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PressCam 8

Installation and Operation Manual

Pressroom Electronics, Inc.

3715 Swenson Avenue

St. Charles, IL  60174

P/N:  28-019r5.0

Customer Service:  630-443-9320 (CST)

(Please have Model #, Serial #, and Software Rev # Available)

Sales and Marketing: 800-937-4334 (EST)

www.pressroomelectronics.com  

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  [email protected]  

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  [email protected]

Summary of Contents for PressCam 8

Page 1: ...PressCam 8 Installation Operations Manual ...

Page 2: ...Rev 5 0 ...

Page 3: ... Automation Controller for info Fax your request to 412 262 1197 Name _____________________________________________________ Title _____________________________________________________ Company _____________________________________________________ Address _____________________________________________________ _____________________________________________________ City State Zip _______________________...

Page 4: ...warranty will not apply to any product which will have been subject to misuse negligence accident restriction and use not in accordance with manufacturer s instructions or which will have been altered or repaired by person s other than the authorized agent or employees of the manufacturer Disclaimer The provisions of the paragraph WARRANTY are the sole obligations of the manufacturer and exclude a...

Page 5: ... 3715 Swenson Avenue St Charles IL 60174 P N 28 019r5 0 Customer Service 630 443 9320 CST Please have Model Serial and Software Rev Available Sales and Marketing 800 937 4334 EST www pressroomelectronics com sales pressroomelectronics com service pressroomelectronics com ...

Page 6: ...Chart 28 108 12 Function Descriptions Operator Interface 13 Adjust Contrast 14 Job Selection 14 Job Number 14 Job Name 14 Limit Switch Die Sensor Names 14 Reset Die Faults RUN Mode Only 14 Reset All Faults PROG Mode Only 14 Minimum Speed 14 Maximum Speed 14 Running Time 14 Counters 15 Die Sensor Setup 15 How to Program a Die Input 16 How to Turn Off a Die Input 16 Die Fault TS Type 16 Automatic Sa...

Page 7: ...Regulations Guidelines for Safe Operation OSHA Regulations 28 ANSI Standard B11 19 1990 29 Safety Guidelines for Management 30 OPTIONAL Tonnage Load Monitor TLM TLM Mounting Connecting Overview 32 Mounting the TLM 32 Connecting Sensors to the TLM Sensor Connection Guidelines 32 Connecting Sensors to the TLM 33 TLM Cam Switch Wiring Connections 34 T400 Installation 36 TLM Installation Using the T40...

Page 8: ...r Connector Cabling 30 9m of cable with connectors is supplied standard If additonal length is needed specify in feet 150 46m maximum 5 Specify Tonnage Monitoring optional T1 One Channel monitoring with strain sensor and cable T2 Two Channel monitoring with strain sensor and cable T3 Three Channel monitoring with strain sensor and cable T4 Four Channel monitoring with strain sensor and cable Examp...

Page 9: ...ch job number stores a name and or number up to 13 characters for easy identification Built in Brake Monitor will issue a warning when the programmed warning time is exceeded and will issue a failure signal when programmed stop time is exceeded True Motion Detection system that checks for Lack of Motion Motion Fault and Unintended Motion Drift Fault SPM Indicator Strokes per Minute Crank angle sho...

Page 10: ...curacy MOTION 0 to 5 9 seconds 1 10 sec increments DRIFT preset to 2 SPM 1 10 SPM increments Crank Angle 0 to 359 degrees 1 increments SPM 0 to 999 strokes minute 1 SPM accuracy Resolver 1º Resolution up to 600 RPM 2º Resolution from 601 to 1000 RPM Shaft loading Radial 400 lbs Axial 200 lbs Standard cable 30 maximum length of 600 Construction Stand Alone Unit All 18 Gauge painted steel NEMA 12 lo...

Page 11: ...mensional layout and Drawing 28 101 for wiring diagram in this section Panel Mount If you purchased a PressCam 8 without its own enclosure then you must find a location on your control cabinet that will allow you to mount the I O board as close as possible to the PressCam 8 controller There is a 40 pin ribbon cable that connects both boards together and must remain as short as possible to prevent ...

Page 12: ...lid state modules are selected for either AC or DC and for the proper voltage current range Determine the output logic you need for your press control i e Sinking Sourcing AC For solid state outputs the NO terminals are the positive side and the C terminals are the ground side For relays all terminals are DRY contacts and the terminal labels are correct For Sinking DC systems you must ground the C...

Page 13: ...5 System Installation Resolver Dimensions Wiring 28 100R3 Dimensions in inches For millimeters multiply by 2 54 Note Rev3 diameter shaft is from 9 2015 forward Rev2 is up to 9 2015 ...

