Operating Manual

Pressing monitor EPW400

 Force/Distance Measuremsent

 Original operating manualFirmware Version V1.09.02

TOX® PRESSOTECHNIK GmbH & Co. KG  Riedstraße 4  88250 Weingarten / Germany
Phone +49 (0) 751/5007-0  www.tox-pressotechnik.com  E-Mail: info@tox-de.com

Introduction

This operating manual applies to devices running firmware version V1.09.02 or higher.

TOX® PRESSOTECHNIK GmbH & Co. KG  Riedstraße 4  88250 Weingarten / Germany
Phone +49 (0) 751/5007-0  www.tox-pressotechnik.com  E-Mail: info@tox-de.com

NOTICE OF COMPLETIONANDINITIAL PRODUCTION INSPECTION
2019-08-30
TOX-PRESSOTECHNIK L L C
MR. ERIC SEIFERTH
4250 Weaver Pkwy
Warrenville, IL, 60555-3924 USA
Our Reference:

File E503298, Vol. D1Your Reference:

Models EPW 400, Smart9 T070E, Smart9 T057, STE 341-xxx T070, STE346-0005, CEP
400T, Touch Screen PLC's

Project Number:

4788525144

Project Scope:

UL Listing to the following standard(s):UL 61010-1, 3rd Edition, May 11, 2012, Revised April 29 2016, CAN/CSA-C22.2 No.
61010-1-12, 3rd Edition, Revision dated April 29 2016

Subject:

Notice of Project Completion with Initial Production Inspection

Dear MR. ERIC SEIFERTH:
Congratulations! UL's investigation of your product(s) has been completed under the above Reference Numbers andthe product was determined to comply with the applicable requirements. The Test Report and records in the FollowUp Services Procedure covering the product are completed and are now being prepared (if you do not have aseparate CB Report, you can to access the Test Report now). Please have the appropriate person in yourcompany that is responsible for receiving/managing UL reports access an electronic copy of the Test Report
and FUS Procedure through the CDA feature on MyHome@UL, or if you desire another method of receiving
the report please contact one of the contacts below. If you are not familiar with our MyHome site or need tocreate a new account in order to access your reports, please click the link HERE.
PLEASE NOTE: YOU ARE NOT AUTHORIZED TO SHIP ANY PRODUCTS BEARING ANY UL MARKS UNTIL
THE INITIAL PRODUCTION INSPECTION HAS BEEN SUCCESSFULLY CONDUCTED BY THE UL FIELD
REPRESENTATIVE.
An Initial Production Inspection (IPI) is an inspection that must be conducted prior to the first shipment of products
bearing the UL Mark. This is to ensure that products being manufactured are in accordance with UL LLC’s
requirements including the Follow-Up Service Procedure. After the UL Representative has verified compliance of yourproduct(s) at the manufacturing locations listed below, authorization will be granted for shipment of product(s) bearing
the appropriate UL Marks as denoted in the Procedure (located in the FUS Documentation of the report).
List of all manufacturing locations (please contact us if any are missing):
Manufacturing
Facility(ies):

TOX PRESSOTECHNIK GMBH & CO. KG
Riedstraße 488250 Weingarten Germany
Contact Name:
Eric SeiferthContact Phone No.:
1 630 447-4615
Contact Email:
ESEIFERTH@TOX-US.COM

It is the responsibility of TOX-PRESSOTECHNIK L L C, the Applicant, to inform its manufacturers of that the IPI mustbe successfully completed before product may be shipped with the UL Mark. Instructions for the IPI will be sent to
our inspection center nearest to each of your manufacturing locations. The contact information of the inspection
center is provided above. Please contact the inspection center to schedule the IPI and ask any questions you may
have regarding the IPI.
Inspections at your production facility will be conducted under the supervision of:Area Manager: ROB GEUIJENIC Name: UL INSPECTION CENTER GERMANY,
Address: UL INTERNATIONAL GERMANY GMBH
ADMIRAL-ROSENDAHL-STRASSE 9, NEUISENBURG, Germany, 63263
Contact Phone: 69-489810-0
Page 1

Email:Marks (as needed) may be obtained from:
Information on the UL Marks, including our new Enhanced UL Certification Marks can be found on the UL website athttps://markshub.ul.com
Within Canada, there are federal and local statutes and regulations, such as the Consumer Packaging and Labeling
Act, requiring the use of bilingual product markings on products intended for the Canadian market. It is the
responsibility of the manufacturer (or distributor) to comply with this law. The UL Follow-Up Service Procedures will
only include the English versions of the markings
Any information and documentation provided to you involving UL Mark services are provided on behalf of UL LLC(UL) or any authorized licensee of UL.
Feel free to contact me or any of our Customer Service representatives if you have any questions.
UL is strongly committed to providing you with the finest customer experience possible. You may receive an email
from ULsurvey@feedback.ul.com inviting you to please participate in a brief satisfaction survey. Please check yourspam or junk folder to ensure receipt of the email. The subject line of the email is “Tell is about your recent
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advance for your participation.

Very truly yours,
Brett VanDoren
847-664-3931
Staff Engineer
Brett.c.vandoren@ul.com

Page 2

Table of contents

Table of contents
1

Introduction .................................................................................................... 10
1.1 Explanation of symbols ........................................................................... 10

2

Brief description ............................................................................................ 11
2.1 Function of the pressing monitor ............................................................. 11

3

2.2

Measuring Mode and Configuration ........................................................ 11

2.3

Version .22 ............................................................................................. 12

Technical data ................................................................................................ 13
3.1 General technical data ............................................................................ 13
3.1.1 Power supply ............................................................................... 13
3.1.2 Hardware configuration ................................................................ 13
3.1.3 Connections ................................................................................. 14
3.1.4 Digital inputs ................................................................................ 15
3.1.5 Digital outputs .............................................................................. 15
3.1.6 USB ............................................................................................. 16
3.1.7 Ethernet ....................................................................................... 17
3.1.8 Environmental conditions ............................................................. 17
3.1.9 Electromagnetic compatibility in line with EC directives................ 18
3.1.10 Sensor: analog standard signals .................................................. 19
3.1.11 Sensor: supply voltage ................................................................. 19
3.1.12 Screw sensor with standard signal output .................................... 19
3.1.13 DMS signals................................................................................. 20
3.2

Overview of built-in version ..................................................................... 21
3.2.1 Mechanical specifications ............................................................ 21
3.2.2 Dimensions of installation housing with two slots ......................... 22
3.2.3 Dimensions of installation housing with three slots....................... 22
3.2.4 Hole pattern of installation housing (rear view) ............................. 23
3.2.5 Built-in version: digital inputs I0 – I15 (37-pin connector) ............. 24
3.2.6 Built-in version: digital outputs Q0 – Q7 (37-pin connector) .......... 25
3.2.7 Built-in version: pin assignment, DMS force transducer (channelY) ................................................................................................. 26
3.2.8 Built-in version: pin assignment, analog signals (channel Y force /channel X distance) for analog standard signals .......................... 27
3.2.9 Built-in version: pin assignment, analog standard signals ............ 29

3.3

Overview of wall-mounted version .......................................................... 31
3.3.1 Power supply ............................................................................... 31
3.3.2 Dimensions of wall-mounted version ............................................ 31

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3.3.3 Wall-mounted housing: digital inputs I0-I15 (25-pin D-sub female
connector).................................................................................... 32
3.3.4 Wall-mounted housing: digital outputs Q0-Q7 (25-pin D-sub female
connector).................................................................................... 33
3.3.5 Standard wall-mounted housing: pin assignment, DMS force
transducer (channel Y) ................................................................. 34
3.3.6 Wall-mounted housing: pin assignment, force transducer (channelY) Only hardware model EPW 400.202.1X ................................ 38
3.4Interfaces ................................................................................................ 40
3.4.1 Profibus ....................................................................................... 40
3.4.2 Fieldbus interface ........................................................................ 42

45Transport ........................................................................................................ 45
4.1 Storage ................................................................................................... 45
4.2

Transport ................................................................................................ 45

4.3

Dispatch for repair .................................................................................. 45

Operating the device ..................................................................................... 46
5.1 Switching on the EPW 400 ..................................................................... 46
5.2

Operating the device via touch screen (touch-sensitive screen)............. 46

5.3

Main menu 'Measuring' ........................................................................... 47
5.3.1 Buttons (from left to right) ............................................................ 47
5.3.2 Icons ............................................................................................ 48
5.3.3 Full screen display: ...................................................................... 49

5.4

Menu 'Zoom' ........................................................................................... 50
5.4.1 Buttons (from left to right) ............................................................ 50

5.5

Menu 'Gauge curve' ................................................................................ 53
5.5.1 Buttons ........................................................................................ 53

5.6

Menu 'Windows' ...................................................................................... 54
5.6.1 Edit window type .......................................................................... 55

5.7

Menu 'Envelope curve' ............................................................................ 61
5.7.1 Text fields .................................................................................... 63

6

Configuring the EPW 400 .............................................................................. 65
6.1 ProcessesScreen.................................................................................... 65
6.1.1 Select process number (64 processes) ........................................ 66
6.1.2 Assign process name (max. 40 characters) ................................. 66
6.1.3 Copy processes ........................................................................... 67
6.1.4 Settings........................................................................................ 68
6.1.5 Saving / restoring parameters ...................................................... 69

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6.2

Configuration .......................................................................................... 70
6.2.1 Force sensor ................................................................................ 70
6.2.2 Distance sensor ........................................................................... 76
6.2.3 Measuring parameters ................................................................. 81
6.2.4 Configuration I/O .......................................................................... 86
6.2.5 Configuring the analog outputs .................................................... 87
6.2.6 Valuation options ......................................................................... 88
6.2.7 Apply configuration ...................................................................... 89

6.3

Data ........................................................................................................ 90
6.3.1 Curve data ................................................................................... 90
6.3.2 Final Values ................................................................................. 91
6.3.3 Settings ........................................................................................ 92
6.3.4 Settings for data export to PC ...................................................... 93

6.4

Lot size ................................................................................................... 94
6.4.1 OrderCounterConfigScreen ......................................................... 94
6.4.2 Shift counter................................................................................. 95
6.4.3 ToolCounterConfigScreen ............................................................ 96

6.5

Diagram settings ..................................................................................... 97

6.6

Supplemnt .............................................................................................. 98
6.6.1 User administration ...................................................................... 99
6.6.2 Language ................................................................................... 102
6.6.3 Communication parameters ....................................................... 102
6.6.4 In-/Outputs ................................................................................. 107
6.6.5 Internal digital I/O ....................................................................... 108
6.6.6 Field bus parameters ................................................................. 109
6.6.7 Profibus / Anybus ....................................................................... 111
6.6.8 Analog inputs ............................................................................. 112
6.6.9 Date/Time .................................................................................. 113
6.6.10 Device name .............................................................................. 114

7

PLC interface pulse diagrams ..................................................................... 115
7.1 Start/Stop.............................................................................................. 115
7.1.1 Changing the program number .................................................. 116
7.1.2 Zero point adjustment ................................................................ 116

8Software module TOX®softWare ................................................................. 117
8.1 Networking via Ethernet ........................................................................ 117
8.2

8

Network server program EPW 400_Server ........................................... 117

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Troubleshooting .......................................................................................... 118
9.1 Listing error and status messages ........................................................ 118
9.2

Battery buffer ........................................................................................ 118

10 Maintenance ................................................................................................. 119
10.1 Change flash card................................................................................. 119
10.2 Battery change ..................................................................................... 120
11 Firmware update .......................................................................................... 121
11.1 Update from version V1.08 ................................................................... 121
12 Decommissioning ........................................................................................ 123
12.1 Storage ................................................................................................. 123
12.2 Disposal ................................................................................................ 123

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Introduction

1

Introduction

1.1

Explanation of symbols
 An arrow at the beginning of a paragraph indicates the action steps you mustcomplete.
 This tick at the beginning of a paragraph indicates a condition that must be met
before beginning the next step.
Danger notifications:
SafetyHere you will find instructions for the prevention of damage.
These safety notes must be strictly observed by the operating company and user of the machine.

