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DiPro 1500 User Manual

15

Ch 2

1092000

Chapter 2
DiPro 1500 Installation

WARNING!

DiPro 1500 should not be used to control clutch / brake timing.
It is designed to be used for auxiliary functions only.

This chapter describes how to install DiPro 1500. It covers:

•

Installation guidelines and overview

•

Checking the press and setting press to top stop

•

Mounting the DiPro 1500 controller

•

Mounting and wiring the resolver

•

Connecting multiple controls to a single resolver

•

Installing the DiPro Remote Connection Box (optional)

•

Connecting the Wintriss Sensor Interface to DiPro 1500 (optional)

•

Connecting AC power, stop circuits and input check circuit

•

Installing programmable cam channels (if cam option purchased)

•

Power-up prechecks and turning power on

•

Zeroing the resolver

•

Installing the position sensor (optional)

• Final checkout

WARNING

PREVENT SHOCK

Disconnect main power before installation. All power to the press, press

control, and other equipment used with the press must be off during

installation. Installation must be performed by qualified personnel only.

Before you start

If you plan to install DiPro yourself instead of leaving the job to Data Instruments service
personnel, read this installation chapter entirely before you start. Find out what is
required and plan your steps before taking any action. DiPro is not hard to install. But
like anything else, when you are working with something new, the best way to proceed is
to learn all you can about it first before cutting wires, drilling holes, and running conduit.

You will need to use the keyboard and display during installation to zero the resolver and
to install the position sensor (installing this sensor is optional). You may also need to
load some settings to run the press for zeroing the resolver. Therefore, before you start
installation, you should have a good general knowledge of how to use the DiPro
keyboard and displays to make settings. This will speed things along.

If you run into any

problems installing DiPro, remember that Data Instruments service advisors are
standing by to help you. Just call us. See the toll free number in the front of the manual.

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Summary of Contents for dipro 1500

Page 1: ...mmable Cam Switch 1092000 Rev B5 July 2010 Tech Support Hotline 800 586 8324 8 5 EST www wintriss com Wintriss Controls Group LLC 100 Discovery Way Unit 110 Acton MA 01720 USA Phone 800 586 8324 Fax 978 263 2048 PRINTED IN USA DA45930 ...

Page 2: ...ly components have been labeled PROVIDE IMPORTANT INFO DURING TROUBLESHOOTING WITH DI TECH SUPPORT Whenever you need to contact Wintriss Controls for technical assistance be ready to provide some important information to expedite a resolution to the problem Please supply product name e g DiPro 1500 installed options e g 8 channel cam and firmware version number e g Vs 2 00 You can determine firmwa...

Page 3: ...e returning We ask that you either fax us a PO for that amount or enclose the PO with the returned item This will enable us to ship the item back to you as soon as the repair has been completed If the item cannot be repaired or there are additional charges you will be contacted for approval Please be sure to carefully pack all returned items and ship to our Acton MA location Expedited Repair Progr...

Page 4: ...r 20 If you replace your resolver 23 Multiple controls connected to a single resolver 24 Wiring a remote reset switch or setup mode disable circuit 25 Installing the DiPro Remote Connection Box RCB 26 Connecting DiPro Sensor Interface or Wintriss Sensor Interface to DiPro 1500 27 Connecting AC wiring stop circuits and input check circuit 28 Connecting programmable cam channels if installing cam 31...

Page 5: ...rs and selecting a sensor to set 70 Naming the sensor 71 Setting sensor type 72 Setting stop type 72 Setting the ready signal for a green sensor 73 Setting counter value for green special sensor 74 Setting the other sensors for the tool 75 Going back to the programming menu 75 What to do about sensor inputs that are not used 75 Going back to the sensor list using the RESET key 76 Fine tuning the s...

Page 6: ... Messages 99 Messages displayed when a sensor signals a fault 99 Fault messages for green sensors 99 Fault message for yellow sensors 102 Fault message for red sensors 103 Fault message for green special sensors 103 Messages displayed when a counter preset is reached 104 Messages displayed for equipment or software problems 105 Appendix A DiPro 1500 Panel Mount 111 Standard Enclosure versus Option...

Page 7: ...lization mode Use it to look up things you need to know about using DiPro in Initialization mode Chapter 5 explains how to use DiPro 1500 in Program mode Use it to look up things you need to know about Program mode Chapters 6 explains how to use DiPro 1500 in Run mode You can look up things you need to know about Run mode Chapter 7 shows you fault messages or other types of messages you will see o...

Page 8: ...equipment which has been subjected to improper installation misuse misapplication negligence accident or unauthorized modification The provisions of this warranty do not extend the original warranty of any product which has either been repaired or replaced by Wintriss Controls No other warranty is expressed or implied Wintriss accepts no liability for damages including any anticipated or lost prof...

Page 9: ...Table of Contents DiPro 1500 User Manual vi TOC 1092000 ...

Page 10: ...tecting your press and die from damage see Theory of Operation for a complete explanation of how DiPro works Here are some of the benefits you will come to appreciate when using your DiPro 1500 You make all settings for sensors and cam channels if installed right at the operator console using DiPro s liquid crystal display LCD and keyboard There are no complicated instructions to learn The message...

Page 11: ...to view error messages when DiPro stops the press Screen contrast This knob adjusts the brightness of the LCD display LED Display Three digit display which shows strokes per minute when the press is running When the press stops the display shows the an gle of the stroke in degrees where the press stopped For in stance it would show 0 for top dead center Program run key Allows you to lock the Progr...

Page 12: ...e stroke to expect a signal from the sensor between 190 and 270 You can set a separate ready signal for each sensor DiPro 1500 checks for the sensor signal at the right time When the press is running and the ram reaches 190 DiPro checks for the signal from the sensor If it does not get a signal from the sensor before the ram reaches 270 it sends a stop command to the press DiPro 1500 makes many de...

