LINK Systems OmniLink II User Manual

OmniLink II

Press Automation

Control

OPERATING MANUAL

Version 1.0

LINK ELECTRIC & SAFETY CONTROL COMPANY
444 McNALLY DRIVE,	NASHVILLE TN 37211
PH (615)-833-4168	FAX [phone]

II OmniLink

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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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	RESOLVER
Eccentric
Shaft

OMNILINK II PRESS AUTOMATION CONTROL

RESOLVER CABLE

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.

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CRANK OR	RESOLVER
ECCENTRIC
SHAFT

OMNILINK II PRESS AUTOMATION CONTROL

RESOLVER CABLE

LINKNET

HIGH SPEED SERAIL BUS CABLE (3 WIRES AND DRAIN)

SERIAL PLC INTERFACE CABLE

FEED

PROGRAMMABLE

LOGIC

CONTROLLER

SERIAL FEED INTERFACE CABLE

UP TO 32 PROGRAMMABLE LIMIT SWITCH AND

32 LOGIC OUTPUTS - 8 OR 16 RELAYSPER MODULE UP TO 80 DIE PROTECTION & PROCESS 16 LOGIC & MONITORING INPUTS PER MODULE

MONITORING INPUTS -- 8 OR 16 PER MODULE

MODEL

MODEL

MODEL 5120

MODEL

				MODEL 5100-5			MODEL 5100-5
			PROGRAMMABLELINKLIMIT SWITCH
							LINK
LINK	LINK		DIE PROTECTION&			&	PROGRAMMABLE LIMIT SWITCH
							DIE PROTECTION &
DIE PROTECTION &	DIE PROTECTION &			PROCESS			PROCESS&MONITOR
PROCESS MONITOR	PROCESS	MORE		MODULE			MODULE
MODULE	MODULE			NUMBER/			NUMBER/
NUMBER/	NUMBER/
		MODULES	LINK ELECTRIC & SAFETY CONTROL				LINK ELECTRIC & SAFETY CONTROL
			444	McNally Drive	Nashville, TN		444 McNally Drive	Nashville, TN
				37211			37211
				Phone: [phone]			Phone: [phone]

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.

802-5 R/D-Brake Monitor Module
Analog Input/Output
Board Option	Microprocessor 2
						Transformer
		Microprocessor 1
	Microproc. 1
	Prog. Memory
	R/D					Output
						Relays
	IC
CON8				CanBus Termination
				Switch		Fuse
1 2 3 4 5
CON7		CON1		CON2	CON5	CON4
R1 2 3 4 5 6 7 8 9 10 11 12 13		SHLD GND CANH	CANL	1 2 3 4 5 6 7 8	L1 L2 G ND 1 2 3 4
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.

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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.

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

SERIAL BUS CABLE AND POWER FOR

MODULES RUN IN SAME CONDUIT

O

O

O

O

O

P

P

P

P

P

T

T

T

T

T

I

I

I

I

I

O

O

O

O

O

N

N

N

N

N

1

2

3

4

5

Figure 2.2 Serial Bus Connections

3.Dual connector plugs are used for each optional module shown in Figure 2.2 for both the highspeed 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			SHIELD MUST BE	SERIAL BUS CABLE
						TO NEXT MODULE
		Terminal			CONNECTED TO PLUG
	White		CANL
	Orange		CANH
	Blue		GND		SERIAL BUS CABLE	PLUGS INTO MODULE
	Bare		Shield		FROM LAST MODULE	CONNECTOR HEADER
						FOR THIS MODULE
						SERIAL BUS CONNECTOR
			115VAC TO NEXT			PLUG FOR THIS MODULE
			MODULE
		L1			16 GA RED, WHITE,
			L2	G	GREEN WIRES
				N
				D	PLUGS INTO MODULE
	115VAC FROM				CONNECTOR HEADER
					FOR THIS MODULE
	LAST MODULE
	16 GA RED, WHITE,	115VAC CONNECTOR PLUG
	GREEN WIRES	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 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.

