User manual

Edition: 09/28/2021, Version: 3

Pressing monitor
EPW 500FP

TOX® PRESSOTECHNIK GmbH & Co. KG
Riedstrasse 488250 Weingarten / Germany
www.tox-pressotechnik.com

2

TOX_Manual_Process-monitoring-unit_EPW500FP_en-US

Table of contents

Table of contents
1

Important information

1.1

Legal note ................................................................................................... 7

1.2

Exclusion of liability ..................................................................................... 7

1.3

Validity of the document.............................................................................. 8

1.3.1

Content and target group ............................................................................ 8

1.3.2

Other applicable documents ....................................................................... 8

1.4

Gender note ................................................................................................ 8

1.5

Displays in the document ............................................................................ 9

1.5.1

Display of warnings ..................................................................................... 9

1.5.2

Display of general notes............................................................................ 10

1.5.3

Highlighting of texts and images ............................................................... 10

1.6

Contact and source of supply.................................................................... 112

Safety2.1

Basic safety requirements......................................................................... 13

2.2

Organizational measures .......................................................................... 14

2.2.1

Safety requirements for the operating company ....................................... 14

2.2.2

Selection and qualifications of personnel.................................................. 15

2.3

Fundamental hazard potential................................................................... 16

2.3.1

Electrical hazards...................................................................................... 16

3

About this product

3.1

Intended use ............................................................................................ 17

3.1.1

Safe and correct operation........................................................................ 17

3.1.2

Foreseeable misuse.................................................................................. 17

3.2

Warranty.................................................................................................... 18

3.3

Product Identification................................................................................. 18

3.3.1

Position and content of the type plate ....................................................... 18

3.4

Function description .................................................................................. 19

3.4.1

Process monitoring system ....................................................................... 19

3.4.2

Measuring Mode and Configuration .......................................................... 19

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Table of contents

4
4.1

Dimensions ............................................................................................... 21

4.2

Weight ....................................................................................................... 21

4.3

CPU module.............................................................................................. 22

4.4Interfaces .................................................................................................. 23

4.4.1

DMS force sensor (X1).............................................................................. 23

4.4.2

Force sensor standard input (X2).............................................................. 24

4.4.3

Analog Out (X3) ........................................................................................ 25

4.4.4

Distance sensor (X4)................................................................................. 25

4.4.5

Digital IO (X5)............................................................................................ 27

4.4.6

Supply voltage (X6)................................................................................... 28

4.4.7

USB interface (X7) .................................................................................... 28

4.4.8

Ethernet RJ45 (X8) ................................................................................... 29

4.5

PLC interface pulse diagrams ................................................................... 30

4.5.1

Start/Stop .................................................................................................. 30

4.5.2

Changing the program number ................................................................. 31

4.5.3

Environmental conditions .......................................................................... 32

5Transport and storage

5.1

Temporary storages .................................................................................. 35

5.2

Dispatch for repair..................................................................................... 35

6
6.1

7

Installation
Holding bracket ......................................................................................... 37

Commissioning

7.1

Preparing System...................................................................................... 39

7.2

Starting system ......................................................................................... 39

8
8.1

4

Technical data

Operation
Monitoring operation ................................................................................. 41

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9

Software9.1

Function of the Software ........................................................................... 43

9.2

Software interface ..................................................................................... 43

9.2.1

Information and status bar ........................................................................ 44

9.3

Control elements ....................................................................................... 44

9.3.1

Function buttons........................................................................................ 44

9.3.2

Checkboxes .............................................................................................. 45

9.3.3

Selection lists ............................................................................................ 45

9.3.4

Input field................................................................................................... 45

9.3.5

Dialog keyboard ........................................................................................ 46

9.3.6

Saving Changes Dialog............................................................................. 48

9.3.7

Icons.......................................................................................................... 49

9.4

Main menus............................................................................................... 50

9.4.1

Channel cockpit......................................................................................... 50

9.4.2

Full-screen display .................................................................................... 51

9.4.3

Status window ........................................................................................... 52

9.4.4

Configuration............................................................................................. 53

9.4.5

Monitoring ................................................................................................. 80

9.4.6Counters.................................................................................................... 96

9.4.7

Processes ............................................................................................... 101

9.4.8

System .................................................................................................... 106

9.4.9

User......................................................................................................... 113

9.4.10

Data......................................................................................................... 115

10

Troubleshooting

10.1

Detecting faults ....................................................................................... 125

10.1.1

Acknowledging Messages....................................................................... 125

10.1.2Error messages....................................................................................... 126

11

Maintenance

11.1

Maintenance and repair .......................................................................... 127

11.2

Safety during maintenance ..................................................................... 128

11.3

Maintenance schedule ............................................................................ 128

11.4

Controller Battery Change....................................................................... 129

11.5

Panel PC Battery Change ....................................................................... 130

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Table of contents

Maintenance table

12
12.1

13

Repairs
Repair work ............................................................................................. 135

Disassembly and Disposal

13.1

Safety requirements for disassembly ...................................................... 137

13.2

Disassembly............................................................................................ 137

13.3

Disposal .................................................................................................. 137

14
14.1

Appendices
Declaration of conformity ........................................................................ 139

Index

6

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Important information

1 Important information
1.1

Legal noteAll rights reserved.
Operating instructions, manuals, technical descriptions and software published by TOX® PRESSOTECHNIK GmbH & Co. KG ("TOX® PRESSOTECHNIK") are copyright and must not be reproduced, distributed and/or otherwise processed or edited (e.g. by copying, microfilming, translation,transmission in any electronic medium or machine-readable form). Any use- including of extracts - contrary to this condition is prohibited without approval in writing by TOX® PRESSOTECHNIK and may be subject to criminal and civil legal sanctions.
If this manual refers to goods and/or services of third parties, this is for example only or is a recommendation by TOX® PRESSOTECHNIK.
TOX® PRESSOTECHNIK does not accept any liability or warranty/guarantee with reference to the selection, specifications and/or usability of thesegoods and services. The use and/or representation of trademarked brands
that do not belong to TOX® PRESSOTECHNIK are for information only; allrights remain the property of the owner of the trademarked brand.
Operating instructions, manuals, technical descriptions and software are
originally compiled in German.