Page 13: ... protection units and all can be used with DiPro Most sensors made by other manufacturers can also be used Detailed application information is available on any of the Wintriss Controls sensors listed below Miniature fiberoptic photoelectric sensors thru beam and reflective types with adjustable sensitivity detect objects as small as 0006 in 015 mm Requires 12 to 24 Vdc for power Proximity sensors ...

Page 14: ...firm sensor contact closure are received by the controller High impedance inputs Inputs 4 5 and 6 are high impedance inputs They recognize a sensor s closure to ground when the resistance in the circuit drops below 7000 ohms These inputs are good for situations where an oil coating prevents a firm sensor contact closure or prevents a good ground Oil can act as an insulator and create resistance in...

Page 15: ...NTS WINTRISS CONTROLS GROUP 1 2 3 Figure 1 3 Remote Connection Box RCB RCB Dimensions Width does not include width of flanges 4 56 11 6 cm Depth 2 56 6 5 cm Height 4 06 10 3 cm Overall width includes width of both flanges 5 75 14 6 cm Vertical distance between mounting holes center to center 3 25 8 3 cm Horizontal distance 5 25 13 3 cm RCB cable 30 or 100 ft is attached Eight wires in cable are fa...

Page 16: ...to be used for auxiliary functions only Settings you can make on DiPro All settings are made using the keys on the DiPro keyboard Up to six sensors can be used with DiPro If the programmable cam switch option is installed four channels for controlling press equipment are available For complete instructions on how to make settings see Chapter 4 Programming Here are settings you can make Assign tool...

Page 17: ...ll them by selecting the tool number from the tool number display You never need to make the same settings for a tool over again You can save up to 200 tool numbers Settings are saved automatically as you make them You do not have to tell DiPro to save settings by pressing a key or issuing a command When you load the stored tool number DiPro loads all the settings for the tool DiPro retains all se...

Page 18: ...her as normally open or normally closed Usually these sensors have amplifiers You change their output using a switch on the amplifier The ready signal The ready signal is the portion of the stroke where a sensor must actuate For many of your sensors like those that monitor part ejection blowoff or feed advance you need to be sure that the event occurs during a specific portion of each stroke If th...

Page 19: ...of each stroke Examples are part ejection stock feed and part transfer DiPro displays the portion of the stroke green sensors actuate when you run the press It displays the degrees of the stroke where the sensor turns on and where it turns off That makes it easy to set the ready signal for the sensor You just make the ready signal a little longer or shorter than the actuation time depending on the...

Page 20: ... never turns on Stop signal sent at end of ready signal Ready Signal KEY Sensor Actuation TDC BDC Figure 1 5 How DiPro interprets signals from a sensor set to green quick check Green constant When you set a sensor input to green constant the sensor must turn on before the ready signal begins and turn off after the ready signal ends That is it must stay actuated constantly during the ready signal H...

Page 21: ...s actuates Red sensors are used where it is more convenient to use a normally closed sensor instead of a normally open one Red sensors can monitor the same types of events as yellow sensors die overload end of stock buckling etc No ready signal is set for red sensors DiPro three modes of operation You can do various things with your screen and keyboard depending on what mode you are in Initializat...

Page 22: ...y signal based on the sensor s actuation angle For instance if you see that a green sensor came on at 190 and went off at 270 you might make the ready signal 180 on 280 off That gives you a tight ready signal for the sensor based on its actuation angle There is no trial and error You then set the ready signal for all your other green sensors in the same way taking note of whether the sensor is of ...

Page 23: ...lectronic sensors NPN only Outputs Power for electronic sensors 12Vdc min 100 mA total Programmable cam switch channels 4 or 8 Top stop emergency stop ratings 0 5A resistive 120V max AC or DC Normally open Held closed fault condition or power off opens relay s Options RCB 4 56 x 2 56 x 4 06 11 6 x 6 5 x 10 3 Programmable cam output assembly NEMA 12 holds up to 8 cams Enclosure 9 x 11 x 3 5 22 9 x ...

Page 24: ...ss must be off during installation Installation must be performed by qualified personnel only Before you start If you plan to install DiPro yourself instead of leaving the job to Data Instruments service personnel read this installation chapter entirely before you start Find out what is required and plan your steps before taking any action DiPro is not hard to install But like anything else when y...

Page 25: ... from the DC control wires run to the cam output enclosure containing the relays for cam channels if installed Never use the DiPro power terminals as a junction point to provide power for devices controlled by the cam switch relays In most cases the AC power supply wires should be connected directly to the press control transformer at the press control The communications wiring must not be run wit...

Page 26: ...own in the drawing If you are installing wiring for communications and you also have the programmable cam switch option you will need to make another knockout in the bottom of the controller Communications wires must not be run with other wires The first step checking the press Before starting the installation make sure the die has been removed from the press Then check all modes of press operatio...

Page 27: ...ional Remote connection box Relay box for cam channels TB105 TB102 TB101 TB103 TB104 DiPro 1500 enclosure Connections for AC wiring top stop wiring emergency stop wiring and the input check circuit should be made inside the press control Press control box or cabinet Figure 2 1 Wiring scheme for DiPro 1500 ...

Page 28: ...e installed at a convenient height for all users An ideal height is to have the top edge of the enclosure at approximately chin level You should also consider mounting the enclosure on a stand or platform so it tilts back about 30 from the vertical This makes it easier to see the display and use the keyboard Experiment to determine a good height for everybody before mounting 2 Drill holes for moun...

Page 29: ...degrees when key is in this position perpendicular to base 1 06 2 69 2 0 5 1 31 79 3 75 9 53 3 00 7 62 1 5 3 81 1 75 4 45 SIDE VIEW TOP VIEW 875 2 22 5 54 14 07 875 2 22 3 4 dia shaft standard key 34 86 Diameter hole size 3 62 9 2 Electrical connector for cable XX XX inches XX XX cm 1 85 4 7 Figure 2 3 Resolver reflects dimensions with military style connector When designing the drive for the reso...

