Schmidt PressControl 3000 User manual

Operator’s manual
SCHMIDT®PressControl 3000
SCHMIDT®press system with force/stroke-monitoring and
SCHMIDT®PressControl 3000

General
SCHMIDT®PressControl 3000 – V1.3
2
0. General
Contact adresses
SCHMIDT Technology GmbH
Feldbergstr. 1
D-78112 St. Georgen
Tel. [phone]
Fax. [phone]
eMail [e-mail]
www.schmidttechnology.de
SCHMIDT Technology Corp.
Cranberry Corporate Center
280 Executive Drive
USA-Cranberry Twp., PA 16066
Tel. [phone]
Tel. [phone]
Fax. [phone]
eMail [e-mail]
www.schmidtpresses.com
SCHMIDT Technology Ltd
Unit 14/18 The Markham Centre
UK-Theale, Reading
Berks RG7 4PE
Tel. [phone]
Fax. [phone]
eMail [e-mail]
www.schmidttechnology.co.uk
SCHMIDT Technology GmbH
Niederlassung Schweiz
Gerbeackerstr. 8
CH-3210 Kerzers
Tel. [phone]
Fax. [phone]
eMail [e-mail]
www.schmidttechnology.ch
©2007 SCHMIDT Technology GmbH
All rights reserved. Printed in the Federal Republic of Germany.
Version and revision date:
Version 1.3 of August 2007
Germany
USA
Great
Britain
Switzerland

General
SCHMIDT®PressControl 3000 – V1.3 3
Table of Contents
Documentation structure.................................................................................5
1Safety.................................................................6
1.1 Designated use.....................................................................................6
1.2 Organisational measures of the system operator.................................7
1.3 Risks .....................................................................................................7
1.4 Safety devices.......................................................................................8
Operational status indicator..................................................................8
Emergency Stop pushbutton.................................................................8
2PressControl 3000.............................................9
2.1 Function ................................................................................................9
2.2 Technical Data....................................................................................10
3Assembly and startup.....................................11
3.1 Transport and storage.........................................................................11
3.2 Connecting the control unit.................................................................12
3.3 Installing the control unit.....................................................................12
4Operation......................................................... 14
4.1 Operating elements.............................................................................14
4.2 User interface......................................................................................14
System functions.................................................................................14
Softkeys and operating levels.............................................................15
4.3 Switching on and off............................................................................16
4.4 Reference run .....................................................................................16
5Data Input ........................................................18
5.1 Default settings ...................................................................................18
5.2 Standard parameters overview...........................................................22
6Text and system outputs................................24
6.1 System outputs ...................................................................................24
6.2 Process data.......................................................................................24
7Press processes..............................................25
7.1 Defining the press process .................................................................25
Press parameters................................................................................25
Return stroke criterion.........................................................................25
Stroke takeover (only two-hand control).............................................26
7.2 Optimisation of the press process ......................................................27
Bend-Up (Yield Factor).......................................................................27

General
SCHMIDT®PressControl 3000 – V1.3
4
Idle-stroke monitoring......................................................................... 30
Block limit window.............................................................................. 31
7.3 Acknowledging an incorrect pressing .................................................32
Acknowledging by means of external luminous button...................... 32
Acknowledging by means of the reject box........................................ 33
7.4 Counter................................................................................................33
Piece counter ..................................................................................... 33
Pre-selection counter ......................................................................... 34
8Further integrated functions ..........................36
8.1 Setup mode for tool change................................................................36
8.2 Operation with ControlTool .................................................................36
8.3 Taring the force value .........................................................................38
8.4 Parts inquiry ........................................................................................38
9Dataset management ......................................40
9.1 Principle of the dataset management .................................................40
9.2 Managing multiple datasets ................................................................41
Creating and storing datasets............................................................ 41
Load dataset....................................................................................... 41
Renaming dataset.............................................................................. 42
10 Quality monitoring ..........................................43
10.1 Curves.................................................................................................43
Curve display...................................................................................... 43
Enlarging details................................................................................. 44
10.2 Tolerances...........................................................................................45
Reference data................................................................................... 45
Force tolerances ................................................................................ 46
Stroke tolerances ............................................................................... 47
Managing tolerances.......................................................................... 48
Move tolerance data........................................................................... 49
11 Maintenance and servicing.............................51
11.1 Setting the force offset........................................................................51
11.2 Calibrating the force sensor................................................................52
11.3 Adjusting the stroke offset...................................................................54
12 Customer Service............................................56

General
SCHMIDT®PressControl 3000 – V1.3 5
Optional
Documentation structure
The operator’s manual for the press system is divided into the following
documentation modules:
Operator's Manual –SCHMIDT®Press
•Structure and function
•Assembly and startup
•Maintenance and servicing
Operator's Manual –SCHMIDT®SafetyModule
•Structure and function
•Mounting and startup
•Maintenance and servicing
Operator's Manual –SCHMIDT®PressControl 3000
•Structure and function
•Assembly and startup
•User interface
•Practical operation
•Maintenance and servicing
Technical documentation – SCHMIDT®press system
•Circuit diagram and pneumatic plan
•Manufacturer’s Declaration or Declaration of Conformity
•Spare part lists
•Test certificates
•Description of special functions
User Manual –SCHMIDT®ControlTool - Teil 1
•Installation
•User interface
•Project and dataset management
•Quality monitoring
•Update and service
User Manual – SCHMIDT®ControlTool - Teil 2
•Fundamentals
•PLC programming
•Range of commands
User Manual –SCHMIDT®SPC
•Structure and function
•User interface
•Practical operation
Optional
Optional