1.2

Exclusion of liability
TOX® PRESSOTECHNIK has checked the contents of this publication toensure that it conforms to the technical properties and specifications of the
products or plant and the description of the software. However, discrepancies may still be present, so we cannot guarantee complete accuracy. The
supplier documentation included with the system documentation is an exception.
However, the information in this publication is checked regularly and any
required corrections are included in subsequent editions. We are gratefulfor any corrections and suggestions for improvement. TOX® PRESSOTECHNIK reserves the right to revise the technical specifications of the
products or plant and/or the software or documentation without prior notice.

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Important information

1.3

Validity of the document

1.3.1

Content and target group
This manual contains information and instructions for the safe operationand safe maintenance or servicing of the product.

1.3.2



All information in this manual is up to date at the time of print.
TOX® PRESSOTECHNIK reserves the right to make technical changes
that improve the system or increase the standard of safety.



The information is intended for the operating company as well as operating and service personnel.

Other applicable documents
In addition to the available manual, further documents can be supplied.
These documents must also be complied with. Other applicable documents
can be, for example:

1.4



additional operating manuals (e.g. of components or of a whole system)

Supplier documentation



Instructions, such as software manual, etc.

Technical data sheetsSafety data sheetsData sheets

Schematics

Gender note
In order to enhance readability, references to persons that also relate to allsexes are normally only stated in the usual form in German or in the corresponding translated language in this manual, thus e.g. "operator" (singular)
for male or female, or "operators" (plural) for male or female". This shouldin no way convey any gender discrimination or any violation of the principleof equality, however.

8

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Important information

1.5

Displays in the document

1.5.1

Display of warnings
Warning signs indicate potential dangers and describe protective measures. Warning signs precede the instructions for which they are applicable.

Warning signs concerning personal injuries
DANGER
Identifies an immediate danger!
Death or severe injuries will occur if appropriate safety measures are nottaken.
è Measures for remedial action and protection.

WARNING
Identifies a potentially dangerous situation!
Death or serious injury may occur if appropriate safety measures are nottaken.
è Measures for remedial action and protection.

CAUTION
Identifies a potentially dangerous situation!
Injury may occur if appropriate safety measures are not taken.
è Measures for remedial action and protection.

Warning signs indicating potential damage
NOTE
Identifies a potentially dangerous situation!
Property damage may occur if appropriate safety measures are not taken.
è Measures for remedial action and protection.

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9Important information

1.5.2

Display of general notes
General notes show information on the product or the described action
steps.
Identifies important information and tips for users.

1.5.3

Highlighting of texts and images
The highlighting of texts facilitates orientation in the document.
ü

Identifies prerequisites that must be followed.

1. Action step 1
2. Action step 2: identifies an action step in an operating sequence thatmust be followed to ensure trouble-free operation.
w Identifies the result of an action.
u Identifies the result of a complete action.
è Identifies a single action step or several action steps that are not in an
operating sequence.
The highlighting of operating elements and software objects in texts facilitates distinction and orientation.

10<In square brackets> identifies operating elements, such as buttons,
levers and (valves) stopcocks.

''with quotation marks'' identifies software display panels, such as windows, messages, display panels and values.



In bold identifies software buttons, such as buttons, sliders, checkboxes and menus.

In bold identifies input fields for entering text and/or numerical values.

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Important information

1.6

Contact and source of supply
Only use original spare parts or spare parts approved by TOX® PRESSOTECHNIK.
TOX® PRESSOTECHNIK GmbH & Co. KG
Riedstraße 488250 Weingarten / Germany
Tel. +49 (0) 751/5007-333
E-Mail: info@tox-de.com
For additional information and forms see
www.tox-pressotechnik.com

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Important information

12

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Safety

2 Safety
2.1

Basic safety requirements
The product is state of the art. However, operation of the product may involve danger to life and limb for the user or third parties or damage to theplant and other property.
For this reason the following basic safety requirements will apply:Read the operating manual and observe all safety requirements andwarnings.

Operate the product only as specified and only if it is in perfect technical condition.

Remedy any faults in the product or the plant immediately.

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Safety

2.2

Organizational measures

2.2.1

Safety requirements for the operating company
The operating company is responsible for compliance with the following
safety requirements:

14The operating manual must always be kept available at the operationsite of the product. Ensure that the information is always complete andin legible form.

In addition to the operating manual, the generally valid legal and otherbinding rules and regulations must be provided for the following content
and all personnel must be trained accordingly:–

Work safety–

Accident prevention–

Working with hazardous substances–First aid–

Environmental protection–

Traffic safety–

Hygiene

The requirements and contents of the operating manual must be supplemented by existing national regulations (e.g. for prevention of accidents and for environmental protection).



Instructions for special operating features (e.g. work organization, work
processes, appointed personnel) and supervisory and reporting obligations must be added to the operating manual.



Take action to ensure safe operation and make sure that the product ismaintained in a functional condition.



Only allow authorized persons access to the product.

Ensure that all personnel work with awareness of safety and potential
dangers with reference to the information in the operating manual.

Provide personal protective equipment.



Maintain all safety and information on dangers regarding the productcomplete and in legible condition and replace as required.



Do not make any changes, carry out attachments or conversions to the
product without the written approval of TOX® PRESSOTECHNIK. Action contrary to the above will not be covered by the warranty or the operating approval.



Make sure that the annual safety inspections are carried out and documented by an expert.

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Safety

2.2.2

Selection and qualifications of personnel
The following safety requirements are applicable for the selection and qualifications of personnel:Only appoint persons to work on the plant who have read and understood the operating manual, and in particular, the safety instructions
before starting work. This is particularly important for persons who only
work on the plant occasionally, e.g. for maintenance work.

Only allow persons appointed and authorized for this work access tothe plant.



Only appoint reliable and trained or instructed personnel.

Only appoint persons to work in the danger zone of the plant who canperceive and understand visual and acoustic indications of danger (e.g.
visual and acoustic signals).



Ensure that assembly and installation work and the initial commissioning are performed exclusively by qualified personnel who have been
trained and authorized by TOX® PRESSOTECHNIK.

Maintenance and repairs must be performed by qualified and trained
personnel only.

Ensure that personnel who are being trained, instructed or are in an apprenticeship can only work on the plant under the supervision of an experienced person.

Have work on electrical equipment performed only by electricians or
trained persons under the direction and supervision of an electrician inaccordance with the electrotechnical regulations.

