operating manual

122 Pages·2004·1.13 MB·English

Press Control
DialogIII
OPERATING MANUAL
preliminary version
Version: DialogIII 05.2004 GB -1
-2 Version: DialogIII 05.2004 GB
TABLE OF CONTENTS
1 TABLE OF CONTENTS
1 TABLE OF CONTENTS
2 GENERAL DESCRIPTION
2.1 Features of the control 8
2.2 Type test 9
3 QUALIFICATION OF THE PERSONNEL
4 SAFETY INSTRUCTIONS
4.1 Explication of terms and symbols 14
4.1.1 User 14
4.1.2 Insured 14
4.1.3 Warnings 14
4.1.4 Skilled personnel 15
4.2 Instructions concerning safety
regulations 16
4.2.1 Setting (observe national regulations) 16
4.2.2 Maintenance (observe national regulations) 17
4.2.3 Instructions of the manufacturer 17
4.2.3.1 General remarks 17
4.2.3.2 Special safety instructions for the insured 18
4.2.3.3 Special safety instructions for the user 19
4.2.4 Safety equipment 20
4.2.5 Annual safety check 20
4.2.5.1 Inspections 20
4.2.5.2 Safety equipment 21
4.2.5.3 Test instructions of the manufacturer 22
5 HARDWARE AND SOFTWARE
6 INSTALLATION / CONFIGURATION
6.1 Delivery condition 26
6.2 Energy supply 26
6.2.1 Connect power supply 26
6.3 Modifications 26
6.4 Service functions 27
6.4.1 General instructions 27
6.4.2 set encoder to zero 28
6.4.3 Change machine data 31
7 OPERATION
7.1 Operating panel 34
7.2 Operating elements 34
7.3 Control Panel 38
7.4 CHANGE OF OPERATING MODE 38
7.5 SWITCH ON / OFF 39
Version: DialogIII 05.2004 GB 1-3
TABLE OF CONTENTS
7.5.1 Switching on 39
7.5.2 Switching off 39
7.6 Move to initial position 40
7.6.1 set encoder to zero 40
7.6.2 Move to home position 40
8 Operating modes
8.1 SYMBOLS - survey and explanation 42
8.2 Operating functions 44
8.2.1 General parameters of the program steps 44
8.2.1.1 TUE - Monitoring time 44
8.2.1.2 TWA - Waiting time 44
8.2.1.3 Parameters indicated in percent (%) 44
8.2.2 Main cylinder 45
8.2.3 Main cylinder on pressure 46
8.2.4 Press pad 47
8.2.5 Lateral slide 48
8.2.6 lateral slide on pressure 49
8.2.7 move removal unit 50
8.2.8 Tilt removal unit 51
8.2.9 Airblast 52
8.2.10 Spraying 53
8.2.11 Dwell time 55
8.2.12 Safety door 56
8.2.13 Pneumatic unit 57
8.2.14 Electric motor 58
8.2.15 Threading unit 59
8.2.16 Sliding table (option) 60
8.2.17 Tilting table (option) 61
8.2.18 output pulse 62
8.2.19 Output with acknowledgement 63
8.2.20 Set output 64
8.2.21 Reset output 65
8.2.22 Input 66
8.2.23 Tool monitoring 67
8.2.24 Release insertion (robot) 68
8.2.25 Release extraction (robot) 69
8.3 Operating mode setting 70
8.3.1 Menu selection manual functions 71
8.3.2 Information 78
8.3.3 Change language 80
8.3.4 Lamp test 81
8.4 Operating mode programming 82
8.4.1 Menu selection programming 82
8.4.2 Program management 83
8.4.2.1 Load program 84
8.4.2.2 Delete program 84
8.4.2.3 Store program 85
8.4.3 Programming 86
1-4 Version: DialogIII 05.2004 GB
TABLE OF CONTENTS
8.4.3.1 Insert program step 87
8.4.3.2 Edit program step 90
8.4.3.3 Delete program step 92
8.4.4 Tool number 94
8.4.5 Branch Commands 94
8.4.5.1 Example: Loading with / without robot 97
8.5 Operating mode
„Single stroke - automatic' 99
8.5.1 Single stroke - manual 100
8.5.2 single stroke robot 101
8.5.3 inching mode (single step) 102
9 APPLICATION SOFTWARE
10 Messages / error messages
10.1 Messages 106
10.2 Fault messages 110
11 APPENDIX
12 GLOSSARY
13 INDEX
Version: DialogIII 05.2004 GB 1-5
TABLE OF CONTENTS
1-6 Version: DialogIII 05.2004 GB
GENERAL DESCRIPTION
2 GENERAL DESCRIPTION
Version: DialogIII 05.2004 GB 2-7
GENERAL DESCRIPTION
2.1 FEATURES OF THE CONTROL
• Easy programming of all functions, even complex sequences, with
operator guiding via dialog with menu technique in teach-in proce-
dure
• Operating menus adapted to the actual accessories of the ma-
chine
• Storage of 40 programs possible in the working memory
• Arbitrary program runs freely programmable
• Automatic preallocation of parameters, e.g. monitoring times, flow
rate, pressure
• Programming and scrolling in programs possible without move-
ment
• Program change within seconds
• Selection of the required program number from program list pos-
sible
• Stored programs can be called in dialog
• Simple program corrections by modification, insertion and deletion
• Comfortable program test by single step mode, returning to home
position in case of tool troubles
• Display of the current program step active in any automatic oper-
ation mode
• Status indication of the PLC I/O can be called via the operator pan-
el in the operating modes setting and automatic
• Automatic diagnosis of errors with description in clear text
• Help texts stored in the operator panel
• Buffered work memory, i.e. in case of power loss, new loading of
program not necessary.
• Freely programmable ram positions
• Control of the ram position over the entire stroke through absolute
encoder
• Change-over rapid speed - crawling speed - work stroke can be
programmed depending on the path
• Exact approach of all positions in both directions with a repeatabil-
ity of +/- 0,5 mm with tolerance monitoring
• Accessory functions for trim tools possible in any position of the
ram
• Side slide speeds programmable
2-8 Version: DialogIII 05.2004 GB
GENERAL DESCRIPTION
• Start and duration for airblast programmable
• Intervals and duration for spray equipment programmable
• Service hours, days and batch counters can be called via the op-
erator panel
• Oil level and temperature monitoring
2.2 TYPE TEST
The high-speed presses of the SEP series equipped with control Di-
alog III was designed in accordance with the European regulations
and tested and certified by the employers’ liability insurance accord-
ing to the machine guideline 98/37/EC.
Version: DialogIII 05.2004 GB 2-9
GENERAL DESCRIPTION
2-10 Version: DialogIII 05.2004 GB