Page 14: ...6 Internal Wiring Diagram 28 101 System Installation ...

Page 15: ...7 Control Box Dimensions 28 102 System Installation ...

Page 16: ...8 Panel Cut Out Dimensions 28 103 System Installation ...

Page 17: ...9 Control Panel Dimensions 28 104 System Installation ...

Page 18: ...10 System Installation External Wiring Diagram 28 105 ...

Page 19: ...11 System Installation I O Board Dimensions 28 106 ...

Page 20: ...windows based on crank angle LS 8 11 can be timer based if desired Output 12 form C J3 Counter Opens when Batch counter incremented or Quality Count reached Output 13 form C J10 Die Fault Remains closed in PROG mode Opens in RUN mode when Die fault occurs Output 14 N O J12 Speed Closes when press speed falls with the Min and Max speed setpoints Output 15 16 N O J14 J16 General Faults Opens when an...

Page 21: ...at a time i e to enter a value 459 dial 4 push knob dial 5 pushknob dial 9 push knob Run Prog Keyswitch In RUN mode you are not allowed to alter any parameter or change JOB s In RUN mode you are only allowed to clear counters and reset die sensor faults When in PROG mode the Die Fault Output 13 and General Fault Outputs 15 and 16 are held closed to allow die setup All other faults will cause the G...

Page 22: ...r desired NOTE After the letter Z There is a backspace to correct mistakes There is an enter to end the Job Name function Limit Switch Die Sensor Names To change the names of either the Limit Switches or Die Sensors you perform the same acts that you would to change the job name 1 Select a job number then hit the knob 2 Once the job name is highlighted turn the knob clockwise until you highlight t...

Page 23: ...mines when the Batch Count increments This can only be changed in PROG mode The Batch Size is based on the Part Increment field size the upper right of the Part counter box Batch Count The Batch Counter is used to indicate the number of batches completed and or stop the machine when a batch is complete using Output Relay 12 This can be reset in RUN or PROG modes NOTE Batch Counter only works when ...

Page 24: ...ome other portion of the cycle i e Die 1 Maintained N C 180 to 270 Die 2 Maintained N O 50 to 120 both Die 1 and 2 inputs tied together How to Program a Die Input NOTE The Screen does not update if you are currently changing a Begin or End angle New or changed information is stored in nonvolatile memory as soon as the entire value is entered The status of all sensor inputs is indicated in the uppe...

Page 25: ... down block from 30 to 80 To perform the Safety Distance test not including control system response time 1 Make sure nothing is attached to the AUX input on the Presscam 8 2 Select the 90 stop test 3 Start the press and don t block the light curtain Time Based Brake Monitor The PressCam 8 is a time based brake monitor as opposed to a position based brake monitor It does not know or care when the p...

Page 26: ...cle speed brake wear and so forth When the stopping time changes as a result of these conditions it may become necessary to change the top stop limit switch position readjust the brake monitor or adjust the brake mechanism If such readjustment is made care should be taken that the safety distance used to locate the safeguarding device is recalculated and if necessary the safeguarding should be rel...

Page 27: ... Interface Output of data is via a RS 232 DB 9 connector located on backside of LCD screen 9600 Baud 8 bit no parity 1 stop bit The PressCam 8 can be configured for either DCE standard J6 J7 jumpers horizontal or DTE optional both jumpers removed and installed vertical straddling both J6 J7 PressCam 8 DB 9 pin out DCE configuration 1 DCD 2 TX TO SERVO 3 RX FROM SERVO 4 DTR 5 GND 6 DSR 7 RTS 8 CTS ...

Page 28: ... the top center to an unknown value Also do not speed compensate Auto Return or Mute Out signals Refer to Speed Compensation below for instructions on how to operate this feature Speed Compensation As the press speeds up beyond its original set point certain outputs may not respond fast enough to keep up with the increased speed of the press Also stop time increases as the press speed increases an...

Page 29: ...ial port to be used as a Remote Status output port RMT ON or allows the use of the External Ethernet board Option TCP ON or for the Servo Control out put RMT OFF default See page 24 for details Language Selection English Spanish French This changes text between languages Now you should have a correctly operating press running at minimum speed 4 Cycle the press at maximum speed Note the angle where...

Page 30: ...This helps with preventing noise on the analog signal P4 connector pin1 top pin Pin Color Function 1 White Left Rear module input from TLM 2 Red Right Rear module input from TLM 3 Green Left Front module input from TLM 4 Blue Right Front module input from TLM 5 NC Do not use this connection for internal voltage reference 6 Black Analog Ground com This is not chassis ground or shield ground Tonnage...