Operating notes:
Note
Provides information on work sequences and methods that facilitate
the use of the machine.

Setting
Indicates important information about setting the operating parameters.

Function
Explains the functioning of the machine or the sequence of a working process.

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Brief description

2

Brief description
The pressing monitor EPW ensures constant monitoring and cares for quality assurance during production.

2.1

Function of the pressing monitor
The Pressing Monitor EPW 400 monitors processes in which precisely defined functional correlations between force and distance have to be verified. For this purpose,the device reads the force/distance data pairs from two measuring channels 'X' and'Y' during the measuring operation. The data are written to memory and can be displayed graphically. The resulting force/distance function is compared with the specified data limits of the set window values or envelope curve. An OK message is issued
if the data limits are complied with, otherwise a NOK message is issued.

2.2

Measuring Mode and Configuration
The device has two operating modes: "measuring" and "configuration". Only during
measuring mode can a registration followed by an evaluation be started. If the settings
on the EPW 400 are changed, e.g. during a program change or zero point adjustment,
or if the settings are being changed via the keyboard, it is not possible to begin ameasuring cycle.
The readiness for measuring is shown on the display by means of readysignal 'RDY'.

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Brief description

2.3

Version .22
Principle display of the Pressing Monitor EPW400 as Version 22, with changeoverfrom channel pair A to channel pair B.
You have the option of setting channels A and B for each process independent offorce and distance.
Note
Only the one channel pair (A or B) can be used to measure and not
both simultaneously!

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Technical data

3

Technical data

3.1

General technical data

3.1.1

Power supply

3.1.2

Input voltage:

24 V / DC, ± 25% (incl. 10% residual ripple)

Current consumption:≤1A

Hardware configurationCPU

ARM9 processor, frequency 200 MHz, passively
cooledMemory storage

1 x 256 MB CompactFlash (can be expanded to 4
GB)
2 MB boot flash
64 MB SDRAM (firmware and parameters)

Data storage

1024 kB RAM, remanent, buffer battery for final
values and counter readings

Real-time clock / accuracy

At 25°C ≤ ± -1 s / day,at 10 to 70C°: ≤ + 1 s to 11 s / day

Display

TFT, backlit, 5.7" graphics-capable
TFT LCD VGA (640 x 480)
Color depth: 16-bit
Backlit LED, switchable via software
Contrast 300:1
Brightness: 220 cd/m2
Viewing angle vertical 100°, horizontal 140°
Analog resistive, color depth 16-bit

Interface extensibility

1 x slot for back plane
1 x keyboard interface for max. 64 buttons withLED

Buffer battery

Lithium cell, pluggable
Battery type Li 3 V / 950 mAh CR2477N
Buffer time at 20°C typically 5 years
Battery monitoring typically 2.65 V
Buffer time for battery change min. 10 minutes
Order number: 300215

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Technical data

Battery change
Recommendation: change battery after 2 years.
To avoid data loss while performing the battery change, turn the device on for at least 10 minutes before the change-over.
1

Disconnect the power supply

2

Discharge any electrostatic charges

3

Remove the cover from the lithium battery

4

Remove the battery. (Do not use uninsulated tools - risk ofshort circuiting)5

Insert new battery with correct polarity

6

Replace the battery cover
Correct:

3.1.3

Connections





14

Incorrect:

16 digital inputs
8 digital outputs



1 USB device
1 CF memory card

1 Ethernet interface

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3.1.4

Digital inputs
16 digital inputs

Isolated

Input voltage

24 V (permissible range: -30 V to +30 V)

Input current

At rated voltage (24 V): 6.1 mA

Delay time of standard inputs

tLOW-HIGH

3.5 mstHIGH-LOW

2.8 msLOW level:≤5V

HIGH level:≥ 15 VLOW level:≤ 1.5 mA

HIGH level:≥ 3 mA

Input voltage

Input current

Input impedance
3.1.5

3.9 kΩ

Digital outputs
8 digital outputs

Isolated

Load voltage Vin

Nominal value 24 V (permissible range
18 V to 30 V)

Output voltage

HIGH levelmin. Vin-0.64 V

LOW level

max. 100 µA • RL

Output current

max. 500 mA

Parallel connection of outputs possible

Max. 4 outputs with Itot = 2 A

Short-circuit proof

Yes, thermal overload protection

Switching frequency

Resistive load 100 Hz
Inductive loadon inductance)
Lamp load

2 Hz (dependentmax. 6 W

Simultaneity factor 100%
Avoid reversing current
Reversing current at the outputs may damage the output drivers.

On devices with field bus interface, the outputs, such as "Ready for operation", arewritten on both the digital outputs and the field bus outputs. Whether the inputs areread on the digital inputs or on the field bus inputs is determined in menu 'Additional>Communication parameters->Anybus-S Subprint'.

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Technical data

3.1.6

USB
Number ofchannels

2 x host (full-speed)
1 x device (high-speed)

USB 2.0

According to USB device specification,
USB 2.0 compatible, type A and B
Connection to high-powered hub/hostMax. cable length 5 m
Pin

MIO

1

+5V

2

Data -

3

Data +

4

GND

Note
With the wall-mounted version of the EPW 400, it is not possible toaccess all the USB interfaces from the outside.

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3.1.7

Ethernet

1 channel

Twisted pair (10/100BASE-T),
Transmission according to IEEE/ANSI 802.3, ISO 8802-3,
IEEE 802.3u

3.1.8

Transmission
speed

10/100 Mbit/s

Connecting line

Shielded,

at 0.14 mm²Max. 300 mm

At 0.25 mm²:

max. 600 mm

LengthMax. 100 mm

Cable

Shielded, impedance 100 ΩConnector

RJ45 (modular connector)

LED status indicator

Yellow: transmission

Green: ready

Environmental conditions
Temperature

Operation

0 to 45°C

Storage-25 to +70°C

Relative humidity without condensation (acc. to RH2) 5 to 90%
Vibrations according toIEC 68-2-6

15 to 57 Hz,

Amplitude 0.0375 mm,
occasionally 0.075 mm

57 to 150 Hz,

Acceleration 0.5 g
occasionally 1.0 g

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Technical data

3.1.9

Electromagnetic compatibility in line with EC directives
Immunity according to EN 61000-6-2 / EN 61131-2
Electrostatic discharge (EN 61000-4-2)
Contactmin. 8 kV

Clearance

min. 15 kV

Electromagnetic fields (EN 61000-4-3)
80 MHz – 1 GHz:

10 V/m 80% AM(1 kHz)900 MHz ±5 MHz:

10 V/m 50% ED(200 Hz)

Fast transients (EN 61000-4-4)Power supply lines

2 kV

Process digital In-output

1 kV

Process analog inputs outputs

0.25 kV

Communication interfaces

0.25 kV

Induced high frequency (EN 61000-4-6)
0.15 – 80 MHz

10 V 80% AM (1 kHz)Surge voltage 1.2/50: min. 0.5 kV (measured at AC/DC converter input)
Emission interference according to EN61000-6-4 / EN61000-4-5
RFI voltage EN 55011

150 kHz – 30
MHz

(Group 1,
Class A)

RFI emissions EN 50011

30 MHz – 1 GHz(Group 1,
Class A)

Compliance with the EC Directive
Compliance with EMC directives requires correct installation in accordance with the device manual.
The person marketing the complete machine is responsible for theelectromagnetic compatibility of the overall system into which thecontrol system is integrated.

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Technical data

3.1.10Sensor: analog standard signals
Measuring is carried out by a sensor with a standardized process signal 0-10 V. The
input is selected in menu 'Configuration'.
Nominal force or nominal distance:

Adjustable via the menu

A/D converter:

12 bit = 4096 steps (for EPW 400.x02.1x)
16 bit = 65536 steps (for EPW 400.x02.0x)

3.1.11

Nominal load of resolution:

Steps see A/D converter, 1 step (bit) = nominal load /steps

Accuracy of measurement:

1%Max. sampling rate:

2000 Hz (0.5 ms)

Sensor: supply voltage
Auxiliary voltage:

24 V ± 5%, max. 100 mA

Reference voltage:

10 V ± 1% nominal signal: 0 – 10 V

Adjustment value
The entries 'Nominal force' or 'Nominal distance' must not bechanged without the agreement of the manufacturer.
3.1.12Screw sensor with standard signal output
Auxiliary voltage:

24 V ± 5%, max. 100 mA

Nominal signal:

0 – 10 V

Tare signal:

0 V = zero adjustment, > 9 V = measuring mode
Adjustment value
The entry 'Nominal force' must not be changed without the agreement of the manufacturer.
Tightening torque: 14 Nm
Zero adjustment before each work cycle
With some types of force transducers or measuring amplifiers withtare function, a decrease of the measuring accuracy is possible after
a certain period of time depending on the process. In order to ensure
repeating accuracy, a zero adjustment should be carried out before
each work cycle or at regular time intervals (e.g. for ZKN model
force transducers after approx. 10 minutes).

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Technical data

3.1.13DMS signals
Force measuring (channel Y) via DMS force transducer. The input is selected in menu
'Configuration'.
Nominal force or nominal distance:

Adjustable in the menu

A/D converter:

16 bit = 65536 steps

Nominal load of resolution:

65536 steps, 1 step (bit) = nominal load / 65536

Gain error:± 0.5 %

Max. sampling rate:

2000 Hz (0.5 ms)

Bridge voltage:

5V

Characteristic value:

Adjustable via the menu

Adjustment value
The entry 'Nominal force' must not be changed without the agreement of the manufacturer.

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Technical data

3.2

Overview of built-in version

3.2.1

Mechanical specifications
Steel panel installation housing

Zinc-coatedDimensions (W x H x D)

168 x 146 x 46 mm

Installation aperture (W x H)

175 x 150 mm

Display front panel (W x H)

210 x 185 mm

Weightapprox. 1.600 kg

Plastic front panel

EM-immune, conductive

Attachment method

8 x threaded bolts M4 x 10

Protection class according to DIN
40050 / 7.80

IP 54 (front panel)

Films

PolyesterIP 20 (housing)Resistance according to DIN 42115
Alcohols, diluted acids and alkalis,
household cleaners

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Technical data

3.2.2

Dimensions of installation housing with two slots

3.2.3

Dimensions of installation housing with three slots

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Technical data

3.2.4

Hole pattern of installation housing (rear view)

Top

T
o
p

Front view

Installation aperture
175 x 150 mm

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Technical data

3.2.5

Built-in version: digital inputs I0 – I15 (37-pin connector)
Pin

OK

Designation1

I0

Program bit 02

I1

Program bit 1

3

I2

Program bit 2

4

I3

Program bit 3

5

I4

Program bit 4

6

I5

Program bit 57

I6

Program strobe

8

I7

Offset external

190V

0 V external

20

I8

Start measurement21

I9

Reserve22

I 10

Control panel interlock

23

I 11

Error reset

24

I 12

Reserve25

I 13

Configurable input

26

I 14

Access level bit 1

27

I 15

Reserve

On devices with field bus interface, the outputs, such as "Ready for operation", arewritten on both the digital outputs and the field bus outputs. Whether the inputs areread on the digital inputs or on the field bus inputs is determined in menu 'Additional>Communication parameters->Anybus-S Subprint'.

