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PWi User`s Manual - Toledo Transducers

1. E g Control Board Figure 1 3 PWi Components Doc 13925 Rev L Page 11 qi Toledo Integrated Systems PWi User s Manual Conduit Hole Selection Follow Figure 1 4 to select the proper conduit hole for cabling The holes are for 1 2 conduit but they can be enlarged in the field if a larger fitting is required BOTTOM VIEW DOOR CONDUIT HOLES wy f e Sensor e Serial Communication AC Line e Analog Sensor e Probe Input e Shutdown Relays e External Reset Switch e Resolver Figure 1 4 Conduit Hole Selection Doc 13925 Rev L Page 12 Toledo Integrated Systems PWi User s Manual AC Power Connection and Configuration AC unit onl AC power is connected to the PWi s Analog Board as shown in Figure 1 5 Use Conduit Hole 3 see Figure 1 4 for the AC Power Wiring Use the proper fuse as indicated With the proper jumper settings the PWi can be powered by either 110 VAC or 220 VAC Factory set at 110 VAC The jumpers are located on the Analog Board as shown below 110VAC Jumpers A amp B 220VAC Jumper C Only Fuse Type TR5 Slow Blow 500mMA 110V ower Connection 250mAQ220V L1 HOT L2 NEUTRAL G GROUND Figure 1 5 AC Power Connection and Jumper Settings
2. V SI LI dI TIVM 9938 3GISNI SHL SHOSN3S TIVLSNI 318ISSOd 4l 18 1 LHOlddN 38 TIM 3 81314 AO SLI Y31139 COM SIL HISN31 1 OL SI HOSN3S V H3SO IO JHL qou alc 3H1 dO ANIM 3 309 AHL LH9IHdfl NAN109 dO H19N31 L AHL SI NOLIVOO I YOSNAS 1539 LH IYdN 555384 dO gt s LL SYNSOTONA 8 S NIN3dO ONILVAH 211 YVAN LINGNOO LON OQ NOILOVO AINO S38IM YOSNAS QVO LAN qQOt PAGE 3 T400 INSTALLATION Rev A Doc 11080 SHOSN3S HLO8 MOHS OL MIIA ONISNOH LNAWLSArdV JANS WVH 3Qri ONIAOW 3 dO LNO NAHL Waal 1 LXAN OL LINGNOOD 2 INSWLLSNrav adris OL ANd SSAOW AHL N3HM Q3Q33N MOVIS d 18V9 SI dOO138n 1 AHL ALON lt A y 81 HO KELLY NI 1 0S OL 1108 HOSNAS HOV3 H3WNO1Sn29 XO8 NOILWNINYAL SEN 9 90 8 3d LAN HLIM HOLO3NNOO 33 13 NIVHIS 88 51 8 ALON 335 ONIGNL NOSAL ZSZ 0FZ H3HSVM 318VO 3n0HOL 3 ALISOddO
3. approx 1 2 inch Figure 1 9 Sensor Cable Stripping 2 Strip approximately of insulation from each of the four signal conductors 3 Trim braid shield so that it is 14 to 1 2 shorter than the signal wires Note If your sensor cable is not double shielded with both foil and a braid electrical noise may affect your output readings Doc 13925 Rev L Page 17 T Toledo Integrated Systems PWi User s Manual Sensors Connection The PWi accepts the signals from Toledo Transducers T 400 sensors as well as other strain gage sensors Figure 1 10 illustrates the sensor connections T400 Sensor T400 Sensor O Tension Compression Force 9 5 5 Column mounted sensor Pitman mounted sensor Tension connection shown For compression connections 481 8 hele switch the red and white lw wires Make sure the shield braid does not contact the signal wire terminals Figure 1 10 Sensor Wiring Doc 13925 Rev L Page 18 Toledo Integrated Systems PWi User s Manual Analog Output The analog outputs are provided on a 9 pin connector for easy access and for interfacing with other peripherals BOTTOM VIEW Analog Voltage Output e Swing between 12V e 1 25V Capacity Figure 1 11 Analog Output Wiring Doc 13925 Rev L Page 19 Toledo Integrated Systems PWi User s Manual Probe Input
4. a ede 20 Probe o 21 Resolver Interface s suan u muu 22 Resolver Interface en 23 Resolver Master Mode Wiring 24 Resolver Slave Mode Wining uid 24 External simt Gu tes i CHIA 26 Seral Connection Sera en opas m sa Eus 27 RS232 Seral Port an t a adu cti e aO tut e iss 28 RS422 Serial Network Wiring aseo 28 Shutdown Relay Wiring a s np a eoa a a a used debate 29 Page 4 qi Toledo Integrated Systems PWi User s Manual 1 Installation Limited Warranty This unit is warranted by the manufacturer Toledo Transducers Inc to be free of defects in workmanship and materials for one year from date of manufacturer s shipment This warranty is limited to repairing or replacing products which manufacturer s investigation shows were defective at the time of shipment by the manufacturer All products subject to this warranty must be returned for examination repair or replacement F O B to Toledo Transducers Inc 6834 Spring Valley Drive Holland Ohio 43528 The express warranty set forth herein is in lieu of all other warranties expressed or implied including without limitation any warranties of merch
5. nesese sinis sssasas 81 a 6 AppendiX P 83 D Sensor Installation Doc u n n nupus 83 ID Calibration Sheets Form 1224 alaban us aa unsi u fu q uuu 83 Doc 13925 Rev L Page 3 Toledo Integrated Systems PWi User s Manual Table of Figures Figure 1 1 Figure 1 2 Figure 1 3 Figure 1 4 Figure 1 5 Figure 1 6 Figure 1 7 Figure 1 8 Figure 1 9 Figure 1 10 Figure 1 11 Figure 1 12 Figure 1 13 Figure 1 14 Figure 1 15 Figure 1 16 Figure 1 17 Figure 1 18 Figure 1 19 Figure 1 20 Figure 1 21 Figure 1 22 Doc 13925 Standard Mounting Dimensions od se 9 Flush Mount Mounting Dimensions zo ee rette ertet deett 10 PW Components Go a poene deoa eene a een en 11 SOLE SHON 6s zie at dioses 12 AC Power Connection and Jumper SettIn gs 13 DC Power Connection nsien eats ices ene to c rcu Praet ub cb eters aps 14 Sensor Configuration Jumper Settings enne enne enne 15 Sensor Input qao Ga dp ddl e osea 16 Sens r Cable Stripping S a l PERDU 17 aa aaa 18 Analog Q tp t WITIBE 19 Probe Input WITITIB os
6. Toledo Integrated Systems PWi User s Manual To lock the Security Code Once a valid security code has been entered the lock indicator will disappear to indicate that the security code is unlocked When the code is unlocked all settings and functions are active After the desired changes have been made by authorized personnel the security code should be locked again so that no further changes are made This is done on the Security Code screen k CODE LOCK 8 To lock the security code press B The PWi will return to the Main screen and the lock indicator will reappear to indicate the security code is once again locked Doc 13925 Rev L Page 55 Toledo Integrated Systems Configuration Mode Overview CAL Calibration menu for setting balance and calibration numbers for setting the communications baud rate ADDR Address menu for setting the network address S CNT Setup Count menu for setting the setup mode stroke limit E STP Stop Relay menu for setting the precision of Learn menu for setting the setpoint learning E Stop menu for enabling the Emergency load processing PWi User s Manual CAP Capacity menu for setting the press capacity values TRIG Trigger menu for setting the trigger method THRES Threshold menu for setting the load thresho
7. Doc 13925 Rev L Page 13 Toledo Integrated Systems PWi User s Manual DC Power Connection DC unit onl DC power is connected to the PWi s Analog Board as shown in Figure 1 6 The external 24VDC power supply should be rated at 1 25A or higher Use Conduit Hole 3 see Figure 1 4 for the DC Power Wiring Use the proper fuse as indicated If the power cable has a shield it can be connected to the Chassis Ground terminal Fuse Type TR5 Slow Blow 1 25A Top DC Power Connection 24V DC DC COM CHASSIS GND Figure 1 6 DC Power Connection Doc 13925 RevL Page 14 Toledo Integrated Systems Sensor Input Configuration PWi User s Manual Each channel input on the PWi Analog Board can be configured to accept a signal from a strain gage sensor a 4 20 mA signal or a 0 10 VDC signal Balance and gain adjustments are made via two potentiometers for each channel When configured for tonnage sensor input gain ranges of X1 and X10 are also selectable Refer to the illustration below for the location of the balance and gain adjustments and available sensor input configurations BALANCE ADJUST 13925 Rev L SENSOR CONFIGURATION JUMPERS SEE RIGHT Figure 1 7 TONNAGE X1 GAIN TONNAGE X10 GAIN 10 52 ABCDE Sensor Configuration Jumper Settings Toledo Integrated Systems PWi User s Manual Load Sensor Connection Note The following instructi
8. New codes match Start new code verify sequence CHAngED KKK CoDE Enter CODE DSABL CHG g k EnTER the new san p security CODE ENTER NEXT code again CHAngE 5 FAILED CODE DSABL New codes different Doc 13925 Rev L Page 73 Toledo Integrated Systems PWi User s Manual To reset the Security Code There is a way to reset the security code to its default value of 4 1 7 0 in case the code is forgotten First navigate to the Configuration mode s Security Code menu Then follow this sequence exactly as shown Sequence to Reset the Security Code Enter First Digit 4 Enter Second Digit 1 Enter Third Digit 7 g EnTER EnTER CoDE CoDE CODE ENTER NEXT CODE ENTER NEXT CODE ENTER NEXT 4 x 4 then EJ x 1 then 2 4 x 7 then 2 On Control Board Enter Fourth Digit 0 Toggle Dip Switch 2 E au ig CHAngED lt CODE DSABL CHG Down then Up only Once the security code is reset to its default value you may then change the code by following the instructions from the To change the Security Code section Doc 13925 RevL Page 74 Toledo Integrated Systems PWi User s Manual 3 Calibration Procedure S If calibrating a PWi unit in STI mode refer to the Calibration Procedure from the PWi STI Supplemental Manual Use the following steps for proper load calibration of the
9. display Channels 5 9 are selected by reverse video on the LCD screen Repeatedly pressing cycles through each of the outer slide channels 0 4 then the inner slide channels 5 9 This method applies to the HI LO and REV deviation values on the Setpoint menu and the capacity values on the Capacity menu Doc 13925 Rev L Page 34 Toledo Integrated Systems PWi User s Manual 6 Channel Configuration The 6 channel configuration is used when six load sensors are required As in the case of a double action press four sensors channels 1 4 are used to report the outer slide load and another two sensors channels 6 amp 7 are used for the inner slide load This configuration shows the load s 958 LOAD associated with the outer slide 476 48 corners channels 1 4 on the outer PEAK RUN OK 7 segment LED displays with the outer slide total shown on the center LED display The load associated with the inner slide sides channels 6 amp 7 are displayed on the bottom corners of the LCD screen with the inner slide total shown in the center of the LCD The function of each of the menus is similar to the 4 channel with a few differences Peak menu All channels show either peak load or variation To toggle between peak load and variation push or 2 until the center menu is showing ON or OFF then push to apply Signature menu When viewing the different corner signatures the quadrant symbol is
