Toledo PWi Forging User manual
17664
PWi Forging
Tonnage Monitor
By Toledo Integrated Systems
User’s Manual
PWi Forging User’s Manual
Doc #17663 Rev A Page
Toledo Integrated Systems
2
Table of Contents
1
1:
:
Installation ........................................................................................................... 5
Limited Warranty............................................................................................................................5
Features Overview..........................................................................................................................6
Specifications..................................................................................................................................7
Mounting the PWi Forging – Standard Installation........................................................................9
Mounting the PWi Forging – Flush Mount Option ......................................................................10
PWi Forging Components.............................................................................................................11
Conduit Hole Selection.................................................................................................................12
AC Power Connection and Configuration....................................................................................13
DC Power Connection ..................................................................................................................14
Sensor Input Configuration...........................................................................................................15
Load Sensor Connection...............................................................................................................16
Sensor Cable Termination ............................................................................................................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 Configuration Mode....................................................................................28
The Security Code Feature ...........................................................................................................29
The Low Battery Indicator............................................................................................................30
Replacing the Backup Battery ......................................................................................................31
Operation Mode - Overview.........................................................................................................32
Operation Mode - Description......................................................................................................33
Home Menu...............................................................................................................................33
Signature Menu.........................................................................................................................35
Setpoint Menu ...........................................................................................................................39
Alarm Menu ..............................................................................................................................41
Reverse Menu............................................................................................................................42
Statistics Menu..........................................................................................................................43
Job Menu...................................................................................................................................45
Station Menu.............................................................................................................................46
Security Code Menu (Operation mode)....................................................................................47
Configuration Mode - Overview...................................................................................................50
Configuration Mode - Description................................................................................................51
Channel Menu...........................................................................................................................51
Decimal Point Menu.................................................................................................................52
Capacity Menu..........................................................................................................................53
Trigger Menu............................................................................................................................54
PWi Forging User’s Manual
Doc #17663 Rev A Page
Toledo Integrated Systems
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Threshold Menu........................................................................................................................ 55
Learn Menu .............................................................................................................................. 56
Delay Menu .............................................................................................................................. 57
Offset 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:
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Calibration Procedure......................................................................................69
4
4:
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Calibration Information Label........................................................................73
5
5:
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Operator’s Guide..............................................................................................75
6
6:
:
Appendix............................................................................................................77
I)Sensor Installation (Doc# 11080).......................................................................................... 77
II)Calibration Sheets (Form# 1224)....................................................................................... 77
PWi Forging User’s Manual
Doc #17663 Rev A Page
Toledo Integrated Systems
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Table of Figures
Figure 1.1: Standard Mounting Dimensions....................................................................................9
Figure 1.2: Flush Mount Mounting Dimensions ...........................................................................10
Figure 1.3: PWi Forging Components...........................................................................................11
Figure 1.4: Conduit Hole Selection ...............................................................................................12
Figure 1.5: AC Power Connection and Jumper 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
Figure 1.11: Analog Output Wiring.................................................................................................19
Figure 1.12: Probe Input Wiring......................................................................................................20
Figure 1.13: Probe Timing...............................................................................................................21
Figure 1.14: External Reset Switch Wiring.....................................................................................22
Figure 1.15: Serial Connection........................................................................................................23
Figure 1.16: RS232 Serial Port Wiring............................................................................................24
Figure 1.17: RS422 Serial Network Wiring ....................................................................................24
Figure 1.18: Shutdown Relay Wiring..............................................................................................25
PWi Forging User’s Manual
Doc #17663 Rev A Page
Toledo Integrated Systems
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1
1:
:
Installation
Limited Warranty
This unit is warranted by the manufacturer, Toledo Transducers, Inc., to be free of
defects in workmanship and materials for one year from date of manufacturer’s
shipment. This warranty is limited to repairing or replacing products which
manufacturer’s investigation shows were defective at the time of shipment by the
manufacturer.
All products subject to this warranty must be returned for examination, repair or
replacement
F.O.B. to: Toledo Transducers, 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 merchant-ability or
fitness for a 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 thereunder. 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.
Any unauthorized repair voids this warranty.
There are no warranties that extend beyond those expressly set forth herein.
PWi Forging User’s Manual
Doc #17663 Rev A Page
Toledo Integrated Systems
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Features Overview
The PWi Forging is a full-featured load monitor that interfaces with load sensors to provide force
measurement for press protection and quality control. Unlike traditional tonnage monitors, the
PWi Forging monitor is designed for the specific needs of forging applications. The total press
load is displayed on high-visibility 7-segment 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 also used to show deviation, alarm data,
settings, and much more.
FEATURES
4 channel load monitoring 2 shutdown relays (Top-Stop and E-Stop)
Reverse load 100 job storage
LCD graphic display with back-lighting One RS422 serial port
5-digit LED display for each channel PressNet Software compatible
Menu-driven user interface Compact dust-proof enclosure
Load signatures
OPTIONS
24VDC power input Mounting bracket for angle viewing
PWi Forging User’s Manual
Doc #17663 Rev A Page
Toledo Integrated Systems
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Specifications
Load Input No. of Channels Four standard (Two optional)
Sensor Inputs Full bridge strain gage sensors
120 to 1,000 ohms
Up to (8) 350 ohm sensors
Sensor Excitation Built-in 12VDC @ 300mA max
(Short circuit protected)
Sensor Input Connections 5-pin .15" pitch Phoenix connector
Balance Adjustment 25-turn potentiometer
Balance Range +/- 1mV/V of offset
Gain Adjustment 25-turn potentiometer
Gain Range Low Gain = 50 to 550 times
High Gain = 500 to 5,500 times
Analog Output 1.25VDC @ Press Capacity
Analog Output Connection 9-pin sub-D connector
Inaccuracy +/- 1% of full scale max
Non-linearity +/- .1% of full scale max
Frequency 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 with threshold trigger
Up to 2,000 SPM with probe trigger
User Interface Display Back-lit 1.5”x2.75” LCD graphical display (64x128 pixel)
(5) LED displays, each consisting of five 7-segment displays
Keypad Menu-driven keypad consisting of six tactile switches
Computer Serial Port 1 RS422 (9,600 to 115,200 baud) for PressNet software interface
Interface Serial Port 2 & 3 (Optional) RS422 (9,600 to 115,200 baud) for data transfer
Probe Input Built-in voltage source (12VDC, 50 mA max) provides power
for the probe. It supports NPN or PNP proximity probes, and
solid state or dry contact relay.
Shutdown Top Stop relay and Mechanical relay with N.O. and N.C. contacts
Relays E-Stop relay 8 AMP @ 250VAC or 30VDC
PWi Forging User’s Manual
Doc #17663 Rev A Page
Toledo Integrated Systems
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Supply Power Requirements 30 Watts max
(AC units) 85-132VAC @ 50-60Hz or
170-264VAC @ 50-60Hz
Power Input is jumper selectable
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 Nonvolatile Data Flash
Live data
(Counters, peak load) 3V Lithium Battery – Type CR-1/3N
Operating 0 to 70 degrees Celsius
Temperature
Dimensions 8.90" W x 6.88" H x 5.00" D, or
226mm W x 175mm H x 127mm D
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