TOX PRESSOTECHNIK CEP400T User Manual Download Page 100

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Troubleshooting

100

TOX_Manual_Process-monitoring-unit_CEP400T_en

9.1.2

Analyzing NOK situations

Stroke (punch
travel)

Pressing force
control by
force sensor

Control dimension ‘X‘
monitoring by precision limit caliper

Error source

Meaning

Measuring point OK (measuring point is within the window)

Press force too high (Display: Error code <MAX>)

Press force too low (Display: Error code <MIN>)

No measurement (No change to display; 'ready to mea-
sure' signal remains present, no edge transition)

Tab. 19

Error sources

Summary of Contents for CEP400T

Page 1: ...User manual Process monitoring CEP400T TOX PRESSOTECHNIK Riedstrasse 4 D 88250 Weingarten www tox pressotechnik com Edition 05 20 2020 Version 2 GmbH Co KG ...

Page 2: ...2 TOX_Manual_Process monitoring unit_CEP400T_en ...

Page 3: ...t and source of supply 11 2 Safety 2 1 Basic safety requirements 13 2 2 Organizational measures 13 2 2 1 Safety requirements for the operating company 13 2 2 2 Selection and qualifications of personnel 14 2 3 Fundamental hazard potential 15 2 3 1 Electrical hazards 15 3 About this product 3 1 Warranty 17 3 2 Product Identification 18 3 2 1 Position and content of the type plate 18 3 3 Function des...

Page 4: ...8 Sensor Analog Standard Signals 39 4 9 Measuring sensor supply voltage 39 4 10 Screw sensor with standard signal output 39 4 11 DMS signals 40 4 11 1 Built in version pin assignment analog standard signals 40 4 11 2 Pin assignment DMS force transducer 41 4 11 3 Wall mounted housing pin assignment of force transducer 42 4 12 Profibus interface 43 4 13 Fieldbus interface 44 4 14 Pulse diagrams 46 4...

Page 5: ...t field 59 8 3 4 Dialog keyboard 59 8 3 5 Icons 61 8 4 Main menus 62 8 4 1 Select process Enter process name 62 8 4 2 Configuration 67 8 4 3 Lot size 79 8 4 4 Supplemnt 86 8 4 5 Valuation options 95 8 4 6 Messages 97 9 Troubleshooting 9 1 Detecting faults 99 9 1 1 Acknowledging Messages 99 9 1 2 Analyzing NOK situations 100 9 1 3 Error messages 101 10 Maintenance 10 1 Maintenance and repair 105 10...

Page 6: ...it_CEP400T_en Maintenance table 11 Repairs 11 1 Repair work 111 12 Disassembly and Disposal 12 1 Safety requirements for disassembly 113 12 2 Disassembly 113 12 3 Disposal 113 13 Appendices 13 1 Declaration of conformity 115 13 2 UL certificate 118 Index ...

Page 7: ... and or usability of these goods and services The use and or representation of trademarked brands that do not belong to TOX PRESSOTECHNIK are for information only all rights remain the property of the owner of the trademarked brand Operating instructions manuals technical descriptions and software are originally compiled in German 1 2 Exclusion of liability TOX PRESSOTECHNIK has checked the conten...

Page 8: ... documents In addition to the available manual further documents can be supplied These documents must also be complied with Other applicable documents can be for example additional operating manuals e g of components or of a whole sys tem Supplier documentation Instructions such as software manual etc Technical data sheet Safety data sheets Data sheets 1 4 Gender note In order to enhance readabili...

Page 9: ...sures are not taken è Measures for remedial action and protection WARNING Identifies a potentially dangerous situation Death or serious injury may occur if appropriate safety measures are not taken è Measures for remedial action and protection CAUTION Identifies a potentially dangerous situation Injury may occur if appropriate safety measures are not taken è Measures for remedial action and protec...

Page 10: ...llowed to ensure trouble free operation w Identifies the result of an action u Identifies the result of a complete action è Identifies a single action step or several action steps that are not in an operating sequence The highlighting of operating elements and software objects in texts facili tates distinction and orientation In square brackets identifies operating elements such as buttons levers ...

Page 11: ...Contact and source of supply Only use original spare parts or spare parts approved by TOX PRES SOTECHNIK TOX PRESSOTECHNIK GmbH Co KG Riedstraße 4 D 88250 Weingarten Tel 49 0 751 5007 333 E Mail info tox de com For additional information and forms see www tox pressotechnik com ...

Page 12: ...Important information 12 TOX_Manual_Process monitoring unit_CEP400T_en ...

Page 13: ...r compliance with the following safety requirements The operating manual must always be kept available at the operation site of the product Ensure that the information is always complete and in legible form In addition to the operating manual the generally valid legal and other binding rules and regulations must be provided for the following content and all personnel must be trained accordingly Wo...

Page 14: ...nly appoint persons to work on the plant who have read and under stood the operating manual and in particular the safety instructions before starting work This is particularly important for persons who only work on the plant occasionally e g for maintenance work Only allow persons appointed and authorized for this work access to the plant Only appoint reliable and trained or instructed personnel O...

Page 15: ...stem and motors of the installation The following basically applies Have work on electrical equipment performed only by electricians or trained persons under the direction and supervision of an electrician in accordance with the electrotechnical regulations Always keep the control box and or terminal box closed Before commencing work on electrical equipment switch off the main switch of the system...