10. Integrated Systems Service Department for assistance if needed Our Service Department can be reached at 419 867 4170 Monday through Friday 8 00 AM to 5 00 PM Doc 13925 Rev L Page 77 Toledo Integrated Systems PWi User s Manual Doc 13925 Rev L Page 78 Toledo Integrated Systems PWi User s Manual 4 Calibration Information Label The Calibration Information Label is provided to document the Gain Numbers CAL and other important configuration data This card is located inside of the unit on the door Below is an example of the information that should be documented CALIBRATION INFORMATION JOHN DoE Date 7 15 12 Press No 3 Address 2 Capacity CHO 2000 unit KN M Thres Value 120 O Probe CH1 CH2 CH3 CH4 caL 1015 1019 994 1006 O STI Value Delay Value 1 3 SEC SSS 1 CalBy The name of the person that performed the calibration procedure 2 Date The date that the calibration was completed 3 Press No The press on which the monitor is installed 4 Address The network communication address for the monitor 5 Capacity CH0 The total capacity of the press For a double action press this is the capacity of the outer slide 6 Unit The type of load being measured Common examples include Tons and KN kiloNewtons 7 Thres Value If the trigger method is set to Threshold check this box and record the configured threshold value 8 Probe If the trigger method is set
11. PWi unit 1 Put the PWi in Setup Mode see page 40 for details 2 Set Press Capacity A Enter the Configuration mode by toggling Dip Switch 1 to the down position see page 32 for location of Dip Switch 1 B Use the or g buttons to navigate to the Capacity menu C Enter the press capacity for the total and each channel Refer to the Capacity Menu section on page 59 for more detail 3 Balance the Tonnage Sensors A Make sure the press is under no load B Use the g buttons to navigate to the Calibration menu C Open the PWi enclosure and locate the Balance and Gain pots on the Analog Board see Figure 1 7 and Figure 1 8 D Adjust the balance pot for CH1 until the balance value for channel 1 reads zero Turn the pot clockwise to increase the balance value and counter clockwise to decrease the balance value Channel 1 4 00 129 is balanced 45 76 98 CAL BAL E Repeat for each of the remaining channels 4 Find the Shut Height of the Press A Jog the press until the ram is at bottom dead center BDC or 180 without any load cells or die in the press B Determine the amount of spacers needed with your load cells Cycle the press without load cells to insure correct height Doc 13925 Rev L Page 75 Toledo Integrated Systems PWi User s Manual 5 Place the Load Cells in the Correct Position in the Press A load cells should be equal distance from the sides and front and rear For
12. STEP 2 3 DRILL 4 4 28 TAP ROTATE FIXTURE STEP 3 90 DEGREES f lt 4 XX CU Sc 4 4 28 X 1 1 4 SCREW 21 DRILL TWO SMALL CENTERED HOLES FOR ENCLOSURE STEP 4 144 28 x 1 SCREWS 114 28 X 1 1 4 SCREW rx Zu SS WELD EACH PAD ON THREE SIDES ONLY STEP 5 ANTI TORQUE Ze WASHERS 114 28 x 3 4 LOC WEL BOLTS PUT RAISED RIB TO PRESS Doc 11080 Rev A STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7 T400 INSTALLATION Remove all paint grease and or rust from surface to be welded Surface should be flat T I R 1 32 of an inch Drill and tap the center hole for mounting the fixture to the press member This hole should be inch deep Optional Bolt the fixture to the press member using the 4 28 by 1 inch long socket head cap screw in the center of the fixture Orient the fixture as shown and drill out the 721 holes to a depth of 3 8 of an inch for the enclosure mounting The fixture is not used for tapping these holes Optional Remove the fixture from the press member Bolt the weld pads to the fixture with 4 28 by 1 inch long socket head cap screws provided Reattach the fixture with the weld pads bolted on using the center hole as in Step 3 Orient the fixture as shown Weld the weld pads to the press member BE SURE TO ONLY WELD THE WELD PADS ON THREE SIDES AS SHOWN A single pass is sufficient Do not remove the fixture until slag is removed and
13. Signature Updating Signature Paused 500MS ANLYZ BACK To save and load signatures 1 2 3 Doc 13925 While the signature is paused and the center menu is showing ANLYZ Push D or g to access the signature analysis tools The center menu is now selected and the right menu now changes to APP Y With the center menu showing MEM push to access the various memory options To save the current signature Push B or g to cycle through the memory options until SAVEI or SAVE2 is selected Push to save the current signature to the corresponding memory location To load a previously saved signature Push B or g to cycle through the memory options until LOAD1 or LOAD2 is selected Push to load the signature While the signature is being viewed the current signature number is shown at the top left corner of the display and the following options are available Push g to cycle through the corners or Push or g to select the Cursor tool for point by point analysis or gt Push to close the signature and resume signature updating Page 44 Toledo Integrated Systems PWi User s Manual To analyze a signature using the Cursor tool 1 While the signature is paused and the center menu is showing ANLYZ Push B or g to access the signature analysis tools The center menu is now selected and the right menu now changes to APP Y With the center menu showing CUR push to turn on
14. The probe supply voltage 12VDC is supplied by the PWi on the Vo terminal The figure below shows the probe input location on the Analog Board and illustrates different wiring possibilities Use Conduit Hole 2 see Figure 1 4 to run the probe wiring After wiring is completed you must configure the unit for Probe triggering see Page 60 SOURCING PROBE NORMALLY OPEN CONTACTS CAM1 ON PROBE CLOSED PROBE INPUT CAM1 OFF PROBE OPEN NPN2 G NPN1 PNP1 Vo Figure 1 12 Probe Input Wiring NORMALLY CLOSED CONTACTS NPN2 NPN1 PNP1 Vo 1500 OHM RESISTOR 1 2 WATT MINIMUM SOLID STATE RELAYS N O NPN2 NPN1 T PNP1 Vo Doc 13925 RevL Page 20 Toledo Integrated Systems PWi User s Manual The timing of the probe should be such that it turns on just before the machine begins generating a load typically at 140 and remains on until the load is removed typically at 240 Load Signal Probe Closed Trigger Probe 140 240 140 PrebeOpemn Figure 1 13 Probe Timing Doc 13925 Rev L Page 21 T Toledo Integrated Systems PWi User s Manual Resolver Connection and Setup optional The PWi resolver input has a built in excitation which supports standard 5 000 Hz rotor excited positional resolvers The input can be configured in Master Mode or Slave Mode In Master Mode the PWi supplies excitation voltage to the resolver a
15. channel x LO x Low setpoint alarm in channel x REV x Reverse setpoint alarm in channel x CCM x CCM alarm in channel x NONE No alarm RST Reset alarm To view the alarm list Push or g to see each alarm if more than one type of alarm has occurred If an alarm is active its associated corner load value will flash To reset an alarm gt Push to reset all alarms Doc 13925 Rev L Page 48 Toledo Integrated Systems PWi User s Manual Reverse Menu e The Reverse menu displays the current reverse snap through load data for each channel lt Reverse load REV Reverse Load Menu To view Reverse Load Reverse load values are shown in the associated corners and the Reverse load as a percentage of capacity is shown on the LCD display Doc 13925 Rev L Page 49 Toledo Integrated Systems PWi User s Manual Statistics Menu e The Statistics menu displays historical load information for the current job Various data such as last alarm highest load number of high alarms etc can be viewed and reset The statistics are automatically reset when a job is loaded lt Peak load ne 623 196 Statistics 145 149 values STAT Statistics Menu LAST ALARM Last alarm load values HI LOAD Highest load values recorded HI ALARM Number of high alarms LAST HI ALARM Last high alarm load values LO LOAD Lowest load values recorded LO ALARM Number of low alarms LAST LO ALARM Last low alarm
16. digit LED display for each channel e PressNet Software compatible e Menu driven user interface e Compact dust proof enclosure e Load signatures OPTIONS e 2 channel and 8 channel models e Mounting bracket for angle viewing e Resolver input for CCM Critical Curve Monitoring e 24VDC power input 2 additional RS422 serial ports Doc 13925 Rev L Page 6 Toledo Integrated Systems Specifications Load Input Job Storage Speed Limit User Interface Resolver optional Computer Interface Probe Input Shutdown Relays No of Channels Sensor Inputs Sensor Excitation Sensor Input Connections Balance Adjustment Balance Range Gain Adjustment Gain Range Analog Output Analog Output Connection Inaccuracy Non linearity Frequency Response Resolution Calibration Shunts Display Keypad Serial Port 1 Serial Port 2 amp 3 Optional Top Stop relay and E Stop relay Doc 13925 Rev L PWi User s Manual Four standard Two and Eight optional Full bridge strain gage sensors 120 to 1 000 ohms Up to 8 350 ohm sensors Built in 12VDC 300mA max Short circuit protected 5 pin 15 pitch Phoenix connector 25 turn potentiometer ImV V of offset 25 turn potentiometer Low Gain 50 to 550 times High Gain 500 to 5 500 times 1 25VDC Press Capacity 9 pin sub D connector 1 of full scale max 1 of full scale max Flat DC to 6 KHz Each channel provides a 5 digit load va
17. followed by either OUT or IN to reflect either the outer or inner slide When viewing the signatures for the outer slide channels 0 4 the 7 segment displays show the load for the outer slide channels When viewing the signatures for the inner slide channels 5 7 the 7 segment displays show the load for the inner slide channels Setpoint menu The HI LO and REV sub menus now show only the percentages for all channels The 7 segment displays show the deviation values for the outer slide and the LCD screen shows the deviation values for the inner slide Separate read only HI SP LO SP and RV SP sub menus display the actual high low reverse setpoint values for each channel Changing channel values When changing values on the Setpoint or Capacity menus channels 0 4 on the 7 segment displays are selected by the blinking decimal point at the top left corner of the display Channels 5 7 are selected by reverse video on the LCD screen Repeatedly pressing cycles through each of the outer slide channels 0 4 then the inner slide channels 5 7 This method applies to the HI LO and REV deviation values on the Setpoint menu and the capacity values on the Capacity menu Doc 13925 Rev L Page 35 di Toledo Integrated Systems PWi User s Manual The Security Code Feature When it is enabled the security code feature restricts unauthorized personnel from making changes while in the Operation mode It requires the
