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PWi Forging User’s Manual

Doc #17663 Rev A Page

Toledo Integrated Systems

Sensor Cable Termination

Strip the sensor cable as shown in the figure below. Be sure not to nick any of the signal
conductors or cut the braid shield.

Figure 1.9: Sensor Cable Stripping

Strip approximately ¼" of insulation from each of the four signal conductors.

Trim braid shield so that it is ¼" to ½" shorter than the signal wires.

Note:

If your sensor cable is not double shielded with both foil and a braid, electrical noise may
affect your output readings.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Страница 86: ...ole as in Step 3 Orient the fixture as shown STEP 5 Weld the weld pads to the press member BE SURE TO ONLY WELD THE WELD PADS ON THREE SIDES AS SHOWN A single pass is sufficient Do not remove the fixt...

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

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