Operating The Die-Tracker

CHAPTER ONE

"Start Up"

FIVE STEPS TO START USING DIE-TRACKER PLUS

STEP ONE:   ACTIVATE POWER

Once the Die-Tracker plus is installed and correctly calibrated, activate power to the Die-Tracker.  Copyright IMCO International Ltd. will first appear on the Alpha/Numeric Display along with the current software version i.e.: 3.60.

After the copyright message, the Die-Tracker will switch to the last page from the factory set up on new systems.  After you have set the initial operating limits the Die-Tracker will always switch to the last readings of the last page used in production.

KEY LOCK SELECTOR SWITCH

STEP TWO :  SETTING LIMITS

~Default limits have been set at IMCO.  You may use these limits or enter your own limits.  If you choose default limits proceed to step 3~   

The "Limits" position is used to enter the limit values or change limit values and to set the amount of parts to be counted on the Pre-Set Parts Counter.   Turn the Key Lock Selector Switch to the "Limits" position.  There are three limit values and the Pre-Set Parts Counter amount that needs to be entered:  1) Press Limit;  2)  Hi/Low Limits;  3)  Tracking Limits;  4)   Pre-Set Parts Counter.  The first "Limit" will appear on the Alpha/Numeric Display, move the arrow buttons to increase or decrease the limit values or select the Die-Trackers pre-programmed limits.   Use the star button to move to the next limit.  Always press the enter button after a new value has been selected.  Pre-Set Parts Counter digits are moved left to right by pressing the star button. The limit digit values are changed by using the arrow button.  Press the enter button after entering the new numbers of parts to be counted not after each entered digit.

STEP THREE : BY PASS  -  SET UP

The "By-Pass" position is used when setting up dies.  Turn the Key Lock Selector Switch to the "By-Pass" position.  Set up the die in the press that is to be used for production.  Make a good part.      ~Press limits are always on even in the By-Pass position.~

STEP FOUR : BY PASS  -  RUN THE PRESS

The adaptive learning "Operate"  has two selector switch positions. Operate "reset on" allows the operator to reset overloads/underloads or Operate "reset off" does not allow the operator to reset overloads. underloads. Turn the Key Lock Selector Switch to operate "reset off" or operate "rest on".  After the Adaptive Learning Feature samples a part within 8 or 16 strokes, the Die-Tracker plus will calculate and set limits.  ~Each time the system is powered up it will keep in memory the last readings.~  Change die after die and never manually set limits again.

STEP FIVE : RELEARN  -  RECALCULATE LIMITS SET POINTS

1) Press Reset Button - system will relearn or  2) Turn Selector Switch to By-Pass then immediately to any position.  System will relearn.

"Limits"

Select the "LIMITS" position on the Key Lock Selector Switch

THE FIRST LIMIT DISPLAY WILL APPEAR:

AUTO HI +08 %  (EXAMPLE)

Use arrows to Increase or Decrease Limit Values

                                            NEXT LIMIT WILL APPEAR

PRT LIMIT - 12345678  (EXAMPLE)

Press Star to move each Part Digit from left to right

                                            NEXT LIMIT WILL APPEAR

PRESS LIMIT 107% (EXAMPLE)

Use Arrows to Increase or Decrease Limit Values

Continue following procedure until all limits have been entered or changed using the Arrow Buttons to Increase or Decrease the limits value, Star Button to move to the next limit or move digits of the parts count (PRT LIMIT) and Enter Button to enter or change all limit values. 

Refer to Chapter Two for description of each limit.

CHAPTER TWO

"Understanding The Key Lock Selector Switch"

KEY LOCK SELECTOR SWITCH

The Key Lock Selector Switch has Four Functions Positions that may be used to operate the Die-Tracker Plus.  The Key Lock Selector Switch can be turned to By-Pass then immediately to any operate position allowing the Die-Tracker Plus to relearn.   
   

~PRESS LIMITS ARE ALWAYS ON~

        TURN KEY LOCK SELECTOR SWITCH TO SELECTED POSITION

The Four Positions Available for Selection:

BY-PASS  -   OPERATE (RESET ON) -  OPERATE (RESET OFF)  -  LIMITS

DESCRIPTION:

BY-PASS                                  

This position is used for die set-up or changing material.  It allows the operator to bypass the Die Limits which have been previously set and disables the Adaptive Learning program  from operating. ~The press limits are always on even in the By-Pass position~ 

Relearn  
The system will relearn by turning the Key Lock Selector Switch to BY-PASS then immediately to any operate position.

