/Output

Boa rd O ption

CON8

1 2 3 4 5

R1 2 3 4 5 6 7 8 9 10 1 1 12 1 3

802-5 R/D-Brake Monitor Module

Microprocessor 2

Micropr oces sor 1

Mi cr opr oc. 1 Prog. Memory

R/ D

CON7

CON1

SHLD

GND

CANH

Can Termination Switc h

1 2 3 4 5 6 7 8

CANL

CON2

L1 L 2 GN D

CON5

Transfo rme r

Output Relays

Fu s e

CON4

1 2 3 4

INSIDE OF OPERATOR TERMINAL EN CLOS URE

SYSTEM 2500 RESOLVER CABLE CONNECTION TO CON7 OF 802-5 R/D-BRAKE MONITOR MODULE. RUN IN 1/2” FLEXIBLE CONDUIT.

CONNECTION FOR CLOCKWISE

ROTATION OF CRANK OR ECCENTRIC

CON 7 CON 7

CONNECTION FOR COUNTER-CLOCKWISE

ROTATION OF CRANK OR ECCENTRIC

6 P IN AM PHENOL RES OLVER CAB LE CONNECTOR

DRAIN

WHIT E/BLACK PAIR W/DRAIN

BLA CK

WHITE

GREE N/BLACK PAIR W/DRAIN

BLA CK

SINE

GREEN

RED/B LACK PAIR W/DRAIN

RED

COS

BLA CK

DRAINS

DRAIN

R10

R11

R12

R13

6 P IN AM PHENOL RES OLVER CAB LE CONNECTOR

WHITE/BLACK

DRAIN

PAIR W/DRAIN

GREEN/BLACK PAIR W/DRAIN

SINE

RED/BLACK PAIR W/DRAIN

COS

BLACK

WHITE

GREEN

BLACK

RED

BLACK

DRAINS

R10

R11

R12

R13

Figure 2.10. Wiring Connections from 2500 Resolver to 802-5 R/D-Brake Monitor Module

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Page 20

Ana lo g Inp u t/Ou tpu t

Boa rd Optio n

1 2 3 4 5

R 1 2 3 4 5 6 7 8 9 10 11 12 1 3

802-5 R/D-Brake Monitor Module

M i cr opr oce ss or 2

M i cr opr oce ss or 1

Mi cr o pr o c. 1 Prog. Memory

R/ D

CON8

CON7

CON1

SHLD

GND

CANH

1 2 3 4 5 6 7 8

CANL

CON 7

Can Termination Swit c h

CON2

CON5

L1 L2 G ND

Transfo rme r

Outpu t Relay s

Fu s e

CON4

1 2 3 4

INSIDE OF OPERATOR TERMINAL EN CLOS URE

SYSTEM 5000 RESOLVER CABLE CONNECTION TO CON7 OF 802-5 R/D-BRAKE MONITOR MODULE. RUN IN 3/4” FLEXIBLE CONDUIT.

14 PIN AMPHENOL RESOLVE R CABLE CONNECTOR

CONNECTION FOR CLOCKWISE

ROTATION OF CRANK OR ECCENTRIC

BROWN/BLACK

DRAIN

PAIR W/DRAIN

BR OWN

BLACK

YELLOW/BLACK PAIR W/DRAIN

YELLOW

BLA CK

RED/B LACK PAIR W/DRAIN

BLA CK

RED

WHIT E/BLACK PAIR W/DRAIN

BLACK

WHITE

BL UE/BLA CK PAIR W/DRAIN

BLACK

SINE

BLUE

GREEN/BLACK PAIR W/DRAIN

GREEN

COS

BLACK

DRAINS

CON 7

R10

R11

R12

R13

CONNECTION FOR COUNTER-CLOCKWISE

ROTATION OF CRANK OR ECCENTRIC

14 PIN AMPHENOL RESOLVE R CAB LE CONNEC TOR

DRAIN

YELLOW/BLACK PAIR W/DRAIN

YELLOW

BLA CK

BROWN/BLACK PAIR W/DRAIN

BR OWN

BLA CK

RED/B LACK PAIR W/DRAIN

BLACK

RED

WHIT E/BLACK PAIR W/DRAIN

BLACK

WHITE

BL UE/BLA CK PAIR W/DRAIN

BLUE

SINE

BLACK

GREEN/BLACK PAIR W/DRAIN

GREEN

COS

BLACK

DRAINS

CON 7

R10

R11

R12

R13

Figure 2.11. Wiring Connections from 5000 Resolver to 802-5 R/D-Brake Monitor Module

August 30, 2002 Manual Version 1.0

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Page 21

Section 2.3.3 Wiring 115VAC Power From Press Control to Operator Terminal

Pull red, white and green 16 gauge wires in the 115VAC conduit between the OmniLink II Operator Terminal enclosure and the press control (along with other wiring to be run in this conduit) and connect as shown in Figure 2.13. The control transformer in the press control will preferably be used to supply the 115VAC power for all the components of the OmniLink II Press Automation Control. As shown previously in Figure 2.3, all the modules for the system have a dual power connector plug so that, normally, power can be wired from module to module without having to put two (2) wires under a single terminal. The exception to this is the dual connector on the R/D-Brake Monitor Module when optional modules are used with the system. Three sets of wires must be wired to the dual terminal for Connector 5 of the R/D-Brake Monitor Module when optional modules are used: the incoming power from the press control, the outgoing power to the OmniLink II LCD Operator Terminal, and the outgoing power to the first optional module. This is shown in Figure 2.12 with two wires under each top terminal.

Figure 2.12 Wiring to the R/D-Brake Monitor Module 115VAC Power Plug

The power consumption of the OmniLink II Press Automation Control base system (Operator Terminal and Resolver) is 24VA (0.2Amp at 115VAC). The maximum power required for each 16 input Die Protection and Process Monitor is 56VA (.48Amp at 115VAC), although this power is dependent on the number and power requirements of sensors used and will rarely be required in most applications. The maximum power required for each PLS/Logic Unit Module is 30VA (.26A at 115VAC). The typical OmniLink II Press Automation Control will usually require less than 1Amp at 115VAC, but as options expand the system, 2 to 3 Amps may be required for very large systems. The control transformer in the existing press control should be adequate to supply the OmniLink II system power for most applications, but for larger systems, an additional control transformer or another source of 115VAC power may be required.

16 GA BLACK, WHITE, GREEN WIRES FROM PRESS CONTROL (115VAC SUPPLY FOR OMNILINK II PRES S AUT OMATIO N CO NT RO L)

16 GA BLACK, WHITE, GREEN WIRES FOR OMNIL IN K II OPERATOR TERMINAL POWER (115VAC)

115VAC TO FIRST OPTI ONAL MODULE (NOT NECESSARY IF N O O PTIO NALMODULES ARE USED)

115 V A C CO NN ECTOR PL UG FO R TH IS MO DU LE

16 GA BLACK, WHITE, GREEN WIRES

PLU GS INTO CO NN E C TOR HE AD ER FO R R/ D- B RAKE MONITOR MODULE

August 30, 2002 Manual Version 1.0

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Page 22

INSIDE OF OPERATOR TERMINAL ENCLOSURE

802-5 R/D-Brake Monitor Module

Analog Input/Output

Board Option

CON8

1 2 3 4 5

R 1 2 3 4 5 6 7 8 9 1 0 11 12 1 3

CON7

Mi cr opro cess or 2

Mi cr opro cess or 1

Micr opr oc. 1 Prog. Me mory

R/D

CON1

SHLD

GND

CA NH

Ca n Term inatio n Swit ch

1 2 3 4 5 6 7 8

CANL

CON2

CON5

L1 L2 GND

Transformer

Output Relays

Fu s e

CON4

1 2 3 4

Contacts on R/D- Brake Monitor Module used to provide both immediate stop and top stop signals from OmniLink to press control. These contacts open immediately when an immediate stop is required and are delayed in opening as appropriate to stop the press on top when top stop is required.

PRESS CO NTROL

CON5

L1 L2 G ND

1 2 3 4

CR1 CR2

CON4

115VAC

115VAC CO NTROL TRANSFORM ER SECONDARY WINDING

FUSE

MOTOR

CONTROLS

CLUTCH/BRAKE

CONTROL

IMME DIATE

CLUTCH STOP

CIRCUIT

CLUTCH/BRAKE DUAL AIR VALVE

BLACK WH ITE GREEN RED RED RED RED

1/2” CONDUIT CONTAINING ONLY

115VAC CONNECTION

CIRCUITS

CONNECTOR 5 TERMINALS L1,L2,GND - 115VAC Power for OmniLink

Press Automation Control from press control transformer.

CONNECTOR 4 TERMINALS 1,2 --- Wire to Press Control Dual Valve

solenoid. Tells OmniLink when press strokes or stops for Brake Monitor & Motion D etector.

3,4--- Wire into immediate clutch

(stroking) stop circuit. Provides both immediate and top stop.

Figure 2.13 115VAC Wiring Between Press Control and Operator Terminal

Note! If press control clutch stop circuit is low voltage instead of 115V, run these wires in conduit for low voltage connecti ons.

August 30, 2002 Manual Version 1.0

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Page 23

Section 2.3.4 Wiring the Valve Voltage Circuit

The OmniLink II Press Automation Control brake monitor and motion detector functions require a signal from the press clutch/brake control that indicates when the press strokes and stops stroking. This signal is derived from the voltage across the dual air valve solenoid (in some cases a hydraulic valve may be used) that controls stroking. Two red wires must be pulled through the 115VAC conduit between press control and the OmniLink II Operator Terminal enclosure. On the press control end the wires must be connected to opposite sides of one solenoid of the dual air valve. On the Operator Terminal end, the wires must be connected to terminals 1 and 2 of the plug for Connector 4. This is shown in Figure 2.13. Some presses have a single dual air valve that operates both clutch and brake. Others have two dual air valves, one for the clutch and one for the brake. When two dual air valves are used, always wire to a solenoid for the valve that controls the clutch.

Section 2.3.5 Wiring the OmniLink Stop Circuit Output

Two cross checked, force guided contacts operated by two separate microprocessors on the 802-5 R/DBrake Monitor Module are used to provide both immediate stop and top stop signals to the press clutch/brake control to stop press stroking when faults are detected by the OmniLink II Press and Automation Control. These contacts, located between terminals 3 and 4 of Connector 4 are normally open, energized closed. They open to give a stop command to the press control. They should be wired into an immediate stop circuit of the press control as indicated in Figure 2.13. An immediate stop circuit is one that can immediately stop stroking of the press and will require use of the operator controls to resume stroking after the stop is removed. On many press controls, placing the contacts in series with the red color stop buttons (often referred to as “Emergency Stop Buttons”) is the desirable wiring method. This circuit used must not drop out motor controls on the press. Link engineers will assist you

in determining where to wire the contacts into the press control if you need help.

If the immediate stop circuit in the press clutch/brake control is a 115VAC circuit (such as in most relay controls), pull two red wires in the 115VAC conduit between the OmniLink II Operator Terminal

enclosure and the press control. Wire to terminals 3 and 4 of Connector 4 on the 802-5 R/D-Brake Monitor Module located in the back of the operator terminal enclosure and into the 115VAC stop circuit in the press control.

If the immediate stop circuit in the press clutch/brake control is a low dc voltage circuit (such as in most solid state controls), pull two blue wires in the low voltage conduit between the OmniLink II

Operator Terminal enclosure and the press control. Wire to terminals 3 and 4 of Connector 4 on the 802-5 R/D-Brake Monitor Module located in the back of the operator terminal enclosure and into the low voltage stop circuit in the press control.

Figure 2.14 illustrates the appropriate stop circuit connections for Link’s SS501 press controls. Since these are solid state controls with low voltage dc circuits, 2 blue wires should be pulled through the low voltage conduit between the OmniLink II Operator Terminal enclosure and the press control for this connection.

August 30, 2002 Manual Version 1.0

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Page 24

R/D-Brake Monitor Module

CONN4

1 2 3 4

Jumpers inside this box if no light curtain is present

15 36

REMOVE JUMPER

Slot 26 501-8A or 501-20 Card

1RCSA

Light Curtain

2RCSA

E.S. Buttons

LINK SS501 CONTROL- STANDARD CARDS

R/D- Brake Monitor Mo du le

CONN4

1 2 3 4

Jump ers inside this bo x if no light curtain is present

Slo t 20 501-16 Timer Card

REMOVE JUMPER

Slo t 26

501-8A or 501-20 Card

1RCSA

Light Curtain

2RCSA

E.S. Buttons

LINK SS 501 CONTROL WITH 501-16 CARD OPTION

Figure 2.14 Stop Circuit Connections from OmniLink II Automation Control to Link Press Controls

August 30, 2002 Manual Version 1.0

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Page 25

Section 2.3.6 Wiring the Optional Setup Mode Input

The OmniLink II Press Automation Control provides an optional setup mode input that is used to bypass certain die protection and process monitoring functions, counters, and tonnage monitor low limits during setup activities that require stroking the press. This avoids nuisance faults that have to be reset on the die protection and tonnage monitor and false part counts based on stroking during setup activities. Most presses will use the INCH mode as the setup mode. It also allows a fixed setup mode speed to be set for variable speed presses with the Analog Input/Output option. An isolated contact that closes in the INCH mode must be used as an input. If you don’t have a spare INCH mode contact on the mode selector switch, one solution is to remove an existing switch contact closed only in INCH from the circuit and add a relay with 2 normally open contacts to the control circuit. Use the contact closed in INCH mode to energize the relay coil, use one normally open contact of the relay to insert in the control circuit where the INCH contact was previously located, and use the second normally open contact as the Setup Mode input to the OmniLink. Figure 2.15 shows the wiring of this setup mode input. Run wiring in a conduit reserved for low voltage circuits between press control and OmniLink operator terminal.

Analog Input/ Output

Board Option

1 2 3 4 5

R1 2 3 4 5 6 7 8 9 10 11 12 13

PRESS CO NTROL

OPTIO NAL CUSTOMER SUPPLIED ISOLATED RELAY CONTACT CLOSED IN SETUP MODE (SUCH AS INCH) ONLY.

SELECTOR SWITCH OR

Figure 2.15. Optional Setup Mode Input Wiring.

802-5 R/D-Brake Monitor Module

Microprocessor 2

Micr oprocessor 1

Microproc. 1 Prog. Memory

R/D

CON8

CON7

CON1

1 2 3 4 5 6 7 8 L1 L2 GND

GND

SHLD

CANH

CANL

BLUE

Transformer

Output Relays

Can Termina tion Sw itch

CON2

LOW VOLTAGE CONDUIT

Fuse

CON5

CON4

1 2 3 4

1 2 3 4 5 6 7 8

12VDC SUPPLIED BY TERMINAL 1

INSIDE O F OPERATOR TERMINAL EN CLOS UR E

CON2

SETUP MODE INPUT

August 30, 2002 Manual Version 1.0

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Page 26

Section 2.3.7 Wiring Optional Analog Input/Output Board Circuits

Section 2.3.7.1 Wiring to Display Motor Load Current

If the optional Analog Input/Output board is specified with the OmniLink II Press Automation Control, and you wish to graphically and numerically display motor load current on the OmniLink II Operator Terminal, refer to Figure 2.16. For fixed speed presses and presses with eddy current variable speed drives, use a current transformer and an instrument transformer and wire as shown in the upper press control illustration in Figure 2.16. These transformers will normally be supplied by Link if your order indicated that motor load current display is desired.

DC Motor Drives and Adjustable Frequency AC Motor Drives will usually provide an analog motor load current output of 0-10V or 4-20ma. Wire as shown in the lower press control illustration in Figure

2.16. If a 4-20ma output is used, throw position 3 of the 4-Pole switch on the Analog Input/Output board to the closed position. If a 0-10V analog output is used, leave position 3 of the switch open.

In addition to the wiring described in this installation section, it will also be necessary to calibrate the % Motor Load current displayed on the OmniLink Operator Terminal. This calibration is described in

Section 4.2.2.5 of this manual.

Section 2.3.7.2 Wiring the Analog Speed Input and Output

The optional Analog Input/Output board also allows you to display the drive SPM for electronic variable speed drives on the OmniLink Operator Terminal, and to set the desired SPM with an analog voltage output from the Operator Terminal rather than with a potentiometer or keypad on the drive itself. Displaying drive SPM allows you to know how fast the press will stroke even when the clutch is not engaged. Without this feature, you can only display the stroking speed while the press is actually stroking.

To wire the isolated analog speed input and output, refer to figure 2.17. If you have an eddy current variable speed drive, refer to the upper box labeled press control. If one side of the tach generator is referenced to ground in the eddy current drive circuit, make sure position 1 on the switch located on the right side of the Analog Input/Output board is closed. If the tach generator drives a bridge rectifier on the eddy current drive, switch position 1 on the switch to open. The SPM OUT terminal on the Analog Input/output board should be wired to the eddy current drive SPM input (the input that sets desired speed). If desired, you may wire analog speed input only, leaving the speed setting to an existing potentiometer or keypad, but it is generally better to integrate press speed setting into the OmniLink II Operator Terminal.

To wire a DC Drive or an Adjustable Frequency AC variable speed drive, refer to the lower box labeled press control in Figure 2.17. Position 1 of the switch on the right side of the Analog Input/Output board should always be closed for DC or AC variable speed drives.

In addition to the wiring described in this installation section, it will also be necessary to calibrate the drive SPM displayed on the OmniLink Operator Terminal and the output signal that sets the speed of the variable speed drive. These calibrations are described in Sections 4.2.2.2, 4.2.2.3, and 4.2.2.4 of this manual.

August 30, 2002 Manual Version 1.0

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Page 27

Current Transformer Motor HP Motor HP Rat io and Turns____

50:5 (2 Primary Turns) 2 to 3 5 to 7.5 50:5 (1 Primary Turn) 5 to 7.5 10 to 15 100:5 (1 Primary Turn) 10 to 15 20 to 30 200:5 (1 Primary Turn) 20 to 30 40 to 75 400:5 (1Primary Turn) 40 to 75 100 to 150

OPEN

1234

CON8

1 2 3 4 5

R1 2 3 4 5 6 7 8 9 10 11 12 13

SP M IN

CON8

1 2 3 4 5

Throw switch 3 to closed position for DC or AC Motor Control with 4-20ma Input. Otherwise leave open.

Current Transformer Ratios & Turns

for Various Size Motors

@220VAC @ 440VAC

802-5 R/D-Brake Monitor Module

Analog Input/Output

Board Option

SWITCH

Micr oprocessor 1

Microproc. 1

1234

Prog. Memory

R/D

CON7

ISO GND

SPM OUT

%L OAD

CON1

SHLD

ISO GND

Can Termina tion Sw itch

1 2 3 4 5 6 7 8 L1 L2 GND

GND

CANH

CANL

CON2

INSIDE OF OPERATOR TERMINAL

Transform er

Output Relays

Fuse

CON5

CON4

1 2 3 4

SIMPSON INSTUMENT

TRANSFORMER BUL 270-5014

FOR FIXED SPEED OR EDDY CURRENT

DRIVE VARIABLE SPEED PRESSE S

EN CLOS URE

PRE SS CONTROL

3 4

1 2

1OL

PRE SS CONT ROL

CURRENT TRANSFORMER X:5 RAT IO 1 PRIMARY TURN OR 2 PRIMARY TURNS

MAI N MOTOR

DC MOT OR DRIVE OR

AC ADJUST ABLE

F REQ UENC Y D RI VE

ANALOG 0-1 0V OR 4-20MA MOTO R LO AD OUTPU T

C OMMON (REF)

FO R DC MO TOR DR IV E O R AC AD JUST ABL E

FR EQ UENC Y D RIVE V ARI ABL E S PEED P RES SES

Figure 2.16 Wiring the Analog Motor Load Current Input

August 30, 2002 Manual Version 1.0

2.18

Page 28

OPEN

Throw switch 1 to closed position if eddy current tach generator is referenced to ground on eddy current drive & for DC or AC motor drives with analog voltage speed outputs. Switch to open posit ion for eddy current tach generator that is input to a bridge rectifier (rarely the case) on the eddy current drive.

Figure 2.17 Wiring to Display and Set SPM Through OmniLink II Operator Terminal

1234

802-5 R/D-Brake Monitor Module

Analog Input/Output

1234

R/D

CON8

1 2 3 4 5

CON7

R1 2 3 4 5 6 7 8 9 10 11 12 13

SPM IN

ISO GND

SPM OUT

ISO GND

%LOAD

CON8

1 2 3 4 5

No Co nnection

SHIELDED CABLE IN LOW VOLTAGE CONDUIT

No Co nnection

SHIELDED CABLE IN LOW VOLTAGE CONDUIT

Board Option

SWITCH

Microproc essor 1

Microproc . 1 Prog. Memor y

CON1

GND

SHLD

CANH

ISOLATED INPUTS & OUTPUT

SHIELD

Can Termination Sw itch

CON2

1 2 3 4 5 6 7 8 L1 L 2 GN D

CANL

INSIDE O F OPERATOR TERMINAL

Transfor mer

Output Relays

Fuse

CON5

CON4

1 2 3 4

TAC H

GENERATOR

FOR EDDY CURRENT DRIVE PRE SSES

FOR DC MOT O R DR IV E OR AC AD JU ST AB LE

FR EQUEN CY D R IVE V ARI ABLE S PEED P RESSE S

ENCL OSURE

PRE SS CONTROL

1OL

EDDY CURRENT COUPLING COIL

EDDY CURRENT DRIVE

DRIVE SPM FEEDBACK

DRI VE GROU ND

DRIVE SPM INPUT

PRE SS CONTROL

DC MOT OR DRIVE OR

AC ADJUSTABLE

FREQUENCY DRIVE

ANALOG 0-10V SPM OUTPUT

DRI VE GROU ND

DRIVE SPM INPUT

MAI N MOTOR

August 30, 2002 Manual Version 1.0

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Page 29

Section 2.3.8 Optional Solid State Relay Outputs

The OmniLink II Press Automation Control provides an optional solid state relay module. It can be supplied with a combination of AC or DC solid state relays specified by the customer. If the module is provided, the relays provide the following functions:

• R1 and R2 – Module programmable limit switches 1 and 2. Simple on at an angle off at an angle PLS’s for limited applications.

• R3 – Provides an output to drive an external light that indicates die protection is bypassed.

• R4 – Provides an output to drive an external light to indicate that a downtime code has been entered

when the optional LinkNet information system software is used.

Figure 2.18 shows the wiring of the relay drive inputs from R/D-Brake Monitor Module connector 2 to the solid state relay module. Wire PLS relay outputs (relay 1 and 2)as desired to sequence auxiliary equipment associated with the press. Wire relay outputs 3 and 4 to indicator lights placed in a highly visible location if you wish an external indication that die protection is bypassed or the press has a downtime condition or event.

