TOX PRESSOTECHNIK CEP400T User manual

User manual
Process monitoring
CEP400T
TOX® PRESSOTECHNIK
Riedstrasse 4
D-88250 Weingarten
www.tox-pressotechnik.com
Edition:05/20/2020, Version: 2
GmbH & Co. KG

2TOX_Manual_Process-monitoring-unit_CEP400T_en

Table of contents
TOX_Manual_Process-monitoring-unit_CEP400T_en 3
Table of contents
1 Important information
1.1 Legal note ................................................................................................... 7
1.2 Exclusion of liability ..................................................................................... 7
1.3 Validity of the document.............................................................................. 8
1.3.1 Content and target group ............................................................................ 8
1.3.2 Other applicable documents ....................................................................... 8
1.4 Gender note ................................................................................................ 8
1.5 Displays in the document ............................................................................ 9
1.5.1 Display of warnings ..................................................................................... 9
1.5.2 Display of general notes............................................................................ 10
1.5.3 Highlighting of texts and images ............................................................... 10
1.6 Contact and source of supply.................................................................... 11
2 Safety
2.1 Basic safety requirements......................................................................... 13
2.2 Organizational measures .......................................................................... 13
2.2.1 Safety requirements for the operating company ....................................... 13
2.2.2 Selection and qualifications of personnel.................................................. 14
2.3 Fundamental hazard potential................................................................... 15
2.3.1 Electrical hazards...................................................................................... 15
3 About this product
3.1 Warranty.................................................................................................... 17
3.2 Product Identification................................................................................. 18
3.2.1 Position and content of the type plate ....................................................... 18
3.3 Function description .................................................................................. 19
3.3.1 Process monitoring ................................................................................... 19
3.3.2 Force monitoring ....................................................................................... 19
3.3.3 Force measurement .................................................................................. 19
3.3.4 Test of the final position of the closed tool ................................................ 20
3.3.5 Networking via Ethernet (Option) .............................................................. 21
3.3.6 Log CEP 200 (optional)............................................................................. 21

Table of contents
4TOX_Manual_Process-monitoring-unit_CEP400T_en
4 Technical data
4.1 Mechanical specifications ......................................................................... 23
4.2 Dimensions ............................................................................................... 24
4.2.1 Dimensions of installation housing............................................................ 24
4.2.2 Hole pattern of installation housing (rear view) ......................................... 25
4.2.3 Dimensions of wall/table housing.............................................................. 26
4.3 Power supply............................................................................................. 26
4.4 Hardware configuration ............................................................................. 27
4.5 Connections .............................................................................................. 28
4.5.1 Digital inputs.............................................................................................. 28
4.5.2 Connections .............................................................................................. 31
4.6 Environmental conditions .......................................................................... 38
4.7 Electromagnetic compatibility ................................................................... 38
4.8 Sensor Analog Standard Signals .............................................................. 39
4.9 Measuring sensor supply voltage.............................................................. 39
4.10 Screw sensor with standard signal output................................................. 39
4.11 DMS signals .............................................................................................. 40
4.11.1 Built-in version: pin assignment, analog standard signals ........................ 40
4.11.2 Pin assignment DMS force transducer...................................................... 41
4.11.3 Wall-mounted housing: pin assignment of force transducer .................... 42
4.12 Profibus interface ...................................................................................... 43
4.13 Fieldbus interface...................................................................................... 44
4.14 Pulse diagrams ......................................................................................... 46
4.14.1 Measuring mode ....................................................................................... 46
4.14.2 Measuring mode ....................................................................................... 47
4.14.3 Offset adjustment via PLC interface force transducer channel 1 + 2........ 50
5 Transport and storage
5.1 Temporary storages .................................................................................. 51
5.2 Dispatch for repair..................................................................................... 51
6 Commissioning
6.1 Preparing System...................................................................................... 53
6.2 Starting system ......................................................................................... 53

Table of contents
TOX_Manual_Process-monitoring-unit_CEP400T_en 5
7 Operation
7.1 Monitoring operation ................................................................................. 55
8 Software
8.1 Function of the Software ........................................................................... 57
8.2 Software interface ..................................................................................... 57
8.3 Control elements ....................................................................................... 58
8.3.1 Function buttons........................................................................................ 58
8.3.2 Checkboxes .............................................................................................. 58
8.3.3 Input field................................................................................................... 59
8.3.4 Dialog keyboard ........................................................................................ 59
8.3.5 Icons.......................................................................................................... 61
8.4 Main menus............................................................................................... 62
8.4.1 Select process / Enter process name ....................................................... 62
8.4.2 Configuration............................................................................................. 67
8.4.3 Lot size...................................................................................................... 79
8.4.4 Supplemnt ................................................................................................. 86
8.4.5 Valuation options....................................................................................... 95
8.4.6 Messages.................................................................................................. 97
9 Troubleshooting
9.1 Detecting faults ......................................................................................... 99
9.1.1 Acknowledging Messages......................................................................... 99
9.1.2 Analyzing NOK situations........................................................................ 100
9.1.3 Error messages....................................................................................... 101
10 Maintenance
10.1 Maintenance and repair .......................................................................... 105
10.2 Safety during maintenance ..................................................................... 106
10.3 Battery change ........................................................................................ 107