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Technical data

3.2.6

Built-in version: digital outputs Q0 – Q7 (37-pin connector)
Pin

OK

Designation

19

0V

0 V external

28

Q0

OK

29

Q1

NOK

30

Q2

NOK alarm

31

Q3

Switching point
S11 / Enable

32

Q4

Switching point
S21 / NOK buzzer

33

Q5

Ready for measurement

34

Q6

Program ACK

35

Q7

Switching point 31/ Item quantity
warning36+ 24 V+24 V external

37+ 24 V+24 V external

Connection example of digital inputs and outputs

1 Output function configurable

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Technical data

3.2.7

Built-in version: pin assignment, DMS force transducer (channel Y)
Only hardware model EPW400.002.0X (with DMS subprint)
9-pin D-sub female connector DMS0 for DMS sensors
Pin

DMS signal

1

Measuring signal DMS +2

Measuring signal DMS -3

Reserve

4

Reserve

5

Reserve

6

Supply DMS V-

7

Sensor cable DMS F-

8

Sensor cable DMS F+

9

Supply DMS V+

Note
For hardware model EPW 400.022.0X (2-channel) the second analog input card is installed for channel pair 2 X/Y!
The connections are occupied the same as for the first card.
Channel Y DMS force transducer
Connection example of DMS0 without sensor cable (CKN / ZAK / ZPS)
9-pin D-sub connector
DMS0

Connection example of DMS0 with sensor cable
9-pin D-sub connector
DMS0

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Technical data

When connecting the DMS using the 4-conductor technique, pins 6 and 7 and pins 8
and 9 are bridged.
3.2.8

Built-in version: pin assignment, analog signals (channel Y force / channel X
distance) for analog standard signals
15-pin D-sub female connector (designation analog I/O)

Pin

Type Input/Output

Analog signal

1

I

Force signal 0 - 10 V channel Y /1

3

I

Ground, force signal channel Y /1

4

I

Travel signal 0 - 10 V channel X /2

6

I

Ground, travel signal channel X /2

7oAnalog output 1: tare +10 V / force / distance28oGround13oAnalog output 2: 0 - 10 V process-bound / force / distance2

14oGround15o+10 V sensor supply

Note
For hardware model EPW 400.022.0X (2-channel) the second analog input card is installed for channel pair 2 X/Y!
The connections are occupied the same as for the first card.
Channel Y force transducer, analog
Connection example of sensor with standard signal 0 - 10 V (ZKN with tare)
15-pin D-sub connector, analog I/O

2 Output function configurable

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Technical data

Channel Y oil pressure sensor
Connection example: ZDO
15-pin D-sub connector, analog I/O

Channel X distance transducer
Connection example of distance potentiometer (ZWW 10 V supply voltage)
15-pin D-sub connector,
analog I/OConnection example of distance transducer (ZKW 24 V supply voltage)
15-pin D-sub connector, analog I/O28

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Technical data

3.2.9

Built-in version: pin assignment, analog standard signals
Only hardware model EPW 400.002.1X (without DMS subprint)
Sub-D 15-pole female connector (designation analog I/O)

Pin

Type Input/Output

Analog signal

1

I

Force signal 0 - 10 V channel Y /1

3

I

Ground, force signal channel Y /1

4

I

Travel signal 0 - 10 V channel X /2

6

I

Ground, travel signal channel X /2

7oAnalog output 1: tare +10 V

8oGround13oAnalog output 2: 0 - 10 V process-bound

14oGround15o+10 V sensor supply

Note
Hardware model (2-channel) Version 22 is not provided with EPW
400.XX2.1X!
Channel Y force transducer
Connection example of sensor with standard signal 0 - 10 V (ZKN with tare)
15-pin D-sub connector, analog I/O

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Technical data

Channel Y oil pressure sensor
Connection example: ZDO
15-pin D-sub connector, analog I/O

Channel X distance transducer
Connection example of distance potentiometer (ZWW 10 V supply voltage)
15-pin D-sub connector,
analog I/OConnection example of distance transducer (ZKW 24 V supply voltage)
15-pin D-sub connector, analog I/O30

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Technical data

3.3

Overview of wall-mounted version

3.3.1

Power supply
Connection

3.3.2

M12 connector

PinvoltageType

Designation

1

24 V DCI

24 V supply voltage

30 V / DCI

GND supply voltage

5

PE

I

PE

Dimensions of wall-mounted version

1 Input / output

7

Supply voltage 24 V DC

2 Profibus interface (optional)

8

Force transducer Y2 (only Version
22)

3 RS232 interface (optional)

9

Distance transducer X2 (only Version 22)

4 Distance transducer X1

10Ethernet interface

5 Force transducer Y1

11

USB interface

6 Main switch

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Technical data

3.3.3

Wall-mounted housing: digital inputs I0-I15 (25-pin D-sub female connector)
Pin, D-SUB
25

OK

Color code

Designation

14

I0

White

Program bit 0

15

I1

Brown

Program bit 1

16

I2

GREEN

Program bit 2

17

I3

YELLOW

Program bit 3

I4

White-blue3

Program bit 4

10

I5

Brown-blue3

Program bit 5

18

I6

Grey

Program strobe

19

I7

White-yellow

Offset external

20

I8White-greyStart measurement

9

I9
21
22

Reserve

I10

White-pink

Control panel interlock

I11

Brown-red3

Error reset

I12

Reserve

I13

White-red3

Configurable input

25

I14

3

Access level bit 1

120V

Brown-green

0 V external (PLC)

110 V internalBlue

0 V internal

23

24 V internal

Pink+24 V from internal (source)

13

3 Must be connected later32

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Technical data

3.3.4

Wall-mounted housing: digital outputs Q0-Q7 (25-pin D-sub female connector)
Pin, D-SUB
25

OK

Color code

Designation

1

Q0

Red

OK

2

Q1

Black

NOK

3

Q2

Yellowbrown

NOK alarm

4

Q3

VioletSwitching point S14 / Enable

5

Q4

Grey-brown

Switching point S24 / NOK buzzer

6

Q5

Grey-pink

Ready for measurement

7

Q6

Red-blue

Program ACK

8

Q7

Pink-brown

Switching point 34 / item quantity warning

12

0V

Brown-green

0 V external (PLC)

24

24 V

White-green+24 V external (PLC)

4 Output function configurable

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Technical data

3.3.5

Standard wall-mounted housing: pin assignment, DMS force transducer(channel Y)
Only hardware model EPW 400.202.0X (with DMS subprint)
Note
For hardware model EPW 400.022.0X (2-channel) the second analog input card is installed for channel pair 2 X/Y!
The connections are occupied the same as for the first card.
(12-pin round socket)
The force measurement on channel Y is optionally carried out using a DMS force
transducer or a measuring sensor with standardized process signal 0 - 10 V.
Standardized measuring sensor
Auxiliary voltage: 24 V ± 5%, max. 100 mA (x = 100 mA, y = 100 mA)
0 – 10 V

Signal:Pin assignment force signal (channel Y)
12-pin round socket

34

Pin

Signal name

Type Input/Output

Notes

C

V+

o

Supply DMS V+

B

V-

o

Supply DMS V-f

S- DMSI

Measuring signal DMS -G

S+ DMSI

Measuring signal DMS +E

F- DMSo

Sensor cable DMS -D

F+ DMSo

Sensor cable DMS+j

ShieldoShieldk

24 V DCo

Auxiliary power for external measuring sensor 24 Va

0 V DCoEarth externalL

Signal +I

Input standardized measuring signalm

Signal -o

Measuring signal earth

H

Tare

Signal tare

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Technical data

When connecting the DMS using the 4-conductor technique, pins C and D andpins B and E are bridged.
Wall-mounted housing: pin assignment, force transducer (channel Y)(12-pin round socket)
Connection example: DMS without sensor cable

Connection example of DMS with sensor cable

Connection example of sensor with standard signal 0 - 10 V (ZKN with tare)
24 V supply voltage

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Technical data

Connection example: ZDO

Pin assignment distance signal (channel X)
The pin assignment is identical in hardware models EPW400.202.0X andEPW400.202.1X.
Note
For hardware model EPW 400.022.0X (2-channel) the second analog input card is installed for channel pair 2 X/Y!
The connections are occupied the same as for the first card.
12-pin round socket
Pin

Signal name

Type Input/Output

Notes

C

10 V+

o

Auxiliary power for external measuring sensor 10 Vk

24 V DCo

Auxiliary power for external measuring sensor 24 Vm

0 V DCoEarth external

G

Signal +I

Input standardized measuring signala

Signal -I

Measuring signal earthjShieldoShieldH

AnalogoAnalog output 0 - 10 V process-boundE

0 V DCoEarth analog output

Connection example of distance transducer potentiometer (ZWW 10 V supply voltage)

36

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Technical data

Connection example: distance transducer (ZKW)OM 100.EPW 400.202207.en

37

Technical data

3.3.6

Wall-mounted housing: pin assignment, force transducer (channel Y)
Only hardware model EPW 400.202.1X
Note
Hardware model (2-channel) Version 22 is not provided with EPW
400.XX2.1X!
(12-pin round socket)
The force measurement on channel Y is optionally carried out using a DMS force
transducer or a measuring sensor with standardized process signal 0 - 10 V.
Standardized measuring sensor
Auxiliary voltage: 24 V ± 5%, max. 100 mA (x = 100 mA, y = 100 mA)
0 – 10 V

Signal:Pin assignment force signal (channel Y)
12-pin round socket

Pin

Signal name

Type Input/Output

Notes

j

ShieldoShieldk

24 V DCo

Auxiliary power for external measuring sensor 24 Va

0 V DCoEarth externalL

Signal +I

Input standardized measuring signalm

Signal -o

Measuring signal earth

H

Tare

C
B
f
G
E

Signal tare

When measuring with internal measuring amplifier, pin E and pin L are bridged.

38

OM 100.EPW400.202207.en

Technical data

Connection example of sensor with standard signal 0 - 10 V (ZKN with tare)
24 V supply voltage

Connection example: ZDOOM 100.EPW 400.202207.en

39

Technical data

3.4

Interfaces

3.4.1

Profibus
According to ISO/DIS 11898, isolated
Min.

max.

Output differential voltage± 1.5 V

±5V

Input differential voltage± 0.2 V

±5V

Input offset voltage- 7 V/+ 12 V (to GND)

Output drive current± 55 mA (Udiff = ± 1.5 V)

Transmission speed

Up to 100 m cable
lengthMax. 12000 kbit

Up to 200 m cable
lengthmax. 1500 kbit

Up to 400 m cable
lengthmax. 500 kbit

Up to 1000 m cable
lengthmax. 187.5 kbit

Up to 1200 m cable
lengthmax. 93.75 kbit

Without repeatermax. 32

With repeater

Max. 126 (every repeaterused reduces the max.
number of subscribers)

Shielded, twisted

Wire cross-section

Number of subscribers per
segment

Connecting line

Min. 0.34 mm²
Wire diameter 0.64 mm
Wave impedance

135 to 165 Ω

Capacitance per unit length< 30 pf/m

Loop resistance110 Ω/km

Recommended cables

For fixed installation of UNITRONIC® BUS L2/FIPor
UNITRONIC® BUS L2/FIP 7-wire
For flexible installation of UNITRONIC® BUS FD P
L2/FIP

Node addresses

40

3 ... 124

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Technical data

Pin

Profibus

3

RXD/TXD-P

4

CNTR-P (RTS)

5

0 V

6

+5V

8

RXD/TXD-N

Note
The output voltage from pin 6 for termination with a terminating resistor is + 5 V.

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41

Technical data

3.4.2

Fieldbus interface
Data length: Byte 0-2

5Inputs I0-I15

Designation

Field bus byte

Field bus bit

I0

Program bit 0

0

0

I1

Program bit 1

0

1

I2

Program bit 2

0

2

I3

Program bit 3

0

3

I4

Program bit 4

0

4

I5

Program bit 5

0

5

I6

Program strobe

0

6

I7

Offset external

0

7

I8

Start measurement

1

0

I9

Reserve

1

1

I 10

Control panel interlock

1

2

I 11

Error reserve

1

3

I 12

Reserve

1

4

I 13

Configurable input

1

5

I 14

Access level bit 1

1

6

I 15

Reserve17Outputs Q0-Q7

Designation

Field bus byte

Field bus bit

Q0

OK

0

0

Q1

NOK

0

1

Q2

NOK alarm

0

2

Q3

Switching point S15

0

3

Q4

Switching point S25

0

4

Q5

Ready for measurement

0

5

Q6

Program ACK

0

6

Q7

Switching point S35

07

Output function options:Switching point S1 / Enable
Switching point S2 / Buzzer
Switching point S3 / Warning piece counter42

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Technical data

Format of final values via fild bus (bytes 3 – 63):
The end values are written on bytes 3 to 55 on the field bus (if this function is activated).


