Link 2600 User manual

PLS / Die Pro.
System 2600
Programmable Limit
Switch and Die
Protection
Installation and Operating
Manual
Doc # L-2600-1023
Rev. 02
Link Electric & Safety Control Co.
444 McNally Drive
Nashville, TN 37211
Phone: [phone]
Fax: [phone]
© 2020

Doc #: L-2600-1023 Page 1 Rev. 02
Table of Contents
1INTRODUCTION .............................................................................................................................. 6
1.1 Features ........................................................................................................................................ 7
1.2 Specifications............................................................................................................................... 8
2DEFINITIONS AND TERMINOLOGY............................................................................................ 9
2.1 Stops............................................................................................................................................. 9
2.1.1 Immediate Stop................................................................................................................... 9
2.1.2 Top Stop.............................................................................................................................. 9
3OPERATION.................................................................................................................................... 10
3.1 Operator Interface ...................................................................................................................... 10
3.1.1 ACC Softkey..................................................................................................................... 12
3.1.2 Espanol/English Softkey................................................................................................... 12
3.1.3 RUN/PROG (Run/Program) Switch................................................................................. 12
3.1.4 Automatic LCD Turn Off ................................................................................................. 12
3.1.5 Parameter Entry ................................................................................................................ 12
3.1.6 Configuration Code........................................................................................................... 14
3.1.7 Access Control Modes...................................................................................................... 14
3.1.8 Access Control Operation................................................................................................. 16
3.1.9 Restricted Items ................................................................................................................ 19
3.1.10 Unrestricted Items............................................................................................................. 19
3.2 Main Operator Terminal Screen................................................................................................. 21
3.2.1 Reason for the Last Stop................................................................................................... 21
3.2.2 Running Status.................................................................................................................. 22
3.2.3 Configure Softkey............................................................................................................. 22
3.2.4 Diagnose Softkey.............................................................................................................. 22
3.2.5 Toggle Setup Mode........................................................................................................... 22
3.3 Die Protection............................................................................................................................. 23
3.3.1 Die Protection Channel Types.......................................................................................... 23
3.3.2 The Die Protection Main Screen....................................................................................... 33
3.3.3 Die Protection Channel Settings Main Screen.................................................................. 35
3.3.4 Die Protection Channel Miscellaneous Settings Screen................................................... 38
3.3.5 Die Protection Channel Window Angles Setting Screen.................................................. 40
3.3.6 Die Protection Bypass Screen........................................................................................... 40
3.3.7 Die Protection Diagnose Screen ....................................................................................... 42
3.4 Limit Switch............................................................................................................................... 44
3.4.1 Limit Switch Main Screen................................................................................................ 44
3.4.2 Limit Switch Settings Screen............................................................................................ 44
3.4.3 Limit Switch Counted Output Settings Screen................................................................. 46
3.4.4 Limit Switch Angle and Time Setting Screen.................................................................. 47
3.4.5 Limit Switch Speed Advance Settings Screen.................................................................. 48
3.5 Counters ..................................................................................................................................... 49
3.5.1 Configuring Production Counters..................................................................................... 50
3.5.2 Production Counters.......................................................................................................... 50
3.5.3 Cycle Counter ................................................................................................................... 52
3.6 The Diagnose Screen.................................................................................................................. 53
3.6.1 Ethernet Diagnostics......................................................................................................... 53
3.6.2 SD Card Diagnostics......................................................................................................... 54

