ALFAMATIC Press-Right Manuale utente

Issue 2 - October 11, 2021

I N S T A L L A T I O N M A N U A L

PRESS-RIGHT

equipped with a VIO10 board

•Installation manual

2 Press Right installation

Press Right installation 3

1Press-Right Installation......................................................................................... 4

1.1 Important notes for installation ..................................................................................4

1.2 Instrument operation.................................................................................................4

1.3 The internal boards...................................................................................................5

1.4 Electric Wiring...........................................................................................................5

2Particular functions ............................................................................................. 15

2.1 Configure the job automatic selection......................................................................15

2.2 Connecting an external reset ..................................................................................15

2.3 Additional controls...................................................................................................15

3Instructions to install Press-Right........................................................................ 17

4Mounting the transducers ................................................................................... 21

4 Press Right installation

1 Press-Right Installation

This chapter explains the steps required to install and connect Press-Right to the

equipment and make prepare it for operation.

The Press-Right instrument is designed to work on its own or in combination with a PLC

(see important information in paragraph 1.4.1).

For operation, the Press-Right instrument must be connected to a PLC via a number of

input and output signals. In addition to it, the instrument must be connected to a force

transducer (typically a load cell) and a position transducer (incremental encoder,

potentiometer or transducer with analogue output).

The load cell and the encoder or the potentiometer are powered by the instrument. The

instrument also includes also the amplifiers which are necessary to condition signals from

the transducers.

Press-Right is supplied with serial ModbusTCP and it can be ordered with a PROFINET or

EthernetIP interface.

1.1 Important notes for installation

This manual refers only to the instrument equipped with a VIO10 expansion card.

Press-Right must be powered at 24VDC. It is possible to obtain an optional

internal power supply that allows the direct connection to the mains.

This instrument is not (and could not be used as) a safety device: the descent of

the press must be governed by elements which are external to it. The instrument

simply synchronizes the descent of the press to its operation.

It is very important that the end of the unshielded load cell cable is as short as

possible

When the instrument is equipped with motors, motors must be equipped with a

noise reducing filter and it must be operated by semiconductor devices.

Always connect the instrument container to a earth conductor.

1.2 Instrument operation

Caution: Press-right is not (and could not be used as) a safety device: the descent

of the press must be governed by elements which are external to it. The instrument

synchronizes the descent to its operation. Usually, the GO output must be

connected in series to the cylinder descent chain. In a nutshell, if the instrument

activates the GO enabling output, the cylinder must not descent if it is not safe.

The operation takes place in the following way: when the instrument START input is

operated an external command, Press-Right activates the GO cylinder descent output, if it

is ready and all ENABLE inputs are active. When the GO signal is active, the cylinder must

continue until the instrument deactivates the signal.

Press Right installation 5

When the GO output is active and the instrument touches the piece, the instrument

activates the BOOSTER output.

Based on the stop parameters achieved (quota, strength, etc.), Press-Right deactivates

the GO signal.

After deactivating the GO signal, the instrument continues the monitor the curve until either

the force and the quota begin to decrease, and the cylinder retracts. The piece it classified

as either good or scrap.

If the piece is good, the GOOD output is activated. On the other hand, if the piece is scrap,

the REJECTED output is activated.

The proper encoder zeroing occurs using its zero notch and the T.D.C. cylinder retracted

signal

1.3 The internal boards

Press-Right consists of two circuit boards:

front PR1MB1 mounts a display, a keyboard and a main CPU.

input and output VIO10 Input and output signals, and transducers are connected to this

board.

All boards are manufactured by us.

1.4 Electric Wiring

The following information is used to perform the instrument electrical wiring.

1.4.1 Connect an external controller (PLC)

The PLC connected to Press-Right must be a PNP logic type. The instrument inputs and

outputs are isolated and protected, and as a result they do not need any interface relay.

Signals which are essential for operation are START, GO, GOOD and REJECTED.

Remember that, in all cases, it is always necessary to connect the instrument T.D.C. input.

The T.D.C. signal can be taken directly from a limit switch operated when the press is in

rest position. However, almost every time the press rest signal also serves the PLC; in this

case the signal to be transmitted to the instrument can be taken in parallel to the one that

is transmitted to the PLC.

1.4.2 VIO10 board wiring

Note: this information applies only to the VIO10 board. Make sure the board is exactly this

version.

6 Press Right installation

The wiring relies on several numbered removable terminal boards (X3, X4, X16...). Each

terminal in each terminal board is numbered. The seventh terminal of the X18 terminal

board will be called X18.7. The numbering of the terminal board is also shown on the

board.

Figure 1

Main power supply terminal board (X24)

The electronic part of Press Right and the transducers are powered by 24VDC current via

the three-pole X24 terminal board.

Name

Function

Terminal

0VDC:

Negative power supply cable

X24.1

Grounding

X24.2

+24 Vdc

Positive power supply cable

X24.3

If the internal power supply is present, the switch behind the instrument must interrupt the

phase and the neutral before reaching the transformer. The power supply output is

connected to the X24 terminal board X24.