Page 16: ...Safety 16 TOX_Manual_Process monitoring unit_CEP400T_en ...

Page 17: ...ributable to one or more of the following causes Non compliance with safety instructions recommendations instructions and or other specifications in the operating manual Non compliance with the maintenance rules Unauthorized and improper commissioning and operation of the ma chine or components Improper use of the machine or components Unauthorized constructional modifications to the machine or co...

Page 18: ...rial number SN Serial number Tab 1 Type plate Type code structure Setup and function of process monitoring CEP 400T 02 04 08 12 are similar to a large extent The number of measurement channels differenti ates the devices Type key Description CEP 400T 02 Two separate measurement channels K1 and K2 CEP 400T 04 Four separate measurement channels K1 to K4 CEP 400T 08 Eight separate measurement channel...

Page 19: ...s the external interfaces provided 3 3 2 Force monitoring Measurement of force For tongs the force is generally recorded via a screw sensor For presses the force is recorded via a force sensor behind the die or the punch monitoring of the maximum value 3 3 3 Force measurement The process monitoring system compares the maximum measured force with the set maximum and minimum limit values MAX limit v...

Page 20: ...ed tool Clinching The process monitoring system measures and evaluates the maximum force reached To make a statement about a clinching process from the set minimum and maximum limits it must be ensured that the clinching tools were fully closed e g with a precision limit button If the measured force is then within the force window it can be assumed that the X control dimension is in the required r...

Page 21: ...CEP 400 devices On termination of a measurement the result will be read and logged by the PC TOX softWare Module CEP 400 The TOX softWare can image the following functions Display and filing of measuring values Processing and filing of device configurations Offline creation of device configurations 3 3 6 Log CEP 200 optional The CEP 200 model can be replaced with a CEP 400T To replace model CEP 20...

Page 22: ...About this product 22 TOX_Manual_Process monitoring unit_CEP400T_en ...

Page 23: ... x H x D 168 x 146 x 46 mm Installation aperture W x H 173 x 148 mm Display front panel W x H 210 x 185 mm Plastic front panel EM immune conductive Attachment method 8 x threaded bolts M4 x 10 Protection class according to DIN 40050 7 80 IP 54 front panel IP 20 housing Films Polyester resistance according to DIN 42115 Alcohols diluted acids and alkalis household cleaners Weight 1 5 kg ...

Page 24: ...Technical data 24 TOX_Manual_Process monitoring unit_CEP400T_en 4 2 Dimensions 4 2 1 Dimensions of installation housing 77 50 123 50 Fig 2 Dimensions of installation housing ...

Page 25: ..._Process monitoring unit_CEP400T_en 25 4 2 2 Hole pattern of installation housing rear view 82 5 82 5 18 20 10 95 200 10 175 150 3 top front view mounting cutout 175 X 150 mm Fig 3 Hole pattern of installation housing rear view ...

Page 26: ...ge 24 V DC 25 incl 10 residual ripple Current consumption 1 A Wall housing 24 V DC M12 connector strip Pin assignment installation housing voltage Type Description 0 V DC I 24 V supply voltage PE I PE 24 V DC I 24 V supply voltage Pin assignment wall housing PIN voltage Type Description 1 24 V DC I 24 V supply voltage 2 not occupied 3 0 V DC I 24 V supply voltage 4 not occupied 5 PE I PE ...

Page 27: ... s to 11 s day Display TFT backlit 5 7 graphics capable TFT LCD VGA 640 x 480 Backlit LED switchable via software Contrast 300 1 Luminosity 220 cd m Viewing angle vertical 100 horizontal 140 Analog resistive color depth 16 bit Interface extensibility 1 x slot for back plane 1 x keyboard interface for max 64 but tons with LED Buffer battery Lithium cell pluggable Battery type Li 3 V 950 mAh CR2477N...

Page 28: ...SB interfaces 2 0 host 2 USB device 1 CF memory card 1 4 5 1 Digital inputs Description Value Input voltage Rated voltage 24 V permissible range 30 to 30 V Input current At rated voltage 24 V 6 1 mA Delay time of standard inputs tLOW HIGH 3 5 ms tHIGH LOW 2 8 ms Input voltage LOW level 5 V HIGH level 15 V Input current LOW level 1 5 mA HIGH level 3 mA Input impedance 3 9 kΩ Tab 2 16 digital inputs...

Page 29: ...ion bit 2 5 I 4 Program strobe Test plan selection bit 2 6 I 5 Offset external Test plan selection cycle 7 I 6 Start measurement Error reset 8 I 7 Start measurement channel 2 only 2 channel device 19 0 V 0 V external Reserve 20 I 8 HMI lock Reserve 21 I 9 Error reset Reserve 22 I 10 Program bit 4 Reserve 23 I 11 Program bit 5 Reserve 24 I 12 Reserve Reserve 25 I 13 Reserve Reserve 26 I 14 Reserve ...

Page 30: ... selected in menu Additional Communication parameters Field bus parameters Fig 5 Connection example of digital inputs outputs Pin D SUB 25 OK Color code Standard CEP 400T CEP 200 IO Option see Networking via Ethernet Option Page 21 14 I0 White Program bit 0 Measure 15 I1 Brown Program bit 1 Reserve 16 I2 GREEN Program bit 2 Test plan se lection bit 1 17 I3 YELLOW Program bit 3 Test plan se lection...