Analog Input/Output

Board Option

CO N8

1 2 3 4 5

R 1 2 3 4 5 6 7 8 9 1 0 1 1 12 1 3

Figure 2.18 Wiring the Optional Solid State Relay Module

INSIDE OF OPERATOR TERMINAL ENCLOSURE

802-5 R/D-Brake Monitor Module

Micro pr ocess or 2

Transfor mer

Micro pr ocess or 1

Mi cr o pr o c . 1 Prog. Memory

Outp u t Relay s

CO N5

1 2 3 4

SOLID S TATE R ELAY DRIVE SIGNALS

CO N7

R/D

CO N1

GND

SHLD

CA NH

CANL

12VDC

Can Termination Switch

CO N2

1 2 3 4 5 6 7 8

L1 L2 GND

Fus e

CO N4

1 2 3 4 5

CON9

OPTIO NAL 802-5

SS RELAY MODULE

R1 R2 R3 R4

CON2

1 2 3 4 5 6 7 8

SO LID S TAT E RELAY OUTP UTS. USE BLUE WIRE FOR DC AND RED WIRE FOR AC RELAY OUTPUTS.

August 30, 2002 Manual Version 1.0

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Page 30

Section 2.4 Additional Mounting and Wiring if the Operator Terminal, R/D-Brake

Monitor Module, and (Optionally) Solid State Relay Module are Provided Without Enclosure for Customer Panel Mounting

The OmniLink II Press Automation Control base system package may be purchased without the operator terminal, R/D-Brake Monitor module, and (optionally) Solid State Relay Module already mounted and pre-wired inside an Operator Terminal enclosure. This allows the customer to install the basic components of the system into his own enclosure(s). When this is the case, the customer will need to perform the additional component mounting and wiring.

Section 2.4.1 Mounting the Base Components in the Customer Enclosure

Mount the OmniLink II LCD Operator Terminal in an enclosure with viewing angle considerations as shown in Figure 2.4 and with clearance to easily operate the membrane keys on the terminal. Figure 2.19 shows the mounting hole dimensions of the operator terminal. The R/D-Brake Monitor module should be mounted on the inside of the enclosure on which the operator terminal is mounted. When furnished for customer panel mount, it will be come mounted on an intermediate fixture that aids customer mounting. See mounting dimensions in Figure 2.20. Similarly, if the optional 4-channel Output Relay Module is provided, this should be mounted on the inside of the enclosure on which the operator terminal is mounted. Mounting Dimensions

Figure 2.19 OmniLink II LCD Operator Terminal Mounting Dimensions

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2.21

Page 31

R12345678910111213

CON7

CON1

CON2

CON5

5678211

CON4

324

Figure 2.20 R/D-Brake-Monitor Module with Mounting Bracket for Mounting in Customer’s Enclosure

Section 2.4.2 Wiring the Base Components in the Customer Enclosure

The only wiring not shown in previous figures where base system components were supplied in an enclosure is the wiring between R/D-Brake Monitor Module and Operator Terminal. You will be supplied a 5’ length of high speed serial bus cable that may be cut to the actual required length. Connect one end of the cable to the bottom row of terminals on the dual plug for Connector 5 on the R/D-Brake Monitor Module and the other end to the lower left connector on the back of the operator terminal. Connect as follows on both connectors.

Cable Wire Color Connector Terminal

White CANL Orange CANH Blue GND Bare Shield

Run individual red, white, and green wires between the power connector (CONN 5) on the R/D-Brake Monitor and the power connector at the upper left of the back of the operator terminal. Connect red to L1 on both connectors, white to L2 on both connectors and green to GND on both connectors. If the 4channel Output Relay Module is supplied, wire from R/D-Brake Monitor Module to Output relay module as shown in Figure 2.18.

Section 2.5 Wiring Serial Ports for Serial Feed Interface, PLC Interface, and

LinkNet Information System Options

Wiring for serial feed interface, PLC Interface, and LinkNet Information System options will be outlined

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in separate documents sent in addition to this manual when these options are purchased with your system.

Section 2.6 Wiring the Parallel Port for Messages from Auxiliary Equipment

(Optional)

The OmniLink II Press Automation Control makes provision to wire inputs to its parallel port on the back of the operator terminal from auxiliary equipment intelligent controllers so that diagnostic messages from auxiliary equipment can be displayed on the brake monitor screen of the operator terminal. Seven isolated signal inputs and an isolated ground constitute the parallel port, which can be wired to provide up to 128 message codes. The OmniLink operator terminal allows entry of an alphanumeric message of up to 40 characters long for each message code input to the parallel port. This is a useful feature when the user wants a simpler solution to diagnostics than having to deal with programming serial port communications between two different intelligent systems. Wire as shown in Figure 2.21.

The seven outputs on the PLC output card can be programmed to output the binary numbers 0000000 – 1111111 (decimal numbers 0-127) as diagnostic message codes. Of course, many times far fewer message codes will be needed, and only the needed number of messages will be programmed.

GN 1 2 3 4 5 6 7 8

GND

PLC OUTPUT

CARD ON

AUXILIARY

EQUIPMENT

CONTROLLER

USE SEVEN SOURCING

OUTPUTS

+(12-24VDC)

Figure 2.21 Seven PLC Outputs Used to Create Message Codes 0000000- 1111111 (0-127)

Once the parallel port inputs are wired to receive message codes as in Figure 2.21, the configuration screens for Names and Messages on the OmniLink II operator terminal allows entry of alpha-numeric auxiliary equipment messages on the operator terminal brake monitor screen. Auxiliary equipment message entry is described in Section 4.3.

PARALLEL PORT TERMINAL

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Section 3 Operator Terminal Basics

Section 3.1 OmniLink II Press Automation Control LCD Operator Terminal

The OmniLink II Operator Terminal features a 9.2” diagonal color TFT liquid crystal display (LCD) with high brightness and large viewing angle, a keypad, and a Program/Run keyswitch. The large display allows far more information to be shown on one screen than smaller ¼ VGA LCD displays, allowing fewer screens to be used to program system settings and view information in a system that has a multiplicity of functions. Unlike monochrome LCD displays, the color display can be used to call operator attention to fault or other messages through color highlighting. This, in conjunction with its softkey driven menu system and help messages provides easy to use operation.

Position Information

TOP

Stroke

Mode

Color LCD

JOB NUM. DESCRIPTION

100000 FRONT BRACKET

COUNTER LIMIT QUANTITY

ORDER BATCH

2000

500

% LOAD

SPM 0

161

MOTOR SPEED

LINK ELECTRIC & SAFETY CONTROL CO.

444 McNALLY DR. NASHVIL LE, TN 37211

PHONE (615) 833-4168

Figure 3.1 OmniLink II Color LCD Operator Terminal

Figure 3.1 shows the operator terminal front panel with the Main Screen selected on the display. The color liquid crystal display (LCD) is divided into fixed areas. Crankshaft position and current stroking mode of the press are displayed in the upper left hand corner of the color LCD screen. This angular position of press crank or eccentric is displayed in both graphical and numeric format. For speeds less than sixty strokes per minute, the pointer, which is enclosed in a circle, will rotate to visually indicate the angular position of the crankshaft. For eccentric and crankshaft driven presses, the top dead center of the stroke is equal 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 in the circle. When the slide is stopped within +/- 5 degrees of top, this box will be green with the letters “TOP”. When the slide is

OmniLink II LCD

OPERATOR TERMINAL

Drive

Speed Stroke

Speed

7 7

SPM

0 0

SPM

STATUS: OK

STATUS: ALL CONDITIONS OKAY

Counter

READY TO STROKE

JOB SETUPS

Softkeys

Order

SYSTEM STATUS

Counter:

MAIN SCREEN

BRAKE

PRESS

MONITOR

CONTROL

AUTO SETS

TONNAGE MONITOR

DIE PROTECTION

LIMIT SWITCH

NALOG

MONITOR

COUNTERS

Screen Legend

Areas for Softkeys

CHG

8 9

5 6

1 2 3

CLR

PROG RUN

Program//Run Key

Four user selected items

Reference

Softkeys

Keypad

ENT

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stopped within +/- 5 degrees of bottom dead center, the box will be yellow with the letters “BOT”. For speeds greater than sixty strokes per minute, two rotating arrows will appear in the circle. These rotating arrows indicate crankshaft motion.

The remainder of the top portion of the screen displays four user selectable items. These four user selectable items can be chosen by the user from a list in the User Configuration menus . The currently available items are:

1. Drive Speed (speed at which a variable speed drive will cause the press to stroke when the clutch is engaged -- requires optional Analog Input/Output Card for the R/D-Brake Monitor Module)

2. Stroking Speed (actual crankshaft SPM -- available only when the press is actually stroking)

3. Auto Press Speed (drive speed when press is not stroking and crankshaft speed when the press is stroking -- requires optional Analog Input/Output Card for the R/D-Brake Monitor Module)

4. System Status (diagnostic messages that indicate anything that prevents the start of stroking)

5. Reason for the Last Stop (diagnostic message that gives the reason for the last stop)

6. Total Tonnage (If the system is equipped with optional Tonnage & Signature monitor)

7. Counterbalance Pressure (If the control is equipped with optional automatic counterbalance adjust)

8. Shut Height (If the system is equipped with optional automatic shut height adjust)

9. Current Order Count

10. Current Down Time Code (If the optional LinkNet shop floor information system is used)

11. Distance to Bottom

The four user items selected can be mode dependent if the user can provide an isolated input to the

operator terminal derived from the press clutch/brake control to indicate when the setup mode (usually Inch) is selected. The user has the option to choose four items for setup mode and four

different items for production modes.

The menu reference area of the display immediately above the right side softkey legends indicates which menu the screen is showing. The largest area of the display is used for displaying control, monitoring, and process information, and settings. It is dependent on the present task being performed and the display screen selected.

Section 3.2 Operator Terminal Modes

There are three modes of operator terminal use: User Configuration Mode, initially used to configure the system for a specific machine and user choices of operation; Program Mode, used to program settings and do certain actions; and Run Mode, where the system provides its programmed functions for a job and may allow certain limited actions and settings without entering Program Mode. The Operator Terminal Configuration Mode screens can only be accessed by the use of the Run/Program key switch and the configuration code for the system, the highest order user password. Use of the Configuration Screens is necessary at the initial installation of the system to configure the system to the particular press and to allow the user to make choices about how the system is used. After the initial configuration, this mode will only be used if it is decided to change configuration settings. See Section 4 of this manual for specific information on the User Configuration Mode.

Run Mode screens and Program Mode screens are very similar for the OmniLink II Press Automation Control. Basically the same information is presented on screens in both modes. However in Run Mode, you can primarily only view the information and settings on the display screens, although the user can

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choose to configure the system to allow certain commonly used settings and actions to be done in Run Mode. Fine adjustment of some angle settings can also be done in Run Mode.

The current commonly used settings and actions that can be user configured to be done either in Run Mode or restricted to Program Mode only are Tonnage Monitor Reset, Die Protection Limited Bypass, Die Protection Reset, Auto Setup Reset, Counter Reset, Counter Settings, Counter Change, and Motor Speed Adjust (when the optional analog input/output card is used to

adjust Motor Speed). Of course, if optional hardware that performs any function described in the foregoing list is not used with the system, configuration of the settings or actions will not be necessary. Also, hardware options to allow the system to perform additional control and monitoring functions may be added to the system at a later time. If so, actions associated with these functions may add to the list of actions that can be done in Run Mode or restricted to Program Mode.

The vast majority of settings and actions for the system must be performed in Program Mode. Once key/code access to Program Mode is achieved, as described in Section 3.9, certain softkeys that can be used to change numbers or other settings for a job will appear. Also, in Program Mode, a cursor in the form of a highlight will appear that allows you to use the arrow keys to select particular settings to change. This cursor will also appear on Run Mode screens if a setting is allowed on a Run Mode Screen. Many of the screens also have on screen help messages that change with the setting to explain the choices available for the setting.

Section 3.3 Softkeys

Areas along the right side of the display and the bottom of the display provide legends for the softkeys located to the right of the LCD and bottom of the LCD. Softkeys are generally used to perform an action in the selected menu (such as reset a fault or change a setting), or select another menu or submenu screen. The softkeys are so named because they perform different functions in different screens, or even in the same screen depending on whether the Operator Terminal is in Run or Program Mode and on previous softkey use. The legend on the display next to the softkey may change within the same screen or from screen to screen to indicate the function the softkey will perform next in that particular screen. When the word “key” is used in this manual it refers to the keys on the keypad that always provide the same function, such as Enter, or provide the same numeric entry (1,2, etc.).

When a screen has been reached through a succession of one or more screens, an EXIT legend will appear next to the bottom right softkey. Each time this key is pressed it will select the previous screen until the Main Screen (Menu) is reached.

Section 3.4 ACC Key

The ACC key is a quick access key. This key will supply direct access from any menu to the Quick Access menu, so that items frequently used by the operator (depending on options) can be accessed by a single keystroke. The quick access menu contains machine notes, die notes, access to Down Time codes, name of current logged in user, log out softkey, and access to auxiliary communications. See Section 5.5 for a detailed description of these functions.

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Section 3.5 CHG Key

This changes the display language from English to Spanish. Depressing the CHG key again will return the display language to English.

Section 3.6 Arrow keys

The Up, Down, Left, and Right arrow keys are used to select settings that may be entered or changed on any display menu where settings are provided. They are also used to select one item from a list of items to enter as a setting. Generally, settings can only be made in Program Mode screens, which are accessed by use of the Program/Run key or the use of a password, as explained in Section 3.9. In some cases, certain settings may be available in Run Mode. When a screen is first entered that allows settings to be programmed, the LCD will highlight an area (called a cursor) in order to inform you which setting or which item in a list is selected. If the highlighted area is a setting, it may have help text on the screen to explain the purpose of the setting. If the highlighted area selected is in a list of items to choose as a setting, pressing the ENT(ER) key or the Select softkey will enter it as the desired setting.

In this manual, SELECT means using the arrow keys to highlight an item or setting.

Section 3.7 Numeric Data Entry

There are numerous settings (parameters) associated with the OmniLink II system that require numeric entry through use of the operator terminal. Some of the settings are contained in the Configuration Mode menus for the system, where the user enters numbers to configure the system for certain machine characteristics (such as stopping time, stroking speed, etc.). Other numeric settings in the Configuration Mode menus are used to allow the employer to make choices specific to his use of the system. These numeric settings are often done only once when the system is installed and don’t have to be repeated unless the user decides to make changes in the initial choices. They require a person in possession of the User Configuration Code (the highest order system password) to gain access to the configuration mode to make the settings.

Another class of numeric settings must be done on a more frequent basis to program the control and monitoring functions of the system for specific jobs. These settings include those for Counters, Die Protection and Process Monitoring channels, Programmable Limit Switch operation, job numbers (for storage and recall of the settings of the system related to a specific job) and other standard and optional functions of the system. Since these settings are critical to whether the process is controlled or monitored correctly, only persons with key/code access to Program Mode (see Section 3.9 of this manual) can make or change most settings. Of course, once a job has been programmed and stored, its settings can be recalled and only the desired parts count for a job run, new jobs, or refinements of old job settings, will necessitate changing settings.

When a screen that is used to program settings is key/code accessed, the arrow keys on the keypad to the right of the LCD display are used to select (highlight) a particular setting. You can either directly enter a number into a selected setting or a CHANGE NUMBER softkey can be pressed which blanks the current setting and underlines the area where newly entered numbers will appear. The highlighted setting can then have its numeric data changed. If the parameter contains a decimal point, it will be positioned automatically by the operator terminal. The new number is entered by use of the number

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keys on the keypad and pressing the ENT (Enter) key after you have changed the number to the desired value. The CLR key will clear the present number being entered, and the entry process is aborted by pressing the EXIT softkey or one of the arrow keys. The numeric data will not change from the previous value if the entry process is aborted. This process is illustrated in Figure 3.2, which shows a portion of the Counter programming screen.

Selected (Highlighted) Number to Change. When highlighted you may use the number keys on the keypad to directly key in a new number OR you may press the CHANGE NUMBER softkey, which will blank the highlighted area and replace it with an entry box into which you may enter the number.

Screen Legend

for Softkey

CHANGE NUMBER

Softkey

COUNTER NAME COUNT LIMIT STATE PERCENT COMPLETE

Order Count Batch Count Quali ty Count Aux 1 Count Aux 2 Count Aux 3 Count Aux 4 Count Aux 5 Count Aux 6 Count Aux 7 Count

Stroke Count 978776

1000

50 90 50

0 0 0 0 0 0

2000

200

100

ON ON OFF

TRIP 0 0 0 0 0 0

OFF

50% 25% 90%

100%

Use the Arrow Keys to Select the Setting to Change.

Press the ENT (Enter) key after keying in the number.

ENT

Figure 3.2 Illustration of Numeric Entry

Section 3.8 Alphanumeric Data Entry

Some settings for the OmniLink II relate to descriptions, names, type of function or notes that may be used to describe jobs, individual monitoring or control channel use, or notes for a particular machine or job. Once access to the Program Mode is gained by the key/code procedure (see Section 3.9), the text, or combination of text and numbers, for names or descriptions can be entered in two ways, depending on the setting to be programmed.

1. A CHANGE SETTING softkey will appear on the screen when a setting for a description of the type of logic function a channel is to perform (such as a die protection channel) is selected (highlighted) by use of the arrow keys on the keypad. When this key is pressed, a popup list of fixed function descriptions will appear. The user may select an item from the list and press the ENT key to make the setting. Only a description from the list can be entered. This type of setting is illustrated in the Die Protection Channel Settings screen shown in Program Mode in Figure 3.3 for the Channel. Type setting.

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Di e Prot. C hannel Settin gs Mo du le: 1 Chan nel: 5

Stroke

TOP

Mode

Channel Type:

Desc ri pti on:

Input Type:

Sto p Ty pe:

Bypa ssed:

Delay Ti me:

Dela y Strokes :

Wi ndow O n:

Wi nd ow O ff:

C ycl ic

Left Front Stripper Normal ly OFF Top Sto p No 0 mse cs 0 Str okes

154

213

Dr i ve

S pee d

Stroke S pee d

SPM

0 0

H elp Sets the typ e of Logic to ap pl y to the channel

Counter

SPM

Order

SYSTEM STATUS

Coun t er O FF

DP Chan Settings

CHANGE SETTI NG

CHANNEL DIAGS

CHANGE SETTING, CHANGE NAME, or CHANGE NUMBER in Program Mode depending on setting selected.

Cyclic - Norm. OFF Used to monitor events that occur once per m achine cycle. The input must b e O N so mew here in the timi ng windo w AND O FF somewher e in t he timing window.

DECREMENT ON ANGLE

IN CREM ENT ON A N GLE

DE CREM ENT OFF ANGLE

180

IN CR EM ENT OFF ANGLE

90270

PRE V IO US CHANNEL

NEXT CHANNEL

EXIT

Sof tKeys

Figure 3.3 The Die Protection Channel Settings Screen in Program Mode

When the Channel Type setting is selected, the upper right softkey legend is CHANGE SETTING. Pressing the CHANGE SETTING softkey will cause a list box to appear as on the screen as shown in Figure 3.4, and the upper right softkey legend will change to SELECT. The arrow keys are used to highlight the desired item on the list after which the SELECT softkey is pressed to enter the selected item and remove the list box.

Not Used Static Cyclic

Transfer

In Position 1 Part Detector Edge 1 Part Detector Pass 2 Part Detector Edge 2 Part Detector Pass Custom

SELECT

Legend for upper right softkey

Figure 3.4 List Box for Die Protection Type and SELECT Softkey

2. A CHANGE NAME softkey will appear on the screen when a description or name setting is selected. In some cases, a screen showing a list of default names or descriptions commonly used for the setting will appear when this softkey is pressed, allowing selection of a name or description to enter by pressing a SELECT softkey that appears for this type of setting. In addition, you may edit (change) existing or unnamed items on the list by selecting the item and pressing an EDIT NAME softkey on the screen after your selection. In this case, another popup menu, the Text Entry menu, will appear that allows you to enter letters, numbers, and spaces for the name or description selected. This also can be illustrated by use of the Die Protection Channel Settings screen. If the setting for Description is selected, the upper right softkey legend will be CHANGE NAME. Pressing this key causes the Die Protection Names screen to appear as shown in figure 3.5

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456

789

NUM Description

1 2

3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20

Stroke

TOP

Mode

Short Feed Long Feed Stock Buckle End of Stock Material in Position Part Detector Slug Buildup Slug Detector Left F ront Stripp er Right Front S tri pper Left Rear St ripp er Right Rear Stripper Left Stripper Right Stripper Front Stripper Rear Stripper Stripper Feed Loop

Die Protecti on Cha nnel Na mes

Drive

Speed

Stroke Speed

0 0

SPM

Order

Counter

SYSTEM STATUS

Counter OFF

Die Pro. Names

EDIT NAME

SELECT NAME

EXIT

Figure 3.5 The Die Protection Channel Names Screen

The first page of names for the Die Protection Names screen is shown in Figure 3.6. Pressing the NEXT PAGE softkey takes you to additional pages where names can be entered. You can enter an existing name from the list shown as the setting for Description by using the arrow keys to highlight a name and pressing the SELECT NAME softkey or the ENTER key on the keyboard. You can add names on this and other “pages” or change existing names by pressing the EDIT NAME softkey. This will cause the popup Text Entry menu that allows the manual entry of letters or a combination of letters and numbers shown in Figure 3.6.

TOP

NUM Descript ion

1 2

3 4 5 6 7 8

9 10 11 12 13 14 15 16 17 18 19 20

Stroke

Mode

Die Protecti on Channel Na mes

Short Feed Long Feed Stock Buckle End of Stock Material in Position Part Detector Slug Bui ldup Slug Det ector Left F ront St ripper Right Front S tri pper Left R ear St ripp er

Use keys to select letters Pres s ENT to save text

ABCDEFGHIJKLMNOPQRSTUVWXYZ . + - = ( ) %< > /

Drive

Speed

Stroke Speed

SPM

0 0

SPM

Order

Counter

SYSTEM STATUS

Counter OFF

TEXT ENTRY

ABORT EDIT

CURSOR LEFT

CURSOR RIGHT

SPACE

SELECT LETTER

LOWER CASE

EXIT

Letter

Channel 20 Description to be entered.

Figure 3.6 Alphanumeric Data Entry Screen for Die Protection Names

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This illustration is for the Die Protection Channel Names Screen that will be present if one or more optional Die Protection and Process Monitoring Modules is used with the system. But, the same pop up text entry box will appear on any other screen that allows entry of alphanumeric names or text. Letters are entered by using the left and right arrow keys to position the letter pointer under the desired letter and then pressing the SELECT LETTER softkey. If the left or right arrow key is pressed 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 currently being displayed in the text box, pressing the LOWER CASE softkey will change the text box to lower case letters. To change a previously entered character, use the CURSOR LEFT and CURSOR RIGHT softkeys to position the data entry line cursor over the letter to be changed and then select the new character. A space is inserted each time the SPACE softkey is pressed, and the CLR key clears all characters that have been entered. Numbers are entered directly from the numeric keypad. The entry process is aborted if the ABORT EDIT softkey is pressed or if you don’t press the ENT(ER) key when finished, leaving the previous data intact. The new description is accepted when the ENT key is pressed. Do not press the ENT (Enter) key until completely done

selecting letters and numbers.

Once you have changed a name or entered a new name, it becomes part of the list. You must still highlight and press either the SELECT softkey or the ENT(ER) key for this name to be selected as the Description setting.

