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LINK ELECTRIC & SAFETY CONTROL COMPANY OmniLink 5000 Operating Manual

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System 5000
Press Control
AUTO SETUP
MODULE
COLOR DISPLAY

OPERATING MANUAL

LINK ELECTRIC & SAFETY CONTROL COMPANY
444 McNALLY DRIVE,
NASHVILLE TN 37211
PH (615)-833-4168
FAX (615)-834-1984

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Summary of Contents for LINK ELECTRIC & SAFETY CONTROL COMPANY OmniLink 5000

  • Page 1: Operating Manual

    System 5000 Press Control AUTO SETUP MODULE COLOR DISPLAY OPERATING MANUAL LINK ELECTRIC & SAFETY CONTROL COMPANY 444 McNALLY DRIVE, NASHVILLE TN 37211 PH (615)-833-4168 FAX (615)-834-1984...

  • Page 2: Table Of Contents

    Section 2.2.6 Access Control Operation ......... . 2.4 Section 2.2.6.1 RUN/PROG Key Switch Operation ......2.4 Section 2.2.6.2 Password System Operation .
  • Page 3 Section 4. Configuration ............4.1 Section 4.1 Setting up the OmniLink 5000 for the Auto-Setup Module .
  • Page 4 Appendix F Specifications ............F.1 Section F.1 5000-10A Pressure Control Board .
  • Page 5 April 17, 2000 Man ual Versio n 1.0...

  • Page 6: Section 1.1 Counterbalance Control

    Section 1 Introduction The 5000-10 Auto-Setup Module (ASM) allows the OmniLink 5000 Press and Automation control to set up press shut height, counterbalance air pressure, cushion air pressures, and hydraulic overload pressure settings automatically when jobs are recalled from memory. It consists of a base 5000-10 microprocessor board that installs in the OmniLink extended card rack, and additional modules that may be mounted on the base board to provide pressure or shut height adjustment functions.

  • Page 7: Section 1.4 Hydraulic Overload Control

    Section 1.3 Shut Height Control When a linear or rotary shut height control module is provided, the OmniLink 5000 can provide accurate, repeatable shut height adjustment on presses that are in reasonable mechanical condition, enhancing parts quality and reducing setup time. This system uses the existing slide motor starter. Section 1.4 Hydraulic Overload Control Most presses use a hydraulic overload system in which an air pressure sets up a much greater hydraulic...

  • Page 8: Section 2.1 Parameter Entry

    Section 2 Parameter Entry and Access Control Section 2.1 Parameter Entry Throughout the OmniLink control, a fairly standard form of data entry is employed. When data entry is allowed, an “editing cursor” will appear on the screen. This cursor can typically be moved from parameter to parameter on the screen with the up, down, left, and right arrow keys.
  • Page 9 Figure 2.1: c) The fist character of the text is highlighted with the text cursor. The CURSOR LEFT and CURSOR RIGHT softkeys will move this cursor. d) Use the left and right arrow keys to point to the letter desired in the letter box next to the text being edited.

  • Page 10: Section 2.2 Access Control

    The OmniLink control employs combinations of two different means to limit access to restricted items. These means are the RUN/PROG key switch on the operator terminal and a user password system. The user password system assigns names and passwords to up to sixteen users. These two means can be used alone or in combination with each other.

  • Page 11: Section 2.2.3 Password Only Mode

    Section 2.2.6.1 RUN/PROG Key Switch Operation The RUN/PROG key switch is located on the lower right side of the operator terminal. This is a two position switch. The key is removable in the RUN position only. If the RUN/PROG key switch is being used as a means to access the restricted items, the switch must be turned to the PROG position.

  • Page 12: Section 2.2.6.2 Password System Operation

    When operating in the Key Only mode the key switch is the only means available to access the restricted items. All restricted items are accessible when the RUN/PROG key switch is switched to the PROG position. When operating in the “Key or Password” mode, the key switch is one of the means available to access the restricted items.
  • Page 13 The user can log out by using the ACC key. This key will directly switch the display to the Quick Access screen. The “LOGOUT” soft key legend will appear along the bottom of the screen. If the operator presses this key, he will log out.

