Toledo Transducers Press Pilot 150 Manual And Installation Manual
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Toledo Transducers Press Pilot 150 Manual And Installation Manual

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Toledo Integrated Systems
Toledo Transducers Inc.
Press Pilot 150
Manual
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Installation guide

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Summary of Contents for Toledo Transducers Press Pilot 150

  • Page 1 Toledo Integrated Systems Toledo Transducers Inc. Press Pilot 150 Manual Installation guide...
  • Page 3 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.
  • Page 4 Doc# 16302 Press Pilot 150 Manual Page 2...

  • Page 5: Table Of Contents

    Brake Monitor......... iii. Last Brake Test....... iv. Prox Info ........v. Most Recent Fault......vi. Previous Fault ........ vii. Two Faults Ago ....... viii. Programmable outputs……………..…… ix. Last stop reason……………………..…… x. Counters ........Doc# 16302 Press Pilot 150 Manual Page 3...
  • Page 6 Configuration Datasheet………………..50 ii. Speed Comp Top Stop Zone Settings . iii. Board replacement parts info ..PP150E E-Net/IP RSLogix 5000 Setup.... PP150E E-Net/IP I/O Mapping ......PP150E E-Net/IP Ladder Examples ....Doc# 16302 Press Pilot 150 Manual Page 4...
  • Page 7 IO Wiring Pg 2 ..........PP150 Dimensions........Flush Mount Cutout........Flush Mount Dimensions ......Remote LCD Cutout ........Remote LCD Wiring ........Remote Proface Screen Cutout Dimensions ... PP150 Ethernet remote screen ..... Doc# 16302 Press Pilot 150 Manual Page 5...

  • Page 8: Revision History

    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 6...
  • Page 9 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 7...

  • Page 10: Incoming Power Connections

    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 Doc# 16302 Press Pilot 150 Manual Page 8...

  • Page 11: Mode Selector Switch

    “Top Stopj” is not a top stop device input. If the auxiliary top stop terminal block “Top Stopj” is used, it must be wired in series with the “Top Doc# 16302 Press Pilot 150 Manual Page 9...

  • Page 12: Viii. Main Motor Forward Contact

    PP150 reset button must be pushed, and then both circuits must be turned back on. Press the clutch reset button again to make sure no faults exist. Doc# 16302 Press Pilot 150 Manual Page 10...
  • Page 13 This fault can only be reset if the input is on. (Wire this input “on” if the solenoid valve does not have a fault contact) Doc# 16302 Press Pilot 150 Manual Page 11...
  • Page 14 Bcam has turned on after a top stop has been commanded. Bcam should turn off at the bottom of the stroke, but after Tcam has turned on. Doc# 16302 Press Pilot 150 Manual Page 12...
  • Page 15 PP150 will stroke the press to top in Single stroke mode, or continue to stroke in Continuous mode. Adjust Tcam off to stop the press at top dead center. Doc# 16302 Press Pilot 150 Manual Page 13...

  • Page 16: User Outputs

    It can be used to tell auxiliary equipment that the clutch is engaged. These are dry contacts so any AC or DC power 250V, 6A rated or less can be used. Doc# 16302 Press Pilot 150 Manual Page 14...

  • Page 17: Binary Fault Outputs

    M0 Message Bit 0 = 1 M1 Message Bit 1 = 2 M2 Message Bit 2 = 4 M3 Message Bit 3 = 8 M4 Message Bit 4 = 16 M5 Message Bit 5 = 32 Doc# 16302 Press Pilot 150 Manual Page 15...

  • Page 18: Screen Navigation Map

    PRESS PILOT 150 SCREENS The pp150 screens have moved to sheet 100. Doc# 16302 Press Pilot 150 Manual Page 16...

  • Page 19: Prompts/Faults

    Limit is the user settable time at which the Brake Monitor will fault out if the Stop Time has surpassed the Stop Limit. these numbers are not changeable on this screen. See Chapter 5 Section XI for setting the brake monitor. Doc# 16302 Press Pilot 150 Manual Page 17...