Page 31: ... Reserve 12 0 V Brown green 0 V external PLC 0 V external PLC 11 0 V internal Blue 0 V internal 0 V internal 23 24 V internal Pink 24 V from in ternal source 24 V from in ternal source Tab 4 Wall mounted housing Digital inputs I0 I15 25 pin D sub female connector 25 pin line required 4 5 2 Connections Description Value Load voltage Vin Rated voltage 24 V permissible range 18 V to 30 V Output volta...

Page 32: ...n parameters Field bus parameters Built in version digital outputs Q0 Q7 37 pin connector Pin OK Standard CEP 400T CEP 200 IO Op tion see Net working via Ether net Option Page 21 19 0 V 0 V external 0 V external 28 Q 0 OK OK 29 Q 1 NOK NOK 30 Q 2 Channel 2 OK only 2 channel de vice Delivery cycle ready for measure ment 31 Q 3 Channel 2 NOK only 2 channel de vice 32 Q 4 Program ACK Reserve 33 Q 5 R...

Page 33: ...Technical data TOX_Manual_Process monitoring unit_CEP400T_en 33 Fig 6 Connection example of digital inputs outputs ...

Page 34: ...asurement 5 Q4 Grey brown Program se lection ACK Reserve 6 Q5 Grey pink Ready for measurement Reserve 7 Q6 Red blue Measure ac tive Reserve 8 Q7 Pink brown Channel 2 measurement in progress only 2 chan nel device Reserve 12 0 V Brown green 0 V external PLC 0 V external PLC 24 24 V White green 24 V external PLC 24 V external PLC Tab 6 Wall mounted housing Digital inputs I0 I15 25 pin D sub female c...

Page 35: ...iption Value Transmission speed 1 200 to 115 200 Bd Connecting line Shielded at 0 14 mm max 300 m at 0 25 mm max 600 m Termination Fixed Tab 8 1 channel non isolated Description Value Min Type Max of Output voltage 3 V 8 V 15 V Input voltage 3 V 8 V 30 V Output current 10 mA Input resistance 3 kΩ 5 kΩ 7 kΩ Description Value Min Max of Output differential voltage 1 5 V 5 V Input differential voltag...

Page 36: ...l speed 1 x device high speed USB 2 0 According to USB device specification USB 2 0 compatible type A and B Connection to high powered hub host Max cable length 5 m Pin MIO 1 5 V 2 Data 3 Data 4 GND Ethernet 1 channel twisted pair 10 100BASE T Transmission according to IEEE ANSI 802 3 ISO 8802 3 IEEE 802 3u Description Value Transmission speed 10 100 Mbit s Connecting line Shielded at 0 14 mm max ...

Page 37: ... 50 m max 500 kBit Cable length up to 150 m max 250 kBit Cable length up to 350 m max 125 kBit Number of subscribers max 64 Connecting line Shielded At 0 25 mm up to 100 m At 0 5 mm up to 350 m Tab 9 1 channel non isolated Description Value Min Max of Output differential voltage 1 5 V 3 V Input differential voltage Recessive Dominant 1 V 1 V 0 4 V 5 V Input offset voltage 6 V 6 V to CAN GND Input ...

Page 38: ...ischarge EN 61000 4 2 Contact min 8 kV Clearance min 15 kV Electromagnetic fields EN 61000 4 3 80 MHz 1 GHz 10 V m 80 AM 1 kHz 900 MHz 5 MHz 10 V m 50 ED 200 Hz Fast transients EN 61000 4 4 Power supply lines 2 kV Process digital In outputs 1 kV Process analog inputs outputs 0 25 kV Communication interfaces 0 25 kV Induced high frequency EN 61000 4 6 0 15 80 MHz 10 V 80 AM 1 kHz Surge voltage 1 2 ...

Page 39: ...ge 10 V 1 nominal signal 0 10 24 V and 10 V are available for the power supply of the measuring sensor They are to be wired according to the type of sensor 4 10 Screw sensor with standard signal output The input is selected in menu Configuration Force sensor configura tion see Configuring the force sensor Page 69 Description Value Tare signal 0 V Zero adjustment active the force sensor should be o...

Page 40: ...djustment value The entry Nominal force must match the nominal value of the force sensor used See the data sheet of the force sensor 4 11 1 Built in version pin assignment analog standard signals One Sub D 15 pole female connector each designation analog I O is available for 4 measurement channels Pin Type Input Output Analog signal 1 I Force signal 0 10 V channel 1 5 9 3 I Ground force signal cha...

Page 41: ...V Start measurement 0 analog output 1 0 V 4 11 2 Pin assignment DMS force transducer Only hardware model CEP400T 2X with DMS subprint Pin DMS signal 1 2 3 4 5 6 7 8 9 1 Measuring sig nal DMS 2 Measuring sig nal DMS 3 Reserve 4 Reserve 5 Reserve 6 Supply DMS V 7 Sensor cable DMS F 8 Sensor cable DMS F 9 Supply DMS V Tab 11 9 pole sub D socket board DMS0 or DMS1 When connecting the DMS using the 4 c...

