Om

niL

ink

5000System 5000Press Control

DIE PROTECTION MODULE

COLOR DISPLAYOPERATING MANUAL

LINK ELECTRIC & SAFETY CONTROL COMPANY

444 McNALLY DRIVE, NASHVILLE TN 37211

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

System 5000

Die Protection Module

Operator Manual

Manual LS-001

Revision 07

i

TABLE OF CONTENTS

Section 1 Introduction to the System 5000 Die Protection Module . . . . . . . . . . . . . . . . . . 1-1Section 1.1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Section 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Section 2.1 Main Menu Status Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Section 2.2 Die Protection Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1Section 2.3 Access Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Section 2.3.1 Key Only Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Section 2.3.2 Key or Password Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2Section 2.3.3 Password Only Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Section 2.3.4 Key and Password Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Section 2.3.5 Die Protection Restricted Items . . . . . . . . . . . . . . . . . . . . . . . . . 2-3Section 2.3.6 Access Control Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Section 2.3.6.1 Program/Run Key Switch Operation . . . . . . . . . . . . . . 2-4Section 2.3.6.2 Password System Operation . . . . . . . . . . . . . . . . . . . . 2-4

Section 2.4 Type of Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6Section 2.4.1 Programming Input Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Section 2.5 Input Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7Section 2.6 Input Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9Section 2.7 Input State . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10Section 2.8 RESET ERRORS key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10Section 2.9 BYPASS ON/OFF key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10Section 2.10 View Channel Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Section 2.10.1 Changing Channel Information . . . . . . . . . . . . . . . . . . . . . . . . 2-11Section 2.10.2 Programming Stop Output . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12Section 2.10.3 Programming Delay Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12Section 2.10.4 Programming Window Setpoints . . . . . . . . . . . . . . . . . . . . . . 2-13Section 2.10.5 Programming Separation Time . . . . . . . . . . . . . . . . . . . . . . . . 2-13Section 2.10.6 Programming Track Channel . . . . . . . . . . . . . . . . . . . . . . . . . 2-13Section 2.10.7 Programming Track Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Section 2.11 Input Capture Capability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14Section 2.12 Programmable Limit Switch Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15Section 2.13 Job Setups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Section 3 Die Protection Input Types and Their Uses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Section 3.1 Static N.O. and Static N.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1Section 3.2 Cyclic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2Section 3.3 Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3Section 3.4 In Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4Section 3.5 1 Part Detector-Edge and 1 Part Detector-Pass . . . . . . . . . . . . . . . . . . . . . 3-5

ii

Section 3.6 2 Part Detector-Edge and 2 Part Detector-Pass . . . . . . . . . . . . . . . . . . . . . 3-6Section 3.7 Track PLS and Track PLS Invert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Section 4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Section 4.1 Extended Card Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Section 4.2 Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Section 4.3 Machine Parameters Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1Section 4.4 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Section 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Section 5.1 Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Section 5.1.1 Main Menu Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1Section 5.1.2 View Channel Status Messages . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Section 5.1.2.1 Static Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2Section 5.1.2.2 Cyclic Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Section 5.1.2.3 Transfer Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3Section 5.1.2.5 1 Part Detector Messages . . . . . . . . . . . . . . . . . . . . . . . 5-4Section 5.1.2.6 2 Part Detector Messages . . . . . . . . . . . . . . . . . . . . . . . 5-4Section 5.1.2.7 Track PLS Messages . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5Section 5.1.2.8 Track PLS Invert Messages . . . . . . . . . . . . . . . . . . . . . 5-6Section 5.1.2.9 General Status Messages . . . . . . . . . . . . . . . . . . . . . . . 5-6

Section 5.2 Diagnostic LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7

1-1

Section 1 Introduction to the System 5000 Die Protection Module

The Die Protection Module is an optional addition to the integrated System 5000 Press Controlwhich is designed for use in monitoring various die conditions that are important to the correctoperation of the die. This is accomplished by installing appropriate sensors and probes in or nearthe die and connecting these sensors to inputs on the Die Protection Module. The inputs are thenprogrammed through the OmniLink Operator Terminal to perform the desired monitoring function.In the event that improper conditions occur the machine can be then be stopped, avoiding excessivedelay in the production process or damage to the die.

The Die Protection Module consists of a circuit card which is installed in the System 5000 card rackand a connector card assembly which interfaces the circuit card to the external sensors.

Section 1.1 Features

The Die Protection Module has 16 inputs available to the operator for use with die sensors andprobes. These inputs may be used to monitor part ejection, stock in place, material in position, stockbuckling, end of stock, or other functions of interest.

Each die protection input can be programmed as any of the following types: Static, Cyclic, Transfer,In Position, Single Part detection, Two Part detection, or Track PLS. For each input programmedas Cyclic, Transfer, In Position, or Part Detector types, the operator can assign to the input its owntiming sequence.

The operator can select an output of either Cycle Stop (immediate stop) or Top Stop for each dieprotection input monitored.

Each time the operator stores a job setup through the System 5000 Press Control, all programmeddie protection data is also stored by the system. Similarly, when the operator recalls a job setup frombackup memory all die protection data is recalled and becomes effective immediately. The modulecan store a total of 105 job setups (corresponding to the setups stored in the press control).

2-1

Section 2 Operation

Section 2.1 Main Menu Status Block

When the Main Menu is displayed on the System 5000 Operator Terminal, one of the softkeys onthe right side of the screen is labeled DIE PROTECTION. To the left of this key is a status blockindicating the current operating status of the die protection module. Under normal operatingconditions the status message will read "All Conditions OK". If the status message reads "ErrorCondition Exists" then a failure has been detected on one of the die protection inputs or a fault existsinternal to the module itself. When this is the case the operator must go to the Die Protection Menuto reset the error or proceed to view the error message. If the status message reads "CommunicationFailure" then a problem exists in the serial communication link between the operator terminal andthe die protection module (see “Main Menu Status Messages” in Section 5). If the status messagereads "Option is NOT Installed", the system may not be configured for die protection. (Refer to“Memory Configuration Requirements” in Section 4 for further details).

Section 2.2 Die Protection Menu

By pressing the DIE PROTECT softkey on the Main Menu, the LCD screen will display the DieProtection Menu (see Figure 2.1). The label "Die Protection” is displayed above the softkeys in theupper right corner. The softkeys available from this screen are labeled CAPTURE INPUTS, LIMITSWITCH, RESET ERRORS, and EXIT. When the user has obtained access control other softkeysthat may appear are CHANGE TYPE, CHANGE SETTINGS, CHANGE NAME, and BYPASSON/OFF. (Softkeys that appear when access control has been obtained are shown as highlighted inFigure 2.1). The function of these keys is described in the sections following. Access control isexplained in Section 2.3. On this screen as on all others, the top of the screen is used for displayingcrankshaft angle, crankshaft speed, and the present stroke mode. The remainder of the screen is usedfor displaying specific information about the die protection inputs.

2-2

Figure 2.1 Die Protection MenuSection 2.3 Access Control

The OmniLink control has several parameters or operations that have limited access. In regards todie protection the ability to perform actions of turning bypass off and on, resetting faults, orchanging die protection settings must be restricted to certain personnel. The OmniLink controlprovides several means to limit access to these parameters or operations. These parameters andoperations are called restricted items.

The OmniLink control employs combinations of two different means to limit access to restricteditems. These means are the Program/Run key switch and a user password system. The userpassword system assigns names and passwords to up to sixteen users. These two means can be usedalone or in combination with each other. When a user employs the proper means to gain accesscontrol, he will have the ability to perform the actions and change the parameters which have beendesignated to his access.

There are four possible modes of operation for the restricted access system. They are the “KeyOnly” mode, the “Key or Password” mode, the “Password Only” mode, and the “Key and Password”mode. The control can be configured to operate in any one of these four modes.

Section 2.3.1 Key Only Mode

The “Key Only” mode is the least complex of the four modes. This mode employs the Program/Runkey as the only means to limit access to restricted items. Any user with the Program/Run key canaccess all of the restricted items. Without the Program/Run key, user access to all of the restricteditems is prohibited.

Although the “Key Only” mode has the advantage of being easy to use, it does have a disadvantage.This mode cannot give a particular user access to only some of the restricted items. When operating

2-3

in this mode, any user with the Program/Run key will have access to all of the restricted items.