7

Byte X (structure):
6

5

4

3

2

1

0

Byte 3:

Status (Status 2 = OK / Status 3 = NOK)

Byte 4, 5, 6, 7:

Running number

Byte 8:Program

Byte 9:Status Warning*

Byte 10, 11:Max. force [kN] * 100

Byte 12, 13:Max. distance [mm] * 100

Byte 14:

SecondByte 15:

MinuteByte 16:

Hour

Byte 17:Day

Byte 18:Month

Byte 19:Year

Byte 20, 21:Window 1, actual force [kN] * 100 (for actual distance [mm])Byte 22, 23:

Window 1, force upper limit [kN] * 100

Byte 24, 25:

Window 1, force lower limit [kN] * 100

Byte 26, 27:Window 1, actual distance [mm] * 100

Byte 28, 29:Window 1, distance upper limit [mm] * 100

Byte 30, 31:

Window 1, distance lower limit [mm] * 100

Byte 32, 33:

Window 2, actual force [kN] * 100 (for actual distance [mm])Byte 35, 35:

Window 2, force upper limit [kN] * 100

Byte 36, 37:

Window 2, force lower limit [kN] * 100

Byte 38, 39:

Window 2, actual distance [mm] * 100

Byte 40, 41:

Window 2, distance upper limit [mm] * 100

Byte 42, 43:

Window 2, distance lower limit [mm] * 100

Byte 44, 45:

Window 3, actual force [kN] * 100 (for actual distance [mm])Byte 46, 47:

Window 3, force upper limit [kN] * 100

Byte 48, 49:

Window 3, force lower limit [kN] * 100

Byte 50, 51:

Window 3, actual distance [mm] * 100

Byte 52, 53:

Window 3, distance upper limit [mm] * 100

Byte 54, 55:

Window 3, distance lower limit [mm] * 100

Byte 56, 57:

Actual value force [kN] * 100

Byte 58, 59:

Actual value distance [mm] * 100

Byte 60 - 63:

Reserve

OM 100.EPW 400.202207.en

Byte X43

Technical data

Legend Byte 9
MeaningValue

No Warning

0

Warning limit: IO error order counter

30

Warning limit: Total error order counter

31

Warning limit: Error shift counter

32

Warning limit: Total error shift counter

33

Warning limit: Tool counter

34

Bytes 56 – 59 Actual Values
The actual distance [mm] of the respective window is determined as follows:
The actual distance [mm] is exactly in the centre of the window in X-direction.
Example:The window extends from 8.00 mm to 11.60 mm => actual distance [mm] = 9.80 mm.
The actual force [kN] is the point where the measurement curve intersects the actual
distance [mm].
Force [kN]
8.00 mm
11.60
mmActual force[mm]

Actual distance [mm]44Distance[mm]

OM 100.EPW400.202207.en

Transport

4

Transport

4.1

Storage






4.2

Cover the electrical connections to protect them from dust, e.g. with adhesive tape.
Protect the display against sharp-edged objects. If necessary, attach a suitable
protective cover (e.g. made of cardboard or hard foam).
Use a dry, ventilated room for storage.
Enwrap the device (e.g. with a plastic bag).
In case of high humidity: add a drying agent to the packaging (e.g. silica gel).

TransportProtective measures: as described in chapter Storage.
Packaging: Use a stable transport container for dispatch that has all-round interior padding.
 Ensure that there is sufficient distance to the walls of the transport container.
 Fix the device securely inside the transport container.


4.3

Accompanying documents (see chapter Dispatch for repair, p. 45)

Dispatch for repair
If you send the device for repair to the manufacturer's works or to an appropriatetechnical service provider, please include the following notes so that we can returnthe device to you as quickly as possible:

A detailed, precise description of the fault (however, while keywords are sufficient,
the brief note 'device is defective' helps very little); if the malfunction is unclear,
include also a brief description of the operating conditions and installations (upstream devices, etc.).
The name of our employee who is informed about the defect or with whom you
have agreed to send the device to the manufacturer.
The name of the contact person in your company for possible queries.

Please also include information even if the matter has already been discussed in detailwith one of our employees.

OM 100.EPW 400.202207.en

45

Operating the device

5

Operating the device

5.1

Switching on the EPW 400
After it has been switched on, the device displays the start screen:Once Windows CE and the necessary applications have loaded, the device will show
the main menu (graphical display of measured values).

5.2

Operating the device via touch screen(touch-sensitive screen)
The touch screen displays the dialogue boxes for measuring mode or configuration of
the EPW 400. Depending on operating mode, the buttons and fields are assigned todifferent displays and functions. The windows are explained in the corresponding
chapters of the operating manual.
The meaning of each button is defined in the description of the different menus.

46

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Operating the device

5.3

Main menu 'Measuring'

During measuring operation, the measuring display appears. The measurement
curve, the configured windows and the envelopes are displayed in graph form. The
selected zoom area displays the plotted force/travel area.
In the upper status bar, the current process number is faded in. The second line displays the process number assigned to the process and the EPW 400 process name.
The third status bar provides an additional numerical display of the measured values
for max. force [kN] and max. distance [mm].
An error is indicated by a red bar, a message by a yellow bar.
5.3.1

Buttons (from left to right)
Zoom

Changes the display detailMeasure curves

Accessories for curve measuring

Edit windows

Opens the menu 'Edit window'

Edit envelope

Opens the menu 'Edit envelope curve'

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47

Operating the device

5.3.2

48

Menu

Opens the 'Maintenance' menu

Error reset

Resets an error. This button appears only incase of an error.

Firmware version

Reads the firmware version.

Measure OK

The last measurement was OK

Measurement NOK

Last measurement was not OK. At least one
evaluation criterion was violated (envelope /window)

Measure active

Measurement is running, values are being recorded.

Measurement
stopped manually

Measurement stopped by clicking on symbol'Measurement OK', 'Measurement NOK', or'Measurement running'. Enable the measurement by clicking on symbol 'Measurement
stopped'.

Device ready tomeasureEPW 400 is ready to start a measurement.

Device not ready tomeasureEPW 400 not ready to start a measurement.

Error

Device signals an error. The exact cause of theerror is highlighted in red at the top of thescreen.

Ethernet interface
not initialized

Connection via Ethernet to a PC not yet possible.

Ethernet interface initialized

Connection via Ethernet to a PC realized

No USB stick inserted

No USB stick foundUSB stick inserted

USB stick detected

Icons

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Operating the device

5.3.3

Full screen display:

A change between normal display and full screen display is possible by tapping on
the diagram. As soon as a measurement is started, a change to full screen modetakes place automatically.

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49

Operating the device

5.4

Menu 'Zoom'
This window contains four text fields with zoom areas(two for each of the X and Y axes).

5.4.1

Buttons (from left to right)
Save user zoom

Saves the current setting as a user zoom

Restore user zoom

Opens the saved user zoom

Cancel zoom

Sets the maximum zoom area (fixed by thenominal load of the sensors)

Enter

Takes over the set zoom area and returns to themain menu

Undo

Goes back to the previous zoom view; this button appears when a change is made to thezoom setting.

The zoom area can be changed by direct input of the required value.
 Tap the input field you wish to change.

50

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Operating the device

A window with a numerical tap field will be displayed: Enter the required value and confirm it with the 'Enter' button.
 It is also possible to change the zoom area graphically by first tapping the diagram
to bring up a crosshair. This crosshair is the starting point for the zoom section:

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51

Operating the device

 Then tap on the graph again to set the place where the end point of the frame willbe:

As soon as a purple frame becomes visible
the <Zoom in frame> button appears for zooming in the selected frame;

When a change is made to the zoom setting, an 'Undo' button appears,
which will take you back to the previous zoom view.

52

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Operating the device

5.5

Menu 'Gauge curve'
By tapping on the gauge curve, the associated pair of values is shown.

5.5.1

Buttons
Back, goes back to main menu "Measuring mode"

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53

Operating the device

5.6

Menu 'Windows'
The evaluation windows are changed, created or deleted in this menu.
The settings in this menu apply to the currently selected process (e.g.,
process 3).
The process can be changed either by means of an external PLC or in the "Processes"
menu (see page 65). A process may include up to 10 windows, with window 0 always
being an online window; this window is monitored during measuring. As soon as a
violation is identified, a signal is forwarded to the PLC in real time so that action canbetaken(e.g. if a press comes down at an angle or there is a premature step-up in force, it will
be opened immediately).
Only one window is selected each time and is recognizable by 'Text field selected
window' or by the yellow window number. A window is selected by tapping on 'Text
field selected window' followed by the input of the window number or by tapping thewindow to be selected in the diagram. Four text fields show the dimensions of theselected window.

54

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Operating the device

5.6.1

Edit window type
By tapping on button 'Edit window type', it is possible to edit the type ofthe selected window.

Online window Window '0'
Three window types are available for online window Window '0' which cannot bechanged:

Online Window TYPE A:

Online Window TYPE B:



Online Window TYPE C:

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55

Operating the device

Window '1' to Window '10':
The following submenu appears in which one can switch between modes 'Entry', 'Exit','Entry/exit possible' and 'No entry/exit' for each boundary of the window (left, right,
top, bottom).

56

Absolute

The selected window remains in the absolute position

Max. X

The selected window is positioned with reference to the maximum
value reached (max. X)

Mean value
X

The selected window is positioned with reference to the last specified OK curves stored (mean value X)

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Operating the device

Window 'Max. X'

The selected window is positioned with reference to the maximum value reached(max. X).
The position can be defined using the 'Absolute distance lower limit' and 'Absolute
distance upper limit' values.
Proceed as follows: Tap on the input field in front of 'Absolute distance lower limit'.
The input window containing the numerical keypad appears.
 Enter the distance lower limit using the numerical keypad (enter a decimal point
before any decimal places; if no decimals places are entered, the display will show
two decimal places '.00').
 Confirm the entry with the 'ENTER' button.
 Tap on the input field in front of 'Absolute distance upper limit'. The input window
containing the numerical keypad appears.
 Enter the distance upper limit using the numerical keypad (enter a decimal point
before any decimal places; if no decimals places are entered, the display will show
two decimal places '.00').
 Confirm the entry with the 'ENTER' button.

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57

Operating the device

Window 'Mean value X'

The selected window is positioned with reference to the last specified OK curves
stored (mean value X)
The position can be defined using the 'Absolute distance lower limit' and 'Absolute
distance upper limit' values.
The "Number of mean values" field specifies the number of OK curves used for the
calculation.
Proceed as follows: Tap on the input field in front of 'Absolute distance lower limit'.
The input window containing the numerical keypad appears.
 Enter the distance lower limit using the numerical keypad (enter a decimal point
before any decimal places; if no decimals places are entered, the display will show
two decimal places '.00').
 Confirm the entry with the 'ENTER' button.
 Tap on the input field in front of 'Absolute distance upper limit'. The input window
containing the numerical keypad appears.
 Enter the distance upper limit using the numerical keypad (enter a decimal point
before any decimal places; if no decimals places are entered, the display willshow two decimal places '.00').
 Confirm the entry with the 'ENTER' button.

The 'Change window side' button switches between 'left-hand side highlighted', 'right-hand side highlighted', 'top highlighted', 'bottom highlighted' and 'entire window highlighted'. The corresponding side can also behighlighted by tapping the line of the window. The whole window is highlighted by tapping in the centre of the window.

58

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Operating the device

The 'Dustbin' button deletes the selected window.

You can change the size of a window By entering the required values in the text fields or By marking one side and tapping on the 'arrow buttons'
Arrow buttons

Move the highlighted
side to the left or the rightMove the highlighted
side up or downMove window button
The third option for moving and highlighting a side is to tap on the graphand bring up a cross (note: do not tap inside a window, or you will selectthe window) and then tap the 'Move window' button.

OM 100.EPW 400.202207.en

59Operating the device

This puts the selected side of the window onto the corresponding axis of the cross.

In the same way as changing the size of a window, also the position can be movedby highlighting the entire window when a cross is visible. Tapping the 'Move window'
button will move the center point of the window to the center of the cross.
It is also possible to move the window (with the whole window highlighted) using thearrow keys , ,  and .

'Accept window' button
Close this window by tapping on the "Accept window" button.
The current window settings will be adopted.

60

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Operating the device

5.7

Menu 'Envelope curve'
In this menu the envelope parameters can be changed.
The settings in this menu apply to the process currently selected (e.g.
process 3).