Page 30: ... conduit as the resolver wires See Installing the position sensor for an illustration of the position sensor the cable is attached You cannot install the position sensor until the resolver is electronically set to 0 at TDC So run the cable through for now and leave installation until later Refer to installation overview Figure 2 1 to see where the position sensor must be installed It is usually ne...

Page 31: ...HK T STOP E STOP POWER TB104 VOLTAGE SELECTOR S102 INPUT CHECK SWITCH S103 SENS PWR INPUT CHECK LED LED BLOCK COMMUNICATIONS TB103 CAM OUTPUT TB102 RESOLVER TB105 MASTER SLAVE JUMPER J102 TB101 SPEED SELECT J101 SENSORS 1 3 LOW IMP SENSORS 4 6 HIGH IMP U105 U104 Figure 2 4 Location of components in DiPro 1500 important items shown and labeled ...

Page 32: ...ockwise rotation viewed from shaft end NOTE Reverse black and yellow wires for counterclockwise rotation Brn Yel Org Grn Blk Shield Red Figure 2 5 Wiring for resolver cable see table below slot for wire tightening screw clamps wire in slot Figure 2 6 Attaching wires to connector Resolver Wiring Table for TB105 Pin Wire Color 1 Shield 2 Black 3 Green 4 Red 5 Yellow 6 Orange 7 Brown If you replace y...

Page 33: ...conduit from TB105 to the bottom right knockout of the master unit If there is a connector on the other end cut it off 3 Pull connector TB105 in the master unit out of its socket 4 Attach the wires to the connector as shown in Figure 2 5 You will be wiring in parallel 4 red to red 5 yellow to yellow etc so that when you are finished you should have two wires of the same color connected to each ter...

Page 34: ...wiring for this connector now so you do not have to disconnect conduit or rethread wires through conduit later Connect wires as instructed below To connect a remote reset switch Connect a wire from TB101 terminal 8 to a normally open switch Connect another wire from the switch to Gnd TB101 terminal 11 DiPro 1500 is reset with a momentary connection to ground To connect the setup mode circuit 1 Con...

Page 35: ...TRISS CONTROLS GROUP unused pin 4 N O input pin 3 24 Vdc to sensor or amplifier pin 1 Ground pin 2 69 17 5 Back view from inside sensor connector Figure 2 7 DiPro 1500 RCB enclosure for sensors with connector pinout To install the RCB and connect wiring 1 Mount the RCB to the press with the shock mounts provided using the mounting holes on each flange Make sure sensor wires can be easily connected...

Page 36: ...r DiPro 1500 connect the cable as shown in Table 2 2 Notice that while there are 8 inputs for sensors at DiPro Sensor Interface or Wintriss Sensor Interface DiPro 1500 has only six inputs for sensors Therefore you will have two unused wires in your WSI cable Refer to the applicable user manual for complete installation and operating instructions Table 2 2 Wiring connections from DSI or WSI to DiPr...

Page 37: ...should be connected directly to the press control transformer at the press control For 115 Vac you need three wires high black neutral white and ground green For 230 Vac wires are black and red with green or green yellow for ground 3 Determine how you will connect the wires from DiPro to your press control top stop circuit and emergency stop circuit You can wire these circuits at your press contro...

Page 38: ...bad clutch to IN A to IN B coils in dual safety valve that control clutch brake Connection for input check circuit must be across one coil Connections can be made at press control Figure 2 8A Schematic of input check circuit push to left for 60 250V push to right for 12 60V Figure 2 8B Input check switch S103 5 Find the 115V 230V voltage selector switch It is just below the power connection to the...

Page 39: ...in Figure 2 10 Leave the ground wire attached to the connector while making connections If you remove this wire in order to pull the connector all the way out of the enclosure be sure to replace it when done 9 Connect power wires as shown in Figure 2 10 For 115 Vac connect black wire to HI terminal and white wire to NEU For 230 Vac connect black wire to HI terminal and red wire to NEU Attach wires...

Page 40: ...ndard relay item number is XI20366A21 The same solid state relays will continue to be used as before item 2212501 for DC solid state item 2215301 for AC solid state If you require more than 4 solid state outputs with the 8 cam assembly contact the factory before installation You connect the cam channels inside the DiPro controller to the cam output assembly The output assembly contains the relays ...

Page 41: ... connected to output board assembly channel 5 4 Find the cable that runs from the DiPro connector TB102 to TB301 inside the cam output enclosure The cable has twelve wires 5 Attach one end of the cable to the connector for TB102 Refer to Table 2 3A for proper wiring The connector should be plugged into the socket 6 Run the cable through conduit to TB301 in the cam output enclosure You can use the ...

Page 42: ...wires to equipment 5 5 14 0 TB303 6 0 15 2 TB301 CAM OUTPUT BOARD allow clearance for 6 screw 4 places sockets for solid state relays only channels 5 through 8 TB302 OPTIONAL OUTPUT ENCLOSURE 312 dia 79 4 places 3 5 8 9 XX X inches XX X cm 10 0 25 4 8 0 20 32 NOTE Standard solid state cannot both be plugged into channels 5 8 ch8 ch7 ch6 ch5 ch4 ch3 ch2 ch1 Figure 2 11A1 Cam outputs assembly ...

Page 43: ...DiPro 1500 Installation DiPro 1500 User Manual 34 Ch 2 1092000 Figure 2 11A2 Location of components Cam outputs assembly ...

Page 44: ...1 B 2 White 12V OUT 10 TB301 Pin TB102 Pin Wire Power Connections Channel Connections Table 2 4A Making connections to relays Module Relay DC Solid State AC Solid State How to connect Type to C to N O SPDT SPST SPST one wire to C one wire to N O or N C polarity does not matter one wire to C one wire to N O polarity does not matter N C C N O CHAN 5 N C C N O CHAN 6 N C C N O CHAN 7 N C C N O CHAN 8...

