SMC Networks 5000 - Manuals

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 2.3 Section 2.2 Access Control The OmniLink control has several parameters or operations that have limited access. In regards to theauto setup module the ability to perform the actions of resetting faults or changing limits must berestricted to certain pe...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 2.5 Figure 2.2: Example Password Entry Sequence When operating in the Key Only mode the key switch is the only means available to access the restricteditems. All restricted items are accessible when the RUN/PROG key switch is switched to the PROGposition....

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 3.1 NOTE: NEVER remove or install any card in the OmniLink 5000 when the power to the control is on. Doing so can damage the control, the card, or both! Figure 3.1: OmniLink 5000 Extended Card Rack Section 3. Installation Section 3.1 Auto-Setup Module Ins...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 3.3 Figure 3.2: Type “A” Valve Configuration Figure 3.3: Type “B” Valve Configuration 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 f...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 3.4 Figure 3.4: Type “C” Valve Configuration Figure 3.5: Typical Counterbalance System Type “C” An integrated Fill/Dump valve with a manual regulator, check valve, and LOX valve, anda four-way valve that selects whether the pressure is set by the automati...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 3.6 Figure 3.8: Acceptable Locations for Mounting Counterbalance PressureTransducer. 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 toraise or low...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 3.7 Figure 3.9: Typical Standard Cushion System Figure 3.10: Cushion System with Type “B” IntegratedValve. Section 3.3.2 Counterbalance Air Valve System Mounting The mounting location of the valve system is not critical. Consideration should be given, how...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 3.8 Figure 3.11: Acceptable Locations for Mounting CushionPressure Transducer. 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 lowerthe pressure of the s...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 3.9 control came configured for a cushion adjust system, then a wiring diagram should have been providedas part of the documentation package. Section 3.5 Hydraulic Overload System Installation Some press hydraulic overload systems use an air pressure to s...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 3.10 NOTE: The cable should remain unbroken except for the connector in this junction box tokeep the shield integrity - do not splice the cable! c) The slide should travel no more than 1 inch per turn of the resolver. d) The cable from the resolver to the...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 3.11 NOTE: The cable should remain unbroken except for the connector in this junction box tokeep the shield integrity - do not splice the cable! b) It may be necessary to order a transducer longer than the slide adjustment range because of mounting limita...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 4.2 Figure 4.2: Example Air Configuration Screen Section 4.2 Configuring the Auto-Setup board The ASM must be configured for the each shut height and pressure module that is installed on it. Theconfiguration necessary depends on the particular kind of mod...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 4.4 For cushions this should be the maximum operating pressure specified by thecushion manufacturer. For hydraulic overloads this value should be the pressure specified by the pressmanufacturer for rated tonnage operation. Min. Pressure This value should ...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 4.5 are pounds (lbs), kilograms (Kgs), tons, and metric tons (Mtons). Note that thedisplay unit can be changed at any time and is independent of the units that themaximum and minimum die weight are using. If a job was stored in tons, and thisunit is chang...