Copy envelope
curve parameters

Copies the lower entered envelope curve parameters to the upper ones or the upper ones
to the lower ones. Depending on what was
taught first.

Change mode

Switches the envelope mode between 'Evaluation', 'Teach' and 'Teach new'Teach-in on request

Specifies whether a curve is taught after confirmation by the user or automatically after
each measurement.

Switch envelope
function on/off

Switches the monitoring system on or off via
the envelope. The set envelope parameters
remain unchanged.

Teach additional
curve

Here a NOK curve can be taught. This button
only appears after a NOK evaluation of thelast curve and a violation of the envelope.

Apply inputs, return
to main menu

The inputs are adopted and the main menu iscalled up.

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61

Operating the device

In 'Teach' mode, the measured curves are plotted and the envelope limits are generated. This results in an upper and a lower envelope.

Upper Envelope

Lower Envelope

In mode 'Teach new', the existing envelopes are cancelled and the envelope end isbuilt again based on the following measurements.
A change from mode 'Evaluation' to mode 'Teach' is always possible for teaching further curves.
If in mode 'Evaluation' a curve violates the upper or the lower envelope, a button appears in menu 'Envelope' where a teach-in of this curve can be added to the envelope.

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Operating the device

5.7.1

Text fields
SY:

Force value by which the selected envelope (upper or lower) is
moved vertically in relation to the corresponding envelope
curve.

End Y:

Upper limit of the envelope.

Begin Y:

Lower limit of the envelope.

Upper / lower:

Choice of whether the parameter applies to the upper or lower
envelope.

SX:

Distance value by which the selected envelope (upper or lower)
is moved horizontally in relation to the corresponding envelope
curve.

Begin X:

Left-hand limit of the envelope.

End X:

Right-hand limit of the envelope.

SX
SY

To teach an envelope, proceed as follows:
Deactivate the 'Envelope' function and draw at least one curve.
 Call up the 'Edit envelope' menu.
 Tap on 'upper' to activate the upper envelope.
 Tap on 'End X' to set the envelope to the achieved final distance of the curve.
 Tap on 'Begin X' to set the value to '0'.
 Tap on 'End Y' to set the envelope to the final force achieved.
 Tap on 'Begin Y' to set the value to '0'.
 Tap on 'lower' to activate the lower envelope.
 Tap on 'End X' to set the envelope to the achieved final distance of the curve.
 Tap on 'Begin X' to set the value to '0'.
 Tap on 'End Y' to set the envelope to the final force achieved.

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63Operating the device Tap on 'Begin Y' to set the value to '0'.
 Change the mode to 'Teach new', or to 'Teach' if previously taught curves are to
be retained.
 Go to the 'Main menu'.
 Draw the required number of curves (measure).
 Go to the 'Envelope' menu again.
 Using SX and/or SY, move the upper / lower envelope horizontally / vertically byentering the desired value.
The upper / lower envelope can be limited or expanded horizontally using Begin
X / End X and limited or expanded vertically using Begin Y / End Y.
 Go to 'Evaluate' mode.
 Go to the 'Main menu'.
 The curves will now be recorded, and evaluated on the basis of the envelope andany windows that have been set.

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6

Configuring the EPW 400
Tapping the 'Menu' button opens the Configuration menu. Here you can call up thesubmenus, which enable you to adjust the settings for the following areas:

6.1

ProcessesScreen
 Select process number (e.g. 5)
 Allocate a name to the process (40 characters max., e.g. process5) Copy processes

12

Close the 'Process' window by tapping on the 'Accept' button. The selected process will be adopted.

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6.1.1

Select process number (64 processes)
 The process number can be selected using the arrows  and .
 The process number can be accessed by numerical input:
Tap the Process No. input field.
A window containing a numerical keypad will open.
 Enter the required process number and confirm this value with the 'Enter' button.

6.1.2

Assign process name (max. 40 characters)
You can assign a name to each process. Tap on Process Name, and a window will
open with an alphanumeric keypad for entering the name:By pressing the shift key  you can switch to capital letters lowercase letters numbers and special characters The entry is adopted using the 'Enter' button.
 You can also enter a number containing up to ten digits for each process. Tap on
the number and a window will open with a numerical keypad, which can be used
to enter the number.

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6.1.3

Copy processes
Tapping on 'Copy Process' opens a window in which you can set theparameters of the current process to be copied to other processes:

By tapping the input fields behind 'from process' and 'to process', the input window
with the numerical keypad will be opened for the direct input of the numbers of theprocesses.
You can specify which process parameters to copy from the current process. Tapping
the input fields next to the parameter designations selects (marked by "X") or deselects (empty field) the individual parameters.
In order to copy the selected parameters to one or to several consecutive processes,
tap on the input field behind 'from process'. This opens the input window with thenumerical keypad. Enter the number of the first process and confirm by pressing'Enter'. Then tap on the input field behind 'until process'. In the input window with thenumerical keypad, enter the number of the last process. A sequence in which process
0 follows process 63 is not allowed.
Attention
When copying data to all or some processes, the previous settings
for these processes will be lost!
 Tap on 'Copy' to start the copying process. Tapping on the "Cancel" button willcancel the process.

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6.1.4

Settings
Here the settings for the processes can be made.

When the "Increment process number after measurement' field is activated, the process number is increased by one (authorization level 1only). This means that the process is changed over to the next process.
By tapping the input fields behind 'Pmin' and 'Pmax', the input window with the numerical keypad will be opened.
1

In field 'Pmin' enter the start process number the counter is to adopt as starting
point.

2

In field 'Pmax' enter the end process number up to which the counter is to increase
the process number.
When the "Increment P-number after measurement' field is activated,
the proces number is increased by one (authorization level 1 only).

By tapping the input field in front of 'Password level to switch processes', the input
window with the numerical keypad will be opened. Here the authorization level can be
set that is necessary for the process changeover (authorization level 3 only).
When the field 'Process selection without strobe is activated, the process is selected in dependence of the created binary pattern on the process preselection bits without strobe (only authorization level 2 or higher).

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6.1.5

Saving / restoring parameters
Actuating button 'Save / restore parameters', opens the submenu forcopying all parameters and processes from the USB stick.
Copy parameters to USB stick
Tapping on the 'Save Parameters on USB Stick' copies all parametersand processes to the USB stick.
Load parameters from USB stick
Tapping on 'Load Parameters from USB Stick' copies all parametersand processes from the USB stick.

Data will be overwritten
When data are copied from the USB stick to the EPW 400, all processes and parameters will be overwritten. All previous processes
and parameters will be lost!

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6.2

Configuration

6.2.1

Force sensor
 Configuration of process-dependent parameters: force sensor, distance sensor, measuring parameters (measured data acquisition,
start/stop conditions) and switching points.
 Configuration of global parameters (valid for all processes):
I/O configuration and valuation options.

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Force sensor, channel Y
In the opened window it is possible to fix the parameters of the force sensor separately
for each process. The setting of the current process can be copied to other processes.
EPW 400.X02.X

EPW 400.X02.0: DMS hardware version

Nominal force of the force sensor (Nominal load) Version 22
In the opened window it is possible to select the parameters of the force sensor separately for each channel pair (measuring board). The setting of the current process
can be copied to other processes.
EPW 400.X02.X

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Configuring the EPW 400

Nominal force of the force sensor (Nominal load)
In this line, you can set the nominal force of the used force sensor. The nominal force
is specified in kN. The nominal force is achieved at the max. measuring signal of theforce transducer. For a standard signal of 0-10 V, the nominal force is 10 V.
 Tap on the input field after 'Nominal force'. The input window containing the numerical keypad appears.
 Enter the nominal force using the numerical keypad (enter a point before decimal
places; if no decimal places are entered, then the display shows two decimal
places '.00').
 Confirm the entry with the 'ENTER' button.
 By tapping on the measurement unit, a window with an alphanumerical keypadappears. You may enter four characters for the measurement unit.
Offset force sensor
In this line you can enter the offset value of the measuring signal in kN.
The 'Offset' parameter adjusts a possible zero point displacement of the analog measurement signal of the sensor.
 Tap on the input field behind 'Offset'. The input window containing the numerical
keypad appears.
 Enter the offset value using the numerical keypad (enter a point before decimal
places; if no decimal places are entered, then the display shows two decimal
places '.00').
 Confirm the entry with the 'ENTER' button.
Force sensor offset adjustment
By tapping on the 'offset adjustment' button, the actual analog measuring signal of the transmitter is taken as offset.
An offset adjustment is always necessary after changing or adding a force transducer.
Make sure the force transducer is not loaded during the adjustment.
Note
Generally, an offset adjustment should be carried out at least once a
day or after about 1000 measurements

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Offset limit force sensor
The offset limit is used set the maximum tolerated offset to 10%, 20% or 100% of thenominal force.
Offset adjustment for sensor with normal signal output:
 TOX® standard sensor: 10% (20% possible for compensation)
 By tapping on the input field behind 'Offset limit', the value of the offset limit canbe changed between '10', '20' and '100'. The value displayed last will be adopted.
Forced offset force sensor
If the 'Forced offset' function is activated, the EPW 400 carries out an offset adjustment for the respective channel automatically every time it is switched on. If this function is not activated, the EPW 400 is ready to measure as soon as it is switched on.
 Tap on the input field next to 'Forced offset' to switch the forced offset on or off.
The last setting displayed will be adopted.
Source force sensor
By tapping on the input field behind 'Source', you can switch between normal signal
and DMS. The last source displayed will be adopted.
If DMS is activated, an additional parameter 'Character number' is displayed.
Nominal characteristic value of force sensor
The characteristic for the DMS force transducer is entered using the 'Characteristic
number' parameter.
Value range: 0.1 – 8 mV/V
 Tap on the input field next to 'Characteristic number'. The input window containing
the numerical keypad appears.
 Enter the characteristic number using the numerical keypad (enter a point before
decimal places; if no decimal places are entered, then the display shows two decimal places '.00').
 Confirm the entry with the 'ENTER' button.
Bridge supply voltage
The bridge supply voltage is 5 V.

FilterSettingsScreen
With the parameter 'Filter' the cutoff frequency of the measuring channel can be set.
Value range: 5 Hz - 1000 Hz

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Force sensor calibration
Calibration: Specifying the allocation of the electric measuring signal
and the measuring value to be displayed. This is a two-point calibration.

Force 1
To teach, click on button 'Teach'.
Read in the current electric measuring signal.
Tap on the 'Force 1' input field.
A window with a numerical tap field will be displayed: Enter the value of the measuring value to be displayed for the electric measuring
signal and confirm this value with the 'Enter' button.
It is also possible to enter the electric measuring signal numerically by tapping on the
input field.
Force 2To teach, click on button 'Teach'.
Read in the current electric measuring signal.
Tap on the 'Force 2' input field.
A window with a numerical tap field will be displayed: Enter the value of the measuring value to be displayed for the electric measuring
signal and confirm this value with the 'Enter' button.
It is also possible to enter the electric measuring signal numerically by tapping on the
input field.

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Accept calibration

Close the window 'Enter nominal force' by tapping on button 'Accept
calibration'. The configuration will be adopted.

