ALFAMATIC CSQVIO8 User manual

Nov. 20, 2013
CSQ-Visual
Version with CSQVIO8 card
Installation manual

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1Installing CSQ-Visual .............................................................................................................3
1.1 Important notes for installation ...................................................................................................... 3
1.2 Operating of the instrument ............................................................................................................ 3
1.3 Internal cards.................................................................................................................................... 4
1.4 Electric wiring................................................................................................................................... 4
2Special functions ...................................................................................................................12
2.1 Configure automatic work selection ............................................................................................. 12
2.2 Configuring the use of the phases.................................................................................................. 13
2.3 Connection of an external reset ..................................................................................................... 14
2.4 SETPOINT output.......................................................................................................................... 14
3Instructions for setting up the CSQ-Visual ........................................................................... 15

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1 Installing CSQ-Visual
This paragraph describes the operations necessary to fit and connect the CSQ-Visual to the machine
and make it operative.
The CSQ-Visual has been designed to be independent: all you have to do is connect the valves and
sensors that will be powered by the instrument. Naturally there’s nothing to stop you from
combined use with a PLC.
To operate, the CSQ-Visual requires different input and output signals. As regards the inputs, a
force transducer (load cell), a position transducer (incremental encoder, potentiometer or 0-10 V
transducer) and various sensors are required. The outputs are connected to the unit descent
enabling valve, the protection closure valve (where installed) and the warning lights.
1.1 Important notes for installation
This manual refers only to the instrument with expansion card CSQVIO8.
The CSQ-Visual has to be powered at 24VDC. An optional internal power feeder is
available, enabling direct connection to the mains power.
This instrument is not (and could not be) a safety device: the descent of the press must be
entrusted to elements outside the instrument. The instrument synchronises the descent of
the press in order for it to work.
It is very important for the load cell wire terminal, which is not sheathed, to be as short as
possible.
When the machine has electric motors, these must be equipped with an anti-interference
filter and be controlled using semiconductor devices.
Always connect the container of the instrument to the earth conductor.
1.2 Operating of the instrument
Attention: the CSQ-Visual is not (and could not be) a safety device: the descent of the press must
be entrusted to external elements. The CSQ-Visual synchronises the descent for its operation.
The GO Output is usually connected serially to the chain of the cylinder descent. In short, if the
CSQ-Visual activates the GO enabling output, the cylinder must not descend if it is not safe.
Operation takes place as follows: when the START input is activated by an external command, the
CSQ–Visual, if ready, activates the protection descent output (PROTECTION) where present and
enables the cylinder descent (GO). When the protection is closed, a safety device must activate the
cylinder until the CSQ-Visual removes the cylinder descent enabling signal (GO). The CSQ-Visual
then commands the arrest of the press, removing the GO signal, controls the curve until the force
begins to diminish or is activated by way of the T.D.C. input (withdraw cylinder signal). Only then
does it indicate whether or not the piece is good or a reject.
If the piece is good, the GOOD output is activated and the PROTECTION output, where present, is
deactivated. If the piece is a reject, the REJECTED output is activated intermittently and the
PROTECTION output, where present, is left active. When the operator presses the reset button,
which can be external or always active, the instrument maintains the REJECTED output as fixed
and removes the PROTECTION output.

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The correct alignment of the encoder takes place using its zero notch and the T.D.C. withdraw
cylinder signal.
1.3 Internal cards
There are two cards inside the CSQ–Visual:
frontal (CSQVMB) supports the display, keyboard and main CPU.
input e output (CSQVIO) for the connection of input signals, output signals and transducers.
We make all the cards ourselves and they can be altered to suit your specific requirements.
1.4 Electric wiring
The following information explains how to install the electric wiring.
1.4.1 Information for connection to an external controller (PLC)
To connect the CSQ-Visual to a PLC, the latter must have PNP positive logic. The inputs and
outputs of the instrument are optoinsulated from the instrument’s control electronics. The power
supply of the instrument’s inputs and outputs must be the same that powers the inputs and outputs
of the PLC. We recommend the use of at least one output (START signal) and three inputs of the
PLC (GO, GOOD and REJECTED). If necessary, with the press controlled directly by the
instrument, it is possible to use a single input to know whether the piece is good (GOOD output)
and a single output to control the start of the pressing cycle (START input).
Remember that, in all cases, it is always necessary too connect the T.D.C. input of the CSQ-Visual.
The T.D.C. signal can be acquired directly by a limit switch activated with the press in the resting
position. However, the signal indicating that the press is in the resting position is almost always
used by the PLC. In this case the signal to be given to the instrument may be taken parallel to that
delivered to the PLC.
1.4.2 CSQVIO8 card wiring
Attention: this information refers only to the CSQVIO8 card. Check that the correct type of card is
fitted.

