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This manual is a comprehensive guide to the IMPAX 2000 Process Control System. It contains
all of the information from the IMPAX Operating Guide plus special instructions on
programming and troubleshooting, plus additional ideas and procedures for getting the best
performance from the system.

This User’s Guide should be read and kept for reference by managers and supervisors
responsible for the setup, operation, and repair of IMPAX monitoring systems. It is assumed
that the software in the IMPAX 2000 is versions 48 or 58.

If you are not sure not sure of the software version in your IMPAX 2000 unit please refer to
chapter 8 in the Supervisor’s Guide.

If you still have a question, problem, or an idea to make our system better, please let us know.

IMPAX Systems are manufactured and
distributed worldwide by:

Process Technologies Group, Inc.

30W106 Butterfield Road
Warrenville, IL 60555
Phone (630) 393-4777 Fax (630) 393-4680
Web: www.impaxptg.com E-Mail: [email protected]

“IMPAX” is designed and manufactured by Process Technologies Group, Inc. And is
produced under the United States and Foreign Patent number 4,481,589. Any additional
patents are pending or applied for. “IMPAX” is a trademark owned by Process
Technologies Group, Inc.

Copyright 1996.

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Summary of Contents for 2000

Page 1: ...2000 Supervisor s Guide ...

Page 2: ... or 58 If you are not sure not sure of the software version in your IMPAX 2000 unit please refer to chapter 8 in the Supervisor s Guide If you still have a question problem or an idea to make our system better please let us know IMPAX Systems are manufactured and distributed worldwide by Process Technologies Group Inc 30W106 Butterfield Road Warrenville IL 60555 Phone 630 393 4777 Fax 630 393 4680...

Page 3: ...Information Displays Quantity Displays Tolerance Displays Error Displays Force Displays Backstroke NoFeed Limilts 5 Tolerance Setting Guide 6 Troubleshooting and Service Problems cause remedy Simple Repairs Initial Installation Customer Service 7 Programming System Fault Procedures Basic Information Function s Channel Definition Machine Relay Defintion 8 Diagnostics 9 Specifications and Drawings 1...

Page 4: ...Specifications Back view of Control Console Satellite Circuit IMPAX Control Console 49 50 51 52 ...

Page 5: ...familiar with its operation Operator attitude is very important when introducing and implementing IMPAX Like any other tool its effectiveness depends on how well it is used If machine operators perceive it as unnecessary complicated an invasion of their routine or a threat to their jobs it will not work even if it is technically perfect It is vital that everyone understand that IMPAX can make form...

Page 6: ...annot fix the problem or restart the machine When a problem is detected a red light turns on to attract your attention and an error message is displayed on the IMPAX unit s display The machine is stopped and any accessories are shut down in an orderly manner A gate or diverter may also be used to trap the part which is suspected to have caused the shutdown error Obviously this system does not dire...

Page 7: ...PAX unit is in The Bypass Key Switch operated by the Supervisor s Key disables the relay which stops the machine and its accessories but has no other effect on operation Note There is no machine protection when the IMPAX monitor is in Bypass mode Up to two Machine Position Sensors are used to sense the machine cycle and synchronize the stop signal Piezoelectric Sensors are installed in stressed lo...

Page 8: ...nformation and the keyswitch enables authorized users to program the unit The function buttons may operate differently depending on the position of the key switch If the key is removed IMPAX will only display information If the key is inserted the Keypad can be used for programming and diagnostics There are three kinds of buttons on the keypad Functions buttons let you command IMPAX to display or ...

Page 9: ...much the force values can change as the machine heats up or tools wear down this feature may be omitted 5 The desired number of exceptions which let by a small percentage of bad parts this feature may also be omitted Setting up the IMPAX unit for a new job may be done any time before beginning the job by anyone who has a Supervisor s Key Clearing the old job Before setting up a new job you must Cl...

Page 10: ...the display shows CLEAR BREAK The IMPAX unit is now asking whether or not you want to reset the counter which makes the periodic stops for tooling changes or inspection If you do not wish to do this press Next No If you desire to press Enter Yes Now the break counter is reset and the display shows CLEAR PROD The IMPAX unit is now asking whether or not you want to completely erase the record of tha...

Page 11: ...lerance and the Error records can be cleared by pressing Clear until the SELECT TO CLEAR screen appears and then pressing the respective button on the Keypad Remember these steps can be avoided without harm to the unit or the data for the next job The IMPAX monitor is now cleared and is ready to be set up for a new job In fact it will not run except for short setup runs until new production quanti...

Page 12: ...nce etc that are based on machine or production cycles Press the number buttons to show the quantity you wish to make without interruption Use the Back Review button if you make a mistake If you do not want any interruptions due to the Break Quantity counter press the 0 button and the IMPAX unit will skip this When you have typed in the correct Break Quantity press the Enter Yes button If toleranc...