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

OmniLink II LCD

OPERATOR TERMINAL

0

0

Driv e

0 SP M

Order

N

Speed

C ount er

Counter OFF

T OP

Strok e

Stroke

0 SP M

SYS TEM STATUS

Mode

OK

Speed

READY TO STROKE

MAIN

SCREEN

STATUS:

BRAKE

CHG

ACC

PRESS

OK

MOCONTRNITORL

11.65

STATUS:

AUTO

(29.59)

ALL CON DITI ONS OKAY

SETS

STATUS:

TONNAGE

7

8

9

11.125

10.4

ALL CON DITI ONS OKAY

MON ITOR

(28.26)

(26.42)

SPM

% LOAD

STATUS:

DIE

4

5

6

0

161

ALL CON DITI ONS OKAY

PROTEC TION

JOB NUMBER

DESCRIPTION

LIMIT

1

2

3

SWITCH

100000

FRONT BRACKET

COUNTER LIMIT

QUANTI TY

STATE

JOB

CLR

0

ENT

ORDER

2000

7

ON

SETUPS

BATCH

500

7

ON

MOTOR

C OUNTERS

SPEED

LINK ELECTRIC & SAFETY C ONTROL CO.	PROG	RUN
444 McN ALLY DR. NASHVILLE, TN 37211
PHONE [phone]

OmniLink II Press Automation Control

Enclosure Depth: 6 (15.24)

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

RESOLVER

CHAIN

PRESS

CROWN

ECCENTRIC

CRANK OR

SHAFT

Figure 2.6 Mounting the 2500 or 5000 Resolver

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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.

		ER
	LV
SO
RE

					SE
				EDBA
			AD
		G	LO
	RIN
	SP

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
11.125	10.5
(28.258)	(26.67)
	6.6
	(16.76)
	4” DEEP
	4.25
	(10.795)

	.312 (.7925) 4 Places
	ENCLOSURE FOR SINGLE
	PLS/LOGIC MODULE
13.75	13.3
(34.925)	(33.782)
	7
	(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

ECCENTRIC

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

RESOLVER

PRESS

PR ESS CONTROL

1/2” Flexible conduit with ground for 115VAC from press control transformer, connections to control dual valve output, stop outputs from OmniLink to press control.

1/2” Flexible liquid tight conduit with ground for high speed serial bus cable and power to OmniLink II Press Automation Control optional modules

			OmniLink II LCD
				OPERATOR T ERMINAL
	0	0		Drive		0 SP M	Or der	CounterONOFF
				S peed			Co unter
TOP	S troke			S troke		0 SP M	SYSTEM ST ATUS
	Mode						OK
				S peed			REA DY TO STROKE
								MAIN
								SCREEN
					S TA TUS:			BRAP ESSKE	CH G		AC C
					OK			MONICON TROLT OR
					S TA TUS:			AUTO
					ALL CONDITIONS OKAY			SETS
					S TA TUS:			TO NNAGE	7	8	9
					ALL CONDITIONS OKAY			MON ITOR
SPM	% LOAD				S TA TUS:			DIE	4	5	6
	161				ALL CONDITIONS OKAY
0								P ROT EC TION
			J OBN UMBER			DES CRIP TION		LIM IT	1	2	3
				1000 00		FRON T BRACKET		SW ITCH
			COU NTER		L MIT	QUANTITY	S TATE	JOB	C LR	0	E NT
			ORDER		2000	7	ON
								SE TUPS
			BATCH		500	7	ON
MOTOR								C OUN TERS
SPEED
L IN K E LECTRIC & SAFET Y CONTROL CO.									PROG		RUN
4 4 M cNALL YDR.			NAS HVIL LE, TN	37 2 1
PH ONE (61 5)		83 3-4 1 68

OmniLink II Press Automation Control

1/2” Flexible liquid tight conduit(s) with ground for other OmniLink system options

1/2” Flexible liquid tight conduit with ground if any optional 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

2.8

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

2.9

802-5 R/D-Brake Monitor Module

Analog Input/Output

INSIDE OF

OPERATOR

Board Option

Micr opr ocessor 2

TERMINAL

Micr opr ocessor 1

Transforme r

ENCLOSURE

Micropr oc. 1

P rog. Me mor y

R/ D

Output

R elays

IC

CON8

C an Terminatio n

Switch

Fuse

1

2

3 4

5

CON7

CON1

CANL

CON2

CON5

CON4

R1

2 3

4

5

6 7

8 9

10 11 12

13

SHLD GND CANH

1

2

3 4 5 6

7

8

L1 L2 GND 1

2 3

4

SYSTEM 2500 RESOLVER CABLE CONNECTION TO

CON7 OF 802-5 R/D-BRAKE MONITOR MODULE.

RUN IN 1/2” FLEXIBLE CONDUIT.