  • Page 14: Section 3.1 Auto-Setup Module Installation

    Section 3. Installation Section 3.1 Auto-Setup Module Installation The 5000-10 Auto-Setup Module (ASM) installs in the OmniLink 5000 extended card rack. Figure 3.1 shows the location of the ASM in the last slot of the extended card rack. To remove the module, loosen the knurled screws at the top and bottom of the board and use them to pull the board straight out of the rack.
  • Page 15 or AS4. The plug in terminals on the modules should stick out of the faceplate of the base card. April 17, 2000 Man ual Versio n 1.0...

  • Page 16: Section 3.2 Valve Systems

    Section 3.2 Valve Systems Counterbalance and cushion systems are very similar in the way they are controlled. Three basic integrated valve configurations are available from Link to be used with the OmniLink 5000 ASM. For clarity in the following sections, these valve configurations are defined here. Type “A”...

  • Page 17: Section 3.3 Counterbalance Control Installation

    Type “C” An integrated Fill/Dump valve with a manual regulator, check valve, and LOX valve, and a four-way valve that selects whether the pressure is set by the automatic system or the manual regulator as shown in Figure 3.4 for cushion and counterbalance adjustment. Unlike the type “B”...
  • Page 18 For automatic control, the pressure regulator and check valve are replaced with an air valve system. Figures 3.6 and 3.7 illustrate systems using the Type “A” and Type “C” valves described in section 3.2. In all cases a pressure transducer is used to monitor the air pressure. Auto-Counterbalance with Type “A”...

  • Page 19: Section 3.3.1 Counterbalance Pressure Transducer Mounting

    Section 3.3.1 Counterbalance Pressure Transducer Mounting The system uses an automatic method of control in which the fill valve or dump valve is energized to raise or lower the pressure of the system and a pressure transducer is used to “tell” the ASM what pressure is in the system.

  • Page 20: Section 3.4 Cushion System Installation

    Section 3.3.2 Counterbalance Air Valve System Mounting The mounting location of the valve system is not critical. Consideration should be given, however, to ease of maintenance, plumbing, and wiring when choosing the mounting location. Also note that sometimes the check valve in the original system may be up at the surge tank itself. The check valve in the original system must be removed for the automatic system to work properly.

  • Page 21: Section 3.4.1 Cushion Pressure Transducer Mounting

    Section 3.4.1 Cushion Pressure Transducer Mounting The system uses a method of control in which the fill valve or dump valve is energized to raise or lower the pressure of the system. The pressure transducer tells the system when it has reached the proper pressure.

  • Page 22: Section 3.5 Hydraulic Overload System Installation

    control came configured for a cushion adjust system, then a wiring diagram should have been provided as part of the documentation package. Section 3.5 Hydraulic Overload System Installation Some press hydraulic overload systems use an air pressure to set up a much greater hydraulic pressure through an air pump to control the trip point (tonnage) at which the hydraulic overload cylinder will dump.

  • Page 23: Section 3.6.2 Rotary Slide Adjust Wiring

    c) The slide should travel no more than 1 inch per turn of the resolver. d) The cable from the resolver to the OmniLink 5000 should not be run with any high voltage wiring (i.e. 120/240 VAC). In fact, this cable should be run in its own shielded conduit. It is not necessary to know the exact gear ratio of slide travel to resolver turns - only that conditions “b”...

  • Page 24: Section 3.6.4 Linear Transducer Slide Adjust Wiring

    b) It may be necessary to order a transducer longer than the slide adjustment range because of mounting limitations. c) Ferromagnetic material (a material readily magnetized - such as iron or steel) should be no closer than .25" from the magnet or the rod end. This includes ferrous screws! Non-ferrous metals such as aluminum, brass, and non-magnetic stainless can be in direct contact with the magnet or rod end.