Page 45: ...11 Install the suppressors across the load or as close to the load as possible Attach suppressors by connecting leads across existing terminals or junction points See Figure 2 13 for the correct way to install them c n o Power in Power Return RIGHT Suppressor Relay module c n o Power in ACCEPTABLE Suppressor not prefered Power Return Power Return Relay module c n o Power in WRONG Suppressor Power ...

Page 46: ...f the board must not touch metal This can cause shorting Do not mount the board in highly travelled areas where it could get damaged Figure 2 11B Output enclosure for Spectrum style relay relays 2 Mount the enclosure using mounting holes on flanges 3 The relay relays that will control your equipment should already be plugged into the enclosure You should have up to four relay relays The type of re...

Page 47: ...losure You can use the knockouts directly below the connectors on each enclosure 7 Attach the other end of the cable to the connector for TB301 See Table 2 3B Note that this socket has only eight terminals A wire from CHAS to a lug on the relay enclosure should already be connected unless you bought the board only Table 2 3B DiPro TB102 to output enclosure s TB301 PIN Box 1 TB301 Wire Brown Purple...

Page 48: ...ay DC Solid State AC Solid State How to connect Type to C to N O SPDT SPST SPST one wire to C one wire to N O or N C polarity does not matter one wire to C one wire to N O polarity does not matter 10 You must install arc suppressors across each inductive load motors relays coils etc that is connected to an output relay Suppressors are supplied with each relay The suppressors reduce electrical nois...

Page 49: ...position sensor remember that we ran wires to the enclosure for it but have not yet connected the wires Tape the ends of these wires and push them into the lower corner of the enclosure get them out of the way for now We will attach these wires after zeroing the resolver Connect AC power wires from DiPro to power source Connect AC power wires from connector TB104 in DiPro to power source Be sure p...

Page 50: ...0 your timing settings will be way off If your press is at TDC If you set the press to TDC 0 2 before starting the installation and have not moved the ram go to the instructions for zeroing If your press is not at TDC If the ram is not at TDC you must inch the press to 0 2 To do this now you have to load settings for a tool DiPro is now connected to your stop circuits so you can no longer run the ...

Page 51: ...shaft by hand until the reading on the Angle SPM readout is 0 It does not matter which way you turn the shaft Set the resolver right at 0 so the readout shows 0 Once the resolver is set tighten the drive mechanism and go to Step 3 3 To zero make sure the display shown in Step 2 is on your screen Double check that the readout is between 330 and 30 Then press ENTER You will see a display like this i...

Page 52: ... checks that the resolver is also signalling 0 If it is not this means the resolver is no longer rotating 1 1 with the press The resolver drive has slipped or has broken or the resolver itself is broken DiPro will signal an emergency stop and display an error message To install the position sensor 1 First you must load a tool number This is so you can switch DiPro to Run mode and see the angle of ...

Page 53: ...g Magnet Front View Rigid bracket to press frame Position Sensor End View crankshaft Mounted dead center 1 16 to 1 8 gap between magnet and sensor Mounted slightly off center Figure 2 14 How to install the position sensor 7 Once the switch is installed wire it to the connector for TB101 Black wire goes to terminal 11 gnd white or clear goes to terminal 10 position sensor red goes to terminal 9 sen...

Page 54: ...d the ram But check anyway If the ram has not moved check the distance between the position switch and the magnet Re adjust if necessary If you got a position sensor incorrect error message after running the press it is also possible that the position sensor may not have enough dwell to provide an adequate signal at high RPM s The larger the di ameter of the object on whch the magnet is mounted th...

Page 55: ... remove the chip from the package you should ground yourself by touching any large metal object the press will do nicely This will remove any static electricity that you may be carrying around A static electricity zap will destroy the chip 7 Once you are grounded remove the chip from its holder Orient the chip so that the notch faces downward If you plug the chip in backwards it will be destroyed ...

Page 56: ...readout If the angle of the crankshaft decreases goes from 359 towards 0 instead of increasing you have to switch two wires on resolver connector TB105 Switch the wires in termi nals 2 and 5 black and yellow The angle will now increase as the ram moves Check for error messages when the press is run 5 Single stroke the press for a few strokes See if the press stops automatically and you get an erro...

Page 57: ... cause of the problem Do not continue with this procedure until you get an immediate stop when you trip the sensor Check cam channels if installed 9 If you have the programmable cam switch installed turn DiPro off Plug in the connector to TB301 Remember we told you to unplug this earlier Go into Run mode and create some settings for your cam channels Load the tool settings go intor Run mode and ru...

Page 58: ...f the Top Stop circuit DiPro cam channel existing top stop mechanical limit switch existing top stop button existing top stop relay For N O circuit For N C circuit existing top stop mechanical limit switch existing top stop relay existing top stop button DiPro cam channel Figure 2 16 Optional top stop wiring How to test the wiring 1 For N O circuit Temporarily do not program the DiPro cam channel ...

Page 59: ...DiPro 1500 Installation DiPro 1500 User Manual 50 Ch 2 1092000 ...

Page 60: ...ing do not be afraid to try things Push the keys Select items on the displays See what happens You cannot hurt DiPro by pushing a wrong key or making a wrong selection This chapter gives you the basics that will get you started Your starting point in each mode When you use DiPro you choose the displays you want to see to get the task at hand done The displays you see depend on the mode of operatio...

Page 61: ...SHOW SENSORS ADJUST SENSORS ADJUST CAMS LOAD TOOL To see this display turn Prog Run key to Program For older systems shipped prior to 10 91 refer to Chapter 5 Programming menu THE CURRENTLY LOADED TOOL IS 6800 SENSORS ENABLED USE CURSOR KEYS TO CHANGE SELECTIONS PRESS ENTER TO ACCESS TOOL NUMBERS PROGRAM LOAD TOOL NUMBERS DISABLE SENSORS First display in Programming mode Before you switch modes th...

