Toledo Transducers Press Pilot 150 Istruzioni per l'installazione e il funzionamento

Toledo Integrated Sy

ems

Toledo Transducers Inc.

Press Pilot 150

Manual

And

Installation guide

Doc# 16302

Press Pilot 150 Manual

Page 1

Article I. Limited Warranty

The software and sensors are warranted by the manufacturer, Toledo

Integrated Systems, to be free from defects in workmanship for one

year from the date of manufacturer’s shipment. This warranty is

limited to the functions of the Press Pilot 150 as stated in this

manual. If modifications are made to the software, Toledo Integrated

Systems will not be responsible for the Press Pilot 150.

All products subject to this warranty must be returned for

examination, repair or replacement to:

F.O.B. Toledo Integrated Systems

6834 Spring Valley Dr.

Holland, OH 43528

The

express warranty

set forth herein is in lieu of all other

warranties, expressed

implied, including without limitation

any

warranties

merchant-ability

fitness

for

particular

purpose. All

such

warranties

are

hereby disclaimed

and

excluded

by the

manufacturer.

Repair or replacement of defective products as provided above is the

sole and exclusive remedy provided there under. The manufacturer

shall not be liable for any further loss, damages, or expenses,

including incidental or consequential damages, directly or indirectly

arising from the sale or use of this product. This includes any

failure inside other manufacturers’ units that the Press Pilot 150 is

tied into.

Any unauthorized repairs or changes to the program will void this

warranty.

There are no warranties that extend beyond those expressly set forth

herein.

Doc# 16302

Press Pilot 150 Manual

Page 2

Doc# 16302

Press Pilot 150 Manual

Page 3

Prompts/Faults

...............................

ii.

Brake Monitor.................................

iii.

Last Brake Test...............................

iv.

Prox

fo ........................................

Most Recent Fault...........................

vi.

Fault

................................

vii.

Two Faults Ago ...............................

viii.

Programmable outputs……………..……

ix.

Last stop reason……………………..……

Counters

........................................

Table of Contents

Revision

story

.............................................. 6

1 Incoming Power

Connections

............................

2 User Inputs

run/inch butto

.............................

ii.

Prox Check

Input.............................

iii.

FAULT Reset Button – LCD

Refresh ..

iv.

Arm Continuous Button ...................

Mode Selector Switch .....................

vi.

Top Stop

Button..............................

VII.

Clutch Air Switch/Counterbalance

Switch ………………………………………….

VIII.

Main Motor Forward

Contac

t ...........

IX.

Immediate Stop Input........................

ESR-1 and

ESR-2.............................

XI.

Resolver/Encoder

Inputs

.................

XII.

Clutch Sol. Valve Flt

Monitor

.........

XIII.

Bcam and Tcam ................................

3 User Outputs

Clutch

1&2

.....................................

ii.

Clutch

Fault

...................................

iii.

Clutch OK.......................................

iv.

Continuous

Armed

...........................

Clutch On to Aux Equipment ............

vi.

Binary Fault Outputs.......................

4 Screens

Screen Navigation Map ........................... 16

Doc# 16302

Press Pilot 150 Manual

Page 4

5 Configuration Screens

Position

Control

.............................

ii.

Resolver

Offset

..............................

iii.

Cam

Settings

...................................

iv.

Press Speed....................................

Arm Continuous 1............................

vi.

Arm Continuous 2............................

vii.

LC Mute/Top-stop.............................

viii.

Speed Comp Top 1............................

ix.

Speed Comp Top 2............................

Misc. Timers ....................................

xi.

Brake Test 1 ...................................

xii.

Brake Test 2 ...................................

xiii.

Led

Display

.....................................

xiv.

Lifetime Counter..............................

xv.

Save Restore ..................................

xvi.

Prox

setup

......................................

Troubleshooting ...........................................

i. Fault Displays and Corrective

Action

............................................ 33

ii. Input Diagnostic

Screens

.................

iii. Resolver wiri

...............................

iv. Resolver Dip

Switching……………………45

7 Start-up

Procedure.......................................

8 Start-up Checklist

........................................

9 Configuration Settings

i. Configuration

Datasheet………………..50

ii. Speed Comp Top Stop Zone

Settings

iii. Board replacement parts

info

..........

10 PP150E E-Net/IP RSLogix 5000 Setup............ 54

11 PP150E E-Net/IP I/O

Mapping

......................... 64

12 PP150E E-Net/IP Ladder

Examples

................. 70

Doc# 16302

Press Pilot 150 Manual

Page 5

13 PP150E E-Net/IP EDS

Install

tion

................. 72

14 PP150E E-Net/IP PP150

settings

................... 76

15 Auto Single/Continuous on Demand................ 77

16 Hydraulic Overload

Monitor

..................... 78

17 Programmable

Outputs

..................................

18 mute LC on upstroke with encoder setup ………83

19 PP150 screen menus

..................................

100

20 Schematics ...........................................101-109

IO Wiring Pg

.............................................

101

IO Wiring Pg 1(with

Footswitch)....................

102

IO Wiring Pg

.............................................

103

PP150

Dimensions.......................................

104

Flush Mount

Cutout....................................