  • Page 25: Section 4.1 Setting Up The Omnilink 5000 For The Auto-Setup Module

    4.2. a) Go to the Press Control (P/C) screen. b) With the RUN/PROG key switch in the PROG position, press the “CONFIGURE” softkey and enter the configuration access code. c) Press the “MACHINE PARAMETERS” softkey.

  • Page 26: Section 4.2 Configuring The Auto-Setup Board

    Go to the “Auto Sets” screen. This screen is reached by pressing the “AUTO SETS” softkey in the Main Menu or Press Control screen. b) With the RUN/PROG key switch in the PROG position, press the “CONFIGURE” softkey and enter the configuration code. Note that the code is provided separately from this manual for administrative control.
  • Page 27 There are several parameters that must be configured in this screen. The editing cursor indicates which parameter is currently selected. Softkey 1 (the uppermost vertical softkey) will change its description based on the parameter and, when pressed, allows the currently selected parameter to be changed. The up and down arrow keys move the editing cursor from one parameter to another.
  • Page 28 For cushions this should be the maximum operating pressure specified by the cushion manufacturer. For hydraulic overloads this value should be the pressure specified by the press manufacturer for rated tonnage operation. Min. Pressure This value should be set to the minimum operating pressure at which you will operate your counterbalance, cushion, or hydraulic overload.
  • Page 29 are pounds (lbs), kilograms (Kgs), tons, and metric tons (Mtons). Note that the display unit can be changed at any time and is independent of the units that the maximum and minimum die weight are using. If a job was stored in tons, and this unit is changed to pounds, the stored job will still be correct.
  • Page 30 choices are pounds (lbs), kilograms (Kgs), tons, and metric tons (Mtons). Note that the display unit can be changed at any time and is independent of the units used for minimum and maximum trip point. If a job was stored in tons, and this unit is changed to pounds, the stored job will still be correct.

  • Page 31: Section 4.2.2 Configuring Slide Adjust Modules

    Go to the “Auto Sets” screen. This screen is reached by pressing the “AUTO SETS” softkey in the Main Menu or Press Control screen. b) With the RUN/PROG key switch in the PROG position, press the “CONFIGURE” softkey and enter the configuration code. The code is provided separately from this manual for administrative control.
  • Page 32 Slide Adjust OFF/ON selector switch is turned to the ON position. MAN means the OmniLink 5000 can control the shut height but the shut height can only be changed from the “Slide Adjust”...
  • Page 33 This value is an electronic upper limit for the slide adjust system that acts as a backup for the mechanical up limit switch. The automatic shut height system will not adjust the shut height above this value, which should be set just below where the mechanical up limit switch open up.

  • Page 34: Section 4.2.2.1 Calibrating Linear Slide Adjust Systems

    Lock Time Most slide adjust systems now use an integrated brake built in to the slide adjust motor that automatically locks the system down when the slide adjust motor is not on. “Lock Time” is used only for slide adjust systems that have a separate locking system that must be disengaged before the slide adjust motor is engaged.

  • Page 35: Section 4.2.2.2 Calibrating Rotary Slide Adjust Systems

    transducer is used) must now be set. This value is listed on the transducer model plate. Press the “CONTINUE SLIDE CAL.” softkey to continue the calibration process or “EXIT” to return to slide configuration. f) Finally, the “Calibration Point” must be set. The slide should be taken to bottom dead center (180 degrees) and the shut height should be measured.
  • Page 36 screen of Figure 4.3. NOTE: It is absolutely critical to set the upper and lower limits correctly before calibrating a rotary slide adjust system. The calibration process uses this information to map the turns from the dual resolver into the measurement space of the slide.
  • Page 37 Press the “CONTINUE SLIDE CAL.” softkey to continue the calibration process or “EXIT” to return to slide configuration. g) Finally, the lower calibration point must be set. Use the “JOG UP” and “JOG DOWN” softkeys to take the slide near the bottom of the adjustment range. The slide should be slightly higher than the lower limit entered on the slide configuration screen.
  • Page 38 4.14 April 17, 2000 Man ual Versio n 1.0...