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Safety

2.3

Fundamental hazard potential
Fundamental hazard potentials exist. The specified examples draw attention to known hazardous situations, but are not complete and do not in any
way provide safety and risk awareness action in all situations.

2.3.1

Electrical hazards
Attention should be paid to electrical hazards particularly inside the components in the area of all assemblies of the control system and motors of theinstallation.
The following basically applies:16Have work on electrical equipment performed only by electricians or
trained persons under the direction and supervision of an electrician inaccordance with the electrotechnical regulations.



Always keep the control box and/or terminal box closed.



Before commencing work on electrical equipment, switch off the main
switch of the system and secure it against being switched back on inadvertently.



Pay attention to the dissipation of residual energy from the control system of the servomotors.

Make sure that the components are disconnected from the power supply when carrying out the work.

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About this product

3 About this product
3.1

Intended use
The pressing monitor ensures constant monitoring of the production
process and quality assurance during production.

3.1.1

Safe and correct operation
Intended use includes the following conduct:

Only operate with the components for which it is specified.



Follow all instructions in this operating manual.

Comply with the specified maintenance intervals and perform maintenance work correctly.

Operate in compliance with the conditions of the technical data.



Operation with fully assembled and functional safety devices.



Activities may only be carried out by persons who are qualified or authorized for this purpose.

Any other use or application beyond this does not come under the scope ofintended use.

3.1.2

Foreseeable misuse
Use contrary to intended use includes the following foreseeable misuse:

Operation under conditions that deviate from the technical data.



Operation without fully assembled and functional connections.



Operation without fully assembled and functional safety devices.



Modifications to the product without prior approval by TOX® PRESSOTECHNIK and the approving authority.



Incorrect parameterization.



Execution of activities by persons who are not qualified or authorized to
do so.

The operating company is exclusively responsible for all personal injury andproperty damage resulting from non-intended use. Non-intended use will
not be covered by the warranty or the operating approval.

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17

About this product3.2

Warranty
Warranty and liability are based on the contractually specified conditions.
Unless specified otherwise:
The TOX® PRESSOTECHNIK GmbH & Co. KG excludes any warranty or
liability claims in the event of defects or damage if these are attributable toone or more of the following causes:
Non-compliance with safety instructions, recommendations, instructions
and/or other specifications in the operating manual.



Non-compliance with the maintenance rules.



Unauthorized and improper commissioning and operation of the machine or components.

Improper use of the machine or components.



Unauthorized constructional modifications to the machine or components or modifications to the software.



Use of non-genuine spare parts. Batteries, fuses and lamps are notcovered by the warranty.

3.3

Product Identification

3.3.1

Position and content of the type plate
The type plate can be found on the back of the device.
Designation on the type plate

Meaning

Type
ID No
SN

Product designation
Material number
Serial number

Tab. 118Type plate

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About this product

3.4

Function description

3.4.1

Process monitoring system
The pressing monitor monitors processes, in which precisely defined functional correlations between force and distance have to be verified.
The device reads the force/distance data pairs from two measuring channels <X> and <Y> during the measuring operation. The data are written tomemory and can be displayed graphically. The resulting force/distancefunction 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.

3.4.2

Measuring Mode and Configuration
The registration of a process with the evaluation can only be started inmeasuring mode. If settings are changed, no measuring cycle can bestarted. This is the case, for example, during a program change, zero-point
adjustment or when you are in the configuration menu.
The readiness for measuring is shown on the display by means ofready signal RDY.

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About this product20

TOX_Manual_Process-monitoring-unit_EPW500FP_en-US

Technical data

4 Technical data
4.1

Dimensions

Fig. 1

4.2

Dimensions

WeightDescription

Value

Weight2.5 kg

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Technical data

4.3

CPU module
Description

Value

ProcessorRAM

ARM Cortex A8 1 GHz
eMMC 8 GB (program and data)
NAND Flash 256 MB (operating system)
Hardware with buffer battery
LCD 7"
800 x 480 (WVGA)
LED, backlit
Contrast 400:1
Luminosity 350 cd/m²
Color depth 256 kbit
Viewing angle vertical 130°, horizontal
140°
Controller: Button cell CR2032
Panel-PC: Button cell CR1220

Real-time clock / accuracy
Display

Buffer battery

22

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Technical data

4.4

Interfaces

4.4.1

DMS force sensor (X1)
D-Sub 9-pin (socket)

1

6

5

9

Pin

SignalDescription

1
2
3
4
5
6
7
8
9
S

V+ 10V
n. c.
S+
n. c.
n. c.
n. c.
Sn. c.
V-DMS Supply voltage +10 VDC
not connected
DMS Sensor signal pos
not connected
not connected
not connected
DMS Sensor signal neg
not connected
Ground 0 VCD
PE shield (housing)

1
V+

3

S-

S+

V9
7
S

Fig. 2Connection example: DMS without sensor cable

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Technical data

4.4.2

Force sensor standard input (X2)
D-Sub 9-pin (socket)

1

6

5

9

Pin

SignalDescription

1
2
3
4
5
6
7
8
9

n. c.
Vn. c.
V+ 24V
Tare 24VS+
n. c.
Sn. c.

not connected
Ground 0 VDC
not connected
DMS Supply voltage +24 VDC
Tare signal
Force signal +10 VDC
not connected
Force signal ground GND
not connected
PE shield (housing)S

Fig. 3

4

V+

2

V-

6

S+

8

S-

5

T

Connection example: sensor with standard signal 0 to 10 V (ZKN with tare, +24
VDC)

4

2
6

Fig. 4

24

+

-

24V

0V
0-10V

Connection example: ZDO

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Technical data

4.4.3

Analog Out (X3)
D-Sub 9-pin (connector)

4.4.4

1

6

5

9

Pin

SignalDescription

1
2
3
4
5
6
7
8
9
S

Analog Out 0
Analog Out 1
Analog Out 2
n. c.
n. c.
0V
0V
0V
n. c.