Page 62: ...e or modify settings for tool run menu Run mode adjust sensors adjust counters adjust cams reset preset counters for tool modify settings for tool enable disable sensors load tool number modify settings for tool move down to do tasks move back to where you started zero resolver initialization menu select names for cam channels Initialization mode set position sensor set security parameters lock se...

Page 63: ...light Disable Sensors above you would press the cursor key marked down The selection bar would surround the words disable sensors as shown THE CURRENTLY LOADED TOOL IS 6800 USE CURSOR KEYS TO CHANGE SELECTIONS PRESS ENTER TO DISABLE SENSORS SENSORS ENABLED DISABLE SENSORS PROGRAM LOAD TOOL NUMBERS Bar moved to second item on menu If you pressed the cursor key the selection bar would move back to p...

Page 64: ...tems on a display and you want to get to the fourth item press the down key three times You can also hold it down until you see the selection bar over the fourth item If you go too far press the up key to go back When you hold a key down the bar keeps moving If you have more than one column of items on a display the bar will move from the bottom of one column to the top of the next column It will ...

Page 65: ...mns they will repeat from the end Entering a number with the cursor keys Whenever you select a menu item where you have to key in a number you will see a display like this NEW TOOL NUMBER 0 0 0 0 0 0 0 USE LEFT RIGHT CURSORS TO SELECT DIGITS USE UP DOWN CURSORS TO CHANGE VALUES PRESS ENTER WHEN DONE RESET TO CANCEL Notice how the displays shows all zeros and a pointer is on top of the 0 at the lef...

Page 66: ... change the number just use the cursor keys to move back to the incorrect digits and change them The left cursor key moves the pointer to the left 5 When you re done press ENTER DiPro will accept the number and move on to the next display DiPro accepts numbers up to seven digits If your number is smaller than that leave unused zeros at the left For instance for 31230 enter 0031230 DiPro will recog...

Page 67: ...oves the left edge to the left Angle off The angle off keys move the right edge of the bar to the off setting The key moves the right edge to the right The key moves the right edge to the left Example using the keys to make a setting You want to set the ready signal for a sensor to 270 on and 20 off You bring up the display below on your screen See Chapter 5 for instructions on how to bring up thi...

Page 68: ...of bar now at 270 This is the ready on setting Now your ready signal is on at 270 off at 0 Setting ready off To make the off setting press the right angle off key You can hold it down so the bar keeps moving The bar will wrap around and begin to extend from 0 towards 90 Stop when the bar reaches 20 This is the required setting Look to see that ready off in the box shows 20 If you go too far use th...

Page 69: ...existing one But if you just want to see the tool numbers then do something else press the RESET key and you go back to the previous display You are always told on the bottom of your screen when you can use the RESET key to go back to the previous display The message will say Press Reset when done or Press Reset to cancel Resetting DiPro after a malfunction is signalled The RESET key is used to re...

Page 70: ...munications number for the unit The first display the Initialization menu NOTE Before changing modes make sure your screen shows the first display in the mode you are in If that display is not shown nothing will happen when you turn the Program Run key In that case keep hitting the RESET key When the first display in the mode is reached you will instantly switch to the new mode For newer systems a...

Page 71: ...tion menu you will see the current zero position of the resolver The number displayed is the position in degrees of the resolver when the press is at top dead center The number should be zero or close to it when the resolver is properly installed and zeroed How to use resolver zero is fully explained in Chapter 2 Installation You only use this menu item when installing the resolver or replacing th...

Page 72: ... the Initialization menu Communications This choice on the Initialization menu lets you set an identification number for your unit if you are using a computer to collect data from DiPro DiPro 1500 can send and receive data from a computer using Wintriss Controls PACNet pressroom monitoring software If you do not use PACNet ignore this item If you are using PACNet select communications to set the n...

Page 73: ...RSOR KEYS TO MAKE SELECTION PRESS ENTER TO SET RESET WHEN DONE CHANNEL 1 CHANNEL 2 CHANNEL 3 CHANNEL 4 2 You can name any channel by selecting it Start with channel 1 You will see this display SELECT NAME FOR CAM CHANNEL 1 USE CURSOR KEYS TO MAKE SELECTION PRESS ENTER TO SET RESET WHEN DONE SPRAY LUBE ZERO CAM CHANNEL 1 CHANNEL 2 CHANNEL 3 MORE NAMES The display shows a list of names with the pres...

Page 74: ...l 2 and select a name for it Continue in this way to name all your cam channels The display showing your channels will not change to show the new channel names It will always say channel 1 channel 2 etc This is so you always know which channel you are naming The channel names will appear in Program and Run modes instead of the channel numbers Cam Channel Names These are the names you can select fo...

Page 75: ...lock or change settings The key has to be at program to get into these modes See Chapter 5 Using DiPro in Program mode and Chapter 6 Using DiPro in Run mode for more information on these modes To lock actions in Run mode 1 Select security access from the Initialization menu You will see the display below The default settings settings made at the factory allow all actions at the left to be made in ...

Page 76: ...SABLE SENSORS PROGRAM AND RUN MODES Personnel can now adjust sensors in Program mode only Locking Reset mode Setting Reset mode to Program only means personnel cannot reset DiPro in Run mode after a malfunction occurs that stops the press DiPro must be switched to Program mode to clear the fault message Pushing the Reset key in Program mode clears the fault The press can be run again once DiPro is...

Page 77: ...Using DiPro 1500 in Initialization mode DiPro 1500 User Manual 68 Ch 4 1092000 ...