  • Page 39: Section 5 Operation

    Section 5 Operation The purpose of the Auto-Setup module is to allow automatic adjustment of such press systems as air counterbalances, air cushions, air operated hydraulic overloads, and slide adjust systems to greatly reduce setup time for different jobs, and to help ensure that these systems are adjusted correctly for different jobs.
  • Page 40 for the shut height setpoint. See section 6 for an explanation of all status messages for the various sub-systems. c) Each configured sub-system has a fault message. Under normal conditions, this fault should read “None”. See section 6 for an explanation of all fault messages for the various sub-systems. d) Air pressure controlled sub-systems (counterbalances, cushions, and hydraulic overload) display the current actual pressure for that system in large numbers for easy visibility.

  • Page 41: Section 5.1 Slide Adjust Operation

    If the key is held down for more than about ½ a second, the slide will move up continuously until the key is released. This key is only available when the keyed slide adjust switch is in the ON position and the editing cursor is on the slide setpoint.

  • Page 42: Section 5.1.1 Slide On, Manual, And Off Settings

    rotary transducer mounted on the slide system of the press. The units for the position can be in inches or millimeters depending on the configuration. See section 4.2.2 for details. Fault If the slide adjust system detects an error it will be reported on this line. A fault occurs when a hardware or firmware problem is diagnosed by the system.
  • Page 43 “ON”. Note that the “AUTO ADJUST” key will only appear when the slide adjust switch is ON and the editing cursor is on the slide adjust setpoint of a slide adjust system.

  • Page 44: Section 5.1.3 Manual Slide Movement

    Section 5.1.3 Manual Slide Movement As noted in the section explaining the softkeys in the slide screen, the slide may be manually moved by pressing the “JOG UP” and “JOG DN” softkeys. Note that the jog keys will only appear when the editing cursor is on a slide adjust setpoint.

  • Page 45: Section 5.2.1 Air System On, Manual, And Off Settings

    setpoint for a previously stored job when that job setup is recalled from memory and the air system is “ON”. This number can be set in pounds, kilograms, tons, or metric tons depending on the configuration as detailed in section 4.2.1. Press Trip Set For hydraulic overloads only, the desired trip point to be set by the air system.

  • Page 46: Section 5.2.3 Air System Fault And Status

    Pressure can be set in one of two ways. First, if the air system was correctly configured, the desired force which the pressure is to create can be entered in the “Force Setpoint” row on the air pressure screen. Second, if preferred, the desired air pressure in psi may be entered into the “pressure setpoint” row.
  • Page 47 If a job is recalled when the slide adjust switch is not on, the slide adjust system will display a status of “Waiting S/A Switch”. When the slide adjust switch is turned on and all other necessary conditions are satisfied, the slide will go to the slide setpoint.

  • Page 48: Section 6.1 Main Module Messages

    Section 6 Diagnostics - Fault and Status Messages When the press control screen reports a stop condition that indicates the auto-setup board asserted or is asserting a stop signal, the “Auto-Sets” screen module status and the individual sub-systems status line will give additional information.

  • Page 49: Counterbalance, Cushion And Hydraulic Overload "Status" Messages

    Pressure Switch Low There is a pressure switch on the input air supply to the air valves. If the input air pressure is too low then the system could open the fill valve intending to raise the pressure but instead vent some air back into the air supply.

  • Page 50: Section 6.4 Slide Adjust "Fault" Messages

    Slide adjust switch failure. If the main 5000 control reports to the auto-setup card that the slide adjust switch is ON but no AC voltage is detected at the slide adjust relays this error will be generated. It is also generated if the 5000 reports slide adjust switch OFF but the auto-setup module does see AC voltage at the relays.

  • Page 51: Section 6.5 Slide Adjust "Status" Messages

    The slide is within tolerance of the slide setpoint. Up Limit Switch Open The slide has hit the mechanical up limit switch and can go no higher. Down Limit Sw. Open The slide has hit the mechanical down limit switch and can go no lower.
  • Page 52 Emergency stop button is depressed. The slide will not automatically move in this condition. Waiting S/A Switch Waiting for the slide adjust switch to be turned on. The slide cannot move while the slide adjust switch is in the off position. LMC is Out The Link Master Control relay is disengaged for some reason (possibly an error at the control).