3. A third way that an alphanumeric setting is entered occurs when there is a choice between only two fixed alphanumeric entries can also be illustrated by the settings for Input Type and Bypassed. Where there are only two fixed choices for a setting, one setting will always initially appear depending on past use. In the case of Input Type, the two choices are “Normally Off” and “Normally On”, meaning that the sensor for a channel is either off when no fault is detected and turns on to indicate a fault or vice versa. The upper right softkey legend is CHANGE SETTING when Input Type is highlighted. Pressing this softkey will toggle the setting between the two choices. The two choices for the Bypassed setting are “Yes” and “No”. Again when this setting is selected, the CHANGE SETTING softkey will toggle the setting between these two choices.

Section 3.9 Access Control Operation for Settings and Actions in Program Mode

Section 3.9.1 Program/Run Key Switch Operation

The Program/Run key switch is located on the lower right side of the operator terminal. This is a two position switch. The key is removable in the RUN position only. If the Program/Run key switch is being used as a means to access the restricted items, the switch must be turned to the PROG position. When the Program/Run key switch is switched to the PROG position, the press will Top Stop and stroking will be prohibited until the switch is returned to the RUN position. If Key Only access mode is selected by the user in the configuration mode, the key switch is the only

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means available to access Program Mode. All settings and actions for the system are accessible to anyone when the Program/Run key switch is switched to the PROG position.

If Code Only access mode is selected by the user in the configuration mode, the Program/Run key will only be used to provide access (in conjunction with the User Configuration Code) to the User Configuration Mode. The Program/Run key will not access Program Mode. Programming Mode is accessed by code (password) only. Up to 16 employees (or employee classifications) may be assigned numeric codes (passwords) and a list of assigned settings and actions that each code assignee may perform in the Program Mode. Each employee assigned a code can use code (password) access without the Program/Run key. Each code will only grant access to perform the settings and actions in Program Mode assigned by the employer for the person with that specific code. Program mode settings and actions not specifically assigned to a code cannot be performed by the code assignee.

If Key or Code access mode is selected by the user in the User Configuration Mode, the key switch is one of two means available to access Program Mode. All settings and actions for the system are accessible when the Program/Run key switch is switched to the PROG position. In addition, Program Mode can be accessed by code. Up to 16 employees (or employee classifications) may be assigned passwords (codes) and a list of assigned settings and actions (permissions) that each code may perform in the Program Mode just as in Code Only access mode.

If Key and Code access mode is selected by the user in the User Configuration Mode, both the key switch and code (password) must be used to access Program Mode. Up to 16 employees (or employee classifications) may be assigned passwords (codes) and a list of assigned settings and actions that each code may perform in the Program Mode just as in Code Only access mode.

Section 3.9.2 Using Key Only Access to Program Mode for Settings and Actions

If Key Only Access Mode is chosen, the only way to enter the Program Mode for screens which require settings or actions (such as reset and bypass) to be made in Program Mode is by use of the Program/Run key to select Program. Generally, the softkeys that are associated with performing settings and actions will appear only when the Run/Program switch is in the Program position. The only softkeys associated with performing settings and actions that will appear in Run Mode are those associated with the limited number of settings or actions that are configured by the user to be allowed in Run Mode, as described in Section 4.2.4.3.2. The following example uses the optional Die Protection and Process Monitoring function of the OmniLink II Press Automation Control to illustrate the Key Only Access Mode.

Figure 3.7 illustrates the main die protection screen for module 1, channels 1-8 when Key Only Access Mode is selected. Note that channel 5 is highlighted in Figure 3.7. With the Program/Run switch in Run position, pressing the CHANNEL SETTINGS softkey will select the channel settings screen shown in Figure 3.8 to allow viewing the settings for channel 5. However, you won’t be able to make changes to the settings unless the Program/Run switch is turned to the Program position, enabling settings to be changed through use of the setting functions provided by the use of the upper right softkey available only in Program Mode in Figure 3.8. Also, note that the RESET FAULT softkey for a Die Protection fault appears only in Program Mode in Figure 3.7. This restricts the action of resetting a die protection fault to Program Mode (Run/Program switch in Program) since no softkey exists to reset the fault in Run Mode. Note! The condition that creates a die protection fault must be cleared before the RESET FAULT softkey will perform a reset.

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TO P

Ch Channel Type Description Status State

1 S tatic Stock Buckle OK Off 2 Not Used OK Off 3 1 Part Detector Edge Part Out OK Off 4 In Position Die Cam Retr acted OK On

5 C yclic Stripper Le ft Front OK Of f 6 C yclic Str ipp er Right Front OK Of f 7 C yclic Stripper Le ft Rear OK Of f 8 Cyclic Stripper Right Rear OK Off

Delay Strokes:

Channel

Status

Mo dule Status: OK

Strok e

Mode

Nor mally OFF Top S top No 0 m secs 0 Strokes 154 213

Input Type:

Stop Typ e:

Bypa ssed:

Delay Time:

Windo w On: Window Of f:

Sys tem Status: OK

Module 1 - Channel 5 Det ails

Drive Speed Stroke Speed

0 0

SPM

180

Order

Counter

SYSTEM STATUS

90270

Counter OFF

Die Protection

CHANNEL SETTINGS

CHANNEL DIAGS

RESET FAULT

EXIT

In Key Only Access Mode, the Channel Settings Softkey will select the DP Channel Settings screen so settings can be viewed

in Run Mode, but the Program/Run switch must be turned to Program to chan ge

settings on the

DP Channel Settings screen.

Appears only with Program/Run switch in Program Position.

Sof tKeys

Figure 3.7 Main Die Protection Screen in Run Mode for Module 1, Channels 1-8

TOP

Di e Prot. C hannel Settin gs Mo du le: 1 Chan nel: 5

Channel Type:

Stroke

Mode

Desc ri pti on:

Input Type:

Sto p Ty pe:

Bypa ssed:

Delay Ti me:

Dela y Strokes :

Wi ndow O n: Wi nd ow O ff:

Dr i ve

S pee d

Stroke S pee d

C ycl ic

Left Front Stripper Normal ly OFF Top Sto p No 0 mse cs 0 Str okes

154

213

SPM

0 0

SPM

H elp Sets the typ e of Logic to ap pl y to the channel

Order

Counter

SYSTEM STATUS

Coun t er O FF

DP Chan Settings

CHANGE SETTI NG

CHANNEL DIAGS

CHANGE SETTING, CHANGE NAME, or CHANGE NUMBER in Program Mode depending on setting selected.

Cyclic - Norm. OFF Used to monitor events that occur once per m achine cycle. The input must b e O N so mew here in the timi ng windo w AND O FF somewher e in t he timing window.

DECREMENT ON ANGLE

IN CREM ENT ON A N GLE

DE CREM ENT OFF ANGLE

180

IN CR EM ENT OFF ANGLE

90270

PRE V IO US CHANNEL

NEXT CHANNEL

EXIT

Sof tKeys

Figure 3.8 Channel Settings Screen for Module 1, Channel 5

Once Program Mode is entered, the upper right softkey on screens throughout the OmniLink II Press Automation Control is used in the editing (change) process of any setting selected by use of the arrow keys on the operator terminal. See Sections 3.7 and 3.8.

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Section 3.9.3 Code (Password) System Operation

If any of the access modes to Program Mode that use a code is chosen in the User Configuration Mode, code access to the system to perform setting(s) or action(s) is a log on operation that requires a user to enter his name (or classification) and a code associated with the user name. The system will also ask for a name and code whenever softkeys that allow access to settings or actions restricted to Program Mode, such as reset or bypass, are pressed. Once the user has logged on with his user code through any

screen, access to other settings and actions permitted by his code in other screens is available until manual or automatic log out.

The following example of code access to Program Mode shows the steps necessary to access settings by code for new entry or change through the Die Protection screen if the User Configuration is set to allow code access. It should be noted that log on may also be required to reset or bypass the die protection function in the example shown when a reset or bypass softkey is pressed. Although screens for programmable limit switch and other functions are somewhat different, a common feature will be that the code request sequence to settings will always be by means of the upper right softkey, whereas the code request sequence for actions is initiated by the softkey that performs the action. Further, a user with proper access code can always log on by pressing the SUPPLY ACCESS CODE softkey that appears at the top of the Brake Monitor and Diagnostic screen in Run Mode. The popup Select User Name table and user name Code Entry box that are shown later in this example will also appear on all other screens where access to settings or actions by code (password) is used.

TO P

Ch Cha nnel T ype D escription Status State

1 S tat ic Sto ck Buck le OK Of f 2 Not Used OK Of f 3 1 Part Detector Edge Part Ou t OK Off 4 In Position Die Cam Retracted OK On

5 Cycl ic Stripp er Left Fro nt OK Off 6 C y clic Str ipp er R igh t F ron t O K Of f 7 Cycl ic Stripp er Le ft Rear OK Off 8 C y clic Str ipp er R igh t R ear OK Of f

Delay Strokes:

Channel

Status

System Status : OK Mo dule Status : OK

Stroke

Mode

Input Type:

Stop Type:

Bypassed:

Delay Time:

Windo w On: Window Off:

Module 1 - Channe l 5 Det ails

Nor mally OFF Top S top No 0 msecs 0 S trokes

154

213

Drive Speed Stroke Speed

0 0

SPM

Figure 3.9 Main Die Protection Screen for Module 1, Channels 1-8

Figure 3.9 shows the main Die Protection screen as it appears with one of the code access options to access Program Mode configured. To change settings for Die Protection with a code, select the screen with the module and channel number(s) for which you wish to enter or change settings. The NEXT PAGE and PREVIOUS PAGE softkeys are used to select a module (in many cases there will only be 1

180

Order

Counter

SYSTEM STAT US

90270

Counter OFF

Die Protection

CHANNEL SETTINGS

CHANNEL DIAGS

RESET FAULT

EXIT

In Code Access Mode, the Channel Settings Softkey will sele ct the DP Chann el Se ttings sc r ee n so settings can be viewed

in Run Mode, but the SUPPLY ACCESS CODE softkey must be pressed and user name and code entered to change settings on the DP Channel Se ttings sc r ee n.

Appears in both Program and Run whe n a Die Pro tectio n fault occu rs.

Sof tKeys

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module) and a group of eight channels for that module. One module may have up to 16 channels. The PREVIOUS PAGE softkey will appear above the NEXT PAGE softkey only after the NEXT PAGE softkey is used to select a group of eight other than those shown on the first page. Use the Up/Down arrow keys to move the cursor (highlight) to a channel whose settings are to be changed. In the figure above, channel 5 on die protection module 1 is selected. Press the upper right softkey (CHANNEL SETTINGS). This will take you to the Die Protection Settings screen for channel 1, module 5, shown in Figure 3.10.

TOP

Die Prot. Channel Configuration Modul e: 1 Channel: 5

Channel Type :

Delay Strokes:

Stroke

Mode

Description:

Input Type:

Stop Ty pe:

Bypassed:

Delay Time:

Window On: Window Off:

Cyclic

Left Front St ripper Normally OFF Top Sto p No 0 msecs 0 Strokes

154

213

Drive

Speed

Stroke Speed

SPM

0 0

Help Sets the type of Logic to apply to the channel

Counter

SPM

Order

SYSTEM STATUS

Counter OFF

Die Protection

SUPPLY ACCESS CODE

CHANNEL DIAGS

Press the SUPPLY ACCESS CODE

Cyclic - Norm. OFF Used to monitor even ts that oc cur once per machine cycle. The in put must be ON somewhere in the timing windo w AN D OFF s omew her e in the timing window.

DECREMENT ON ANGLE

INCR EMEN T ON ANGLE

DECREMENT OFF ANG LE

180

INCR EMEN T OFF ANG LE

90270

PREVIOUS CHANNEL

NEXT CHANNEL

EXIT

SoftKe

Figure 3.10 Die Protection Channel Settings Screen

Note that the Die Protection Channel Settings screen is channel specific, i.e., since channel 5 of die protection module 1 was selected when the CHANNEL SETTINGS softkey was pressed in Figure 3.1, the Die Protection Configuration screen that appears will allow you to settings for this particular channel. The upper right softkey is now labeled SUPPLY ACCESS CODE. Pressing this softkey will cause a popup table to appear listing user names as shown in Figure 3.11.

When the user name is selected in the screen shown in figure 3.11, the user name code entry box will appear as shown in Figure 3.12. Use the number keys on the Operator Terminal keypad to input the code associated with the user name and press the ENTER key.

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Die Prot. Channel Configuration Module: 1 Channel: 5

Stroke

TOP

Mode

Channel Type :

Descript

Input T

Stop T

Bypass

Delay Ti

Delay Stro

Window Window

Cyclic

Select a User Name

John

Jane Ed Sam Joe Ted

Drive

Speed

Stroke Speed

SPM

0 0

Help Sets the type of Logic to apply to the channel

Counter

SPM

Order

SYSTEM STATUS

Counter OFF

DP Chan

DP Chan Confi g

Settin

SELECT

Press Select after using Use Up/Down arrow keys to highlight your user name in list

Cyclic - Norm. OFF Used to monito r events that oc cur once per mach ine cycle. The input must be ON somewhere in the timing windo w AND OFF som ewher e in the timing window .

90270

180

EXIT

SoftKeys

Figure 3.11 User Selection Box Appears on Die Protection Configuration Screen

TO P

Die Prot. Channel Con figuration Module: 1 Cha nnel : 5

Stroke

Mode

Channel Type:

Description:

Select a User Name

Input Type:

Stop Type:

Cyc lic

Left Fro nt St rip per Nor mally OFF Top S top No 0 msecs 0 S trokes

154

213

Drive

Speed

Stroke Speed

J OH N CODE :

SPM

0 0

SPM

Help Set s th e type of L ogi c

Order

Counter

Counter OFF

SYSTEM STAT US

DP Chan

DP Chan Config

Settings

CHANGE SETTING

Enter the code (Pasword)for John

Cyc lic - Norm. OFF Used t o m onitor events that occur once per machine cycle. T he input must be ON s omewhere i n t he tim ing win dow AND OFF somewhere in th e tim ing windo w.

90270

180

EXIT

Sof tKeys

Figure 3.12 User Name Code Entry Box on the Die Protection Configuration Screen

After entry of a valid access code, the popup table and code entry box will disappear and the Program Mode screen of Figure 3.13 will appear, allowing settings to be made. The user will have access to all restricted items, including settings and actions for functions other than die protection that have been designated for his access in the configuration mode.

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Di e Prot. C hannel Settin gs Mo du le: 1 Chan nel: 5

Stroke

TOP

Mode

Channel Type:

Desc ri pti on:

Input Type:

Sto p Ty pe:

Bypa ssed:

Delay Ti me:

Dela y Strokes :

Wi ndow O n:

Wi nd ow O ff:

C ycl ic

Left Front Stripper Normal ly OFF Top Sto p No 0 mse cs 0 Str okes

154

213

Dr i ve

S pee d

Stroke S pee d

SPM

0 0

H elp Sets the type of Logic to ap pl y to the channel

Counter

SPM

Order

SYSTEM STATUS

Coun t er O FF

DP Chan Settings

CHANGE SETTI NG

CHANNEL DIAGS

CHANGE SETTING, CHANGE NAME, or CHANGE NUMBER in Program Mode depending on setting selected.

Cyclic - Norm. OFF Used to monitor events that occur once per m achine cycle. The input must b e O N so mew here in the timi ng windo w AND O FF somewher e in t he timing window.

DECREMENT ON ANGLE

IN CREM ENT ON A N GLE

DE CREM ENT OFF ANGLE

180

IN CR EM ENT OFF ANGLE

90270

PRE V IO US CHANNEL

NEXT CHANNEL

EXIT

Sof tKeys

Figure 3.13 Die Protection Channels Settings Program Mode Screen . To perform a reset action when a die protection fault occurs with a Code Access Mode, press the RESET FAULT softkey that appears in either Run or Program Mode on the main Die Protection Screen shown in Figure 3.9 when the Fault occurs. The popup User Name entry box will appear, allowing a name to be selected. When the name is selected, the popup User Code box will appear to allow entry of a code. Entry of a valid code will reset the fault. Note! The condition that creates a die protection fault must be cleared before a reset can occur.

This access will remain until the user performs a log out or until the user is automatically logged out by a timeout or limited number of strokes function set in the configuration menu and described in this section. The user can log out by using the ACC key. This key will directly switch the display to the Quick Access screen. The LOGOUT soft key legend will appear along the bottom of the screen. If the operator presses this key, he will log out. He will have to log on again for renewed access to the restricted items.

Section 3.9.4 Automatic Log Out

In addition to the manual log out, the system contains an automatic logout. The intent of automatic

log out is to reduce the possibility of users other than the intended user from having access to restricted 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 would be available from the log in time until power was removed from the OmniLink II. This presents the possibility of users other than the intended user having access to restricted items. Automatic log out is based upon both time and press strokes. During system configuration automatic Access Timeout parameters are entered. Automatic access timeout time and automatic access timeout strokes can be entered. The time entered is the amount of time after the last keystroke the user. For example, if the automatic access timeout is set to 60 seconds, the user will be logged out 60 seconds after the last keystroke. If the user depresses a key before the 60 seconds have elapsed, a

that will be allowed before the system will automatically log out

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new 60 second cycle will be started. The number of strokes that are entered is the number of press strokes after the last keystroke that will be allowed before the system automatically logs out the user. For example, if the automatic timeout is set to 10 strokes, the user will be logged out when the press completes ten strokes after the last keystroke. If the user depresses a key before 10 strokes have been completed, a new 10 stroke cycle will be started.

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Page 50

Section 4 Device and Main Configuration Menus

After your OmniLink II Press Automation Control is first installed and BEFORE you begin to use the system, you must configure the OmniLink II for and its components for its use on the particular press.

The system provides access to two sets of configuration menus that set up the base system for all press operations, the Device Configuration Menu, and the Main Configuration Menu. Configuration Menus for hardware options such as Die Protection & Process Monitoring, PLS/Logic Modules, Tonnage Monitor Modules, Automatic Setup Modules, and Analog Process Monitoring Modules are also provided when optional hardware modules are used with the base system. Configuration of these hardware options will be covered in the respective sections of this manual that cover these options. The foregoing Configuration Menus are normally only done when the system is initially installed, or if initial configuration choices are to be changed at a later time. In addition, the OmniLink II Counters are configurable on a job by job basis, as opposed to a machine basis. These counters can be configured for multiple parts out per stroke, multiple strokes per part out, and other factors that depend on the specific job. Counter configuration will be discussed in the section of this manual that discusses counter use.

It is IMPORTANT TO NOTE that the only settings for optional modules contained in the Main Configuration Menus are those that restrict or permit certain optional module operator actions if the modules are used. The Device Configuration Menu is used to tell the system which optional modules are being used with the system. Configuration menus for all other settings for optional modules will be accessed through screens associated with the optional modules. These screens will only appear if these modules are installed and their presence is set to “Yes” in the Device Configuration Menu. The same User Configuration Code is used to gain access to all user configuration menus for the system.

CAUTION. Certain configuration settings affect safety considerations, such as Brake Monitor limits, and others could affect whether elements of your production process are properly controlled or monitored by the OmniLink II Press Automation System. User configuration should be limited to persons who have read this manual completely and who are authorized by the employer to configure the system. Incorrect Brake Monitor limit settings may indirectly expose an operator to danger at the point of operation if stopping time is allowed to increase beyond the value used to calculate safety distance for presence sensing or two hand control safeguarding devices. Incorrect sequencing or monitoring caused by incorrect settings may lead to damaged dies, press, or auxiliary equipment.

Section 4.1 Device Configuration Menu

The first step in configuring the OmniLink II Press Automation Control is to configure the system for the specific hardware devices used with your system. The OmniLink system uses distributed

intelligence in a variety of logic modules so that it offers maximum flexibility for specific applications. The OmniLink II Operator Terminal is the central integrating intelligence that communicates over a high-speed network with each hardware module to allow seamless programming of monitoring and control functions and display of information for each module. The Device Configuration Menu is used to “tell” the OmniLink II Operator Terminal the specific hardware modules used with the particular system with which it needs to communicate. You will need to configure the system for the devices used with it initially, and at any time you add modules to the system. Each hardware module used with the system must be have power and its high speed serial cable connected during device configuration.

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The Device Configuration menu is also used to update the software in the various modules used with the system when needed or desired, although this normally will not need to be done when you

initially configure your system. The OmniLink II Operator Terminal provides for the insertion of a smart media card with updated software to download to the various modules used with the system.

The Device Configuration Menu is accessed from the Quick Access screen shown in Figure 4.1. Pressing the ACC key on the operator terminal keypad causes the Quick Access screen to be displayed.

TOP

Stroke

Mode

Current Login: None

Drive

Speed

Stroke Speed

MACHINE NOTES

SPM

0 0

SPM

Order

Counter

SYSTEM STATUS

Counter OFF

Quick Access

EDIT NOTES

NOTES FOR JOB #

DEVICE CONFIG

LOGOUT

AUXILIARY COMM.

EXIT

Figure 4.1 The Quick Access Screen with Program/Run Switch in Program

The DEVICE CONFIG softkey in the lower left corner of the screen appears only with the Run/Program switch in the program position. Pressing the DEVICE CONFIG softkey causes a box to popup which requests that you enter the User Configuration Code, the highest order user password. After entry of the correct code, the first page of the Device Configuration screen, shown in Figure 4.2, is displayed.

TOP

Device Used Status

Syste m 500 0 Card Ra ck

Syste m 500 0 Com m Mod ule R/D - Brake Monitor Module Prog. Limit Switch (1-8) Prog. Limit Switch (9-16) Prog. Limit Switch (17-24) Prog. Limit Switch (25-32)

Stroke

Mode

Drive

Speed

Stroke Speed

Devic e Conf igurat ion

No No Yes Yes Yes No No

SPM

0 0

SPM

Order

Counter

SYSTEM STATUS

Counter OFF

Device Confi g

TOGGLE USED

UPDATE PROGRAM

Hardware Detected :

Hardware Version : Bootc ode Version :

Software Ve rsion :

Avail. Version :

EXIT

Figure 4.2 Device Configuration Screen, First Page.

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The left column of the Device Configuration screen lists hardware modules that can be used with the system. The center column indicates whether the device is used with this particular OmniLink system. The right column is used to indicate information pertaining to device status, such as “detected”, which means the Operator Terminal has established communication with the module. The TOGGLE USED softkey will toggle the “Used” column for the highlighted (selected) device from No to Yes or Yes to No. The UPDATE PROGRAM softkey is used only in rare instances where it is desired to update software for a selected device to a newer version. The NEXT PAGE softkey will take you to a similar screen with additional device listings and a PREVIOUS PAGE softkey will appear so that you can return to the first page of the menu. Some hardware options planned for the system are not yet available and are not listed in the Device Configuration menu at this time. These will be added to operator terminal software updates that will be sent out as optional modules are available and purchased.

The first page of the Device Configuration screen indicates the following devices that you must indicate whether or not are used with your system.