18. if there are four channels Doc 13925 Rev L Page 59 Toledo Integrated Systems PWi User s Manual Trigger Menu e The Trigger menu determines the method that the monitor uses to capture the load TRIG Trigger Menu THRES Triggered by a threshold value PROBE _ Triggered by an external probe RSVR Triggered by a resolver CHG Change trigger method APPY Apply the changes To change the Trigger Method 1 Push to enter change mode Current setting is then selected 2 Push or g to change the setting 3 Push to accept the change or push to cancel the change Notes e When the trigger method is changed to threshold the threshold value is automatically set to 6 of capacity e Choose resolver triggering only if the optional Resolver Board is installed Doc 13925 Rev L Page 60 Toledo Integrated Systems PWi User s Manual Threshold Menu only available when trigger mode is set to Threshold e When using threshold triggering for load capture the Threshold menu provides a means of adjusting the load value at which the monitor will capture the stroke Total loads below this value will be ignored 50 Threshold value Usually set at 6 THRES CHG of press capacity THRES Threshold Menu CHG Change threshold value APPY Apply the changes To change the Threshold Value T 1 Push to enter change mode Current setting is then selected 2 Push B or v to change the setting or Push D or g to change in a l
19. load values ALL Clear all statistics CLR Clear the selected statistics APPY Apply the changes To view statistics 1 Push B or g until the desired statistic is shown 2 Statistics values are shown in the associated corners Doc 13925 Rev L Page 50 Toledo Integrated Systems PWi User s Manual To clear individual statistics 1 Push B or g until the desired statistic is shown gt 2 Push to enter clear mode All channels are then selected and the cleared statistics values for each channel are shown 9 3 Push to accept the clear or push to cancel the clear To clear all statistics 1 Push Or g until ALL is shown gt 2 Push to enter clear mode All channels are then selected and the cleared statistics values for each channel are shown 3 3 Push to accept the clear or push to cancel the clear Doc 13925 Rev L Page 51 Toledo Integrated Systems PWi User s Manual Job Menu e Jobs provide a convenient way to save and recall the settings associated with a particular part Setpoints and benchmark data can be saved to a particular job number and recalled later when needed The Job menu displays the active job number and allows the user to change to a previously created job or create a new job lt Peak load Variation shown as a percentage of the benchmark JOB Job Menu 89 Current job number loaded CHG Change job number APPY Apply the changes To change the Job Nu
20. or assembly has cooled When welding cast iron use a dry nickel rod such as Lincoln Electric Soft Weld Hobart NI Cast 99 or MB Weld Prod MG 210 Strike arc on steel then puddle into the cast iron Remove the weld fixture DO NOT WELD AFTER FIXTURE IS REMOVED The 4 screws holding the pads to the fixture and the 1 center screw may be discarded DO NOT USE THE FOUR 1 INCH LONG SCREWS TO ASSEMBLE SENSOR The sensor kit contains four 34 inch long screws for assembling the sensor to the press member Weld pad surface must be clean no weld bumps scratches etc Be sure the weld pad tapped holes are clean and bottom of holes are free of weld flash Mount the sensor with the raised rib to the press The anti torque washers should go between the screw and the sensor body Torque each 4 28 x in long socket head screw to 150 LB IN or 12 5 LB FT PAGE 6 SENSOR ENCLOSURE MOUNTING USE 10 32 TAP IN THE TWO 3 8 DEEP HOLES THAT WERE DRILLED WITH THE FIXTURE IN THE PREVIOUS INSTRUCTIONS MOUNT THE ENCLOSURE TO THE PRESS MEMBER AND RUN 1 2 INCH CONDUIT TO THE LOAD MONITOR ENCLOSURE gem m E TAP THESE HOLES WITH 10 32 TAP E Uem Sue 10 32 x 3 8 PAN HEAD MACHINE SCREW 1 4 28 x 3 4 SOC HD SCREW SENSOR ENCLOSURE Doc 11080 Rev A RUN SENSOR CABLE THROUGH CONDUIT PLACE SENSOR ON MOUNTING HOLES PLACE ANTI TORQUE WASHERS OVER SENSOR HOLES SCREW IN SENSORS
21. provides both Normally Open N O and Normally Close N C contacts A toggle switch is provided to manually bypass the shutdown relays if necessary CAUTION Bypassing the shutdown relays is a potentially dangerous situation The monitor will not shut down the press when this switch is in the bypass position Equipment can be damaged and personnel may be seriously injured without shut down protection Use Conduit Hole 3 see Figure 1 4 for the Shutdown Relay Wiring Relay Contacts NC Normally Close Contact C Common NO Normally Open Contact Ratings 8 AMP 250VAC or 30VDC Type Mechanical Relay T STP ON TOP STOP RELAY IS OPEN E STP ON E STOP RELAY IS OPEN BYP ON SHUTDOWN RELAYS ARE BYPASSED Bypass Switch Figure 1 22 Shutdown Relay Wiring Shutdown Relay Terminals T Stop For use in the Press Top Stop circuitry E Stop For use in the Press Emergency Stop circuitry Note that using the E Stop under heavy loads may result in the ram becoming locked at the bottom Refer to the Configuration Menu section for instructions on enabling the E Stop relay Doc 13925 Rev L Page 29 Toledo Integrated Systems PWi User s Manual Doc 13925 Rev L Page 30 Toledo Integrated Systems PWi User s Manual 2 Operation User Interface The PWi is equipped with an easy to use menu driven user interface The six push buttons are used to view and change parameters The fol
22. s Manual Mounting the PWi Flush Mount Option An optional flush mounted installation is possible as shown in Figure 1 2 The flush mount option has built in anti shock components therefore external shock mounts are not required As with the standard installation the flush mount option allows the PWi to be mounted directly to the press or to an adjacent structure It should be positioned so that the display is easily read and the instrument is readily accessible 10 25 260mm 5 125 130mm S eo 7 64 194mm Ry 8mm 11 12 282mm HOLE CUTOUT 4 221 DIA FOR SIZE 10 SCREW TYPICAL 6 PLACES Figure 1 2 Flush Mount Mounting Dimensions Doc 13925 Rev L Page 10 Toledo Integrated Systems PWi User s Manual PWi Components Analog Board
23. speed for the PressNet RS422 1 Port APPY Apply the changes To change the Baud Rate 1 Push to enter change mode Current setting is then selected 2 Push or g to change the setting 3 Push to accept the change or push to cancel the change Doc 13925 Rev L Page 69 Toledo Integrated Systems PWi User s Manual Calibration Menu e The Calibration menu allows for balance and gain adjustment for each load channel Balance values Gain numbers CAL Calibration Menu BAL Display Balance value of each channel GAIN Display Gain value of each channel PEAK Display Peak load of each channel To view the Balance Values Gain Numbers or Peak Load 1 Push D or g until the desired item is shown 2 Values are shown in the associated corners To change the Balance Values and Gain Numbers e Balance values are changed by adjusting the corresponding Balance pot for each channel The Balance pots are located on the Analog Board near the sensor input e Gain numbers are changed by adjusting the corresponding Gain pot for each channel The Gain pots are located on the Analog Board near the sensor input Note The calibration procedure is explained in Section 3 Doc 13925 Rev L Page 70 Toledo Integrated Systems PWi User s Manual Security Code Menu Configuration mode e The Security Code menu is used to configure and change the 4 digit security code When the security code is enabled most functions i
24. su sBuipeaJ uoisseJduuoo JO uonoeuuoo jndui 1861 y u Josues eu si SSAUYOIU JUOI OU JI sow 1 siu eui ui sjosues yUNOW Us uey s ss uyo u 110 eui Jl INOHJ SSANMOIHL AHL 33 SV3IN gt X AAYHL AP AIdILINW SSANMOIHL 3 AYNSVAW x 1538 3 ANIWYALAG OL MOH ease pepeus au Ul UMOUS sseJd eu JO JeeJ y JO UOJ y suoneoo peuiuuejep eq 1snui uoneoo Josuegs IN3IN3OV ld YOSNAS S310H LNO MOONM JHL NI SJ3IT3M NIVMLIS 2 1 9NISn LS3SSnS 3M aasn SI dl S3 10H LNO MOON ANIONI SAYNSOTONS 3S3HL SAONVD 5 00 1 IHL LO931O 3d SSSHL SAYNSOTONA HOSN3S 2 z SHOSNGS 2 L SALON PAGE 2 T400 INSTALLATION Rev A Doc 11080 131S 1O08 HO NMOSWO JHL H LGIM 1 NVH L H39S019 SHOSN3S SNI1VOO1 3181SSOd 41 S3SVO 11 NI 3AO8V Qdardosad SV Sd OH GIOAV 9385 80049 1SV31 40 NV NI SHOSN3S TIVLSNI edssSdtd AAV3H AHSA HO 5355 8 3I VH LSVO dO JINN agg 315709 1 l AWVds 953 AHL NI LNO LNO JVH L S31OH 3 dO 3903 WOLLOS 3904 dOl JHL INO NVHL 35 19 SHOSN3S ONITIVLSNI GIOAV 55 dive TIVM
25. to Probe check this box 9 CAL CH1 4 Record the Gain Numbers from step 11 of the Calibration Procedure here 10 STI Value If the mode is set to STI check this box and enter the STI configuration number here 11 Delay Value The configured delay value if used 12 Notes Enter any important notes related to the monitor s configuration in this area Doc 13925 Rev L Page 79 Toledo Integrated Systems If the optional Resolver Board was purchased an additional calibration label is included to document the PWi User s Manual resolver information and or the channel 6 9 analog input information 13 Capacity CH5 The total capacity associated with load sensors 6 9 For example in the case of a double action press Capacity CH5 4000 Resolver Offset Value 285 CH6 CH7 CH8 CH9 1575 1569 1611 1543 Input Resolver Analog Board Sri CH6 CH7 CH8 CH9 01154 Additional Resolver Resolver Configuration e 152 53 Wiring and setup for CH6 9 are similar to CH1 4 where sensors 6 9 are used to measure the load for the inner slide the CH5 capacity is the total capacity for the inner slide 14 Resolver If the trigger method is set to Resolver check this box 15 Offset Value When using Resolver triggering enter the offset value that is requi
26. ton capacity press is making good parts at 50 tons If the high and low setpoints are set to 20 the following setpoints will be calculated after the Learn function is used e Capacity method 200 tons 20 40 tons Hi Setpoint 50 tons 40 tons 90 tons Lo Setpoint 50 tons 40 tons 10 tons e Benchmark method 50 tons 20 10 tons Hi Setpoint 50 tons 10 tons 60 tons Lo Setpoint 50 tons 10 tons 40 tons In this example choosing the Benchmark method will produce a much tighter range of good values 20 tons than the Capacity method 80 tons Doc 13925 Rev L Page 62 Toledo Integrated Systems PWi User s Manual Delay Menu only available when trigger mode is set to Threshold e When using threshold triggering for load capture the Delay menu provides a means of manually controlling the duration of the stroke capture Load capture begins when the load crosses the threshold value and ends after the fixed delay time This is advantageous for applications that normally see the load drop below and then rise above the threshold value more than once within a single press stroke 1 9 a double hit 2 500 Delay value seconds DELAY CHG DELAY Delay Menu CHG Change delay value APPY Apply the changes Hit 1 In this example of a double hit the load rises above the threshold value peaks and then drops below the threshold to end Hit 1 However the load then rises Hit 2 slightly above thre