Table of contents
6TOX_Manual_Process-monitoring-unit_CEP400T_en
Maintenance table
11 Repairs
11.1 Repair work ............................................................................................. 111
12 Disassembly and Disposal
12.1 Safety requirements for disassembly ...................................................... 113
12.2 Disassembly............................................................................................ 113
12.3 Disposal .................................................................................................. 113
13 Appendices
13.1 Declaration of conformity ........................................................................ 115
13.2 UL certificate ........................................................................................... 118
Index

Important information
TOX_Manual_Process-monitoring-unit_CEP400T_en 7
1 Important information
1.1 Legal note
All rights reserved.
Operating instructions, manuals, technical descriptions and software pub-
lished by TOX®PRESSOTECHNIK GmbH & Co. KG ("TOX®PRES-
SOTECHNIK") are copyright and must not be reproduced, distributed and/
or otherwise processed or edited (e.g. by copying, microfilming, translation,
transmission in any electronic medium or machine-readable form). Any use
- including of extracts - contrary to this condition is prohibited without ap-
proval in writing by TOX®PRESSOTECHNIK and may be subject to crimi-
nal and civil legal sanctions.
If this manual refers to goods and/or services of third parties, this is for ex-
ample only or is a recommendation by TOX®PRESSOTECHNIK.
TOX®PRESSOTECHNIK does not accept any liability or warranty/guaran-
tee with reference to the selection, specifications and/or usability of these
goods and services. The use and/or representation of trademarked brands
that do not belong to TOX®PRESSOTECHNIK are for information only; all
rights remain the property of the owner of the trademarked brand.
Operating instructions, manuals, technical descriptions and software are
originally compiled in German.
1.2 Exclusion of liability
TOX®PRESSOTECHNIK has checked the contents of this publication to
ensure that it conforms to the technical properties and specifications of the
products or plant and the description of the software. However, discrepan-
cies may still be present, so we cannot guarantee complete accuracy. The
supplier documentation included with the system documentation is an ex-
ception.
However, the information in this publication is checked regularly and any
required corrections are included in subsequent editions. We are grateful
for any corrections and suggestions for improvement. TOX®PRES-
SOTECHNIK reserves the right to revise the technical specifications of the
products or plant and/or the software or documentation without prior notice.

Important information
8TOX_Manual_Process-monitoring-unit_CEP400T_en
1.3 Validity of the document
1.3.1 Content and target group
This manual contains information and instructions for the safe operation
and safe maintenance or servicing of the product.
All information in this manual is up to date at the time of print.
TOX®PRESSOTECHNIK reserves the right to make technical changes
that improve the system or increase the standard of safety.
The information is intended for the operating company as well as oper-
ating and service personnel.
1.3.2 Other applicable documents
In addition to the available manual, further documents can be supplied.
These documents must also be complied with. Other applicable documents
can be, for example:
additional operating manuals (e.g. of components or of a whole sys-
tem)
Supplier documentation
Instructions, such as software manual, etc.
Technical data sheet
Safety data sheets
Data sheets
1.4 Gender note
In order to enhance readability, references to persons that also relate to all
sexes are normally only stated in the usual form in German or in the corre-
sponding translated language in this manual, thus e.g. "operator" (singular)
for male or female, or "operators" (plural) for male or female". This should
in no way convey any gender discrimination or any violation of the principle
of equality, however.

Important information
TOX_Manual_Process-monitoring-unit_CEP400T_en 9
1.5 Displays in the document
1.5.1 Display of warnings
Warning signs indicate potential dangers and describe protective mea-
sures. Warning signs precede the instructions for which they are applicable.
Warning signs concerning personal injuries
DANGER
Identifies an immediate danger!
Death or severe injuries will occur if appropriate safety measures are not
taken.
èMeasures for remedial action and protection.
WARNING
Identifies a potentially dangerous situation!
Death or serious injury may occur if appropriate safety measures are not
taken.
èMeasures for remedial action and protection.
CAUTION
Identifies a potentially dangerous situation!
Injury may occur if appropriate safety measures are not taken.
èMeasures for remedial action and protection.
Warning signs indicating potential damage
NOTE
Identifies a potentially dangerous situation!
Property damage may occur if appropriate safety measures are not taken.
èMeasures for remedial action and protection.