Page 42: ...ng signal DMS channel 1 5 9 5 E K2 o Supply DMS V channel 2 6 10 6 S K1 I Measuring signal DMS channel 1 5 9 7 S K2 I Measuring signal DMS channel 2 6 10 8 E K2 o Supply DMS V channel 2 6 10 9 E K3 o Supply DMS V channel 3 7 11 10 S K2 I Measuring signal DMS channel 2 6 10 11 S K3 I Measuring signal DMS channel 3 7 11 12 S K3 I Measuring signal DMS channel 3 7 11 13 E K4 o Supply DMS V channel 4 8...

Page 43: ...p to 350 m Input offset voltage 7 V 12 V to GND Output drive current 55 mA Udiff 1 5 V Number of subscribers per segment Without repeater max 32 With repeater max 126 every repeater used reduces the max number of sub scribers Connecting line shielded twisted surge impedance 135 to 165 Ω Capacitance per unit length 30 pf m Loop resistance 110 Ω km Recommended cables Fixed installation UNITRONIC BUS...

Page 44: ... 10 Program bit 2 1 2 I 11 Program bit 3 1 3 I 12 Program bit 4 1 4 I 13 Program bit 5 1 5 I 14 HMI lock 1 6 I 15 Reserve 1 7 Tab 12 Data length Byte 0 3 Outputs Q0 Q31 Designation Field bus byte Field bus bit Q 0 OK 0 0 Q 1 NOK 0 1 Q 2 Ready for op 0 2 Q 3 Program selection ACK 0 3 Q 4 Measure active 0 4 Q 5 Channel 2 OK only 2 channel device 0 5 Q 6 Channel 2 NOK only 2 channel device 0 6 Q 7 Me...

Page 45: ...OK 3 7 Format of final values via fild bus bytes 4 39 The end values are written on bytes 4 to 39 on the field bus if this function is activated BYTE Designation 4 to 7 Running number 8 Process number 9 Status 10 Second 11 Minute 12 Hour 13 Day 14 Month 15 Year 16 17 Channel 1 force kN 100 18 19 Channel 2 force kN 100 20 21 Channel 3 force kN 100 22 23 Channel 4 force kN 100 24 25 Channel 5 force ...

Page 46: ...put I Output O Designation A0 o Part is OK OK A1 o Part is not OK NOK A6 o Measure active A5 o Ready for measurement ready E6 I Start measurement Tab 14 Basic device signals The contacts in the plug connector depend on the shape of the housing see pin allocation of wall mounted housing or mounting version 1 0 1 0 1 0 1 0 1 0 1 2 3 4 5 2 3 4 5 Cycle IO Cycel NIO IO O1 NIO O2 Meas running O7 Ready O...

Page 47: ...nal that was not set must be used for the NOK evaluation See the sequence at active warning limit number of pieces 4 14 2 Measuring mode This description applies to versions with active warning limit monitoring and number of pieces monitoring Signal name Type Input I Output O Designation A0 o Part is OK OK K1 A1 o Part is not OK NOK K1 A6 o Measure K1 in progress A5 o Ready for measurement ready E...

Page 48: ...be evaluated in the external control Plant control system check the readiness of measurement Before the command Start measurement it must be checked whether th CEP 400T is ready for measuring The process monitoring system might not be ready to measure due to a manual input or a fault It is therefore always necessary prior to an automatic sequence to check the Ready to measure output of the system ...

Page 49: ...ection of a test plan 0 63 At 1 the test plan number 3 bit 0 and 1 high is set and selected by set ting the Cycle signal At 2 the acknowledgment signal of the CEP device is set The test plan selection cycle must remain set until the reading in of the new test plan number has been acknowledged After the return of the timing signal the acknowledgment signal is reset Bit Program no 0 1 2 3 4 5 0 0 0 ...

Page 50: ...see pin allocation of wall mounted housing or mounting version 1 0 1 0 1 0 1 0 1 0 1 2 3 4 5 6 BIT 0 I0 Offset alignment external I5 Cycle I4 Acknowledgement O4 Ready O5 Fig 10 External offset adjustment via PLC interface channel 1 With the end of the cycle 3 the external offset adjustment of the selected channel is started While the offset adjustment is running maximum of 3 seconds per channel th...

Page 51: ... e g with a plastic bag Store the device only in closed dry dust free and dirt free rooms at room temperature Add drying agent to the packaging 5 2 Dispatch for repair If the device is sent to TOX PRESSOTECHNIK for repair the following in formation is required Detailed description of the fault Operating conditions and installations e g upstream devices etc Contact person at TOX PRESSOTECHNIK Conta...

Page 52: ...Transport and storage 52 TOX_Manual_Process monitoring unit_CEP400T_en ...

Page 53: ...ect required lines and devices e g sensors and actuators 3 Connect supply voltage 4 Make sure that the correct supply voltage is connected 6 2 Starting system ü System is prepared See Chap 6 1 Preparing System Page 53 è Switch on the plant u The device starts the operating system and the application u The device switches to the start screen ...

Page 54: ...Commissioning 54 TOX_Manual_Process monitoring unit_CEP400T_en ...

Page 55: ...l_Process monitoring unit_CEP400T_en 55 7 Operation 7 1 Monitoring operation No operating steps are necessary during ongoing operation The operating procedure must be monitored constantly in order to detect faults in time ...

