Document Outline

• INTRODUCTION
  • 1.1 Features
  • 1.2 Specifications
• 2 DEFINITIONS AND TERMINOLOGY
  • 2.1 Tonnage
    • 2.1.1 Channel Tonnage
    • 2.1.2 Total Tonnage
    • 2.1.3 Reverse Tonnage
  • 2.2 Data Windows
    • 2.2.1 Data Window Start Angle
    • 2.2.2 Data Window End Angle
  • 2.3 Limits
    • 2.3.1 Machine Rating Limit
    • 2.3.2 Low Limits
    • 2.3.3 High Limits
    • 2.3.4 Reverse Limits
    • 2.3.5 Total Tonnage Limit
  • 2.4 Stops
    • 2.4.1 Cycle Stop
    • 2.4.2 Top Stop
    • 2.4.3 Intelli-Stop
• 3 OPERATION
  • 3.1 Main Operator Terminal Screen
  • 3.2 The Tonnage Monitor Main Screen
    • 3.2.1 Selecting a View
      • 3.2.1.1 Viewing the Peak and Data Window Tonnages and Settings
      • 3.2.1.2 Showing Forward and Reverse Tonnage
    • 3.2.2 Setting Limits
      • 3.2.2.1 Setting High Limits
      • 3.2.2.2 Setting Low Limits
      • 3.2.2.3 Setting Reverse Limits
      • 3.2.2.4 Automatically Setting Limits
      • 3.2.2.5 Turning Low Limits ON or OFF
      • 3.2.2.6 Turning Reverse Limits ON or OFF
    • 3.2.3 Setting Additional Data Window Parameters
      • 3.2.3.1 Turning Data Windows ON or OFF
      • 3.2.3.2 Setting the Data Window “Start Angle”
      • 3.2.3.3 Setting the Data Window “End Angle”
    • 3.2.4 Bypassing the Tonnage Monitor
    • 3.2.5 Tonnage Alarms
      • 3.2.5.1 Low Alarm
      • 3.2.5.2 High Alarm
      • 3.2.5.3 Reverse Alarm
      • 3.2.5.4 Machine Rating Alarm
      • 3.2.5.5 Reverse Rating Alarm
      • 3.2.5.6 Total Alarm/Stop Condition
      • 3.2.5.7 Resetting Tonnage Alarms
    • 3.2.6 Error Conditions
      • 3.2.6.1 Module Error Messages
      • 3.2.6.2 Channel Errors
      • 3.2.6.3 Resetting Errors
  • 3.3 The Tonnage Monitor Diagnostic Screen
  • 3.4 The Tonnage Monitor Bypass Setup Screen
  • 3.5 The Tonnage Monitor Graph Screen
    • 3.5.1 Graph Start Angle
    • 3.5.2 Graph End Angle
    • 3.5.3 Selecting the Channel to Graph
    • 3.5.4 Graph Pan/Zoom Mode
    • 3.5.5 Graphically Setting Values
    • 3.5.6 Sending the Graph
    • 3.5.7 Reference Waveforms
  • 3.6 The Tonnage Monitor Graph Settings Screen
• 4 CONFIGURATION
  • 4.1 Turning the Tonnage Monitor ON in Device Config
  • 4.2 Setting the Number of Channels
  • 4.3 The Tonnage Monitor Configuration Screen
  • 4.4 The Tonnage Monitor Machine Settings Screen
    • 4.4.1 Units
    • 4.4.2 Machine Rating
    • 4.4.3 Machine Rating Alarm Level
    • 4.4.4 Max Forward Setpoint Level
    • 4.4.5 Max Reverse Setpoint Level
    • 4.4.6 Number of Data Windows
    • 4.4.7 Filter Frequency
    • 4.4.8 Sample Window Start Angle
    • 4.4.9 Sample Window End Angle
    • 4.4.10 Auto-Zero Start Angle
    • 4.4.11 Auto-Zero End Angle
    • 4.4.12 Peak High Limit Stop Type
    • 4.4.13 DW High Limit Stop Type
    • 4.4.14 Auto Unbypass Leaving Setup Mode
    • 4.4.15 Bypass Low Limits in Setup Mode
    • 4.4.16 Resetting Alarm Counters
  • 4.5 The Tonnage Monitor Calibration Screen
  • 4.6 The Machine Rating De-rate Table Screen
• 5 JOB SETUPS
  • 5.1 New Die Installation
• 6 INSTALLATION
  • 6.1 Mounting the Module
  • 6.2 Faceplate Connections and Indicators
  • 6.3 Wiring Power for the Module
  • 6.4 Wiring High Speed Serial Bus Cable
  • 6.5 Setting the High Speed Serial Bus Termination Switch
  • 6.6 Strain Gage Locations
    • 6.6.1 "C" Frame Machines
    • 6.6.2 Straight Side Machines
  • 6.7 Strain Gage Mounting
    • 6.7.1 Direct Machine Mounting
    • 6.7.2 Intermediate Weld Pad Mounting
  • 6.8 Strain Gage Wiring
  • 6.9 Installation Procedure
• 7 CALIBRATION
  • 7.1 Dynamic Calibration with Load Cells
  • 7.2 Replacing System 1000/1100 Tonnage Monitors
  • 7.3 Replacing System 5000 Tonnage Monitors
  • 7.4 Incorrect Tie Rod Tension
• 8 OPTIONAL COMPONENTS
  • 8.1 The 5100-8A Channel Expansion Option
  • 8.2 The 5100-8C Die Protection and Programmable Limit Switch Option
• 9 TROUBLESHOOTING
  • 9.1 Communication Errors
    • 9.1.1 “Communication Failure”
    • 9.1.2 “CTM F. Comm. Fail”
    • 9.1.3 “No Resolver Info”
  • 9.2 “Press Running at Startup”
• 10 PART TRACKING
• 11 PARAMETER ENTRY AND ACCESS CONTROL
  • 11.1 Parameter Entry
    • 11.1.1 Numeric Entries
    • 11.1.2 Text Entry
  • 11.2 Configuration Code
  • 11.3 Access Control Modes
    • 11.3.1 Key Only Mode
    • 11.3.2 Key or Password Mode
    • 11.3.3 Password Only Mode
    • 11.3.4 Key and Password Mode
  • 11.4 Access Control Operation
    • 11.4.1 RUN/PROG Key Switch Operation
    • 11.4.2 Password System Operation
  • 11.5 Restricted Items
  • 11.6 Unrestricted Items