ALFAMATIC PRESS -RIGHT User manual

INSTALLATION MANUAL
PRESS -RIGHT
With VIO10 card
•Installation manual

2 Press Right installation

Press Right installation 3
1Press-Right Installation......................................................................................... 4
1.1 Important notes for installation ..................................................................................4
1.2 Instrument operation.................................................................................................4
1.3 Internal cards............................................................................................................5
1.4 Electrical wiring.........................................................................................................5
2Special functions................................................................................................. 16
2.1 Configure automatic job selection ...........................................................................16
2.2 Connecting an external reset ..................................................................................16
2.3 Additional controls...................................................................................................16
3Instructions for assembling the Press-Right........................................................ 18
4Transducer assembly.......................................................................................... 19

4 Press Right installation
1 Press-Right Installation
This chapter describes the operations required to assemble and connect the Press-Right to the
machine and to make it operational.
The Press-Right instrument has been designed to work stand-alone or combined with a PLC (see
important information in section 1.4.1).
For operation, the Press-Right instrument must be connected to a PLC via various input and output
signals. In addition to this, the instrument must be connected to a force transducer (typically a load
cell) and to a position transducer (incremental encoder, potentiometer or transducer with analog
output).
The load cell andencoder or potentiometer are powered bythe instrument itself. The instrument also
contains the amplifiers needed to condition the signals coming from these transducers.
The Press-Right is supplied with ModbusTCP as standard and can be requested with PROFINET or
EthernetIP interface.
1.1 Important notes for installation
If you use an incremental encoder, even if you use the fieldbus, the TDC signal must
always be connected to the relevant digital input (X3.3). Furthermore, the use of the GO
and BOOSTER digital outputs for cylinder command, instead of the relative fieldbus
signals, reduces stop delays to a minimum, considerably improving the pressing quality.
This manual refers only to the instrument with VIO10 internal card.
This instrument is not (and could not be) a safety device: the movement of the press must
be entrusted to external elements. The instrument simply synchronizes the movement of
the press for its own operation.
It is very important that the unshielded end of the load cell cable be as short as possible.
When electric motors are present, these must be equipped with an anti-interference filter
and must be controlled by means of semiconductor devices.
Press-Right instrument must be powered at 24VDC. It is possible to have an optional
internal power supply that allows direct connection to the mains voltage.
Always connect the instrument case to the earth conductor.
1.2 Instrument operation
Attention: Press-Right instrument is not (and could not be) a safety device: the movement
must be entrusted to elements external to it. The instrument synchronizes the movement for
its own operation. Usually, the GO and BOOSTER outputs are connected in series to the

Press Right installation 5
cylinder safety chain. In short, if the instrument activates the outputs, the cylinder must not
move if the machine is not in safety.
Operation occurs as follows: when the START input of the instrument is activated by an external
command, the Press-Right, if ready and with all ENABLE inputs active, activates the downward
output of cylinder GO. With the presence of the GO signal, the cylinder must advance until the
instrument removes the same signal.
With GO output active, the instrument activates the BOOSTER output when it reaches contact on
the piece.
According to the stop parameters reached (position, force, etc.) the Press-Right removes the GO
signal.
After removing the GO signal, the instrument continues to control the curve until either the force and
height begin to decrease and the cylinder retracts. This is provided with the signal of good or bad
piece.
If the piece is good, the OK output is activated. Conversely, if the piece is rejected, the KO output is
activated.
The correct zeroing of the encoder takes place using its zero signal and the TDC back cylinder
signal.
1.3 Internal cards
The Press-Right is made up of two electronic components:
PR2MB2 front panel this component mounts the display, the keyboard, the memory and the
CPU.
VIO10 Input and output the digital input and output, the transducers and the communication
port are connected to this card.
All cards are made by us.
1.4 Electrical wiring
The following information is needed to carry out the electrical wiring of the instrument.
1.4.1 Information for connecting to an external controller (PLC)
The PLC connected to the Press-Right must be PNP positive logic. The inputs and outputs of the
instrument are isolated and protected and consequently there is no need for interfacing relays.
The essential signals for operation are START, GO, OK and KO.
Remember that in all cases it is always necessary to connect the TDC input of the instrument. The
TDC signal can be taken directly from a limit switch activated with the press in rest position. When
the press signal in the rest position is also needed by the PLC, the signal to be supplied to the
instrument can be taken in parallel with the one connected to the PLC.
1.4.2 Wiring with VIO10 card
When closing the instrument, make sure that the display cables are not crushed between
the frame and the case.