Section 2.3.2 Key or Password Mode

The key or password mode allows for either of two means to gain access to the restricted items. Auser with Program/Run key can access all of the restricted items. A user with the correct passwordcan access the restricted items that have been designated for the particular user’s access only. Thesystem allows for passwords to be assigned to sixteen users. Each user can be assigned access toany or all of the restricted items.

The following is an example of a “Key or Password” mode operation. The Program/Run key isgiven to the die set-up personnel. A press operator is assigned a user name and password. With thepassword the operator can reset die protection faults. This is the only die protection related itemto which the operator has access. In order to load a die, the set-up personnel uses the Program/Runkey to recall a job from job storage. The set-up personnel will also be able to make changes to dieprotection settings. Once the set-up personnel sets the die and verifies its correct operation, theoperator is left to run the die. If a die protection fault occurs, the operator can enter the correctpassword and then reset the fault. However, the operator cannot change die protection settings orbypass the die protection. This will allow the operator to keep running the job and reset faults thatoccur. However, if consistent stops occur because a die protection setting needs changing, the set-uppersonnel must be called to change the die protection setting.

The example above can be taken one additional step, if two press operators are given different usernames and different passwords. One operator can be assigned the ability to change die protectionsettings in addition to the ability to reset die protection faults, while the other operator is notassigned the ability to change the die protection settings.

Section 2.3.3 Password Only Mode

The “Password Only” mode allows for sixteen users. Each user can be assigned access to some orall of the restricted items. This mode does not use the Program/Run key.

The example listed above indicated that setup personnel required access to all restricted items. Inthe “Key or Password” mode, the setup personnel used the Program/Run key to gain access to allof the restricted items. In the “Password Only” mode, the setup personnel can still have access toall of the restricted items, but the system must be configured as such. The setup personnel must beassigned a user name and password. In addition, all restricted items would be assigned access to thesetup personnel.

Section 2.3.4 Key and Password Mode

The “Key and Password” mode requires the user to have the Program/Run key, user name, and userpassword. Operation is basically the same as the Password only mode, except that in addition to

2-4

entering the password the user must switch the Program/Run key to the PROG position.

Section 2.3.5 Die Protection Restricted Items

The following table lists the die protection restricted items name and function.

DIE PROTECTION RESTRICTED ITEMS

NAME FUNCTION

DP Bypass Bypass the Die Protection

DP Reset Reset the Die Protection

DP Settings Change the Die Protection type, settings, and name.

Section 2.3.6 Access Control Operation

To gain access control the user must use one of two means or a combination of these two means.These means are the Program/Run key or the user password system.

Section 2.3.6.1 Program/Run Key Switch Operation

The Program/Run key switch is located on the lower right side of the operator terminal. This is atwo position switch. The key is removable in the RUN position only. If the Program/Run keyswitch is being used as a means to access the restricted items, the switch must be turned to the PROGposition. When the Program/Run key switch is switched to the PROG position, the press will TopStop and stroking will be prohibited until the switch is returned to the RUN position.

When operating in the Key Only mode the key switch is the only means available to access therestricted items. All restricted items are accessible when the Program/Run key switch is switchedto the PROG position.

When operating in the “Key or Password” mode, the key switch is one of the means available toaccess the restricted items. All restricted items are accessible when the Program/Run key switch isswitched to the PROG position.

When operating in the “Key and Password” mode, the key switch and password must be used toaccess the restricted items. In this mode, the user will be granted access only to the restricted itemsthat have been assigned to him.

When the Program/Run switch is in the Program position, the softkeys highlighted in Figure 2.1 will

2-5

appear and will be active.

Section 2.3.6.2 Password System Operation

Figure 2.2 displays a typical password entry sequence. This example shows the steps necessary tochange a die protection channel setting. This is typical for password entry for all restricted items.

Figure 2.2 Password Entry Sequence

Step A: Select the restricted item. In the example shown in Figure 2.2 the restricted item isdie protection Change Type. Once the parameter is selected then Softkey # 1 theupper vertical softkey (Softkey # 1 is highlighted in Figure 2.2) , will display thelegend “Select”.

Step B: A list of users that have access to this restricted item will appear. In the example

2-6

shown in Figure 2.2 only User Number One, User Number Two, and User NumberFive have access to this restricted parameter. The system may have several moreusers, but the three users listed on the screen are the only users that have access tochange a die protection setting. The user must use the arrow keys to position thecursor on his user name. After placing the cursor on the correct name, the user mustpress the SELECT softkey. The SELECT softkey must be pressed even if there isonly one user name displayed.

Step C: The display will show the selected user name and request the user password. Theuser must enter the correct password and then depress the ENT key.

Step D: Upon entry of the correct password, the user will be allow access to the restricteditem. the example shown in Figure 2.2, the user will have access to change the dieprotection type.

After performing the steps listed above, the user will be logged in to the password system. The userwill have access to all restricted items that have been designated for his access. This access willremain until the user performs a log out or until the user is automatically logged out.

The user can log out by using the ACC key. This key will directly switch the display to the QuickAccess screen. The LOGOUT soft key legend will appear along the bottom of the screen. If theoperator presses this key, he will log out. He will no longer have access to the restricted items,unless he repeats steps A through D.

In addition to the manual log out, the system contains an automatic logout. The intent of automaticlog out is to reduce the possibility of users other than the intended user from having access torestricted items. If there were no provisions for automatic log out and a user forgot to manually logout, all restricted items to which the user had been designated for access would be available fromthe log in time until power was removed from the OmniLink control. This presents the possibilityof users other than the intended user having access to restricted items. Automatic log out is basedupon both time and press strokes. During system configuration automatic Access Timeoutparameters are entered. An automatic access timeout time and automatic access timeout strokes areentered. The time entered is the amount of time after the last key stroke that will be allowed beforethe system will automatically log out the user. For example, if the automatic access timeout is setto 60 seconds, the user will be logged out 60 seconds after the last key stroke. If the user depressesa key before the 60 seconds have elapsed, a new 60 second cycle will be started. The number ofstrokes that are entered is the number of press strokes after the last key stroke that will be allowedbefore the system automatically logs out the user. For example, if the automatic timeout is set to 10strokes, the user will be logged out when the press completes ten strokes after the last key stroke.If the user depresses a key before 10 strokes have been completed, a new 10 stroke cycle will bestarted.

Section 2.4 Type of Sensor

2-7

The Die Protection Menu displays the programmed types for the die protection input channels. Thechannel numbers under the "CH" column on the left correspond to the input terminal numbers onthe connector card assembly for the die protection module.

For each of the inputs, the information under the "Type of Sensor" column describes how the inputis programmed to operate. This is determined in advance by the operator according to whatcondition in the die the input is to monitor. The type determines, for example, whether the sensorconnected to an input should remain in a certain state at all times or whether it should switch openand closed with each press stroke. If the input is to switch, the type also determines timingrestrictions within the stroke as to when and how the input must switch. For any input there areeleven different program types from which to choose, or the operator may program the input asUnused. (Several different input types are illustrated in the sample screen of Figure 2.1). Moreinformation is provided for choosing the correct type for a die protection input in Section 3. Specificinformation on how to program an input to be a certain type is given in Section 2 in the portion titled“Programming Input Type”.

Section 2.4.1 Programming Input Type

The type of die protection input is programmed by the operator and specifies how the input is tointerpret the action of the sensor which is wired to its input terminal. There are eleven active Typeswhich can be chosen:

Static Normally OpenStatic Normally ClosedCyclicTransferIn Position1 Part Detector (Edge Only or Pass Completely)2 Part Detector (Edge Only or Pass Completely)Track PLSTrack PLS Invert

Alternately, the input type can be programmed as Unused if the input is not to be used. Informationon how the different types operate and how they can be used in different applications is found inSection 3. (Refer to Section 3 of this manual when determining how to set up sensors and programtheir inputs to accomplish the desired die monitoring).