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The wiring is supported by removable terminal blocks (X3, X4, X5...). Every terminal on every
terminal block is numbered. For example, when terminal X5.7 is indicated, reference is made to the
seventh terminal of terminal block X5. The numbers are also printed on the printed circuit of the
card.
Figure 1
Main power terminal block (X24)
The electronics of the CSQ-Visual and the transducers are powered at 24VDC via the X24 three-
pole terminal block.
Name Function Terminal
0VDC Negative power X24.1
PE Earth connection X24.2
+24VDC Positive power X24.3
If the internal power feeder is fitted, the switch behind the instrument has to interrupt the phase and
neutral before reaching the power feeder. The power feeder output must be connected to terminal
block X24.

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Inputs terminal block (X3)
The inputs are optoinsulated and compatible with clean contact signals or 24 VDC PNP transistor
outputs.
Name Terminal Default
Input 0 X3.1 START
Input 8 X3.2
Input 1 X3.3 T.D.C.(1)
Input 9 X3.4
Input 2 X3.5
Input 3 X3.6
Input 4 X3.7
Input 5 X3.8
Input 6 X3.9
Input 7 X3.10
0VDC X3.11 Negative power supply
+24VDC X3.12 Positive power supply
(1) T.D.C. input in always on input 1.
The function of each input is configurable. Each input can have one of the following functions:
Name Default Function
START 0 Request for starting a new cycle. If remove the acquisition is stopped.
T.D.C.(1) 1 Signal "top dead center", used as a reset for a new cycle and ANDed with
the zero mark of the encoder to the zeroing the absolute position
JOB SELECTOR The binary value of these inputs select automatically a jobs (see 2).
PHASE SELECTOR The binary value of these inputs select automatically the phase of job.
BASKET 1 2 Input for sensor for the detection of normal rejected (basket)
BASKET 2 3 Input for sensor for the detection of special rejected (basket)
BASKET AUTO-CHECK Input for sensor for the detection of auto-check samples (basket)
RESET 2 Re-enable the instrument after a rejected
SESPEND ACQUIRE Suspends the acquisition of the curve useful in hydraulic presses in case
of stop in halfway.
ENABLE # See 2.4
TEST SIGNAL # #1=4 See 2.4
BOOSTER CYL BACK Used for the repetition of the working stroke
BOOSTER CYL END Used for the repetition of the working stroke
MAINTENANCE 5 Disable all controls
TABLE IN POS Signal for piece in the working position
IMPULSIVE START Left=6
Right=7
Request for start of a new cycle
NO EMERGENCY Machine is not in emergency
SAFETY Machine security (guards closed)
DRIVER ATIVATE Driver actived (servo presses)
IN POSITION Position reached (servo presses)
(1) T.D.C. input in always on input 1.

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Outputs terminal block (X4)
Outputs for 24VDC loads. For inductive loads such as valves and relays, it is necessary to have a
diode parallel to the coils to eliminate peaks in voltage.
Nome Morsetto Default
Output 0 X4.1 GOOD
0V X4.2 Negative power supply
Output 1 X4.3 REJECTED 1
Output 8 X4.4
Output 2 X4.5 PRESS
Output 3 X4.6 PROTECTION
Output 4 X4.7 CONTACT/BOOSTER
Output 5 X4.8
Output 6 X4.9
Output 7 X4.10
The function of each output is configurable. Each output can have one of the following functions:
Name Default Function
GOOD 0 Good piece signal. Active after the return of the cylinder until the next
start.
REJECTED 1 1 Normal rejected piece signal. Active after the return of the cylinder until
the next start. The output is intermittent until the reset signal.
REJECTED 2 7 Special rejected piece signal. Active after the return of the cylinder until
the next start. The output is intermittent until the reset signal.
REJECTED AUTO-CHECK Auto-check sample piece signal. Active after the return of the cylinder
until the next start. The output is intermittent until the reset signal.
PRESS 2 Enables the press. Active after the start if the instrument is ready and
deactivated upon reaching the stoppage value.
DOOR 3 Command for the closure of the protection
BUZZER 4 Command for the closure of the acoustic signal.
TEST OUTPUT 6 Activation of external measuring TEST SIGNAL 1
CONTACT/BOOSTER Contact to piece or start working stroke
CHECK POINT OUT # Output activated at a programmable position (up to 3 outputs)
PHASE BIT 0 Active when working the phase 2 or 4
PHASE BIT 1 Active when working the phase 3 or 4
MANUAL Active when you choose a job that is not a selectable job
BRAKE Output for a brake to reduce speed
ENABLE RETURN 5 Enable return of the cylinder when detecting a good piece or after reset
ENABLE MANUALE Control for electric lock lever on mechanical presses
OPEN GREEN BOX Command for opening basket of the good pieces
CLOSE PK TANK Closing command of the tank on the Alfamatic PK cilinders
BLOCK OF THE TABLE Block piece for work
PULL LEVER Cylinder control help return cylinder (for heavy tools)
RESET DRIVER Driver reset fault (servo presses)
ENABLE DRIVER Driver enable (servo presses)