Page 78: ...top the press when malfunctions occur You cannot run the press in Program mode That can be done only in Run mode Here is how you use the two modes In Program mode you can make settings for all your tools but you cannot run the press In Run mode you can run the press and make certain adjustments for the installed tool only The first display the programming menu To get into programming mode first ma...

Page 79: ... item and press ENTER Bringing up the display of sensors and selecting a sensor to set To bring up the display of sensors and select a sensor 1 Select Program load tool numbers from the first display in Program mode You will see the tool number display It will look like the one shown here with the word NEW in the first column and a list of tool numbers If no tool numbers have been created you will...

Page 80: ...RESET WHEN DONE 5 Select Set sensors You will see this display This is your list of sensors DIE PROTECTION SENSORS FOR TOOL 4400 USE CURSOR KEYS TO MAKE SELECTION PRESS ENTER TO SELECT PRESS RESET WHEN DONE SENSOR 1 SENSOR 2 SENSOR 3 SENSOR 4 SENSOR 5 SENSOR 6 SENSOR 1 6 You can select any sensor but it is a good idea to start with the first sensor Select sensor 1 which is already highlighted Afte...

Page 81: ...ess Setting sensor type After selecting the sensor name you will see this display You can set sensor type Notice that the sensor name now appears at the top right of the display This display shows part ejection DIPRO SENSOR 1 PART EJECTION NOT USED RED NC YELLOW NO GREEN GREEN QUICK CHECK QC GREEN CONSTANT CONS GREEN SPECIAL USE CURSOR KEYS TO CHANGE SELECTION PRESS ENTER TO SELECT RESET WHEN DONE...

Page 82: ...for a green sensor After selecting stop type for a green sensor you will see the display shown below You can set the ready on angle and ready off angle the ready signal The ready signal is the degrees of the stroke where the sensor must actuate or DiPro sends the stop signal to the press SENSOR 1 PART EJECTION GREEN USE THE ANGLE KEYS TO SET THE READY PRESS RESET WHEN DONE 0 90 180 270 360 0 0 ON ...

Page 83: ...ing the ready signal press RESET to go back to your list of sensors Setting counter value for green special sensor After setting the sensor type for a green special sensor you will see the following display You can set the maximum number of strokes that the press can make without this sensor actuating The preset limit is 99 Use your up or down v cursor keys to adjust the value Then press the reset...

Page 84: ...gain instead of choosing to make more settings you will see a display allowing you to load modify or delete the tool number If you press RESET again you go back to the Programming menu the first display in Program mode NOTE DiPro saves your settings automatically You do not have to push any key or issue any command to save settings NOTE When you change settings for a loaded tool number a display w...

Page 85: ...Chapter 6 Using DiPro 1500 in Run Mode Set Cams If you purchased the programmable cam switch option with your DiPro 1500 you can set cam timing DiPro must be in Program mode to set cam channels To set cam channels you need to Bring up the display of cam channels for the tool Select a channel and make an on off or timed output setting for the channel Set all other channels for the tool SELECT HIGHL...

Page 86: ...rent names Remember you can select your own names for cam channels in Initialization mode PART BLOW OFF FEED ADVANCE PILOT RELEASE SPRAY LUBE PROGRAMMABLE CAMS FOR TOOL 4400 USE CURSOR KEYS TO MAKE SELECTION PRESS ENTER TO SET PART BLOW OFF PRESS RESET WHEN DONE Selecting a channel and making an on off setting An on off setting means you set the stroke angle where you want the channel to come on a...

Page 87: ...gle where you want the channel to turn on and the time in milliseconds that you want the channel to stay on This means channel on time is independent of press speed With on off settings the on time decreases with press speed Timed output setting are recommended for controlling air lubricators etc Also when you use the timed setting the channel will turn off after the set time even if the press sto...

Page 88: ...like this the setings here are 270 on 250 mS on time TOOL 4400 PART BLOW OFF 0 90 180 270 360 USE THE ANGLE KEYS TO SET START ANGLE USE OFF ANGLE KEYS TO SET DURATION MSEC PRESS RESET WHEN DONE ANGLE 270 TIME 250 T250 time when channel comes on time channel stays on T and number move across screen when you press angle keys 6 Press RESET to go back to the list of channel names Setting other channel...

Page 89: ...r batch counter 1 Highlight the number under count you want to reset Press ENTER to select The counter goes to zero 2 Press RESET to go back to the previous display To reset the hits counter 1 Highlight the number displayed in the count column and press ENTER 2 You will see this message PRESS THE RIGHT ON KEY IF YOU REALLY WANT TO CLEAR THE TOTAL HITS COUNTER PRESS RESET IF YOU DO NOT Press the ri...

Page 90: ...ment a feed transfer mechanism lubricator etc may start if the press crankshaft is within the on off setting for that device All employees must stay away from the press and equipment that the cam operates before tool settings are loaded To load the settings for a tool number 1 Select Program load tool numbers from the programming menu the first display in programming mode To select highlight the i...

Page 91: ... and run the press Delete the tool information When you delete a tool number you remove it from the tool number display and from DiPro s memory All tool information will be lost To delete a tool number 1 Select Program load tool numbers from the programming menu first display in Program mode To select highlight the item and press enter 2 Select the tool number you want to delete from the tool numb...

Page 92: ...gramming menu the first display you see in programming mode on your screen Here is the display THE CURRENTLY LOADED TOOL IS 8600 USE CURSOR KEYS TO CHANGE SELECTIONS PRESS ENTER TO ACCESS TOOL NUMBERS SENSORS ENABLED DISABLE SENSORS PROGRAM LOAD TOOL NUMBERS The second line shows whether sensors are enabled or disabled The factory setting is enabled In the display shown above sensors are enabled 2...