27. used for die setup Only capacity limits are active in Setup mode Learn mode is used to teach the monitor new alarm setpoints After the unit is placed in Learn mode the next 8 strokes are used to generate a new benchmark and new high and low setpoints The monitor then switches to Run mode to continue production Doc 13925 RevL Page 40 Toledo Integrated Systems PWi User s Manual To change the operating mode 1 Push B or g until the desired mode RUN SETUP or LRN is shown 2 Push to accept the change or push to cancel the change Note When Setup mode is enabled the capacity is displayed in place of the variation This is a reminder that only capacity limits are active in Setup mode Doc 13925 Rev L Page 41 Toledo Integrated Systems PWi User s Manual Signature Menu e The Signature menu displays the load signature for the current stroke for analysis and troubleshooting purposes I SIG Signature Menu Cycles through the signature for each corner and the total PAUSE Freeze the signature updating and open the memory options Doc 13925 RevL Page 42 Toledo Integrated Systems PWi User s Manual Signature Detail for Probe or Threshold Trigger Capacity for the current corner High Low Setpoints for the current corner Signature length milliseconds Load signature for the current corner Current Corner Left Rear shown Signature Detail for Resolver Trig
28. 533530 08 31001 SHOSN3S OML HOSN3S 0071 KINO 33H H3HSVM 318VO PAGE 4 T400 INSTALLATION Doc 11080 Rev A USING THE T400 SENSOR INSTALLATION FIXTURE KIT No 1977 749 METRIC INSTALLATION FIXTURE KIT No 1974 749 DRILL AND TAP METHOD FOR MOUNTING SENSORS BE SURE THE SENSOR LOCATION FOLLOWS THE BEST LOCATION DESCRIBED ON THE PREVIOUS PAGES 3 DRILL STEP 2 QM i 2 1 4 28 TAP METRIC 6 1 3 DRILL 5mm X ORY DRILL THROUGH FOUR SMALL HOLES STEPS 3 4 1 4 28 X 1 1 4 SCREW METRIC 6 1 X 35 ROTATE FIXTURE 90 DEGREES 2041 STEP 5 O 21 DRILL 8 lt DRILL THROUGH THE TWO SMALL CENTERED HOLES ROTATE FIXTURE 90 DEGREES S1 4 28 TAP STEPS 6 7 METRIC 6 1 TAP THROUGH FOUR LARGE HOLES _ ANTI TORQUE lt WASHERS STEP 9 1 4 28 x 3 4 LOC WEL BOLTS PUT RAISED RIB TO PRESS Doc 11080 Rev A STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7 STEP 8 STEP 9 T400 INSTALLATION Remove all paint and grease from sensor mount area If the machine surface is flat total indicated reading of 002 and smooth 125 in the load sensor can be bolted directly to the surface Drill and tap the center hole for mounting the fixture to the press member This hole should be 1 2 inch 13mm deep Bolt the fixture to the press member usi
29. AL NO CCMOFFSET _ STI DEGREES IN CHANNEL No 1 STI REFERENCE NUMBER LOW ____ TRIGGERED FROM PROBE YES NO TRIPPED ALARM RELAY STOPS PRESS YES _ ALL STICKERS AND DOCUMENTS FILLED OUT YES NO IF NOT EXPLAIN WHY TFP No HIGH2 LOW 2 COMMENTS HGH4__ 4____ Show threshold value if not triggered from probe HIGH NO EXPLAIN HGH6 ___ LOW6 HIGH8 LOW 8 TESTS MADE BY MAIL ADDRESS TOLEDO TRANSDUCERS INC P O BOX 10 HOLLAND OHIO 43528 TESTS ACCEPTED BY SHIPPING ADDRESS TOLEDO TRANSDUCERS INC PHONE 1 419 867 4170 6834 SPRING VALLEY DR FAX 1 419 867 4180 HOLLAND OHIO 43528
30. BOLTS 4 EACH FINGER TIGHT USE ONLY 1 4 28 x 3 4 LOC WEL BOLTS THAT ARE IN THE SENSOR PACKAGE TORQUE EACH 1 4 28 3 4 SCREW TO 150 LB IN OR 12 5LB FT ASSEMBLE BOX COVER d A LOAD MODEL T400 S N x 7 gt T400 INSTALLATION CONDUIT PAGE 7 TOLEDO TRANSDUCERS INC PRESS CALIBRATION TEST DATA HOLLAND OHIO U S A COMPANY DATE PRESS SERIAL No PRESS Type and amp No CONTACT PRESS CAPACITY PHONE LOAD MONITOR MODEL SERVICE ORDER CC MONITOR SERIAL No SLIDE ADJUST INDICATOR LINEARITY PLOT USING TONS SHOWN ON TOTAL DISPLAYS TOTAL LOAD DISPLAYED ON MONITOR L J _ Jl e TOTAL TONNAGE APPLIED TO LOAD CELLS ON PRESS F1224 Rev A DRAW IN e CHANNEL NUMBER e SENSOR LOCATION e MONITOR LOCATION e LOAD CELL LOCATION e DIRECTION OF MATL FLOW SHUNT RESISTORS ONE MEG YES OTHER RESISTORS CHAN 1 CHAN 2 CHAN 3 CHAN 4 TYPE OF LOAD CELLS _ MATERIAL FLOW draw arrowhead FRONT OF PRESS BED TYPE OF LOAD CELL READOUT TONNAGE SENSORS CALIBRATION LOAD CELLS CAPACITY TONS SERIAL NO CCMOFFSET _ STI DEGREES IN CHANNEL No 1 STI REFERENCE NUMBER LOW ____ TRIGGERED FROM PROBE YES NO TRIPPED ALARM RELAY STOPS PRESS YES _ ALL STIC
31. KERS AND DOCUMENTS FILLED OUT YES NO IF NOT EXPLAIN WHY TFP No HIGH2 LOW 2 COMMENTS HGH4__ 4____ Show threshold value if not triggered from probe HIGH NO EXPLAIN HGH6 ___ LOW6 HIGH8 LOW 8 TESTS MADE BY MAIL ADDRESS TOLEDO TRANSDUCERS INC P O BOX 10 HOLLAND OHIO 43528 TESTS ACCEPTED BY SHIPPING ADDRESS TOLEDO TRANSDUCERS INC PHONE 1 419 867 4170 6834 SPRING VALLEY DR FAX 1 419 867 4180 HOLLAND OHIO 43528 TOLEDO TRANSDUCERS INC PRESS CALIBRATION TEST DATA HOLLAND OHIO U S A COMPANY DATE PRESS SERIAL No PRESS Type and amp No CONTACT PRESS CAPACITY PHONE LOAD MONITOR MODEL SERVICE ORDER CC MONITOR SERIAL No SLIDE ADJUST INDICATOR LINEARITY PLOT USING TONS SHOWN ON TOTAL DISPLAYS TOTAL LOAD DISPLAYED ON MONITOR L J _ Jl e TOTAL TONNAGE APPLIED TO LOAD CELLS ON PRESS F1224 Rev A DRAW IN e CHANNEL NUMBER e SENSOR LOCATION e MONITOR LOCATION e LOAD CELL LOCATION e DIRECTION OF MATL FLOW SHUNT RESISTORS ONE MEG YES OTHER RESISTORS CHAN 1 CHAN 2 CHAN 3 CHAN 4 TYPE OF LOAD CELLS _ MATERIAL FLOW draw arrowhead FRONT OF PRESS BED TYPE OF LOAD CELL READOUT TONNAGE SENSORS CALIBRATION LOAD CELLS CAPACITY TONS SERI
32. LO REV BENCH CAP CHG APPY To view setpoints 1 Push B or g until the desired setpoint is shown 2 Setpoint values are shown in the associated corners Doc 13925 Rev L Toledo Integrated Systems lt Setpoint values Setpoint Menu High Setpoint Low Setpoint Reverse Setpoint Benchmark Read Only Capacity Read Only Change setting Select channels Apply the changes Page 46 PWi User s Manual To change setpoints 1 Push to enter change mode Total channel is then selected gt 2 Push to select the desired channel 3 Push or g to change the value or Push g to change in a larger increment 4 Push to accept the change the next channel will be selected or push to cancel the change 5 Repeat from Step 2 to make changes on other channels 6 Push to exit change mode Note To bypass a channel s setpoint change the channel s setpoint to zero For example to disable reverse alarms for channel 4 change the REV for channel 4 to zero To disable all reverse alarms set channel 0 s REV to zero Doc 13925 Rev L Page 47 Toledo Integrated Systems PWi User s Manual Alarm Menu e The Alarm menu displays detailed alarm information for each of the channels If there is an active alarm it can be reset from this menu Variation from benchmark ALARM Alarm Status Menu CAP x Capacity alarm in channel x HI x High setpoint alarm in
33. P Wi Production Monitor By Toledo Integrated Systems User s Manual 16043 PWi User s Manual PWi User s Manual Revision L Scan to visit u on the web Doc 13925 Rev L Page 1 di Toledo Integrated Systems PWi User s Manual Table of Contents 1 Installaatio 5 Limited Warranty 5 A 6 A usa 7 Mounting the PWi Standard Installation 9 Mounting the PWi Flush Mount Option 10 PWITCG6mpon e ntSu aS E E Aaa a tial eed hee 11 Conduit Hole Selection is uq asas nn dec Doe ue Cn Ya ATUM e ORIS orsa o SUN DNO 12 AC Power Connection and Configuration r 13 qn 14 Sensor Input ConfieWratIO n E d UE 15 Sens de S 16 Sensor Cable PermralroTi cou SSS cu A eos 17 Sensors Connection Su a m due ase 18 ICU Mc 19 lp ined 20 Resolver Connection and Setup optional a enne 22 External Res
34. WEEN THE COMMON AND THE Rx422 232 SHIELD Senconinc 22 232 Rx422 7 Rx422 d 5422 232 lt A ORG ORG WHT Rx422 _ Rx232 7 74 l J CTS232 Tx422 232 Tx422 RTS422 232 COMMON N gt PN L RTS422 v F CIM800 RTS422 COMMON 422 _ ee 232 RTS422 RTS232 COMMON mmmmmmmummm BLUE BLUE WHT USE BELI TO COMPUTER RS232 INTERFACE 9 PIN CONNECTIONS Pin 2 to Sencon Rx 232 Pin 3 to Senson Tx422 232 Pin 5to Sencon COMMON Doc 13925 25 PIN CONNECTIONS Pin 2 to Sencon Rx 232 Pin 3 to Senson Tx422 232 Pin 7 to Sencon COMMON TO MONITOR RS422 INTERFACE FLASHES EACH TIME MONITOR RESPONDS FLASHES EACH TIME COMPUTER REQUESTS DATA Figure 1 21 RS422 Serial Network Wiring Toledo Integrated Systems qi DEN CABLE 8103 CABLE LENGTH 4 000 FT MAX TO THE LAST UNIT Page 28 PWi User s Manual Shutdown Relays The PWi provides a Top Stop Relay and an E Stop Emergency Stop Relay When enabled the E Stop Relay is used to stop the press immediately in case of a capacity violation Each relay
35. and 0 9 0 5 for viewing and changing job E changing set number points PEAK RUN OK STAT Statistics menu for viewing and resetting load statistics ALARM Alarm menu for viewing and resetting alarms REV Reverse load menu for viewing reverse load To view other menus Push or g until the desired menu is shown To return to the Home menu E From any menu push to return to the Home menu The home symbol ft on the bottom left corner of the display indicates that the current menu is home Doc 13925 Rev L Page 39 Toledo Integrated Systems PWi User s Manual Operation Mode Description Home Menu e The Home menu displays the current peak load and the variation from the benchmark load Setup and Learn mode can be enabled from this menu and the alarm and bypass status can be viewed If the unit is configured for resolver triggering the position is displayed here as well Variation shown as a percentage of the benchmark Resolver position if using resolver triggering PEAK Standard Peak load monitoring mode RUN Run mode SETUP Setup mode LRN Learn mode OK Forming loads are within limits ALARM Load limits are violated BYP Some limits are bypassed About the operating modes The operating mode determines how the monitor reacts to the current load e Run mode is used for production All setpoint alarms are active in Run mode e Setup mode is
36. ant ability or fitness for a particular purpose All such warranties are hereby disclaimed and excluded by the manufacturer Repair or replacement of defective products as provided above is the sole and exclusive remedy provided thereunder The manufacturer shall not be liable for any further loss damages or expenses including incidental or consequential damages directly or indirectly arising from the sale or use of this product Any unauthorized repair voids this warranty There are no warranties that extend beyond those expressly set forth herein Doc 13925 Rev L Page 5 Toledo Integrated Systems PWi User s Manual Features Overview The PWi is a full featured load monitor that interfaces with load sensors to provide force measurement for press protection and quality control Load of each channel is displayed on high visibility 7 segment LED displays The user interface consists of six tactile switches and a back lit LCD graphic display module that provides a user friendly menu system The LCD is also used to show deviation alarm data settings and much more 21 25 PEAK RUN ALARM FEATURES e 4channel load monitoring 2 shutdown relays Top Stop and E Stop e Reverse load e 100 job storage e LCD graphic display with back lighting One RS422 serial port e 5