To select a die protection type, the user must first obtain access control. Access control is describedin Section 2.3. If the user obtains access control by using the password system, the user must beconfigured to have access to change die protection settings. To begin the change type process, firstposition the cursor to the channel that is to be changed. If operating in a keyed access mode, placethe Program/Run switch in the PROG position. This step is not required if operating in a passwordaccess mode. Then press the CHANGE TYPE softkey. If operating in a password mode, access

2-8

control must be obtained as described in Section 2.3. A selection box will appear. This box willlist all of the channel types. Move the cursor to the channel type that is required, and press theSELECT softkey.

Section 2.5 Input Description

Input descriptions are helpful labels which aid the operator in identifying which sensor is tied to aparticular input and what that input is monitoring. This is of particular value if many die protectioninputs are used. Since the input "Type" labels are by necessity general in nature, an input descriptioncan be used to give more specific information to the operator. For example, suppose two separatesensors are being used to check for two different pilot holes in the part. The die protection inputswhich these sensors are wired to would both be programmed as Cyclic type inputs to check properoperation of the sensor (pilot hole both present and absent at different points in the stroke). In thisapplication it would be helpful to specify a description for each input such as "PILOT HOLE LEFT"and "PILOT HOLE RIGHT" so that if a failure occurred the operator would know immediatelywhich hole was not seen.

To edit a die protection input name, the user must first obtain access control. Access control isdescribed in Section 2.3. If the user obtains access control by using the password system, the usermust be configured to have access to change die protection settings. To begin the edit name process,first position the cursor to the channel that is to be changed. If operating in a keyed access mode,place the Program/Run switch in the PROG position. This step is not required if operating in apassword access mode. Then press the CHANGE NAME softkey. If operating in a passwordmode, access control must be obtained as described in Section 2.3. The Die Pro Names screen willappear. This screen is shown in Figure 2.3.

Figure 2.3 Selecting Die Protection Names

The system stores 45 names. Each name can be 20 characters in length. The screen shown in Figure

2-9

2.3 contains 15 names. The other names can be accessed by pressing the NEXT GROUP softkeyor using the arrow keys and moving the cursor past the first or last name.

To select a name fro the list of 45 names, position the cursor to the name that is to be selected andpress the ENT key.

If the desired name does not appear, either one of the existing names can be changed or a unusedlocation programmed with the desired name. To edit or add a name, move the cursor to the locationfor the new name and press the change name softkey. The alphanumeric text edit box will appear.This is shown in Figure 2.4. Letters are selected by using the left and right arrow keys to positionthe letter pointer under the desired letter, then pressing the SELECT LETTER softkey. If the leftor right arrow key is pressed and held, the pointer will automatically move to successive letters.Upper or lower case letters can be selected by the LOWER CASE/UPPER CASE softkey. If uppercase letters are currently being displayed in the text box, pressing the LOWER CASE softkey willchange the text box to lower case letters. To change a previous entered character, use the CURSORLEFT and CURSOR RIGHT softkeys to position the data entry line cursor over the letter to bechanged and then select the new character. A space is inserted each time the SPACE softkey ispressed, and the CLR key clears all characters that have been entered. Numbers are entered directlyfrom the numeric keypad. The entry process is aborted if the ABORT EDIT softkey is pressed,leaving the previous data intact. The new description is accepted when the ENT key is pressed.

Figure 2.4 Alphanumeric Data Entry

If it is decided to assign no name to the select channel, press the NO NAME softkey.

The EXIT softkey will return the display to the Die Protection menu.

2-10

Section 2.6 Input Status

In the Die Protection menu display, the column on the right labeled "Status" indicates the presentstatus of each individual input. If the die condition which the input is monitoring is satisfactory(sensor is seeing the proper inputs within the desired timing restrictions) then the message for theinput will be "OK". If the sensor input is not satisfactory, the message "ERROR" will be displayedfor the input. In the event of an internal fault on the die protection module itself, all the inputchannels will display the "ERROR" message. If an input channel displays the "ERROR" message,it will be necessary for the operator to position the cursor to the channel that is in error. A statusmessage explaining the error will appear at the bottom of the screen. Figure 2.1 indicates that DieProtection Channel 03 has an error condition, while the other channels displayed are all "OK".

If the Die Protection function has been bypassed, all the input channels will display the message"BYPASS" (see the topic “BYPASS ON/OFF key” in Section 2 for more information).

Section 2.7 Input State

The column labeled "State" on the Die Protection Menu allows the operator to view the present logicstate of each input, i.e., whether the input is HIGH or being held LOW by its external wiring and/orsensor. Using this information the operator can see what the Die Protection Module views thevoltage level of its inputs to be without using a voltmeter to actually measure each input. Note thatall inputs are active LOW and that all unconnected inputs will automatically read HIGH (see“Wiring” in Section 4). Since the update rate of the display may not be fast enough to catch someinput changes that occur, a momentary change in the state of an input may not be seen on thedisplay. In a case such as this it will be necessary for the operator to use the Capture Input featureof the View Channel screen to see the change on that input (see the topic “Input Capture Capability”in Section 2).

(Note: If a communication failure occurs between the Operator Terminal and the Module, all inputstates will be displayed as LOW regardless of their actual states).

Section 2.8 RESET ERRORS key

The RESET ERRORS softkey is used to unlatch errors that have been discovered by the DieProtection Module. Any error which occurs on a die protection input channel causes a stop signalto occur and the error to be latched. To resume using the machine the operator must first correct thecondition which caused the error to occur (i.e. out of material, part did not eject from die, etc.).

To perform a die protection reset, the user must first obtain access control. Access control isdescribed in Section 2.3. If the user obtains access control by using the password system, the usermust be configured to have access to reset die protection faults. Once the machine is again readyto run, the RESET ERRORS softkey can be pressed to unlatch the error in the Module and returnall inputs to a status of "OK".

2-11

(Note: If a Memory Data Loss error occurs on any input, the RESET ERRORS softkey will notclear the error until the data for that input has been reprogrammed.)

Section 2.9 BYPASS ON/OFF key

The monitoring function of the die protection module can be ‘turned off’ if desired, by placing themodule in Bypass mode. In this mode, it is not necessary for the die protection inputs to respondproperly according to their programmed input types. This is very useful when setting up or makingadjustments to the die. The "State" indication for each input and the CAPTURE INPUT functioncontinue to operate normally in the Bypass mode; the operator can therefore use the display toproperly set up the die protection sensors without nuisance stops. However, since using Bypassmeans that any improper action of the sensors will no longer cause an error or stop condition tooccur, the option should be used with caution to prevent unintentionally operating without dieprotection while in production.

To enter or exit Bypass mode, the user must first obtain access control. Access control is describedin Section 2.3. If the user obtains access control by using the password system, the user must beconfigured to have access to bypass die protection. Once access control is obtained, the BYPASSON/OFF softkey is used to enter and exit BYPASS mode.

For additional protection against accidental or unauthorized use of Bypass mode, a configurationoption is provided in the system setup that will force the module out of Bypass when the machineis run in Continuous stroke mode. This is described in Section 4.3, “Machine ParametersConfiguration”. If the Die Protection parameter is set to a value of 002, then the module will betaken out of bypass (e.g., monitoring will be made active) whenever the stroking mode is set toContinuous. If however the Die Protection parameter is set to a value of 001, then the module isallowed to be bypassed in any stroking mode.

Section 2.10 View Channel Information

The Die Protection Menu gives the operator general information about the type, description, status,and state of all the inputs. However, it is necessary to display more detailed information about aninput when programming and during operation of the machine so that the function of the input canbe understood. To access more detailed information about a particular input, move the cursor to theinput that is desired. More information concerning that particular channel will be displayed at thebottom of the screen.

This additional information defines how the sensor which is wired to this input should switch if thedie condition being monitored is behaving properly and the sensor is working. Depending on theType programmed for the input, there may also be additional lines for information such as WindowON, Window OFF, Separation Time, and so forth. These items are explained in the sectionsfollowing.

2-12

In the example Die Protection Screen shown in Figure 2.1, the information shown is for Channel 01and includes Type of Stop Output, Window ON, and Window OFF, Number of Stroke Delay, anda bar graph showing the timing window.