Page 13: ...ghter than a 9 will give or looser than a 1 will give without being zero If you enable this the screen by pressing it will show C1 LOW LIM 0 It is asking you what you want the lower limit to be Enter the lower limit and press Enter The next screen will say C1 HIGH LIM 0 The monitor is now asking for the upper limit of tolerance Enter the value and press Enter If you go to the Force screen you will...

Page 14: ...ted error which you can allow the monitor to ignore This feature is extremely useful if you have a diverter installed on the machine If a diverter is installed you can set one of the relays to be an exception relay and it will trip the diverter and divert the part without stopping the machine CUMU stands for cumulative This means that IMPAX will allow a certain number of errors out of 100 to be ig...

Page 15: ... on in Channel Definition the display will show R1 CONS NF 0000 or R1 CUMU NF 0000 You can enter a number between 1 and 9999 In a threadrolling application this feature is extremely functional since it will allow the machine to keep running even though the feed rail is not completely full or does not feed a part every time No Feed Exceptions No Feed Exceptions is a special feature which will diver...

Page 16: ... group of x cycles the machine runs without feed Example If the number programmed here is 100 nd the machine runs 600 cycles without feed the forces will be allowed outside normal limits during the first 6 machine cycles during which the feed is again detected Enter the proper number and press the Enter Yes key The next display will show ALL FACTORS SET ...

Page 17: ...on the number will be counting up Press Next No again and the display changes to TO GO 99250 which is the number of parts remaining to be made This number counts down when the machine is running Press Next No again and the display changes to SHIFT 750 which means that 750 parts have been made during the current shift Press Next again and IMPAX shows B MADE 750 which means that 750 parts have been ...

Page 18: ...n At any time pressing Back moves backward to the previous choice in the order listed above You may select which counter you wish to be displayed while the machine is running To do so display the chosen counter as explained above then press Enter Yes The selected counter will remain visible Tolerance Displays numbers are for example only Be sure the Supervisor s Key is removed or turned off vertic...

Page 19: ... Next No The display will show the next channel for instance STATION 2 8 6 which would mean that channel 2 is set for tolerance level 8 but should be set lower IMPAX is suggesting that it would run on a tolerance of 6 Press Next No again and the next channel will be displayed This may be repeated until all the desired channels have been displayed Press Back at any time to return to the previous di...

Page 20: ... limits was breached Press Next No The display will now show SINGLE HIT This means that the force change was severe enough to warrant stopping after just one hit It may instead show LO COUNT MED COUNT or HI COUNT these tell how many parts were run before the force difference became severe enough to stop HI COUNT means a small change in force was detected over an average of many blows Generally a s...

Page 21: ...ce measurement which caused the IMPAX to stop the machine Note that the middle number must always be either above the upper limit or below the lower limit for an error to occur in force In this case it is above the upper limit The number 6 is the current tolerance setting The 3 is the variance IMPAX is detecting in the forming process Press Next No The display will show CHANNEL 1 ERROR This is inf...

Page 22: ...ement for the next channel channel 2 Pressing Next always advances the display to the next channel pressing Back returns to the previous channel Press 1 The display for the channel being shown will change to C2L 110 124 140 The first digit shows that it is still channel 2 and the force measurement middle number remains approximately the same The L means that the measurement now shown is a Low Coun...

Page 23: ...ay not be sensitive enough to notice a tool chip because the force measurement varies too much The High Count limits will not stop a smashup quickly enough but may notice a small chip and stop the machine after a few dozen have been made The Trend program can catch tool wear and other gradual changes Remember that all of these limits are working all the time the force display only controls which o...

Page 24: ... Definition then this display will show C2 N 043 128 045 The first number is the NoFeed Threshold This can be used to check if Nofeeds are working correctly Just stop the feed and the Average Force Value should go below the 043 Nofeed limit The middle number is once again the force and the last number does not mean anything Note For backstroke and nofeeds to display these features must be turned o...

Page 25: ...aph above When IMPAX catches every problem but seldom stops when nothing is wrong the tolerance is set properly To set the tolerance on a new job begin with a fairly high number such as 7 8 or 9 Watch the job and if it runs well set the tolerance lower after each few thousand parts are made Look at the force display to see how close the limits have been set When the IMPAX begins to stop the machin...

Page 26: ...ob is running well the Auto Tolerance numbers may be used as a guide Remember that the worst mistake is setting too loose a tolerance high numbers or no tolerance at all zero IMPAX will count parts but it will not catch important process changes The Supervisor s Key is needed to set or change the tolerance settings This helps to prevent tampering by those who are not authorized to set tolerances ...