CONNECTION FOR CLOCKWISE

CONNECTION FOR COUNTER-CLOCKWISE

ROTATION OF CRANK OR ECCENTRIC

ROTATION OF CRANK OR ECCENTRIC

CON 7

CON 7

R1

R1

R2

R2

R3

R3

R4

R4

6 PIN AMPHENOL RESOLVER

6 PIN AMPHENOL RESOLVER

CABLE CONNECTOR

CABLE CONNECTOR

R5

R5

WHITE/BLACK

R6

WHITE/BLACK

R6

PAIR W/DRAIN

PAIR W/DRAIN

DRAIN

BLACK

R7

DRAIN

BLACK

R7

WHITE

WHITE

R8

R8

GREEN/BLACK

GREEN/BLACK

DRAIN

PAIR W/DRAIN

DRAIN

PAIR W/DRAIN

BLACK

R9

GREEN

R9

SINE GREEN

SINE BLACK

R10

R10

RED/BLACK

RED/BLACK

DRAIN

PAIR W/DRAIN

DRAIN

PAIR W/DRAIN

RED

R11

RED

R11

COS

COS

BLACK

BLACK

R12

R12

DRAINS

DRAINS

R13

R13

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

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2.10

802-5 R/D-Brake Monitor Module

INSIDE OF

Analog Input/Output

OPERATOR

Boa rd Option

Micr opr ocessor 2

TERMINAL

Tra nsforme r

ENCLOSURE

Micr opr ocessor 1

Mi cropr oc. 1

P rog. Memor y

R/ D

Output

Relay s

IC

CON8

C an Terminatio n

Switch

Fus e

1 2

3

4

5

CON7

CON1

CANL

CON2

CON5

CON4

R1 2 3

4

5

6 7

8 9

10 11 12

13

SHLD GND CANH

1

2

3 4 5 6

7

8

L1 L2 GND 1

2 3

4

CON 7

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

CONNECTION FOR CLOCKWISE
ROTATION OF CRANK OR ECCENTRIC
14 PIN AMPHENOL RESOLVER
CABLE CONNECTOR
	BROWN/BLACK
DRAIN	PAIR W/DRAIN
		CON 7
		BROWN	R1
		BLACK	R2
	YELLOW/BLACK
DRAIN	PAIR W/DRAIN
		YELLOW	R3
		BLACK	R4
	RED/BLACK
DRAIN	PAIR W/DRAIN
		BLACK	R5
		RED	R6
	WHITE/BLACK
DRAIN	PAIR W/DRAIN
		BLACK	R7
		WHITE	R8
	BLUE/BLACK
DRAIN	PAIR W/DRAIN
		BLACK	R9
	SINE
		BLUE	R10
	GREEN/BLACK
DRAIN	PAIR W/DRAIN
		GREEN	R11
	COS	BLACK	R12
		DRAINS	R13

CONNECTION FOR COUNTER-CLOCKWISE
ROTATION OF CRANK OR ECCENTRIC
14 PIN AMPHENOL RESOLVER
CABLE CONNECTOR
	YELLOW/BLACK
DRAIN	PAIR W/DRAIN
		CON 7
		YELLOW	R1
		BLACK	R2
	BROWN/BLACK
DRAIN	PAIR W/DRAIN
		BROWN	R3
		BLACK	R4
	RED/BLACK
DRAIN	PAIR W/DRAIN
		BLACK	R5
		RED	R6
	WHITE/BLACK
DRAIN	PAIR W/DRAIN
		BLACK	R7
		WHITE	R8
	BLUE/BLACK
DRAIN	PAIR W/DRAIN
		BLUE	R9
	SINE
		BLACK	R10
	GREEN/BLACK
DRAIN	PAIR W/DRAIN
		GREEN	R11
	COS
		BLACK	R12
		DRAINS	R13

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

August 30, 2002 Manual Version 1.0

2.11

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.

16 GA BLACK, WHITE, GREEN WIRES FROM PRESS CONTROL (115VAC SUPPLY FOR OMNILINK II PRESS AUTOMATION CONTROL)

L1	L2	G
		N
		D

PLUGS INTO CONNECTOR HEADER FOR R/D-BRAKE MONITOR MODULE

		115VAC CONNECTOR PLUG
	16 GA BLACK, WHITE,	FOR THIS MODULE
	GREEN WIRES FOR	16 GA BLACK, WHITE,
	OMNILINK II OPERATOR
		GREEN WIRES
	TERMINAL POWER
	(115VAC)

115VAC TO FIRST OPTIONAL

MODULE (NOT NECESSARY

IF NO OPTIONALMODULES ARE USED)

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.