37. arger increment 3 Push to accept the change or push to cancel the change Notes e If the threshold value is set to zero the trigger method will automatically be set to probe If the threshold value is set to capacity the trigger method will automatically be set to resolver Doc 13925 Rev L Page 61 Toledo Integrated Systems PWi User s Manual Learn Menu e The Learn menu provides a way to control the method that is used to calculate the high and low setpoints when the Learn function is used LEARN CHG LEARN Learn Menu Setpoints are calculated based on the benchmark 9oCAP Setpoints are calculated based on the capacity CHG Change learn method APPY Apply the changes To change the setpoint learning method gt 1 Push to enter change mode Current setting is then selected 2 Push or to change the setting 3 Push to accept the change or push to cancel the change Choosing a setpoint learning method While either method can be chosen it is important to understand how the setpoint learning method will affect the high and low alarm setpoints As a general rule choosing to learn setpoints based on a percentage of capacity will generate a larger range of good load values than choosing to learn based on a percentage of the benchmark This effect is more evident if your normal running peak load is relatively small compared to the capacity Consider the following example A 200
38. e load associated with each of the four press corners on the outer 7 segment LED displays while the total of the four corners is shown on the center LED display The LCD screen provides additional information for each of the corners and their total In the example at left the LCD screen is showing the variation from the benchmark tonnage The 2 channel configuration is used when only two sensors are required The load is no longer described as corners as in the 4 channel configuration Instead the total load is divided into a left and right side This configuration shows the load associated with the left and right sides of the press on the bottom left and bottom right 7 segment LED displays while the total is shown on the upper center LED display The LCD screen functions much like the 4 channel configuration except that the data displayed reflects the left right sensor layout Page 33 PWi User s Manual 8 Channel Configuration The 8 channel configuration is used when eight load sensors are required As in the case of a double action press four sensors channels 1 4 are used to report the outer slide load and another four sensors channels 6 9 are used for the inner slide load 958 This configuration shows the load LOAD associated with the outer slide 241 237 corners channels 1 4 on the outer PERK RUN OK 7 segment LED displays with the outer slide total channel 0 shown on the center LED dis
39. entry of a 4 digit code before performing the following functions e Changing the mode Run Setup Learn e Changing setpoints High Low and Reverse e Resetting tonnage alarms e Clearing statistics e Changing jobs As a reminder of the current security status a lock indicator appears at the top of the LCD display when a security code has not been entered Locked 02 00 01 car 05 04 PERK RUN OK To manage the security code functions there is a Security Code menu on both the Operation mode and the Configuration mode Each Security Code menu has different functions Security Code menu functions for the Operation mode e Locking and unlocking the security code Security Code menu functions for the Configuration mode e Enabling and disabling the security code feature e Changing the 4 digit security code e Resetting the security code to its default Refer to the Operation mode and Configuration mode sections for more details Doc 13925 Rev L Page 36 Toledo Integrated Systems PWi User s Manual The Low Battery Indicator All critical settings including system configuration Capacities threshold etc and job related setpoints are stored in nonvolatile flash memory to prevent data loss However some non critical information including alarm counts statistics and live load values are stored in battery backed memory When the battery s voltage becomes low a low battery indicator appears
40. ept the current digit and advance to the next digit 3 Repeat steps 1 and 2 until all four digits have been entered If the security code is incorrect the first digit will once again be highlighted If the security code was accepted the screen will return to the Home menu and lock indicator will be gone to indicate that all features are now unlocked Note The default security code is 4 1 7 0 The following example demonstrates the sequence to enter a security code Doc 13925 Rev L Page 53 Toledo Integrated Systems PWi User s Manual Sequence to Enter a Security Code Example Enter First Digit 3 Enter Second Digit 5 Entering a security code of 3 5 0 6 p k ETER CoDE CoDE CODE ENTER NEXT CODE ENTER NEXT 5 5 4 x 3 then E x 5 then E Enter Third Digit 0 Enter Fourth Digit 6 EnTER kk d EnTER CoDE CoDE CODE ENTER NEXT CODE ENTER NEXT J only 4 x 6 then Notes e Highlighted digits start with a value of zero To enter a zero like the third digit in the above example simply press without pressing any other button e Digits can be entered with either the or g buttons For example the digit 9 can be entered by pressing B nine times or by pressing g one time e If you suspect that an incorrect digit was entered you can press to cancel the code entry and start again at the first digit Doc 13925 Rev L Page 54
41. er s Manual Serial Port Connection An RS422 serial port is available for interfacing the PWi with a computer running the PressNet software RS422 allows the implementation of a daisy chain multi drop serial network as a standard feature The RS422 1 port can be configured for the following baud rates e 9600 38 4k 76 8k e 115 2k The figure below details the location of the RS422 1 port Wiring diagrams can be found on the next page FLASHES WHEN DATA IS SENT BY THE MONITOR FLASHES WHEN DATA IS RECEIVED BY THE MONITOR Figure 1 19 Serial Connection Doc 13925 Rev L Page 27 Toledo Integrated Systems PWi User s Manual Computer to single PWi monitor wiring SHIELD TO CONNECTOR CASE SHIELD TX232 Pin 2 RX232 Pin 3 25 PIN D CONNECTOR TO MONITOR GND Pin 7 CABLE LENGTH 9 600 BAUD 50 FEET MAX 115 200 BAUD 10 FEET MAX SHIELD 9 PIN D CONNECTOR TO MONITOR GND Pin 5 Figure 1 20 RS232 Serial Port Wiring Computer to multiple PWi monitors wiring Networking COMPUTER RS232 SERIAL PORT THESE ARE THE CONNECTIONS FOR A 25 OR 9 PIN D CONNECTOR TO NEXT TO MONITOR MONITOR TOP VIEW OF CIM800 INPUT CONFIGURATION SWITCH SETTINGS COMPUTER SIDE MUST BE SET TO RS232 MONITOR SIDE MUST BE SET RS422 A 120 OHM RESISTOR MUST BE CONNECTED AT THE CONVERTER BET
42. et Switch Connection A SE 26 Serial Port COMME CUO s a Su qoa uti en Sea 27 Shutdown Relays usss sqa d a 29 L 2 LB ITO RS TET LESEN ua TNT TIT 31 User Interface u ays 31 Operation Mode and Configuration Mode 32 Understandine oss ai aee qa tisaq u 33 The Security Code Peat re oops E a ead teak 36 The L w Battery Indicator AS sta Re A 37 Replacing the Backup Battery hee ee 38 Operation Mede OVefVISWius y Sun ai qaq isuu ua 39 Operation Mode 40 40 Sienature Mehl ees ee CI ER 42 46 ai 48 Reverse MenWs c h eT ee et i u 49 Aree gr ut 50 JoD MCN 22 Security Code Menu Operation mode ie tati iet ae sive ive a
43. example 12 from the sides 10 from front and rear Load cells are typically placed at each corner of the press s bed B Cycle the press without hitting the load cells first C Place cardboard on the top and bottom of the load cells 6 Cycle the Press A While still in the Calibration menu push or Bal to display the PEAK tonnage B Further adjust the shut height so that the press impacts the load cells and generates a load at 100 of press capacity See warning below WARNING Depending on the press capacity and the size of the load cells being used loading the press at capacity with load cells could indent the ram or bolster To prevent this situation from happening do one of the following a Calibrate the press only up to 80 of capacity or b Use larger load cells to increase the loading surface For instance to calibrate a 400 Ton press at capacity use 4 250 Ton load cells instead of 4 100 Ton load cells 7 Gather Record and Enter Data A Record the load cell numbers for each of the channels These are the load values of the press corners B Record the peak tonnage values from the PWi C While still in the Calibration menu push or g to display the GAIN numbers This enables the PWi s shunt Record the Gain numbers 107 CAL E Repeat the calculation for each channel Doc 13925 Rev L Page 76 Toledo Integrated Systems PWi User s Manual F Adjust the gain pot for CH1 unti
44. ger Load signature for the current corner Press position degrees To view each corner s signature The corners are represented graphically by four quadrants on the signature menu which correspond to the corner symbols on the front of the monitor For example in the signature detail above the upper left quadrant is filled in while the remaining three quadrants are empty This indicates that the Left Rear corner is currently displayed If all four quadrants are filled in the Total is currently displayed To select other corners 1 If the signature is not paused push or until the desired corner is shown 2 If the signature is paused push g until the desired corner is shown As each corner is selected the quadrant symbols on the menu will change to indicate the current corner Doc 13925 Rev L Page 43 Toledo Integrated Systems PWi User s Manual To pause and resume the signature updating 1 2 While the right menu is showing PAUSE gt Push to stop the signature updating The right menu now changes to BACK In this state the press can continue to run but the signatures will not update Also notice that the corner selection menu option has shifted from the center menu to the left menu position While the signature is paused the and g buttons are used to cycle through each of the corners While the right menu is showing BACK gt Push again to resume the signature updating