  • Page 20: Last Brake Test

    Once a new fault has occurred, the new fault will show on this page, and the fault that was on this page will move to the Previous Fault screen. See chapter 5 for fault messages and troubleshooting. Doc# 16302 Press Pilot 150 Manual Page 18...

  • Page 21: Previous Fault

    170° and off at 190° (typical pilot release example). The second example shows the second output turning on at 270° and turning off at 90° (typical feed window). Doc# 16302 Press Pilot 150 Manual Page 19...

  • Page 22: Last Stop Reason

    Fault Present, Check History 90 Degree Stop Test Counters Done E-Stop Opened Run Buttons Released Main Motor Forward Input Off Auto-Run Input Off Auto Enable Input Off Fault Reset PB Diagnostic Dip Switch Changed Doc# 16302 Press Pilot 150 Manual Page 20...

  • Page 23: Counters

    LIFETIME This counter shows the amount of strokes since the PP150 was installed. This counter is able to be reset from the Counters screen via the Calibration m Doc# 16302 Press Pilot 150 Manual Page 21...

  • Page 24: Configuration Screens

    1700 Strokes Per Minute. The Encoder based system can run up to 500 Strokes Per Minute, and the Cam based system can run up to 300 Strokes Per Minute. Doc# 16302 Press Pilot 150 Manual Page 22...

  • Page 25: Resolver Offset

    See the graph in Chapter 2 Section XIII for typical Cam settings. To change the cam settings, press the right set of Up/Down keys to scroll to the cam settings to change, and press key. Doc# 16302 Press Pilot 150 Manual Page 23...

  • Page 26: Press Speed

    Tcam off and Bcam on. Window lets the user define a window that the press needs to be in before it can be continuous armed. This window can be set on the Arm Continuous 2 screen. Doc# 16302 Press Pilot 150 Manual Page 24...

  • Page 27: Arm Continuous 2

    This setting is important when interfacing with a system that can give Doc# 16302 Press Pilot 150 Manual Page 25...

  • Page 28: Speed Comp Top 1

    Slow Spm speed. These settings are active only when Enable Speed Comp is checked on the Speed Comp Top 2 screen. Doc# 16302 Press Pilot 150 Manual Page 26...

  • Page 29: Speed Comp Top 2

    T-cam off parameter and enter the new number into the T-cam off angle. Once the fast stop Spm and angle have been calculated, go to the Speed Comp Top 1 screen and enter Doc# 16302 Press Pilot 150 Manual Page 27...

  • Page 30: Misc. Timers

    11 degrees from the calculated stop angle, in turn attempting to stop the press earlier. MISC. TIMERS This screen is not visible when Hard Cams are chosen on the Position Control screen. Doc# 16302 Press Pilot 150 Manual Page 28...

  • Page 31: Brake Test 1

    TEST SPEED: This is the speed at which the press will perform the test. Once the brake test is initialized the press speed will need to be adjusted to this preset. When the press reaches this speed the brake test will start. Doc# 16302 Press Pilot 150 Manual Page 29...

  • Page 32: Brake Test 2

    This screen is visible when Hard Cams are chosen on the Position Control screen, but not all settings are available. This screen allows the user to change the information displayed on the led display when the press is in motion. If the user Doc# 16302 Press Pilot 150 Manual Page 30...

  • Page 33: Lifetime Counter

    SAVE/RESTORE From this screen the user is able to save the current setup, restore the last saved setup, or restore the factory defaults. Doc# 16302 Press Pilot 150 Manual Page 31...