6 Press Right installation
When closing the instrument, check that the USB and LAN connectors fit well in the
relevant holes to avoid crushing them.
This information refers only to the VIO10 card. Check that the card in question is exactly
this version.
Terminal number 1 of the terminal blocks is always at the bottom
Each terminal of each terminal block is numbered. The seventh terminal of the X18 terminal block
will be called X18.7. The numbering of the terminal blocks is also shown on the board itself.
Figure1
Main power terminal block (X24 )
Press-Right electronics and transducers are powered at 24VDC via the three-pole terminal block
X24.
Name
Terminal
Function
0VDC
x24.1
Negative power supply
PE
X24.2
Earth connection
+24VDC
X24.3
Positive feeding
If the internal powersupply is present, the switch behind the instrument must interrupt the phase and
the neutral before reaching the power supply itself. The power supply output is connected to terminal
block X24.

Press Right installation 7
Input terminal block (X3 and X17 )
The inputs are isolated and compatible with clean contact signals or with PNP 24VDC transistor
output. Terminal block X17 is optional.
Name
Terminal
Default
Input 0
X3.1
START
Input 8
X3.2
Input 1
X3.3
TDC (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
Power mass
+24VDC
X3.12
Power positive
(1) The TDC input (cylinder back) must always be input 1.
Name
Terminal
Default
Input 10
X17.7
Input 11
x17.8
Input 12
x17.9
Input 13
x17.10
Input 14
X17.11
0VDC
X17.12
.
The function of each input is configurable. Each input can have one of the following functions:

8 Press Right installation
Name
Preferred
Function
START
0
Request to start a new cycle. If it is removed, the acquisition is interrupted.
TDC (1)
1
"Top dead centre" signal, used as a reset for a new cycle and in AND with
the zero notch of the encoder for the zero of the absolute positions
BIT JOB SELECTOR
These inputs are used to select a job with their binary combination.
BIT PHASE SELECTOR
These inputs are used to select the work phase with their binary
combination.
RED BASKET 1
2
Sensor for normal waste container
RED BASKET 2
3
Sensor for the special waste container
SELF-CHECK BASKET
Sensor for the sample container used in self-test
RESET
2
Re-enables the tool after a discard
AIR PRESENCE
Pneumatic supply presence sensor
ENABLE #
See chapter 2.3
TEST SIGNAL #
#1=4
See chapter 2.3
PICK-TO-LIGHT SENSOR
Sensor for pick-to-light box
MAINTENANCE
5
Turn off all controls
TABLE IN POSITION
Manual slide signal in working position
IMPULSIVE STARTS
Left=6
Right=7
Request to start a new cycle
NO ALARM
No emergency commands
SAFETY
Machine in safety (guards closed)
(1) The TDC input must always be input 1.

Press Right installation 9
Output terminal block (X4 and X17 )
Outputs are 24VDC PNP. For inductive loads, such as valves and relay coils, a diode must be fitted
in parallel to eliminate overvoltage. Tterminal block X17 and the output 8 on X4.4 are optional.
Name
Terminal
Default
Output 0
X4.1
GOOD
0V
X4.2
Power ground
Output 1
X4.3
REJECTED 1
Output 8
X4.4
Output 2
X4.5
GO
Output 3
X4.6
Output 4
X4.7
CONTACT/BOOSTER
Output 5
X4.8
Output 6
X4.9
Output 7
X4.10
Name
Terminal
Default
Output 9
X17.1
Output 10
X17.2
Output 11
X17.3
Output 12
X17.4
Output 13
x17.5
Output 14
X17.6
The function of each output is configurable.