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6.2.2

Distance sensor
The parameters for the distance sensor can be specified individually for each process
in the window that is called up. The setting of the current process can be copied toother processes.
No resistance potentiometer

Resistance potentiometer

Distance sensor Version 22
In the opened window it is possible to select the parameters of the distance sensor
separately for each channel pair (measuring board). The setting of the current process
can be copied to other processes.
No resistance potentiometer76

Resistance potentiometer

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Nominal distance of the distance sensor (nominal load)
In this line you can set the nominal distance for the distance transducer used. The
nominal distance is specified in mm. The nominal distance is achieved at the maximum measuring signal (10 V) of the distance transducer. In the above example, thesensor has an output voltage of 10 V for a distance of 50 mm.
 Tap on the input field behind 'Nominal distance'. The input window containing thenumerical keypad appears.
 Enter the nominal distance using the numerical keypad (enter a point before decimal places; if no decimal places are entered, then the display shows two decimal
places '.00').
 Confirm the entry with the 'ENTER' button.
 By tapping on the measurement unit, a window with an alphanumerical keypadappears. You may enter 4 characters for the measurement unit.
 When using a resistance potentiometer, you must enter the potentiometer resistance in kΩ (as per data sheet) in order to optimize the linearity of the measuring
chain.
Distance sensor offset
In this line the offset value of the measurement signal is entered in mm.
The 'Offset' parameter adjusts a possible zero point displacement of the analog measurement signal of the sensor.
 Tap on the input field behind 'Offset'. The input window containing the numerical
keypad appears.
 Enter the offset value using the numerical keypad (enter a point before decimal
places; if no decimal places are entered, then the display shows two decimal
places '.00').
 Confirm the entry with the 'ENTER' button.
Offset adjustment of distance sensor
By tapping on the 'offset adjustment' button, the actual analog measuring signal of the transmitter is taken as offset.
An offset adjustment is always necessary after changing or adding a distance transducer. Make sure the distance transducer is not loaded during the alignment.
Note
Generally, an offset adjustment should be carried out at least once a
day or after about 1000 measurements

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Offset limit of distance sensor
The offset limit is used set the maximum tolerated offset to 10%, 20% or 100% of thenominal distance.
Offset adjustment for sensor with normal signal output:
TOX® standard sensor: 10% (20% possible for compensation)
 By tapping on the input field behind 'Offset limit', the value of the offset limit canbe changed between '10', '20' and '100'. The value displayed last will be adopted.
Forced offset of distance sensor
If the "Forced offset" function is activated, the EPW 400 carries out an offset adjustment for the respective channel automatically every time it is switched on. If this function is not activated, the EPW 400 is ready to measure as soon as it is switched on.
 Tap on the input field next to 'Forced offset' to switch the forced offset on or off.
The last setting displayed will be adopted.
FilterSettingsScreen
With the parameter 'Filter' the cutoff frequency of the measuring channel can be set.
Value range: 5 Hz - 1000 Hz78

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Distance sensor calibration
Calibration:
This function is used to specify the allocation of the electric measuring
signal and of the measuring variable to be displayed. This is a pure twopoint calibration.

Distance 1:
To teach, click on button 'Teach'.
Read in the current electric measuring signal.

 Tap on the 'Distance 1' input field.
A window will open with a numerical keypad.
 Enter the value of the measuring value to be displayed for the electric measuring
signal and confirm this value with the 'Enter' button.
It is also possible to enter the electric measuring signal numerically by tapping on the
input field.

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Distance 2:
To teach, click on button 'Teach'.
Read in the current electric measuring signal.

 Tap on the 'Distance 2' input field.
A window will open with a numerical keypad.
 Enter the value of the measuring value to be displayed for the electric measuring
signal and confirm this value with the 'Enter' button.
It is also possible to enter the electric measuring signal numerically by tapping on the
input field.

Accept calibration

Close the window 'Enter nominal force' by tapping on button 'Accept
calibration'. The configuration will be adopted.

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6.2.3

Measuring parameters
By actuating button 'Measuring parameters' a window is opened
branching into the menus 'Meas. Parameters' and 'Start/Stop condition':

Measured data acquisition (measuring parameters)
The mode for measuring data acquisition is always set for the process currently activated only. For opening the submenu 'Measuring data acquisition' tap on button'Meas. parameters':

In the top line, you can switch between the following four options by tapping on thetext: distance increasing
 distance increasing or decreasing
 force or distance changing
 time triggered

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Distance rising
The measured values are measured with max. measuring intervals (2000 Hz) but only
stored if the distance compared to the last measured value has changed by the Xinterval entered.
This mode is recommended if negative changes of the distance are not intended to
be stored (usually clinch applications or pressing applications where only positive distance changes are relevant).
The number of pairs of values to be stored remains small. The measuring curve occupies little storage place and can be quickly drawn and evaluated.
If the final force can increase without changing the distance (block force), the option'Add max. force at end of curve' can be selected. With this mode, the max. force andthe max. distance measured with max. sampling rate are recorded (comparable to a
maximum indicator). This pair of values is added to the curve.
distance increasing or decreasing
The difference with regard to the 'distance increasing' mode is that, here, the pairs ofvalues are stored when the distance has changed in the positive or negative direction
since the last stored value.
This mode is recommended if also negative distance changes have to be recorded(e.g. pressing application with snap-back effects).
The number of pairs of values to be stored remains small. The measuring curve occupies little storage place and can be quickly drawn and evaluated.
force or distance changing
In this mode, a pair of values is stored if, since the last stored pairs of values, either
the distance has changed by the X-interval in the positive or negative direction, or theforce has changed by the Y-interval in the positive or negative direction.
This mode is recommended if the force can change without a change in distancetaking place (e.g. applications with large slip-in effects).
time triggered
With this mode, a timed storage of a pair of values takes place after x ms each.
If no changes are detected, similar pairs of values offering no information but occupying storage place and decelerating the evaluation and the drawing of the curve arestored with this mode.
Should the work cycle run more slowly than specified in the measurement time, thebuffer for the acquisition of measured data will be full before the termination of a cycle
and there will be no record of the complete clinching/pressing process. In contrast,
the other measurement modes are independent of the execution time of the clinching/pressing process. Therefore, this mode is recommended for special applications
only where other modes do not lead to satisfying results.
Tapping on the value after the text "X interval" opens the input window with the numerical keypad. Here you can determine the accuracy of measurement up to 1/100
mm.

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Insert max. force at the end of the curve
Independent of the acquisition of measured data, the max. force at the end of thecurve can be displayed. This function can be switched on or off (practical for 'distanceincreasing' or 'distance increasing or decreasing').
Close the window 'Measuring data acquisition' by tapping on button 'Accept'. The configuration will be adopted.

Maximum sampling rate
The maximum sampling rate is usually 2000 Hz.

Start/stop condition
In menu 'Meas. parameters' you tap on button 'start/stop condition'.

In the top line you may select among the following options by tapping on the entry:
 distance-triggered
 force triggered start/stop from PLC
distance-triggered
A measurement is started as soon as the distance set at 'Start' is exceeded, andstopped as soon as the distance set at 'Stop' is not reached. With option 'Set force tozero at start' it is enforced that at the moment of exceeding the start threshold, theactual force is used as offset for measurement.

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Force-triggered
A measurement is started as soon as the force set with 'Start' is exceeded, andstopped as soon as the force set with 'Stop' is not reached. With option 'Set distanceto zero at start' it is enforced that at the moment of exceeding the start threshold, theactual distance is used as offset for measurement.
Start/stop from PLC
A measurement is started and terminated via the digital signal of an external control.
Using the option 'Trigger' means that when a particular force or distance value is exceeded, the other measured value is adjusted to zero.
SwitchingPoint ConfigurationScreen
In the opened window you can define for each measurement program
separately:– three switching points, either for a force signal or for a distance– an analog output signal 0 - 10 V (if it is set)
The setting for the current program can be copied into other programs.

In the fields of column 'Value' you enter the value in kN (with signal 'force') or in mm(with signal 'distance') for the switching points SP 1 to SP 3 with the help of the numerical keypad. In column 'Signal' you change between force and distance measurement by tapping on the input fields. With 'Active', the corresponding switching point is
activated or deactivated. A switching point can only be activated if it has been activated in the Configuration I/O menu.
The field 'abs.' indicates whether or not a triggered measurement is based on theabsolute zero point.
The 'analog out' field is only displayed if the analog outputs are configured in the
Configuration I/O menu.

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If a switching point is set, it is visualized with a yellow line in the measuring display.
If the switch point reacts to force, the line is horizontal, if the switch point reacts to
distance, it is vertical.

Close the 'switching points' window by tapping on the 'Accept' button.
The configuration will be adopted.

Note: Firmware version EPW 400
Up to EPW 400 version V1.06 the outputs of switching points SP1SP3 are only updated while measurement is in progress.
From EPW 400 version V1.07 onwards, the outputs of switching
points SP1-SP3 are constantly updated.

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6.2.4

Configuration I/O
In this window you may fix the switching function of the digital outputs 3,
4 and 7 as well as of the digital input 13:

Output 3:
Output 4:

Selection

Function

Switching point 1

Refer to switching points

ReleaseChange condition at NOK or reset

Switching point 2

Refer to switching points

NOK buzzer

Change switching state if NOK,For activation see 'Evaluation options'

Output 7:

Input 13:

Switching point 3

Refer to switching points

Warning piececounter

Change of the switching condition whenreaching the taught-in number in the ordercounter, view counter or tool counter.

TDC sensor

For activation see 'Evaluation options'

Authorization bit 0

After activation, the user level can be selected from a control system.

Reset

For activation see 'Evaluation options'

The switching logic can be switched between the settings 'High' and 'Low'.

By tapping on the input fields, a shift to the corresponding function takes place.
In this window, the analog outputs are configured.

Close the window 'Configuration I/O' by tapping on the button 'Accept'.
The configuration will be adopted.

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6.2.5

Configuring the analog outputs

Depending on requirements, the relationship between outputs 0 and 1 can be defined
here.

Output 0:

Output 1:

Selection

Function

Actual distancevalue [V]Outputs the actual value of the distancesensorActual force value[V]

Outputs the actual value of the force sensor

Tare signal

Outputs a tare signal

DeactivatedOutput 0 is deactivated

Actual distancevalue [V]Outputs the actual value of the distancesensorActual force value[V]

Outputs the actual value of the force sensor

Process-dependent
value

Outputs a predefined voltage which is set
in the 'Switching points' menu

DeactivatedOutput 1 is deactivatedClose the 'Configure analog outputs' window by tapping on the "Accept"
button. The configuration will be adopted.

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6.2.6

Valuation options
In this window you may enable the following valuation functions (only in
combination with the valuation box):

The corresponding function is activated (X) or deactivated by tapping on the input
field.
Activate NOK buzzer (NOK buzzer)
In the event of a NOK, an acoustic signal sounds for the duration of the time interval
set under 'Buzzer time length'. If 0 sec. is set under 'Buzzer time length' then the
acoustic signal sounds until the NOK is acknowledged.
NOK acknowledge external (reset)
Acknowledgement of NOK via digital input I13
NOK acknowledge via display (reset)
Acknowledgement of NOK direct on the display.
Monitor TDC-sensor
The TDC sensor (TDC position) must be exited when measuring is started, otherwise
an error message will be emitted.
Close the window 'valuation parameters' by tapping on the button 'Accept'. The configuration will be adopted.

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6.2.7

Apply configuration
After each change you will be asked when leaving the menu whether the change shallbe stored for the current process only, be copied to all the 64 processes, or be copied
to several consecutive processes:

 Tap on the corresponding button in order to adopt the entry for the activated process, for all 64 processes or for several consecutive processes.
Tie rods serve as HZ fastening.
When copying data to all or some processes, the previous settings
for these processes will be lost!
To copy the values to several consecutive processes, tap on the input field behind'from process'. The input window containing the numerical keypad appears. Enter thenumber of the first process and confirm by pressing 'Enter'. Then tap on the input field
behind 'until process'. In the input window with the numerical keypad, enter the number of the last process and confirm by pressing "Enter".
Tie rods serve as HZ fastening.
A sequence in which process 0 follows process 63 is not allowed.

You can close this window without applying the values using the 'Cancel input' button.
Thereafter a window will be opened again asking you whether you wish to undo thechanges, tip on the button 'yes' or 'no' to answer the question.

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6.3

Data
Here you can see a display of the recorded pairs of distance/force values (curve data) and the final values for the current channel. You canalso adjust the settings for the final values and for exporting data.

6.3.1

Curve data
To open this submenu, tap the 'Curve data' button in the 'Data' menu:

This window contains a list of the recorded value pairs (distance/force) on the lastmeasured curve. The list provides the running index numbers (ascending), the X value
in mm, and the Y value in kN.
You can scroll up or down using the "" and "" arrow keys. The number of measured
values in the last measurement is displayed in the top right-hand corner. The numberof measured values should ideally be approximately 250.

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Delete the curve data by tapping the 'Dustbin' button.