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Position transducer input terminal block (X5)
An incremental encoder and a 0-10V signal can be connected to the X5 terminal block. A 12VDC
power supply is available for the encoder. A very high-precision 10VDC power supply is available
for the potentiometer.
Name Terminal Description
0V X5.1 Screened wire sheath
0V X5.2 Earth of the encoder or potentiometer
+12V X5.3 encoder power J3A=12V J3B=5V
+10V X5.4 10V potentiometer power (10mA max)
Phase A X5.5 PHASE A signal
Phase B X5.6 PHASE B signal
Phase Z X5.7 Zero notch signal
POT X5.8 Potentiometer cursor or 0-10V input (with J4 this imput accept 0-20mA signal)
Electrical features of terminals X5.5, X5.6 and X5.7
Electrical features of terminal X5.8
Load cell terminal block (X6)
Input for load cell with resistive bridge with a sensitivity of 2mV/V or 4mV/V. The power for
supply the load cell is also available on this terminal block.
Name Terminal Description
0VL X6.1 Logic earth
IN+ X6.2 Positive input
IN- X6.3 Negative input
0V X6.4 Power earth
0V X6.5 Screened wire sheath
+10V X6.6 Power positive (60mA max)

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Terminal X6.2 e X6.3 circuit
J5 J6 J7
Load cell 2mV/V working in compressed only mode * A A OUT
Load cell 2mV/V working in compressed and traction B OUT OUT
0-10V signal OUT B IN
0-5V signal OUT B OUT
* default

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Tipical connection

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Connector D-Sub RS232
The RS232 pinout:
Pin 2: RX interface input signal to the CSQ-Visual.
Pin 3: TX interface output signal from the CSQ-Visual.
Pin 5: GND
1.4.3 CSQVIO8 card options
The CSQVIO8 card can be supplied with special optional features:
Option for several load cells
It is possible to connect up to six load cells to the instrument to simultaneously check six curves. In
this case there will be several six-pole terminal blocks identical to X6, marked as shown in the table
below:
Terminal
block
Description
X6 Channel 1 load cell
X7 Channel 2 load cell
X8 Channel 3 load cell
X9 Channel 4 load cell
X10 Channel 5 load cell
X11 Channel 6 load cell

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2 Special functions
.
2.1 Configure automatic work selection
The CSQ-Visual supports the automatic selection of work using the combination of the inputs or a
command sent to the serial port. This selection can be useful for automatically recognising the
piece or the tool fitted.
To enable the automatic selection of work it is necessary to give the instrument the maximum
number of selectable works and the way in which they are selected.
To do this, select the TOOLS > ADVANCED OPTIONS > MACHINE TYPE > WORKS PHASES
CHANNELS menu and change the Number of selectable works value; then indicate the selection
mode, changing the Automatic selection code.
After changing the configuration, the instrument will create the selectable works, initially empty; to
make an empty work suitable for use, use the WORKS MANAGEMENT > CHANGE WORK command
and press enter on the work required. Now change the name of the work. The CREATE NEW WORK
item in the WORKS MANAGEMENT menu enables the creation of extra works which can be used
separately from the work selected automatically; to create an extra work and use a work other than
that selected automatically the unlock password in required.
Automatic selection only works if the instrument START input is not active.
2.1.1 Selection through inputs
The work number is obtained from the binary combination of the inputs. The binary code of the
first work is zero, i.e.: no input active. The maximum number of selectable works, if enough inputs
are available, is 64 (with binary codes from 0 to 63).
The wiring is connected to a terminal block inside the instrument marked X3.
The highest inputs must be used for selection.
Example: assuming the use of the CSQVIO card, which has 8 inputs, if it is necessary to select a
maximum of 4 works, inputs 7 and 8 will be used: input 8 will be the least significant bit, while
input 7 will be the most significant.
2.1.1.1 Connection of sensors for work selection
It is possible to use positive logic sensors (PNP) or clean contacts for connection to positive.
For example, if it is necessary to connect 4 sensors to the instrument (selection from 9 to 16 works)
which has 8 inputs, inputs 5, 6, 7 and 8 must be used. Input 8 will be the least significant bit, while
input 5 will be the most significant.