Table 4.2: Servo-Valve Control Types A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 4.7 Wilkerson ER1 Series 0-90psi 0-10V 5 SMC ITV2050-31T2S4 0-130psi 0-10V 6 Section 4.2.2 Configuring Slide Adjust Modules To get to the configuration screen for slide adjust modules: a) Go to the “Auto Sets” screen. ...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 4.9 Upper Limit This value is an electronic upper limit for the slide adjust system that acts as abackup for the mechanical up limit switch. The automatic shut height system willnot adjust the shut height above this value, which should be set just below w...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 4.10 Lock Time Most slide adjust systems now use an integrated brake built in to the slide adjustmotor that automatically locks the system down when the slide adjust motor is noton. “Lock Time” is used only for slide adjust systems that have a separate lo...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 5.1 Figure 5.1: Example Auto-Sets Screen Section 5 Operation The purpose of the Auto-Setup module is to allow automatic adjustment of such press systems as aircounterbalances, air cushions, air operated hydraulic overloads, and slide adjust systems to gre...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 5.3 “CONFIGURE” Allows the individual options such as counterbalance, cushion, and slideadjust modules to be configured during initial installation of the system andwill not be used for production operation setup. Note that this key is onlyavailable when ...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 5.5 NOTE! A counterbalance pressure that is far too low or far too high during any shut heightadjustment may place excessive load on the shut height adjust motor and may evenstall the motor. This condition can also occur with non-automatic motorized slide...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 5.7 setpoint for a previously stored job when that job setup is recalled from memoryand 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 Fo...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 5.8 Pressure can be set in one of two ways. First, if the air system was correctly configured, the desiredforce which the pressure is to create can be entered in the “Force Setpoint” row on the air pressurescreen. Second, if preferred, the desired air pre...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 6.2 Unable to Fill The system was unable to make progress when trying to raise the air pressure. This could be a bad connection to the fill valve, a failed fill valve, or no plantair pressure. Probably the most common cause would be a bad air leak in thes...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 6.3 Ctr-Bal Vented -Stop A pressure setpoint of 0 was entered for a counterbalance. The dump valve isleft open in this condition. Unlike a cushion, this is considered a stopcondition. Hyd Overload Tripped The hydraulic overload operation screen will displ...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 6.4 a hardware failure of the relay. Lock Relay Shorted The “Lock” solid state relay on the slide adjust module failed shorted. Indicates a hardware failure of the relay. Transducer Fail For linear slide systems, indicates that the linear transducer is no...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 A.1 Appendix A Configuration Examples This section of the manual will go though an example setup of each kind of system on a “typical” press. Each example assumes that the hardware installation has been completed and the system is ready forconfiguration. ...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 A.2 Note that units to the right of the number are also an editable parameter. When the editing cursor isplaced on the Max Die Weight units, we can press the “CHANGE UNIT” softkey to get a list ofsupported units. The units can be pounds, kilograms, tons, ...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 A.3 Using the arrow keys, we move the cursor to the “Transducer Type” line. Looking at table 4.1, we seethat the transducer type for any model pressure transducer with a 250 psi pressure range and a 4 to 20 maoutput is “Type 3”. We hit the “CHANGE TYPE” s...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 A.5 Finally, we go back to the “Mode” line and use the “CHANGE MODE” softkey to toggle the mode to“ON”. The “Auto Sets” operation screen can now be used to set the air pressure or trip tonnage. Seesection 5.2 for operation details. Section A.4 Example Lin...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 A.7 Now it is time to hit the “AUTO ADJUST” softkey. The slide moves up past 14.000 (the slide setpointwe entered in the operation screen) and stops momentarily at 14.025. It then comes back down andstops at 13.996. The “Pulse Distance” value is set too h...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 A.8 Before calibrating the slide, we MUST make sure the slide is properly counterbalanced, if acounterbalance is used on our press. If the slide is not properly counterbalanced, the slide calibrationwill be flawed because clearances will not be taken up b...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 B.1 Figure B.1: Typical Counterbalance Wiring Diagram. Appendix B Typical Wiring Diagrams

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 B.2 Figure B.2: Typical Cushion Wiring Diagram.

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 B.3 Figure B.3: Conceptual Dual Resolver Mounting.

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 B.4 Figure B.4: Typical AMCI Dual Resolver Wiring Diagram.

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 B.5 Figure B.5: Typical GEMCO Dual Resolver Wiring Diagram

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 B.6 Figure B.6: Conceptual Linear Transducer Mounting

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 B.7 Figure B.7: Typical GEMCO Linear Transducer Wiring

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 B.8 Figure B.8: Typical MTS Temposonics II Linear Transducer Wiring

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 C.1 Figure C.1: Logic Module Firmware Chip Locations Appendix C Installation Of OmniLink 5000 Firmware Firmware for the OmniLink 5000 press control is contained on two integrated circuits. Please followthe instructions listed below for replacing the OmniL...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 D.1 Note! Step 1 MUST be done even if a LOX valve is opened in step 2 since the control may try to pressurize the system using the Fill/Dump valve if thepower is on! Appendix D Lockout Procedure For Air Controlled Systems Section D.1 General Lockout Consi...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 E.3 Section E.2 Shut height Calibration Sheets Linear Transducer Slide Configuration Slide Configuration Slot #1 Board Linear TransducerName _________________ Wire Speed __________ Upper Limit __________ Lower Limit __________ Tolerance __________ Pulse D...

A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 F.1 Appendix F Specifications Section F.1 5000-10A Pressure Control Board AC Output Relays: Voltage: 120VAC Current: 1Amp Continuous20 Amp 16ms5 Amp 75ms Fuse: 2 Amp Fast-Blow Picofuse Section F.2 5000-10B Linear Shut Height Control Board AC Output Relays...