1. System 5000 Card Rack and System 5000 Comm Module. Link makes provision to retrofit optional modules used with the OmniLink II Press Automation Control to previously sold System 5000 Press Controls equipped with the OmniLink II LCD Operator Terminal. First, high-speed serial interface chips must be inserted in sockets in the in the operator terminal and new software must be installed. Then a System 5000 Comm(unication) Module must be inserted into the 5000 card rack. A communication cable must then be run between the System 5000 Comm Module and the OmniLink II LCD Operator Terminal, as described in the Installation section of this manual. When this is done, you must toggle the System 5000 Card Rack “Used” setting to Yes. This enables the new operator terminal software to communicate with the 5000 Card Rack through its RS 485 port. Also, the “Used” setting for System 5000 Comm Module must be toggled to Yes. This enables the System 5000 control to send information to the Operator terminal and other system modules via the highspeed serial network used by the OmniLink II Press Automation Control. Both of these “Used” settings should remain No if you are not retrofitting an existing System 5000 Control.

2. R/D – Brake Monitor Module. This module is used in all OmniLink II Press Automation Control operator terminals except those to be retrofit to existing Link System 5000 Press Controls. Since it will be included in the same package as the OmniLink II LCD Operator Terminal and will be pretested at the factory, this setting should already be Yes for the “Used” column. If it is not, toggle it to Yes for non-retrofit applications

3. Programmable Limit Switch Outputs. The system provides for up to 32 programmable limit switch outputs. These outputs are options that come in groups of 8. Each group of 8 channels is prenumbered and will be recognized by the operator terminal to be the specific pre-numbered group. You must toggle the “Used” setting for each specific group of 8 channels used with the system to be Yes.

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Pressing the NEXT PAGE softkey causes the second page of the Device Configuration menu to be displayed, as shown in Figure 4.3.

TOP

Devic e Used Status

Die P rotection Module 1 Die P rotection Module 2 Die P rotection Module 3 Die P rotection Module 4 Die P rotection Module 5

Stroke

Mode

Devic e Conf igur atio n

Drive

Speed

Stroke Speed

Yes No No No No

0 0

SPM

Order

Counter

SYSTEM STATUS

Counter OFF

Device Confi g

TOGGLE USED

UPDATE PROGRAM

Hard ware Dete cted :

Hardware Version : Bootcode Ve rsi on :

Software Version :

Avail. Version :

EXIT

Figure 4.3 Device Configuration Menu, Second Page.

The OmniLink II Press Automation Control provides for up to 5 Die Protection and Process Monitoring Modules, each with either 8 or 16 inputs. Before toggling a Die Protection and Process Monitoring Module to a “Used” setting of Yes, you must assign each module a module number. This is done by opening the door of each module and setting a rotary switch in the module you wish to designate as module 1 to the number 1. For each module used, set a different successive number on the rotary switch that indicates module number. When you have finished, an LED number display in the front door of each module indicates module number when power is on. Once you have assigned a module number to each die protection module to be used with the system, toggle to Yes for the “Used” setting for each module number used.

Section 4.2 The Main Configuration Menu

The Main Configuration Menu is used to configure:

1. Settings based on the characteristics of the press upon which the OmniLink is installed. Brake Monitor Stop Time Limits, Clutch Engagement Time Limit, and stroke length are examples of settings that depend on the individual press.

2. Settings for Encoder Offset, Auto Top Stop Compensation, Top of Stroke Angle

3. Choices of what you wish to show on areas of the Operator Terminal Display in certain areas reserved for user customization.

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4. Configuring the Operator Terminal serial ports for any software options, such as serial feed interface and PLC Interface used.

5. Choosing whether certain bypass or reset actions for both standard and optional features are unrestricted, or whether these actions can only be done by persons you have chosen to do so in the security settings of the system.

6. Setting up the key/code access security system of the OmniLink to restrict certain reset or bypass actions and settings in programming menus to specific personnel or by Program/Run key.

7. Entering any diagnostic Messages that may be sent to the Operator Terminal parallel port by outputs from an auxiliary equipment PLC controller.

You must be able to stroke the machine to do certain parts of configuring the OmniLink II Press Automation control in the Main Configuration Menu. The system has outputs that are connected to the stop circuits of your press control that will be activated if a fault occurs. At this time you need to make sure that any monitoring or control functions associated with optional Die Protection, PLS, and other modules that you are using with the system will not generate a fault that you will have to repeatedly reset each time you stroke. As shipped from the factory, any optional modules shipped with the system are generally not programmed to perform monitoring or control actions and will not generate faults. However, if anyone at your facility has experimented with programming various monitoring functions before the system is configured, you may have to reprogram them to prevent faults when you stroke as follows: make sure all counters are turned off; if Die Protection or Analog Process Monitor options are provided, set all channels to Unused; if Tonnage and Signature Monitor option is provided, press the BYPASS softkey to bypass both high and low limits.

The Main Configuration Menu is accessed from the Brake Monitor menu. The CONFIGURE softkey is available only in the Brake Monitor Menu when the Program/Run switch is in the PROG position. The Brake Monitor menu is shown in Figure 4.4 with Program/Run switch in PROG position.

Brake Monito r Limit Stoptime

Top S tr oke S to p 0 200 183 mSec

Mid Stroke Stop 0250 0 mSec

Clutch time 0275 0250 mSec

Critical Angle: 145

Auto Si ngle Stroke Time ……… 5 Sec

Stopping Degrees: 57

Feed Complete Position ……… 25 Degs

Cont. on Demand Time ………. 10 Mins

Auxiliary Equipment Message

Option is not Installed

Reason for the Last Stop

Po wer Up

Present Running Status

Ready to Stroke

CONFIGURE

Stroke

TOP

Mode

Die Protection Stop

AUXILIARY

COMM.

Single Str ok e

Lim it Ac tual

Drive

Speed Stroke

Speed

APPEARS ONLY IN PR OGRAM

ANALOG PROC MON

DIAGNOS

SPM

0 0

SPM

Order

Counter

READY TO STROKE

% LOAD

SPM

161

OPERATOR STATON

Counter OFF

PC STATUS

SYSTEM STATUS

Brake

PRES S

Monitor

CONTROL

SUPPLY

CHANGE

ACCESS

NUMBER

CODE

SPEED

MOTOR

ADJUST

SPEED

TONNAGE

MONITOR

MONITO R

AUTO RESET

RESET

SETS

ERROR

AUTO

FAULT

SETS

DIE

PROT ECTION

PROTECTIO N

EXIT

The SUPPLY ACCESS CODE Softkey legend w ill not pre sent if k ey on ly acce ss mode is cho sen in the configuration menu. This area w ill b e blan k in R un an d will have CHANGE NUMBER in Program.

Appears Only When Fault Exists

Figure 4.4 Brake Monitor Menu

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If the CONFIGURE softkey is pressed, the display will ask for the configuration code. This user configuration code is user programmable and is the highest order user password for the system. An original code is sent from the factory to a person designated when the control is ordered. The user has the option of keeping the original code or changing to another during the initial configuration or at a later time if desired. This user configuration code is used to access the Main Configuration menu, as well as all other configuration menus and must be provided to qualified personnel only. When the code is entered, the Main Configuration Menu shown in Figure 4.5 appears.

TOP

Stroke

Mode

Top Stop Calibration

Machine Parameters

Operator Terminal

Name s and Messa ges

Exit Configuration

Drive

Speed

Stroke Speed

SPM

0 0

SPM

Order

Counter

SYSTEM STATUS

Counter O FF

Main Confi g

TOP STOP CALIBRATE

MACHINE PARAMETERS

OPERATOR TERMIN AL

NAMES

EXIT

Figure 4.5 Main Configuration Menu

The Main Configuration menu presents a list of other submenus that may be selected by softkey to enter settings for parameters. Once access to the Main Configuration menus is obtained, the Program/Run switch may be switched back and forth between PROG and RUN. It will be necessary to switch back to the Run position and stroke the press for certain Main Configuration Menu calibrations that may be required, as discussed in later sections. Also, some of the Run Mode and Program Mode screens will be available from certain Configuration Mode menus to aid in calibration or settings. The configuration mode will remain in effect until manually exited by pressing the EXIT softkey repetitively until the display returns to the Brake Monitor menu.

Settings can only be made in the configuration mode with the Program/Run switch turned to PROG. The arrow keys are used to position the cursor onto the configuration setting to be changed.

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Section 4.2.1 Machine Parameters Menu

Pressing the Machine Parameters softkey in the Main Configuration menu accesses the Machine Parameters menu, shown in Figure 4.6. This menu is where you will begin the configuration process.

NOTE! The last two items are not setting s them. They are actu al measured times for stopping and clutch engagement that a ppear each t ime the p ress starts and stops. T hey are used t o de termine the proper brake monitor and clutch engagement ti me limits in the configuration process as d escribed in the co nfiguration sections for br ake monitor and cl utch engage ment ti me.

Stroke

Mo de

Clutch Engagement Ti me Limit :

Brake Monit or T op Stop Limit :

Brake M onitor Mid Stroke Stop Limit :

Brake Monitor Actual S top Time :

Clutc h Actual Engagement Time :

Appear s only when st op limit or cl utch engage ment time lim it is exceeded

Dr i v e

Speed

Stroke Speed

Encoder Type :

Enc o der Of fs et :

Top of Stroke Angle :

Minimum Press Speed :

Loss of Mot ion Time :

Use Mode Input :

and a val ue c anno t be entered f or

0 0

2500

20 0 20 0

15 0

SPM

0 0 2

SPM

msecs

msecs msecs msecs

msecs msecs

Orde r

Counter

SYSTEM STAT US

(TOP)

Counter OFF

Machine Params

CHANGE SE TTING

SPE ED CONFIG

RESET FAULT

MID STOP

TO P STOP

EXIT

Figure 4.6 Machine Parameters Configuration Menu

Note that some numeric settings may already be programmed when you receive the unit. These settings were made during the checkout of your unit at the factory and must be reprogrammed as you configure the system based on the specific characteristics of your press.

Section 4.2.1.1 Configuring the Encoder (Resolver) Type

The first step after you have initially installed the OmniLink II system will be to select the Encoder Type setting on the Machine Parameters menu. An encoder is provided with each

OmniLink II Press Automation Control to be driven in a one-to-one ratio by the crankshaft of the press to supply crankshaft angular position information to the system. The angular position display in the upper left corner of the screen displays the angle provided by the encoder.

Link offers two different encoders with the OmniLink II Press Automation Control. The standard encoder is the 2500 Resolver. An optional 5000 Resolver is also offered that combines a resolver and an optical encoder in the same enclosure to allow cross checking of the angular position information. You must determine which resolver you ordered with your system and set either “2500” or “5000” as the Encoder Type setting, the first menu item in the Machine Parameters Menu. This setting will be selected (highlighted) when the screen first appears. When the Encoder Type setting is selected, pressing the Change Setting softkey will toggle the setting between “2500” and “5000”. If you have a 2500 resolver and the setting already appears as 2500 in the highlighted area, you don’t need to push the Change Setting softkey.

Section 4.2.1.2 Setting Top of Stroke Angle

After setting the Encoder Type, look at the Top of Stroke Angle setting, the third menu item from the

SOFTKEYS WHEN ENCODER OFFSET IS SELECTED

CHANG E NUMBER

SET ZERO

RESET FA UL T

MID STOP

TO P STOP

EXIT

SOFTKEYS WHEN NUMERIC SETTINGS SELECTED

CHANGE NUMBER

RESET FAULT

MID STOP

TOP STOP

EXIT

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top on the Machine Parameters menu. This setting comes from the factory as 00 since it is most likely that your press will have simple eccentric motion instead of the more complex link drive motion. If your press slide is directly driven by a crankshaft, an eccentric shaft, or eccentric gear you do not need

to change the 0

setting. Go to the setting discussed in the next section of this manual.

If the press has a link drive system you must refer to the manual for the press to find what crank or eccentric angle represents top of stroke. This angle will normally be somewhere between 315

and 335

depending on the specific press design. Use the arrow keys to select the Top of Stroke Angle setting, use the number keys to key in the correct angle, and press the ENT(ER) key when done.

Section 4.2.1.3 Setting Minimum Press Speed and Loss Of Motion Time

The OmniLink II Press Automation Control uses a motion detection system to detect any coupling failure that results in the encoder (resolver) not being driven by the crankshaft. If the resolver decoupling occurred, the system would then be unable to perform its monitoring and control functions that depend on crankshaft angular position. The motion detector generates an immediate stop signal if it senses motion below the SPM (strokes per minute) configured in the Minimum Press Speed setting for a period of time greater than the setting for Loss of Motion Time. The Loss of Motion Time setting is used to compensate for erratic motion on some geared presses where the gears cog back and forth as the press strokes, resulting in temporary dips below the Minimum Press Speed SPM setting, i.e., the motion detector threshold as shown in Figure 4.7.

SPM

Minimum Press Speed SPM

Average SPM

Periodic Dips below Minimum Press Speed setting

TIME

Figure 4.7 Erratic Crankshaft Motion Typical of Some Geared Presses

The Minimum Press Speed setting is limited to values between 2 and 100 SPM, and a entry of a number beyond these values is rejected. A value well below the actual minimum press stroking speed should be entered as this configuration setting, preferably in the range of 25% to 30% of actual minimum press stroking speed although lower and higher values may also be suitable.

The value to enter for the Loss of Motion Time setting depends on the characteristics of the individual press. Use the following formula to determine your initial configuration setting in milliseconds for this parameter.

Loss of Motion Time = 3000 divided by maximum press strokes/min (milliseconds)

Example: A variable speed press provides stroking speeds from 20 SPM to 60 SPM. Since 60 SPM is the maximum strokes/min, 3000/60 = 50 milliseconds. Enter 50 as the initial Loss of Motion Time setting.

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If the loss of motion time value calculated by the formula is not longer than the time that motion can dip below the Minimum Press Speed, loss of motion faults will result. If these occur, you may increase the time calculated by the formula but, in no case, should this time be increased more than 2.5 times the value calculated by the formula.

Section 4.2.1.4 Temporarily Setting Other Items on the Machine Parameter Screen So that the

Press Can be Stroked Without Generating Brake Monitor or Motion Detector Faults

The previous configuration settings could be done without having to stroke the press to a particular position in the stroke. The next setting in the Machine Parameter configuration menu, Encoder Offset, will require you to Inch the press slide to either the top or the bottom of the stroke. The OmniLink II Press and Automation Control provides a Brake Monitor and a Motion Detector as a standard feature. If the clutch engagement time limits or either the top stop or mid stroke stop limits are set below the actual clutch engagement time or the actual stopping time of your press, they will generate faults that will have to be reset. To avoid these faults, temporarily make these settings:

1. Clutch Engagement Time Limit : 200 msecs (milliseconds)

2. Brake Monitor Top Stop Limit : 500 msecs

3. Brake Monitor Mid Stroke Stop Limit : 500 msecs

These settings will prevent faults for most presses. But, if you have a press with clutch engagement time greater than 200 milliseconds or stop time greater than 500 milliseconds, you may have to increase the settings listed above to prevent having to reset faults during the next configuration steps that require stroking of the press. Note! These are temporary settings only! You will need to refine these

settings later in the configuration process as described in section 4.1.1.8.

Section 4.2.1.5 Setting Encoder Offset

Once the Encoder Type is set, use the down arrow key to select Encoder Offset. The Encoder Offset setting must be performed so that your system indicates the correct crank or eccentric shaft angle.

The Encoder Offset is a setting that compensates for limited (+/-10o) mechanical angular misalignment between the resolver shaft angular position and the crank or eccentric shaft angular position, so that the resolver and crank do not have to be perfectly mechanically aligned during installation. Two methods of setting the encoder offset are described in this section, one with the slide positioned at top dead center (TDC), and one with the slide positioned at bottom dead center (BDC). For simple eccentric motion mechanical presses (which constitute the vast majority of presses), with slide driven by crankshaft, eccentric shaft, or eccentric gear, the top of stroke position always occurs with the crank at

the 0

(TDC) angular position and bottom of stroke at the1800 (BDC) position. You may use either

method of encoder offset for simple eccentric motion presses.

For Link Drive presses, bottom of stroke still occurs at the180

generally occur at a crank or eccentric angle between 315

(BDC) position, but top of stroke will

and 3350, depending on the specific design.

You must use the method that positions the slide at BDC for link drive presses.

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Method 1. Slide at Top of Stroke

1. Inch the press to position the crankshaft within +/- 1 degrees of top dead center (0

0 --

slide at top of stroke). This is important because the system uses the crank angle as its absolute reference and will assume that the crankshaft position is at zero degrees when it calculates the Encoder Offset. If the crankshaft is actually 50 from top dead center when you press the SET ZERO softkey or manually enter an offset, as described in the following steps, you will incorporate a 50 error into the crankshaft angle indication of the OmniLink II Operator Terminal. Make sure the Encoder Offset setting shown on the screen is 0. If other than zero, select Encoder Offset and manually enter a setting of zero before going to the next step by pressing the 0 number key and then the ENT(ER) key.

2. When you have positioned the crankshaft as closely as possible to top dead center, read the angle display on the OmniLink II Operator Terminal. The number displayed must between 3510 and 100.

This is because a maximum misalignment of resolver to crankshaft of +/-10 Encoder Offset function. If the displayed angle is more than 10

from 0, you must manually de-

can be corrected by the

couple the resolver/encoder from the crankshaft and re-couple it within the required 3510 to 100.

3. When steps 1 and 2 are complete, use the arrow keys to select the Encoder Offset item on the menu and press the SET ZERO softkey. The offset angle value will be automatically entered into the Encoder Offset setting . This is the number that must be added to the actual resolver reading to get

0. If the resolver/crank misalignment angle was within the allowable limit of 3510 to 100 when SET ZERO was pressed, the angular display value will indicate 0Ε.

Alternatively, you may enter the encoder offset manually using the number keys on the operator terminal keyboard. To do this, refer to Figure 4.8.

0o & 360

354

a. b.

Figure 4.8 Determining Encoder Offset

Figure 4.8 illustrates how to manually determine encoder offset. If the crankshaft is positioned at TDC (00) and the angular position indicated by the angle display at the upper left corner of the operator terminal screen reads 3540, as in Figure 4.8a, you need to add an encoder offset of 60 to

to get 3600. For a circle 00 and 3600 are the same point, but the angle display will always

354 display 00 rather than 3600. If you manually use the number keys to set 60 as the offset and press the enter (ENT) key, the angle display will then change to agree with the actual crankshaft angle of 00.

If the crankshaft is positioned at TDC (0 the upper left corner of the operator terminal screen reads 5 to the 5

to be at 00 (3600). The operator terminal does not make provision for negative offsets.

) and the angular position indicated by the angle display at

, as in Figure 4.8b, you need to add 3550

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Thus, regardless of whether you have a negative or positive misalignment of encoder to crankshaft, the Encoder Offset to manually enter when you calibrate the resolver with the slide at the top of stroke position is determined by the relation:

Encoder Offset = 3600 – Display Angle (with current Encoder Offset setting of 0)

4. Verify that the angle display changes to 00 after you press the Set Zero softkey or manually enter an offset. Manual entry of numbers between 00–90 and 3500–3590 is allowed. If you have manually

entered the wrong offset and the angle display doesn’t change to 0

, press the CLEAR key while

Offset Encoder is selected to return the offset to 0 and then manually enter the correct offset angle.

Method 2. Slide at Bottom of Stroke

1. Inch the press to position the crankshaft within no more than a couple of degrees of bottom dead center 1800 (slide at bottom of stroke). This is important because the system uses the crank angle as its absolute reference and will assume that the crankshaft position is at 180o degrees when you calculate and manually enter the Encoder Offset. If the crankshaft is actually 50 from bottom dead center when you manually enter an offset, as described in the following steps, you will incorporate a 50 error into the angle indication of the OmniLink II Operator Terminal. Make sure the Encoder Offset setting shown on the screen is 0. If it is a value other than zero, manually enter a setting of zero before going to the next step.

2. When you have positioned the crankshaft as closely as possible to bottom dead center (use of a dial indicator gage between bolster and slide may be a useful tool to accurately determine bottom of stroke), read the angle display on the OmniLink II Operator Terminal. The number displayed must be within +/-100 of 1800, i.e., it must be between1700 and 1900. This is because a maximum misalignment of resolver to crankshaft of +/-100 can be corrected by the Encoder Offset function. If the displayed angle is less than 1710 or more than 1900, you must manually decouple the resolver/encoder from the crankshaft and recouple it within the required angle range.

3. You must determine the required Encoder Offset to manually enter. The Set Zero softkey must not be used when determining offset in the bottom of stroke position. Determine the Encoder Offset angle to use as follows. Read the value on the angle display of the operator terminal with the crankshaft at BDC.

a) If the angle display indicates a value between 171

and 1790, calculate the Encoder Offset as:

Encoder Offset = 180

b) If the angle display indicates a value between 181

– Display Angle (with Encoder Offset setting of 0)

and 1900, calculate the Encoder Offset as:

Encoder Offset = 5400 – Display Angle (with Encoder Offset setting of 0)

4. Use the number keys to key in the Encoder Offset you have calculated and press the ENT (Enter) key when finished. The operator terminal angle display should now read 1800. If not, you may have calculated the wrong offset angle or tried to offset a misalignment of more than +/- 10

. Manually

enter 0 as the Encoder Offset and repeat this procedure.

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Section 4.2.1.6 Use Mode Input Setting

The OmniLink II Press Automation Control provides an input that allows the user to provide an isolated contact to the operator terminal, when this can be derived from the press clutch/brake control, to indicate when the setup mode (usually Inch) is selected. When this input is provided, it allows die protection functions and counters to be bypassed when a setup mode is selected, if desired. Manual bypass of die protection and counters is also always available even when the Use Mode Input setting is Yes.

If this contact is wired as an input as described in the installation section of this manual, The CHANGE SETTING softkey should be used while Use Mode Input is selected to toggle the setting to “Yes”. If the Mode Input is not used, select “No” as the setting.

Section 4.2.1.7 Setting Clutch Engagement Time Limit

When the press control sends an electrical signal to the clutch/brake valve(s) to start stroking the press, there is a time delay before the air (or hydraulic on a few presses) flow can push the clutch plates together and ramp up crank speed (the clutch plates slip till flywheel or gear RPM is reached) to the setting made for Minimum Press Speed (see section 4.2.1.3). This is illustrated in Figure 4.9

CRANK RPM

FLYWHEEL RPM

Minimum Press Speed SPM

Clutch Eng.

TIME

Figure 4.9 Illustration of Clutch Engagement Time.

The Clutch Engagement Time Limit is used two ways by the system. First, the motion detector will not issue a fault, which stops stroking when the press clutch/brake control sends a stroking signal to clutch/brake valve, as long as motion starts within the time limit set for clutch engagement. Secondly, the Clutch Engagement Time limit provides useful diagnostic information relating to clutch wear. As clutch plates wear, increasing the volume of air that must flow into and be stored in the clutch air operator, clutch engagement time gradually increases. The increased volume of air stored in the clutch also takes longer to flow out when the air valve dumps pressure to stop stroking, resulting in longer stopping time for the press. When clutch wear reaches the point where actual clutch engagement time exceeds the limit, a fault will result that stops stroking and will be displayed as the reason for the last stop. Most (though not all) presses provide for adjustment or shimming to compensate for clutch wear. Exceeding the clutch engagement time limit tells you that clutch adjustment or shimming should be performed. When possible, it is preferable to adjust the clutch clearance to the press manufacturers recommended setting to determine the clutch engagement time with optimum clearance.