This button saves the recorded curves to a connected USB stick as a
CSV file. Depending on the size of the recorded curves, up to 100
curves are saved and copied on the USB stick. The name of the EPW
400 device as well as date and time will be used as name of the data
file. The data can be found on the USB stick in the "Tox\Archive" folder.
Close the 'Curve data' menu by tapping on 'Exit'.

6.3.2

Final Values
To open this submenu, tap the 'Final values' button in the 'Data' menu:

After each measurement, a dataset of final values is stored. This dataset includes thefollowing information:
No.

Number of the measurement. 1000 final values are stored in a circular buffer, i.e. with each new measurement, the oldest dataset (= no.
999) is discarded and the newest is added (last measurement = no.
0)

Run. no.

Indicates a unique running number that increases by one after eachmeasurement

Prog.

Assignment of the measurement to a program
State no. '2': Measurement OK (green background)
Status no. '3': Measurement NOK (red background) Status(see chapter 9.1 'Listing error and status messages')

StatusForcemaximum force

Distance

Maximum distance

Date

Date of measurement (dd.mm.yy)

TimeTime of measurement (hh:mm:ss)

W1 F_inForce entry in window 1

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W1 D_inDistance entry in window 1

W1 F_out

Force exit in window 1

W1 D_out

Distance exit in window 1

W1 F_mid

Force average in window 1

You can scroll upwards, downwards, right and left using the arrow keys , ,  and.
Close the 'Curve data' menu by tapping on 'Exit'.

Delete the final values by tapping the 'Dustbin' button.

Additional display of sampling rate and valuation time in ms (authorization level 3 only).
This button saves the recorded curves to a connected USB stick as a
CSV file. The last 1000 end value data sets will be saved and then copied to the USB stick. The name of the EPW 400 device as well as date
and time will be used as name of the data file. The data can be foundon the USB stick in the "Tox\Archive" folder.
6.3.3

Settings

Here you can choose whether to receive a message after a measurement or whether
the final values will be stored.
If the control box is activated, the operator must confirm after each measurement
whether the measurement shall be saved with the final values or not.
If the control box is not activated, each measurement will be automatically added tothe end values.

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6.3.4

Settings for data export to PC

Here you can adjust the settings for exporting data to a PC. After the export, the data
are available as a '.csv-file' in the corresponding directories (to be set in TOX®softWare).
If the 'Quit' field is ticked, the PC will confirm receipt of the measurement data. If no
confirmation takes place, the data transfer has failed and no further measurement ispossible.
Close the window 'Settings for data export to PC' by tapping on button'Accept'. The displayed values will be adopted.

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6.4

Lot size
Three independent counters are available in the EPW 400:

6.4.1

OrderCounterConfigScreen

Counts the OK/total parts of an order in progress

Shift counter

Counts the OK/total parts of a shift

ToolCounterConfigScreen

Counts the total parts that have been processed with the current tool set.

OrderCounterConfigScreen
To open this menu, tap on the 'Job counter' button:

In the text fields of the first two bars of this menu, all OK parts as well as the total
number of the parts of a current job are displayed. Both counter readings are set tozero by pressing the 'Reset' button.
If in text field 'Message at' a certain quantity of the counter is entered with the numerical keypad, a message with a yellow background will be displayed as soon as thisreading is reached. The work cycle is not stopped with this function.
If a certain quantity is entered in text field 'Switch off at' using the numerical keypad,
the work cycle will be stopped when this reading is reached. A counter value message(with a red background) is issued. A continuation of the process is only possible after
the acknowledgement of the error. The counter reading must first be reset, as otherwise the counter will once more be exceeded and the machine will stop again at thenext process.
The value '0' of the text fields 'Message at' and 'Switch off at' deselects the corresponding option (no message or no switching-off of the machine).

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If the tick is set in 'Main menu', the value will be displayed in the second line of themain menu. Only one counter can be displayed in the main menu.
Close the 'Job counter' window by tapping on the 'Accept' button. The
displayed values will be adopted.
6.4.2

Shift counter
To open this menu, tap on the 'Shift counter' button:

In the text fields of the first two lines of this menu all OK parts as well as the total
number of parts produced in a shift are displayed. Both counter readings are set tozero by pressing the 'Reset' button.
If in text field 'Message at' a certain quantity of the counter is entered with the numerical keypad, a message with a yellow background will be displayed as soon as thisreading is reached. The work cycle is not stopped with this function.
If a certain quantity is entered in text field 'Switch off at' using the numerical keypad,
the work cycle will be stopped when this reading is reached. A counter value message(with a red background) is issued. A continuation of the process is only possible after
the acknowledgement of the error. The counter reading must first be reset, as otherwise the counter will once more be exceeded and the machine will stop again at thenext process.
The value '0' of the text fields 'Message at' and 'Switch off at' deselects the corresponding option (no message or no switching-off of the machine).
If the tick is set in 'Main menu', the value will be displayed in the second line of themain menu. Only one counter can be displayed in the main menu.
Close the 'Shift counter' window by tapping on the 'Accept' button. The
displayed values will be adopted.

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Configuring the EPW 400

6.4.3

ToolCounterConfigScreen
Tap on button 'Tool counter' to open this menu:

In the text field of the first line of this menu, the total number of parts produced withthis tool (OK and NOK parts) is displayed. The counter reading is set to 'zero' bypressing the 'Reset' button.
If in text field 'Message at' a certain quantity of the counter is entered with the numerical keypad, a message with a yellow background will be displayed as soon as thisreading is reached. The work cycle is not stopped with this function. It is therefore
possible to display, for example, 1000 cycles before the end of the service life of atool, a message and to change the tool set during the next standstill for service.
If a certain quantity is entered in text field 'Switch off at' using the numerical keypad,
the work cycle will be stopped when this reading is reached. A counter value message(with a red background) is issued. A continuation of the process is only possible after
the acknowledgement of the error. The counter reading must first be reset, as otherwise the counter will once more be exceeded and the machine will stop again at thenext process.
The value '0' of the text fields 'Message at' and 'Switch off at' deselects the corresponding option (no message or no switching-off of the machine).
If the tick is set in 'Main menu', the value will be displayed in the second line of themain menu. Only one counter can be displayed in the main menu.
Close the window 'Tool counter' by tapping on button 'Accept'. The displayed values will be adopted.

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6.5

Diagram settings
In this window the settings for the display of the diagrams are made.

The number of last curves that can be displayed on the touch screen is increased or
decreased using the  und  arrows.
The corresponding function is activated (X) or deactivated by tapping on the checkbox(up to the last nine curves can be displayed):Redraw view after changing process:

After a process change (program change) the measuring display will be newly drawn,e.g. process-depending Zoom settings become active.
The 'Redraw view after changing process' function will briefly interrupt the machine's
readiness to measure, until the display is updated (approx. 100 ms). If the measurement shall be started immediately after the program change, this function must be
deactivated. The display will then be updated after the measurement.
If the Function 'draw curve online while measurement is running' is activated, a measurement must not be started before the display is updated completely. That is why the
PLC has to request the signal 'Acknowledge process change'.

Draw curve online while measurement is in progress:

If the curve is drawn on the measurement display during measurement, the optimum
sampling rate will be reduced to approx. 200 Hz because of the system load.
This function may be used for set-up operations or for lever presses.
Close the 'Diagram settings' window by tapping the 'Accept' button. The
number of curves displayed on the input field will be adopted.

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6.6

Supplemnt
In this menu you reach the following submenus by tapping on the corresponding entry:

98

User administration

Manage authorization levels / password

LanguageScreen

Change the language version

Communication parameters

PC interface, field bus parameters

In-/Outputs

Current status of digital inputs/outputs

Date/Time

Display of current time and date

DeviceNameScreen

Enter a designation for the EPW 400

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6.6.1

User administration

6.6.1.1 Access administration via user log-on
The rights of the EPW 400 are managed in four authorization levels. After each start,
the program will be on authorization level 0. For changing the access level, tap on
button 'User administration':

Authorization level 0
Machine operator: permission only for functions related to starting process monitoringand overseeing the process.
Authorization level 1
Level for foreman, supervisor and experienced machine operators: language change,
counter reset, error reset, zoom area, diagram settings, date / time, copy parameters
to USB stick.
Authorization level 2
Level for authorized staff for setup: configuration of monitoring windows, configurationof sensors, counter setup, copy processes, restore parameters from USB stick.
Authorization level 3
Highest authorization level for plant construction and maintenance: inputs/outputs,
configuration of I/O, delete final values, evaluation options.
When field 'leave main menu after type password' is activated, the submenus are only accessible after input of the corresponding authorization level.

 Press the 'Log on' button in the icon bar.
 In the 'Log on' dialog box, enter the password for the highest access level available
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Configuring the EPW 400

Default setting:Authorization level 1:

TOX

Authorization level 2:

TOX2

Authorization level 3:

TOX3

Note: the system is case-sensitive!
 Confirm the password with the 'Enter' button.

Log off when inactive
Log off takes place automatically after 10 minutes of inactivity.

Close the 'User administration' menu by tapping on button 'Exit'. The
level selected last will be adopted.

Change password
Pay attention to the authorization level
The change of password will take effect only in the authorizationlevel in which you are logged on. To change the passwords of theother authorization levels you have to log on to those levels andchange the password there.
 Tap in menu 'User administration' on item 'change password'.
 First enter the correct combination of figures from the former password with thehelp of the keypad window and confirm the entry with 'OK'.
Incorrect entry of a password is indicated by a corresponding message; press the'Cancel' button to return to the "Extras" menu.
If the input of the password is correct, the window 'New password:' appears
 Use the keypad window to enter the new password and confirm by pressing "OK".
 In the next window, you will need to re-enter the new password as a check. To
apply the new password, close this dialog box by pressing 'OK'.
The message 'Password changed' is displayed.

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Access administration via digital inputs
The access level can also be pre-selected via the digital inputs.
For this purpose, Input 13 must be set to 'Authorization Bit 0' (see chapter Configuration I/O, p. 86)
The access level is then pre-selected with inputs 13 and 14.
Input

Status

Input

StatusAccess level

I13

1

I14

0

Level 1

I13

0

I14

1

Level 2

I13

1

I14

1

Level 3

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Configuring the EPW 400

6.6.2

LanguageIn this submenu, you can change the current language. Select your preferred language.
To open this window, tap on the 'Language' button in the 'Supplement'menu.
Tap on the appropriate button to switch to the new language.
Close this window by tapping on the 'Accept' button. The language selected last will be adopted.

6.6.3

Communication parameters
In this menu, the settings for the PC interface (field bus, Ethernet) aremade

For the version with Profibus an integrated Profibus module is used, for other fieldbuses an Anybus-S module from HMS is used which is available for almost all common field buses.

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6.6.3.1 IP address
To change the Ethernet IP address, tap the 'IP-address' button.

Restart required following the change
After changing the IP address, you must restart the device!

Tap the desired input field to enter an address using the numerical keypad. The entry
is adopted using the 'Enter' button.
IP address will be automatically obtained from a DHCP server (requires
access level 2).
Close this window by tapping on the 'Accept' button. The displayed parameters will be adopted.

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Configuring the EPW 400

6.6.3.2 Settings for barcode scanner
The EPW400 can record a DMC code (Data Matrix Code) with a maximum length of
56 characters and store it with the measured results in the final values.
This DMC code can be written either via the field bus interface, such as from a PLC(see chapter 6.6.6. Field bus parameters), or recorded by a barcode scanner connected to the EPW400 by USB.
The prerequisite for scanning via barcode is that the USB barcode scanner is recognized as input device by WindowsCE 5.0. The function was tested with barcode scanners Honeywell 1300G – 2 and SICK Surescan IDM260-100S

Scanning in the measurement menu:
If the EPW400 is in the main menu, i.e. the diagram with the measuring curve is displayed, the EPW400 responds to inputs via the barcode scanner.
The scanned characters are taken over as DMC code.