Page 31: ...ltage meter to help you set the proper voltages 0 counts 0v 512 counts 2 5v full load 1024 5 0v 3 You must set the Min column above 0 to activate that sensor and just below the minimum tonnage you expect for this job The sensor input is turned off if this is set to 0 4 Set your Max column to the maximum tonnage for this job but less than 1 4th of the total machine capacity 5 Go to Limit Switch Set...

Page 32: ...us H Fault codes1 Word see Appendix A each bit fault1 represents a fault code I Fault codes2 Word see Appendix A each bit fault2 represents a fault code J Fault codes3 Word see Appendix A each fault3 bit represents a fault code K StopTime Word 0 to 999 msec stoptime L Runtime meter Long in seconds runtime M Strokes Long strokes N Parts Long parts O Batches Long batches P Tonnage CH 1 Word tonnch1 ...

Page 33: ... fields for the particular job 12 Select the Limit Switch Setup field Select the proper open close windows to satisfy your press control inputs LS 1 11 Select the hold time for the timed outputs LS 8 11 13 Cycle the press check the press control adjust the Limit Switch Outputs Repeat this step until all outputs are correct 14 Set up Speed Compensation if running variable speed 15 Select the Die Se...

Page 34: ...ress moved faster than 1 SPM when the control was not signaled to move i e no clutch signal Cure 1 Check that the LED on the I O Board for the brake clutch input is lighting up when the brake is released 2 Value set in DRIFT may be too low and the press may be vibrating from nearby machinery 3 Examine brake clutch and valves on the press 4 Resolver miss wired or bad FEATURE NOT AVAILABLE Cause The...

Page 35: ...44 ohms GRN to BLK or WHT to BLK wires SLAVE FAILURE Cause The slave computer is not sending valid data back to the master Cure 1 Excessive electrical noise 2 Computer failure SLV DATA or JOB FLT Cause Data transfer between computers failed Cure 1 Check for Electrical Noise 2 Check Job memory chip 3 Check Hardware SPM 999 Cause Unit is only designed to operate up to 999 SPM If you are not operatin...

Page 36: ... protected by the presence sensing device 1910 217 C 3 iii Additional requirements for safeguarding Where the operator feeds or removes parts by placing one or both hands in the point of operation and a two hand control presence sensing device or Type B gate or movable barrier on a part revolution clutch is used for safeguarding i The employer shall use a control system and a brake monitor which c...

Page 37: ...es not detect false signals from other devices in the area Usually the electro optical presence sensing device is used in a manner that provides a protected zone in front of the primary work area with auxiliary devices or guards used to protect secondary access areas In some cases however mirrors may be used in conjunction with the device to provide 2 3 or 4 sided protection The machine stop time ...

Page 38: ...cting and training others to perform as operators 13 Management must decide that personnel protective safety equipment is required to perform each job safely Items such as safety glasses shoes gloves helmets hand pads spats protective sleeves and material handling equipment are common in the metal working industry If noise levels are excessive protective headsets and earmuffs are recommended 14 Wh...

Page 39: ...all levels must enforce every safety rule and regulation Strong disciplinary measures are sometimes required They should consist of a warning written reprimand work suspension transfer demotion or possibly a dismissal All infractions must be reported and recorded Once an infraction in noted it shows that an unsafe practice or condition has existed This may be the result of poor planning or imprope...

Page 40: ...on the sensor input 0 0v 512 2 5v 1024 5 0v 2 5v machine tonnage capacity 4 Tonnage on all 4 channels can be viewed while in RUN mode The tonnage for any channel will only be displayed on the RUN screen when the minimum tonnage value is set above 0 You can still only change the setpoints from the Tonnage Setup screen in the PROG mode Tonnage Load Monitor optional Mounting Connecting Mounting the T...

Page 41: ... do not crimp too tight and risk smashing the wires This could cause them to short to ground Figure 2b shows a side view of the completed operation after crimping Figure 2a Figure 2b 4 Attach the wire lug to a ground terminal on the front of the TLM Use a 6 32 x screw for the grounding lug connection Note If your sensor is not double shielded with both foil and a braid electrical noise may affect ...

Page 42: ...100mA fuse for 115 VAC or a 50mA fuse for 220 VAC These jumpers can be accessed by removing the six screws securing the cover and then pulling the cover off from the front 115 VAC Jumpers A C 220 VAC Jumper B Only TLM Cam Switch Wiring Connections Tonnage Load Monitor optional Mounting Connecting Figure 4 TLM Printed Circuit Board Figure 4a Front Panel A C Power Connections ...

Page 43: ... be used The LED directly above the probe input connector PROBE SENSE indicates the actual state of the probe This LED should turn on at 140 and turn off at 240 If it is working just the opposite simply flip the N C N O Dip Switch If the probe is ON during this time the DIP switch may be moved to N C to invert the logic of the probe signal in the TLM The state of the LED is not affected with this ...

Page 44: ...36 Tonnage Load Monitor optional Installation T400 Installation ...

Page 45: ...ust the input connection for compression readings instead of tension TIE ROD AND NUT CONDUIT FOR LOAD SENSOR WIRES ONLY CAUTION DO NOT RUN CONDUIT NEAR TIE ROD HEATING OPENINGS CROWN OF PRESS COLUMN UPRIGHT BOLSTER BED 1 3 L 1 3 L 1 3 L L LENGTH OF COLUMN OR UPRIGHT RULE OF THUMB FOR CAST FRAME PRESSES OR VERY HEAVY FRAM PRESSES INSTALL SENSORS IN AN AREA OF LEAST CROSS SECTION AVOID HOLES AS DE S...

Page 46: ...ess member using the 1 4 28 by 1 1 4 inch M6 1 X 35 long socket head cap screw in the center of the guide Step No 4 Insert the number 3 drill 5mm into the smaller hole and drill out all four holes to a depth of 3 4 of an inch Step No 5 Loosen the drill guide Rotate the drill guide 180 such that the larger holes line up with the fresh drilled holes in the press member Insert a tap to be sure the ho...

Page 47: ...and tight Weld the weld pads to the press member Be sure to only weld the weld pads on three sides as shown A single pass is sufficient Do not remove fixture until slag is removed and or assembly has cooled The four screws may be discarded Do not use screws to assemble sensor When welding to cast iron use a dry nickel rod such as Lincoln Electric Soft Weld Hobart NI Cast 99 MB Weld Prod MG 210 Str...

Page 48: ... level is reset and the auto zeroing function is resumed notice the dotted line in Figure 6 Tonnage Load Monitor optional Installation The timing of the probe should be such that it turns on just before the machine begins generating a load 140 and remains on until the load is removed 240 and the TLM outputs have been read The Analog Output Connector The analog outputs are provided on a 6 pin Phoen...

Page 49: ...nsor location Normally we locate our sensors Ch1 Left Rear Ch3 Left Front Ch2 Right Rear Ch4 Right Front Step 5 Coat the sensors with silicone if you are calibrating a forging press This will help prevent water damage when the presses are washed Put the sensor enclosure covers on each box Step 6 Without load cells in the press cycle the press and stop it at bottom dead center Measure between the r...

Page 50: ...hing other than a 1 meg shunt Step 1 Locate the following information from the load cell calibration data sheet Shunt Output Resistance ____________ Shunt Output Voltage in mV V ________ Step 2 Find the New Shunt Output by completing the following formula 000001 x Shunt Output Resistance x Shunt Output Voltage New Shunt Output Voltage Step 3 Set your TLM to a Full Scale voltage Common settings are...

Page 51: ...at the external probe signal is turned on before the load is generated and off after the operation is complete If the logic of the probe is reversed use the N C N O switch to invert the probe signal logic or adjust the probe accordingly Step 4 Set the TRACK PEAK switch to the desired mode While in TRACK mode each channel s output will follow the loading on the sensor as the load on the machine inc...

Page 52: ...Only 24 VDC devices Compression The force generated by the sensor or load cell by compressing It is usually found in the rear of a C Frame press or on a Pitman arm Gain Span Gain also called Span is the amplification used by the monitor A small amount of elongation of the sensor needs a large amount of gain to show a high reading The gain is adjusted during calibration Reverse Load The snap throug...

Page 53: ...nage Controller 3 or 4 channel input unit 30 010 Replacement Tonnage Sensors 35 of cable 30 013 Replacement Tonnage Controller 1 or 2 channel input unit 32 001 Safety Valve Relay blue or white Dold clear or green Elesta 32 038 Ouput Module Solid State AC 32 039 Ouput Module Solid State DC 32 041 Output Relay G2R 1 S 35 065 EEPROM JOB memory chip 100 jobs 39 051 RUN PROG Keyswitch with keys and cab...

Page 54: ...___ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ _________________________________ ______________________...

Page 55: ...are no warranties which extend beyond the above warranty LIMITATION OF LIABILITY In the event of any claim or breach of any obligations of manufacturer under any order whether expressed or implied and particularly in the event of any claim or a breach of the warranty or warranties contained in the paragraph Warranty or of any other warranties expressed or implied which might despite the paragraph ...

Page 56: ...r unknown is interdependent upon the performance of other equipment not manufactured installed secured or maintained by Pressroom Electronics Inc We cannot and do not accept responsibility for any overall system performance when factors such as these are beyond our control www pressroomelectronics com sales pressroomelectronics com service pressroomelectronics com Sales and Marketing Offices Unite...

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