Doc #: L-2600-1023 Page 2 Rev. 02
3.6.3 OIT Info Screen ................................................................................................................ 54
3.6.4 Event Log.......................................................................................................................... 54
4CONFIGURATION.......................................................................................................................... 55
4.1 The Main Configuration Screen................................................................................................. 55
4.2 The General Settings Configuration screen ............................................................................... 55
4.2.1 Allow Speed Advanced Outputs....................................................................................... 55
4.2.2 Machine Running Timeout ............................................................................................... 55
4.2.3 Setup Mode Input.............................................................................................................. 56
4.2.4 Log External Stops............................................................................................................ 56
4.2.5 Inhibit Asserts Top Stop ................................................................................................... 56
4.2.6 Top of Stroke Angle.......................................................................................................... 56
4.3 Encoder Settings Configuration Screen ..................................................................................... 57
4.3.1 Trigger Mode .................................................................................................................... 57
4.3.2 Encoder Offset .................................................................................................................. 57
4.3.3 Encoder Reversed ............................................................................................................. 57
4.3.4 Crankshaft Hysteresis ....................................................................................................... 57
4.4 RUN (Clutch/Brake) Input Settings Configuration Screen........................................................ 57
4.4.1 Engagement Time Limit................................................................................................... 58
4.4.2 Motion Threshold.............................................................................................................. 59
4.4.3 Loss of Motion Time ........................................................................................................ 59
4.5 Bypass Settings Configuration Screen....................................................................................... 60
4.5.1 Limited Bypass Maximum Strokes and Maximum Time................................................. 60
4.5.2 System Bypass Allowed ................................................................................................... 60
4.5.3 Auto Unbypass When Switching to Production Mode..................................................... 60
4.6 Editing the Die Protection Name List........................................................................................ 61
4.7 Editing the Limit Switch Name List .......................................................................................... 61
4.8 Restricting and Unrestricting Die Protection Channels ............................................................. 62
4.9 Restricting and Unrestricting Limit Switch Channels................................................................ 62
4.10 Output Relays Configuration.................................................................................................. 63
4.11 Operator Terminal Configuration........................................................................................... 65
4.11.1 Top Area Display.............................................................................................................. 65
4.11.2 Rod Length and Stroke Length......................................................................................... 65
4.11.3 Setting the Date and Time................................................................................................. 66
4.11.4 Access Configuration........................................................................................................ 66
4.11.5 Configure Auxiliary Communications.............................................................................. 69
5JOB SETUPS.................................................................................................................................... 70
5.1 Store Setup ................................................................................................................................. 70
5.2 Recall Setup................................................................................................................................ 71
5.3 Erase Setup................................................................................................................................. 71
5.4 Data Storage............................................................................................................................... 72
5.5 New Die Installation................................................................................................................... 72
6BACKING UP AND RESTORING THE SYSTEM 2600............................................................... 73
6.1 Backup Procedure ...................................................................................................................... 73
6.2 Restore Procedure ...................................................................................................................... 74
6.3 Memory Swap-out Procedure..................................................................................................... 76
7INSTALLATION ............................................................................................................................. 77
7.1 Preliminary Installation Considerations..................................................................................... 77
7.2 Mounting the System 2600 ........................................................................................................ 78

Doc #: L-2600-1023 Page 3 Rev. 02
7.3 Mounting the Encoder................................................................................................................ 80
7.4 Installing the 805-3 Communications Card ............................................................................... 83
7.5 System Wiring............................................................................................................................ 84
7.5.1 Conduit Runs .................................................................................................................... 84
7.5.2 Wiring Power for the System............................................................................................ 86
7.5.3 Wiring the Stop Outputs ................................................................................................... 87
7.5.4 Wiring the RUN (Clutch/Brake) Input ............................................................................. 87
7.5.5 Wiring the 5100-11 Rotary Transducer............................................................................ 88
7.5.6 Wiring the Auxiliary Inputs.............................................................................................. 89
7.5.7 Wiring the Die Protection Inputs...................................................................................... 89
7.5.8 Wiring Optional Limit Switch Modules........................................................................... 91