To determine the value to enter as the Clutch Engagement Time Limit, put the press in Single Stroke Mode and stroke the press several times. Record the Clutch Actual Engagement Time indicated by the system on the Machine Parameters screen at the end of each stroke. Some margin for wear must

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be accommodated so that adjustment on a frequent basis is not necessary. A typical wear margin of 20% is usually sufficient. To determine the number to enter for the Clutch Engagement Time Limit with a 20% wear margin, take the longest time recorded and multiply it by 1.2. For example., if the longest time recorded is 100 milliseconds, enter a value of 120 milliseconds for the Clutch Engagement Time Limit.

Section 4.2.1.8 Setting Brake Monitor Top Stop and Brake Monitor Mid Stroke Stop Limits

The Brake Monitor Top Stop Limit and the Brake Monitor Mid Stroke Limits are set on the Machine Parameters menu. However, during your initial system configuration only, before performing the

steps listed in this section of the manual to determine the settings for Brake Monitor limits:

1. If you have a variable speed press and are planning to adjust stroking speed through use of the OmniLink II LCD Operator Terminal and the Analog Input/Output Board, you should first access the Speed Configuration menu by pressing the SPEED CONFIG softkey on the Machine Params menu and perform the steps described in Section 4.2.2 of this manual. If not, proceed directly to step 2.

2. You should then return to the Main Configuration menu. Push the Top Stop Calibration softkey to go to the Top Stop Calibration menu and perform the Top Stop Calibration for the press as described in section 4.2.3 of this manual.

Once you have finished the Top Stop Calibration

, return to the Machine Parameters menu and determine the proper Brake Monitor Top Stop and Mid Stroke Stop Limits as described in the following paragraphs of this section of the manual.

To determine Brake Monitor Top Stop Limit and Brake Monitor Mid Stroke Limit settings:

1. It advisable to determine stopping time of the press with the heaviest upper die that you use in the

press and, if the press is a variable speed press, to run at the highest stroking speed for which the die is run in the press. Adjust the press shutheight so that the upper and lower dies don’t close. If the press has a slide counterbalance, it should be set for the weight of the upper die. The stopping time of the press will increase with upper die weight and stroking speed, and will vary with counterbalance pressure. It is also recommended to make adjustments (when adjustment is provided) to set clutch and brake clearance to the minimum value specified by the press manufacturer. This should reduce stopping time.

The worst case stopping time is what you are trying to determine, so that it is not necessary for you to have to repeatedly change the brake monitor stop limit settings as different dies are used in the press. Of course, you may add production jobs at a later time where die weight or stroking speed produces stop times that exceed the initial worst case values, requiring limits to be increased.

2. Turn the Run/Program switch to Run and start the press stroking in Continuous Mode. After the

press has made two or three strokes, press the Top Stop softkey on the Machine Parameter menu screen. The OmniLink II Press Automation Control will top stop the press and a stopping time will be displayed in milliseconds (thousandths of a second) for Brake Monitor Actual Stop Time. To the right of the stop time (TOP) should appear, indicating that this is a top stop time measurement. Record this top stop time and repeat this step, recording top stop time each time you stop.

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3. Take the longest stop time recorded in step 2 and add a 10% to 20% margin for wear and other factors that affect this time to determine the Brake Monitor Top Stop Limit setting. For example, if your longest recorded stopping time is 170 milliseconds, 20% of this value is 34, and a setting of 204 milliseconds for the Brake Monitor Top Stop Limit would allow top stopping time to increase by 34 milliseconds before a brake monitor fault would prevent a successive stroke. A 10 % margin would allow less increase in stopping time before a fault occurred. Turn the Run/Program switch to Program and select the Brake Monitor Top Stop Limit setting. Enter the number you have determined in this step for the Brake Monitor Top Stop Limit.

4. Next, return the Run/Program switch to Run and again start the press stroking in Continuous Mode After the press has made two or three strokes, press the Mid Stop softkey on the Machine Parameter menu screen. The OmniLink II Press Automation Control will initiate a stop signal near mid stroke and a stopping time will be displayed in milliseconds (thousandths of a second) for Brake Monitor Actual Stop Time. To the right of the stop time (MID) should appear, indicating that this is a midstroke stop time measurement. Record the mid stroke stop time and repeat this step, recording mid stroke stop time each time you stop.

5. Take the longest stop time recorded in step 4 and add a 10% to 20% margin for wear and other factors that affect this time to determine the Brake Monitor Mid Stroke Stop Limit setting. For example, if your longest recorded stopping time is 200 milliseconds, 20% of this value is 40, and a setting of 240 milliseconds for the Brake Monitor Mid Stroke Stop Limit would allow mid stroke stopping time to increase by 40 milliseconds before a brake monitor fault would prevent a successive stroke. A 10 % margin would allow less increase in stopping time before a fault occurred. Note! Because of the characteristics of the reciprocating motion of a mechanical power press, mid stroke stopping time is normally greater than top stopping time. Turn the Run/Program switch to Program and select the Brake Monitor Mid Stroke Stop Limit setting. Enter the number you have determined in this step for the Brake Monitor Mid Stroke Stop Limit.

Section 4.2.2 Speed/Load Configuration Menu Settings

The Speed/Load Configuration menu shown in Figure 4.10 is used to make calibration settings related to press speed and percent motor load display. This menu is accessed with the SPEED/LOAD CONFIG softkey on the Machine Parameters Menu. If you don’t purchase the optional Analog Input/Output option with your system, there are no settings that need be made on this menu. The factory default setting for Speed Mode, located at the top of the screen, will be “Not Used” and should be left as “Not Used”. If you do have the Analog/Input Output option, the following sections discuss the choices and settings that can be made.

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Stroke

Mode

Maximum Input SPM :

SPM Input Offset :

SPM Input Cal # :

Percent Load Cal # :

Minimum Output SP M :

Minimum Output Ca l # :

Mid Range Output S PM :

Mid Rang e Outp ut Cal # :

Maximum Output SPM :

Prod. Mode Min SP M :

Setup Mode Fixed SPM :

Motor Speed Reading (S PM) :

Percent Load Readi ng :

Drive

Speed

Stroke Speed

Speed Mode:

Calibratio n Parameters

Speed and Load Readings

Not Used

0 0 0 0

0 0 0 0 0

Speed Parameters

0 0

SPM

Order

Counter

SYSTEM STATUS

Counter OFF

Speed /Load Config

CHANGE SETTING

ENTER CAL. MODE

MOTOR SPEED

EXIT

Figure 4.10 Speed/Load Configuration Menu

Section 4.2.2.1 Setting Speed Mode

If you have the optional Analog Input/Output board, the Speed Mode setting at the top of the menu

is the first setting you will make. If your press is a fixed speed press, leave the Speed Mode setting at the top as “Not Used”. The only use of the Analog Input/Output board will be to allow Percent Motor Load to be displayed, and the only setting you will make on this menu is for “Percent Load Cal #”. If your press has a variable speed drive, three Speed Mode choices that make use of the Analog Input/Output board are possible. Pressing the CHANGE SETTING softkey with the Speed Mode setting highlighted will cause a selection box to appear as shown in Figure 4.11.

Stroke

Mode

Speed Mode:

Maximum Input SPM :

Minimum Output SPM :

Minimum Output Cal # :

Mid Range O utput SPM :

Mid R ange O utput Cal # :

Maximum Output SPM :

Prod. Mode Min SP M :

Setup Mode Fixed SPM :

Motor Speed Reading (SPM) :

Percent Load Reading :

Calib ration Paramet ers

SPM Input Offse t :

SPM Input Cal # :

Perce nt Load Cal # :

Speed and L oad Re adin gs

Drive

Speed

Stroke Speed

Not Used

Input Only Output Without Recall

Output With Recall

0 0 0

0 0 0 0 0

Speed Param eters

0 0

SPM

Order

Counter

SYSTEM STATUS

Counter OFF

Speed/Load Config

CHANGE SETTING

ENTER CAL. MODE

MOTOR SPEED

EXIT

Figure 4.11 Selection Box for Speed Mode

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Use the arrow keys to select your choice of 3 Speed Mode settings; Input Only, Output Without Recall, or Output With Recall. The significance of these settings is:

• Input Only. If Input Only is selected, an analog speed input signal must be provided to the Analog Input/Output Board from the variable speed drive as shown in Section 2.3.7.2 of this manual. This will allow display of the selected drive stroking speed, and stroking speed of the press can be displayed even when the press is not stroking. You will also need to enter Calibration settings related to Input SPM near the top of the screen.

• Output Without Recall. If Output Without Recall is selected, in addition to the requirements of Input Only, the analog output SPM output on Link’s Analog Input/Output board must be wired to the press variable speed drive, This is generically shown in Section 2.3.7.2. This allows stroking speed to be set by the OmniLink II LCD Operator Terminal, but not recalled on a job by job basis for the press. Both Input SPM and Output SPM Calibration Parameters will need to be entered on the Speed/Load configuration menu in order to calibrate input and output SPM. When Output Without Recall is selected you can also set the Speed Parameters shown on the menu. Setup Mode Fixed SPM automatically set a fixed low speed for Setup Mode (usually INCH mode). Prod. Mode Min SPM sets a minimum SPM at which the press will stroke in production modes to avoid sticking the press on bottom due to insufficient flywheel energy.

• Output With Recall. Same as Output Without Recall except that you may set and store a speed which will be recalled and set by the OmniLink system on a job by job basis.

Section 4.2.2.2 Calibrating Variable Speed Drive Input SPM When “Input Only” is Selected

If “Input Only” is selected for Speed Mode, the Analog Speed Output by which speed is set by the OmniLink II Operator Terminal will not be used. Drive SPM will be set by the same method (a potentiometer or keypad associated with the drive) as before the OmniLink II Press Automation Control was installed. An analog speed input from the drive to the OmniLink Analog Output/Input board as shown in Section 2.3.7.2 is necessary. Calibrate the Drive Speed input to the OmniLink Analog Input/Output board as follows:

1. Go to Section 4.2.4.1 of this manual and configure Stroking Speed to be displayed in the top area of

the operator terminal display “When in a Production Mode”. Stroke Speed is determined by the resolver attached to the crankshaft and is always accurate. However it will be zero unless the press clutch is engaged (turning the crankshaft) and the press is actually stroking.

2. Use the potentiometer or keypad that sets the speed of the variable speed drive to set the highest

speed (SPM) for the press.

3. Make certain Input SPM Offset is set to zero.

4. Set Maximum Input SPM to about 10% more than the actual highest stroking speed of the press, ie.,

if highest stroking speed is 100SPM, set Maximum Input SPM to 110.

5. Turn the Program/Run switch on the Operator Terminal to the RUN position so the press can stroke.

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6. Select the CONTINUOUS stroking mode on the press stroking selector and initiate press stroking.

7. The actual stroking speed will be shown at the top of the OmniLink Operator Terminal display beside Stroke Speed as long as the press is stroking. This Stroke Speed will be used to calibrate the Motor (Drive Speed). If the Input SPM Cal # parameter is set to 0, the Motor Speed (Drive Speed) at the bottom of the screen will be 0. Calibration numbers between 0 and 4095 can be entered for the Input SPM Cal #. Enter calibration numbers by trial and error until the Motor Speed agrees with Stroke Speed. To do this press the CHANGE SETTING softkey with Input SPM Cal # selected and enter the calibration #. Do not use the ENTER CAL. MODE softkey for the Input SPM Cal #. The ENTER CAL. MODE softkey is used only when calibrating Output SPM calibration numbers where the OmniLink is used to set press stroking speed.

8. Adjust the variable speed drive till the Stroke Speed display at the top of the screen indicates the minimum stroking speed at which you will operate. If the Motor Speed Reading at the bottom of the display is within 1 or 2 SPM of the Stroke Speed displayed at the top of the screen at the minimum SPM stop here, you are finished. If not, it will be necessary to enter small numbers (start with the number 5) for the SPM Input Offset parameter, gradually entering greater numbers until the Motor Speed Reading equals Stroke Speed at the minimum SPM.

9. Return the press to the highest stroking speed and refine the Input SPM Cal # to make Drive Speed again agree with Stroke Speed if necessary.

Section 4.2.2.3 Calibrating Variable Speed Drive Input SPM When Output Without Recall or

Output With Recall is Selected for Speed Mode

When either Output Without Recall or Output With Recall is selected for Speed Mode, the analog Output SPM signal from the OmniLink to the variable speed drive that sets drive speed must be calibrated and drive adjustments must be made so that the Drive SPM will actually track the speed settings entered by use of the OmniLink II Operator Terminal. This calibration/adjustment procedure, described in Section 4.2.2.4 must be performed first, before calibrating Input SPM, so that the Operator Terminal can be used to set the drive speeds required in the Input SPM calibration procedure.

Once the analog Output SPM from OmniLink to variable speed drive is calibrated follow the procedure of Section 4.2.2.2 to calibrate the Input SPM. In step 2 of the procedure, adjust drive speed by pressing the MOTOR SPEED softkey on the Speed/Load Configuration menu to take you to the motor speed adjustment screen and enter the desired speed. You will return to the Speed/Load Configuration menu when the EXIT softkey is pressed once speed is set.

Section 4.2.2.4 Calibrating the Analog Output SPM Signal to Give Correct Drive Speed

If either Output Without Recall or Output With Recall is selected for Speed Mode, the analog Output SPM signal from the OmniLink to the variable speed drive (see Section 2.3.7.2) that sets drive speed must be calibrated and drive adjustments must be made so that the Drive SPM will actually track the speed settings entered by use of the OmniLink II Operator Terminal. The calibration adjustment procedure is as follows:

1. Go to Section 4.2.4.1 of this manual and configure Stroking Speed to be displayed in the top area of the operator terminal display “When in a Production Mode”.

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2. Return to the Speed/Load Configuration menu and set Speed Mode to Output Without Recall or Output With Recall as desired. Set all parameters on the Speed/Load Configuration menu to 0, except for Minimum Output SPM and Maximum Output SPM. Set these values to the press manufacturer’s specified lowest and highest speed.

3. Enable the Output SPM calibration mode by pressing the ENTER CAL. MODE softkey, which causes a legend that “Output Cal Mode Is Active” to appear at the bottom of the screen and a popup Output Cal # entry box that appears under the legend. The softkey that read ENTER CAL MODE will also now read EXIT CAL MODE. Calibration mode allows Cal #’s to be entered into the popup entry field. The calibration number that is entered is converted directly into an analog output voltage as described in the information below.

Analog output (Vdc) = Calibration # x 10.00 4095 Cal. # Output Vdc 4095 10.00 3890 9.50 3687 9.00 3481 8.50 3276 8.00 3071 7.50 2867 7.00 2662 6.50 2457 6.00 2252 5.50 2048 5.00 1843 4.50 1638 4.00 1433 3.50 1229 3.00 1024 2.50 0819 2.00 0614 1.50 0410 1.00 0205 0.50 0000 0.00

This voltage is input to the variable speed drive to set speed. The first objective of Output SPM calibration is to cause the variable speed drive to cause the press to stroke at the maximum rated stroking speed when the analog voltage is set to its highest value – 10VDC (Cal # 4095).

4. Instead of entering the highest calibration number (4095) initially, enter a value of 1000. This should be done to ensure that the drive does not cause the flywheel RPM to exceed the value that produces the maximum intended stroking speed.

5. Turn the Program/Run switch to RUN so that the press can stroke, turn the press stroking selector to the CONTINUOUS mode, and initiate stroking.

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6. Observe the Stroke Speed indicator at the top of the operator terminal display. This is the true stroking speed derived from RPM that the crankshaft turns in Continuous stroking. If the SPM indicated is less than the Maximum SPM for the press, successively enter larger Output SPM Cal numbers until either the highest Cal # of 4095 is reached without producing the Maximum SPM, or until a Cal # lower than 4095 produces the maximum stroking speed. If a Cal # of 4095 produces a stroking speed less than the specified maximum stroking speed of the press, follow the variable speed drive manufacturer’s instructions and adjust the drive speed until it reaches maximum stroking speed with the 10Vdc signal produced by the Cal # of 4095. If a Cal # lower than 4095 causes the stroking speed to reach the specified maximum SPM, do not continue to increase the Cal #. Rather, adjust the drive speed downward until well below the Maximum SPM and then begin to increase the Cal # till 4095 is reached without exceeding maximum SPM. If necessary, re-adjust the drive speed upward to the maximum SPM after the Cal # is set to 4095, its maximum value. Once this step is complete, a Cal # of 4095 (and an analog voltage of 10Vdc) represents the highest stroking speed of the press. Leave the press stroking, do not exit calibration mode, and proceed to step 7.

7. Next, the Cal # that will produce the minimum stroking speed of the press must be found. A first approximation of this Cal # may be derived by assuming (as is usually the case) that the drive speed input responds in a fairly linear fashion to the analog voltage that the Cal # determines. For example, if a variable speed press is intended to stroke from a low of 50 SPM to a high of 150 SPM and the drive is adjusted to produce 150 SPM at a Cal # of 4095 in step 6, a first approximation of the Cal # that would produce 50 SPM , which is 1/3 of 150 SPM, would be 1/3 of 4095, or 1365. Enter this number into the popup Output Cal # entry box at the bottom of the screen. The stroking speed should slow down. Observe the Stroke Speed indicator at the top of the operator terminal display until the speed has stabilized at the lower value determined by the Cal # entered. If the SPM is lower or higher than the minimum stroking speed of the press, increase or decrease the Cal # until the specified minimum stroking speed is reached. Once the correct Cal # is determined by entry into the popup Cal # box, use the arrow keys to highlight the Minimum Output Cal # setting on the menu and enter this number. Leave the press stroking, do not exit calibration mode, and proceed to step 8.

8. The Mid Range Output SPM and Mid Range Output Cal # settings are provided to linearize the press speed with respect to the analog input when needed. Typically dc and variable frequency drives exhibit linear characteristics and it is not necessary to set a mid range parameter. However, eddy current drives can exhibit nonlinear behavior. To test for linearity, add the setting for Minimum Output Cal # to 4095 and divide by 2. Enter this value into the popup Output Cal # entry box at the bottom of the screen. The Stroke Speed indicator at the top of the operator terminal display should display a stroking speed halfway between the minimum and the maximum stroking speed ([minimum stroking speed + maximum stroking speed/2). If the Stroke Speed Indication is within 2 or 3 SPM of the expected value you do not need to enter Mid Range settings. If the display differs by more than 2 or 3 SPM from the expected value, enter the Mid Range Output SPM and increase or decrease the Cal # in the popup Output Cal # entry box until the Stroke Speed SPM is equal to the Mid Range Output SPM that you entered. Once the correct Cal # is found, enter the Cal # as the Mid Range Output Cal # setting.

9. Calibration of press drive speed is now complete. Pressing the EXIT CAL MODE softkey will take you out of the Output SPM calibration mode and automatically set the press stroking speed to the lowest value on the Motor Speed adjustment screen. It is now possible to set stroking speed by entering numbers or using the SPM UP and SPM DOWN softkeys on the Motor Speed screen. Now calibrate Input SPM as described in Section 4.2.2.3.

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Section 4.2.2.5 Calibrating Percent Motor Load

If an input signal is provided to the OmniLink Analog Input/Output board as shown in Figure 2.16, this input must be calibrated to show correct Percent Motor Load. The calibration procedure is as follows.

1. Turn on the main press drive motor and place an ammeter on a motor lead. Do not stroke the press. This would cause variation in the motor current.

2. Read the current being drawn by the ammeter, divide the ammeter current by the full load current of the motor and multiple the result by 100. This is the Percent Load you are drawing while not stroking or stamping and should normally be less than 30%. The full load current of the motor should be on the motor legend plate or available from a table.

3. Enter numbers by trial and error into the Percent Load Cal # until the Percent Load Reading at the bottom of the screen agrees with the number you calculated in step 2. Start with a Cal # of 2000. Note! The Percent Load Reading displayed varies inversely with the Cal #. If the Cal # of 2000 produces a Percent Load Reading that is higher than you calculated in step 2, increase the Cal #. If lower than your calculation, decrease the Cal #. You are finished when a Cal # produces the same Percent Load Reading that you calculated in step 2.

Section 4.2.2.6 Setting Speed Parameters

Speed Parameters should only be set for variable speed presses equipped with the OmniLink Analog Input/Output option and with press speed set by the OmniLink analog speed input.

The purpose of the Prod. Mode Min SPM setting is to prevent operator entry of stroking speeds below the minimum stroking speed recommended by the press manufacturer when the press is used in a production mode. This could cause both motor overload and sticking on bottom because of insufficient flywheel energy when stamping. If you don’t want to use this feature, simply leave its setting at zero. If you do want to set a minimum speed entry when in a production mode, enter the minimum speed setting.

The purpose of the Setup Mode Fixed SPM parameter is to allow the user to enter a fixed speed that the OmniLink analog speed output will automatically set when a setup mode (usually INCH) is selected on a variable speed press. This feature requires a setup mode input as shown in Figure 2.16.

Section 4.2.3 Top Stop Calibration Menu Settings

Both stopping time and stopping distance (in degrees) vary greatly with press speed and depend on die weight and counterbalance pressure (if the press has a counterbalance).to a lesser degree. Before calibrating top stop for the OmniLink II press and Automation Control, it is advisable to set a die in the press and adjust the counterbalance (if the press has a counterbalance) to the proper pressure for the upper die weight used. It is preferable to use a die that has one of the heaviest upper die weights used in the press, since this can then be used to determine the Brake Monitor settings that you will make next as prescribed in Section 4.2.1.8. If you do place a die in the press for this calibration procedure, adjust the slide shutheight so that the dies don’t close as you perform the top stop calibration and the following Brake Monitor settings. The Top Stop Calibration menu, shown in Figure 4.12, is reached by pressing the Top Stop Calibrate softkey in the Main Configuration Menu.

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TOP

Stroke

Mode

Speed Adjusted Top Stop Calibration

1 2

3 4

5 6

Low Spe ed Degrees Bef ore To p Dead Center :

High Speed Degrees Before Top Dead Center :

Calculated Degrees Before Top Dead Center :

Drive

Speed

Stroke Speed

Low Speed RPM :

High Speed RPM :

Speed A t Stop Ini tiati on :

0 0

SPM

Order

Counter

Program/R un Swi tch

120 110

75 69

Counter OFF

SYSTEM STATUS

Spd. Adj . Top Stop

CHANGE NUMBER

Co A : Co B :

400 330

TOP STOP

MOTOR SPEED

EXIT

Figure 4.12 Speed Adjusted Top Stop Calibration Menu

There are 7 items indicated on the Speed Adjusted Top Stop Calibration Screen, which is used to calibrate top stop for both variable speed presses and fixed speed presses. These items are:

1. Low Speed SPM. This is a setting that must be entered for the lowest strokes/min for a variable speed press. For a fixed speed press, both the Low Speed SPM and the High Speed SPM of item 3 will be entered as the nominal speed of the press in strokes/min.

2. Low Speed Degrees Before Top Dead Center (00). This is an angle setting that must be entered to initiate a stop for a variable speed press stroking at the Low Speed SPM that will result in stopping within a couple of degrees of Top Dead Center. For a fixed speed press, the number entered here will be the same as for High Speed Degrees Before top Dead Center in item 4.