Page 27: ...check forces and tolerance IMPAX stops header repeatedly but Tolerance is too tight for job Force measurements no problem is found with parts made Are changing Check tooling header material Uniformity Run header observe forces and parts Produced Check for loose tooling IMPAX fails to stop header when problems Tolerance is set too wide of set to zero Enter occur smashups breakage dropped parts lowe...

Page 28: ...lens which covers it Do not unscrew the ring which surrounds it Be sure the power to the lamp is turned off then remove it by pressing the bulb in slightly and turning it one sixth of a turn counter clockwise It will then pull straight out If it is burned out replace only with a 1893 or other approved equivalent Many standard 12 volt bulbs will not be very bright Cable Inspection If there is reaso...

Page 29: ...at the mark at the end faces the same way as the others Line up the pins on one edge and gently enough to engage the pins on the other side then when every pin is lined up press the chip home into the socket Inspect to be sure no pins are bent Repeat the procedure for the other 2 chips Replace the top circuit board Re insert the gray edge connector and the white power supply connector until they c...

Page 30: ...roximity switch then the sensor should be adjusted If the proximity switch is a 12mm one it needs to be even closer A voltmeter must be used to make sure that 10 volts is applied to the red and black wires of the sensor and that the white wire switches when metal is placed in front of the sensor these wires may be checked on the terminal strip of the circuit board inside the Satellite Box If the s...

Page 31: ...enuity and fabrication If no reasonable solution to a problem can be found the IMPAX installers can offer advice or assistance All work should be neat solidly attached shake proof and should not interfere with operation maintenance or repair practices Console Location The IMPAX console should be mounted near the machine it controls ideally visible from the operating station It is usually not advis...

Page 32: ...ly Apply a coating of adhesive to the recess then press the sensor disk into place with the brass side of the disk against the piece The epoxy should set up in 1 to 2 hours For best results allow the epoxy to set overnight before running machine Installation of Position Sensors The Position Sensor a proximity switch is a non contacting switch which is used to provide timing information Each time t...

Page 33: ... make and the model of the header roller or other machine which it controls This makes it possible to quickly pinpoint and solve the problem Before calling you should know IMPAX Serial number on side of console ___ ___ ___ Software Version Version_________ should be in the form of XXXXX XX Definition Package P___TH___D___ Note Refer to Chapter 8 of the Supervisor s Guide for instructions on access...

Page 34: ...tested or installed If the prompts shown in this guide differ from the prompts on your IMPAX unit this may be due to changes made by the installer at the time of installation These changes were made for good reasons and may be necessary for the proper operation of your IMPAX system We suggest that you carefully consider your changes before changing a custom setup and that you document the changes ...

Page 35: ...in advance that this is going to happen it is recommended that the counts be recorded so that they can be re entered The sequence for recovery is as follows SYSTEM FAULT CALL SUPERVISOR ENTER ACCESS X X X X ENTER CALL PTG ENTER CLEAR MEMORY ENTER COUNTS OLD TOTAL OLD PARTS MADE OLD SHIFT COUNT OLD BREAK OLD BREAK MADE ENTER COUNTS ENTER If counts are known ENTER XXXXXXXX ENTER XXXXXXXX ENTER XXXXX...

Page 36: ...e IMPAX interacts with the machine See the section on Relay Definition for more details Function 6 will send you to the Timers Area See the Section on Timers for more information Function 7 will send you to the Downcode Area See the Section on Downcodes for more information Function 8 will send you to the Accumulated Downcodes Area See the Section on Accumulated Downcodes for more information Func...

Page 37: ...loped to make your IMPAX unit better equipped to your particular machine and application When you have pressed Enter Yes to select a channel IMPAX will display CHAN ENABLED or CHAN DISABLED Press Next No if you wish to change this then press enter If you disable the channel it will simply not exist in the operation The channel definition program will go on to the next channel number automatically ...

Page 38: ... Installation Guide The display will now show BKST H LIM ON or BKST H LIM OFF BKST stands for Backstroke the return stroke of the moveable die on a flat die threadroller BKST H LIM when enabled helps the IMPAX unit interact with a threadroller by allowing the IMPAX to detect a part stuck to the die during the backstroke If not detected by IMPAX such a condition could damage the tooling Press Next ...

Page 39: ...st protection possible This is useful because you may not want your machine to go unprotected for 120 parts every time the machine stops and goes through another LEARN cycle IMMEDIATE LIMITS limits the LEARN cycle to only four parts It takes the force values from the last good part and stores them in memory When the machine starts back up it compares the average force values of the first four part...

Page 40: ...mends FIXED DISABLED except under special circumstances Press Next No to select one choice or the other then press Enter Yes The next display is FAST LIMITS OFF or FAST LIMITS ON FAST limits LEARNS just like a normal LEARN cycle it just does it a lot faster This is useful if you need faster protection than a normal LEARN cycle will give you The next display is TREND LIM OFF or TREND LIM ON The tre...