10 Press Right installation
Each output can have one of the following functions:
Name
Default
Function
GOOD
0
Good piece signal. It is activated when the cylinder has returned to its rest
position. It should not be used to interrupt pressing.
REJECTED
1
Normal rejected signal. It is activated when the cylinder has returned to its
rest position. It should not be used to interrupt pressing.
REJECTED 2
7
Special rejected signal. It is activated when the cylinder has returned to
its rest position. It should not be used to interrupt pressing.
GREEN LAMP GOOD
0
Good piece indicator.
RED LAMP REJECTED 1
1
Normal rejected indicator.
RED LAMP REJECTED 2
Special rejected indicator.
AUTO-CHECK REJECTED
Sample reject piece signal used in self-test
GO
2
Pressing consent. Activated after the start if the instrument is ready and
deactivated when the stop value is reached.
CLOSE THE DOOR
Guard closing command
OPEN THE DOOR
Guard opening command
BUZZERS
3
Acoustic signal command.
TRIGGER TEST
Activation signal for TEST SIGNAL 1 See 2.3
CONTACT/BOOSTER
4
Workpiece contact signal and start of the power phase. Note: This signal
is activated only if the TDC signal is missing
JOB BIT
Binary combination of active job number
PHASE BIT
Binary combination of active phase number
PICK-TO-LIGHT LAMP
Light for pick-to-light box
OPEN GREEN BOX
Good pieces basket opening command
BLOCK OF THE TABLE
Manual slide lock control
PULL LEVER
Cylinder return aid cylinder control (for heavy tools)
Transducer terminal block (X12 )
An incremental encoder, a potentiometer or a transducer with analog output can be connected to
terminal block X12.

Press Right installation 11
The power supply for the transducers can also be taken from this terminal block. A supply voltage of
12VDC (J3A*) or 5VDC (J3B) is foreseen for the encoder. A 10VDC precision voltage supply is
provided for the potentiometer.
Name
Terminal
Description
Phase Z
X12.1
Zero signal
Phase B
X12.2
PHASE B signal
Phase A
X12.3
PHASE A signal
+FR
X12.4
12V power supply with J3A or 5V with J3B
0VDC
X12.5
Mass
AIN-
X12.6
Analog input negative (with J8 inserted it is at Ground for shielded
cable shield)
+10VDC
X12.7
Analog transducer power supply
AIN+
X12.8
Positive analog input
Electrical characteristics of terminal X12.4 with J3A*
Output voltage
12V ±10%
Continuous output current
200mA
Protections
Current, Temperature
Electrical characteristics of terminal X12.4 with J3B
Output voltage
5V ±10%
Continuous output current
200mA
Protections
Current, Temperature
Electrical characteristics of terminal X12.7
Output voltage
10V
Continuous output current
10mA
Protections
Current, Temperature
Input circuit terminals X12.1, X12.2 and X12.3
X12 analog input type selection
J4
J9
J11
J12
0-10V input *
OPEN
IN
IN
OPEN
0-5V input
OPEN
OPEN
IN
OPEN
0-20mA input
IN
IN
IN
OPEN
4-20mA input
IN
IN
OPEN
IN
* default

12 Press Right installation
Load cell terminal block (X11)
Input for resistive bridge load cell with sensitivity of 2mV/V or differential analog input 0-10V or 0-5V.
The transducer power supply is also present on this terminal block.
Name
Terminal
Description
Gefran TU
AEP TC4
IN+
X11.1
Positive input
Yellow
Yellow
IN-
X11.2
Negative input
Red
White
0V
X11.3
Shield
Fits
Fits
0V
X11.4
Power ground
Green
Black
+VDC
X11.5
J10A=10V J10B=5V
White
Red
Electrical characteristics of terminal X11.5 voltage 10V
Output voltage
10V ±10%
Continuous output current
60mA
Protections
Current, Temperature
Electrical characteristics of terminal X11.5 voltage 5V
Output voltage
5V ±10%
Continuous output current
100mA
Protections
Current, Temperature
X11 analog input type selection
J5
J6
J7
J10
Load cell 2mV/V 10V compression only *
TO
TO
OPEN
TO
Load cell 2mV/V 10V compression and traction
b
OPEN
OPEN
TO
Load cell 2mV/V 5V compression and traction
TO
OPEN
OPEN
b
0-10V input
OPEN
b
IN
TO
0-5V input
OPEN
b
OPEN
b
* default
Optional encoder terminal block 422 (X18).
This terminal block is used to connect an encoder with 422 signals. This terminal block is optional.
Name
Terminal
Description
0V
X18.1
Signal reference voltage
ENC_C-
X18.2
Zero mark signal -
ENC_C+
X18.3
Zero mark signal +
ENC_A-
X18.4
Phase A signal -
ENC_A+
X18.5
Phase A+ signal
ENC_B+
X18.6
Phase B+ signal
ENC_B-
x18.7
Phase B signal -
+VDC
X18.8
Power supply: 12V with J3A or 5V with J3B
0VDC
X18.9
Shield