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Scanning with a separate dialog:
With this option, a button is displayed in the main menu.
The button calls up a dialog in which the barcode can be scanned.
Main menu with the button for calling up the scanner dialog:

Scanner dialog:

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Configuring the EPW 400

The EPW400 responds to inputs via the barcode as long as this dialog is displayed.
The scanned characters are taken over in the input text field as DMC code.
Alternatively, the DMC code can also be entered manually.
The screen keypad opens with a click on the input text field, which allows the DMC
code to be entered if, for example, the barcode cannot be scanned due to damages
to the label.
If both options "Scan barcode in measuring menu" and "Scan barcode in separate
dialog" are activated, the barcode can be scanned if it is in the main menu of the
EPW400; however, it can also be called up from the main menu of the scanner dialog
to be able to enter the DMC code manually.
Deleting code after measurement
If this option is selected, the DMC code is deleted automatically after every measurement.
Removing BTB if the code is not set
This option only enables the EPW400 for measurement when a DMC code has beenscanned or entered. As soon as an entered or scanned code exhibits two or morecharacters, it is acccepted as valid. If the EPW400 is not ready for measurement because it is waiting on scanning or the entry of a DMC code, the following icon is displayed in the main menu:

6.6.3.3 Remote access
Remote maintenance can be activated after consultation with TOX®
PRESSOTECHNIK (requires authorization level 2).

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6.6.4

In-/Outputs
In this window, the actual state of the digital inputs/outputs and of theanalog input is monitored. When tapping in menu 'Supplement' on ’inputs/outputs' you reach this selection window:

 Tap on the corresponding button for calling up the required submenu.

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Configuring the EPW 400

6.6.5

Internal digital I/O
An activated input/output is marked by a green rectangle, a deselected input/output
is marked by a red rectangle. The function of the occupied inputs and outputs is described in clear text.

Inputs:

The status of the digital inputs on the EPW 400 is displayed.

Outputs:

The outputs to which a signal is currently being emitted by the
EPW 400 are displayed.

 By tapping on the button of the corresponding output, the output is activated ordeactivated. The color of the rectangle will correspondingly change.
Changes are applied without further confirmation. The changes remain effective until
the 'Inputs/outputs' submenu is exited.
Using the arrow keys you may change between byte 0 andbyte 1.
To close the window, tap the 'Exit' button.

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6.6.6

Field bus parameters
Only for devices with field bus interface!
For changing the Anybus-S parameters, tap on button 'Parameter Anybus-S'

Profibus address (only for Profibus version) The arrows  and  can be used to decrease or increase the Profibus addressby a value of 1 each time.
 When tapping on the input field between the arrows, you can change the numberof the Profibus address with the help of the numerical keypad.
Note:
After changing the Profibus address, a new start of the device is required!

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Configuring the EPW 400

Read inputs to Anybus-S module
Activation of the device via field bus
Activation of the device via digital inputs/outputs.

 For changeover, tap on the input field next to 'read inputs from anybus module'.
Log final values on field bus
The final values will be output to the field bus interface

 For changeover, tap on the input field before 'read final values on anybus module'.
Close this window by tapping on the 'Accept' button. The displayed parameters will be adopted.

Write actual values
When this checkbox is activated, the measured values of force and distance are continuously output on the field bus.
Read DMC code
This field can be used to specify that the data matrix code is to be read via field bus.
The data matrix code is a piece part designation with a max. of 56 characters.

The character 0 (0x00) applies as the end of the string for less than 56 characters.
There are options that the string is read with the start of measurement, here it
must be applied to the bus before the start of measurement, or at the end of
measurement, here it must be applied before the end of measurement.
Number of IO bytes
With this field the number of I/O bytes configured on the bus are specified. A maximumof 64 bytes for inputs and outputs is possible.
The value refers each to the inputs and outputs, while the number of inputs and outputs is always equal. The value 16 would therefore activate 16 input bytes and 16
output bytes on the bus. The functions on input and output bytes 17 - 63 could therefore not be reached.

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6.6.7

Profibus / Anybus
An activated input/output is marked by a green rectangle, a deselected input/output
is marked by a red rectangle. The function of the assigned inputs and outputs is described in plain text. This window displays 8 inputs and 8 outputs. Use the input fieldin the first row to switch between the inputs and outputs: enter '0' to view inputs/outputs 1 to 8, and enter '1' to view inputs/outputs 9 to 16.

Inputs:

The status of the field bus inputs on the EPW 400 is displayed. Achange of the inputs is only possible via field bus.

Outputs:

The field bus outputs to which a signal is currently being emitted
by the EPW 400 are displayed.

 By tapping on the button of the corresponding output, the output is activated ordeactivated. The color of the rectangle will correspondingly change.
Changes are applied without further confirmation. The changes remain effective until
the 'Inputs/outputs' submenu is exited.
To close the window, tap the 'Exit' button.

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Configuring the EPW 400

6.6.8

Analog inputs
In this window the analog measured values are displayed.

Version 22:
The corresponding value is displayed here depending on whichmeasuring board is selected or set.
To close the window, tap the 'Exit' button.

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6.6.9

Date/TimeIn this menu the current time as well as the date are displayed.

 For changing the time or the date, tap on the corresponding field.
The numerical keypad field appears on the display.
 Tap on the field for the value that needs to be changed (date: dd.mm.yyyy, time:
hh:mm:ss).
Close this window by tapping on the 'Accept' button. The current timeand date are adopted.

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Configuring the EPW 400

6.6.10Device name

Here a name for the EPW 400 can be allocated.
If several EPW 400 devices are used, it is reasonable to give each EPW 400 device
a different name. If, for example, you wish to store data on a USB stick, the assigned
name is used as file name, so that the saved data can be allocated to a certain EPW
400 device.

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PLC interface pulse diagrams

7

PLC interface pulse diagrams

7.1

Start/StopOKNOKNOK alarm
Switchingpoint SP1
Switchingpoint SP2
Ready formeasurement
Start measurement1

Output OK or NOK is set dependent on the measured result.
Delay time after start = 0 - 10 ms

2

Output NOK_alarm is set dependent on the measured result in the online window.

3

Start of measuring operation with start signal and any additional start/stop
conditionX

History of last measurement
Note:
The EPW 400 might not be ready to measure due to a manual input
or a fault. It is therefore always necessary prior to an automatic sequence to check the 'Ready' output from the system controller before setting the 'Start measuring' signal.
When measuring has started, the signals 'Ready for measuring','OK', 'NOK' and 'NOK_Alarm' are reset. In case of an automatic sequence, this signal condition should be checked by the plant control
as feedback for a started measurement.
Up to EPW 400 firmware version V1.06, the outputs of switching
points SP1-SP3 are only updated while measurement is in progress.
From firmware version V1.07 onwards, the outputs of switching
points SP1-SP3 are constantly updated.

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PLC interface pulse diagrams

7.1.1

Changing the program number
Program bit 0-5
Program strobe
Program ACK

7.1.2

1

Delay time Strobe / Ack: min 10 ms, max. 20 ms

2

New program number applied and data read, max. 100 ms

X

History

I5

I4

I3

I2

I1

I0

Program

0

0

0

0

0

0

0

0

0

0

0

0

1

1

0

0

0

0

1

0

2

0

0

0

0

1

1

3

0

0

0

1

0

0

4

1

1

1

1

0

0

60

1

1

1

1

0

1

61

1

1

1

1

1

0

62

1

1

1

1

1

1

63

Zero point adjustment
Program bit 01

Channel X = 0 / Channel Y = 1

Offset external
Program strobe1
Program ACK2
Ready for measurement
1

Delay time Strobe / Ack: min 10 ms, max. 20 ms

2

Duration of zero point adjustment: max. 4 sec

 Program bit0 = Zero point adjustment either for channel X or channel Y
Program bit0 = 0: X-channel
Program bit0 = 1: Y-channel
 Program bit1: If program bit 1 is set, zero point adjustment will take place simultaneously for channel X and channel Y116

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Software module TOX®softWare

8

Software module TOX®softWare

Display and filing of measuring values
Processing and filing of device configurations
Offline - setup of device configurations

Please observe the comprehensive separate operating manuals for TOX ®softWare
WORX and the EPW 400 software module.

8.1

Networking via Ethernet
Transfer of measuring data to the PC – Ethernet
The PC used for data acquisition can communicate with several EPW 400 devices via
the Ethernet interface. The IP address of the individual devices can be set via a menu.
The central PC cyclically monitors the status of all EPW 400 devices. On terminationof a measurement, the result will be read and logged by the PC.

8.2

Network server program EPW 400_Server
The network program EPW 400_Server establishes a connection between the
TOX®softWare Worx and the EPW 400.
A connection can only be established between the TOX®softWare Worx and the EPW
400 when the EPW 400_Server has been started.

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9

Troubleshooting

9.1

Listing error and status messages

9.2

Error- / Statusno.

Error and status message0

No error1

Measurement is running2

Measurement OK

3

Measurement NOK

4Started, not ready to measure

5

Measurement aborted

8

Not ready to measure

9

Online window violated

10

OK job counter limit reached

11

Total job counter limit reached12

OK shift counter limit reached

13

Total shift counter limit reached14

Tool counter limit reached

15

Error transmit online window

16

Piece part NOK17

TDC sensor not left

18

Measurement not started

26

Measured value buffer full

27

Offset limit force sensor exceeded

28

Offset limit distance exceeded

Battery bufferThis data is stored on the battery buffered SRAM and may be lost in case of an empty
battery:






118

Set language
Currently selected process
Counter values
End value data and sequential number of end values

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Maintenance

10

Maintenance

10.1

Change flash card
The flash card is located on the back of the inside (display), the housing may have to
be dismantled.

 Device is de-energized.
 Person is electrostatically discharged.
1

Loosen screw and turn safety device to the side.

2

Remove the flash card upwards.

3

Insert new flash card.

4

Slide safety device back over flash card and tighten screw.

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119Maintenance

10.2

Battery change

Note
TOX® PRESSOTECHNIK recommends a battery change after 2
years at the latest.

 Device is de-energized.
 Person is electrostatically discharged.
 Electrically non conductive tool for removing the battery.

120

1

Remove the cover of the lithium battery.

2

Pull the battery out with an insulated tool.

3

Install new lithium battery in the correct polarity.

4

Install the cover.

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Firmware update11

Firmware update

11.1

Update from version V1.08
To import new firmware you will need a USB stick.
 On this USB stick create a folder 'TOX' directly in the root directory:

Example: LW 'USB_128k (D:) Tox
 Unzip the files you have received from TOX® PRESSOTECHNIK into the 'TOX'
folder.
 Connect the USB stick to the EPW 400
The 'USB stick' icon should now be highlighted in green(within about 5 s).
This icon appears in the main menu (see chapter 5.3 'Main menu 'Measuring'')
In the main menu, click on the button with the version number.

Click on button 'firmware update'

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Firmware update Clickonbutton'Yes'
toinstall
After the update, the following message will appear:

122

the

update.

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Decommissioning

12

Decommissioning

12.1

Storage







12.2

Use original packaging
Cover the electrical connections to protect them from dust, e.g. with adhesive tape.
Protect the display against sharp-edged objects. If necessary, attach a suitable
protective cover (e.g. made of cardboard or hard foam).
Use a dry, ventilated room for storage.
Enwrap the device (e.g. with a plastic bag).
In case of high humidity: add a drying agent to the packaging (e.g. silica gel).

Disposal
Environmental protection
When disposing of the battery, the worn and spare parts, and thepressing monitor and its accessories, the national regulations onenvironmental protection currently in force must be observed.
 The batteries and accumulators must not be disposed of in thenormal household waste.
 The batteries and accumulators must only be disposed of at an
approved collection site.
Disposal
Dispose of the packaging sorted according to type.
Use the local options for the collection of paper and cardboard.
Disposal
Old electronic devices must not be disposed of in the household
waste.
Dispose of the old pressing monitor at the nearest electronic disposal site or contact TOX® PRESSOTECHNIK.
The labels on the product, accessories and in the associated documentation specify
that the product and accessories (e.g. power supply units, USB cables) must not be
disposed of in the normal household waste at the end of their service life. Pleasedispose of this device and its accessories separated from other waste, to prevent theenvironment and human health from being damaged due to the uncontrolled disposalof waste.
With recycling, the re-use of materials, or other forms of recycling of old devices andaccumulators, you make an important contribution to the protection of the environment.

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