Page 93: ...rs sensors or cams 1 Select Program load tool numbers from the first display in programming mode the programming menu to see the list of tool numbers already cre ated You will see the tool number display as shown here NEW 17 34 567 666 TOOL s 24 USED 176 AVAILABLE 6789 4400 4567 6666 8600 9656 24561 35650 65233 100000 250000 1150000 2150000 3456789 5500000 USE CURSOR KEYS TO CHANGE SELECTION PRESS...

Page 94: ...SET WHEN DONE PART EJECTION END OF STOCK OVERFEED OIL PRESSURE STOCK WIDTH MISFEED PILOT 1 PART EJECTION 2 To change a setting select the sensor you want to change Then modify set tings in the same way you originally made them See Making sensor settings for a tool earlier in this chapter You can change any setting for a sensor Or you can leave any setting the same by not changing the selection alr...

Page 95: ...y setting the same by not changing the selection already made 3 When you are done making changes display your list of cam channels then press RESET to see the display to select other settings counters sensors If you press RESET again you see the display allowing you to load modify or delete the tool number Press RESET once more and you go back to the first display in Programming mode Modifying cou...

Page 96: ... changes to red or yellow sensors since they have no timing settings Why some tasks are duplicated in each mode If you are wondering why certain tasks like loading a tool number and adjusting timing are duplicated in Run mode and Program mode here is why Sometimes you may not want personnel to get into Program mode So you keep DiPro in Run mode by setting the key to run and removing the key Now Pr...

Page 97: ...ed before DiPro will allow the press to run If you try to switch to Run mode without a tool number loaded you will get this error message on your screen NO TOOL NUMBER HAS BEEN LOADED If so turn the Program Run key to Program Press RESET to clear the error message Then load a tool number Now set the Program Run key to Run You will go into Run mode Important If you have a DiPro 1500 shipped prior t...

Page 98: ...S FOR TOOL 4440 ADJUST MODE LOCKED USE CURSOR KEYS TO MAKE SELECTION PRESS ENTER TO SELECT PRESS RESET WHEN DONE PART EJECTION END OF STOCK SHORT FEED OIL PRESSURE STOCK WIDTH MISFEED PILOT 1 PART EJECTION Indicates sensor settings are locked Adjust mode locked means you cannot adjust sensors You can display the sensors but nothing will happen when you press the keys to adjust the ready signal If ...

Page 99: ... see the above screen To disable sensors simply select Disable sensors You will see this display ENABLE SENSORS COUNTERS SHOW SENSORS ADJUST SENSORS ADJUST CAMS LOAD TOOL USE CURSOR KEYS TO MAKE SELECTION PRESS ENTER TO ACCESS SELECTION TOOL 6800 SENSORS ARE ENABLED 3 The second line at top left of the display shows that sensors are now disabled To enable settings again you simply select Enable se...

Page 100: ...f all your sensors at once You can use it while the press is running or stopped When you select Show sensors you see a display like this SENSOR STATUS 1 2 3 4 5 6 G GCON RED GQC YEL GS11 Ground block indicates sensor grounded Letter s indicates sensor type number indicates max strokes allowed for green special PRESS RESET WHEN DONE The display shows the status of every sensor for a loaded tool num...

Page 101: ...akes a stroke without the sensor activating the counter will count down to 10 If another strokes occurs without a sensor actuation the counter drops down to 9 and so forth When the sensor activates the counter automatically resets to 11 Unused sensors It is possible to see a ground block This may occur if you had a sensor connected to the input by mistake The display shows any change in an input s...

Page 102: ...RT EJECTION END OF STOCK SHORT FEED OIL PRESSURE STOCK WIDTH SLUG DETECTION PART EJECTION 3 Choose the sensor you want to adjust The display will show the sensor number name and type For green sensors it will show the ready signal and sensor actuation angle If you choose a yellow or red sensor settings will be displayed but you cannot make any changes 4 For green green quick check and green consta...

Page 103: ...or on off marker sensor on off shown in degrees This display is for a part ejection sensor The display shows the sensor turns on and off within the ready signal You can change the ready signal by lengthening or shortening the bar across the bottom using the angle on and off keys If you are unfamiliar with these keys see Angle keys in Chapter 3 Sensor on off marker Notice the sensor on off box at t...

Page 104: ...nsor and the latest off angle that is shows an increase in the actuation angle For sensors set to green constant it shows the latest on angle and earliest off angle shows a decrease in the actuation angle For instance if a green quick check sensor s on angle fluctuates between 190 and 195 from stroke to stroke DiPro would show 190 However if the on angle changed to 189 or lower DiPro would immedia...

Page 105: ...EASE SPRAY LUBE PROGRAMMABLE CAMS FOR TOOL 6800 USE CURSOR KEYS TO MAKE SELECTION PRESS ENTER TO SET PART BLOW OFF PRESS RESET WHEN DONE 2 Select the channel you want to change You adjust the on off time for the channel the same way you made settings in Program mode using the angle on and off keys If you are unfamiliar with these keys see Angle keys in Chapter 3 for complete instructions For instr...

Page 106: ...ool from the Run menu You will see the Tool Number Display 17 34 567 666 TOOL s 24 USED 176 AVAILABLE 6789 4400 4567 6666 8600 9656 24561 35650 65233 100000 250000 1150000 2150000 3456789 5500000 USE CURSOR KEYS TO CHANGE SELECTION PRESS ENTER TO SELECT RESET WHEN DONE The display is the same as in Program mode but you can only select an existing tool number You cannot select NEW to create a new t...

Page 107: ...ed You can always check which tool number is loaded on this display WARNING Equipment may operate when you load tool settings When you load a tool number both the DiPro settings and cam timing settings are loaded if you have the DiPro 1500 cam timing option installed When the cam timing settings are loaded auxiliary press equipment feed transfer mechanism lubricator etc may start if the press cran...