Doc #: L-2600-1023 Page 4 Rev. 02
Table of Figures
Figure 1: System 2600................................................................................................................................ 6
Figure 2: System 2600.............................................................................................................................. 10
Figure 3: Top Info Area with 5100-11 Encoder........................................................................................ 11
Figure 4: Example Numeric Entry Screen................................................................................................ 13
Figure 5: Example Text Entry................................................................................................................... 13
Figure 6: Example List Selection.............................................................................................................. 14
Figure 7: Example Password Entry Sequence .......................................................................................... 17
Figure 8: Operator Terminal Main Screen................................................................................................ 21
Figure 9: Static Normally Off Example.................................................................................................... 24
Figure 10: Static Normally On Example .................................................................................................. 24
Figure 11: Cyclic Input Example.............................................................................................................. 25
Figure 12: Timing Window Examples for a Cyclic Input ........................................................................ 25
Figure 13: “In Position” Input Example ................................................................................................... 26
Figure 14: Timing Window Examples for an “In Position” Input............................................................ 27
Figure 15: “1 Part Detector Edge” Input Example ................................................................................... 28
Figure 16: Timing Window Example for a “1 Part Detector Edge” Input ............................................... 28
Figure 17: “1 Part Detector Pass” Input Example .................................................................................... 29
Figure 18: Timing Window Example for a “1 Part Detector Pass” Input ................................................ 29
Figure 19: “2 Part Detector Edge” Input Example ................................................................................... 30
Figure 20: Timing Window Example for a “2 Part Detector Edge” Input ............................................... 30
Figure 21: “2 Part Detector Pass” Input Example .................................................................................... 31
Figure 22: Timing Window Example for a “2 Part Detector Pass” Input ................................................ 31
Figure 23: Timing Window Example for a “Transfer” Input................................................................... 32
Figure 24: Die Protection Main Screen .................................................................................................... 33
Figure 25: Die Protection Main Screen with Error................................................................................... 35
Figure 26: Die Protection Channel Settings Screen.................................................................................. 35
Figure 27: Wiring Sensors in Series and Parallel ..................................................................................... 38
Figure 28: Die Protection Channel Misc. Settings Screen........................................................................ 38
Figure 29: Die Protection Channel Angle Setting Screen ........................................................................ 40
Figure 30: Die Protection Bypass Screen ................................................................................................. 40
Figure 31: Die Protection Diagnose Screen.............................................................................................. 42
Figure 32: Limit Switch Main Screen....................................................................................................... 44
Figure 33: Limit Switch Settings Screen.................................................................................................. 44
Figure 34: Limit Switch Counted Output Screen ..................................................................................... 46
Figure 35: Limit Switch Angle and Time Setting Screen......................................................................... 47
Figure 36: Limit Switch Speed Advance Screen...................................................................................... 48
Figure 37: Counter Screen ........................................................................................................................ 49
Figure 38: Counter Group Screen............................................................................................................. 49
Figure 39: Counter Configuration Screen................................................................................................. 50
Figure 40: Main Diagnostic Screen .......................................................................................................... 53
Figure 41: Event Log Screen .................................................................................................................... 54
Figure 42: Event Log Detail Information Screen ..................................................................................... 54
Figure 43: Main Configuration Screen..................................................................................................... 55
Figure 44: General Settings Configuration Screen................................................................................... 55
Figure 45: Encoder Settings Screen.......................................................................................................... 57
Figure 46: RUN Input Settings Screen ..................................................................................................... 57