August 30, 2002 Manual Version 1.0

2.12

INSIDE OF OPERATOR TERMINAL ENCLOSURE

802-5 R/D-Brake Monitor Module
Analog Input/Output
Board Option
Microprocessor 2
					Transformer
Microprocessor 1
Microproc. 1
Prog. Memory
R/D					Output
					Relays
IC
CON8			Can Termination
			Switch		Fuse
1 2 3 4 5
CON7	CON1	CANL	CON2	CON5	CON4
R 1 2 3 4 5 6 7 8 9 1 0 11 12 1 3	GND CANH		1 2 3 4 5 6 7 8	L1 L2 G ND 1 2 3 4
HLDS

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											CR1 CR2
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 CONTROL		CON5	CON4
			L1 L2 GND 1	2	3	4
	115VAC CONTROL TRANSFORMER
115VAC	SECONDARY WINDING
	FUSE
						Note! If press
						control clutch
		BLACK				stop circuit is
		WHITE				low voltage
		GREEN
						instead of 115V,
		RED
		RED				run these wires
	MOTOR	RED				in conduit for
		RED
						low voltage
	CONTROLS	1/2” CONDUIT CONTAINING
						connections.
		ONLY 115VAC CONNECTION
		CIRCUITS
	CLUTCH/BRAKE	CONNECTOR 5 TERMINALS
		L1,L2,GND - 115VAC Power for OmniLink
	CONTROL
			Press Automation Control from
			press control transformer.
	IMMEDIATE	CONNECTOR 4 TERMINALS
	CLUTCH STOP
	CIRCUIT	1,2 ---	Wire to Press Control Dual Valve
			solenoid. Tells OmniLink when
			press strokes or stops for Brake
			Monitor & Motion Detector.
		3,4---	Wire into immediate clutch
CLUTCH/BRAKE DUAL AIR VALVE			(stroking) stop circuit. Provides
			both immediate and top stop.

Figure 2.13 115VAC Wiring Between Press Control and Operator Terminal

August 30, 2002 Manual Version 1.0

2.13

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/D- Brake 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

2.14

R/D-Brake Monitor Module

CONN4

1 2 3 4

				Jumpers inside this box if no
				light curtain is present
				1RCSA		E.S. Buttons
15	X X X	36	Slot 26	76	20	6
X			501-8A or
	REMOVE		501-20 Card	Light Curtain	60	46
	JUMPER			2RCSA
			LINK SS501 CONTROLSTANDARD CARDS

R/D-Brake Monitor Module

CONN4 1 2 3 4

				Jumpers inside this box if no
				light curtain is present
Slot 20				1RCSA		E.S. Buttons
			Slot 26
15 501-16	30	36		76	20	6
Timer	X X		501-8A or
			501-20 Card	Light Curtain
Card					60	46
	REMOVE

JUMPER

2RCSA

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

2.15

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.

802-5 R/D-Brake Monitor Module

INSIDE OF

Analog Input/Output

OPERATOR

Board Option

Microprocessor 2

TERMINAL

Microprocessor 1

Transformer

ENCLOSURE

Microproc. 1

Prog. Memory

R/D

Output

Relays

IC

CON8

Can Termination

Switch

Fuse

1 2 3 4 5

CON7

CON1

CON2

CON5

CON4

R1 2 3 4 5

6

7

8

9 10 11

12 13SHLD GNDCANH CANL

1

2 3 4 5 6

7

8

L1 L2 GND1

2 3

4

PRESS CONTROL

OPTIONAL CUSTOMER SUPPLIED ISOLATED SELECTOR SWITCH OR RELAY CONTACT CLOSED IN SETUP MODE (SUCH AS INCH) ONLY.

					CON2
		1	2	3	4	5	6	7	8
		1						7
BLUE	12VDC								SETUP MODE
	SUPPLIED BY
BLUE	TERMINAL 1								INPUT

LOW VOLTAGE CONDUIT

Figure 2.15. Optional Setup Mode Input Wiring.

August 30, 2002 Manual Version 1.0

2.16

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

2.17

	4
OPEN	2 3
	1

						802-5 R/D-Brake Monitor Module									INSIDE OF
							Analog Input/Output
															OPERATOR
								Board Option
								SWITCH							TERMINAL
						4		Microprocessor 1				Transformer			ENCLOSURE
						3
						2		Microproc. 1
						1
								Prog. Memory
							R/D					Output
												Relays
							IC
	CON8									Can Termination
										Switch			Fuse
1	2 3	4	5
				CON7				CON1		CON2		CON5	CON4
R1	2 3	4	5	6	7	8	9 10 11	12 13SHLD GNDCANH CANL	1	2 3 4 5 6 7	8	L1 L2 GND1	2 3	4

	SPM IN	ISO GND	SPM OUT	%LOAD	ISO GND
		CON8
	1	2	3	4	5
Throw switch 3
to closed position				4	5

for DC or AC Motor Control with 4-20ma Input. Otherwise leave open.