3. High Speed SPM. This is a setting that must be entered for the highest strokes/min for a variable speed press. For a fixed speed press, both the High Speed SPM and the Low Speed SPM of item 1 will be entered as the nominal speed of the press in strokes/min.

4. High Speed Degrees Before Top Dead Center(00). This is an angle setting that must be entered to initiate a stop for a variable speed press stroking at the High Speed SPM that will result in stopping within a couple of degrees of Top Dead Center. For a fixed speed press, the number entered here will be the same as for Low Speed Degrees Before top Dead Center in item 4.

5. Speed At Stop Initiation. This is a measured speed of the crank or eccentric at the angle that a stop signal intended to stop the press at TDC is initiated. It automatically appears each time the press strokes and intended to aid in the automatic top stop calibration process for variable speed presses. You cannot enter a setting for this item.

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6. Calculated Degrees Before Top Dead Center. For variable speed presses, the OmniLink II Press Automation Control uses a nonlinear equation whose coefficients are based on the settings made in items 1-4 for highest and lowest speed. This equation calculates the correct angle before TDC to apply a stop signal to stop the press at the top of the stroke based on the measured stroking speed, shown as the Speed At Stop Initiation in item 5. This angle appears on the screen each time the press stops as the number indicated as Calculated Degrees Before Top Dead Center, and will vary with actual stroking speed. This calculated number aids in refining settings in items 2 and 4 to stop near top as you perform the automatic top stop calibration for variable speed presses. You cannot enter a setting for this item.

7. Co A and Co B. These are the coefficients of the nonlinear equation that compensates the top stop signal for variable speed presses for different speeds. These numbers are based on the settings you make in items 1-4. They have no utility other than possibly being useful for troubleshooting with Link personnel over the phone. For fixed speed presses, these coefficients will both be 0 since both Low Speed SPM and High Speed SPM will be entered as the nominal speed of the press, and Low Speed and High Speed Degrees Before Top Dead Center will be set the same. You cannot enter

settings for these coefficients.

Section 4.2.3.1 Top Stop Calibration for Fixed Speed Presses

To set up the stop initiation angle for fixed speed presses:

1. Go to the Speed Adjusted Top Stop Compensation screen. Turn the Run/Program Switch to Program. Enter settings for both the Low Speed SPM and the High Speed SPM that are equal to the nominal press strokes/min. If the press legend plate indicates that the press strokes at a fixed 60 strokes/min, this is the value that should be entered. Enter settings of 00 for both the Low Speed Degrees Before Top Dead Center and High Speed Degrees Before Top Dead Center.

2. Turn the Run/Program switch to Run, select the Continuous mode of operation on the press control and initiate Continuous Stroking. After a few strokes, press the TOP STOP softkey on the Speed Adjusted Top Stop screen (do not

top stop the press using any top stop button that may be provided with the press control). Since both Low Speed and High Speed Degrees Before Top Dead Center were set to 0 in step 1, the OmniLink operator terminal will initiate a stop signal at Top Dead Center (00), and the press will travel into the downstroke before stopping. Look at the operator terminal angle display in the upper left corner of the display to read the angle at which the press slide comes to a stop. Since the stop angles (Low and High Speed Degrees before Top Dead Center) entered in step 1 were both 0, the reading on the angle display is the number of degrees the press took to stop.

3. Turn the Run/Program switch back to Program. Enter the number on the Operator Terminal angle display into both the Low Speed and High Speed Degrees Before Top Dead Center as an approximate setting

4. Return the Run/Program switch back to Run and initiate Continuous stroking again. Press the Top Stop softkey on the Speed Adjusted Top Stop screen and read the operator terminal angle display to observe where the press stopped. Since the stopping time and distance (angle) for the press may be different depending on the angular region over which the press stops, the settings in step 5 may not stop the press as close to the top as desired. To refine the adjustment, turn the Run/Program key

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to Program so that you can change the settings made in step 3. If the press has stopped X degrees beyond Top Dead Center, add X degrees to the settings made in step 3. If the press has stopped X degrees before Top Dead Center, subtract X degrees from the settings made in step 3.

5. Repeat step 4, if necessary, until the press is stopping within a few degrees of top each time you push the Top Stop softkey. It is normal for a small variation to occur in the stop angle of the press as the press is stopped multiple times.

Section 4.2.3.2 Variable Speed Press Auto Top Stop Calibration

Section 4.2.3.2.1 General Considerations

Variable speed presses take longer in time and further (in crankshaft degrees) to stop as stroke speed is increased. This is not a linear function because the energy stored in the rotating parts and the slide is a function of the square of the stroking speed. Signals that tell the press clutch/brake control when to start stopping so that the slide will top stop are generated from angular position indicating devices such as rotating cam limit switches or encoders, that are connected to the press crank or eccentric shaft. These can be adjusted by trial and error to give a stop signal at a crankshaft position in the upstroke that results in the press stopping at top. But on a variable speed press, as speed increases, the stopping distance will increase, causing the press to overrun its top of stroke position for a fixed setting of the angular position indicating device. Similarly, if the angular position indicating device is set to stop the slide at top at a high speed, the slide will stop short of top at lesser speeds. On presses with a wide speed range, a fixed stop signal may even result in the press stopping at or near bottom at some speeds instead of near top.

The OmniLink II Press Automation Control provides, as standard, an Auto Top Stop Compensation function for variable speed presses for top stop commands that it initiates to the press clutch/brake control in conjunction with faults detected by its production system monitoring functions that require top stop. This function is calibrated in the configuration mode of the OmniLink II so that, as speed increases or decreases, the top stop signal is sent at an earlier or later crankshaft angle as necessary to stop the press slide near top position.

In addition, IF the optional PLS/Logic Module is provided with the OmniLink II, it may be possible to use PLS relays in conjunction with the existing hard cams for some press controls on variable speed presses to auto compensate the anti-repeat function that stops the press near top in single stroke modes for changes in speed. It is often possible to use the existing cams associated with the clutch/brake control to set a default stop position at the lowest stroking speed and use the OmniLink II PLS outputs to give an earlier stop signal as speed increases. This must not be done if, when the existing hard cams are adjusted to stop the press at top at the lowest stroking speed, this adjustment would result in a stop

past 80

in the downstroke at the highest stroking speed. See the installation section of this manual.

WARNING! Never use the OmniLink II Press Automation Control PLS

outputs to simply REPLACE

the cams or other devices that provide the anti-repeat function (which automatically stops the press at the end of each stroke) required by OSHA standards for SINGLE STROKE MODE of a press clutch/brake control. The PLS outputs are not control reliable and may not stop the press if a failure occurs. Serious injury to operators can result if the press fails to stop at the end of a stroke as required in single stroke mode.

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It is IMPORTANT TO NOTE that the OmniLink II cannot provide Auto Top Stop Compensation for top stop signals that it does not initiate to the press clutch/brake control in automatic modes. Top stop signals from auxiliary equipment or top stop operator controls that are wired directly to the clutch/brake control cannot be compensated. Exception! If the anti-repeat cams used for single stroke are also the cams used to provide top stop in automatic modes, the PLS outputs used to auto top stop compensate the anti-repeat function in single stroke will also compensate top stop signals from auxiliary equipment and top stop operator controls in automatic modes. If approved by Link engineers, Link Systems SS501 controls with at least 4 mechanical cam switches available for use with the anti-repeat function may be augmented with PLS outputs from the OmniLink II Press Automation Control to provide auto top stop compensation from all top stop sources.

Section 4.2.3.2.2 Calibration Procedure for Variable Speed Presses

The suggested auto top stop calibration procedure for variable speed presses is as follows.

1. Go to the Speed Adjusted Top Stop Compensation screen. Turn the Run/Program Switch to Program. Enter a setting equal to the lowest strokes/min for the variable speed press for the Low Speed SPM. Enter a setting equal to the highest strokes/min for the variable speed press for the High Speed SPM. Enter settings of 00 for both the Low Speed Degrees Before Top Dead Center and High Speed Degrees Before Top Dead Center. With both Low Speed and High Speed Degrees Before Top Dead Center set to the same value, the press control will not calculate a stopping angle based on speed but will use the programmed setting (00) to generate a stop signal at all speeds.

2. Turn the Run/Program switch to Run, select the Continuous mode of operation on the press control, and set the speed of the press to the value entered for Low Speed SPM. If your system has the optional analog input/output card and it is set up to control stroking speed, press the Motor Speed Softkey in the lower left corner of the operator terminal and enter a speed setting equal to Low Speed SPM. If not, use the speed pot or other speed setting device for your variable speed drive to adjust stroking speed to the value entered for Low Speed SPM. Initiate Continuous stroking. After a few strokes, press the TOP STOP softkey on the Speed Adjusted Top Stop screen (do not top stop the press using any top stop button that may be provided with the press control). Since both Low Speed and High Speed Degrees Before Top Dead Center were set to 0 in step 1, the OmniLink operator terminal will initiate a stop signal at Top Dead Center (00), and the press will travel into the downstroke before stopping. Look at the operator terminal angle display in the upper left corner of the display to read the angle at which the press slide comes to a stop. Since the stop angles (Low and High Speed Degrees before Top Dead Center) entered in step 1 were both 0, the reading on the angle display is the number of degrees the press took to stop.

3. Turn the Run/Program switch back to Program. Enter the number shown on the Operator Terminal angle display into both the Low Speed and High Speed Degrees Before Top Dead Center as an approximate setting.

4. Return the Run/Program switch back to Run and initiate Continuous stroking again. Press the Top Stop softkey on the Speed Adjusted Top Stop screen after a few strokes, read the measured SPM displayed by the Speed At Stop Initiation on the Operator Terminal display and compare this number to the number you entered for Low Speed SPM. It is normal for speed to vary slightly throughout a stroke, and the measured SPM at the point the stop was initiated may be a few strokes/min different than the value set for Low Speed SPM. If so, change the number for Low Speed SPM to be the same as the measured Speed At Stop Initiation value.

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5. The stopping time and distance (angle) for the press may be different depending on the angular region over which the press stops. Thus, the settings for Low Speed and High Speed Degrees Before Top Dead Center made in step 3 may not stop the press as close to the top as desired. To refine the adjustment, turn the Run/Program key to Program so that you can change the settings made in step 3. If the press has stopped X degrees beyond Top Dead Center, add X degrees to the settings made in step 3. If the press has stopped X degrees before Top Dead Center, subtract X degrees from the settings made in step 3 for both Low Speed and High Speed Degrees before Top Dead Center.

6. Repeat step 4, if necessary, until the press is stopping within a few degrees of top each time you push the Top Stop softkey at the Low Speed SPM. It is normal for a small variation to occur in the stop angle of the press as the press is stopped multiple times.

7. Now that the stop at Low Speed SPM has been calibrated, set the press stroking speed to the highest stroking speed, stroke the press in Continuous a few strokes and press the Top Stop softkey to stop the press. Compare the measured speed displayed as Speed At Stop Initiation on the Operator Terminal with the value you entered into the High Speed SPM. If different, change the setting for High Speed SPM to the measured value. Since the press was stroking at a higher speed, it will have gone well past Top Dead center before stopping. Also, verify that the calculated stop initiation angle displayed as Calculated Degrees Before Top Dead Center is the same as the value programmed for both Low Speed and High Speed Degrees Before Top Dead Center.

8. For high speed presses, the press may take more than one stroke or even multiple strokes to stop at the high speed, so the angle at which the press stops could be anywhere in the stroke. Regardless of whether the press stops in less than a stroke or more than one stroke, calculate an approximate angle setting to replace the current High Speed Degrees Before Top Dead Center by adding the angle displayed on the Operator Terminal angle display (which shows where the press actually stopped) to the angle displayed for Calculated Degrees Before Top Dead Center. Turn the Run/Program switch to Program and replace the existing High Speed Degrees Before Top Dead Center setting with the approximate angle setting calculated by the method in the previous sentence.

9. Return the Run/Program switch back to Run and initiate Continuous stroking again. Press the Top Stop softkey on the Speed Adjusted Top Stop screen after a few strokes and read the Operator Terminal angle display to see where the press stopped. Since the stopping time and distance (angle) for the press may be different depending on the angular region over which the press stops, the approximate setting made for High Speed Degrees Before Top Dead Center made in step 8 may not stop the press as close to top as desired. To refine the adjustment, turn the Run/Program key to Program so that you can change the setting made in step 8. If the press has stopped X degrees beyond Top Dead Center, add X degrees to the setting made in step 8. If the press has stopped X degrees before Top Dead Center, subtract X degrees from the settings made in step 8 for both Low Speed and High Speed Degrees before Top Dead Center.

10. Repeat step 9, if necessary, until the press is stopping within a few degrees of top each time you push the Top Stop softkey at the High Speed SPM. It is normal for a small variation to occur in the stop angle of the press as the press is stopped multiple times. How much variation occurs depends on the stopping characteristics of the press.

11. As a final step, stay in the Speed Adjusted Top Stop Calibration menu and stroke the press in

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Continuous mode at various speeds between the low and high speeds. For each speed, press the Top Stop key and verify that the press stops within a few degrees of top for each speed.

Section 4.2.4 Operator Terminal Configuration

Section 4.2.4.1 Top Area (Screen) Display Configuration

Pressing the OPERATOR TERMINAL softkey on the Main Configuration menu causes the Top Display Area Configuration Screen shown in Figure 4.13 to be displayed.

When in a Setup Mode (Inch, Timed Inch, Etc. )

Area 1 : Area 2 : Area 3 : Area 4 :

Figure 4.13 Top Display (Screen) Area Configuration.

The OmniLink II LCD Operator Terminal provides for some user customization of the information displayed in the top areas of the screen to the right of the angle display. When any of the items beside Area 1, Area 2, etc. at the top of the screen are highlighted pressing the change setting softkey will cause a box to appear listing all items not already currently assigned to another area. Select the desired item and press the ENT(ER) key. The currently available items are:

1. Drive Speed. Speed at which a variable speed drive will cause the press to stroke when the clutch is engaged -- requires optional Analog Input/Output Card for the R/D-Brake Monitor Module

2. Stroking Speed. Actual crankshaft SPM -- available only when the press is actually stroking

3. Auto Press Speed. Drive speed when press is not stroking and crankshaft speed when the press is stroking-- requires optional Analog Input/Output Card for the R/D-Brake Monitor Module

4. System Status. Diagnostic messages that indicate anything that prevents the start of stroking

5. Reason for the Last Stop. Diagnostic message that gives the reason for the last stop

6. Total Tonnage. If the system is equipped with optional Tonnage & Signature monitor

Stroke

Mode

Top Display Area Configuration

Drive Speed Stroking Speed Shut Hei ght System Status

Date :

4/24/2002

Time :

10:20:46 AM

Rod/Stroke Units :

Rod Length :

Stroke Length :

Default Language : English

0.000 in

Drive

Speed

Stroke Speed

SPM

0 0

SPM

When in a Production Mode (Single S troke, Cont. , E tc. )

Area 1 : Area 2 : Area 3 : Area 4 :

Drive Speed Stroking Speed Order Counter System Status

Order

Counter

Counter OFF

SYSTEM STATUS

Top Disp Config

CHANGE SETTING

ZERO STROKE COUNT

ACCESS CONFIG

AUXILIARY COMM SETUP

EXIT

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7. Counterbalance Pressure. If the control is equipped with optional automatic counterbalance adjust

8. Shut Height. If the system is equipped with optional automatic shut height adjust

9. Current Order Count

10. Current Down Time Code. If the optional LinkNet shop floor information system is used

11. Distance to Bottom. Available only if you enter settings for the Rod Length and Stroke Length of the press in this menu

The four items selected by the user for display can be mode dependent if the user can provide an

isolated input to the operator terminal derived from the press clutch/brake control to indicate when the setup mode (usually Inch) is selected. The user has the option to choose four items for setup

mode and four different items for production modes when this setup mode input is available and when the Use Mode Input setting is set to yes in the Machine Parameters Menu. Only one group of four items will be displayed for all modes if no setup mode input is provided.

You may also make settings for the real time clock of the operator terminal on this screen to correct discrepancies or change to daylight savings time.

The operator terminal can convert crankshaft angle into distance from bottom of stroke and display this distance if you enter the connection rod length from crank to slide and the stroke length of the press. Before entering Rod Length and Stroke Length, note that the default Rod/Stroke Units setting is in(inches). If a setting in mm(millimeters) is desired, select Rod/Stroke Units and press the CHANGE SETTING softkey to toggle the setting to mm. Enter settings for Rod Length and Stroke Length in the dimensional units chosen for Rod/Stroke Units.

The OmniLink II LCD Operator Terminal provides both Spanish and English screens as standard. The Default Language setting on the Top Display Area Configuration screen determines which language will automatically be presented on power up of the system. If Default Language is set to English, the screens will appear in English upon power up and the CHG key can be used to toggle the language between English and Spanish. Configure Spanish as the Default Language setting on this screen if you wish Spanish as the desired language each time the system is powered up.

Section 4.2.4.2 Zeroing Stroke Count

The Stroke Counter for the OmniLink II Operator Terminal cannot be reset or changed in either Run or Program screens since it is intended to count cumulative strokes the press makes from the time the OmniLink Press Automation Control is installed. However, if you wish to zero the stroke counter because you reinstall the OmniLink system on another press, or for other reason, press the ZERO STROKE COUNT key on the Top Display Area Configuration screen. This will result in a code entry box appearing on the screen as shown in Figure 4.14.

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Stroke

Mode

Top Display Area Configuration

When in a Setup Mode (Inch, Timed Inch, Etc. )

Rod/Stroke Uni ts :

Stroke Length :

Defau lt Languag e : E ngli sh

Date :

Time :

Rod Length :

4/24/2 002 10:20 :46 AM

0.000 in

Drive

Speed

Stroke Speed

When in a Production Mode (Single Stroke, Cont. , Etc. )

Enter Code # :

SPM

0 0

SPM

Order

Counter

SYSTEM STATUS

Counter OFF

Top Disp Confi g

CHANGE SETTING

EXIT

Figure 4.14 Code Entry Screen to Zero Stroke Count

Entering the two digit code sent for zero stroke count sent separately from your unit for security purposes and pressing the ENT(ER) key will set the stroke counter to zero.

Section 4.2.4.3 Key/Code Access Configuration

As described in Section 3, the OmniLink II Press Automation Control provides a user configurable security system to limit access to system settings and actions to those authorized by the employer. The configuration menu of the OmniLink II Press Automation Control is used to select how settings and other operations, such as reset of faults, job storage and job recall may be done and who may perform these actions. Settings, reset, bypass, and job storage actions fall into four access categories:

1. Those parameter settings that may be made only

in the Configuration Menus, which can only be accessed by a person(s) using the Program/Run key and the highest user level password, the User Configuration Code. These settings include those settings that are based on machine characteristics such as stroke length, top stop angle, etc., and those settings that relate to safety issues, such as brake monitor limits.

2. Configuration settings made in the configuration menu at the user’s discretion to either allow certain reset/bypass actions to be made by anyone at any time, or to require a key/code permission to restrict access to reset/bypass functions to those persons specifically authorized by the user. Die protection reset or bypass is an example of actions that could be restricted or not.

3. Configuration settings made in the PLS Configuration Menu to choose whether settings for individual channels of a PLS (programmable limit switch) are restricted from being changed even by persons who have key/code access to make settings for PLS channels. Of course the person with key/code access could still make settings for those PLS channels that are not restricted in the configuration menu.

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4. Those settings and operations that the system always requires Key/Code access to Program Mode to make.

Section 4.2.4.3.1 Choosing Access Mode

Access configuration begins with choosing Access Mode on the Access Configuration screen shown in Figure 4.15. This screen appears when the ACCESS CONFIG softkey on the Top Display Area Configuration screen of Figure 4.13 is pressed.

TOP

1 2 3

Access Timeout: Access Timeout:

User Description Used Opera tor Level # 1 Yes Opera tor Level # 2 Yes Setup Yes

Stroke

Mode

Access Mode:

Drive

Speed

Single Stroke

ACCESS CODE CONFIGURATION

Key Only

20 Secon ds 10 Strokes

Stroke Speed

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

0 0

SPM

Order

Counter

Access Mode: “Key and Code” requir es acce ss code and RUN/PROG Key for any changes. “C ode Only” requires access code and ignores RUN/PROG Key. “Key or Code” requires an access code or the RUN/PROG Key but not both. “Key Only” requires RUN/PROG Key and does not use access code.

PC STATUS

Program/R un Switch

HELP

Counter OFF

ACCESS CONFIG

SET CONFIG. CODE

RESTRICT/ UNRESTRICT ACTIONS

EXIT

CHANGE SETTING

CHANGE NUMBER

EDIT USER

Figure 4.15 Access Configuration Screen

There are four access modes available for those settings and actions that are restricted to Key/Code access. These are Key and Code, Code Only, Key or Code, and Key Only. These modes are explained in Section 3.9. The access mode selected applies to all users. Note! If Key Only access mode is

chosen, you will not have to perform the calibration steps related to Access Timeout or user descriptions and codes that are described in the following sections. You will need to choose to choose to restrict or unrestrict the certain actions as described in Section 4.2.3.4.1.

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

Section 4.2.4.3.2 Settings and Actions That Can Be Restricted to Program Mode Only or are

Available in Both Run and Program Modes

Regardless of which access mode is chosen in the previous section, there are a few commonly

performed actions and settings that the system allows the user to choose to be restricted to Program Mode only or to be done in Run Mode screens as well as Program mode. To configure whether these items are restricted to program mode or not, press the RESTRICT/UNRESTRICT ACTIONS softkey on

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the Access Configuration screen shown in Figure 4.15. The Restrict/Unrestrict configuration screen shown in Figure 4.16 will be displayed.

The following permissions can b e set to allow anyone access to the actions listed at any time. If “Yes” APPEARS AFTER THE LISTED ACTION THEN NO PROGRAM KEY OR CODE WILL BE REQUIRED TO PERFORM THE ACTION! User permissions as set in the “Us er Configuration” screen will be overridden by these settings.

Stroke

Mode

Drive

Speed

Stroke Speed

0 0

SPM

Order

Counter

SYSTEM STATUS

Counter OFF

Restr ict/ Unrestri ct

CHANGE SETTING

ACTIONS THAT REQUIRE NO KEY OR CODE

DP Limited Bypass :

Motor Speed Adjust :

TM Rese t :

DP Reset :

Auto Setup Reset :

Counter Reset :

Counter Settings :

Counter Change :

Yes

No Yes No No No Yes No

EXIT

Figure 4.16 Restrict/Unrestrict Actions Configuration Screen

The actions listed on this screen are those current at the time this manual was written. Later versions of OmniLink II software may list additional actions to restrict or unrestrict. With the exception of actions related to Counters, which are standard, the actions listed need to be configured only if the optional hardware for these functions is used with the system. For example, if no Tonnage Monitor is used with the system, simply leave the TM Reset setting as “No”.

Select (highlight) the settings for all actions listed on the screen that you wish to be unrestricted and press the CHANGE SETTING softkey to toggle the setting to “Yes”. Use settings of “No” if you wish the action to be restricted to Program Mode.