Doc #: L-2600-1023 Page 5 Rev. 02
Figure 47: Clutch Engagement Time........................................................................................................ 58
Figure 48: Loss of Motion Time and Motion Threshold.......................................................................... 59
Figure 49: Bypass Settings Configuration Screen.................................................................................... 60
Figure 50: Edit Die Protection Names Screen.......................................................................................... 61
Figure 51: Edit Limit Switch Names Screen ............................................................................................ 61
Figure 52: Restrict/Unrestrict Die Protection Screen............................................................................... 62
Figure 53: Restrict/Unrestrict Limit Switch Screen.................................................................................. 62
Figure 54: Output Relays Configuration Screen....................................................................................... 63
Figure 55: Output Relays Function Configuration Screen ....................................................................... 63
Figure 56: Operator Terminal Configuration Screen................................................................................ 65
Figure 57: Date and Time Setting Screen................................................................................................. 66
Figure 58: Access Configuration Screen .................................................................................................. 66
Figure 59: User Access Configuration Screen.......................................................................................... 67
Figure 60: Restrict/Unrestrict Screen........................................................................................................ 68
Figure 61: Set Config Code Screen .......................................................................................................... 68
Figure 62 Jobs Screen............................................................................................................................... 70
Figure 63 Store Jobs Screen...................................................................................................................... 70
Figure 64 Recall Jobs Screen.................................................................................................................... 71
Figure 65: SD Card Location.................................................................................................................... 73
Figure 66: SD Card Location.................................................................................................................... 76
Figure 67: OIT Viewing Angles............................................................................................................... 78
Figure 68: Enclosure Dimensions Side View with Shock Mounts........................................................... 78
Figure 69: Enclosure Dimensions............................................................................................................. 79
Figure 70: Resolver Mounting to Shaft .................................................................................................... 80
Figure 71: Encoder on Spring Base.......................................................................................................... 80
Figure 72: 5100-11 Encoder Dimensions ................................................................................................. 81
Figure 73: Spring Base with 5100-11 Encoder Dimensions..................................................................... 82
Figure 74: 805-3 Comm. Board Mounting............................................................................................... 83
Figure 75: General View of Wiring Runs for Installation........................................................................ 85
Figure 76: 2600-2 Board Connections...................................................................................................... 86
Figure 77: Breakaway of Run/Stop Connector......................................................................................... 87
Figure 78: 5100-11 Encoder Connections ................................................................................................ 88
Figure 79: Auxiliary Inputs Connection for Setup Mode......................................................................... 89
Figure 80: Die Protection Inputs Connection Wiring Example with Internal Power Supply................... 89
Figure 81: Die Protection Inputs Connection Wiring Example with External Power Supply.................. 90
Figure 82: Model 2620 Sensor Interface .................................................................................................. 90
Figure 83: Electro-Mechanical Limit Switch Module.............................................................................. 91
Figure 84: Limit Switch Module Wiring.................................................................................................. 91
Figure 85: Limit Switch Outputs .............................................................................................................. 92

Doc #: L-2600-1023 Page 6 Rev. 02
1INTRODUCTION
The System 2600 is a
stand-alone die protection
and, optionally,
programmable limit switch
(PLS) unit that can be used
with any existing press
control. It serves two
primary purposes - die
protection and automation.
The die protection
capabilities of the System
2600 offer enough
flexibility to meet the needs
of almost any die protection
application.
The System 2600 features
six built-in die protection
channels which are
designed for use in
monitoring various material
and tool conditions that are important to the correct operation of the stamping process such as:
•Misfeed of the material (long feed, short feed, stock buckle)
•Verification of part ejection
•Stripper position
•Verification of slug ejection / detection of slug stacking
•End of stock
This is accomplished by installing appropriate sensors and probes in or near the die and connecting these
sensors to the die protection channel inputs of the operator terminal. The channels are then programmed
through the operator terminal to perform the desired monitoring function for the connected input. In the
event that improper conditions occur, the machine can be stopped, avoiding excessive delay in the
production process or damage to the tooling and/or press.
Either solid state (NPN or PNP) sensors or probes and mechanical sensors may be used to drive the
inputs. This is configurable on a per-channel and per-job basis so using a variety of sensors is a valid
option. Once configured, these settings will be automatically recalled with each job.
The System 2600 can be programmed to monitor each individual die protection input in the manner
necessary to ensure that the process is operating in the intended manner. Each channel can be
programmed to function as one of several logic types, which are covered in the configuration section.
SYSTEM 2600
PLS/DIE PROTECTION
USE ONLY FINGERS TO OPERATE TOUCH SCREEN
RUN
PROG
LINK ELECTRIC & SAFETY CONTROL CO.
444 McNALLY DR. NASHVILLE, TN. 37211
PHONE [phone]
359
TOP
Stroke Speed
0SPM
Espanol
Diagnose
ACC
Reasonfor
the Last Stop
Running
Status
System 2600TonnageMonitor
Job: 1233
Lower Bracket Die Protection
All Conditions OK
Counter Count Limit
Part
Batch 334
84 3000
250
Power Up
All Conditions OK
Mode:Production
Limit Switch
All Conditions OK
Figure 1: System 2600