Important information
10 TOX_Manual_Process-monitoring-unit_CEP400T_en
1.5.2 Display of general notes
General notes show information on the product or the described action
steps.
Identifies important information and tips for users.
1.5.3 Highlighting of texts and images
The highlighting of texts facilitates orientation in the document.
üIdentifies prerequisites that must be followed.
1. Action step 1
2. Action step 2: identifies an action step in an operating sequence that
must be followed to ensure trouble-free operation.
wIdentifies the result of an action.
uIdentifies the result of a complete action.
èIdentifies a single action step or several action steps that are not in an
operating sequence.
The highlighting of operating elements and software objects in texts facili-
tates distinction and orientation.
<In square brackets> identifies operating elements, such as buttons,
levers and (valves) stopcocks.
''with quotation marks'' identifies software display panels, such as win-
dows, messages, display panels and values.
In bold identifies software buttons, such as buttons, sliders, check-
boxes and menus.
In bold identifies input fields for entering text and/or numerical values.

Important information
TOX_Manual_Process-monitoring-unit_CEP400T_en 11
1.6 Contact and source of supply
Only use original spare parts or spare parts approved by TOX®PRES-
SOTECHNIK.
TOX®PRESSOTECHNIK GmbH & Co. KG
Riedstraße 4
D - 88250 Weingarten
Tel. [phone]
E-Mail: [email protected]
For additional information and forms see www.tox-pressotechnik.com.

Important information
12 TOX_Manual_Process-monitoring-unit_CEP400T_en

Safety
TOX_Manual_Process-monitoring-unit_CEP400T_en 13
2 Safety
2.1 Basic safety requirements
The product is state of the art. However, operation of the product may in-
volve danger to life and limb for the user or third parties or damage to the
plant and other property.
For this reason the following basic safety requirements will apply:
Read the operating manual and observe all safety requirements and
warnings.
Operate the product only as specified and only if it is in perfect techni-
cal condition.
Remedy any faults in the product or the plant immediately.
2.2 Organizational measures
2.2.1 Safety requirements for the operating company
The operating company is responsible for compliance with the following
safety requirements:
The operating manual must always be kept available at the operation
site of the product. Ensure that the information is always complete and
in legible form.
In addition to the operating manual, the generally valid legal and other
binding rules and regulations must be provided for the following content
and all personnel must be trained accordingly:
– Work safety
– Accident prevention
– Working with hazardous substances
– First aid
– Environmental protection
– Traffic safety
– Hygiene
The requirements and contents of the operating manual must be sup-
plemented by existing national regulations (e.g. for prevention of acci-
dents and for environmental protection).
Instructions for special operating features (e.g. work organization, work
processes, appointed personnel) and supervisory and reporting obliga-
tions must be added to the operating manual.

Safety
14 TOX_Manual_Process-monitoring-unit_CEP400T_en
Take action to ensure safe operation and make sure that the product is
maintained in a functional condition.
Only allow authorized persons access to the product.
Ensure that all personnel work with awareness of safety and potential
dangers with reference to the information in the operating manual.
Provide personal protective equipment.
Maintain all safety and information on dangers regarding the product
complete and in legible condition and replace as required.
Do not make any changes, carry out attachments or conversions to the
product without the written approval of TOX®PRESSOTECHNIK. Ac-
tion contrary to the above will not be covered by the warranty or the op-
erating approval.
Make sure that the annual safety inspections are carried out and docu-
mented by an expert.
2.2.2 Selection and qualifications of personnel
The following safety requirements are applicable for the selection and quali-
fications of personnel:
Only appoint persons to work on the plant who have read and under-
stood the operating manual, and in particular, the safety instructions
before starting work. This is particularly important for persons who only
work on the plant occasionally, e.g. for maintenance work.
Only allow persons appointed and authorized for this work access to
the plant.
Only appoint reliable and trained or instructed personnel.
Only appoint persons to work in the danger zone of the plant who can
perceive and understand visual and acoustic indications of danger (e.g.
visual and acoustic signals).
Ensure that assembly and installation work and the initial commission-
ing are performed exclusively by qualified personnel who have been
trained and authorized by TOX®PRESSOTECHNIK.
Maintenance and repairs must be performed by qualified and trained
personnel only.
Ensure that personnel who are being trained, instructed or are in an ap-
prenticeship can only work on the plant under the supervision of an ex-
perienced person.
Have work on electrical equipment performed only by electricians or
trained persons under the direction and supervision of an electrician in
accordance with the electrotechnical regulations.