45. l the gain number for channel 1 equals the new calculated gain number Turn the pot clockwise to increase the gain number and counter clockwise to decrease the gain number Repeat for each of the remaining channels G Push or g to display the BAL balance values Use the balance pots to re balance the channels if needed H Push or g to display the GAIN numbers If they are not equal to the calculated gain numbers re adjust them Repeat steps F H as needed 8 Verify Results and Repeat A While still in the Calibration menu push or g to display the PEAK tonnage B Cycle the press C Verify that the load cell values and the PWi s peak tonnage values are same If not repeat step 7 until the values are the same 9 Make Linearity Check A Raise the shut height in 020 to 030 inch increments to decrease tonnage B Cycle the press and impact the load cells C Compare the tonnage applied to the load cells to the tonnage displayed on the PWi These values should be documented 10 Document calibration details on the Calibration Sheet Form 1224 provided and file it for future reference 11 Record Gain Numbers A While still in the Calibration menu push a or g to display the GAIN numbers B Record these numbers on the calibration card located on the door inside of the unit See section 4 for details on the calibration card 12 Calibration Complete The calibration procedure is now complete Contact Toledo
46. ld value DELAY Delay menu for setting the threshold time delay value LEARN method To view other menus Push or g until the desired menu is shown Note Depending on the trigger method and mode selected some menus will not be shown Doc 13925 Rev L Page 56 Toledo Integrated Systems PWi User s Manual Configuration Mode Description Channel Menu e The Channel menu controls the number of load channels that the monitor will display CHAN Channel Menu 04 4 channel unit for 4 sensor inputs CHG Change number of channels APPY Apply the changes To change the Number of Channels gt 1 Push to enter change mode Current value is then selected 2 Push or g to change the value 3 Push to accept the change or push to cancel the change Note When the number of channels is set to 2 for a 2 channel unit the total load is divided into a left half Channel 1 and a right half Channel 2 The left channel is viewed in the lower left corner of the display and the right channel is viewed in the lower right corner of the display The illustrations in this manual reflect a 4 channel configuration The appearance of the menus for the 2 channel configuration may vary from those shown in this manual but their functions remain the same Doc 13925 Rev L Page 57 Toledo Integrated Systems PWi User s Manual Decimal Point Menu e The Decimal Point menu controls the p
47. lowing describes the layout of the LCD screen and the push buttons Security Code Lock Indicator Data for Current Menu Mode Change Menu Course Settings 77 Adjustment M p t Select Cancel Home Change Mode Fine Settings Adjustment Doc 13925 Rev L Page 31 Toledo Integrated Systems PWi User s Manual Operation Mode and Configuration Mode The Operation Mode is used in normal operation and the Configuration Mode is for initial setup Dip Switch 1 in SW1 is used to select these modes SW1 is located on the side of the Control Board which is mounted on the inside of the door To select the Operation Mode Side of Door Set Dip Switch 1 to up position To select the Configuration Mode Set Dip Switch 1 to down position Dip Switch 1 Doc 13925 Rev L Page 32 Toledo Integrated Systems Understanding the Displays PWi User s Manual The layout of the menus and data on the 7 segment LED displays and the center LCD screen are designed to be highly intuitive and require little explanation However some functions and layout can vary depending on the number of channels needed Some of the differences are highlighted below 4 Channel Configuration OK 13925 Rev L Toledo Integrated Systems The 4 channel configuration is the most common one As such the illustrations and procedures in this manual focus on this layout This configuration shows th
48. lue in 1024 count resolution 1 Meg Ohm 0 1 resistor 100 jobs Up to 400 SPM with threshold trigger Up to 2 000 SPM with probe trigger Back lit 1 5 x2 75 LCD graphical display 64x128 pixel 5 LED displays each consisting of five 7 segment displays Menu driven keypad consisting of six tactile switches Built in excitation supports standard 5000 Hz rotor excited positional resolver RS422 9 600 to 115 200 baud for PressNet software interface RS422 9 600 to 115 200 baud for data transfer Built in voltage source 12VDC 50 mA max provides power for the probe It supports NPN or PNP proximity probes and solid state or dry contact relay Mechanical relay with N O and N C contacts 8 AMP 250VAC or 30VDC Page 7 T Toledo Integrated Systems Supply Power AC units Supply Power DC units Data Storage Operating Temperature Dimensions Requirements Fuse Requirements Fuse Configuration Jobs Live data Counters peak load Doc 13925 PWi User s Manual 30 Watts max 85 132VAC 50 60Hz or 170 264VAC 50 60Hz Power Input is jumper selectable 0 5A for 110VAC input 0 25A for 220VAC input TRS type Slow Blow 24VDC 1 25A minimum 1 25A TRS type Slow Blow Nonvolatile Data Flash Lithium Battery Type CR 1 3N 0 to 70 degrees Celsius 8 90 W x 6 88 H x 5 00 D or 226mm W x 175mm H x 127mm D Page 8 Toledo Integrated Systems PWi User s Man
49. m fp renee M LG LB me AS Shielded Twisted Pair MASTER DEVICE e g BELDEN CABLE 8103 TT 2038 222 Figure 1 16 Resolver Master Mode Wiring Slave Mode Wiring Do not connect SHIELD to Monitor a f SHIELD roe fp Er SHL MASTER DEVICE E Lo E m ose p MONITOR AS SLAVE DEVICE TO RESOLVER Shielded Twisted Pair Cable e g BELDEN CABLE 8103 TT 2038 222 Note TTI labels 51 53 and S2 S4 as stator pairs but some manufacturers label 51 52 and 53 54 as pairs Pay attention to this when connecting the monitor as a slave system Figure 1 17 Resolver Slave Mode Wiring Doc 13925 RevL Page 24 Toledo Integrated Systems PWi User s Manual MASTER Resolver Input Setup 121315 1 Set all DIP switches to the OFF left position STAT2 12 315 2 Determine whether the resolver input should be in MASTER mode or SLAVE mode and make the proper setting Master Mode Slave Mode 3 Make resolver connection 4 With the system on press can be either running or not running check to see if the ROT LED turns on Scale down the rotor input voltage by 4X if the ROT LED does turn on Scale Down 4X 5 With the press running check to see if the STAT LED turns on If it turns on scale down both stator input voltages first by 2X If it still turns on scale it down further b
50. mber 1 Push to enter change mode Current job number is then selected 2 Push or g to change the setting 3 Push to accept the change or push to cancel the change Notes e Up to 100 jobs 0 99 can be stored and recalled When a previously unused job number is selected a new job is created When this happens the setpoints from Job 0 are used as a template Doc 13925 Rev L Page 52 Toledo Integrated Systems PWi User s Manual Security Code Menu Operation mode only available when the security code is enabled In the Operation mode the Security Code screen is used to enter the 4 digit security code to unlock access to the protected features and to lock the unit again after the desired changes are made 4 Digit Security Code k EnTER First digit selected CoDE CODE ENTER NEXT CODE Security Code Menu ENTER Increase Decrease value of currently selected digit NEXT Select next digit of security code To enter the Security Code The security code consists of four numerical digits each with a range of 0 9 For security reasons the digits are not displayed on the LCD as they are entered The digits are represented by with the currently selected digit highlighted Digits are incremented and decremented with the middle arrow buttons B or g The button accepts the current digit and advances to the next digit 1 Push B or g to increment or decrement the current digit 2 Push to acc
51. n the Operation mode are restricted until the security code is entered 4 Digit Security Code x Enter First digit selected CoDE CODE ENTER NEXT CODE Security Code Menu ENTER Increase Decrease value of currently selected digit NEXT Select next digit of security code To enter the Security Code The security code consists of four numerical digits each with a range of 0 9 For security reasons the digits are not displayed on the LCD as they are entered The digits are represented by with the currently selected digit highlighted Digits are incremented and decremented with the middle arrow buttons B or g The button accepts the current digit and advances to the next digit 1 Push B or g to increment or decrement the current digit 2 Push to accept the current digit and advance to the next digit 3 Repeat steps 1 and 2 until all four digits have been entered If the security code is incorrect the first digit will once again be highlighted If the security code was accepted the option to enable disable or change the security code will appear For an example of how to enter the security code see page 54 Doc 13925 Rev L Page 71 Toledo Integrated Systems PWi User s Manual To enable or disable the Security Code feature Once a valid security code has been entered the following options will appear X CHAngE CoDE CODE DSABL CHG 5 If the security code feature is curren
52. nd is wired directly to the resolver In Slave Mode the PWi does not supply excitation voltage to the resolver and is wired to the resolver input terminal of a Master device where the resolver signal is shared Use Conduit Hole 2 see Figure 1 4 for the resolver cable The resolver input consists of the following components Resolver Configuration DIP switches Optional Resolver Board Resolver Connector Channel 6 Channel 9 Channel 7 Channel 8 Note Resolver Board may not be equipped with sensor input channels 6 9 If channels 6 9 are available they will be terminated and configured in a similar manner as channels 1 4 Figure 1 14 Resolver Interface overview Doc 13925 Rev L Page 22 Toledo Integrated Systems 13925 Rev L PWi User s Manual Turns on if ROTOR voltage is too high Turns on if the 2 STATOR voltages are too high ROT STA OFF ON Master and Slave Selections R1 R2 Voltage Scaling 51 53 Voltage Scaling MASTER 2 3 5 2 3 5 52 54 Voltage Scaling CONNECTOR WIRING SHL R2 R1 S4 S2 S3 S1 Figure 1 15 Resolver Interface detail Page 23 T Toledo Integrated Systems PWi User s Manual Master Mode Wiring SHIELD Do not connect SHIELD to resolver SHIELD
53. nde aaa de 53 Configuration Mode OVvervIew asss 56 Configuration 57 Channel Meni haga La saa a nas 57 Decimal Point WA CI ahaa neato So a 58 Capacity Mehl al pata nels erae 59 Doc 13925 Rev L Page 2 Toledo Integrated Systems PWi User s Manual Trigser CHU testes 60 Threshold Menw is coeds 61 Learn Meno o man anus us a mau 62 Delay edite 63 Offset Meu upachu quna aa h een ay cea 64 Mode Menus mani nha a u v etii te 65 aqa aaa a et Hed de ep Hei se uu ha anaes 66 Count Menti 67 Address Meni oaa u k S E N a 68 Bud R te oie Ri AR kuat 69 Calibration Men sees e e aS a eee 70 Security Code Menu Configuration mode eese 71 3 Calibration Procedure 75 B 4 Calibration Information Label 79 5 a Operator ca