Section 2.10.1 Changing Channel Information

To edit die protection channel information, the user must first obtain access control. Access controlis described in Section 2.3. If the user obtains access control by using the password system, the usermust be configured to have access to change die protection settings. To begin the change settingprocess, first position the cursor to the channel that is to be changed. If operating in a keyed accessmode, place the Program/Run switch in the PROG position. This step is not required if operatingin a password access mode. Then press the CHANGE SETTINGS softkey. If operating in apassword mode, access control must be obtained as described in Section 2.3. The cursor will moveto the View Channel information that is at the bottom of the screen.

Once all changes have been made, press the END CHANGE softkey to return the cursor to the dieprotection inputs.

Section 2.10.2 Programming Stop Output

The Die Protection Module is capable of issuing a Cycle Stop (immediate stop) or a Top Stop to thepress if any die protection input does not respond as desired. The type of stop to be used for aparticular input must be determined by the operator according to the application. Some applications,such as insuring that material is in position, require an immediate stop if a failure occurs. Otherapplications such as monitoring the end of stock might require only that the press stop on top.

To change the stop type, gain access to the Channel Information Area (see Section 2.10.1), positionthe cursor over the current stop type and press the CHANGE SETTINGS softkey.

Section 2.10.3 Programming Delay Time

When an input is programmed as a Static type, the Channel Information Area will be "Delay Time".This feature allows the operator some flexibility in handling static inputs which have nuisance tripsdue to momentary bouncing of the sensor. When the Delay Time is programmed with some valueother than zero, then the delay timer will begin to count down if the input changes to the improperstate (i.e., an "open" on an input programmed as normally closed.) If the input returns to the properstate before the programmed delay times out, the timer is reset and no fault occurs. If the delay timeexpires before the input returns to the proper state, a fault is generated. In this way, a momentarychange on the input can be ignored but a long term change on the input will cause a fault.

The range of values for the delay time is 0 seconds to 65.500 seconds in 0.001 second increments.If the delay time is programmed as zero, a fault will occur immediately whenever the input goes tothe improper state.

2-13

To change the delay time, gain access to the Channel Information Area (see Section 2.10.1), use thearrow keys to the current Delay time then press the CHANGE NUMBER softkey. The operatormust then enter a value for the time (0 to 65.500 seconds) and press the ENT key on the keyboard.

Section 2.10.4 Programming Window Setpoints

When using Cyclic, Transfer, In Position, and 1 Part or 2 Part Detector types for die protectioninputs, it is necessary to define an area of the press stroke where the input must be active (low) forsome period of time. This is called defining a "window" in the stroke. In this way timinginformation is provided for the die protection module so that it knows when to expect the sensor forthat input to become active. The operator must enter a "Window ON" setpoint to define the start ofthe window and a "Window OFF" setpoint to define the end of the window. Information on howthe timing windows operate for each of the various die protection types is found in Section 3.

The "Window ON" and "Window OFF" information will be displayed in the Channel InformationArea , when any of the above mentioned types have been programmed for the input. To change awindow setpoint, gain access to the Channel Information Area (see Section 2.10.1), use the arrowkeys to move the cursor to the window setpoint as desired, then press the CHANGE NUMBERsoftkey. The operator must then enter a crankshaft angle for the setpoint (0 to 359 degrees) and pressthe ENT key on the keyboard.

Section 2.10.5 Programming Separation Time

When an input is programmed as a 2 Part Detector type, the operator must also program a SeparationTime. This is due to the fact that some parts are irregularly shaped or have holes which may causethe detector to give multiple signals to the die protection input for one part. To ensure that thedetector counts only once for the first part, the module will wait through a programmed delay afterseeing the first part before it begins to look for the second part. This programmed delay must beentered by the operator and is called Separation Time. When an input is programmed as a 2 PartDetector, the separation time is displayed in the Channel Information Area. The range of allowedvalues for the separation time is 4 milliseconds to 999 milliseconds in 1 millisecond increments. Theproper value for a particular application will have to be determined by experimentation.

To change the separation time, gain access to the Channel Information Area (see Section 2.10.1), usethe arrow keys to the current Separation time then press the CHANGE NUMBER softkey. Theoperator must then enter a value for the time (4 to 999 ms) and press the ENT key on the keyboard.

Section 2.10.6 Programming Track Channel

The Track PLS type is used when it is desired that the die protection input channel track the actionof a mechanism controlled by a System 5000 programmable limit switch output. This type of

2-14

monitoring is described in the “Track PLS and Track PLS Invert” topic of Section 3. When an inputis defined as a Track type input, the Channel Information Area will display the PLS channel to betracked (labeled Track PLS Ch #). The operator must specify which PLS output channel is to betracked for proper operation. The system is capable of tracking PLS outputs 1 through 8.

To change the PLS channel to be tracked, gain access to the Channel Information Area (see Section2.10.1), use the arrow keys to move the current Track PLS #, then press the CHANGE NUMBERsoftkey. The operator must then enter number 1 through 8 for the PLS channel to be tracked andpress the ENT key on the keyboard.

Section 2.10.7 Programming Track Time

As detailed in the “Track PLS and Track PLS Invert” topic of Section 3, Track PLS type inputs mustfollow the switching action of a System 5000 PLS output. There are, however, electrical andmechanical delays involved from the time that the PLS output activates until the tracking sensorwhich is wired to the die protection input is activated. To allow for these delays, the operator mustprogram a Tracking Time for any input set up as Track PLS. The Tracking Time is the time allowedafter the PLS output switches before the die protection input set up as Track PLS must also switch.It is displayed in the Channel Information Area for any input programmed as Track. This time canbe from 4 milliseconds to 999 milliseconds in 1 millisecond increments.

To change the tracking time, gain access to the Channel Information Area (see Section 2.10.1), usethe arrow keys to move the cursor to the current Track Time, then press the CHANGE NUMBERsoftkey. The operator must then enter a value for the time (4 to 999 ms) and press the ENT key onthe keyboard. .

Section 2.11 Input Capture Capability

There may be instances where it is desirable to find the exact crankshaft angle where a die protectioninput changes (i.e., where the sensor wired to the input changes). This is especially true with a fastchanging input where the operator may not be able to see the change on the "State" display of theDie Protection Menu. For example, if a part detector is being used it would be very desirable to seeexactly where the part passes the detector. This information would be helpful in setting up thetiming window for that input. By using the Capture Input feature for any input, the operator canview the crankshaft angle at which that particular input changes.

In the Die Protection screen for any input, there will be a softkey which is labeled CAPTUREINPUT (see Figure 2.1). The block displayed above the CAPTURE INPUT softkey displays thepertinent information. The "Capture Status" line informs the operator of whether or not the capturefeature is active, while the "Closed at" line will display the crankshaft angles when the inputchanges. To arm the capture for this input, the operator must press the CAPTURE INPUT softkey.Once the capture is armed the module will begin to look for the crankshaft to pass through the 170degree point (just prior to bottom dead center). Monitoring is done for one stroke beginning near

2-15

bottom rather than beginning at top dead center since in many applications parts are ejected near thetop of the stroke. When the press moves through 170 degrees the monitoring begins, and until 170degrees is passed again the die protection input will be monitored for any change. The first time thatthe input closes (is connected to machine ground) the angle at which this occurs will be displayedin the status block beside the message reading "Closed at". When the input opens (becomes inactiveor ungrounded) the angle at which this occurs will be displayed beside the message "Opened at".The status labels displayed during this procedure are summarized below:

Action or state Capture Status label1) Prior to using capture "Not Armed"2) Press the CAPTURE INPUT softkey "Armed"3) Machine moves through 170 degrees “Armed (Active)”4) When this input is first connected to ground, “Armed (Active)” the angle where this occurs is displayed beside “Closed At”5) When this input opens (is disconnected from “Armed (Active)” ground) the angle where this occurs is displayed beside “Opened At”6) Machine moves through 170 degrees again “Not Armed”

The display of the angles where the input closes and opens is tailored for parts monitoring. If thedie protection input closes and opens multiple times, only the angle of the first closure will bedisplayed. This is done in order to save the crankshaft angle at which the leading edge of the partentered the detector. In addition, after multiple closing and opening of an input the angle displayedwill be the position of the last time that the input opened. This is done so that if the part has holesthat cause the detector to switch on and off, the final off point (or trailing edge of the part) will besaved and displayed.