Safety
TOX_Manual_Process-monitoring-unit_CEP400T_en 15
2.3 Fundamental hazard potential
Fundamental hazard potentials exist. The specified examples draw atten-
tion to known hazardous situations, but are not complete and do not in any
way provide safety and risk awareness action in all situations.
2.3.1 Electrical hazards
Attention should be paid to electrical hazards particularly inside the compo-
nents in the area of all assemblies of the control system and motors of the
installation.
The following basically applies:
Have work on electrical equipment performed only by electricians or
trained persons under the direction and supervision of an electrician in
accordance with the electrotechnical regulations.
Always keep the control box and/or terminal box closed.
Before commencing work on electrical equipment, switch off the main
switch of the system and secure it against being switched back on in-
advertently.
Pay attention to the dissipation of residual energy from the control sys-
tem of the servomotors.
Make sure that the components are disconnected from the power sup-
ply when carrying out the work.

Safety
16 TOX_Manual_Process-monitoring-unit_CEP400T_en

About this product
TOX_Manual_Process-monitoring-unit_CEP400T_en 17
3 About this product
3.1 Warranty
Warranty and liability are based on the contractually specified conditions.
Unless specified otherwise:
The TOX®PRESSOTECHNIK GmbH & Co. KG excludes any warranty or
liability claims in the event of defects or damage if these are attributable to
one or more of the following causes:
Non-compliance with safety instructions, recommendations, instructions
and/or other specifications in the operating manual.
Non-compliance with the maintenance rules.
Unauthorized and improper commissioning and operation of the ma-
chine or components.
Improper use of the machine or components.
Unauthorized constructional modifications to the machine or compo-
nents or modifications to the software.
Use of non-genuine spare parts. Batteries, fuses and lamps are not
covered by the warranty.

About this product
18 TOX_Manual_Process-monitoring-unit_CEP400T_en
3.2 Product Identification
3.2.1 Position and content of the type plate
The type plate can be found on the back of the device.
Designation on the type plate Meaning
Type Product designation
ID No Material number
SN Serial number
Tab.1 Type plate
Type code structure
Setup and function of process monitoring CEP 400T-02/-04/-08/-12 are
similar to a large extent. The number of measurement channels differenti-
ates the devices:
Type key Description
CEP 400T-02: Two separate measurement channels 'K1' and
'K2'.
CEP 400T-04: Four separate measurement channels 'K1' to 'K4'.
CEP 400T-08: Eight separate measurement channels 'K1' to 'K8'.
CEP 400T-12: Twelve separate measurement channels 'K1' to
'K12'.

About this product
TOX_Manual_Process-monitoring-unit_CEP400T_en 19
3.3 Function description
3.3.1 Process monitoring
The process monitoring system compares the maximum force during a
clinching process with the target values that are set in the device. Depend-
ing on the result of the measurement, a good/bad message is issued both
on the internal display as well as the external interfaces provided.
3.3.2 Force monitoring
Measurement of force:
For tongs, the force is generally recorded via a screw sensor.
For presses, the force is recorded via a force sensor behind the die or
the punch (monitoring of the maximum value)
3.3.3 Force measurement
The process monitoring system compares the maximum measured force
with the set maximum and minimum limit values.
MAX limit value
Peak value of
poining process
MIN limit value
Monitoring control dimension 'X' by precision limit caliper
Pressforce
control by
load cell
Fig.1 Force measurement

About this product
20 TOX_Manual_Process-monitoring-unit_CEP400T_en
Changes in a process, e.g. clinching process, results in deviations in the
press force. If the measured force exceeds or drops below the fixed limit
values, the process is stopped by the monitoring system. To ensure that
the process stops at "natural" deviations of the press force, the limit values
must be chosen correctly and not to narrow.
The function of monitoring equipment depends mainly on the setting of the
evaluation parameter.
3.3.4 Test of the final position of the closed tool
Clinching
The process monitoring system measures and evaluates the maximum
force reached.
To make a statement about a clinching process from the set minimum and
maximum limits, it must be ensured that the clinching tools were fully
closed (e.g. with a precision limit button).
If the measured force is then within the force window, it can be assumed
that the 'X' control dimension is in the required range.
The value for control dimension 'X' (residual bottom thickness) is specified
in the rest report and can be measured on the piece part with a measuring
sensor.
The limits of force must be adjusted to the minimum and maximum values
of the control dimnesion 'X' specified in the test report.
Punch
Die
Control dimension 'X'
(resulting bottom thickness)