Section 4.2.4.3.3 Setting Access Timeout

If an access mode that uses a code is chosen, you should make Access Timeout settings. A user that

gains access by using his code (password) will be logged in until he manually logs out or is automatically logged out. See Section 3.9.3. Automatic log out can be either time based or stroke based. The log out time and the log out number of strokes are programmed in the Access Configuration menu shown in Figure 4.15.

The timed log out is based upon the time between keyboard activity. If the user does not press any key on the operator terminal within the time programmed, the control will automatically log out the user. To program the Access Timeout time move the cursor to Access Timeout time, press the Change Number softkey, enter the desired time, and press the ENT key. This time can be programmed from 0 to 999 seconds. A timeout time of 0 seconds turns off the timed log out. If the Access Timeout time is set to 0 seconds, there is no time based automatic log out.

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The stroke log out is based upon a number of press strokes between keyboard activity. If the user does not press any key on the operator terminal within the number of strokes programmed, the control will automatically log out the user. To program the Access Timeout number of strokes move the cursor to the Access Timeout strokes, press the Change Number softkey, enter the desired time, and press the ENT key. The number of strokes can be programmed from 0 to 999. An Access Timeout strokes setting of 0 strokes turns off the stroke based automatic log out, and there will be no stroke based automatic log out.

Section 4.2.4.3.4 Editing Users

If an access mode that uses a code is chosen (any mode besides Key Only), the system allows for up

to sixteen users to have the ability to gain access to Program mode through individual codes. Each user can be assigned a name and a password. The Access Configuration menu is used to select a user and to enter the user edit menu. To edit a user, position the cursor on a user name to be edited (or a blank space if a user is to be added) under the User Description in the Access Configuration screen shown in Figure 4.15 is and press the EDIT USER softkey. The User Configuration menu, Figure 4.17, will be displayed.

Stroke

TOP

1 2 3

PLS Settings/Names:

TM Peak High Limits:

TM Peak Low Limits:

TM Reverse Limits:

TM Data Windows:

Auto Setup Settings:

Single Stroke

Mode

USER CONFIGURATION

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

PLS Bypass:

TM Bypass:

TM Reset:

DP Bypass:

DP Reset:

DP Settings:

Auto Setup Reset:

Counter Reset:

Counter Settings:

Figure 4.17 User Configuration Menu

Drive

Speed Stroke

Speed

PERMISSIONS

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

SPM

0 0

SPM

Counter Change:

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

Special Interface:

Auto SS/COD Time:

Reset Brake Monitor:

Store Jobs:

Recall Jobs:

Erase Jobs:

Order

Counter

PC STATUS

Program/Run Switch

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

Counter OFF

USER CONFIG

EXIT

CHANGE TEXT

CHANGE NUMBER

CHANGE SETTING

When the “User” setting is selected, pressing the CHANGE TEXT softkey will cause the popup text entry box to appear, so that an alphanumeric name or description can be entered for “User”. Selecting the “Code” setting allows entry of up to a 4 digit number. The “Used” setting can be toggled between “Yes” and “No” by use of the CHANGE SETTING softkey to quickly turn the ability of a user to access the Program Mode off and on without having to reprogram all settings.

Once the user has been assigned a name, code, and a “Yes” setting has been entered for “Used”, a list of settings and actions that a particular user is allowed, or not allowed, to perform can be configured. Select each setting listed under PERMISSIONS and press the CHANGE SETTING softkey to assign a “Yes” or “No” for the setting or action.

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Note! The list of permissions shown on the screen is shown as an example. New software versions and hardware modules developed to perform new functions may add to this list. Also, any action that was chosen to be unrestricted in the screen of Figure 4.15 will appear in red in the permissions list and such actions will not be restricted to Program Mode, regardless of whether you select “Yes” or “No” under the used column for this item.

Section 4.2.4.3.5 Changing the User Configuration Code

Pressing the SET CONFIG. CODE softkey in the Access Configuration Menu, Figure 4.15, will display the User Configuration Code screen, Figure 4.18. This screen allows the User Configuration Code to be changed. This is the configuration code that protects against access to configuration screens by untrained and/or unauthorized persons. It is imperative that this code be given only to authorized personnel who are familiar with the control and with the consequences of incorrect parameter settings.

This Configuration Code is used to gain access to ALL config uration screens associated with both sta ndard and op tional features of the Automation Control. This code should only be known to persons who have the technical knowledge and the authorization of the employer to configure the Automation Control.

Caution! Certain configu ration settings, such as Brake Monito r limits, affect safety considerations. Others can affect whether elements of the production system are properly controlled or monitored by the OmniLink II Press Automation Control.

Make sure you record and keep this code in a secure place. If it is lost, you will have to contact Link Systems to restore access to the configuration screens.

Stroke

Mode

Drive

Speed

Stroke Speed

0 0

SPM

Order

Counter

Program/R un Switch

Counter OFF

SYSTEM STATUS

Config. Code

CHANGE NUMBER

Configuratio n Cod e :

Up to 4 digit configurati on code appea rs here

EXIT

Figure 4.18 User Configuration Code Screen

The original configuration code is set at the factory. It is suggested that this code not be changed unless the security of the configuration code has been jeopardized. If a configuration code has been obtained by persons you do not wish to access the configuration parameters, it must be changed. When this code is changed, the previous code will no longer be valid. The new code should be documented and stored in a secure place.

If the current User Configuration Code is lost, the factory must be consulted to restore access to configuration screens.

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

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Section 4.2.4.4 Auxiliary Communications Setup

The AUXILIARY COMM. SETUP softkey provides access to the configuration screens for the communication options. These options include serial communication ports for interfacing to electronic servo feeds, auxiliary equipment (such as PLCs), a laptop interface for downloading messages, and a network interface. See the manual pertaining to the particular device that is connected for communication for auxiliary communications setup for that device.

Section 4.2.5 Auxiliary Equipment Messages

The OmniLink II Press Automation Control makes provision to wire inputs to its parallel port on the back of the operator terminal from the intelligent controller (such as a PLC) of auxiliary equipment so that diagnostic messages from auxiliary equipment can be displayed on the brake monitor screen of the operator terminal. Wiring is shown in Figures 2.20 in Section 2.6 of this manual. The OmniLink II operator terminal interprets inputs 2 – 8 on the parallel input port as binary number bits with input 2 representing 20 (the least significant binary bit) and input 8 as 26. Input 1 on the parallel port must be connected to the ground of the controller sending the signals to inputs 2-8. The 128 binary numbers available for message codes and their decimal equivalents are:

Binary Decimal 0000000 0 0000001 1 0000010 2 0000011 3 0000100 4 0000101 5 0000110 6 0000111 7 etc. etc.

The message codes sent to the parallel port from auxiliary equipment may indicate conditions that prevent stroking the press, such as “Feed Fault”, or may simply give information about the status of auxiliary equipment, such as “Feed Automatic Mode” or “Feed Manual Mode”. In either case, the person that programs the PLC to send the desired message codes needs to prioritize the messages sent to the parallel port in case several conditions that are assigned a message code are present at the same time.

Generally, all message codes from auxiliary equipment that are associated with the assertion of a stop signal from auxiliary equipment to the press clutch/brake control should take priority over messages that provide status information. A simple way to prioritize is to always have the PLC assert the lowest binary number message code when more than one condition exists. Assign all message codes associated with the assertion of a stop signal from auxiliary equipment to the press clutch/brake control to a lower group of binary numbers. Also, within this group, the lower the binary number the higher the priority in the order that you want the message displayed. Assign all messages associated with status information (and no associated stop signal) to a higher group of numbers than those message codes associated with stop signals from auxiliary equipment to clutch/brake control. Again, within this group, the lower the binary number assigned, the higher the priority in the order that you want the message displayed.

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To enter the alpha-numeric messages associated with each input message code (number) go to the Auxiliary Names configuration screen shown in Figure 4.19. This screen is accessed from the Main Configuration menu shown in Figure 4.5 by pressing the NAMES softkey. To turn the auxiliary equipment message option ON, press the OPTION ON/OFF key.

Number Descrip tion

000 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 001 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 002 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

003 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 004 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 005 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 006 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 007 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 008 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 009 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 010 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 011 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 012 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 013 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 014 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 015 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Stroke

Mode

Auxil iary Eq uipme nt Message OFF

Drive

Speed

Stroke Speed

SPM

0 0

SPM

Order

Counter

SYSTEM STATUS

Counter OFF

Auxil iary Names

CHANGE NAME

NEXT GROUP

OPTION ON/OFF

ERASE NAME

EXIT

Figure 4.19 The Auxiliary Equipment Message (Names) Configuration Screen.

To enter or edit messages, select the desired message number to edit and press the CHANGE NAME softkey. The Text Entry screen in Figure 4.20 will appear to allow message entry (see Section 3.8). For messages indicate conditions where the auxiliary equipment asserts a stop to the clutch/brake control, it is useful to start the message with “STOP:” and then state the diagnostic message.

Number Descrip tion

003 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 004 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 005 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 006 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 007 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 008 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 009 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 010 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 011 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 012 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 013 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 014 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - 015 - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -

Stroke

Mode

Auxil iary Eq uipme nt Message OFF

Use K eys to s elect letter Press E NT to s ave tex t

ABCDEFGHIJKLMNOPQRSTUVWXYZ.+-=()%<>/

Drive

Speed

Stroke Speed

SPM

0 0

SPM

Order

Counter

SYSTEM STATUS

Counter OFF

Text Entry

ABORT ENTRY

CURSOR LEFT

CURSOR RIGHT

SPACE

SELECT LETTER

LOWER CASE

EXIT

Figure 4.20 The Text Entry Screen for Auxiliary Equipment Messages (Names)

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Section 5 Using the OmniLink II Press Automation Control Standard

Functions and Optional Speed Adjust Function

Read Section 3 of this manual for a general understanding of the use of the operator terminal before reading this section. The Main Menu (screen) of the OmniLink II Press Automation Control (Figure 5.1) provides a view of the major functions available and brief status information for each function. The operator may select the system standard Brake Monitor, Module Limit Switch, Job Setups, and Counters screens available with the base system hardware (Operator Terminal, R/D-Brake Monitor Module, resolver and its cable) by pressing the softkey adjacent to the softkey legend area on the screen. The Speed Adjust softkey legend will also appear on the Main Menu if the press is a variable speed

press and the optional Analog Input/Output board is provided and used with the system to adjust stroking speed.

Screens associated with PLS/Logic, Automatic Setups, Tonnage & Signature Monitor, Die Protection & Process Monitor, and Analog Monitor functions are also accessed from the Main Menu by pressing the softkey adjacent to their softkey legend area on the display if your system has the optional hardware modules associated with these functions. The optional Serial Feed Interface and PLC Interface functions are also performed with the base system hardware, but special software must be activated to perform these functions. These functions are accessed by pressing the ACC key, which brings up the Quick Access screen for frequently used functions.

NOTE! Only the Brake Monitor, Job Setups, Counters, Module Limit Switch, and optional Speed Adjust optional functions will be covered in this section of this manual. Functions enumerated in

the second paragraph of this subsection such as PLS/Logic, Automatic Setups, etc will be individually covered in subsequent sections of this manual. The optional Serial Feed Interface and PLC Interface functions will be covered in separate manuals provided when your system has these options.

Section 5.1 Main Menu (Screen)

Figure 5.1 shows the Main Operating Menu for the OmniLink II Press Automation Control in Run mode. The central area of the LCD display provides the following information.

• The current job number and the job description.

• The Order and Batch Count and associated limits.

• The status of the functions described by the softkey legends along the right side of the display.

• A Strokes/Min bar graph and numeric value only if your system is on a variable speed press and you

use the optional Analog Input/Output board to report SPM.

• A % Motor Load bar graph and numeric value only if your system uses the optional Analog Input/Output board to report motor load.

The softkeys on this screen are used only to navigate to other screens. There are no settings that can be made on this screen and no additional screens that can be accessed by softkeys from this menu when in Program mode. When you turn the Run/Program key to Program, this screen remains the same.

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St roke

TOP

Mode

JOB NUM. DE SCRIPTION

100000 FRO NT BRACKET

COUNTER LIMIT QUANTITY

ORDER BATCH

200 0

500

SP M 0

% LOAD

161

SP EED

ADJUST

OmniLink II LCD

OPERATOR TERMINAL

Drive

Spee d

St roke Spee d

7 7

SP M

0 0

SP M

STATUS:

STATUS: ALL CONDITIONS OKAY

STATUS:

ALL CONDITIONS OKAY

STATUS: ALL CONDITIONS OKAY

STATUS:

ALL CONDITIONS OKAY

STATUS:

ALL CONDITIONS OKAY

Orde r

Counter

SY STEM STA TUS

READY TO STROKE

JOB SE TUPS

Count er OFF

MAIN SCREE N

BRAKE PRE SS

MONITOR

CONTROL

AUTO

SE TS

TONNAGE MONITOR

DIE

PROT ECTIO N

LIMIT

SWI TCH

ANALO G MONITOR

COUNTERS

CHG

ACC

789

456

12 3

CLR ENT

LINK ELECTRIC & SAFETY CONTROL CO.

444 McNALLY DR. NASHVILLE, TN 37211

PHONE (615) 833-4168

PROG RUN

Figure 5.1 Main Menu of the Operator Terminal

Section 5.2 Brake Monitor and Diagnostic Screen

Pressing the Brake Monitor softkey causes the Brake Monitor and Diagnostic screen to appear. This screen is shown in Figure 5.2.

TOP

Bra ke Mon ito r Limit Stop time

Top Stroke Stop 0200 183 mSec

Mid Stroke Stop 0250 0 mSec

Clutch time 0275 0250 mSec

Auto S ingle Stroke Ti me ……… 5 Se c

Stop ping De gree s: 57

Fee d Complete Position ……… 25 Degs

Cont. on Demand Time ………. 10 Mins

Au xiliary Equipm e nt M ess age

Option is not Installe d

Rea son fo r th e La st St op

Power Up

Pr esen t Running St a tus

Rea dy to Strok e

CONFIGURE

Figure 5.2 The Brake Monitor and Diagnostic Screen

Stroke

Sing le Str oke

Mode

Limit Actual

Crit ic al Ang le : 1 45

Die Protection S top

AUXILIARY

COMM.

Drive

Speed Stroke

Speed

APPEARS ONLY IN PROGRAM MODE

ANALOG PROC MON

0 0

DIAGNOS

SPM

SP M 0

OPERATOR STATON

Order

Counter

S YSTEM STATUS

READY TO STROKE

% LOAD 161

Counter OFF

PC STATUS

Brake

PRE SS

Monitor

CONTROL

SUP PLY CHANG E ACCESS NUMBER CODE

SP EED

MOTOR

ADJUST

SP EED

TONNAGE

MONITOR

AUTO

RESET

SETS

ERROR

AUTO

FAULT

SE TS

DIE

PROT ECTIO N

MODULE LIMIT SWITCH

EX IT

The SUPPLY ACCESS CODE Sof tke y leg end wil l not pre se nt if Ke y On ly acces s mode is chose n in the configuration menu. This area will be blank in Run a nd will have CHANGE NUMBER in P rogr am.

Optional

Ap pears O nl y W hen Fault Exis ts or in P rogr am Mode fo r Brak e Mo ni t or fault when Key Only access is chosen.

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The central portion of the display provides the following information:

1. A brake monitor used when the press stops at the top of the stroke.

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

3. The actual last stopping time of the press, measured by the brake monitor, and stop time limits

that can be independently set for top stops and stops at any position other then stop.

4. Clutch engagement time monitor with preset limit and actual measured clutch engagement time.

5. A Critical (Stop) Angle which may be set for each job for use with the intellistop function of die

protection and process monitoring. This is the only setting (made in Program Mode) on this screen.

6. Stopping Degrees – the number of degrees traveled during the last stop of press stroking

7. Messages from auxiliary equipment if this option is used.

8. Reason for the Last Stop. A diagnostic message that indicates the last event that caused the press

to stop stroking.

9. Present Running Status. Diagnostic messages that indicate any event or condition that is keeping

the press from stroking.

Section 5.2.1 Brake Monitor

The OmniLink II Press Automation Control incorporates a control reliable brake monitor that measures stopping time and stopping angle every time the press stops, regardless of stopping position. Separate stop time limits are provided for top stops and stops at positions other than top (mid-stroke). This is because stopping time usually varies with stopping position, with worst case stopping time usually occurring at mid downstroke. The separate top stop and mid-stroke limits allow relatively tight limits to be set for top stop time without causing nuisance brake monitor alarms when longer mid-stroke stopping occurs. Since the system knows whether the slide top stops, or stops elsewhere in the stroke, it automatically displays the stopping time as a top stopping time or a mid-stroke stopping time and compares it to the top stop or mid-stroke limit as appropriate.

The stop time limits for both top stop and mid-stroke stopping are set in the Machine Parameters configuration menu as described in Section 4.2.1.8 of this manual. The settings may be made with 2msec resolution.

If the actual stop time at either top stop or mid-stroke stop exceeds its preset limit, the Present Running Status diagnostic message will read “Brake Monitor Alarm” highlighted in red, and the actual stop time shown by the brake monitor display will also be highlighted in red. Further stroking will be prevented until the brake monitor is reset.

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WARNING! When your press is equipped with two-hand control devices and/or presence sensing devices for point of operation protection, only qualified personnel with a knowledge of the latest ANSI (B11.1), OSHA (CFR 1910.217), and other regulations that govern the relationship 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 on which the safety distance is based.

Section 5.2.2 Clutch Engagement Time Monitor

The clutch engagement time is measured each time the clutch/brake valve is engaged as the time from valve activation until crankshaft rotation exceeds the "minimum strokes/min" threshold. If the actual time exceeds a maximum limit, the stroke is aborted and the Reason for the Last Stop diagnostic message will be “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). If this message appears, you can reset the fault and try to stroke the press again, but generally the same fault will occur again.

The Clutch Engagement Time Limit is used two ways by the system. First, the Motion Detector which makes sure the resolver is turning when the press is stroking will not stop stroking at the beginning of a stroke as long as motion starts within the time limit set for clutch engagement. Secondly, the Clutch Engagement Time limit provides useful diagnostic information relating to clutch wear. As clutch plates wear, increasing the volume of air that must flow into and be stored in the clutch air operator, clutch engagement time gradually increases. The increased volume of air stored in the clutch also takes longer to flow out when the air valve dumps pressure to stop stroking, resulting in longer stopping time for the press and perhaps tripping out the brake monitor. Most (though not all) presses provide for adjustment or shimming to compensate for clutch wear. In some, you must replace the friction plates when worn by a certain amount. Exceeding the clutch engagement time limit tells you that clutch adjustment or shimming should be performed. When possible, it is preferable to adjust the clutch clearance to the press manufacturers recommended setting to determine the clutch engagement time with optimum clearance.

Section 5.2.3 Critical Angle and Intellistop

The critical angle setting on the Brake Monitor and Diagnostic screen is used, in conjunction with Link’s Intellistop stop function, to decide whether to apply an Cycle Stop (immediate stop) or a Top Stop to press stroking. When sensors associated with Die Protection, Analog Process Monitor, or PLS/Logic inputs detect a fault, each channel monitoring a sensor has a choice of Cycle Stop, Top Stop or Intellistop settings that the user may program for each job. Generally, when a sensor detects a fault, the ideal situation is to either Top Stop or Cycle Stop the press before the dies close again to prevent possible damage to the die or press. But whether this can be done depends on where in the press cycle the fault is detected and how many crankshaft degrees are traveled after the stop signal is applied. If press stroking cannot stop when a sensor detects a fault before the dies close, it is then usually best to apply a Top Stop to prevent the possibility of sticking the press on bottom (dies closed).

When the Intellistop setting is chosen for a sensor channel, the OmniLink II Press Automation Control automatically makes the decision to Cycle Stop or Top Stop stroking. It makes this decision based

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on where in the stroking cycle the fault occurs and how many degrees the press crankshaft will travel after the stop is applied. Figure 5.3 illustrates the Intellistop function.

TOP STOP ANGLE

BLA CK AR C - CYC LE STO P GRAY ARC - TOP STOP

INTELLISTOP ANGLE

BLA CK ARC - CY C L E STO P GRAY ARC - TOP STOP

INTELLISTOP ANGLE

180

CRITICAL ANGLE

TOP STOP ANGLE

180

CRITICAL ANGLE

a. Intellistop at Lower SPM b. Intellistop at Higher SPM

Figure 5,3 Illustration of Speed Advanced Intellistop Function

The terms used to describe various angles in Figure 5.3 and the way they may be determined are as follows.

1. Critical Angle. The critical angle for a given die in a given press is the greatest downstroke angle that can occur without upper die parts closing on material or lower die parts. The top of the press stroke occurs at the 00 position of crank or eccentric shaft and the bottom at the1800 position as shown in Figure 5.3. The downstroke angle at which the upper die closes on material depends on the die design. Draw Dies may close on material at a downstroke crank angle of as little as 1000, i.e., several inches above the bottom of the stroke. Blanking dies may not close on material till the downstroke crank angle is 1700 or more, i.e., only a fraction of an inch above bottom of stroke. Any stop signal that results in stopping beyond the critical angle increases risk of sticking the press on bottom. Any stop signal that causes the press to stop before the critical angle will keep the press from sticking on bottom and reduce the risk of damaged die or press.

Determine critical angle for a set of dies with the dies in the press and adjusted to their proper shutheight. Inch the press slide downward until just before dies close on material and then stop the inching process. Actually, it is preferable to determine where the dies would close on a double thickness or more of material, since a fault may result from a condition that could cause a double or greater thickness of material in the die. Once you have inched the slide to the position described in the preceding sentences, observe the angle display at the upper left of the operator terminal display. Enter a critical angle setting equal to the angle indicated on the display.

2. Intellistop Angle. The Intellistop angle is the last angle at which a Cycle Stop signal may be given to stop the press at or before the critical angle. The press crankshaft will turn through an angular arc that represents angular stopping distance in degrees. The angular stopping distance depends on upper die weight, counterbalance pressure (when the press has a counterbalance), brake and clutch wear, and stroking speed if the press is a variable speed press.

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The Intellistop angle is automatically computed by the OmniLink based on the angle of travel during top stopping. The angle labeled Top Stop Angle in Figure 5.3, is the angle at which a stop signal must be given which will result in the press stopping on top (00). The angular distance traveled in top stopping is also used to compute the Intellistop angle. For a variable speed press, both the top

stop and the Intellistop angle are automatically advanced to compensate for the increased stopping distance at higher speeds as shown in Figure 3.5. The mechanics of stopping in the

downstroke are somewhat different than stopping at top of stroke. Also gradual clutch and brake wear will increase stopping distance. For this reason, it is advisable to subtract about 100 from the critical angle as determined in the preceding item 1 of this discussion to allow for these factors.

Another aid to determine the angular stopping distance, is the Stopping Degrees display shown below Critical Angle on the operator terminal display. This angular stopping distance is

measured and displayed every time the press stops regardless of where in the press stroke the stop occurs. You can stop the press such that it stops in the downstroke and read the actual stopping distance from the display. Of course, this is also a great aid in determining whether a regular Top Stop or Cycle Stop setting should be chosen for cyclic sensor channels where the fault will occur within a known timing window.