	PRESS CONTROL
	SIMPSON INSTUMENT
	TRANSFORMER BUL 270-5014
	3	1	CURRENT
	4	2
			TRANSFORMER
			X:5 RATIO
			1 PRIMARY TURN OR
			2 PRIMARY TURNS
	1OL		MAIN MOTOR
	1OL		1M
	1OL

Current Transformer1 Ratios & Turns

for Various Size Motors

Current Transformer	Motor HP	Motor HP
Ratio and Turns____	@220VAC	@ 440VAC
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

Figure 2.16 Wiring the Analog Motor Load Current Input

FOR FIXED SPEED OR EDDY CURRENT DRIVE VARIABLE SPEED PRESSES

PRESS CONTROL

DC MOT OR DRIVE OR

AC ADJUST ABL E

FREQUENCYDRIVE

ANALOG 0-10V OR 4-20MA

MOTOR LOAD OUTPUT

COMMON (REF)

FOR DC MOTOR DRIVEOR AC ADJUST ABL E FREQUENCYDRIVE VARIABLE SPEED PRESSES

August 30, 2002 Manual Version 1.0

2.18

	4
OPEN	2 3
	1

						802-5 R/D-Brake Monitor Module											INSIDE OF
								Analog Input/Output
																	OPERATOR
									Board Option
									SWITCH								TERMINAL
						4			Microprocessor 1					Transformer			ENCLOSURE
						3
						2			Microproc. 1
						1
									Prog. Memory
							R/D							Output
														Relays
								IC
	CON8										Can Termination
											Switch				Fuse
1	2 3	4	5
				CON7					CON1		CON2			CON5	CON4
R1	2 3	4	5	6	7	8	9	10	11 12 13SHLD GNDCANH CANL	1	2 3 4 5 6	7	8	L1 L2 GND1	2 3	4

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 position for eddy current tach generator that is input to a bridge rectifier (rarely the case) on the eddy current drive.

S PMIN	ISOGND	SPMOUT	%LOAD	ISOGND ISOLATED	PRESS CONTROL
					1OL	MAIN MOTOR
	CON8			INPUTS &	1OL
				OUTPUT		1M
1	2	3	4	5
					1OL
		No Connection
				SHIELDED CABLE
				IN LOW VOLTAGE		EDDY CURRENT
				CONDUIT	TACH	COUPLING COIL
				SHIELD	GENERATOR	EDDY CURRENT DRIVE
						DRIVE SPM FEEDBACK
						DRIVE GROUND
						DRIVE SPM INPUT

1

2

3

FOR EDDY CURRENT DRIVE PRESSES

No Connection

SHIELDED CABLE

PRESS CONTROL

IN LOW VOLTAGE

CONDUIT

DC MOTOR DRIVE OR

AC ADJUSTABLE

SHIELD

FREQUENCY DRIVE

ANALOG0-10V SPM OUTPUT

DRIVE GROUND

DRIVE SPM INPUT

FOR DC MOT OR DRIVE OR AC ADJUSTABLE

FREQUENCY DR IVE VARIABLE SPEED PRESSES

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

August 30, 2002 Manual Version 1.0

2.19

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.

				INSIDE OF OPERATOR TERMINAL ENCLOSURE
				802-5 R/D-Brake Monitor Module
Analog Input/Output													1	2		3	4	5
Boa rd Option					Microprocess or 2										CON9
													OPTIONAL 802-5
										Transfor mer			SS RELAY MODULE
						Microprocess or 1
						Microproc. 1
						Prog. Memory
										Outp ut			R1		R2		R3		R4
					R/D
										Relays
					IC											CON2
									Can Terminatio n				1	2	3	4	5	6	7	8
CO N8
									Switch		Fuse
1 2	3	4	5
				CO N7		HLDS	CO N1		CO N2	CO N5	CO N4		SOLID STATE RELAY
							GND CANH ANLC						OUTPUTS. USE BLUE
R1 2	3	4	5	6 7 8 9	10 11 12	13		1	2 3 4 5 6 7 8	L 1 L2 G ND 1	2 3	4
													WIRE FOR DC AND
													RED WIRE FOR AC
													RELAY OUTPUTS.

			SOLID STATE RELAY
12VDC
			DRIVE SIGNALS

Figure 2.18 Wiring the Optional Solid State Relay Module

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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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