Analog Out 0
Analog Out 1
Analog Out 2
not connected
not connected
Ground analog signal
Ground analog signal
Ground analog signal
not connected
PE shield (housing)Distance sensor (X4)
D-Sub 15-pin (socket)

1

9

8

15

Pin

SignalDescription

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
S

V+ 24V
Signal 1
Vout 10V
Signal 2
V+ 24VM1
n. c.
La
V Ground
0V
0V
V Ground
0V
0V
Lb

DMS Supply voltage +24 VDC
Signal 1
Supply of potentiometric button
Signal 2
Supply voltage
Monitor output signal 1
not connectedInternal use
Supply voltage ground
Signal ground
Signal ground
Supply voltage ground
Signal ground
Signal ground
Internal use
PE shield (housing)

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Technical data

3
V-Out 10 V
S+
2
0V
10
S

Fig. 5Connection example: distance transducer potentiometer (ZWW 10 V supply voltage)

1

24V

9

0V

2

S+

10

S-

S

Fig. 626

Connection example: distance transducer (ZKW)

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Technical data

4.4.5

Digital IO (X5)
D-Sub 25-pin (socket)

1

14

13

25

Pin

SignalDescription

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
S

Q0
Q1
Q2
Q3
Q4
Q5
Q6
Q7
I4
I5
0V
0V
I11
I0
I1
I2
I3
I6
n. c.
I8
n. c.
I10
24 V
24 V
I 12

OK
NOK
Acute NOK
Switching point 1
Switching point 2 / NOK buzzer
Ready for measurement
Program ACK
Switching point 3
Program bit 4
Program bit 50 V internal
0 V external
Reserve
Program bit 0
Program bit 1
Program bit 2
Program bit 3
Program strobe
not connectedStart measurement
not connected
Error reset
24 V internal
24 V external
Reserve
PE shield

Digital inputs
Description

Value

Digital inputs
Input voltage
Input current
Input impedance

13 (isolated)
24 V
At rated voltage (24 V): 3 mA
10 kΩDigital outputs
Description

Value

Digital outputs
Load voltage

8 (isolated)
Rated voltage 24 V
(permissible range: 18 V to + 30 V)
max. 500 mA
Yes, thermal overload protection

Vin output current
Short-circuit proof

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Technical data

4.4.6

Supply voltage (X6)1

Pin

SignalDescription

1
2
3

24 V
GND
PE

DMS Supply voltage +24 VDC
Ground 0 VDCPE shield

2
3

Description

Value

Rated voltage+24 VDC, ±25 %(incl. 10% residual ripple)≤1 A

Current consumption

4.4.7

USB interface (X7)

1

2

3

4

SignalDescription

1
2
3
4

+5V
Data Data +GND

Supply voltage
Data Data +GroundDescription

Value

Number of channels
USB 2.0

1 x host (full-speed)
according to USB device specification
USB 2.0 compatible, type A and B
Connection to high-powered hub/hostmax. 5 mm

Cable length

28

Pin

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Technical data

4.4.8

Ethernet RJ45 (X8)

8

1

Pin

SignalDescription

1
2
3
4
5
6
7
8

TxD+
TxDRxD+n. c.
n. c.
RxDn. c.
n. c.

Transmit Data +Transmit Data Receive Data +not connected
not connected
Receive Data not connected
not connected

DescriptionValue

1 channel

twisted pair (10/100BASE-T)
Transmission in accordance with IEEE/ANSI 802.3, ISO 8802-3, IEE-E802.3u
10/100 Mbit/sshielded
at 0.14 mm²: max. 300 m
at 0.25 mm²: max. 600 m
max. 100 mm
Shielded, impedance 100 Ω
RJ45 (modular connector)

Transmission speed
Connecting line

LengthCable
Connector

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Technical data

4.5

PLC interface pulse diagrams

4.5.1

Start/Stop

Start measurement
OK

1 2

NOK

1 2

4

Acute NOK

1 2

5

NOK buzzer
Ready for measurement

Fig. 7

1
2
3
4
5
6

30

3

6
2

Signal path diagram

Dependent on the previous measured result.
When the <Start measuring> signal is active, the conditions of the previous
measurement are reset after a maximum of 1 ms.
When the measurement has been completed, the OK or NOK signal is set
after 1 ms.
If the measurement is assessed as NOK during the measurement, the NOK
signal is set after a maximum of 1 ms.
Depending on the <Acute NOK> option, the signal is set after a maximum of
1 ms after the measurement has been assessed as NOK.
Depending on option <NOK beeper>, after the measurement has been assessed as NOK, the signal is set for the duration adjusted in the settings after a maximum of 1 ms.

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Technical data

4.5.2

Changing the program number

Program Bit 0 - 5

1

Program Strobe
Program ACK

Fig. 8

1
2
3

2

3

Signal path diagram

Selected program via bits.
Delay time Strobe high ACK high maximum of 180 ms.
Delay time Strobe low ACK low 1 ms.

During transfer of the new parameters, the "Ready for measurement" signal
is set to "low". Before the next measurement, the "Ready for measurement"
signal must be checked for "high". The maximum delay time of "Strobe" to"Ready for measurement" is 600 ms.
I5

I4

I3

I2

I1

I0

Program

0
0
0
1
1
1
1

0
0
0
1
1
1
1

0
0
0
1
1
1
1

0
0
0
1
1
1
1

0
0
1
0
0
1
1

0
1
0
0
1
0
1

0
1
2
60
61
62
63

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Technical data

4.5.3

Environmental conditions
Description

Value

Temperature

Operation: 0 °C to +50 °C
Storage: -20 °C to +60 °C
5 % to 80 %Relative humidity without condensation(acc. to RH2)

Sensor Analog Standard Signals
Measuring is carried out by a sensor with a standardized process signal 0
to 10 V. The input is selected in the <Configuration> menu.
Description

Value

Nominal force
Nominal distanceadjustablesee Setting Nominal Force / Nominal Distance Parameters, Page 54.
16 bit = 65536 steps
Steps see A/D converter, 1 step (bit) =nominal load / steps
1%
2000 Hz (0.5 ms)

A/D converter
Nominal load of resolution
Accuracy of measurement
Max. sampling rate

Supply Voltage Sensor
Description

Value

Auxiliary voltage
Reference voltage

24 V ±5 %, max. 100 mA
10 V ±1 % standard signal : 0 V to 10 V

Sensor with Standard Signal Output

32

Description

Value

Auxiliary voltage
Nominal signal
Tare signal+24 VDC ±5 %, max. 100 mA
0 V to 10 V
0 V with zero adjustment, >9 V during
measuring mode

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Technical data

With some types of force transducers or measurement amplifiers with tarefunction, a decrease of the measuring accuracy is possible after a certain
period of time depending on the process.