Press Limits  - Press Capacity Overload Limit.  ~Press Limits are always on and cannot be ~Press Limits are always on and cannot be By Passed.~

Chapter Three

"Normal Operating Capabilities"

Die-Tracker Plus has six page selections in which the Die-Tracker normally functions:

Tons - Total Percent - Reverse Load - Strokes Per Minute (SPM) - Parts Count- Tracking Limits

PAGES 1 THROUGH 5 SHOWS THE STATUS OF THE SET LIMITS

TOTAL TONS

TOTAL PERCENT

REVERSE LOAD

STROKES PER MINUTE

PRE-SET PARTS COUNTER

PAGE SIX SHOWS THE HIT TO HIT REPEATABILITY OF THE SET LIMITS

TRACKING LIMITS

The allowable hit to hit repeatable variation in tonnage.  If the load changes more than the tracking limits, in any single stroke, the system signals the press to stop.  Tracking Limits overlook gradual changes in load and allow tight tolerances of plus and minus one percent (1%) to be set from one stroke to the next.  Miss feeds, broken punches, part ejection failure and material run out can be detected.  It is not affected by temperature changes or stock variation.  Tracking Limits assure the repeatability of quality parts.

CHAPTER FOUR

"Tonnage Trend - Hi/Low Limits"

Can be set and left for all dies regardless of tonnage or can be specifically set for each die.  This allows the operator to select the percentage above or below the tonnage for a particular job at which the Hi or Low Limit will be actuated, allowing for variations in material hardness or thickness in any one coil of material.

CHAPTER FIVE

"Viewing Load Readings"

TOTAL TONS

STROKES PER MINUTE

PARTS COUNT

REVERSE LOAD

TOTAL PERCENT

TRACKING LIMITS

The die load is displayed on the Left and Right Side display in percentage of load.

CHAPTER SIX

"Buttons"

RESET BUTTON   -  ENTER BUTTON  -  ARROW BUTTONS  -   STAR BUTTON 

RESET BUTTON

The main system RESET BUTTON is used to reset Overloads, Underloads or the Pre-Set Parts Counter values that have been reached. 

RELEARN
Pressing the RESET BUTTON while the press is running will allow the Die-Tracker Plus to relearn.

ENTER BUTTON

The ENTER BUTTON must be used when changing Limit values or the Pre-Set Parts Counter values.  When entering new Limit values or Pre-Set Parts Counter values, the ENTER BUTTON must be pressed or the new limit or pre-Set Parts Count values will not be accepted.

ARROW BUTTONS

A.
The ARROW BUTTONS are used to select a Page from the SIX PAGE SELECTIONS, Chapter Three, which shows the status of the limits or hit to hit repeatability.  The Page selected appears on the Alpha/Numeric Display.  Pages can be moved forward or reverse using the ARROW BUTTONS while the press is running to review all the load monitoring information which is occurring.

B.
When the Key Lock Selector Switch is in the Limits position the ARROW BUTTONS will increase or decrease the Limit values.  Press ENTER BUTTON when changing Limit values or the new Limit value information will not be accepted.  Press the STAR BUTTON (see below) to move to the next Limit.

STAR

The STAR BUTTON is used to move to the next Limit selection when the Key Lock Selector Switch has been turned to the Limits position.

Press the STAR BUTTON to move the digits on the Pre-Set Parts Counter from left to right. The digit parts count values are changed by using the ARROW BUTTONS.  Press the ENTER BUTTON after the new total number of parts to be counted, not after changing each digit parts count value.

PRESS IS NOT RUNNING

Press the STAR BUTTON from any of the SIX PAGE SELECTION to enter the LIMITS.  Use ARROW BUTTONS to scroll forward or reverse to review the Limits that have been set.  Limits may reviewed, but not changed.  The Die-Tracker Plus will time out after 5 seconds and return to the last page selection or return to the last page selection when the press starts up.

NOTE:
DIE NUMBER, PART NUMBER, STROKE PER PART AND QC COUNT (QUALITY CONTROL COUNT) WILL APPEAR, BUT CAN ONLY BE ACTIVATED WITH OPTION #925 HAND HELD KEYPAD.

PRESS IS RUNNING

Press the ARROW BUTTONS to select Page Five PARTS COUNT. The Alpha/Numeric Display will change each time the STAR BUTTON is pressed to show Limit information.  This information can be reviewed but not changed.  The Die-Tracker Plus will time out after 5 seconds and return to the last page selection.

NOTE:
DIE NUMBER, PART NUMBER, STROKE PER PART AND QC COUNT (QUALITY CONTROL COUNT) WILL APPEAR, BUT CAN ONLY BE ACTIVATED WITH OPTION #925 HAND HELD KEYPAD.

CHAPTER SEVEN

"Specifications"

EQUIPMENT

POWER

RELAY CONTACT RATING

SPEED

DISPLAYS