Page 56: ...Operation 56 TOX_Manual_Process monitoring unit_CEP400T_en ...

Page 57: ...s Configuration of the interface by setting the software parameters 8 2 Software interface 1 3 2 Fig 11 Software interface Screen area Function 1 Information and status bar The information and display bar displays General information about process monitoring Current pending messages and infor mation for the main area displayed in the screen 2 Menu bar The menu bar displays the specific sub menus f...

Page 58: ...n red Output is deactivated 4 Button green Output is activated 5 Call up Configuration menu Opens the Configuration menu 6 Call up Firmware version menu Opens the Firmware version menu 7 Button shift Serves for the brief switchover of the key board to the second allocation level with uppercase letters and special characters 8 3 2 Checkboxes 1 2 Fig 13 Checkboxes Display control panel Function 1 No...

Page 59: ...ns The input field displays the value currently entered Values can be entered or changed in an input field This function is de pendent on the user level and is not normally available for all user lev els 8 3 4 Dialog keyboard Keyboard dialogs are needed for entering and changing values in input fields Fig 15 Numerical keyboard ...

Page 60: ...ent uppercase è Keep pressing the Shift button until the keyboard displays uppercase letters w The keyboard displays uppercase letters Activating permanent lowercase è Press Shift button until the keyboard displays lowercase letters u The keyboard displays lowercase letters Numbers and special characters è Keep pressing the Shift button until the keyboard displays numbers and special characters u ...

Page 61: ... OK Measurement NOK Last measurement was not OK At least one evaluation criteria was violated envelope curve window Warning limit The measurement is OK but the set warning limit has been reached Measure active The measurement is in progress Device ready to measure The process monitoring system is ready to start a measurement Device not ready to mea sure The process monitoring system is not ready t...

Page 62: ...e process num bers and processes can be selected Fig 17 Menu Processes Select process Enter process name Selecting Processes Selection by entering a Value ü The user is logged in with a suitable user level The necessary write permissions are available 1 Tap on process number input field w The numerical keyboard opens 2 Enter process number and confirm with button ...

Page 63: ...Editing min max limits When setting up the process monitoring system the parameters for the maximum and minimum limit values must be specified in order to evaluate the measurement values correctly Specifying limit values ü TOX Analysis assistance is available 1 Clinching approx 50 to 100 piece parts at simultaneous measurement of the press forces 2 Checking the clinching points and piece parts con...

Page 64: ...e Minor Max input field under the channel whose value is to be changed w The numerical keyboard opens 2 Enter the value and confirm with the button Copying the process In the Select process Enter process name Copy process menu source process can be copied to several target processes and parameters saved and restored again Fig 18 Copy process Save parameters menu ...

Page 65: ...menu Select process Enter process name Copy process Copy process is open 1 Tap on the From process input field w The numerical keyboard opens 2 Enter the number of the first process to which the values are to be copied and confirm with the button 3 Tap the Up to process input field w The numerical keyboard opens 4 Enter the number of the last process to which the values are to be copied and confir...

Page 66: ...a USB stick or read in from a USB stick Fig 20 Saving restoring parameters menu Copy parameters to USB stick ü The user is logged in with a suitable user level The necessary write permissions are available ü The menu Select process Enter process name Copy process Save restore parameter is open ü USB stick is inserted è Tap on Copy parameters to USB stick button w The parameters are copied on the U...

Page 67: ...ns are available ü USB stick is inserted è NOTE Data loss The old parameters in the target process are over written by copying Tap theLoad the parameters from the USB stick button w The parameters are read from the USB stick 8 4 2 Configuration The process dependent parameters of warning limit and force sensor are set in the Configuration menu Fig 21 Configuration menu ...

Page 68: ...s must be monitored by the overriding control system Setting the warning limit The value fixess the warning limit with regard to defined tolerance windows that are defined in the process ü The user is logged in with a suitable user level The necessary write permissions are available 1 Tap on Warning limit input field w The numerical keyboard opens 2 Enter a value between 0 and 50 and confirm with ...

Page 69: ... measurement the yellow symbol Warning limit message is displayed The counter is automatically reset when a further measuring result lies within the set warning limit window The counter is also reset after a restart of the device ü The user is logged in with a suitable user level The necessary write permissions are available 1 Tap on the Measuring cycles input field w The numerical keyboard opens ...

Page 70: ...al force maximum of 4 characters 4 Offset Offset value of the measuring signal for adjusting a possible zero point offset of the analog measuring signal of the sen sor 5 Offset limit Maximum tolerated force sensor offset 6 Forced offset NO The process monitoring system ready to measure directly after being switched on YES The process monitoring system carries out an offset adjustment for the respe...

Page 71: ...um of 4 characters 4 Offset Offset value of the measuring signal for adjusting a possible zero point offset of the analog measuring signal of the sen sor 5 Offset limit Maximum tolerated force sensor offset 6 Forced offset NO The process monitoring system ready to measure directly after being switched on YES The process monitoring system carries out an offset adjustment for the respective channel ...

Page 72: ...m with 3 If necessary Tap on the Nominal force unit input field w The alphanumeric keyboard opens 4 Enter the value for the desired unit of the nominal force and confirm with Adjusting the offset force sensor The Offset parameter adjusts a possible zero point offset of the analog measurement sensor of the sensor An offset adjustment must be carried out once a day or after approx 1000 measurements ...

