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Die Sentry Manual
Table Of Contents
Introduction
Mounting a Device
Wiring a Device
Using the Die Sentry
Appendix A - I/O Modules
Appendix B - Die Sentry Errors
Appendix C - Troubleshooting Die Protection
INTRODUCTION
The Rexcon Die Sentry combines powerful die protection
capabilities with simple programming and operation and puts it all in
one small package. Five probes are provided which can be
independently programmed into any one of four modes of
operation. This manual contains instructions on installation and
operation of the Die Sentry.
MOUNTING A DEVICE
There are a few general things to be considered when mounting
any of the machine monitoring devices in the Rexcon family. The
suggestions that follow should always be considered when a new
installation is made.
DIRT
All Rexcon devices are housed in NEMA Type 12 Oil-tight
enclosures. The micro-electronics in the Rexcon devices, while
powerful, are not very tolerant of a dirty environment. It is important
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Summary of Contents for Electrex Rexcon Die Sentry
- Page 1 Appendix B - Die Sentry Errors Appendix C - Troubleshooting Die Protection INTRODUCTION The Rexcon Die Sentry combines powerful die protection capabilities with simple programming and operation and puts it all in one small package. Five probes are provided which can be independently programmed into any one of four modes of operation.
- Page 2 that they not be removed from the supplied enclosure. Also, make sure the enclosure remains tightly sealed while in operation, and that the punched holes be located and sealed properly to avoid leakage into the enclosure. VIBRATION The Rexcon devices are intended to be used with machines - and are designed to survive in such an environment.
- Page 3 "on" position to operate the device. I/O CONNECTIONS All connections to the Rexcon Die Sentry are made through optically isolated I/O modules. The modules are available in several versions including DC input (WHITE), DC output (RED), AC input (YELLOW), and AC outputs (BLACK).
- Page 4 NORMALLY CLOSED need only a probe connection. For detailed information about timing or probe signals, refer to the section on probe THEORY OF OPERATION. The diagram shows a Die Sentry wired with all probes connected. The Die Sentry has a built-in +12 Volt DC power supply to operate the probes.
- Page 5 Typical 5 Probe Wiring FAULT CONNECTIONS The Die Sentry main board has space for two (2) outputs but only one is actually used. The output labeled as FAULT 1 is used to stop the press whenever a fault condition has been detected by the Die...
- Page 6 Sentry. The unused output should not be connected to anything. USING THE DIE SENTRY The following sections provide all of the information about the actual operation of the Rexcon Die Sentry. The Theory of Operation behind die protection is discussed, in addition to the OPERATION of the Die Sentry.
- Page 7 Probe Timing - CAM Mode The TIMED MODE of OPERATION is basically the same as the CAM MODE with one exception - the length of the examine period is determined by the user entered TIME. In TIMED Mode, the operator (or supervisor) sets a probe time from 0.001 seconds up to...
- Page 8 9.000 seconds. When the limit switch goes ACTIVE, the examine period starts just like in the CAM MODE. However, once the examine period begins, the Die Sentry begins waiting for the specified probe TIME setting. At the end of the SET TIME, the examine period ends.
- Page 9 Probe Timing - Timed Mode The final aspect of probe operation is that of a probe or limit switch stuck "ON" or "OFF" while in TIMED OR CAM modes. In both modes, if a probe has not changed states before the next examination period begins, a fault will occur and a probe time of zero will be reported.
- Page 10 Because the limit switch is used to start the examine period, it is harder to tell if it is stuck in one position or the other. If the optional IN-CYCLE program is installed, the Die Sentry provides a MODE of OPERATION that requires any TIMED or CAM MODE limit switches to be seen in both states (ON and OFF) on every press cycle.
- Page 11 MODES OF OPERATION Die Sentry can be in two basic Modes of Operation - SETUP Mode and RUN Mode. Most of the time the key switch should be in the RUN position for complete process monitoring. SETUP MODE This mode is used when installing probes or changing dies and coils.
- Page 12 after any changes have been made, always remember to move the key switch back to RUN when done to allow the Die Sentry to save the new settings. As mentioned in the section THEORY of OPERATION, the Die Sentry can be set to check for stuck limit switches on every press cycle.
- Page 13 changed. Go back to the SETUP Mode and make a change. If the above described failure occurs - or any other unit failures occur - a Rexcon service representative should be contacted. There are no user serviceable parts inside the Die Sentry Units. APPENDIX C - TROUBLESHOOTING PROBLEM: NUISANCE STOPS CAUSE: REMEDY:...
- Page 14 base timing) or TIME (TIME base timing) for examine window. PROBLEM: PRESS STOPS AFTER BDC (BOTTOM DEAD CENTER) CAUSE: REMEDY: 1. Low counterbalance pressure. Adjust pressure. 2. Feeder feeding too late in cycle. Adjust feeder to advance material as soon as possible at low speed (stroke per minute) of press.
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