Press Right installation 7

Input terminal board (X3 and X17)

Inputs are isolated and are compatible with clean contact signals or with 24VDC PNP

transistor output. The X17 input terminal board is optional.

Name

Terminal

Default

Input 0

X3.1

START

Input 8

X3.2

Input 1

X3.3

T.D.C.(1)

Input 9

X3.4

Input 2

X3.5

Input 3

X3.6

Input 4

X3.7

Input 5

X3.8

Input 6

X3.9

Input 7

X3.10

0VDC:

X3.11

Power supply ground

+24 Vdc

X3.12

Positive power supply cable

(1) The T.D.C. input must always be Input 1.

Name

Terminal

Default

Input 10

X17.7

Input 11

X17.8

Input 12

X17.9

Input 13

X17.10

Input 14

X17.11

0VDC

X17.12

8 Press Right installation

The function of each input may be set up. Each input can have one of the following

functions:

Name

Preferred

input

Function

START

Request to start a new cycle. If removed, the acquisition is interrupted.

T.D.C.(1)

The "upper dead point" signal, used as a reset signal for a new cycle and

in "AND" with the encoder zero point for the "zero" of the absolute

dimensions

JOB SELECTOR

These inputs are used to select a job with their binary combination (see

2.1.1).

PHASE SELECTOR

These inputs are used to select a job phase with their binary combination.

BASKET 1

Sensor for normal scrap baskets

BASKET 2

Sensor for special scrap baskets

BASKET AUTO-CHECK

Sensor for self-test sample baskets

RESET

Re-enables the device after a scrap

SESPEND ACQUIRE

It suspends the acquisition of the useful curve on hydraulic or electric

presses, in case of incomplete cycle

ENABLE #

See 2.3

TEST SIGNAL #

#1=4

See 2.3

BOOSTER CYL BACK

Used to repeat a cycle

BOOSTER CYL END

Used to repeat a cycle

MAINTENANCE

Disables all commands

TABLE IN POS

Manual slide signal in operating position

IMPULSIVE START

Left=6

Right=7

Request to start a new cycle

NO EMERGENCY

No emergency commands

SAFETY

Safe machine operation (protections closed)

DRIVER ATIVATE

Active Driver (electric press)

IN POSITION

Position reached (electric press)

(1) The T.D.C. input must always be Input 1 and, therefore, clamp X3.3.

Press Right installation 9

Output terminal board (X4 and X17)

Outputs for 24VDC utilities. For inductive loads, such as valves and the relay coils,

mounting a diode in parallel is necessary to prevent surges. All the X17 terminal board and

output 8 of the X4 terminal board are optional.

Name

Terminal

Default

Output 0

X4.1

GOOD

X4.2

Power supply ground

Output 1

X4.3

REJECTED 1

Output 8

X4.4

Output 2

X4.5

Output 3

X4.6

PROTECTION

Output 4

X4.7

Output 5

X4.8

Output 6

X4.9

Output 7

X4.10

Name

Terminal

Default

Output 9

X17.1

Output 10

X17.2

Output 11

X17.3

Output 12

X17.4

Output 13

X17.5

Output 14

X17.6

10 Press Right installation

The function of each output may be set up. Each output can have one of the following

functions:

Name

Default

Function

GOOD

Good piece signal Active after the return of the cylinder, until the

following start.

REJECTED 1

Normal scrap signal

REJECTED 2

Special scrap signal

REJECTED AUTO-CHECK

Sample scrap signal used during self-test

Press permission. Active after start, if the device is ready and turned off

when the stop value is reached.

DOOR

Protection block command

BUZZER

Buzzer command.

TEST OUTPUT

Activation signal for TEST SIGNAL 1 See 2.3

CONTACT/BOOSTER

Piece contact signal and start of power phase. Note: this signal is only

activated if the T.D.C. signal is absent

CHECK POINT OUT #

Output activated at a programmable portion (maximum 3 outputs)

PHASE BIT 0

Active during phase 2 and 4

PHASE BIT 1

Active during phase 3 and 4

MANUAL

Active when a job not included in the list of available jobs, is run

BRAKE

Output for shock absorber command

ENABLE RETURN

Consents the return of the active cylinder where a good piece is detected

or after reset

ENABLE MANUAL

Command for mechanical press lever electric block

OPEN GREEN BOX

Command to open good piece basket

CLOSE PK TANK

Command to close the tank on PK model thrust units

BLOCK OF THE TABLE

Command to block the manual slide

PULL LEVER

Cylinder command to help cylinder return (for heavy tools)

RESET DRIVER

Driver reset fault (electric press)

ENABLE DRIVER

Enables driver (electric press)

Transducer terminal board (X12)

An incremental encoder, a potentiometer or an analog output encoder may be connected

to the X12 terminal board.

On this terminal board, it is also possible to supply power to the transducers. The encoder

requires a 12VDC (J3A*) or 5VDC (J3B) power supply voltage. The potentiometer requires

a high-precision 10VDC supply voltage.

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