  • Page 34: Xvi. Prox Setup

    XVII. Ethernet settings (Refer to section 10, Page 50) Doc# 16302 Press Pilot 150 Manual Page 32...

  • Page 35: Troubleshooting

    Note: The left and right run buttons of any station being used must include a NO and a NC contact. These contacts must be wired into the PP150 correctly, and must change state when depressed. Doc# 16302 Press Pilot 150 Manual Page 33...
  • Page 36 To reset this fault, Attempt to reset with the PP150 Flt reset PB. If the PB will not reset the fault, cycle power to the PP150. If the error persists, contact Toledo Integrated Systems for further assistance. Doc# 16302 Press Pilot 150 Manual Page 34...
  • Page 37 Press the PP150 reset button to reset the fault. Note: Clutch, Watchdog and Mute relays must be replaced using original factory supplied components. If the fault cannot be reset, Contact Toledo Integrated Systems for replacement parts. Doc# 16302 Press Pilot 150 Manual Page 35...
  • Page 38 PP150, this fault will occur. This fault will also occur if the resolver is not wired correctly. See the electrical schematics for wiring the resolver to the PP150. Doc# 16302 Press Pilot 150 Manual Page 36...
  • Page 39 PP150 to accurately advise of incorrect pressure. Check the pressure switch, and press the PP150 reset button to reset the fault. Doc# 16302 Press Pilot 150 Manual Page 37...
  • Page 40 Tcam do not overlap. It can also be the case that Bcam never cycled before Tcam came on. Check to make sure that the cams are working properly and the windows are set correctly. Press the PP150 reset button to reset the fault. Doc# 16302 Press Pilot 150 Manual Page 38...
  • Page 41 Push the Continuous Arm button to Arm the press. Once the button has been pushed, the Press will stay armed for a user defined time limit. Once the time is up, the button will need to be pushed again. Doc# 16302 Press Pilot 150 Manual Page 39...
  • Page 42 This prompt indicates that in order to Arm the press in continuous, the press must be in the user defined zone. Once the press is in this zone, it can be armed for continuous mode. Doc# 16302 Press Pilot 150 Manual Page 40...
  • Page 43 The prox must be set to cycle mute light curtains on upstroke between 71-130 degrees. See the with encoder setup Section (18) for a description of the process. Doc# 16302 Press Pilot 150 Manual Page 41...

  • Page 44: Input Diagnostic Screens

    “b” processor. Four other outputs can be tested from this screen including pp150 reset (ok), pp150 fault (fault), continuous arm (c-arm) and output 1 (out1). Doc# 16302 Press Pilot 150 Manual Page 42...
  • Page 45 The last screen tests the top three dip switch outputs on the door of the PP150 and the six buttons on the front of the pp150. The screen below indicates that second dip switch is on. Doc# 16302 Press Pilot 150 Manual Page 43...

  • Page 46: Resolver Wiring

    ROT STA ROT STA SLAVE MASTER Master and Slave Selections R1/R2 Voltage Scaling STAT1 /2 /3 /5 S1/S3 Voltage Scaling STAT2 /2 /3 /5 S2/S4 Voltage Scaling CONNECTOR WIRING Resolver Interface (detail) Doc# 16302 Press Pilot 150 Manual Page 44...

  • Page 47: Resolver Dip Switching

    STAT1 /2 /3 /5 STAT2 STAT2 STAT2 STAT2 /2 /3 /5 /2 /3 /5 /2 /3 /5 /2 /3 /5 & & STAT = Scale Down 2X (4&6,7&9 Left – 5&8 Right) Doc# 16302 Press Pilot 150 Manual Page 45...

  • Page 48: Start-Up Procedure

    If using hard cams: i. Adjust hard cams (see page 11). ii. Continue to step 6 of the start-up procedures. 2. Adjust soft cam settings (see page 22). Doc# 16302 Press Pilot 150 Manual Page 46...
  • Page 49 Note: you can view the current prox angles and window from the operator’s prox info screen (see page 17). 5. adjust the “speed compensation” settings (see page 25-26). Doc# 16302 Press Pilot 150 Manual Page 47...
  • Page 50 8. adjust the “lc mute/top stop” settings to the desired values (see page 24). 9. adjust the brake monitor/test settings. (see page 28) Note: if you are using hard cams, skip this step and proceed to step 10. Doc# 16302 Press Pilot 150 Manual Page 48...
  • Page 51 This is done from the “save/restore” screen in the configuration screens (see page 30). Doc# 16302 Press Pilot 150 Manual Page 49...