54. ng the 4 28 by 1 inch M6 1 x 35 long socket head cap screw in the center of the fixture Insert the number 3 drill Smm into the smaller corner hole and drill out all four holes to a depth of 4 of an inch 19mm Loosen the fixture Rotate the fixture 90 degrees clockwise Tighten the center screw of the fixture Insert the number 21 drill into the small centered hole and drill out both holes to a depth of 3 8 of an inch These holes are for mounting the sensor enclosure The fixture does not allow for tapping these holes They are tapped without the fixture Enclosure mounting is not done in metric Loosen the fixture Rotate the fixture another 90 degrees clockwise such that the larger corner holes line up with the holes drilled in Step 4 Insert a tap to be sure the holes line up Lock the fixture in place by tightening the center screw Insert the tap into the larger tap guide holes and tap each hole BE SURE TO USE PLENTY OF TAPPING FLUID Remove the fixture and repeat Steps 1 7 for each additional sensor mounting position Mount the sensor with the raised rib to the press The anti torque washers should go between the screw and the sensor body Torque each 4 28 x in long socket head cap screw to 150 LB IN or 12 5 LB FT PAGE 5 USING THE T400 SENSOR INSTALLATION FIXTURE KIT No 1977 749 WELD PAD METHOD FOR MOUNTING SENSORS BE SURE THE SENSOR LOCATION FOLLOWS THE BEST LOCATION DESCRIBED ON THE PREVIOUS PAGES
55. ning the Offset Value needed 1 Cycle the press to the top position This should be 0 2 Subtract the resolver position shown in the total window from 360 to get the offset value Refer to the following section to enter the offset To change the Offset Value 1 Push to enter change mode Current setting is then selected 2 Push B or g to change the setting or Push Or g to change in a larger increment 3 Push to accept the change or push to cancel the change After entering the offset value the resolver position should read zero If not re calculate the offset value as described above Doc 13925 Rev L Page 64 Toledo Integrated Systems PWi User s Manual Mode Menu e The Mode menu provides an alternate method for processing load data MODE PEAK CHG MODE Mode Menu PEAK Standard Peak mode STI Slide Tonnage Isolation mode CHG Change load processing mode APPY Apply the changes To change the Load Processing Mode gt 1 Push to enter change mode Current setting is then selected 2 Push or g to change the setting 3 Push to accept the change or push to cancel the change Notes e STI mode is only available for units with eight sensor inputs e Refer to the PWi STI Supplemental Manual for more details about the Slide Tonnage Isolation mode Doc 13925 Rev L Page 65 Toledo Integrated Systems PWi User s Manual E Stop Menu e The E Stop menu configures the operation of the Emergency Sto
56. on Doc 13925 RevL Page 81 di Toledo Integrated Systems PWi User s Manual Doc 13925 Rev L Page 82 Toledo Integrated Systems PWi User s Manual 6 Appendix I Sensor Installation Doc 11080 ID Calibration Sheets 2 Form 1224 Doc 13925 Rev L Page 83 T Toledo Integrated Systems INSTALLING T400 LOAD SENSORS FIVE HOLES DRILLED AND TAPPED IN PRESS MEMBER 400 LOAD SENSOR TWO ANTI TORQUE WASHERS FOUR LOC WEL BOLTS 3 4 INCH LONG TORQUE EACH 1 4 28 x 3 4 IN LONG SOCKET HEAD SCREW TO 150 LB IN OR 12 5 LB FT WELD PADS ARE WELDED ON THREE SIDES ONLY T400 LOAD SENSOR TWO ANTI TORQUE WASHERS FOUR LOC WEL BOLTS 3 4 INCH LONG TORQUE EACH 1 4 28 x 3 4 IN LONG SOCKET HEAD SCREW TO 150 LB IN OR 12 5 LB FT The above illustrations represent the proper arrangement of Model T400 Load Sensor kit parts using either the Drill and Tap method or the Weld method A proper installation is necessary to produce good results Before installing the sensors please read the appropriate instructions listed below Sensor Placement Page 2 Press Frame Page 3 Pitman Mount Page 4 Drill and Tap Method of Installing Sensors Page 5 Weld Method of Installing Sensors Page 6 T400 Enclosure Mounting Details Page 7 Doc 11080 Rev A T400 INSTALLATION PAGE 1 NOISN3 L SSANMOIHL LNO J NOISS3HdlNOO SSANMOIHL YVAN E Uoisue Jo pe
57. on the LCD display on the Home menu Low Battery Indicator Doc 13925 Rev L Page 37 Toledo Integrated Systems PWi User s Manual Replacing the Backup Battery The backup battery is a 3V Lithium type CR 1 3N and is commonly sold at most electronics retailers including RadioShack It is located on the Control Board which is mounted on the inside of the unit s door To replace the battery 1 Remove power from the PWi unit 2 Open the enclosure door and locate the Control Board It is the board mounted on the door 3 Remove the 6 screws that secure the cover plate to the Control Board Place the screws and the cover plate aside 4 Locate the battery Refer to the following diagram PWi Control Board 5 Remove the old battery from its socket 6 Insert the new battery Note the battery polarity printed on the circuit board 7 Reinstall the cover plate using the 6 screws that were removed in step 3 8 Close the enclosure door 9 Apply power Doc 13925 Rev L Page 38 Toledo Integrated Systems PWi User s Manual Operation Mode Overview 4 Home menu for viewing peak load and changing modes CODE Security Code menu for locking and unlocking access SIG Signature menu for viewing and analyzing load signatures JOB 01 11 SETPT Job menu 0 1 Setpoint menu for viewing
58. ons refer to standard 4 channel units If the unit is equipped with additional load channels 1 6 6 or 8 channel units on the optional Resolver Board they will be connected in a similar method to the steps below Refer to Figure 1 8 for the procedures below to connect tonnage sensors properly 1 Power down the unit Open the door of the PWi enclosure 2 Run Load Sensor cables through Conduit Hole 1 see Figure 1 4 and route cables upward to the Analog Board 3 Prepare the sensor cable for termination as described on page 17 4 Remove the four 5 pin Phoenix plugs from the analog board and wire each sensor cable as described on page 18 5 The 5 pin phoenix plugs can then be inserted into the corresponding sockets The load sensor cable connections are now complete Analog Board Channel 1 Channel 2 Channel 3 Channel 4 Left Rear Sensor Right Rear Sensor Left Front Sensor Right Front Sensor Figure 1 8 Sensor Input Locations Doc 13925 Rev L Page 16 Toledo Integrated Systems PWi User s Manual Sensor Cable Termination 1 Strip the sensor cable as shown in the figure below Be sure not to nick any of the signal conductors or cut the braid shield approx 2 inches CABLE JACKET SIGNAL WIRES BRAIDSHIELD
59. p E Stop shutdown relay See page 29 for E Stop relay location and wiring ESTP CRP CHG E STP E Stop Menu OFF E Stop relay is disabled CAP ALARM E Stop relay opens for capacity and CCM alarms CHG Change E Stop operation APPY Apply the changes Description of Emergency Stop relay operation When E Stop is set to OFF e All alarms including capacity alarms cause the Top Stop relay to open at the end of the stroke e The E Stop relay has no function When E Stop is set to CAP ALARM e Capacity alarms cause the E Stop relay to open immediately when an over capacity load occurs This also applies to CCM alarms if the optional resolver board is installed Warning Using the E Stop relay under heavy loads may result in the ram becoming locked at the bottom of stroke If this is a concern the E Stop relay should not be used e The Top Stop relay will open for high low and reverse setpoint violations To change the E Stop relay operation gt 1 Push to enter change mode Current setting is then selected 2 Push B or g to change the setting 3 Push to accept the change or push to cancel the change Doc 13925 Rev L Page 66 Toledo Integrated Systems PWi User s Manual Setup Count Menu e The Setup Count is the maximum number of strokes allowed in Setup mode It provides a way to ensure that the monitor will not be left in Setup mode indefinitely protected only by the capacity limits Af
60. play The load associated with the inner slide corners channels 6 9 are displayed on the corners of the LCD screen with the inner slide total channel 5 shown in the center of the LCD The function of each of the menus is similar to the 4 channel with a few differences e Peak Home menu All channels show either peak load or variation To toggle between peak load and 46 variation push B or g until the center menu is showing ON or OFF then push to apply e Signature menu When viewing the different corner signatures the quadrant symbol is followed by either OUT or IN to reflect either the outer or inner slide When viewing the signatures for the outer slide channels 0 4 the 7 segment displays show the load for the outer slide channels When viewing the signatures for the inner slide channels 5 9 the 7 segment displays show the load for the inner slide channels e Setpoint menu The HI LO and REV sub menus now show only the percentages for all channels The 7 segment displays show the deviation values for the outer slide and the LCD screen shows the deviation values for the inner slide Separate read only HI SP LO SP and RV SP sub menus display the actual high low reverse setpoint values for each channel e Changing channel values When changing values on the Setpoint or Capacity menus channels 0 4 on the 7 segment displays are selected by the blinking decimal point at the top left corner of the
61. recision with which the load values are displayed Up to 3 decimal places can be displayed DP Decimal Point Menu 01 Load values are shown with 1 decimal place CHG Change decimal place number APPY Apply the changes To change the Decimal Point 1 Push to enter change mode Current value is then selected 2 Push B or to change the value 3 Push to accept the change or push to cancel the change Doc 13925 RevL Page 58 Toledo Integrated Systems PWi User s Manual Capacity Menu e The Capacity menu allows the user to enter the rated capacity value for the press Channel Capacity values 4 corners total CAP Capacity Menu CHG Change capacity values Select channels APPY Apply the changes To view Capacity Values Capacity values are shown in the associated corners To change Capacity Values 1 Push to enter change mode Total channel is then selected 2 Push to select the desired channel 3 Push B or ba to change the value or Push 6 Or g to change in a larger increment 4 Push to accept the change or push to cancel the change 5 Repeat from step 2 to make change on other channels i 6 Push to exit change mode Note When the Total Channel value is changed the values of the corner channels are updated automatically with a value of Total Capacity divided by the number of channels For example if a total capacity of 800 is entered the corner channel capacities will become 200 800 4