The Capture Input feature is especially useful during setup of a die protection input and its sensor.If the function to be monitored is a cycling type (programmed as Cyclic, Transfer, In Position, orPart Detector), a timing window must be entered by the operator to provide the unit with informationregarding where the input is expected to cycle. A simple way to determine approximately where thetiming window boundaries should be set is to first program the input as Unused (capture is availablefor an input even if the input is programmed as Unused) and cycle the machine with the sensor inoperation. The action of the sensor can then be monitored using Capture Input, and the sensor switchpoints can be determined without nuisance machine stops due to the input being programmed for anactive die protection type. (If the machine is running in Continuous mode, the CAPTURE INPUTkey can be pressed on each stroke to re-arm the function and repeat the monitoring.) Once the sensorswitch points are determined, the input can be programmed for its proper type and the appropriatetiming window entered for the sensor.

Section 2.12 Programmable Limit Switch Menu

2-16

The Die Protection screen has a LIMIT SWITCH softkey. This key will allow direct access to theprogrammable limit switch screen. During setup of Die Protection it may be necessary to adjustprogrammable limit switch channels. This softkey will allow that direct access. If the Limit Switchscreen is entered from the Die Protection screen, pressing the EXIT softkey in the Limit SwitchScreen will return the display to the Die Protection screen.

Section 2.13 Job Setups In the System 5000, all pertinent information for the current job such as programmable limit switchsetpoints and automatic feed settings can be stored for later use as a block of information called a"job setup". Since this programmed data may change from job to job or as machine dies arechanged, saving a job setup prevents the operator from having to manually change all thisinformation when dies are changed. The operator can simply recall the appropriate job setup whichhe previously stored and the press is ready to run. The System 5000 has memory capability forstoring 500 job setups. Information on storing, recalling, or erasing job setups in the System 5000manual.

The Die Protection Module will also store or recall all its pertinent data when the operator stores orrecalls a job setup. This includes all programmed information for each input including type,description, stop output, window settings, separation times, track channels, and track times. Thesystem has storage capability for 500 setups to correspond to the memory for press control and limitswitch storage. The operator need not perform any additional or separate operations to store or recalldie protection information; simply follow the standard procedure for job setups listed in the System5000 manual and the setup change is done automatically in the Die Protection Module.

Note: If the Die Protection Module is installed in the System 5000 as an option after the system hasbeen in operation, there may be job setups stored in the press control that have not been stored in theDie Protection Module. This situation might also arise if a Die Protection Module is swapped fromone System 5000 control to another. In this case when one of those previously stored jobs is recalledfrom memory by the operator, the Die Protection Module will not be able to find any informationstored. If this occurs a message will be displayed on the job setup screen which reads "No DieProtect Settings". The die protection input types will remain unchanged from what they were priorto the recall. The operator MUST in this case verify that the die protection inputs are programmedas desired and make changes if necessary. Otherwise there is the risk of die damage due to operationof the machine with the die protection module programmed incorrectly for the current job. Once thedie protection programming is complete, the setup can be stored again under the same job numberand name so that the die protection information will also be part of the stored setup.

3-1

Figure 3.1Probes used with Static,Normally Open inputs

Section 3 Die Protection Input Types and Their Uses

Each of the sixteen die protection inputs can be programmed for any one of eleven different dieprotection types: Static Normally Open, Static Normally Closed, Cyclic, Transfer, In Position, 1 PartDetection (Edge Only or Pass Completely), 2 Part Detection (Edge Only or Pass Completely), TrackPLS, and Track PLS Invert. In addition, any input can be programmed as Unused if desired.

Section 3.1 Static N.O. and Static N.C.

Static inputs are used for sensors thatmonitor events that are independent of theproduction machine cycle. Examples aresensors monitoring end of stock, stockbuckling, and misfeed. If the input isprogrammed as Static Normally Open(labeled as Static N.O.) then the inputshould NOT be grounded under normaloperation. In this case, connection of theinput to ground will cause a stop to occur.If the input is programmed as StaticNormally Closed (labeled Static N.C.) thenthe input should be grounded under normaloperation. In this case, if the groundconnection to this input is opened (as byswitch or sensor breaking the connection)then a stop will occur.

An example of the use of a normally openinput is stock buckling detection, as shown in Figure 3.1, part A. The stock to be fabricated is placedbetween a dual probe in the normal position. The probe remains open (ungrounded) unless the stockbuckles upward or downward far enough to touch the upper or lower portion of the probe, closing(grounding) the normally open input, causing a fault.

An example of the use of a normally closed input is an end of stock sensor, as shown in Figure 3.2.A probe is mounted so that it is grounded by the stock being fed into the production machine. Whenthe end of stock is reached, the probe will no longer contact the stock, opening the input and causinga fault.

An additional feature of Static type inputs is the delay timer which is programmable by theoperator.* A programmed time of zero forces ordinary operation of the static input as described

3-2

Figure 3.2Probes used with Static,Normally Closed inputs

Figure 3.3A cyclic input used to monitor

shut height changes

above, i.e., if the input is not in the 'normal'state, a fault will occur immediately.However, if a value other than zero isprogrammed the input is allowed to changefrom the normal state for the length of timeprogrammed without a fault occurring. Ifthe input does not return to the normal statebefore the time expires, a fault is generated.This allows the operator to avoid nuisancefaults from sensors that 'bounce' open orclosed momentarily. The delay time canrange from 0 to 65.500 seconds in 0.001second increments.

*The delay timer on Static inputs isavailable when firmware revision 1.4 orgreater is installed on the board

Section 3.2 Cyclic

Cyclic inputs are derived frommonitored events that occur onceeach machine cycle when theproduction process is functioningnormally. An example of a cyclicevent is shut height monitoring asshown in Figure 3.3. In normaloperation, when the die closes aswitch or probe will be closed; then,when the die opens again, theswitch will open. If parts shouldstack up in the die, the switch willnot close and a fault will bedetected.

When programming an input for cyclic mode, the operator must enter crankshaft angles to mark ONand OFF points for a timing 'window' for the cyclic event. The timing window On and Off setpointsshould be programmed so that the window is ON during the portion of the stroke that the cyclicevent should happen (see Figure 3.4).

An additional feature for use on Cyclic type inputs is the stroke delay counter which isprogrammable by the operator.* The counter provides the flexibility to use the Cyclic type to

3-3

Figure 3.4Cyclic input timing

Figure 3.5Transfer input timing

monitor events in the production process that may not occur every stroke, but must occur withinsome number of strokes. An example of such an application is slug detection, where under normaloperation slugs are allowed to build up and be ejected after several strokes. In such a scenario, a slugwould not be detected by the sensor on every stroke, and this would produce a fault were the strokedelay counter not used. The delay counter allows the operator to enter a number representing themaximum number of strokes that can be run consecutively without the sensor becoming activewithin the timing window. If the sensor does not become active within the window for a numberof strokes exceeding the counter number, then a fault will be generated. By contrast, if the sensordoes become active within the window on some stroke before the counter expires, then the counteris reset and the full count is again allowed. If the operator desires that the sensor be required tobecome active on every stroke, then a value of zero should be entered into the counter. (Note thatalthough the sensor is allowed to remain inactive throughout a stroke when the stroke counter isused, the opposite is not true; e.g., the sensor is not allowed to remain active through an entire strokeor a fault is generated.)

*The stroke delay counter on Cyclic inputs is available whenfirmware revision 2.2 or greater is installed on the board

Section 3.3 Transfer

Transfer type inputs are used to monitor automatic transfermechanisms. Some progressive dies cut the part away from thestock at an early stage in the die. Automatic transfer mechanismsare then used to move the separate pieces to the next stage in thedie. Each gripper on the transfer mechanism should have aswitch to detect that each part is in place in the transfermechanism. These switches can be wired to inputs programmed

3-4

Figure 3.6Sensors used with In Position inputs

Figure 3.7In Position input timing

as Transfer type to monitor the mechanism for dropped parts during the transfer.