105

Flush Mount

Dimensions

.............................. 106

Remote LCD Cutout

.....................................

107

Remote LCD Wiring

......................................

108

Remote Proface Screen Cutout

Dimensions

... 109

21 PP150 Ethernet remote

screen

.....................

110

Doc# 16302

Press Pilot 150 Manual

Page 6

PP150 Firmware revision history

(Current Rev. 3032)

Rev.# Modification Notes

2023 initial release

2024 addition of Ethernet

2025 de-bounce mode input

-Bypass all faults during watchdog check on powerup

-Brake monitor test mode and main motor fwd added to

Ethernet i/o table

2026 added ability to bypass motion detect in inch mode

-Modified Saving/Recalling Parameters

2027 Ethernet communications speed upgrade

2028 (never released)

2029 added clutch engagement fault

2030 modified logic for clutch on no motion fault

2031 modified z-pulse (encoders use only)

2043 Speed Comp Zone Settings

-Auto Single and Cont. on Demand

-Modified Resolver Resolution for SPM/Top Stop Calc.

2044 Modified Encoder Brake Monitor

2045 Added T-Cam Off to Ethernet settings

2047 Changed Clutch Motion Timer (Never Released)

2048 Added Hydraulic Overload Monitoring

2051 Added “Excessive Stop Time” Fault

2054 Added 2 Programmable Outputs

-Added PLS, motion detect bit and spm to Ethernet

-Modified Hyd. OL to include Pumping

2056 Added functionality to counters

2060 added prompt..”must inch 1st stroke”.

2061 modified t-cam off to be speed comp default stop.

2062 modified multiple run bar check.

2063 modified auto-single to unarm if t-stop is push and

clutch is still on.

2064 added count to the remote display.

2065 allow count to reset always from reset button,

(uncheck mute & 10ms bm time (defaults)), add screen after save

chgs.

2067 major release..modified the speed comp top stop..added last

stop reason to enet (word 18 in plc).

3000 new version (3.00) for remote screen implementation.

3003 major release..Modified last stop reason.

3006 modifications for proface screen not saving data

3007 modified bm to store actual test spm….changed so it saves

everytime you leave config screen

3008 added complete interrupt vector table to eliminate reboots that

occur due to spurious interrupts

3009 modified encoder spm calculation

3011 modified auto single/cont on demand armed logic

3012 improved checksum method for the battery ram data

3014 fixed cam single stroke not stopping at top

Doc# 16302

Press Pilot 150 Manual

Page 7

3016 fixed when inch top stop is used with speed compensation

3017 auto single timeout min to 1sec-fix pls faulting data flash

3018 cont arm not arming, change toenet so it saves to data flash

3019 z-pulse only in window…delay spm on display…always compute

speed compoff

3020 not released

3021 inch stop attop fixed, tcamoff only save if screen over enet,

counters only with screen, extended clutch no motion timer

3022 modified pls save tosave after they leave the pls screen

3023 modified the clutch on and nomotion fault timer

3024 Modified the I/O Board Replacements Parts Info

3027 Z-Pulse Mute on upstroke programming

3028 Arm Auto Single Stroke bug fix

3029 Digital filter for Resolver Position

3030 Clutch engagement fix for single stroke mode w/light

curtain mute

3031 Fix for irregular stopping when speed comp is used with an

early stop position

3032 Digital filter for encoder Z-Pulse signal near reset position.

Doc# 16302

Press Pilot 150 Manual

Page 8

1 Incoming Power Connections

L1 and L2 – Incoming 120 VAC

The customer supplied120VAC power must be from a clean

and continuous source. The PP150 has its own internal

+24VDC power supply for all I/O applications. This DC

power should only be used for I/O on the Press Pilot, and

is limited to 1Amp service.

2 User Inputs

I. Run/Inch Buttons

The system requires one set of two Run/Inch Buttons in

order to function, and is expandable up to four sets. Each

button must have a set of normally open and normally

closed contacts. The inputs into the PP150 are labeled “L-

RUN(x) NO/NC” and “R-RUN(x) NC/NO” where ‘x’ is the

station number of the run buttons, NC stands for

Normally closed, and NO stands for normally open. Anti-

tie down has been built into the system in order to inhibit

the ability to “tie down” one or both of the run buttons. An

anti-tie down fault will occur within 500ms (milliseconds)

of an incorrect contact state on the run buttons. This

fault is automatically reset when an anti-tie down situation

is cleared.

II. Prox Check Input

The system requires a proximity switch to check position in a

settable window throughout each stroke. The proximity

switch must be mounted separately from the

resolver/encoder in order to account for chain break or

slippage on the press position device. A fault will be

generated if the prox switch cycles twice without seeing the

BCAM or TCAM change state. A fault will also be generated

if the prox switch does not cycle inside the window.

III. Fault Reset Button

The PP150 Reset Button will reset any current PP150

fault when pressed. This button needs to have one

normally open contact sending a signal to the “FAUL RST”

input on the PP150.

IV. Arm Continuous Button

The system requires the use of a Prior Action “Continuous

Arm” Button and should be equipped with a normally open

contact sending a signal to the “arm cont” input on the

PP150. When the mode selector switch is in continuous

mode and this button is pressed, “Continuous” will be

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