DMS signals
Force measuring (channel Y) via DMS force transducer. The input is selected in menu <Configuration / Sensors>.
Description

Value

Nominal force
Nominal distanceadjustablesee Setting Nominal Force / Nominal Distance Parameters, Page 54.
16 bit = 65536 steps
65536 steps, 1 step (bit) = nominal load /65536±0.5 %
2000 Hz (0.5 ms)
10 V
1.1 mV / V

A/D converter
Nominal load of resolution
Gain error
Max. sampling rate
Bridge voltage
Characteristic value

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Technical data

34

TOX_Manual_Process-monitoring-unit_EPW500FP_en-US

Transport and storage

5 Transport and storage
5.1

5.2

Temporary storages

Use original packaging.



Make sure that all electrical connections are covered to prevent dust
ingress.

Protect the display against sharp-edged objects e.g. due to cardboard
or hard foam.

Wrap the device, e.g. with a plastic bag.

Store the device only in closed, dry, dust-free and dirt-free rooms atroom temperature.



Add drying agent to the packaging.

Dispatch for repair
To dispatch the product for repair to TOX® PRESSOTECHNIK, please proceed as follows:Fill in the "Accompanying repair form". This we supply in the service
sector on our website or upon request via e-mail.



Send us the completed form via e-mail.



Then you will receive the shipping documents from us via e-mail.



Send us the product with the shipping documents and a copy of the"Accompanying repair form".

For contact data see: Chap. 1.6 Contact and source of supply, Page 11or
www.tox-pressotechnik.com.

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Transport and storage

36

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Installation

6 Installation
6.1

Holding bracket

Fig. 9Hole pattern of holding bracket

With the holding bracket the device to be used as a table, wall device or to
be fixed to an outrigger.

TOX_Manual_Process-monitoring-unit_EPW500FP_en-US37

Installation

38

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Commissioning

7 Commissioning
7.1

Preparing System
1. Check installation and mounting.
2. Connect required lines and devices, e.g. sensors and actuators.
3. Connect supply voltage.
4. Make sure that the correct supply voltage is connected.
See Chap. 4.4 Interfaces, Page 23.

7.2

Starting system
üSystem is prepared.
See Chap. 7.1 Preparing System, Page 39.

è Switch on the plant.
u The device starts the operating system and the application.
u The device switches to the start screen.

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Commissioning

40

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Operation

8 Operation
8.1

Monitoring operation
No operating steps are necessary during ongoing operation.
The operating procedure must be monitored constantly in order to detect
faults in time.

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Operation

42

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9 Software
9.1

Function of the Software
The software fulfils the following functions:9.2

Clear representation of the operating parameters for operation monitoring

Displaying of fault messages and warningsConfiguration of the operating parameters by setting individual operating parametersConfiguration of the interface by setting the software parameters

Software interface

1

2

3

Fig. 10

Software interface

Screen area

Function

1

Information and status bar

2

Menu-specific screen area

3

Menu bar

The information and display bar displays: General information on the pressing
monitor Current pending messages and information for the main area displayed in
the screen.
The menu-specific screen area displays
the specific contents for the screen currently open.
The menu bar displays the specific submenus for the menu currently open.

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Software

9.2.1

Information and status bar

1
Fig. 11

2

4

3

6

Display/control panel

Function

1
2
3
4
5
6

Call up "System / Version" menu
Call up access authorization
Display of current menu
Display of current process
Information and status display
Warning symbol

Opens "System / Version" menu
Opens login dialog

7

Start screen

9.3

Control elements

9.3.1

Function buttons

Fig. 12

Displays connection problems with external memory expansion
Opens "Canal Cockpit" menu

2

Function buttons

Display/control panel
1
2

7

Information and status bar

1

44

5

Function

NormalHighlighted (with a grey background)

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Software

9.3.2

Checkboxes

1

Fig. 13

Checkboxes

Display/control panel
1
2

9.3.3

2

Function

Not selected
Selected

Selection lists

Fig. 14

Selection lists

A value can be selected from a specified list of values via the selection list.

9.3.4

Input field

Fig. 15

Input field

The input field has two functions.


The input field displays the value currently entered.

Values can be entered or changed in an input field. This function is dependent on the user level and is not normally available for all user levels.

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Software

9.3.5

Dialog keyboard
Keyboard dialogs are needed for entering and changing values in input
fields.

Fig. 16

Numerical keyboard

Fig. 17

Alphanumeric keyboard

It is possible to switch between four modes with the alphanumeric keyboard:Permanent lowercase

Uppercase and special characters for the next entry

Permanent uppercase and special charactersOther special characters

Activating permanent lowercase

è Press Shift button until the keyboard displays lowercase letters.

46

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Activating uppercase and special characters for the next entryü"permanent" lowercase mode is activated. The keyboard only displays
lowercase letters and numbers.

è Press Shift button once.
u The keyboard displays uppercase letters and special characters.
u After entering a character, the keyboard returns again to the "permanent" lowercase mode.
Activating permanent uppercase and special charactersü"permanent" lowercase mode is activated. The keyboard only displays
lowercase letters and numbers.

è Press Shift two times.
w The lettering "Shift" becomes red and is underlined.
w The keyboard displays uppercase letters and special characters.
w Any number of uppercase letters or special characters can be entered.
Activating other special charactersü"permanent" lowercase mode is activated. The keyboard only displays
lowercase letters and numbers.

è Press Shift three times.
u The keyboard displays other special characters, e.g. "€".
u After entering a character, the keyboard returns again to the "permanent" lowercase mode.

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Software

9.3.6

Saving Changes Dialog
The ''Save changes'' dialog appears if a menu should be exited without
saving changes beforehand.

2

1Fig. 18

48

3''Save changes'' dialog

Display/control panel

Function

1

Save

2

Do not save3

CancelThe changed values are saved and thecurrent menu is exited.
The changed values are discarded andnot saved. The current menu is exited.
Cancellation of the action. Returns to thecurrent menu.

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Software

9.3.7

Icons
Display/control panel

Function

Measure OK

The last measurement was OK.

Measured result undefined

The measured result is not yet
known.

Measurement NOK

Last measurement was not OK.
At least one evaluation criteria
was violated (envelope curve,
window).

No message

No messages are pending.

Warning

One warning is pending.

Fault

One error is pending.