62. red to zero the press angle 16 CAL CH6 9 Record the Gain Numbers from step 11 of the Calibration Procedure here 17 Resolver Configuration Record the resolver dip switch settings from the Resolver Board here Doc 13925 Toledo Integrated Systems Page 80 PWi User s Manual gt Operator s Guide Peak load for Right Rear corner CH2 of press Corner Load Displays Variation from LCD Display BENCH benchmark for 05 Right Rear corner 2 of press The PWi displays a variety of information by organizing it into menus The Home menu is shown above The Corner Displays show peak load and the LCD Display shows Variation from the Benchmark From this menu you can place the PWi into Setup Mode or Learn Mode and view the run status gt While setting a die in the press place the PWi into Setup Mode by pressing the B and buttons until the LCD Display shows SETUP Press the lt button to accept Run material through the press until a good part is formed If running an established part whose setpoints have been saved to a job number follow the instructions below to load the job Otherwise place the PWi into Learn Mode by pressing the B and buttons until the LCD Display shows LRN Press the CZ button to accept After 8 strokes the PWi establishes a new benchmark and calculates new high and low setpoints based on the percentage settings from the Setpoint menu Job
63. s save the setpoints related to a part so that you do not have to relearn them every time that part is ran To load a job use the and M buttons to access the JOB menu The current job number is shown above the Ban buttons on the LCD Display To change the job number press the button then press the B or buttons to increase or decrease the job number When the desired job number is shown press the button to load it To avoid nuisance alarms and shutdowns while adjusting the press put the PWi in Setup Mode as described above Setup Mode still protects the press from an over capacity hit but it will not shut the press down for a high or low setpoint violation The high and low setpoints can be displayed by using the and amp buttons to access the SETPT Setpoint menu While on the Setpoint menu use the B and buttons to display the HI High LO Low and other setpoints The high and low percentages are shown on the LCD Display for each channel and the actual high and low setpoints are shown on the Corner Displays When an alarm occurs the status on the Home menu will change to ALM and the Corner Display s for the violated channel s will flash Press the amp button to go to the ALARM Menu The type of alarm and the channel number are shown above the ana Kl buttons on the LCD Display If more than one alarm has occurred you can use these buttons to scroll through the list of alarms To reset an alarm press the CZ butt
64. shold once again before finally Threshold A Af dropping once more Hit 2 This behavior will commonly cause the peak tonnage to update twice which prevents the monitor from displaying the true lt gt peak at the end of the stroke This can be remedied by 1 Sec entering a delay value 1 second in this example which prevents the stroke from ending too early To change the Delay Value 1 Push to enter change mode Current setting is then selected 2 Push or g to change the setting or Push or to change in a larger increment 3 Push to accept the change or push to cancel the change Notes e You can choose any time delay value from 0 seconds up to 9 999 seconds e Setting the time delay value to zero disables the delay feature The load capture will end when the load drops below the threshold value Doc 13925 Rev L Page 63 Toledo Integrated Systems PWi User s Manual Offset Menu only available when trigger mode is set to Resolver e The press stroke can be viewed as a 360 circle with the top position at 0 fully opened and the bottom dead center position at 180 fully closed When using resolver triggering for load capture the offset value allows the resolver position to be zeroed The offset can be adjusted from 0 no offset to 359 Resolver position degrees 103 Resolver offset value degrees a OFFST Offset Menu CHG Change offset value APPY Apply the changes Determi
65. ter the Setup Count value has been reached the monitor will enter Run mode SCNT O50 CHG S CNT Setup Count Menu 050 Setup Count value CHG Change the Setup Count value APPY Apply the changes To change the Setup Count 1 Push to enter change mode Current setting is then selected 2 Push B or g to change the value 3 Push to accept the change or push to cancel the change Notes e The Setup Count can be set from zero to 200 e To disable the Setup Count feature change the value to zero Doc 13925 Rev L Page 67 Toledo Integrated Systems PWi User s Manual Address Menu e The Address menu displays the current communications address of the monitor and allows it to be changed to provide a unique networking address for use with PressNet or other communications software ADDR 27 CHG ADDR Address Menu 27 Network Address of this unit CHG Change communication address APPY Apply the changes To change the Address 1 Push to enter change mode Current setting is then selected 2 Push or g to change the setting 3 Push to accept the change or push to cancel the change Doc 13925 RevL Page 68 Toledo Integrated Systems PWi User s Manual Baud Rate Menu e The Baud Rate menu allows the communications speed for the PressNet RS422 1 Port to be adjusted BAUD 1154 CHG BAUD Baud Rate Menu 9600 9 600 baud 38400 38 400 baud 76800 76 800 baud 115K 115 200 baud CHG Change communication
66. the Cursor tool 2 To view load signature details when using probe or threshold triggering Push D or g to Increase the time value in the center menu and move the cursor along the load signature As the cursor moves the corner displays update with the load for the selected point on the curve Current cursor position milliseconds 285ms Push r or g to cycle through the corners or gt Push to close the signature and resume signature updating 3 To view load signature details when using resolver triggering Push or g to Increase the press angle value in the center menu and move the cursor along the load signature As the cursor moves the corner displays update with the load for the selected point on the curve Cursor on load signature position degrees 190 m Push to toggle the cursor between the load signature and the CCM press curve When the cursor is on the CCM press curve the corner displays provide the load for the press curve at the selected position Push g to cycle through the corners or gt Push to close the signature and resume signature updating Doc 13925 Rev L Page 45 Toledo Integrated Systems Setpoint Menu PWi User s Manual e The Setpoint menu displays information for the various types of setpoints and allows each channel s setpoint value to be adjusted Other information such as Capacity and Benchmark values can be viewed SETPT HI
67. tly enabled the DSABL Disable option appears In this case pressing B will disable the security code Once disabled all settings and features in the Operation mode will be unrestricted and the Operation mode s Security Code menu will not appear Similarly if the security code feature is currently disabled the ENABL Enable option appears In this case pressing B will enable the security code for the Operation mode To change the Security Code Once a valid security code has been entered the authorized user then has the option to change the CHAngE security code if desired You will notice message CoDE on the LCD asking if you wish to change the security code CODE DSABL CHG To begin changing the security code press the button The familiar security code entry screen appears Enter the new 4 digit code After the new security code has been entered the LCD will prompt you to verify the new code Enter the same new 4 digit security code again If you entered the exact same code both times you will get a message that the code was changed If not you will be informed that the change failed See the following example for the sequence Doc 13925 Rev L Page 72 Toledo Integrated Systems PWi User s Manual Sequence to Change the Security Code Start new code Press to begin entry sequence Entera H or security CODE DSABL CHG CODE ENTER NEXT code
68. ual Mounting the PWi Standard Installation Note This section is for mounting standard PWi units If the flush mount option was purchased refer to the next section for instructions on mounting the PWi with the flush mount option The PWi is an electronic instrument and must therefore be protected from physical stresses such as shock and vibration Shock mounts are provided with every standard PWi for this purpose Failure to use these shock mounts may result in premature failure of the instrument and possibly void your warranty The PWi may be mounted directly to the press or to an adjacent structure It should be positioned so that the display is easily read and the instrument is readily accessible Figure 1 1 below provides the mounting dimensions and demonstrates the proper attachment of the provided shock mounts 1 4 20 STUD SHOCK MOUNT ASSEMBLY 8 90 226mm am ap 3 E E 5 23 8 RUN m 5 C LJ Z Ldi Lo pet 6 88 175mm Ru 5 00 127mm Figure 1 1 Standard Mounting Dimensions Doc 13925 Rev L Page Toledo Integrated Systems PWi User
69. y and then by 5X until the STAT LED is not turned on Perform the test in this order to give our unit the highest workable voltage and therefore more accurate results NOTE Two stator inputs must have the same scale down factor Therefore the setting of STATI must be the same as STAT2 No Scale Scale Down 2X Scale Down 3X Scale Down 5X MASTER MASTER 6 Record all DIP switch settings on the calibration card 7 Resolver setup is basically completed Refer to the Operation section of this manual for resolver offset adjustment Doc 13925 Rev L Page 25 Toledo Integrated Systems PWi User s Manual External Reset Switch Connection Two terminals are provided for connecting an external reset switch The rating of the switch and wiring can be minimal because they interface with a small signal Use Conduit Hole 2 see Figure 1 4 to run the wiring for the reset switch NOTE In order to reduce noise that may trigger false reset e Use twisted pair wires for the connection e Do not run this pair of wires along with any high voltage or high current cables e Keep the wiring no longer than 12 feet CAM2 ON EXT RESET SWITCH CLOSED PROBE INPUT CAM2 OFF EXT RESET SWITCH OPEN NPN2 G NPN1 PNP1 Vo NORMALLY OPEN MOMENTARY SWITCH Figure 1 18 External Reset Switch Wiring Doc 13925 Rev L Page 26 Toledo Integrated Systems PWi Us

PWi User`s Manual - Toledo Transducers

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