  • Page 52: Start-Up Checklist

    25-26 9. Adjust brake monitor settings (Run brake test) …Pages 29-30 10. Adjust desired led display…Page 11. Reset lifetime counter…Page 12. Save settings to backup…Page 9 PP150 configuration settings Configuration data sheet Doc# 16302 Press Pilot 150 Manual Page 50...
  • Page 53 ° Stop Early Stop Angle ° Zone 3: If Speed > Stop Offset ° Stop Early Stop Angle ° Zone 4: If Speed > Stop Offset ° Stop Early Stop Angle ° Doc# 16302 Press Pilot 150 Manual Page 51...

  • Page 54: Speed Comp Top Stop Zone Settings . 51 Iii. Board Replacement Parts Info

    Doc# 16302 Press Pilot 150 Manual Page 52...
  • Page 55 Doc# 16302 Press Pilot 150 Manual Page 53...

  • Page 56: Pp150E E-Net/Ip Rslogix 5000 Setup

    3. Settings in the PLC are explained in the next 15 pages A. Open your project in RSLogix 5000 B. Right click on your Ethernet module and select “New Module…” (Figure 10.1) Figure 10.1 Doc# 16302 Press Pilot 150 Manual Page 54...
  • Page 57 C. Select The communications modules and open the list by clicking on the plus (+) symbol. (Figure 10.2) Figure 10.2 D. Select Ethernet-Module and then click ok (Figure 10.3) Figure 10.3 Doc# 16302 Press Pilot 150 Manual Page 55...
  • Page 58 E. Enter the name you want to refer to the PP150 in your programming. Sample: PP150EthernetIP (Figure 10.4) Figure 10.4 F. Select the Comm Format to be Data – INT. (See Sample: Figure 10.5) Figure 10.5 Doc# 16302 Press Pilot 150 Manual Page 56...
  • Page 59 Figure 10.6. All six of these values must be entered correctly or communication will fail. Figure 10.6 I. Enter the correct value for the requested packet interval (Figure 10.7) Figure 10.7 Doc# 16302 Press Pilot 150 Manual Page 57...
  • Page 60 J. Right click on your MainTask Folder and select “New Program…” (Figure 10.8) Figure 10.8 K. Enter the Name of the New Program as PP150 (See example below…Figure 10.9) Figure 10.9 Doc# 16302 Press Pilot 150 Manual Page 58...
  • Page 61 L. Right click on the new program (PP150) that you just made and select “New Routine…” (Figure 10.10) Figure 10.10 M. Enter the Name of the New Routine as PP150Routine (See example below…Figure 10.11) Figure 10.11 Doc# 16302 Press Pilot 150 Manual Page 59...
  • Page 62 N. Right click on the New Program (PP150) and select “Properties” (Figure 10.12) Figure 10.12 Doc# 16302 Press Pilot 150 Manual Page 60...
  • Page 63 O. Under the configuration tab, select PP150 as the Main Routine (See example below…Figure 10.13) Figure 10.13 P. Copy the rungs 1-9 from the sample program supplied with the PP150 (See example below…Figure 10.14) Figure 10.14 Doc# 16302 Press Pilot 150 Manual Page 61...
  • Page 64 This will ensure that the imported tags (section 10.R) works correctly (See example below…Figure 10.15) Figure 10.15 R. IMPORT Program Tags by selecting Tools, then “Import…” (See example below…Figure 10.16) Figure 10.16 Doc# 16302 Press Pilot 150 Manual Page 62...
  • Page 65 S. Select the PP150EthernetIP-Tags.csv file from the cd supplied with the controller. (See example below…Figure 10.17) Figure 10.17 Doc# 16302 Press Pilot 150 Manual Page 63...

  • Page 66: Pp150E E-Net/Ip I/O Mapping

    11 P150 Ethernet I/O Mapping Figures 11.1 thru 11.8 show the mapping for all the PP150 I/O. Input Word 0 (Figure 11.1) Input Word 1 (Figure 11.2) Doc# 16302 Press Pilot 150 Manual Page 64...
  • Page 67 Input Word 2 (Figure 11.3) Input Word 3 (Figure 11.4) Doc# 16302 Press Pilot 150 Manual Page 65...
  • Page 68 Input Word 4 (Figure 11.5) Input Word 15 (Figure 11.6) Doc# 16302 Press Pilot 150 Manual Page 66...
  • Page 69 Input Words 4-40 (Figure 11.7) Doc# 16302 Press Pilot 150 Manual Page 67...
  • Page 70 Output Words 0-20 (Figure 11.8) Output Word 0 (Figure 11.9) Note: For communication, Output Word0.0 must be 1 (Enabled) Doc# 16302 Press Pilot 150 Manual Page 68...
  • Page 71 Output Word 1 (Figure 11.10) Doc# 16302 Press Pilot 150 Manual Page 69...