Press Right installation 13
Encoder Alfamatic EMAG1
Type: incremental quadrature encoder
Resolution: 0,01 mm
Index pulse: every 5 mm
Colour
Function
White
0 V
X12.6
Brown
+ VDC
X12.4
Green
Signal A
X12.3
Yellow
Signal B
X12.2
Black
Signal Z
X12.1
Violet
Signal A inverted
Orange
Signal B inverted
Gray
Signal Z inverted
Screen
PE
X12.5

14 Press Right installation
Other transducer connection

Press Right installation 15
Optional internal serial port terminal block (X23).
The RS485 serial port can only be used for connection RFID radio device. This terminal block is
optional.
Name
Terminal
Description
0V
X23.1
Serial reference GND
A+485
X23.2
RS485 interface signal
B-485
X23.3
RS485 interface signal
Optional analog output terminal block (X16 ).
There are two analog outputs on terminal block X16. Analog output 1 can be used to drive a
proportional valve for regulating the cylinder operating pressure. This terminal block is optional.
Name
Terminal
Description
CLK+
X16.1
Do not connect
CLK-
X16.2
Do not connect
DIR+
X16.3
Do not connect
DIR-
X16.4
Do not connect
ANA2
X16.5
Analog output 2
ANA1
x16.6
Analog output 1
0V
x16.7
Signal reference voltage

16 Press Right installation
2 Special functions
This chapter describes the special functions of the inputs and outputs.
2.1 Configure automatic job selection
The Press Right supports automatic job selection by combining inputs or via a bar-code scanner.
The selection via inputs can be useful for the automatic recognition of the piece or of the mounted
tool.
To enable the automatic selection of jobs, select the menu TOOLS > SETUP > JOBS SELECTION.
2.1.1 Selection via inputs
With selection by inputs, the instrument changes its job when the state of the inputs changes. The
instrument ignores the job change command when the START signal is active.
The job number is derived from the binary combination of the inputs.
2.2 Connecting an external reset
When a reject is detected, the tool blocks preventing the execution of other pieces. To unlock the
instrument it is necessary to reset the deviation. To reset the deviation, press the RESET key or
activate a RESET input. It is to avoid locking the instrument with reject by disabling the keyboard
reset from the general options menu in the instrument configuration.
2.3 Additional controls
Up to six additional controls can be connected to the instrument.
Three of these are used as consent to start the press, the other three are used to determine the
good or bad outcome of the job or as other consents to start.
The first three are called ENABLE, the second three are called TEST SIGNAL. It is possible to assign
a name to each additional control from the instrument configuration menu.
It is possible to establish in each job whether to exclude the additional checks.
The TEST SIGNAL 1 control can also be associated with an output signal useful for activating the
control itself.
To use the additional controls you need to configure the instrument by indicating which inputs the
signals are connected to.
After configuring the inputs, it is possible to assign an identification name to each of the six signals.
The enabling signals are checked when the START signal is activated: if an enabling signal is
missing, the instrument displays the message absence of enabling signal.
The test signals condition the good or rejected outcome: if a test signal is missing, the piece is
rejected.
The moment in which the presence or absence of each test input is checked is individually
configurable.
The time when the test signals are checked can be chosen in the job options. Note that only the
input tests 1 all possibilities.
at the start the signal is checked when the starting input is activated
upon arrest the signal is monitored when the stop is commanded

Press Right installation 17
in the end the signal is checked when the cylinder has moved back
continuous the signal is controlled from start to stop
enabling the signal is used as a start enable signal

18 Press Right installation
3 Instructions for assembling the Press-Right
Always disconnect the instrument from the power supply before opening it.
Open the instrument by unscrewing the four screws placed in the corners of the panel.
Pull out the internal card.
Remove the terminal block assemblies.
To fix the instrument it is possible to drill the container on the sides or above or below in a central
position (first remove all the boards).
Fit the cable glands and plugs.
Thread the wires through the cable glands and start wiring.
It is very important that the unshielded end of the load cell cable be as short as possible
After wiring, insert the cards
Finally, insert the groups of terminal blocks paying attention to the correct insertion direction.
Pay attention to the cables that must not be crushed on the bottom of the instrument.
Once the wiring is completed, it is possible to power the instrument and follow the next steps:
•Configure the tool.
•Check the operation of the inputs and outputs, using the commands in the DIAGNOSIS
•Calibrate transducers.

Press Right installation 19
4 Transducer assembly
Encoder and load cell for Alfamatic cylinders.