  • Page 53: Section A.1 Example Counterbalance Configuration

    A type “C” integrated valve controls the pressure (see section 3.1 for a discussion of valve types). Now we go to the “Auto Sets” screen and with the RUN/PROG switch in PROG hit the “CONFIGURE” softkey. After typing the configuration code, we press the “CONFIGURE AIR” softkey.

  • Page 54: Section A.2 Example Cushion Configuration

    A type “B” integrated valve controls the pressure (see section 3.1 for a discussion of valve types). Now we go to the “Auto Sets” screen and with the RUN/PROG switch in PROG hit the “CONFIGURE” softkey. After typing the configuration code, we press the “CONFIGURE AIR” softkey.

  • Page 55: Section A.3 Example Hydraulic Overload Configuration

    Using the arrow keys, we move the cursor to the “Transducer Type” line. Looking at table 4.1, we see that the transducer type for any model pressure transducer with a 250 psi pressure range and a 4 to 20 ma output is “Type 3”.
  • Page 56 An SMC ITV2050-31T2S4 servo-valve will be used to control the pressure. This valve is 0-130 psi with a 0-10V input. Now we go to the “Auto Sets” screen and with the RUN/PROG switch in PROG hit the “CONFIGURE” softkey. After typing the configuration code, we press the “CONFIGURE AIR” softkey.

  • Page 57: Example Linear Slide Adjust Configuration

    From the nameplate on the press or the press manual, we find that the minimum shut height is 12.500 inches and the maximum shut height is 16.000 inches. Now we go to the “Auto Sets” screen and with the RUN/PROG switch in PROG hit the “CONFIGURE” softkey. After typing the configuration code, we press the “CONFIGURE SLIDE” softkey.
  • Page 58 14.074 inches for our calibration position, the present position should read 14.073 to 14.075 inches. Now we take the press back to the top of the stroke. With the slide adjust switch on, “JOG UP” and “JOG DOWN” softkeys should be displayed in the slide configuration screen.

  • Page 59: Example Rotary Slide Adjust Configuration

    From the nameplate on the press or the press manual, we find that the minimum shut height is 12.500 inches and the maximum shut height is 16.000 inches. Now we go to the “Auto Sets” screen and with the RUN/PROG switch in PROG hit the “CONFIGURE” softkey. After typing the configuration code, we press the “CONFIGURE SLIDE” softkey.
  • Page 60 In this example, assume we had entered 14.074 inches for our lower calibration point. Now we take the press back to the top of the stroke. With the slide adjust switch on, “JOG UP” and “JOG DOWN” softkeys should be displayed in the slide configuration screen.
  • Page 61 “.04" sec. Repeating the test, we find that it now takes 1 to 2 pulses to move .001 inch - an acceptable value. Now it is time to hit the “AUTO ADJUST” softkey. The slide moves up past 14.000 (the slide setpoint we entered in the operation screen) and stops momentarily at 14.025.

  • Page 62: Appendix B Typical Wiring Diagrams

    Appendix B Typical Wiring Diagrams Figure B.1: Typical Counterbalance Wiring Diagram. April 17, 2000 Man ual Versio n 1.0...
  • Page 63 Figure B.2: Typical Cushion Wiring Diagram. April 17, 2000 Man ual Versio n 1.0...
  • Page 64 Figure B.3: Conceptual Dual Resolver Mounting. April 17, 2000 Man ual Versio n 1.0...
  • Page 65 Figure B.4: Typical AMCI Dual Resolver Wiring Diagram. April 17, 2000 Man ual Versio n 1.0...
  • Page 66 Figure B.5: Typical GEMCO Dual Resolver Wiring Diagram April 17, 2000 Man ual Versio n 1.0...
  • Page 67 Figure B.6: Conceptual Linear Transducer Mounting April 17, 2000 Man ual Versio n 1.0...
  • Page 68 Figure B.7: Typical GEMCO Linear Transducer Wiring April 17, 2000 Man ual Versio n 1.0...
  • Page 69 Figure B.8: Typical MTS Temposonics II Linear Transducer Wiring April 17, 2000 Man ual Versio n 1.0...
  • Page 70 Figure B.9: Typical Slide Motor Starter Wiring With Auxiliary Contactor Figure B.10: Typical Slide Motor Starter Wiring Without Auxiliary Contactor Figure B.11: Typical Slide Air Motor Solenoid Wiring April 17, 2000 Man ual Versio n 1.0...
  • Page 71 B.10 April 17, 2000 Man ual Versio n 1.0...