Page 108: ... the letters Err will blink in the LED display For most fault messages triggered by a sensor the angle where DiPro received the signal from the sensor is also listed in the LCD display If the press stops because the preset count is reached the letters ctr will blink on the LED How to clear the fault or error message from the display To resume operation after an error message occurs clear the error...

Page 109: ... on the remote connection box Remember if no sensor is connected to a sensor input that input must be set to unused Check connections be tween sensors and controller Sensor came on late SENSOR 3 sensor name LATE THIS GREEN SENSOR WENT ON AFTER ITS READY AT DEGREES Problem A green or green quick check turned on late That is it turned on within 50 milliseconds after the end of the ready signal If a ...

Page 110: ...nce a part wedged against a sensor or a pinched wire Green constant fault SENSOR 1 sensor name THIS GREEN CONSTANT SENSOR WENT OFF IN ITS READY AT DEGREES Problem A green constant sensor turned off during its ready signal Green constant sensors must stay on throughout the entire ready signal The angle where the sensor turned off is shown Remedy Check for the malfunction that the sensor was suppose...

Page 111: ...misfeed etc Check for a part wedged against the sensor a shorted sensor a pinched wire or other cause that would keep the sensor on or cause it to go on outside its ready signal Make sure the ready signal is set correctly Fault message for yellow sensors SENSOR 5 sensor name YELLOW FAULT THIS N O SENSOR HAS BEEN GROUNDED AT DEGREES Problem A yellow sensor turned on there was a contact closure to g...

Page 112: ...or detached wiring at the remote connection box or controller Check for a severed wire from the sensor to the RCB or controller Fault message for green special sensors SENSOR 5 SLUG DETECTION GREEN SPECIAL FAULT THE PRESS MADE 11 STROKES WITHOUT THIS SENSOR GOING ON this number varies depending upon the number set in Program mode Problem A green special sensor did not actuate within the maximum nu...

Page 113: ...u would need to change tooling material etc You can then run the press again NOTE When this message appears the good parts count is automatically reset to 0 Batch parts counter BATCH PARTS COUNTER PRESET REACHED Problem The count set for the batch counter has been reached The press should stop at top dead center Remedy Press RESET to clear the message You may need to empty or replace the parts con...

Page 114: ...entatives available to help you by phone Never hesitate to call Data Instruments if you have trouble with DiPro 1500 Once you have corrected the problem press RESET If the problem is corrected you will be able to run the press again If not you will get the same fault message Input failure INPUT CHECK CIRCUIT FAILURE THE RESOLVER TURNED FIVE TIMES WITHOUT INPUT CHECK BEING TURNED ON Problem The res...

Page 115: ...he press crankshaft is turning Also you may have low air pressure to the clutch or a bad clutch so the crankshaft and therefore the resolver did not move even though the clutch control valve has been activated An internal DiPro problem could also have occurred or the resolver could be defective Remedy Check resolver and resolver drive Check and repair clutch If these solutions do not work an inter...

Page 116: ...resolver drive has slipped or broken It is also possible that the position sensor may not have enough dwell to close totally at high RPM s See Figure 2 15 in Chapter 2 for a discussion of this problem Also the resolver or position sensor may be defective or not installed properly Check the wiring and installation of the resolver and position sensor See the installation procedures in Chapter 2 If t...

Page 117: ...lver wiring and connections for shorts breaks or loose connections See Chapter 2 Mounting the resolver for complete information about resolver wiring If the wiring is not the problem the resolver is probably bad and will have to be replaced NOTE This fault cannot be cleared by pressing the RESET key You must turn DiPro off then on to clear the fault Tool number checksum incorrect TOOL NUMBER CHECK...

Page 118: ...After the game he counts everybody who gets on the bus He does not leave until he counts the same number getting on as got off the checksums must match Remedy The checksums may not match if DiPro 1500 is turned off while in the middle of programming or adjusting settings for a tool It will also happen if the stored tool number settings get damaged due to an internal DiPro malfunction If the proble...

Page 119: ...DiPro 1500 Fault messages DiPro 1500 User Manual 110 Ch 7 1092000 This page intentionally left blank ...

Page 120: ...1 for mounting dimensions 3 Prop DiPro near the location where it will ultimately be mounted see Figure A 1 You can do this by connecting ty wraps from two of the left holes on the panel to the corresponding holes on the enclosure for a hinge like effect Allow up to 9 of service loop when performing the wiring connections Also make sure all cables will reach 4 Refer to Chapter 2 of the DiPro 1500 ...

Page 121: ...DiPro 1500 Panel Mount DiPro 1500 User Manual 112 Appendix A 1092000 Figure A 1 Mounting and cutout dimensions for DiPro 1500 panel and your enclosure ...

Page 122: ...cuit 28 enable sensors 83 90 E Enter key 60 Entering a number 56 error message 99 F Fault message for green special sensors 103 Fault message for red sensors 103 Fault message for yellow sensors 102 fault messages 99 Green constant fault 101 Green quick check sensor came on outside ready 102 green special fault 103 Input failure 105 Loss of rotation 106 No tool number loaded 106 Position sensor in...

Page 123: ...panel enclosure 111 N NEMA 12 protection 30 31 new tool number 70 normally closed 9 normally open 9 number 56 O off angle 95 on angle 95 on off setting 77 operation DiPro 3 P PACNet 14 16 63 panel mount 111 pointer 56 position sensor 21 43 62 power supply cover 28 preset 104 Program load tool numbers 70 Program run key 2 programmable cam switch 8 programming menu Disable sensors 83 Program load to...

Page 124: ...a sensor 70 set more sensors 75 set sensor type 72 set stop type 72 set the ready signal 73 setting counter for green special 74 setting ready off 59 setting ready on 58 setting sensor type 72 setting stop type 72 setting the ready signal 73 settings 7 settings locked 89 setup mode disable circuit 25 90 show sensors 91 specifications 14 suppressors 36 39 T theory of operation 3 tool number 7 70 76...

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