Page 41: ... will present a row of dashes over which the alphanumeric characters can be entered Up to nine 9 characters can be entered for a Channel Name and up to sixteen 16 characters can be entered for a Tag Name The last character on the display will tell you whether or not you are set up to enter letters or numbers There will be a present if the unit is set up to have numbers entered There will be a pres...

Page 42: ...a few seconds followed by the production counter If the display shows REDEFINE you have entered the correct access code and you may now change the access code to a different one If you want to change the access code answer the question by pressing the Enter Yes key The display will show NEW _ You may enter a 1 2 3 or 4 digit number and then press the Enter Yes key As you enter the numbers an will ...

Page 43: ... IMPAX unit to accumulate time in the four modes Off Stop Test and Production When you press the Enter Yes key the next display is TIMERS ENABLED or TIMERS DISABLED You can toggle between these two selections with the Next No key If you select Enabled the next display will show T OFF HHHH MM which shows how many hours and minutes the IMPAX unit has been turned off since the Timers were last cleare...

Page 44: ...ED or COMM DISABLED You can toggle between these two entries with the Next No key If you choose Enabled the next display will show 1200 BAUD At this point you can select between 1200 2400 4800 and 9600 BAUD However it has been determined that because IMPAX is first and foremost a process monitor and secondly a data communications node that the IMPAX unit will not perform any faster than 1200 BAUD ...

Page 45: ...ture This feature allows the user to select the INDEX or LINKING capability of the IMPAX unit INDEX is intended to be used only on Somavis headers LINKING is used as a special function on some multi station headers for special applications You cannot turn them both on at the same time Both of these features are normally turned OFF Press the Enter Yes key and the next display will show SET DOWN COD...

Page 46: ...n you have finished entering the Tag Label press the Enter Yes key After the Tag Labels have all been entered the next display will show DEFINE RELAY 1 Programming the IMPAX Relays There are four relays in the IMPAX 2000 monitor Each of them can be programmed independently The relays can be connected to the emergency stop circuit of the machine to a diverter or trap chute to a conveyor to a feed s...

Page 47: ...isplay will now show 0 00 SECONDS Enter the time delay 0 00 to 9 99 and press Enter Yes The display will show PROX SW LINE 1 This indicates which position sensor will be used to count the number of cycles for the delay Enter 1 or 2 and press Enter Yes The next display is ON WHEN ON and pressing Next No will toggle the ON OFF This means that the relay changes states when the position sensor is on a...

Page 48: ... will show DIAGNOSTICS If you wish to redefine the access code press Enter Yes at the REDEFINE prompt The IMPAX will ask you for a NEW access code Press any four digit number combination then press Enter Yes The display now shows ACCESS _ Press the same four digit code you just entered then press Enter Yes The display will now show DIAGNOSTICS You can exit the diagnostics mode at any time by press...

Page 49: ...andard Limits 01 indicates Tight Limits 02 indicates Tighter Limits ZZ refers to the definition package 00 is for 1 Die 2 Blow 01 is for 2 Die 3 Blow or 2D4B 02 has 2 force line capability 03 has 3 force line capability 04 has 4 force line capability 05 has 5 force line capability 06 has 6 force line capability 07 has 7 force line capability 08 has 8 force line capability 09 is for Roller 10 is fo...

Page 50: ...ey The display shows BYPASS IMPAX Press the Enter Yes key The display now shows 5 GRN 6 YL 7 RED Pressing the number 1 2 3 or 4 key will activate relays 1 2 3 or 4 respectively Pressing the number 5 6 or 7 key will activate the green yellow or red lights respectively Note each time a number is pressed the previous relay or light is turned off Press Enter Yes The display shows Press Next No to step...

Page 51: ...is to much sensor signal for that channel to properly tune into the Peak or Integrate target YY is the current input signal value converted into hexadecimal format this value should be very close to the hexadecimal equivalent of the Peak target The hexadecimal equivalent to the standard Peak target of 96 is 60 ZZ is the current input signal value converted into hexadecimal format this value should...

Page 52: ...t settings Machine Control Four relays operating independently Immediate timed or cycled delay Each rated 8 amps 250 volts AC maximum May be used to stop machine feed output diverter or other accessories Power Requirements 115 volts at 1 amp or 230 volts at amp 50 60 Hz AC IMPAX is protected against surges and motor interference Dimensions Satellite Box 8 H x 6 W x 4 D Control Console 11 3 4 H x 1...

Page 53: ...DRAWINGS Backview of the Control Console ...

Page 54: ...Satellite Box Circuitry ...

Page 55: ...IMPAX 2000 Control Console ...

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