  • Page 72: Appendix C Installation Of Omnilink 5000 Firmware

    Appendix C Installation Of OmniLink 5000 Firmware Firmware for the OmniLink 5000 press control is contained on two integrated circuits. Please follow the instructions listed below for replacing the OmniLink 5000 firmware. 1) Remove all power from the OmniLink 5000 press control. Insure that the power to the OmniLink card rack and the OmniLink Operator Interface terminal has been removed.
  • Page 73 April 17, 2000 Man ual Versio n 1.0...

  • Page 74: Section D.1 General Lockout Considerations

    Appendix D Lockout Procedure For Air Controlled Systems Section D.1 General Lockout Considerations The OmniLink 5000 auto-setup card automatically controls pressures in cushions and counterbalances. Because of this there are special considerations to keep in mind when locking an air system out (at 0 pressure).

  • Page 75: Valve Type "B" Lockout Procedure

    Section D.3 Valve Type “B” Lockout Procedure The type “B” valve has a manual regulator in parallel with the automatic section that prevents the pressure it is controlling from going below a minimum. To lock this valve out: 1) Set the pressure setpoint for the air system to 0 psi. At this point the manual regulator will try to fill the system while the automatic section tries to dump.

  • Page 76: Section E.1 Air System Calibration Sheets

    Appendix E Configuration Sheets Section E.1 Air System Calibration Sheets Air Pressure Configuration Air Pressure Configuration Board ___________________________ Name ___________________________ Transducer Type __________ Max. Pressure __________ Min. Pressure __________ Max. Force __________ Min. Force __________ Fault Time __________ Tolerance __________ Air Pressure Configuration Air Pressure Configuration...
  • Page 77 Air Pressure Configuration Air Pressure Configuration Board ___________________________ Name ___________________________ Transducer Type __________ Max. Pressure __________ Min. Pressure __________ Max. Force __________ Min. Force __________ Fault Time __________ Tolerance __________ Air Pressure Configuration Air Pressure Configuration Board 0-10 Volt Out Name ___________________________ Transducer Type __________ Valve Type...

  • Page 78: Section E.2 Shut Height Calibration Sheets

    Section E.2 Shut height Calibration Sheets Linear Transducer Slide Configuration Slide Configuration Slot #1 Board Linear Transducer Name _________________ Wire Speed __________ Upper Limit __________ Lower Limit __________ Tolerance __________ Pulse Distance __________ Pulse Time __________ Lock Time __________ Orientation __________ Linear Transducer Slide Configuration...
  • Page 79 Rotary Transducer Slide Configuration Slide Configuration Slot #1 Board Rotary Transducer Name ___________________ Upper Limit __________ Lower Limit __________ Tolerance __________ Pulse Distance __________ Pulse Time __________ Lock Time __________ Resolver Turns __________ Rotary Transducer Slide Configuration Slide Configuration Slot #2 Board Rotary Transducer Name ___________________...

  • Page 80: Section F.2 5000-10B Linear Shut Height Control Board

    Appendix F Specifications Section F.1 5000-10A Pressure Control Board AC Output Relays: Voltage: Current: Fuse: Section F.2 5000-10B Linear Shut Height Control Board AC Output Relays: Voltage: Current: Fuse: Section F.3 5000-10C Rotary Shut Height Control Board AC Output Relays: Voltage: Current: Fuse:...

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