When programming an input for transfer type, the operator must enter crankshaft angles to mark ONand OFF points for a timing 'window' during which the transfer will occur (see “ProgrammingWindow Setpoints” in Section 2). The Window ON setpoint should be set to an angle just after thepart is gripped. The window OFF setpoint should be set to an angle just before the part is releasedinto the next stage of the die (see Figure 3.5). With this type, the input must remain closedthroughout the entire timing window or an error will occur.

Section 3.4 In Position

In Position type inputs are used to monitor whether material is fully fed into the die on each cycleof the press. A sensor should be used to detect when the material to be fabricated is fully fed intothe die. Figure 3.6 illustrates two examples of the use of sensors with inputs programmed as InPosition type.

When programming an input for In Position type,the operator must enter crankshaft angles to markON and OFF points for a timing 'window' duringwhich the material will move into place (see

3-5

Figure 3.8One Part Detector input timing

“Programming Window Setpoints” in Section 2). The Window ON angle should be set to a pointwell before the feed takes place. The Window OFF angle should be set to a point after the materialhas been fed into place and is making contact with the sensor. If the material is not in contact withthe sensor when the timing window turns off, a fault will be generated. The OFF angle must alsobe set so that the fault will stop the press before the die closes. An illustration of the In Positiontiming sequence is shown in Figure 3.7.

Section 3.5 1 Part Detector-Edge and 1 Part Detector-Pass

The One Part Detector input type is used tomonitor parts ejection for dies producing one partper stroke. The 1 Part input type functions muchlike the Cyclic type, the difference being that thetiming window must turn on before, not while,the part is being ejected (activating the sensor).In other words, the Part Detector type requiresthat the sensor NOT be active when the windowturns ON, and then become active at some pointduring the window.

When programming an input as a Part Detectortype, the operator must choose whether it will berequired for the part to completely pass the detector during the timing window. If it is desired thatthe part completely pass (i.e., the detector will become inactive again before the timing window turnsoff), then the input should be programmed as '1 Part Detector-Pass'. If it is only required that thepart enter the detector during the window but does not have to completely pass through until afterthe window, then the input should be programmed as '1 Part Detector-Edge'. This signifies that onlythe leading edge of the part must be seen during the window, as might be the case for a very longpart. (See Programming Window Setpoints” in Section 2 for timing window entry instructions.)Note: If the input is programmed as ‘1 Part Detector - Pass’, the sensor is not allowed tobecome active outside the window or a fault will be generated. This provides protection againsta part ‘bouncing’ on a probe-type detector and satisfying the die protection input erroneously.

The Window ON angle should be set to a point well before the part is ejected. The Window OFFangle is dependent on whether the ‘Edge’ or ‘Pass’ type is used, as shown in Figure 3.8.

An illustration of the Link 3040 Infrared Parts Detector is shown in Figure 12. Examples of otherprobes used with Part Detector inputs are shown in Figure 13.

Section 3.6 2 Part Detector-Edge and 2 Part Detector-Pass

The Two Part Detector input type is used to monitor parts ejection for dies producing two parts perstroke. The ejection of parts must be sequenced so that they do not overlap when ejected, or the

3-6

Figure 3.9Two Part Detector input timing

sensor used to detect the part will see only one part, causing nuisance production stops. Parts withholes or irregular shapes can look like two parts to probes and infrared sensors, giving false signals.

When programming an input as a 2 Part Detector type, the operator must choose whether it will berequired for the second part to completely pass the detector during the timing window. If it isdesired that the second part completely pass (i.e., the detector will become inactive again before thetiming window turns off), then the input should be programmed as '2 Part Detector-Pass'. If thesecond part is only required to enter the detector during the window but does not have to completelypass through until after the window, then the input should be programmed as '2 Part Detector-Edge'.This signifies that only the leading edge of the second part must be seen during the window. (Forinformation on programming the timing window, see “Programming Window Setpoints” in Section2). Note: If the input is programmed as ‘2 Part Detector - Pass’, the sensor is not allowed tobecome active outside the window or a fault will be generated. As in the case of ‘1 Part Detector- Pass’, this provides protection against a part ‘bouncing’ on a probe-type detector and satisfying thedie protection input.

When programming an input for 2 Part type, theoperator must also program a separation timebetween parts (see “Programming SeparationTime”, Section 2). The separation interval helpsin avoiding false signals. The die protectionmodule will delay this amount of time afterrecognizing the first part before monitoring forthe second part. If the parts are irregularly shapedor have holes that might cause a part to becounted more than once, the forced delay willallow the first part to get completely through thedetector without this occurring. The separationtime can be from 4 to 999 milliseconds in 1 msincrements.

The Link 3040 Infrared Parts Detector is illustrated in Figure 3.10. Examples of other probes used

3-7

Figure 3.103040 Infrared Parts Detector Light Screen

with Part Detector inputs are shown in Figure 3.11.

Section 3.7 Track PLS and Track PLS Invert

Tracking type inputs are used to monitor events that should closely follow (track) a System 5000PLS output. On the die protection module, any input channel can be programmed to track a PLSoutput within a specified length of time. If the input fails to follow the on/off switching of the PLSoutput within the specified time, a stop is generated. Tracking is limited to the first eight PLSoutputs of the System 5000.

When programming an input for Track type the operator must enter the number of the PLS channelto be tracked. This can be any PLS channel from 1 through 8. The Track Time must also be enteredby the operator (the amount of time that the die protection input is allowed to 'lag' behind the PLSoutput). The Track Time can range from 4 ms to 999 ms in 1 ms increments. (See “ProgrammingTrack Channel” and “Programming Track Time” in Section 2 for specific instructions on enteringthese values.)

If the sensor or switch used on the input is such that the die protection input will be ‘off’ (notgrounded) in response to the PLS channel being ‘on’ (N.O. relay contacts pulled closed), then TrackPLS Invert should be chosen as the input type. For Track PLS Invert inputs, the module will readthe state of the input and then invert that reading internally before comparing it to the PLS output.

3-8

Figure 3.11Probes used with Part Detector inputs

3-9

Figure 3.12A Track PLS Invert type input is used

to monitor an air cylinder

An example of the use of a Track PLS Invert type on an input is the monitoring of an air cylinderused for parts ejection, as shown in Figure 14. Suppose a PLS output on the System 5000 is usedto activate the cylinder, with the power source for the cylinder switched through the N.O. contactsof the PLS relay. A probe type switch is located such that it will close and ground the die protectioninput when the air cylinder is retracted (at the home position). Should the air cylinder jam in theextended position, the switch will not close when the output turns off. The die protection modulewill then detect a fault and stop the press before the dies can close on the cylinder.

Notice in this example that when the PLSoutput turns on, the air cylinder extends;this in turn opens the switch, turning offthe die protection input. In this case theon/off state of the input is inverted from thePLS output state. In this application andother similar ones, Track PLS Invert shouldbe chosen as the input type. As previouslydescribed, for Track PLS Invert inputs themodule will read the state of the input andthen invert that reading internally beforecomparing it to the PLS output.

4-1

Section 4 Installation

Section 4.1 Extended Card Rack

The Die Protection Module is designed for use in the Extended Card Rack of the System 5000. Tofield install the Extended Card Rack (in systems which are not already equipped) first remove theright end cover plate on the standard card rack, keeping the mounting screws and nuts for use insecuring the extended rack. Mounting holes must be drilled in the enclosure backplate for theextended rack, using the mounting dimensions shown in the System 5000 Press Control OperatingManual. The motherboard in the extended rack must then be plugged into the motherboard of thestandard rack using the DIN connectors mounted at the edge of each board. Once the extendedmotherboard has been firmly plugged into the standard motherboard, the extended rack can beattached to the backplate of the enclosure with mounting screws. Finally, the standard and extendedracks can be secured to one another using the mounting screws and nuts which originally held theend plate in place.

Section 4.2 Module Installation

Power down the system and remove the cover panel over slot 3 (the centermost slot) of the extendedrack. Insert the die protection circuit card into the card guides at the top and bottom of the rack. Thecard should be oriented with the red and green LED indicators near the top. When the card is fullyin the rack, press firmly to be sure that it is completely seated in its connector while using the latchesat the top and bottom of the card to lock it into place. The Die Protection connector card assembly(the panel with terminal strip connections) should then be put into the rack and plugged into thecircuit card. Tighten the screw fasteners on the connector card assembly to hold it in place.