Device ready to measure

Pressing monitor is ready tostart a measurement.

Device not ready to measure

Pressing monitor is not ready tostart a measurement.

Measure active

The measurement is inprogress.

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Software

9.4

Main menus

9.4.1

Channel cockpit

1
2

3

4

11

12
Fig. 19

50

10

9

8

7

6

5

Menu ''Channel cockpit''

Display/control panel

Function

1
2
3

User zoom
Reduce zoom factor
Job counter4

Full-screen display

5
6
7
8
9
10
11
12

Data
User
SystemProcesses
Counters
Monitoring
Configuration
Menu backRestores user zoom
Reduces zoom factor
Counter \ … that is displayed in the start
screen.
Changes to full-screen display
see Full-screen display, Page 51.
Opens Data menu
Opens User menu
Opens System menu
Opens Processes menu
Opens Counter menu
Opens Monitoring menu
Opens Configuration menu
Changes to the higher menu

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Software

9.4.2

Full-screen display

1 2 3

Fig. 20

1
2
3

Menu ''Full-screen display''

Display/control panel

FunctionFull-screen display
User zoom
Zoom factor

Closes the full-screen display
Restores user zoom
Reduces zoom factor

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Software

9.4.3

Status window
The status window displays all configured information about the work
process.

1
2
3
4
5
7

6

Fig. 21

Status window

Display field
1
2
3
4
5
6
7

52

Device nameCurrent process
Measured result
Messages (warning / error)
Process monitoring system ready to measure
Maximum distance of the last work process
Maximum force of the last work process

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Software

9.4.4

Configuration
All settings in the ''Configuration'' menu can be customized for every single
process.

Sensors
The nominal force, nominal distance and offset of the sensors are set in the''Configuration\Sensors'' menu. Furthermore, the sensors connected to thepressing monitor are calibrated.
Sensors have to be calibrated if they were replaced or if the system should
be recalibrated.
In these instructions, the nominal force is specified in kN and the nominal
distance is specified in mm.

1

2

4

3

5

6
7
22
21

8

20
19
18
17

16

Fig. 22

15

14

13

12

11

10

9

Menu ''Configuration \ Sensors''

ButtonFunction

3

Teach

5
6
7
8
9
10
11

Offset
Undo
Save
Calibration
Hardware
NOK options
Switching points

Reads in the actual value of the force or
distance sensor
Offset adjustment
Undoes the entry
Saves the entry
Determines the calibration
Opens Hardware menu
Opens Evaluation Options menu
Opens Switching points menu

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Software

ButtonFunctionStart/Stop
Measuring parameters
IO Config
Sensors

Opens Start/Stop menu
Opens Measuring parameters menu
Opens IO Config menu
Opens Sensors menu
Changes to the higher menu

Input fields

Function

1

Nominal force (value)

2

Nominal force (unit)

4
17

OffsetDistance 2

18

Distance 1

19

Nominal distance (unit)

20

Nominal distance (value)

21

Force 222

Force 1Max. force of the force sensor at max.
measurement signal.
Measurement unit of the force sensor(max. 4 characters).
Offset for the corresponding sensor.
Measurement value of the 2nd measurement point
Measurement value of the 1st measurement point
Measurement unit of the distance sensor(max. 4 characters).
Max. distance of the distance sensor atmax. measurement signal.
Measurement value of the 2nd measurement point.
Measurement value of the 1st measurement point

12
13
14
15
16

Setting Nominal Force / Nominal Distance Parameters
When setting up the pressing monitor, the nominal force and nominal distance parameters must be defined in order to evaluate the measurement
values correctly.
üThe user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on Nominal force input field.
w The numerical keyboard opens.
2. Enter max. nominal force and press the OK button to confirm.
3. Tap on Nominal force \ Unit input field.
w The alphanumeric keyboard opens.
4. Enter unit and press the OK button to confirm.
5. Repeat steps 1 to 4 for the Nominal distance parameter.
6. Tap on Save button to save the values.

54

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Adjusting Force Sensor or Distance Sensor Offset
The Offset parameter adjusts a possible zero point offset of the analog
measurement sensor of the sensor.
An offset adjustment must be carried out:

once a day or after approx. 1000 measurements.



when a sensor has been changed.

Adjustment using Offset adjustment buttonü

The user is logged in with a suitable user level. The necessary write
permissions are available.

ü

Sensor is load-free during the offset adjustment.

1. Tap on Offset adjustment button.
w The current measurement signal (V) is applied as offset.
2. Tap on Save button to save the values.
Adjustment via direct Value Inputü

The user is logged in with a suitable user level. The necessary write
permissions are available.

ü

Sensor is load-free during the offset adjustment.

1. Tap on Offset input field.
w The numerical keyboard opens.
2. Enter zero point value and press the OK button to confirm.
3. Tap on Save button to save the values.

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Software

Calibrating Sensors
Sensors have to be recalibrated if they were replaced of if the systemshould be recalibrated.
The sensors are calibrated after the two-point calibration process. During
the two-point calibration, the exact linear path of the measurement chain
characteristic is determined via two measurement points. In this way, thegradient and offset of the measurement chain characteristic is determined.
üThe user is logged in with a suitable user level. The necessary write
permissions are available.

ü

The reference measuring instrument is connected.

1. Move to first measurement point.
2. Apply value using Teach button.
3. Tap on Force 1 or Distance 1 input field
w The numerical keyboard opens.
4. Enter displayed value on the reference measuring instrument and press
the OK button to confirm.
5. Move to second measurement point.
6. Apply value using Teach button.
7. Tap on Force 2 or Distance 2
w The numerical keyboard opens.
8. Enter displayed value of the reference measuring instrument and press
the OK button to confirm.
9. Apply value using Calibration button.
w The gradient and offset between both measurement points are calculated.
10. Tap on Save button to save the values.

56

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IO Config
The inputs of the sensors and the outputs are configured in the ''Configuration \ IO Config'' menu.

1
2

10

Fig. 23

1
2
3
4
5
6
7
8
9
10

9

8

7

6

5

4

3

''Configuration \ IO Config'' menu

ButtonFunction

Undo
Save
HardwareEvaluation Options
Switching points
Start/Stop
Measuring parameters
IO Config
Sensors

Undoes the entry
Saves the entry
Opens Hardware menu
Opens Evaluation Options menu
Opens Switching points menu
Opens Start/Stop menu
Opens Measuring parameters menu
Opens IO Config menu
Opens Sensors menu
Changes to the higher menu

Configuring Inputs/Outputs
ü

The user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on selection field of the input or output.
w Selection list opens.
2. Select value.
3. Tap on Save button to save the values.