Page 73: ...appears after the offset adjustment This for example can prevent that an offset is taught when the press is closed ü The user is logged in with a suitable user level The necessary write permissions are available ü The Configuration Force sensor configuration menu is opened è Tap on the Offset limit input field w Each tap changes the value between 10 20 100 Forced offset force sensor If the forced ...

Page 74: ... of force sensor Nominal force the measured electrical signal is converted to the corresponding physical unit with the values of nominal force and offset If the values for nominal force and offset are not known they can be determined via the cal ibration For this a 2 point calibration is carried out The first point here can be the opened press with 0 kN force applied for example The second point f...

Page 75: ... panel Function 1 Signal 2 Force 3 Force 1 4 Teach 1 5 Measuring value 1 Is faded in when Teach 1is tapped Dis play Input field of measured value 6 Force 2 7 Teach 2 8 Measuring value 2 Is faded in when Teach 2is tapped Dis play Input field of measured value 9 Nominal Force 10 Offset 11 Accept calibration The calibration of the sensors is ac cepted 12 Accept Saves the changes ...

Page 76: ...ring sig nal to be displayed and confirm with 5 Move to the second point e g closing the press with a certain press force 6 Determine the currently applied force and simultaneously if possible tap the Teach 2 button for reading the applied force w The current electrical measuring signal is accepted and displayed in a new display input field Measuring value 2 next to the Teach 2 button 7 Tap on the...

Page 77: ... a request dialog is displayed when exiting the menu In this window the following options can be selected Only for this process The changes only apply to the current process and overwrite the previ ous values settings in the current process Copy to all processes The changes apply to all processes and overwrite the previous values settings in all processes Copy to the following processes The change...

Page 78: ... dataset no 999 is dis carded and the newest is added last measurement no 0 inc no Unique consecutive number The number is counted up by value 1 after each mea surement proc Assignment of the measurement to a process state Status of a measurement Green background Measurement OK Red background Measurement NOK f01 f12 Measured force of channels 01 to 12 date Date of measurement in format dd mm yy ti...

Page 79: ... for a running job Shift counter Number of OK parts and the total number of parts of a shift Tool counter Total number of parts that have been processed with the current tool set Job counter In menu Lot size Job counter the respective counter readings for the current job are displayed 10 1 2 6 7 8 9 5 4 3 Fig 24 Menu Lot size Job counter Field Meaning 1 Counter value OK Number of OK parts of the r...

Page 80: ... display 9 Switch off at total The number of the total parts reached at which the working process is ended and a stored red message is issued on the display 10 Accept The settings are applied The window will close Job counter Switch off at OK A limit value can be entered in the input field Switch off at OK Once the counter value reaches the value the Ready signal is switched off and an error messa...

Page 81: ...ing message is issued The value 0 deactivates the corresponding option The system is not shut down and no message is issued ü The user is logged in with a suitable user level The necessary write permissions are available ü Menu Lot size Job counter is open 1 Tap on the Switch off at total input field w The numerical keyboard opens 2 Enter the limit value and confirm with Value 0 deactivates the fu...

Page 82: ...ading 4 Main menu OK The counter reading is displayed in the main menu when the checkbox is acti vated 5 Main menu total The counter reading is displayed in the main menu when the checkbox is acti vated 6 Message at OK The number of the OK parts reached at which a stored yellow message is issued on the display Value 0 deactivates the function 7 Message at total The number of the total parts reache...

Page 83: ...n The system is not shut down and no message is issued ü The user is logged in with a suitable user level The necessary write permissions are available ü Menu Lot size Shift counter is open 1 Tap on the Switch off at OK input field w The numerical keyboard opens 2 Enter the desired value and confirm with Value 0 deactivates the function Reset Switch off at OK counter 1 When the limit value in inpu...

Page 84: ... The numerical keyboard opens 2 Enter the limit value and confirm with Value 0 deactivates the function Reset Switch off at total counter 1 When the limit value in input field Switch off at total has been reached 2 Reset the counter by tapping on the Reset button 3 Start process again Tool counter In menu Lot size tool counter the respective counter readings for the current job are displayed 6 1 4...

Page 85: ...ettings are applied The window will close Tool counter Switch off at total A limit value can be entered in the input field Switch off at total Once the counter value reaches the value the working process shuts down and a corresponding message is issued The value 0 deactivates the corresponding option The system is not shut down and no message is issued ü The user is logged in with a suitable user ...

Page 86: ...ic user level Log out from the active user level Change the password Log user in and out The process monitoring system has an authorization management system that can limit or enable different operating options and configuration op tions Authorization Description Password Level 0 Machine operator Functions for observing the measurement data and program selection are enabled No password required Le...

Page 87: ...ered incorrectly a message will appear and the login procedure will be canceled u The actual authorization level is displayed at the top of the screen Log out user ü Menu Supplement User administration is open ü The user is logged in with level 1 or higher è Tap on the Logout button u The authorization level changes to the next lower level u The actual authorization level is displayed at the top o...

Page 88: ...assword and confirm with w A dialog window opens with the request to enter the new password w The alphanumeric keyboard opens 3 Enter the new password and confirm with w A dialog window opens with the request to enter the new password again w The alphanumeric keyboard opens 4 Enter the new password again and confirm it with Changing Language Fig 27 Menu Supplement Language In the Supplement Langua...