Section 4.3 Machine Parameters Configuration

In order for the OmniLink Operator Terminal to recognize and communicate with the Die ProtectionModule, the Machine Parameters configuration setting for that module must be properlyprogrammed. This is evidenced by the fact that even after the Die Protection Module is physicallyinstalled, the die protection status message (on the Main Menu of the operator terminal) still reads"Option is NOT Installed". In order to access the Machine Parameters configuration, the operatormust follow these steps:

1. Turn the keyswitch on the Operator Terminal to the PROG position;2. Select “PRESS CONTROL” from the Main Menu (Press Control menu is displayed);3. On the Press Control menu, select the CONFIGURE softkey and enter the

Configuration Code. The P/C Config. menu is displayed.4. Press the MACHINE PARAMETERS softkey. The Machine Parameters menu is

displayed.5. Press the FACTORY CONFIG softkey. The Factory Parameters screen is displayed.

4-2

On the Factory Parameters screen, one of the parameters displayed is Die Protection. Use the downarrow key to move the cursor to the Die Protection parameter and enter one of the following values:

Value Description

001 Die Protection enabled; Bypass of die protection is allowed in all strokingmodes (if operator has access control for this feature)

002 Die Protection enabled; Bypass mode allowed in all stroking modes exceptContinuous (e.g., when Continuous stroking mode is selected, the dieprotection module will be forced out of Bypass). Activation/deactivationof Bypass in other stroking modes requires that operator have accesscontrol.

(Refer to Section 2.9 for a description of the use of Bypass mode on the module.) Once a value isentered for the Die Protection parameter, the operator can then exit back to the Main Menuwhereupon the die protection status area should display a different message than the “Option is NOTinstalled” message.

Section 4.4 Wiring All inputs to the Die Protection Module have internal pullups such that if an input is left unconnectedit will go to the HIGH state (the inactive state) and will be read as HIGH on the Operator Terminalscreen. Any input can be activated by connecting it to ground, which will be read as LOW on theOperator Terminal screen. Any sensor or probe to be used with the die protection module shouldbe designed so that when it is active it connects the input to ground. For example, if a limit switchis used as an input device, one side of the switch should be connected to machine ground (frame)and the other side of the switch should be wired to an input of the die protection module. If a sensorwith a solid state output is to be used (such as a proximity switch), the output of the sensor shouldbe of the current sinking type (NPN, Open Collector) to sink current from the die protection inputto ground.

5-1

Section 5 Troubleshooting

Section 5.1 Status Messages The following sections are listings of status messages generated by the System 5000 Die ProtectionModule, firmware version 2.2. For each message an explanation of the cause is given.

Section 5.1.1 Main Menu Status Messages

One of the messages below will always be present in the status block beside the softkey labeled DIEPROTECT on the Main Menu.

“All Conditions OK”

This message indicates that there are no faults currently detected by the Die Protection Module andthat it is not issuing a Stop command to the press control.

"Error Condition Exists"This message indicates that an error has been discovered by the die protection module. The mostlikely cause is that one of the die protection inputs did not react as its programmed type requires,thus forcing a stop. It is also possible that an internal error has been discovered on the die protectionmodule unrelated to the die protection inputs or their external sensors. In either case, the operatorshould go to the Die Protection Menu and examine the "Status" column on the upper half of thescreen. If one of the inputs has an "ERROR" status message in this column, the operator should usethe "VIEW CHANNEL" capability (see the “View Channel” heading of Section 2) to view the errormessage. Input channel error messages are detailed in the “View Channel Status Messages” topiclater in this section. If no "ERROR" status is shown, the operator should use the "NEXT GROUP"key to view inputs 9-16 and find the channel with the error.

"Communication Failure"The die protection module communicates with the operator terminal through a serial communicationlink. If the terminal loses communication with the module, this error will appear. If this occurs, theoperator should power down the unit, remove the connector card assembly, then remove the dieprotection card from the rack. Reinstall the card in its slot, verifying that the card seats firmly intoits motherboard connector, then replace the connector card assembly and power up the unit. If thisdoes not correct the problem, verify that the wiring from the operator terminal to the powerconnector module of the System 5000 is correct (terminals A through E).

"Option is NOT Installed"This message indicates that the operator terminal has not been configured to accept the die protectionmodule. See the “Machine Parameters Configuration” topic of Section 4 for information regardingconfiguration of the system for use of this module.

5-2

Section 5.1.2 View Channel Status Messages

The Status block of the View Channel screen for any input (see Figure 2) will display informationregarding the present condition of that input and of the module in general. If the sensor wired to theinput is operating properly and the module has no error conditions present, the status block will read"OK". If an error has been detected in the operation of the sensor wired to this input, an errormessage will appear describing the failure that was detected. The specific message displayed willdepend on the die protection type for which this input is programmed. These messages are groupedaccording to input type in the listings below. The operator must find the type for the input and thenlook under that type heading below to locate the error message and its accompanying description.

If a failure occurs in the module itself (unrelated to the inputs or their sensors), a general statusmessage describing the failure will appear on the View Channel screens for every input. Thesemessages are listed under “General Status Messages” later in this section.

Section 5.1.2.1 Static Messages

"Input has closed - should stay open through stroke"This die protection input is programmed as Static Normally Open which requires the input to remainopen (not grounded). If the input closes to ground for a time longer than the Delay Timeprogrammed, then this message is displayed indicating that the monitored condition has occurred(i.e., stock buckle, etc.) and a stop is required. Check the monitored condition and correct ifnecessary.

"Input has opened - should stay closed through stroke"This die protection input is programmed as Static Normally Closed which requires the input toremain grounded at all times. If the input opens (becomes ungrounded) for a time longer than theDelay Time programmed, then this message is displayed indicating that the monitored condition hasoccurred (i.e., end of stock, etc.) and a stop is required. Check the monitored condition and correctif necessary.

Section 5.1.2.2 Cyclic Messages

"Input failed to close during Timing Window"This error message occurs only when the stroke delay counter is set to zero; the Cyclic type thenrequires the input to close (to ground) at some point during the timing window on every stroke. Thismessage indicates that the input was never grounded during the timing window, indicating that themonitored event did not occur. Check the monitored condition and correct if necessary.

"Input failed to open outside Timing Window"The Cyclic type requires the input to open (e.g., be released from ground) at some point outside thetiming window. On this stroke the input was grounded through the entire stroke, possibly indicating

5-3

a failed or stuck sensor.

“Input failed to close throughout stroke delay”This error message occurs only when the stroke delay counter is set to some number other than zero.When this is true, the input is not required to close (to ground) within the timing window on everystroke, but it must close within the window on at least one stroke before the number of strokesentered in the counter has passed. This error message indicates that the input was never groundedwithin the timing window during the consecutive number of strokes entered into the counter. Checkthe monitored condition and correct if necessary.

Section 5.1.2.3 Transfer Messages

"Input was not closed at start of Timing Window"The Transfer type requires that the input be closed (grounded) at the beginning of the timingwindow, all during the window, and at the end of the window; and then open at some point outsidethe window. However, the input was not closed at the beginning of the timing window (the ONsetpoint) indicating that the part was not gripped properly and therefore requiring a stop.

"Input did not stay closed during Timing Window"The Transfer type requires that the input be closed (grounded) at the beginning of the timingwindow, all during the window, and at the end of the window; and then open at some point outsidethe window. However, the input did not remain closed during the entire timing window indicatingthat the part was dropped and therefore requiring a stop.

"Input was not closed at end of Timing Window"The Transfer type requires the input to be closed (grounded) at the end of the timing window (theOFF setpoint). However, the input was not closed at the end of the window indicating that the partwas not gripped properly and therefore requiring a stop.

"Input failed to open outside Timing Window"The Transfer type requires the input to open (be released from ground) at some point outside thetiming window. On this stroke the input did not open outside the timing window, possibly indicatinga failed or stuck sensor.

Section 5.1.2.4 In Position Messages

"Input was not closed at end of Timing Window"The In Position type requires that the input be closed (grounded) at the end of the timing window(the OFF setpoint). However, the input was not closed at the end of the window indicating thatmaterial was not in position and therefore requiring a stop.

