Page 2 - Table of Contents; Section 1
A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 i Table of Contents Section 1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1 Section 1.1 Counterbalance Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 5 - iv
Page 6 - Causes less total energy to be used by the press.; Cushion Control
A p r i l 1 7 , 2 0 0 0 Man ual Versio n 1.0 1.1 Section 1 Introduction The 5000-10 Auto-Setup Module (ASM) allows the OmniLink 5000 Press and Automation control toset up press shut height, counterbalance air pressure, cushion air pressures, and hydraulic overloadpressure settings automatically when...
Page 10 - Access Control
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...
Page 12 - Example Password Entry Sequence
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....
Page 14 - NEVER; OmniLink 5000 Extended Card Rack; Installation
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...
Page 16 - Valve Systems; Type “A”; minimum; value set by the; must not; be set higher than the lowest pressure that the
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...
Page 17 - Counterbalance Control Installation
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...
Page 19 - Section 3.3.1 Counterbalance Pressure Transducer Mounting; a) A spare port on the counterbalance surge tank.
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...
Page 20 - Typical Standard Cushion System; Section 3.3.2 Counterbalance Air Valve System Mounting; in; Section 3.3.3 Counterbalance System Wiring
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...
Page 21 - Section 3.4.1 Cushion Pressure Transducer Mounting; a) A spare port on the cushion surge tank.; Section 3.4.2 Cushion Air Valve System Mounting; must
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...
Page 22 - the; must not result; in more than 100 turns at the resolver.
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...
Page 23 - c) The slide should travel; no more; than 1 inch per turn of the resolver.
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...
Page 24 - Read; that came with the transducer for other possible issues; Section 3.6.4 Linear Transducer Slide Adjust Wiring
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...
Page 26 - Example Air Configuration Screen; Section 4.2 Configuring the Auto-Setup board; the Main Menu or Press Control screen.
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...
Page 28 - Display Weight As
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 ...
Page 29 - This should; This parameter only appears when a cushion is being configured.; Set this; Set this
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...
Page 31 - Wilkerson ER1 Series; Section 4.2.2 Configuring Slide Adjust Modules; To get to the configuration screen for slide adjust modules:
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. ...
Page 33 - above; the desired setpoint. The system will then incrementally; less; end up; below; Pulse Time
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...
Page 34 - Lock Time
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...
Page 39 - Example Auto-Sets Screen; Section 5; The main features of this screen are:
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...
Page 41 - Slide Adjust Operation; The
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 ...
Page 43 - Note that a slide setpoint of 00.000 (used to store a job that will not; movement is subject to the following conditions:; correct; pressure setpoint for the counterbalance has
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...
Page 45 - Section 5.2.2 Pressure and Force Setpoints
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...
Page 46 - There are a few things to keep in mind for job storage and recall:; not; be stored for later recall; unless; you store the job again while the
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...
Page 49 - Counterbalance, Cushion and Hydraulic Overload “Status” Messages; The air system is within tolerance of its target pressure.
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...
Page 50 - Slide Adjust “Fault” Messages
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...
Page 51 - a hardware failure of the relay.; Slide Adjust “Status” Messages; The slide is within tolerance of the slide setpoint.
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...
Page 53 - Example Counterbalance Configuration
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. ...
Page 54 - Example Cushion Configuration
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, ...
Page 55 - Example Hydraulic Overload Configuration
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...
Page 57 - Example Linear Slide Adjust Configuration
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...
Page 59 - See section 5.1 for further details on slide adjust operation.; Example Rotary Slide Adjust Configuration; A 100 turn AMCI series dual resolver is mounted on the press slide.
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...
Page 60 - be set outside the actual minimum and maximum shut heights.
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...
Page 62 - Typical Counterbalance Wiring Diagram.; Appendix 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
Page 63 - Typical Cushion Wiring Diagram.
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.
Page 64 - Conceptual Dual Resolver Mounting.
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.
Page 65 - Typical AMCI Dual Resolver Wiring Diagram.
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.
Page 66 - Typical GEMCO 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
Page 67 - Conceptual Linear Transducer Mounting
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
Page 68 - Typical GEMCO Linear Transducer Wiring
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
Page 69 - Typical MTS Temposonics II 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
Page 72 - Logic Module Firmware Chip Locations; Appendix C Installation Of OmniLink 5000 Firmware; ) Remove the logic board from the card rack.
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...
Page 74 - Step 1; MUST; be done even if a LOX valve is opened in step 2 since the; before; Valve Type “A” Lockout Procedure; To lock out type “A” valves:
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...
Page 78 - Section E.2 Shut height Calibration Sheets
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...
Page 80 - 000-10B Linear Shut Height Control Board; Amp Fast-Blow Picofuse; 000-10C Rotary Shut Height Control Board; Amp Fast-Blow Picofuse
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...