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57

Software

DMS Characteristic Value
The characteristic for the DMS force transducer is entered using the Characteristic value parameter.
üThe user is logged in with a suitable user level. The necessary write
permissions are available.

ü

DMS sensor is selected at the force sensor input.

1. Tap on DMS Characteristic Value input field.
w The numerical keyboard opens.
2. Enter characteristic value and press the OK button to confirm.
3. Tap on Save button to save the values.

Measuring parameters
In the ''Configuration \ Measuring parameters'' menu, the type of measurement data acquisition is configured via the acquisition type parameter.
The following modes are available:58

Distance risingDistance rising or falling

Force or distance increasing

Force or distance changeTime-triggered

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Software

Selecting <Distance rising> Mode
This mode is suitable for positive value changes, e.g. clinch applications orpressing applications. The measurement values are measured at maximum
sampling rate (2000 Hz). The measurement values are read in if the distance to the measurement value last read in has increased by the X-stepentered.
If an end force is still increasing without a change in distance (block force),
the values (max. force/distance) can be read in and the curve can be inserted via the <insert max. force at the end of the curve> function.

1
2
3

4

5

13

Fig. 24

1
3
6
7
8
9
10
11
12
13

12

11

10

9

8

7

6

''Measuring parameters'' menu, Distance rising mode

ButtonFunction

Undo
Save
HardwareEvaluation Options
Switching points
Start/Stop
Measuring parameters
IO Config
Sensors

Undoes the entry
Saves the entry
Opens Hardware menu
Opens Evaluation Options menu
Opens Switching points menu
Opens Start/Stop menu
Opens Measuring parameters menu
Opens IO Config menu
Opens Sensors menu
Changes to the higher menu

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SoftwareüInput fields

Function

2

Acquisition type4

X-Step5Insert max. force at the end of
the curve

Max. force of the force sensor at max.
measurement signal
Minimum change in distance to the value
last read in
Display end force (block force) at the endof the curve

The user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on Acquisition type input field and select Distance rising mode.
2. Tap on X-step input field.
w The numerical keyboard opens.
3. Enter value in [mm] and press the OK button to confirm.
4. Tap on Insert max. force at the end of the curve input field and select whether the force should be inserted or not.
5. Tap on Save button to save the values.

60

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Select <Distance rising or falling> modeThis mode is recommended if negative distance changes should be also
recorded, e.g. applications with snap-back effects. The measurement values are measured at maximum sampling rate (2000 Hz). The measurement
values are read in if the distance in positive or negative direction to themeasurement value last read in has changed by the X-step that was read
in.

1
2
3

4

12

Fig. 25

11

10

9

8

7

6

5

''Measuring parameters'' menu, Distance rising or falling mode

ButtonFunction

Undo
Save
HardwareEvaluation Options
Switching points
Start/Stop
Measuring parameters
IO Config
Sensors

Undoes the entry
Saves the entry
Opens Hardware menu
Opens Evaluation Options menu
Opens Switching points menu
Opens Start/Stop menu
Opens Measuring parameters menu
Opens IO Config menu
Opens Sensors menu
Change to the higher menu

Input fields

Function

2

Acquisition type4

X-StepMax. force of the force sensor at max.
measurement signal
Minimum change in distance to the value
last read in

1
3
5
6
7
8
9
10
11
12

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Softwareü

The user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on Acquisition type input field and select Distance rising or falling mode.
2. Tap on X-step input field.
w The numerical keyboard opens.
3. Enter value in [mm] and press the OK button to confirm.
4. Tap on Save button to save the values.

62

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Select <Force or distance rising> modeThis mode is recommended for positive force or distance changes. In thismode, a pair of values is read in if since the last pair of values that wasread in ...
the distance has increased by the X-step.



the force has increased in positive direction.

1
2
3
4
5

13

Fig. 26

1
3
6
7
8
9
10
11
12
13

12

11

10

9

8

7

6

''Measuring parameters'' menu, Force or distance rising mode

ButtonFunction

Undo
Save
HardwareEvaluation Options
Switching points
Start/Stop
Measuring parameters
IO Config
Sensors

Undoes the entry
Saves the entry
Opens Hardware menu
Opens Evaluation Options menu
Opens Switching points menu
Opens Start/Stop menu
Opens Measuring parameters menu
Opens IO Config menu
Opens Sensors menu
Change to the higher menu

Input fields

Function

2

Acquisition type4

Y-Step5

X-StepMax. force of the force sensor at max.
measurement signal
Minimum change in force to the value
last read in
Minimum change in distance to the value
last read in

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Softwareü

The user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on Acquisition type input field and select Force or distance rising mode.
2. Tap on Y-step input field.
w The numerical keyboard opens.
3. Enter value in [kN] and press the OK button to confirm.
4. Tap on X-step input field.
w The numerical keyboard opens.
5. Enter value in [mm] and press the OK button to confirm.
6. Tap on Save button to save the values.

64

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Software

Select <Force or distance change> modeThis mode is recommended if the force can change while no distancechanges occur, e.g. for applications with large slip-in effects. In this mode,a pair of values is read in if since the last pair of values that was read in ...
the distance has changed in positive or negative direction by the Xstep.



the force has changed in positive or negative direction by the Y-step.

1
2
3
4
5

13

Fig. 27

12

11

10

9

8

7

6

''Measuring parameters'' menu, Force or distance change mode

ButtonFunction

Undo
Save
HardwareEvaluation Options
Switching points
Start/Stop
Measuring parameters
IO Config
Sensors

Undoes the entry
Saves the entry
Menu Hardware
Opens Evaluation Options menu
Opens Switching points menu
Opens Start/Stop menu
Opens Measuring parameters menu
Opens IO Config menu
Opens Sensors menu
Change to the higher menu

Input fields

Function

2

Acquisition type4

Y-Step5

X-StepMax. force of the force sensor at max.
measurement signal
Minimum change in force to the value
last read in
Minimum change in distance to the value
last read in

1
3
6
7
8
9
10
11
12
13

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Softwareü

The user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on Acquisition type input field and select Force or distancechange mode.
2. Tap on Y-step input field.
w The numerical keyboard opens.
3. Enter value in [kN] and press the OK button to confirm.
4. Tap on X-step input field.
w The numerical keyboard opens.
5. Enter value in [mm] and press the OK button to confirm.
6. Tap on Save button to save the values.