Doc #: L-2600-1023 Page 7 Rev. 02
If the monitor detects a process fault, a stop signal will be sent to the press control. There are two types
of stops than can be assigned to an individual channel - Immediate Stop or Top Stop.
The programmable limit switch can be used to drive and/or time automation systems in the stamping
process such as:
•Feeds
•Transfer systems
•Lube systems
•Robotic systems
•Air blow off
•Part diverters
•Gagged tools
1.1 Features
•Storage for 500 jobs of settings associated with the standard and optional functions of the
system.
•The unit can be operated in English or Spanish language. The language can be switched at any
time (including while the press is running) with a softkey that is always present in the upper right
corner of the display.
•Extensive and flexible security is provided for setting parameters and resetting faults. This can
be based on having the RUN/PROG key, passcodes, or both. With optional communications
card, it can even be based on RFID cards or fingerprint readers.
•Additional auxiliary inputs can be configured for such things as indicating setup mode.
•Six die protection inputs are supplied. Each input is individually configurable on a job-by-job
basis for NPN or PNP sensors, channel logic parameters, and a user supplied description.
•Each die protection channel can be individually set on a job-by-job basis to automatically bypass
when in a setup mode (and un-bypass when not in setup mode), if desired. This feature can
eliminate the need to manually bypass all channels when setting up the die and the associated
risk of forgetting to un-bypass them.
•Extensive diagnostics are supplied showing in real time where in the stroke sensors are actually
detected both graphically and in numeric form. After a stop, not only the last stroke but several
previous strokes can be viewed. This allows the actual condition that caused a stop to be viewed
in cases where higher speed presses take more than one stroke to stop. An “Overlay” mode can
also superimpose multiple strokes on the screen so that sensor hit-to-hit variation can be directly
viewed an adjusted for.
•If bypassing of the entire unit is needed or desired, a setting is available that will automatically
un-bypass it when switching back to a production mode.

Doc #: L-2600-1023 Page 8 Rev. 02
•Up to 8 programmable limit switch outputs can be added (4 at a time). Both electromechanical
and solid-state outputs are available. Each output is individually configurable on a job-by-job
basis for output logic, related parameters, and a user supplied description.
•Separate “Top Stop” and “Immediate Stop” relay contacts are provided for interface to the press
control.
•Up to 4 programmable output relays can be installed that can be configured to indicate various
conditions such as “Crank in Motion”, “Bypassed”, “Down Time Code Active”, “In Setup
Mode”, “Inhibit Condition Active”, and others.
•Status messages for each channel indicate the first alarm condition that occurred during the
stroke.
•Powerful counting capability with up to two flexibly configured counter sets (each set with part,
bin, and scrap counters that can be driven by stroke or with part sensors).
•The system uses an encoder tied to the crankshaft of the press so that position dependent
parameters such as die protection windows, PLS angles, and so on are entered directly in degrees
and require no external cam switches.
•The Clutch/Brake signal of the press can be monitored by the 2600 to detect problems with the
coupling of the encoder to the crankshaft such as a broken chain.
•The crank angle is always displayed both graphically and in degrees.
•Crank speed, distance to bottom, and a number of other readouts are available in the top info
area.
•An optional communications card is available with 2 serial ports and an Ethernet port. The
communications card enables the use of the following features:
•The optional LinkNet shop floor information collection system networks the unit, collects
downtime, production, and other information, and offers extensive reporting and
management features.
•An optional MODBUS protocol (RTU or TCP) can be used over serial port or Ethernet
port for connectivity to PLC’s or data collection programs.
•An optional serial feed interface can display and set length, speed, and acceleration for a
wide range of supported servo feeds.
•An optional security system interface can allow the use of RFID card readers or
fingerprint readers for user permissions.
1.2 Specifications
Size: 8.75” wide, 6.75” high, 4.5” depth.
Input Power: 90-264 VAC, 47-63 Hz, 17 VA or
24VDC +/- 10% (0.4 Amps).
Press Speed Capability: Up to 2000 strokes per minute