1 Safety
SCHMIDT®PressControl 3000 – V1.3
6
1 Safety
The press system has been built, manufactured and tested ex works for its
function and safety in accordance with current safety regulations and state-
of-the-art methods. This guarantees its operational safety. Nevertheless the
press system can involve risks, if
•it is not used in accordance with its designated use,
•it is operated by untrained personnel,
•it is modified or converted incorrectly or
•the safety regulations are not observed.
The press system may only be used if it is in technically perfect condition. All
required safety devices must be in place and fully functional.
Apart from the instructions listed in this operating manual, the current
country-specific safety and accident prevention regulations provided by law
apply.
1.1 Designated use
The control unit may be operated on a SCHMIDT PneumaticPress or a
SCHMIDT HydroPneumatic Press only in connection with the SCHMIDT
SafetyModule.
The control unit may only be used, together with the above mentioned
components, for the following press processes:
•Assembling
•Riveting
•Crimping
•Bonding
•Forming
•Pressing
•Flaring
•Punching
Using the system for purposes other than those described above is contrary
to the designated use. The manufacturer cannot be held liable for any
damage resulting from such a use. The risk lies entirely with the user.
Do not make any changes to the press system which could impair safety.
The manufacturer cannot be held liable for any damage resulting from such
a use. The risk lies entirely with the user.
Designated use also includes:
•compliance with the documentation
•compliance with the inspection and maintenance measures

1 Safety
SCHMIDT®PressControl 3000 – V1.3 7
1.2 Organisational measures of the system
operator
Use as safety component
If the control has been delivered not ready for use (with a Declaration of
Conformity according to Annex II b of the Machinery Directive 98/37/EC) the
operator or the system manufacturer must ensure observance of the safety
regulations.
 Of the safety regulations, observe in particular the Machinery Directive
98/37/EC and the standards DIN EN 349, DIN EN 292 and DIN EN 294.
The operator must make sure that
•the instructions contained in the operating manual concerning
startup, operation and maintenance are observed.
•the press system is properly operated, tested and maintained and
the responsibilities for these tasks are clearly set out.
•those persons responsible for activities on the press system have
read this operating manual and, in particular, chapter “1 Safety”,
before starting work. This also applies to persons who work only
occasionally.
•this operating manual is always kept within easy reach at the
workplace.
1.3 Risks
The press system is constructed so as not to put any persons at risk when
used in accordance with its designated use. However, certain parts of the
press system cannot be protected without limiting its functionality and
usability. Thus, despite constructional safety measures, a residual danger
remains.
Safe press operation requires the interaction of press, control unit, tools,
safety devices and conduct of the user in accordance with the safety
measures.
Injuries or death caused by touching live parts
During assembly and repair work you may come into contact with parts
which carry dangerous voltage in operation. Touching live parts may cause
death.
 Any work on the electrical system or equipment must be carried out
only by trained electricians or by specially instructed persons under the
control and supervision of a trained electrician and in accordance with
the applicable electrical engineering rules and regulations.
DANGER
!
DANGER
!

1 Safety
SCHMIDT®PressControl 3000 – V1.3
8
1.4 Safety devices
Figure 1-1: PressControl 3000
1 Operational status indicator 2 EMERGENCY STOP pushbutton
Operational status indicator
The operational status indicator is located on the display of the control unit.
The status indicator is lit in green permanently when the press system has
been switched on and is ready for operation.
Emergency Stop pushbutton
There is an EMERGENCY STOP pushbutton on the control panel of the
control unit.
 Press the Emergency Stop pushbutton immediately in case of
emergency.
The press system is taken to a safe operating state. All moving
machines are stopped immediately and the press system is
depressurised.
 Eliminate the error.
 Unlock the Emergency Stop pushbutton by turning and pulling it.
 Switch the press system on again at the control unit.
1
2
What to do in an
emergency
Start af
ter Emergency
Stop

2 PressControl 3000
SCHMIDT®PressControl 3000 – V1.3 9
2 PressControl 3000
2.1 Function
The SCHMIDT®Press System with force/stroke monitoring and SCHMIDT®
PressControl 3000 operates according to the following principle:
The sequence control of the press process is done via a PLC program. The
PLC program carries out the following functions:
•Control of the process data acquisition sequence
•Monitoring of the press process on the basis of the set quality
parameters
•Plain text output on the display.
Additional functions (e.g. feeds, workpiece detection, sorting of OK and Not
OK parts, etc.) are effected via the PLC program.
Figure 2-1: Block circuit diagram
Sequence control

2 PressControl 3000
SCHMIDT®PressControl 3000 – V1.3
10
2.2 Technical Data
Figure 2-2: Dimensions of the control unit
Technical Data
Display Liquid crystal display (128 x 240 pixels) with
background illumination, 16 lines of 40 columns
each, with touch screen functions
Keypad Touch screen
Interfaces USB
Mains connection 100 up to V AC / 50 up to 60 Hz max. back-up
fuse 16 A
Supply voltage 24 V DC
Current consumption 350 mA / 230 V or
700 mA / 110 V or
2.5 A / 24 V
Weight 5.5 kg incl. external power supply unit
Ambient temperature 0 up to 40° C
Air humidity up to max. 95% relative, non condensing
Protection type IP 54
Dimensions
~ 290
~ 320
~ 80