Page 89: ... and the default gateway can be changed Defining IP address via the DHCP protocol ü The user is logged in with a suitable user level The necessary write permissions are available 1 Tap on DHCP checkbox 2 Tap the Accept button 3 Restart the device Defining IP Address by entering a Value ü The user is logged in with a suitable user level The necessary write permissions are available 1 Tap on the fir...

Page 90: ...uts to Profibus Activate or deactivate the selected func tion 2 Log final values on Profibus Activate or deactivate the selected func tion 3 Accept Closes the window The displayed parameters will be adopted Selection by entering a Value ü The user is logged in with a suitable user level The necessary write permissions are available 1 Tap on the Profibus address input field w The numerical keyboard...

Page 91: ...cessary write permissions are available ü Menu Supplement Configuration parameters Remote access is open è Tap on the Remote access button w Remote access is enabled In Outputs In the Supplement In Outputs menu the user can Check the current status of the internal digital inputs and outputs Check the current status of the field bus inputs and outputs Checking the internal In Outputs In menu Supple...

Page 92: ... becomes effective immediately u The change remains effective until the Inputs outputs menu is exited Change byte ü The user is logged in with a suitable user level The necessary write permissions are available ü Menu Supplement In Outputs Internal digital I O is opened è Tap the cursor button at the top edge of the screen u The byte changes from 0 to 1 or reverse BYTE Bit 0 0 7 1 8 15 Check field...

Page 93: ...ated or deactivated u The change becomes effective immediately u The change remains effective until the Field bus menu is exited Change byte ü The user is logged in with a suitable user level The necessary write permissions are available ü Menu Supplement In Outputs Field bus I O is opened è Tap the cursor button at the top edge of the screen u The byte changes from 0 to 15 or reverse BYTE Bit BYT...

Page 94: ...nfirm with Change device name The device name is used for example to create a folder with the device name on the data medium during the creation of a backup on a USB stick This makes it clear in case of several process monitoring systems on which device this backup was created ü The user is logged in with a suitable user level The necessary write permissions are available ü The Menu Supplement Dev...

Page 95: ...nu Button Function 1 External NOK acknowledgement The NOK message must always be ac knowledged via an external signal 2 NOK acknowledgement per dis play The NOK message must be acknowl edged via the display 3 Separate measurement of chan nels The measurement for channel 1 and channel 2 can be started ended and evaluated separately Only available with a process monitoring system with 2 channels 4 W...

Page 96: ... checkbox to activate the acknowledgement per display 2 Tap on the checkbox With password to enter the password of autho rization level 1 the one who can perform the acknowledgment 3 Tap on the Accept button to save the values Separate measurement of channels In case of a 2 channel device the measurement for channel 1 and channel 2 can each be started ended and evaluated separately ü The user is l...

Page 97: ...g or error occurs Yellow background Warning message Red background Error message The following messages are displayed in the meaurement menu OK job counter limit reached Total job counter limit reached OK shift counter limit reached Total shift counter limit reached Tool counter limit reached Offset limit force sensor exceeded piece part NOK ...

Page 98: ...Software 98 TOX_Manual_Process monitoring unit_CEP400T_en ...

Page 99: ...r warnings Alarm Type Display Meaning Warning Text with a yellow background in the measurement menu of the device Fault Text with a red background in the measurement menu of the device The next measurement is dis abled and must be eliminated and acknowledged 9 1 1 Acknowledging Messages After a fault the button Error resetappears in the main screen è Tap on the Error reset button u The fault is re...

Page 100: ...orce sensor Control dimension X monitoring by precision limit caliper Error source Meaning a Measuring point OK measuring point is within the window B Press force too high Display Error code MAX C Press force too low Display Error code MIN D No measurement No change to display ready to mea sure signal remains present no edge transition Tab 19 Error sources ...

Page 101: ...Troubleshooting TOX_Manual_Process monitoring unit_CEP400T_en 101 9 1 3 Error messages ...

Page 102: ...ith the correct number of sheet layers Deposits in the die Only affects individual points Clean affected dies Oil dirt remains of paint etc in the ring channel of the die If the problem contin ues dismantle and clean the die polishing or chemical etching may be carried out fol lowing discussions with TOX PRESSOTECH NIK Sheet surface is very dry rather than be ing lightly oiled or greased Check the...

Page 103: ...s oiled or greased rather than being very dry Check the state of the sheet surface Carry out a washing step prior to joining Change to the working process e g washing step prior to joining omitted If necessary Draw up a special testing program for greased oiled sheet surface Broken punch Joining point hardly present or not at all Replace faulty punch Broken die Joining point is no longer round in ...

Page 104: ...ed Status signal Number of pieces reached is set Check tool for wear and replace if necessary re set the lifetime counter Warning limit in succession Error Warning limit exceeded The preset warning limit has been ex ceeded n times Status signal Warning limit in succession is set Check tool for wear and replace if necessary re set the counter by quit ting the measurement menu ...

Page 105: ...nance work must be observed The correct and proper repair of the TOX PRESSOTECHNIK product can only be assured by appropriately trained specialists The operating com pany or the personnel in charge of the repair must ensure that the repair personnel are properly trained in the repair of the product The repairers themselves are always responsible for the work safety ...