  • Page 72: Pp150E E-Net/Ip Ladder Examples

    Example Ladder Logic for (Required) Heartbeat and Enable bits (Figure 12.1) Example Ladder Logic for (optional) Heartbeat Monitoring (Figure 12.2) Example Ladder Logic for (Optional) Heartbeat Fault Capture (Figure 12.3) Doc# 16302 Press Pilot 150 Manual Page 70...
  • Page 73 Doc# 16302 Press Pilot 150 Manual Page 71...

  • Page 74: Pp150E E-Net/Ip Eds Installation

    To view the PP150 as known device in your RSLinx you must install the EDS file using the RSLinx EDS Hardware Installation Tool. Figures 13.1 thru 13.7 will walk you through the installation process. Run the EDS Hardware Installation Tool Program. (Figure 13.1) Doc# 16302 Press Pilot 150 Manual Page 72...
  • Page 75 Click on the “Add” button. (Figure 13.2) select “Register a single file” and Browse…to search for the EDS file supplied by Toledo Integrated Systems. (Figure 13.3) Doc# 16302 Press Pilot 150 Manual Page 73...
  • Page 76 Click on the “Next” button to let Rockwell test the file. (Figure 13.4) Click on the “Change Icon…” Button. (Figure 13.5) Doc# 16302 Press Pilot 150 Manual Page 74...
  • Page 77 Click on Browse…then search for the PP150-Icon.ico file supplied by Toledo Integrated Systems. (Figure 13.6) Click on Next and the Installation will be complete. (Figure 13.7) Doc# 16302 Press Pilot 150 Manual Page 75...

  • Page 78: Pp150E E-Net/Ip Pp150 Settings

    3. 90 ° Brake Monitor Test 4. T-Cam Off Value 5. PLS Outputs Ethernet screen with example IP address set to 192.168.16.146 (Default) (Figure 14.1) Ethernet screen with example Subnet Mask set to 255.255.255.0 (Default) (Figure 14.2) Doc# 16302 Press Pilot 150 Manual Page 76...

  • Page 79: Auto Single/Continuous On Demand

    4. Arm Timeout: This is the time that the unit will stay armed without the clutch being engaged. This timer is in seconds and has a max of 1800 seconds (30 minutes). Setting this to zero will bypass the timer. Doc# 16302 Press Pilot 150 Manual Page 77...

  • Page 80: 16 Hydraulic Overload Monitoring

    There is one relay (Dry Contact) output [tb 72 &73] to control the Hydraulic OL “Pump/Reset/Hold” solenoid. This output can also be configured to be low or hi. When the “output hi” has a checkmark, the output will remain on when Doc# 16302 Press Pilot 150 Manual Page 78...
  • Page 81 Once in the top zone, the PP150 will again stop the press and turn on the Hydraulic OL “pump/hold” output. Once the input turns back on for 10 continuous seconds, the Hydraulic OL fault will be cleared. Doc# 16302 Press Pilot 150 Manual Page 79...
  • Page 82 Relays may need to be added to the output in order to integrate the system into the hydraulic overload system (ex, if the system has 2 valves, ect). (Figure 16.3) (Figure 16.4) Doc# 16302 Press Pilot 150 Manual Page 80...
  • Page 83 (Figure 16.5) (Figure 16.6) Doc# 16302 Press Pilot 150 Manual Page 81...

  • Page 84: 17 Programmable Outputs

    DC relay.) Safety Note: The Programmable Outputs should NEVER be run into the prox. Check input. Doc# 16302 Press Pilot 150 Manual Page 82...