"Input failed to open at any point in the stroke"

5-4

The In Position type requires that the input be closed (grounded) at the end of the timing window(the OFF setpoint) and then be open at some other point in the stroke. This message indicates thatthe input never opened at any point in the stroke, thus indicating a possible failed or stuck sensor.

Section 5.1.2.5 1 Part Detector Messages

"Part was not seen during the Timing Window"This input is programmed as a "1 Part Detector-Edge" which requires that the input be open(ungrounded, no part in the detector) at the start of the timing window, then close at some pointbefore the end of the window (i.e., the part contacting the detector). This error message indicatesthat one of these conditions was not met, signifying that the part was not seen and generating a stop.

"Part failed to completely pass during Timing Window"This input is programmed as a "1 Part Detector-Pass" which requires that the input be open(ungrounded, no part in the detector) at the start of the timing window, then close at some pointduring the window (i.e., the part contacting the detector), then open again before the end of thewindow. The system interprets this sequence of conditions from the sensor to indicate that a parthas completely passed through the detector during the timing window. This error message indicatesthat one of these conditions was not met, signifying that the part was not seen and generating a stop.

"Input closed outside of Timing Window"This input is programmed as a "1 Part Detector-Pass" which requires that the sensor cannot becomeactive outside the timing window. This requirement is made so that parts which are trapped andvibrating on a probe-type detector will cause a fault rather than repeatedly satisfying the dieprotection input every stroke. This error message indicates that the sensor became active (closed theconnection from input to ground) outside the timing window, violating the above requirement.

Section 5.1.2.6 2 Part Detector Messages

"First part not seen during Timing Window"This input is programmed as a "2 Part Detector-Edge" which requires that the input be open(ungrounded, no part in the detector) at the start of the timing window, close at some point duringthe window (i.e., the first part contacting the detector), open again for the interval between parts,then close again before the end of the window as the second part contacts the detector. This errormessage indicates that the first open/close sequence was not seen thereby signifying that the first partwas not detected.

"Second part not seen during Timing Window"This input is programmed as a "2 Part Detector-Edge" which requires that the input be open(ungrounded, no part in the detector) at the start of the timing window, close at some point duringthe window (i.e., the first part contacting the detector), open again for the interval between parts,then close again before the end of the window as the second part contacts the detector. This errormessage indicates that the first open/close/open sequence was seen but the final closure was not seen

5-5

thereby signifying that the second part was not detected.

"First part did not pass completely during Timing Window"This input is programmed as a "2 Part Detector-Pass" which is identical to the "2 Part Detector-Edge" type except that the second part seen must completely pass the detector (i.e., the input mustfinish open or ungrounded when the timing window ends). This error message indicates that the firstopen/close/open sequence was not seen thereby signifying that the first part did not pass completelythrough the detector.

"Second part did not pass completely during Timing Window"This input is programmed as a "2 Part Detector-Pass" which is identical to the "2 Part Detector-Edge" type except that the second part seen must completely pass the detector (i.e., the input mustfinish open or ungrounded when the timing window ends). This error message indicates that the firstopen/closed/open sequence was seen (signifying that one part was detected) but that the secondclosed/open sequence was not seen, thereby signifying that the second part did not pass completelythrough the detector.

"Input closed outside of Timing Window"This input is programmed as a "2 Part Detector-Pass" which requires that the sensor cannot becomeactive outside the timing window. This requirement is made so that parts which are trapped andvibrating on a probe-type detector will cause a fault rather than repeatedly satisfying the dieprotection input every stroke. This error message indicates that the sensor became active (closed theconnection from input to ground) outside the timing window, violating the above requirement.

Section 5.1.2.7 Track PLS Messages

"Input opened before PLS Output turned Off"This input is programmed as a Track PLS type so that the input must follow the PLS channelprogrammed under "Track PLS Channel". This message indicates that the input opened (releasedfrom ground) without the PLS output turning off to initiate this input action. This could be causedby a failure of the mechanism being monitored, a failure of the sensor, or a loose wire.

"Input closed before PLS Output turned On"This input is programmed as a Track PLS type so that the input must follow the PLS channelprogrammed under "Track PLS Channel". This message indicates that the input closed (to ground)without the PLS output turning on to initiate this input action. This could be caused by a failure ofthe mechanism being monitored or a failure of the sensor.

"Input did not open in time after PLS turn Off"This input is programmed as a Track PLS type so that the input must follow the PLS channelprogrammed under "Track PLS Channel". This message indicates that the PLS output turned off andthe tracking time expired before the input opened (e.g., released from ground) in response. Thiscould be caused by a failure of the mechanism being monitored, a failure of the sensor, or by the

5-6

tracking time being set for too small a value for this operation.

"Input did not close in time after PLS turn On"This input is programmed as a Track PLS type so that the input must follow the PLS channelprogrammed under "Track PLS Channel". This message indicates that the PLS output turned on andthe tracking time expired before the input closed (to ground) in response. This could be caused bya failure of the mechanism being monitored, a failure of the sensor, a loose wire from the sensor, orby the tracking time being set for too small a value for this operation.

Section 5.1.2.8 Track PLS Invert Messages

"Input opened before PLS Output turned On - Invert"This input is programmed as a Track PLS Invert type so that the input must inversely follow the PLSchannel programmed under "Track PLS Channel" (i.e., the input should open when the PLS outputturns on). This message indicates that the input opened (became ungrounded) without the PLSoutput turning on to initiate this action. This could be caused by a failure of the mechanism beingmonitored, a failure of the sensor, or a loose wire.

"Input closed before PLS Output turned Off - Invert"This input is programmed as a Track PLS Invert type so that the input must inversely follow the PLSchannel programmed under "Track PLS Channel" (i.e., the input should close when the PLS outputturns off). This message indicates that the input closed (became grounded) without the PLS outputturning off to initiate this action. This could be caused by a failure of the mechanism beingmonitored or a failure of the sensor.

"Input did not open in time after PLS turn On"This input is programmed as a Track PLS Invert type so that the input must inversely follow the PLSchannel programmed under "Track PLS Channel" (i.e., the input should open when the PLS outputturns on). This message indicates that the PLS output turned on and the tracking time expired beforethe input opened (e.g., released from ground) in response. This could be caused by a failure of themechanism being monitored, a failure of the sensor, or by the tracking time being set for too smalla value for this operation.

"Input did not close in time after PLS turn Off"This input is programmed as a Track PLS Invert type so that the input must inversely follow the PLSchannel programmed under "Track PLS Channel" (i.e., the input should open when the PLS outputturns off). This message indicates that the PLS output turned off and the tracking time expiredbefore the input closed (to ground) in response. This could be caused by a failure of the mechanismbeing monitored, a failure of the sensor, a loose wire from the sensor, or by the tracking time beingset for too small a value for this operation.

Section 5.1.2.9 General Status Messages

5-7

"At Least One Die Protect Input Must be Used"If the die protection system is not bypassed, then at least one of the sixteen inputs must beprogrammed as some type other than "Unused". The operator must program at least one input to oneof the eleven active types.

"Memory Data Loss, Must Re-Program Input"This message indicates that the programming information for this input has become corrupt andcannot be used. The operator must first reprogram the input type either as Unused or as one of theeleven active die protection types. When this is done, all other data values which are associated withthis type such as description, stop output, window setpoints, etc. will be displayed. These must alsobe reprogrammed before continuing.

"Die Protection Board Fault XX"This message will appear followed by a fault number (in the XX spaces above) if an internal faultoccurs on the module. The fault can be cleared by pressing the RESET ERROR softkey or bycycling power to the unit.

Section 5.2 Diagnostic LEDs

The 5000-7 Die Protection Module has two LED indicators which provide status information for themodule. These are visible above the terminal strip on the connector card assembly and are labeledas follows:

+5V This green LED indicates the status of the internal +5 volt power supply forthe unit. It should normally be ON when power is on the unit and if offindicates a fault in the System 5000 card rack.

RESET This red LED turns on for approximately 1/2 second when power is appliedto the card rack. It should never turn on during normal running conditionsand if it does indicates a fault on the die protection module.