Page 106: ... intervals if present and stipulated Maintenance intervals may vary from the stipulated maintenance inter vals The maintenance intervals may have to be verified with the manufac turer if necessary Perform only maintenance work that is described in this manual Inform operating personnel before starting repair work Appoint a supervisor ...

Page 107: ...change after 2 years at the latest ü Device is de energized ü Person is electrostatically discharged ü Electrically non conductive tool for removing the battery 1 Remove the cover of the lithium battery 2 Pull the battery out with an insulated tool 3 Install new lithium battery in the correct polarity 4 Install the cover ...

Page 108: ...Maintenance 108 TOX_Manual_Process monitoring unit_CEP400T_en ...

Page 109: ...ance table The specified intervals are only approximate values Depending on the area of application the actual values may differ from the guide values The ac tual intervals can be found in the system control Maintenance cycle Additional information 2 years 10 3 Battery change ...

Page 110: ...Maintenance table 110 TOX_Manual_Process monitoring unit_CEP400T_en ...

Page 111: ...Repairs TOX_Manual_Process monitoring unit_CEP400T_en 111 11 Repairs 11 1 Repair work No repair work is necessary ...

Page 112: ...Repairs 112 TOX_Manual_Process monitoring unit_CEP400T_en ...

Page 113: ...rsonnel 12 2 Disassembly 1 Shut down system or component 2 Disconnect system or component from the supply voltage 3 Remove all connected sensors actuators or components 4 Disassemble system or component 12 3 Disposal When disposing of packaging consumables and spare parts including the machine and its accessories the relevant national environmental protection regulations must be complied with ...

Page 114: ...Disassembly and Disposal 114 TOX_Manual_Process monitoring unit_CEP400T_en ...

Page 115: ...Appendices TOX_Manual_Process monitoring unit_CEP400T_en 115 13 Appendices 13 1 Declaration of conformity ...

Page 116: ...Appendices 116 TOX_Manual_Process monitoring unit_CEP400T_en ...

Page 117: ......

Page 118: ...Appendices 118 TOX_Manual_Process monitoring unit_CEP400T_en 13 2 UL certificate ...

Page 119: ...CTS BEARING ANY UL MARKS UNTIL THE INITIAL PRODUCTION INSPECTION HAS BEEN SUCCESSFULLY CONDUCTED BY THE UL FIELD REPRESENTATIVE An Initial Production Inspection IPI is an inspection that must be conducted prior to the first shipment of products bearing the UL Mark This is to ensure that products being manufactured are in accordance with UL LLC s requirements including the Follow Up Service Procedu...

Page 120: ... and documentation provided to you involving UL Mark services are provided on behalf of UL LLC UL or any authorized licensee of UL Feel free to contact me or any of our Customer Service representatives if you have any questions UL is strongly committed to providing you with the finest customer experience possible You may receive an email from ULsurvey feedback ul com inviting you to please partici...

Page 121: ... Communication parameters 89 Connections 28 Contact 11 Control elements 58 Counter Switch off at OK 80 83 Switch off at total 81 83 85 D Date Set 93 Declaration of conformity 115 description Function 19 Device name Change 94 Dialog Keyboard 59 Digital inputs 28 Digital outputs 31 32 34 35 36 37 Dimensions 24 Hole pattern of installation housing 25 Installation housing 24 Wall table housing 26 Disa...

Page 122: ...tons 58 Function description 19 Force measurement 19 Force monitoring 19 Test of the final position 20 G Gender note 8 H Hardware configuration 27 Hazard Electrical 15 Hazard potential 15 I Icons 61 Identification Product 18 Images Highlighting 10 Important information 7 information Important 7 Input field 59 Inputs 91 Interface Software 57 IP address Change 89 J Job counter Switch off at OK 80 Jo...

Page 123: ... Tool counter 84 User administration 86 Valuation options 95 Message acknowledge 99 Error 101 Messages 97 Min max limits 63 Mode Measuring 46 47 mode sequence Measuring 46 47 Monitoring Operation 55 Process 19 N name Enter process 62 Process 62 Network server program 21 Networking Ethernet 21 Nominal load Force sensor 72 Note Gender 8 General 10 Legal 7 Warning signs 9 Numbers 60 O Offset adjustme...

Page 124: ...ess 62 Selection Personnel 14 Selection of personnel 14 Sensor Adjust offset 72 Analog standard signals 39 Setting Date 93 Force sensor filter 74 Offset limit of force sensor 73 Time 93 Setting the filter Force sensor 74 Shift counter Switch off at OK 83 Switch off at total 83 Software 57 Function 57 Interface 57 Source of supply 11 Special characters 60 Starting System 53 Storage 51 Temporary sto...

Page 125: ...er supply 26 Profibus interface 43 44 Pulse diagrams 46 Screw sensor with standard signal output 39 Sensor 39 Test of the final position 20 Clinching 20 Texts Highlighting 10 Time set 93 Tool counter Switch off at total 85 Transfer of measuring data 21 Transport 51 Troubleshooting 99 Type plate 18 U UL certificate 118 Uppercase permanent 60 User Log in 86 User administration 86 Change password 87 ...

Page 126: ...Index 126 TOX_Manual_Process monitoring unit_CEP400T_en ...

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TOX PRESSOTECHNIK CEP400T, User Manual

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