  • Page 85: Mute Lc On Upstroke With Encoder Setup

    18 mute light curtains on upstroke with encoder setup If the user selects mute curtains under lc mute/top stop and an encoder is used, the z-pulse and prox must be timed as below. Doc# 16302 Press Pilot 150 Manual Page 83...
  • Page 107 Toledo Integrated Systems Toledo Transducers Inc. Press Pilot 150 Remote Display Manual Installation guide Doc# 16302 Press Pilot 150 Manual Page 110...
  • Page 108 8) Touch the brake monitor button to navigate to the brake monitor page. (See section 4) 9) Touch the counters button to navigate to the counters page. (See section 5) 10) Touch the PP150 setup button to navigate to the settings menu page. (See section 6) Doc# 16302 Press Pilot 150 Manual Page111...

  • Page 109: Remote Lcd Wiring

    Navigate to the PRESS ANGLE screen by touching the press angle display on the HOME screen. This screen shows a graphic representation of the current press angle and strokes per minute (SPM). Touch the HOME button to return to the HOME screen. Doc# 16302 Press Pilot 150 Manual Page112...
  • Page 110 This screen shows (1) the most recent fault, (2) the previous fault, (3) and two faults ago. The fault number and a brief description are given. Touch the HOME button to return to the HOME screen. Doc# 16302 Press Pilot 150 Manual Page113...

  • Page 111: Remote Proface Screen Cutout Dimensions

    4) Last 90 degree test stop time (mS). 5) Last 90 degree test degrees to stop (Degrees). 6) Last 90 degree test actual speed (mS). 7) Current prompt/fault. Touch the HOME button to return to the HOME screen. Doc# 16302 Press Pilot 150 Manual Page114...

  • Page 112: Pp150 Ethernet Remote Screen

    5) Batch count: Shows the number of parts made in the batch. 6) Preset: Sets the number of parts per batch. 7) SPM: Current strokes per minute. Touch the HOME button to return to the HOME screen. Doc# 16302 Press Pilot 150 Manual Page115...
  • Page 113 1) Pilot Press 150 input/output button. 2) Press Angle Settings button. 3) Break Monitor Settings button. 4) Programmable Limit Switch button. 5) Screen Settings button. Touch the HOME button to return to the HOME screen. Doc# 16302 Press Pilot 150 Manual Page116...
  • Page 114 All inputs and outputs are shown. If the bubble next to the name of a signal is lit blue the signal is currently on. These screen shows: 1) Example input off. 2) Example input on. Touch the RETURN button to return to the SETTINGS MENU screen. Figure 7 Doc# 16302 Press Pilot 150 Manual Page117...
  • Page 115 Figure 8 Figure 9 Doc# 16302 Press Pilot 150 Manual Page118...
  • Page 116 3) Programmable Limit Switch 2 turn on angle (Push to change). 4) Programmable Limit Switch 2 turn off angle (Push to change). 5) Current SPM and press angle. Touch the RETURN button to return to the SETTINGS MENU screen. Doc# 16302 Press Pilot 150 Manual Page119...
  • Page 117 3) Enter desired angle to turn off clutch during a single stroke of top situation. 0 will bypass the screen’s setting and use what is in the PP150. Touch the RETURN button to return to the SETTINGS MENU screen. Doc# 16302 Press Pilot 150 Manual Page120...
  • Page 118 Touch SCREEN SETUP on the settings menu (Figure 6). Then, enter the correct password to access this screen. This screen is for use by Toledo Integrated Systems. If access is required, please contact Toledo Integrated Systems. Touch the RETURN button to return to the SETTINGS MENU screen. Doc# 16302 Press Pilot 150 Manual Page121...
  • Page 119 4) Last 90 degree test stop time (mS). 5) Last 90 degree test degrees to stop (Degrees). 6) Last 90 degree test actual speed (mS). 7) Current prompt/fault. Touch the RETURN button to return to the SETTINGS MENU screen. Doc# 16302 Press Pilot 150 Manual Page122...
  • Page 120 Figure 13 provides the dimensions needed for the cutout in order to mount the Remote Display, as well as the size of the Remote Display itself. Figure 14 Figure 14 displays the method for connecting the remote display to the Press Pilot 150, including the proper designation of IP addresses. Doc# 16302...

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