Thus, as shown in Figure 5.3, if Intellistop is chosen for a sensor channel, the order of stopping will be as follows.

• If a sensor fault occurs after the Intellistop Angle but before the Top Stop Angle, a Top Stop will result.

• If a sensor fault occurs after the Top Stop Angle but before the Intellistop Angle a Cycle Stop will result.

NOTE! Intellistop will revert to Top Stop if the angular stopping distance of the press exceeds

1800.

It is not necessary to determine the Critical Angle each time the die is used in the press. Once the Intellistop angle is initially determined, it will be stored as part of the job by the OmniLink and recalled with the job. As stopping distance can gradually increase with brake wear and clutch wear, it may be necessary to adjust the clutch and brake periodically to maintain stopping at or before the critical angle.

Section 5.2.4 Stopping Degrees

Each time a stop signal is applied to press stroking, the press crank or eccentric shaft travels for period of time and through an angular distance before stopping. The Stopping Degrees displayed is the angular stopping distance traveled the last time the press stopped. The stopping degrees are measured and displayed each time the press stops regardless of where the press stops in the stroke as long as the

clutch has been engaged long enough to cause a crankshaft speed above the minimum speed threshold configured for the system. The display may not change when inching the press so quickly

that minimum speed is not attained. Stopping Degrees can be extremely useful in determining whether a Top Stop or Cycle Stop setting should be made for a sensor channel when a fault is detected.

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Section 5.2.5 Auxiliary Equipment Messages

The OmniLink II Press Automation Control makes optional provision to wire inputs to its parallel port on the back of the operator terminal from the intelligent controller (such as a PLC) of auxiliary equipment so that diagnostic messages from auxiliary equipment can be displayed on the brake monitor screen of the operator terminal. The messages are entered in the configuration menu as detailed in Section 4.2.5. When this option is used the messages appear under the Auxiliary Equipment Messages legend on the Brake Monitor and Diagnostic screen.

Section 5.2.6 Reason for the Last Stop

Diagnostic information is provided to show the reason the press stops. Once a stroke is initiated, the first stopping action is latched and displayed. This is done to capture transient conditions that may return to their proper state after the press stops. This information remains latched until press stops again. The only reasons for the stop of press stroking that the OmniLink II Press Automation Control can display under Reason for the Last Stop are those for stops that it initiates. Because it monitors the voltage to the valve that controls the clutch and brake, the OmniLink knows each time the press stops stroking. If it initiated the stop, the reason that it initiated the stop will be displayed. Stops that are not the result of the OmniLink will result in a display of “Non-OmniLink II Stop” under Reason for the last stop.

Additional information concerning press stops is archived in the Event Log. See Section 5.2.8.

Section 5.2.7 Present Running Status

The Present Running Status message indicates in English (or Spanish) any current condition of the OmniLink II Press Automation Control that results in a stop output to the press control and prevents stroking. Any condition that prevents stroke initiation is displayed as long as it exists. If no

stop condition exists, an “OK” message indicates that only the correct run buttons are required to initiate the stroke.

The OmniLink II Press Automation Control cannot show any reason why the stroke may not be initiated caused by the press control or other equipment.

Section 5.2.8 Diagnostics

Additional OmniLink diagnostics are available through the DIAGNOS softkey. Pressing the DIAGNOS softkey will result in the main Diagnostic screen appearing as shown in Figure 5.4. This screen shows:

• The states of the four outputs available on the R/D-Brake Monitor Module, including the two module PLS outputs.

• The state of the two inputs for the R/D-Brake Monitor Module, including the optional input to indicate whether the press control is in a setup or production mode is shown.

• The state of the output relays that provide stop signals to the press control.

• Raw analog input signal information from the R2D decoder and the optional speed input, analog

speed output and % Motor Load input.

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TOP

Stroke

Mode

R2D/ Brake Mo nito r Module CON2 States

PLS 1 (CON2, Pi n 2) : On PLS 2 (CON2, Pi n 3) : Off Out 3 (CON2, Pin 4): Off Out 4 (CON2, Pin 5): Off

Setup/Prod Mode Input (CON2, Pin 6): On

In 1 (CON2, Pin 6): Off

R2D/Brake Monitor Module Stop Relays

Stop Relay 2 (Right): On

R2D/Brake Monitor Module Other

Drive

Speed Stroke

Speed

Stop Relay 1 (Left): On

Raw R2D: 007C

Raw Speed Input: 0000

Raw Spe ed Out put:0000

Raw Motor Load Input: 0000

0 0

SPM

Order

Counter

SYSTEM STATUS

Counter OFF

Diagn ostic

EVENT LOG

H. S. COMM DIAGS

KEYBOARD TEST

S. MEDIA INFO

VERSION INFO

EXIT

Figure 5.4 Diagnostics Screen

The softkeys along the bottom of the screen navigate to other screens where high speed serial communication, memory, and software version information diagnostics are shown. This raw information is only useful for user diagnostics in the field as an aid in diagnosing possible problems over the phone with Link technicians. The phone service technician will direct you to these screens if necessary.

The EVENT LOG softkey is used to access the Event Log screen, which stores the last 128 Reason for the Last Stop messages with a date and time (the OmniLink incorporates a battery operated clock) stamp.

Section 5.2.9 Module Limit Switch

The R/D-Brake Monitor provides the logic for two simple programmable limit switch outputs as standard. Since these outputs can only sink 8ma of dc current, enough to operate solid state ac or dc relays, optional solid state relays must be provided to make these two Module PLS channels practical for driving larger loads. Link provides an optional 802-5 Solid State Relay Module (shown in Figure 2.18) that can provide up to 4 solid state relays, 2 for Module PLS channels 1 and 2, and 2 for optional indicator functions that may be driven by the R/D-Brake Monitor Module.

The Module Limit Switch screen can always be accessed by pressing the MODULE LIMIT SWITCH softkey on the Brake Monitor screen. If no optional PLS/Logic Module is used with the system, the LIMIT SWITCH softkey on the Main Menu will also access the Module Limit Switch screen. If one or more PLS/Logic Modules is used with the system, the LIMIT SWITCH softkey on the Main Menu will access the PLS/Logic Module screens, and only the MODULE LIMIT SWITCH softkey on the Brake Monitor screen will access the Module Limit Switch screen.

The Module Limit Switch screen simply shows the two channel numbers and the ON and OFF angles for each. You can view the information in Run mode and make settings in Program mode.

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Section 5.3 Counters

From the Main Menu, Figure 5.1, depressing the COUNTER softkey displays the menu shown in Figure

5.5 and provides the operator certain production information. The present quantities of the order counter, batch counter, quality counter, auxiliary counters, scrap counter, and stoke counter can be viewed. Depending on how you configure the system, changes may be made in Run Mode or Program Mode only. See Section 4.2.4.3 for configuration choices Key/Code Access to Program Mode and for items that may be chosen to be unrestricted (settings and actions made in Run Mode of the operator terminal). See Section 3.9 for how to use Key/Code Access modes to settings and actions restricted to Program Mode.

Stroke

TOP

Job Number Job Description 1 FRONT BRACKET

Present Running Status Program/Run Switch

COUNTER NAME COUNT LIMIT STATE PERCENT COMPLETE

Order Count Batch Count Quality Count Aux 1 Count Aux 2 Count Aux 3 Count Aux 4 Count Aux 5 Count Aux 6 Count Aux 7 Count

Stroke Count 978776

Scrap Count 4 Scrap Rate 0.3984%

Mode

DECREMENT SCRAP

Single Stroke

1000

50 90 50

0 0 0 0 0 0

Drive

Speed Stroke

Speed

2000

200 100

0 0 0 0 0 0

INCREMENT SCRAP

ON ON OFF TRIP OFF OFF OFF OFF OFF OFF

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

Figure 5.5 Counter Menu

The display provides the following information:

1. The current Job Number and Description

2. Present running status of the press control

3. Current Count, Limit, State, and Percent Complete of the Order, Batch, Quality, and all Auxiliary Counters. These are called Production Counters.

4. Current Stroke Count

5. Current Scrap Count and Scrap Rate

Section 5.3.1 Production Counters

The OmniLink control has up to ten production counters. The first three production counters have dedicated names. These are Order, Batch and Quality. These three counters will always appear on the screen. The other seven counters are auxiliary counters. Auxiliary counters can be enabled or disabled

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in the counter configuration. If an auxiliary counter is enabled in the counter configuration, it will appear on the screen. If an auxiliary counter is disabled in the counter configuration, it will not appear on the screen. Also during counter configuration, each of the auxiliary counters can be assigned a sixteen character name. This counter configuration is on a job basis. The configuration information will be stored with the job. The stored information includes the counter name. When a job is recalled, the configuration information will also be recalled. For example, if the first auxiliary counter is being used on job number one, it will be recalled when 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 counters that are turned on will increment as the press strokes, when the press is operating in a production mode. If the optional Setup/Production mode input is supplied to the R/D-

Brake Monitor input as shown in Figure 2.15, the counters will not count in a setup mode.

Normally each counter will increment by one counter per press stroke. However, all of the counters have the option to configured to increase by multiple counts every press stroke or by multiple counts every programmed number of press strokes. The values of the increment and the number of press strokes before a count changes are programmed in the counter configuration menu. For example, an operation 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 lamination die that requires ten strokes per part would have the counter increase by one every ten press strokes. As a final example, an operation that runs a four part out lamination die that requires ten strokes per part would have the counter increase by four every ten press strokes.

When the current count reaches the programmed limit, a top stop will be issued. This stop will remain active until the counter is reset or is turned off.

All counters can be configured so that the current count value is loaded with the last count from the previous run of a job. For example, Job A was running on a machine and it was decided that Job B should be run on the machine before finishing Job A. 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 memory. The next time that Job A is 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. All counters can also be configured so that the count is also zero when recalled

The three dedicated counters are Order, Batch, and Quality. The Order counter usually records the total 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 that can be made between quality inspections.

The reset, settings, and manual change of count for all production counters can be configured to be either Restricted (changed in Program mode only), or Unrestricted (changed in either Run or Program Mode). See Section 4.2.4.3.2 of this manual. Counter configuration settings are done in Program mode only.

Section 5.3.1.1 Production Counters On/OFF

Production counters can be turned on or turned off. If “counter settings” are restricted to Program Mode in the configuration menu, the user must use the Key/Code Access Mode configured for his system to

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access Program Mode in order to turn the counters on or off. If the user accesses Program Mode by using the password system, the user must be configured to have permission 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 stop to the press control.

A production counter is turned 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 changed. The cursor can be either in the COUNT column or in the LIMIT column. Once the cursor is positioned over the proper counter, depressing the COUNTER OFF/ON softkey will turn the counter off if it is currently on and will turn the counter on if it is currently off.

Section 5.3.1.2 Production Counters Change Limit

Each production counter has a limit setting. When this limit is reached, a top stop will be issued. The slide will stop at the top of the stroke and further stroking will be prevented until the counter is reset or until the counter is turned off. If “counter change limit” is restricted to Program Mode in the configuration menu, the user must use the Key/Code Access Mode configured for his system to access Program Mode in order to change limits. If the user accesses Program Mode by using the password system, the user must be configured to have permission to change counter settings.

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 limit using the numeric keypad. After the correct limit is entered, press the ENT key.

Section 5.3.1.3 Production Counters Reset

A counter reset will set a production counter’s current count to zero. If “counter reset” is restricted to Program Mode in the configuration menu, the user must use the Key/Code Access Mode configured for his system to access Program Mode in order to reset counters. If the user accesses Program Mode by using the password system, the user must be configured to have permission to reset a counter.

A counter is reset by first selecting the counter and depressing the COUNTER RESET softkey. To reset a counter, use the arrow keys to position the cursor on the counter that is to be reset. The cursor can be either in the COUNT column or in the LIMIT column. Once the cursor is positioned on the counter to 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 counters can be configured to reset when the Order Count is reset.

Section 5.3.1.4 Production Counters Increment/Decrement

Production counters can be manually increased by one count or decreased by one count. If “counter change” is restricted to Program Mode in the configuration menu, the user must use the Key/Code Access Mode configured for his system to access Program Mode in order to increase or decrease the count. If the user accesses Program Mode by using the password system, the user must be configured to

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have permission 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 column or in the LIMIT column. Once the cursor is positioned on the counter to be changed, depress the INCREMENT key to increase the count by one or the DECREMENT key to decrease the count by one

Section 5.3.1.5 Production Counters Change Count

The current count value of a production counter may be changed. If “counter change” is restricted to Program Mode in the configuration menu, the user must use the Key/Code Access Mode configured for his system to access Program Mode in order to change the count. If the user uses a password, the user must be configured to have permission 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 counter, use the arrow keys to position the cursor on the count value that is to be changed. Once the cursor is positioned on the count value to be changed, press the CHANGE COUNT softkey. Then enter the new count using the numeric keypad. After the correct limit is entered, press the ENT key.

Section 5.3.2 Stroke Counter

The stroke counter increments anytime the crankshaft travels from the top of the stroke to the bottom of the stroke. This counter increments in all press operating modes, unlike the production counters that increment in production modes; Single Stroke, Continuous, Automatic Single Stroke, Continuous on Demand or Maintained Continuous modes, only. The stroke counter can only be reset from the press control configuration menu.

Section 5.3.3 Scrap Counter

The scrap counter is used to keep track of the number of scrap parts that have been produced. This counter is automatically increased when the tonnage monitor registers an out of limit hit. It may be changed, added to, subtracted from, increased by one, or decreased by one manually. When the scrap counter is manually increased by a count, all production counters are automatically decreased by the same count. When the scrap counter is manually decreased by a count, all production counters are automatically increased by the same count.

Note: The total number of parts in the system is constant. If there are 1000 parts in the order count and 100 parts in the scrap count, there is a total of 1100 parts in the system. Changing the scrap count to 500, will result in the order count being changed to 600. Since there are only 1100 parts in the system, the scrap count cannot be changed to a value greater than 1100.

If “counter change” is restricted to Program Mode in the configuration menu, the user must use the Key/Code Access Mode configured for his system to access Program Mode in order to change the count by entering numbers. If the user obtains access control by using the password system, the user must be configured to have permission for counter change. Incrementing and decrementing the scrap counter by one count at a time is allowed in the Run Mode of the operator terminal.

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To change the value of the scrap count, position the cursor on the scrap counter and select the CHANGE SCRAP softkey. Then enter the new count using the numeric keypad. After the correct value is entered, press the ENT key. If the scrap count is increased, the amount by which it is increased is subtracted from the production counters. If the scrap count is decreased, the amount by which it is decreased is added to the production counters.

To add a number of scrap parts to the scrap counter, position the cursor on the scrap counter and select the ADD TO SCRAP softkey. Then enter the number to be added using the numeric keypad and press the ENT key. The number entered is added to the scrap count and subtracted from the production counters.

To subtract a number of scrap parts from the scrap counter, position the cursor on the scrap counter and select the SUBTRACT FROM SCRAP softkey. Then enter the number to be subtracted using the numeric keypad and press the ENT key. The number entered is subtracted from the scrap count and added to the production counters.

To increase the scrap counter count, press the INCREMENT SCRAP softkey. The value of the scrap counter will increase by one. The current count value of all production counters with a current value greater than zero and which are turned on, will decrease by one.

To decrease the scrap counter press the DECREMENT SCRAP softkey. The value 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 displayed on the counter screen. The scrap rate is the calculated by dividing the scrap count by the sum of the scrap count and the current order count. If the Order 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 available. It should be noted that if the user ignores the decimal point 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 5.3.4 Configure Counters

As described in Section 5.3.1 production counters can be configured on a job basis. The user must use the Key/Code Access Mode configured for his system to access Program Mode in order to change counter configuration. If the user obtains access control by using the password system, the user must be configured to have permission for counter configuration. The counter configuration information is stored with other job related information.

Depressing the CONFIG COUNTER softkey from the Counters menu, Figure 5.6, will display the Counter Configuration menu, Figure 5.6. This screen can only be viewed unless Key/Code Access to Program mode is used. Once in Program Mode counters can be configured. If password access to Program mode is configured the upper right softkey will have the legend SUPPLY ACCESS CODE when in Run Mode to initiate the password sequence to Program Mode.

Section 5.3.4.1 Configure Auxiliary Counter Names

The names of the seven auxiliary counters can be programmed by the user. The names of the Order,

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Batch, and Quality counters are fixed and cannot be programmed.

To change an auxiliary counter name, position the cursor on the counter name to be changed and press the CHANGE NAME softkey. The text edit box will appear and the name can be entered. Press the ENT key to save the name and exit the text editor.

Section 5.3.4.2 Configure Counter Count By Value

The Count By value of all counters can be programmed. Normally 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 value. If a die produced two parts each stroke, the Count By value of the Order Counter should be two. The counter will increase its value by two every 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 the ENT key

TOP

COUNT ER 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. Cou nter 1 1 NO Y ES Aux 5. Cou nter 1 1 NO Y ES Aux 6. Cou nter 1 1 NO Y ES Aux 7. Cou nter 1 1 NO Y ES

Stroke

Mode

Sin gle Str oke

COUNTS BY

Drive

Speed Stroke

Speed

EVERY HOW MANY STROKES

SPM

0 0

SPM

RESET WHEN ORD ER COUNT ER RESET

Order

Counter

PC S TATUS

Pr ogra m/Ru n Swi tch

EN ABL E COUNT ER

1000

COUNT ER CONFI G

SUP PLY ACCESS CODE

CHANGE INCREMENT

CHANGE STROKES

CHANGE SETTING

CHANGE NAME

Set Co unts to Zero When Job Reca lled : YES

EXIT

Figure 5.6 Counter Configuration Menu

Section 5.3.4.3 Configure Counter Every How Many Stroke Value

The number of 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 should be set to ten. The counter will increase its count every ten press strokes.

To change the number of strokes value position the cursor on the Counts By value to be changed, press the CHANGE Strokes softkey, enter the new number, and press the ENT key

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Section 5.3.4.4 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 the counter can be reset when the Order counter is reset.

To change the Reset When Order Counter Reset setting of a counter position the cursor on the value to be changed, press the CHANGE SETTING softkey.

Section 5.3.4.5 Configure Counter Enable

Each of the seven auxiliary counters can be enabled or disabled. When a counter is enabled, it will appear on the counter screen. When a counter is disabled it will not appear on the counter screen. The Batch, Order, and Quality counters are always enabled.

To change the Enable Counter setting of a counter position the cursor on the value to be changed, and press the CHANGE SETTING softkey.

Section 5.3.4.6 Configure Reset Counters When Job Recalled

This configuration provides the user with the option to restore the counters’ previous count when a job is recalled. If set to “No”, all counters will be loaded with the previous counts that were registered when the last job run was terminated. A job is terminated when another job is recalled. For example, Job A was running on a machine and it 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, the current count for Job A’s Order Counter, 1020, was stored in memory. The next time that Job A is loaded with a Recall, the count for the Order Counter will be set to 1020.

If a job is not terminated by a recall of another job, the current counter information will be lost. In the example above, if Job B was not loaded from memory with a Recall, but instead was set-up by changing some of the settings that were already loaded for Job A, the current counter information at the end of Job A would be lost.

A “Yes” configuration will set the current count for all counters to 0 when the job is recalled.

To change the “Reset Counter When Job Recalled” setting of a counter position the cursor on the value to be changed, and press the CHANGE SETTING softkey.

Section 5.4 Motor Speed Adjustment (Option)

If the OmniLink II Press and Automation control is equipped with the Analog Input/Output board option

and the press is a variable speed press, the System 5000 allows the operator to enter stroking speed from the keyboard as shown in Figure 5.7, and automatically sends this command (as an analog signal) to the motor drive. The stroking speed can be set over the entire speed range of the press (determined by the configuration) in all production modes. The OmniLink II Press Automation Control can automatically limit the speed setting in the INCH mode if the optional setup mode input to the R/D-Brake Monitor Module as shown in Figure 2.15 is wired. For example, a press that has a maximum stroking speed of 400 SPM may be configured to provide an INCH mode speed setting of 80 SPM. In this situation, the operator can enter a speed setting up to 400 in any mode but the command signal to the drive will go no

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higher than 80 SPM when INCH mode is selected. If the press control is configured for fixed setup (INCH) mode speed, a message on the speed screen informs the operator that “Setup speed is fixed at 80 SPM”

As shown in Figure 5.7, both drive speed, (SPM), and motor current, (% Load), are displayed in numeric and bar graph formats. The SPM bar graph ranges from 0 SPM to the maximum strokes/minute of the press. The % Load bar graph ranges from 0 to 200 %.

Stroke

TO P

Motor Speed . . . . . . . 200 SPM

Inch Mode Speed is Fixed at . . . . . . 50 SPM

M aximum Single Stroke Speed is . . 250 SPM

SPM 200

Figure 5.7 Motor Speed Adjustment

Mode

% L O AD 161

Single Stroke

Drive

Speed Stroke

Speed

200

SPM

Order

Counte r

PC STATUS

Ready to St roke

Counter OFF

MOTOR SPEED

C HANGE NU MBER

SPM UP

SPM DOW N

EXIT

If “motor speed adjust” is restricted to Program Mode in the configuration menu, the user must use the Key/Code Access Mode configured for his system to access Program Mode in order to adjust speed. Key/Code Access mode to Program Mode is described in Section 3. If the user accesses Program Mode by using the password system, the user must be configured to have permission to change motor speed.

Motor speed can be changed by either entering 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 correct motor speed value is entered, press the ENT key.

Section 5.5 Quick Access (ACC key)

The upper right hand key, ACC, can be used from any screen view the Quick Access screen. This screen is shown in Figure 5.8.

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Stroke

TOP

CURRENT LOGIN IN: OPERATOR # 1

Press lube should be type xyz. Check level daily Flywheel belt deflection should be not more that 1” at mi dpoint.

Use material lube abc for this part Material should have a maximum thic kness of .161

Mode

Single Stroke

Drive

Speed Stroke

Speed

MACHINE NOTES

NOTES FOR JOB # 1

200

LOGOUT

SPM

Order

Counter

PC STATUS

Ready to Stroke

Counter OFF

QUICK ACCESS

EDIT NOTES

AUXILIARY COMM.

EXIT

Figure 5.8 Quick Access Screen

This display provides the following information:

1. The name of the current user who has access control. If the user logged in using a password.

2. Machine notes. These are notes that pertain to the machine.

3. Job notes. These are notes that pertain to the job. These notes will be saved and recalled with the

job setup.

Section 5.5.1 Machine Notes

The Machine Notes area allows information concerning the machine to be entered and displayed. This information will not change as the current job is changed. This area allows for eight lines of text with each line containing up to 59 characters.

Section 5.5.2 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 eight lines of text with each line containing up to 59 characters.

Section 5.5.3 Editing Machine Notes and Job Notes

The machine notes and job notes can be changed by first selecting the EDIT NOTES softkey. The user must access Program Mode by use of the Key/Code Access Mode configured for the system to edit these notes. If the user accesses Program Mode control by using the password system, the user must be configured to have permission 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 the ENT key to save the text on the line. If another line is to be edited, position the cursor to that line and repeat the steps above. The arrow keys will move the cursor for the Machine Notes box to the Job Notes box.

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LINK Systems OmniLink II User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual