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Toledo PWi Forging, User Manual

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PWi Forging User’s Manual 

Doc #17663     Rev A                                                                                                                                           Page 

      

 

 

Toledo Integrated Systems 

2

Table of Contents 

1

1

:

:

 

 

Installation ........................................................................................................... 5

 

Limited Warranty ............................................................................................................................ 5

 

Features Overview .......................................................................................................................... 6

 

Specifications .................................................................................................................................. 7

 

Mounting the PWi Forging – Standard Installation ........................................................................ 9

 

Mounting the PWi Forging – Flush Mount Option ...................................................................... 10

 

PWi Forging Components ............................................................................................................. 11

 

Conduit Hole Selection ................................................................................................................. 12

 

AC Power Connection and Configuration .................................................................................... 13

 

DC Power Connection .................................................................................................................. 14

 

Sensor Input Configuration ........................................................................................................... 15

 

Load Sensor Connection ............................................................................................................... 16

 

Sensor Cable Termination ............................................................................................................ 17

 

Sensors Connection ....................................................................................................................... 18

 

Analog Output ............................................................................................................................... 19

 

Probe Input .................................................................................................................................... 20

 

External Reset Switch Connection ............................................................................................... 22

 

Serial Port Connection .................................................................................................................. 23

 

Shutdown Relays .......................................................................................................................... 25

 

2

2

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Operation .......................................................................................................... 27

 

User Interface ................................................................................................................................ 27

 

Operation Mode and Configuration Mode .................................................................................... 28

 

The Security Code Feature ........................................................................................................... 29

 

The Low Battery Indicator ............................................................................................................ 30

 

Replacing the Backup Battery ...................................................................................................... 31

 

Operation Mode - Overview ......................................................................................................... 32

 

Operation Mode - Description ...................................................................................................... 33

 

Home Menu ............................................................................................................................... 33

 

Signature Menu ......................................................................................................................... 35

 

Setpoint Menu ........................................................................................................................... 39

 

Alarm Menu .............................................................................................................................. 41

 

Reverse Menu ............................................................................................................................ 42

 

Statistics Menu .......................................................................................................................... 43

 

Job Menu ................................................................................................................................... 45

 

Station Menu ............................................................................................................................. 46

 

Security Code Menu (Operation mode) .................................................................................... 47

 

Configuration Mode - Overview ................................................................................................... 50

 

Configuration Mode - Description ................................................................................................ 51

 

Channel Menu ........................................................................................................................... 51

 

Decimal Point Menu ................................................................................................................. 52

 

Capacity Menu .......................................................................................................................... 53

 

Trigger Menu ............................................................................................................................ 54

 

Summary of Contents for PWi Forging

Page 1: ...17664 PWi Forging Tonnage Monitor By Toledo Integrated Systems User s Manual...

Page 2: ......

Page 3: ...PWi Forging User s Manual Doc 17663 Rev A Page Toledo Integrated Systems 1 PWi Forging User s Manual Revision A...

Page 4: ...17 Sensors Connection 18 Analog Output 19 Probe Input 20 External Reset Switch Connection 22 Serial Port Connection 23 Shutdown Relays 25 2 2 Operation 27 User Interface 27 Operation Mode and Configu...

Page 5: ...Menu 58 Mode Menu 59 E Stop Menu 60 Setup Count Menu 61 Address Menu 62 Baud Rate Menu 63 Calibration Menu 64 Security Code Menu Configuration mode 65 3 3 Calibration Procedure 69 4 4 Calibration Inf...

Page 6: ...Settings 13 Figure 1 6 DC Power Connection 14 Figure 1 7 Sensor Configuration Jumper Settings 15 Figure 1 8 Sensor Input Locations 16 Figure 1 9 Sensor Cable Stripping 17 Figure 1 10 Sensor Wiring 18...

Page 7: ...ducers Inc 6834 Spring Valley Drive Holland Ohio 43528 The express warranty set forth herein is in lieu of all other warranties expressed or implied including without limitation any warranties of merc...

Page 8: ...gment LED displays for up to four forging stations The user interface consists of six tactile switches and a back lit LCD graphic display module that provides a user friendly menu system The LCD is al...

Page 9: ...cy Response Flat DC to 6 KHz Resolution Each channel provides a 5 digit load value in 1024 count resolution Calibration Shunts 1 Meg Ohm 0 1 resistor Job Storage 100 jobs Speed Limit Up to 400 SPM wit...

Page 10: ...ctable Fuse 0 5A for 110VAC input 0 25A for 220VAC input TR5 type Slow Blow Supply Power Requirements 24VDC 1 25A minimum DC units Fuse 1 25A TR5 type Slow Blow Data Storage Configuration Jobs Nonvola...

Page 11: ...Shock mounts are provided with every standard PWi Forging for this purpose Failure to use these shock mounts may result in premature failure of the instrument and possibly void your warranty The PWi...

Page 12: ...rnal shock mounts are not required As with the standard installation the flush mount option allows the PWi Forging to be mounted directly to the press or to an adjacent structure It should be position...

Page 13: ...PWi Forging User s Manual Doc 17663 Rev A Page Toledo Integrated Systems 11 PWi Forging Components Control Board Analog Board Figure 1 3 PWi Forging Components...

Page 14: ...select the proper conduit hole for cabling The holes are for conduit but they can be enlarged in the field if a larger fitting is required Serial Communication Probe Input External Reset Switch R l C...

Page 15: ...4 for the AC Power Wiring Use the proper fuse as indicated With the proper jumper settings the PWi Forging can be powered by either 110 VAC or 220 VAC Factory set at 110 VAC The jumpers are located on...

Page 16: ...shown in Figure 1 6 The external 24VDC power supply should be rated at 1 25A or higher Use Conduit Hole 3 see Figure 1 4 for the DC Power Wiring Use the proper fuse as indicated If the power cable has...

Page 17: ...justments are made via two potentiometers for each channel When configured for tonnage sensor input gain ranges of X1 and X10 are also selectable Refer to the illustration below for the location of th...

Page 18: ...nd route cables upward to the Analog Board 3 Prepare the sensor cable for termination as described on page 17 4 Remove the four 5 pin Phoenix plugs from the analog board and wire each sensor cable as...

Page 19: ...t to nick any of the signal conductors or cut the braid shield Figure 1 9 Sensor Cable Stripping 2 Strip approximately of insulation from each of the four signal conductors 3 Trim braid shield so that...

Page 20: ...rain gage sensors Figure 1 10 illustrates the sensor connections T400 Sensor T400 Sensor Column mounted sensor Pitman mounted sensor W S R S B G E E SHL RED WHITE GREEN BLACK SHIELD Figure 1 10 Sensor...

Page 21: ...in connector for easy access and for interfacing with other peripherals BOTTOM VIEW 1 2 3 4 5 6 7 8 9 G R O U N D C H A N N E L 6 C H A N N E L 7 C H A N N E L 8 C H A N N E L 9 C H A N N E L 1 C H A...

Page 22: ...w shows the probe input location on the Analog Board and illustrates different wiring possibilities Use Conduit Hole 2 see Figure 1 4 to run the probe wiring After wiring is completed you must configu...

Page 23: ...21 The timing of the probe should be such that it turns on just before the machine begins generating a load typically at 140 and remains on until the load is removed typically at 240 Figure 1 13 Probe...

Page 24: ...l Use Conduit Hole 2 see Figure 1 4 to run the wiring for the reset switch NOTE In order to reduce noise that may trigger false reset Use twisted pair wires for the connection Do not run this pair of...

Page 25: ...n of a daisy chain multi drop serial network as a standard feature The RS422 1 port can be configured for the following baud rates 9600 38 4k 76 8k 115 2k The figure below details the location of the...

Page 26: ...17663 Rev A Page Toledo Integrated Systems 24 Computer to single PWi Forging monitor wiring Figure 1 16 RS232 Serial Port Wiring Computer to multiple PWi Forging monitors wiring Networking Figure 1 1...

Page 27: ...nd personnel may be seriously injured without shut down protection Use Conduit Hole 3 see Figure 1 4 for the Shutdown Relay Wiring Bypass Switch NC COM T STOP SHUTDOWN RELAYS NO COM NC NO E STOP CAM2...

Page 28: ...PWi Forging User s Manual Doc 17663 Rev A Page Toledo Integrated Systems 26...

Page 29: ...egrated Systems 27 2 2 Operation User Interface The PWi Forging is equipped with an easy to use menu driven user interface The six push buttons are used to view and change parameters The following des...

Page 30: ...d in normal operation and the Configuration Mode is for initial setup Dip Switch 1 in SW1 is used to select these modes SW1 is located on the side of the Control Board which is mounted on the inside o...

Page 31: ...der of the current security status a lock indicator appears at the top of the LCD display when a security code has not been entered To manage the security code functions there is a Security Code menu...

Page 32: ...ion Capacities threshold etc and job related setpoints are stored in nonvolatile flash memory to prevent data loss However some non critical information including alarm counts statistics and live load...

Page 33: ...from the PWi Forging unit 2 Open the enclosure door and locate the Control Board It is the board mounted on the door 3 Remove the 6 screws that secure the cover plate to the Control Board Place the s...

Page 34: ...Systems 32 Operation Mode Overview To view other menus Push or until the desired menu is shown To return to the Home menu From any menu push to return to the Home menu The home symbol on the bottom le...

Page 35: ...isplays The 4 outer 7 Segment displays show the total peak load for stations 1 4 As the press cycles and the peak values update the last station indicator a dot in the upper left corner of the display...

Page 36: ...generate a new benchmark and new high and low setpoints The monitor then switches to Run mode to continue production To change the operating mode 1 Push or until the desired mode RUN SETUP or LRN is s...

Page 37: ...Wi Forging User s Manual Doc 17663 Rev A Page Toledo Integrated Systems 35 Signature Menu The Signature menu displays the load signature for the current stroke for analysis and troubleshooting purpose...

Page 38: ...le in the signature detail above the upper left quadrant is filled in while the remaining three quadrants are empty This indicates that the Left Rear corner is currently displayed If all four quadrant...

Page 39: ...is paused and the center menu is showing ANLYZ Push or to access the signature analysis tools The center menu is now selected and the right menu now changes to APPY With the center menu showing MEM pu...

Page 40: ...cursor moves the corner displays update with the load for the selected point on the curve Push or to cycle through the corners or Push to close the signature and resume signature updating 3 To view lo...

Page 41: ...nformation for the various types of setpoints and allows each station s setpoint value to be adjusted Other information such as Corner Tonnage Distribution Capacity and Benchmark values can be viewed...

Page 42: ...on will be selected or push to cancel the change 5 Repeat from Step 2 to make changes on other stations 6 Push to exit change mode Note To bypass a station s setpoint change the station s setpoint to...

Page 43: ...f the stations If there is an active alarm it can be reset from this menu To view the alarm list Push or to see each alarm if more than one type of alarm has occurred If an alarm is active its associa...

Page 44: ...grated Systems 42 Reverse Menu The Reverse menu displays the current reverse load data for each station To view Reverse Load Reverse load values are shown in the associated stations and the Reverse lo...

Page 45: ...storical load information for the current job Various data such as last alarm highest load number of high alarms etc can be viewed and reset The statistics are automatically reset when a job is loaded...

Page 46: ...ode All stations are then selected and the cleared statistics values for each station are shown 3 Push to accept the clear or push to cancel the clear To clear all statistics 1 Push or until ALL is sh...

Page 47: ...Job menu displays the active job number and allows the user to change to a previously created job or create a new job To change the Job Number 1 Push to enter change mode Current job number is then s...

Page 48: ...enter change mode Current number of stations is then selected 2 Push or to change the setting 3 Push to accept the change or push to cancel the change Notes When less than four stations are selected t...

Page 49: ...digits are represented by with the currently selected digit highlighted Digits are incremented and decremented with the middle arrow buttons or The button accepts the current digit and advances to the...

Page 50: ...o enter a zero like the third digit in the above example simply press without pressing any other button Digits can be entered with either the or buttons For example the digit 9 can be entered by press...

Page 51: ...ed When the code is unlocked all settings and functions are active After the desired changes have been made by authorized personnel the security code should be locked again so that no further changes...

Page 52: ...l Doc 17663 Rev A Page Toledo Integrated Systems 50 Configuration Mode Overview To view other menus Push or until the desired menu is shown Note Depending on the trigger method and mode selected some...

Page 53: ...channels that the monitor will display To change the Number of Channels 1 Push to enter change mode Current value is then selected 2 Push or to change the value 3 Push to accept the change or push to...

Page 54: ...Decimal Point menu controls the precision with which the load values are displayed Up to 3 decimal places can be displayed To change the Decimal Point 1 Push to enter change mode Current value is the...

Page 55: ...to select the desired channel 3 Push or to change the value or Push or to change in a larger increment 4 Push to accept the change or push to cancel the change 5 Repeat from step 2 to make change on o...

Page 56: ...ethod 1 Push to enter change mode Current setting is then selected 2 Push or to change the setting 3 Push to accept the change or push to cancel the change Notes When the trigger method is changed to...

Page 57: ...capture the stroke Total loads below this value will be ignored To change the Threshold Value 1 Push to enter change mode Current setting is then selected 2 Push or to change the setting or Push or to...

Page 58: ...rn setpoints based on a percentage of capacity will generate a larger range of good load values than choosing to learn based on a percentage of the benchmark This effect is more evident if your normal...

Page 59: ...drops below the threshold to end Hit 1 However the load then rises slightly above threshold once again before finally dropping once more Hit 2 This behavior will commonly cause the peak tonnage to upd...

Page 60: ...usted from 0 no offset to 359 Determining the Offset Value needed 1 Cycle the press to the top position This should be 0 2 Subtract the resolver position shown in the total window from 360 to get the...

Page 61: ...method for processing load data To change the Load Processing Mode 1 Push to enter change mode Current setting is then selected 2 Push or to change the setting 3 Push to accept the change or push to c...

Page 62: ...E Stop is set to CAP ALARM Capacity alarms cause the E Stop relay to open immediately when an over capacity load occurs This also applies to CCM alarms if the optional resolver board is installed War...

Page 63: ...in Setup mode indefinitely protected only by the capacity limits After the Setup Count value has been reached the monitor will enter Run mode To change the Setup Count 1 Push to enter change mode Curr...

Page 64: ...mmunications address of the monitor and allows it to be changed to provide a unique networking address for use with PressNet or other communications software To change the Address 1 Push to enter chan...

Page 65: ...Rate Menu The Baud Rate menu allows the communications speed for the PressNet RS422 1 Port to be adjusted To change the Baud Rate 1 Push to enter change mode Current setting is then selected 2 Push o...

Page 66: ...shown 2 Values are shown in the associated corners To change the Balance Values and Gain Numbers Balance values are changed by adjusting the corresponding Balance pot for each channel The Balance pot...

Page 67: ...the LCD as they are entered The digits are represented by with the currently selected digit highlighted Digits are incremented and decremented with the middle arrow buttons or The button accepts the...

Page 68: ...ars In this case pressing will enable the security code for the Operation mode To change the Security Code Once a valid security code has been entered the authorized user then has the option to change...

Page 69: ...PWi Forging User s Manual Doc 17663 Rev A Page Toledo Integrated Systems 67 Sequence to Change the Security Code...

Page 70: ...default value of 4 1 7 0 in case the code is forgotten First navigate to the Configuration mode s Security Code menu Then follow this sequence exactly as shown Sequence to Reset the Security Code Once...

Page 71: ...ail 3 Balance the Tonnage Sensors A Make sure the press is under no load B Use the or buttons to navigate to the Calibration menu C Open the PWi Forging enclosure and locate the Balance and Gain pots...

Page 72: ...apacity and the size of the load cells being used loading the press at capacity with load cells could indent the ram or bolster To prevent this situation from happening do one of the following a Calib...

Page 73: ...g s peak tonnage values are same If not repeat step 7 until the values are the same 9 Make Linearity Check A Raise the shut height in 020 to 030 inch increments to decrease tonnage B Cycle the press a...

Page 74: ...PWi Forging User s Manual Doc 17663 Rev A Page Toledo Integrated Systems 72...

Page 75: ...network communication address for the monitor 5 Capacity CH0 The total capacity of the press For a double action press this is the capacity of the outer slide 6 Unit The type of load being measured Co...

Page 76: ...mple in the case of a double action press where sensors 6 9 are used to measure the load for the inner slide the CH5 capacity is the total capacity for the inner slide 14 Resolver If the trigger metho...

Page 77: ...learn them every time that part is ran To load a job use the and buttons to access the JOB menu The current job number is shown above the and buttons on the LCD Display To change the job number press...

Page 78: ...PWi Forging User s Manual Doc 17663 Rev A Page Toledo Integrated Systems 76...

Page 79: ...PWi Forging User s Manual Doc 17663 Rev A Page Toledo Integrated Systems 77 6 6 Appendix I Sensor Installation Doc 11080 II Calibration Sheets 2 Form 1224...

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Page 81: ...A proper installation is necessary to produce good results Before installing the sensors please read the appropriate instructions listed below Sensor Placement Page 2 Press Frame Page 3 Pitman Mount...

Page 82: ...Doc 11080 Rev A T400 INSTALLATION PAGE 2...

Page 83: ...Doc 11080 Rev A T400 INSTALLATION PAGE 3...

Page 84: ...Doc 11080 Rev A T400 INSTALLATION PAGE 4...

Page 85: ...o the press The anti torque washers should go between the screw and the sensor body Torque each 28 x in long socket head cap screw to 150 LB IN or 12 5 LB FT STEP 8 Remove the fixture and repeat Steps...

Page 86: ...ole as in Step 3 Orient the fixture as shown STEP 5 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 the fixt...

Page 87: ...Doc 11080 Rev A T400 INSTALLATION PAGE 7...

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