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Example of wiring of three sensors (selection of 5 to 8 works):
2.1.2 Selection through serial command
The CSQ-Visual supports serial communication through which it is possible to select a work
remotely. Using serial communication, it is possible to select up to 250 works. To be able to
operate it is necessary to enable slow serial communication and set the Automatic selection code.
For the use of serial communication, see the relative manual.
2.2 Configuring the use of the phases
It is sometimes necessary to perform different machining process on the same piece, for instance,
different gears are fitted onto a drive shaft one after the other: hence the need to analyse all the
different machining phases.
The CSQ-Visual is able to manage up to four phases for each single process. The choice of the
phase may take place automatically, in succession or through the digital inputs of the instrument.
For every work process is it possible to decide whether to exclude one or more phases.
To enable a function for several phases, it is necessary to indicate the maximum number of phases
supported. To do this, select the TOOLS > ADVAN
TOOLS > ADVANTOOLS > ADVAN
TOOLS > ADVANCED OPTIONS > MACHIN
CED OPTIONS > MACHINCED OPTIONS > MACHIN
CED OPTIONS > MACHINE TYPE > WORKS
E TYPE > WORKS E TYPE > WORKS
E TYPE > WORKS
PHASES CHANNELS
PHASES CHANNELSPHASES CHANNELS
PHASES CHANNELS menu and change the Number of phases value. As well as indicating the
number of phases, it is necessary to indicate the way to behave, changing the Automatic selection
code.
If the maximum number of phases is changed, it will be necessary to cancel all the works created
previously:
Figure 2

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If required, it is possible to save them first on the computer using the WinScope program.
2.3 Connection of an external reset
When a reject is detected, the instrument blocks, preventing the machining of other pieces. The
release the instrument it is necessary to reset the reject. It is possible to connect an external reset
signal which can be a button, key or sensor. The reset signal can be left active at all times to have
the autoreset function. Like all the other inputs, the reset signal has to have a 24VDC clean contact
or an electronic sensor with a PNP (positive logic) output.
2.4 SETPOINT output
The CSQ-Visual has an auxiliary output which can be activated when a determined absolute
position or a determined force have been reached. The value of this position or force of the
setpoint can be different for every single work.
Once the absolute position or force value has been reached, the output is activated and kept active
until the press stops.
With the CSQ Visual Setup program it is possible to assign a descriptive name to this output.
This output is normally used to command a hydraulic brake or the start of the press power.
Naturally it can be used for any other function.
To set the setpoint activation threshold use the CHANGE WORK > PARAME
CHANGE WORK > PARAMECHANGE WORK > PARAME
CHANGE WORK > PARAMETERS > OTHER LIMITS
TERS > OTHER LIMITSTERS > OTHER LIMITS
TERS > OTHER LIMITS
command.

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3 Instructions for setting up the CSQ-Visual
Always disconnect the instrument from the electricity supply before opening it.
Open the CSQ-Visual by loosening the four screws in the corners of the front panel.
Figure 3
Pull out the internal cards by a few centimetres. Then release the cards from the front panel.
Figure 4
Pull out all the cards from the container and remove the five terminal block units.
To fasten the instrument in place it is possible to perforate the container on the top or bottom (after
removing all the cards) in the middle.
Fit the wire passage and plugs. To fit a larger wire passage, the hole C8 can be enlarged using a
stepped cutter.

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Figure 5
Slot the wires through the wire passage and start wiring.
It is extremely important for the end of the wire of the load cell which is not covered by a
sheath to be as short as possible:
Figure 6
After completing the wiring, insert the card:
Lastly, insert the terminal block units, paying attention to the direction.
Make sure that cables are not squashed on the bottom of the instrument.
After completing the wiring it is possible to supply power to the instrument, switching it on using
the switch on the back and proceeding as follows:
•Configure the instrument.
•Check the operation of the inputs and outputs, using the controls of the DIAGNOSIS menu.
•Calibrate the transducers.