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Selecting <time-triggered> ModeIn this mode, all values are read in time-controlled at the specified frequency. This mode is recommended if the other modes do not lead to any
satisfactory results. At a sampling of 2000 Hz, the buffer is filled after approx. 2.5 s. The smaller the sampling rate, the longer the sampling data canbe written into the buffer.

1
2
3
4

12

Fig. 28

11

10

9

8

7

6

5

''Measuring parameters'' menu, time-triggered mode

ButtonFunction

Undo
Save
HardwareEvaluation Options
Switching points
Start/Stop
Measuring parameters
IO Config
Sensors

Undoes the entry
Saves the entry
Opens Hardware menu
Opens Evaluation Options menu
Opens Switching points menu
Opens Start/Stop menu
Opens Measuring parameters menu
Opens IO Config menu
Opens Sensors menu
Change to the higher menu

Input fields

Function

2

Acquisition type4

Sampling rate

Max. force of the force sensor at max.
measurement signal
Sampling rate for the measurements

1
3
5
6
7
8
9
10
11
12

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The user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on Acquisition type input field and select Time-triggered mode.
2. Tap on sampling rate input field.
w A drop-down list opens.
3. Select sampling rate in [Hz].
4. Tap on Save button to save the values.

Start/Stop
In the ''Start/Stop'' menu, you set when and how the measurement should
be started and stopped.
The illustrated screens serve as examples. The start / stop types provided
can be combined with each other.

Fig. 29''Configuration \ Start/Stop'' menu

The following modes are available:

68

Distance-triggered

Force-triggered

Digital IN triggeredTime-triggered (only available with stop type)

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Selecting <Distance-triggered> Mode
A measurement is started or stopped as soon as the distance set underStart or Stop is exceeded or fallen short of edge-dependent.

Fig. 30

ü''Configuration \ Start/Stop'' menu

The user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on Start type or Stop type selection field and select distancetriggered.
2. Tap on Start or Stop input field
w The numerical keyboard opens.
3. Enter value in [mm] and press the OK button to confirm.
4. Tap on edge type selection field and select whether the Start or Stopof the measurement should begin with rising or falling edge.
5. Tap on Save button to save the values.

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Selecting <Force-triggered> Mode
A measurement is started or stopped as soon as the force set under Start
or Stop is exceeded or fallen short of edge-dependent.

Fig. 31ü''Configuration \ Start/Stop'' menu

The user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on Start type or Stop type selection field and select force-triggered.
2. Tap on Start or Stop input field
w The numerical keyboard opens.
3. Enter value in [kN] and press the OK button to confirm.
4. Tap on edge type selection field and select whether the Start or Stopof the measurement should begin with rising or falling edge.
5. Tap on Save button to save the values.

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Selecting <Digital IN triggered>A measurement is started or stopped via the digital signal.

Fig. 32

ü''Configuration \ Start/Stop'' menu

The user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on Start type or Stop type selection field and select Digital IN
triggered.
2. Tap on edge type selection field and select whether the Start or Stopof the measurement should begin with rising or falling edge.
3. Tap on Save button to save the values.

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Selecting <time-triggered> Mode
A measurement can only be stopped time-triggered.

Fig. 33

ü''Configuration \ Start/Stop'' menu

The user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on Start type> or Stop type selection field and select time-triggered.
2. Tap on Measurement duration input field
w The numerical keyboard opens.
3. Enter value in [s] after which the measurement should be stopped andpress the OK button to confirm.
4. Tap on Save button to save the values.

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Configuring Switching Points
Several switching points are available, which can be used for different signals (force or distance). The setting for the current program can be copied
into other programs.

Fig. 34''Configuration \ Switching points'' menu

The SP2 switching point can be activated or deactivated via the ''IO config''
menu. If the switching point is grayed out, the <NOK beeper> function was
assigned to the <Digital Out 4> output.
ü

The user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on Signal field and set the switching point to the required signal.
w The displayed signal switches between distance and force.
2. Tap on value input field.
w The numerical keyboard opens.
3. Enter value in the corresponding dimension and press the OK button toconfirm
4. Tap on Inv field and set the switching point to inverse (X) or normal.
5. Tap on Active field and activate switching point (ON) or deactivate(OFF).
6. Tap on Save button to save the values.

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NOK options
If an acknowledgement type was selected, a NOK must be acknowledged
before the pressing monitor is ready to measure again.

1
2
3

Fig. 35

74''Configuration \ NIO options'' menu

ButtonFunction1

activate NOK buzzer

2

External NOK acknowledgement

3

NOK acknowledgement per display

If an external buzzer is connected, an
acoustic signal always sounds in thecase of NOK.
The NOK message must always be acknowledged via an external signal.
The NOK message must be acknowledged via the display.

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Activating NOK buzzer
activate NOK buzzer and sec. buzzer time can be activated ordeactivated via the ''IO config'' menu. If the entries are grayed out, the<switching point> function was assigned to the <Digital Out 4> output.
ü

The user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on activate NOK buzzer checkbox to activate beeper.
2. Tap on buzzer time input field.
w The numerical keyboard opens.
3. Enter value in [s] and press the OK button to confirm.
If the value "0" is entered, the acoustic signal sounds until the NOK is
acknowledged.
4. Tap on Save button to save the values.

Activate external NOK acknowledgement
ü

The user is logged in with a suitable user level. The necessary write
permissions are available.

ü

NOK acknowledgement per display is not activated.

1. Tap on external NOK acknowledgement checkbox to activate external acknowledgement.
2. Tap on Save button to save the values.

Activating NOK acknowledgement per displayüThe user is logged in with a suitable user level. The necessary write
permissions are available.

üexternal NOK acknowledgement is not activated.

1. Tap on NOK acknowledgement per display checkbox to activate theacknowledgement per display.
2. Tap on authorization level for acknowledgement input field and select user level that can carry out the acknowledgement.
3. Tap on Save button to save the values.

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Hardware
The following information is displayed in the ''Hardware'' menuCurrent process values in real time

Digital inputs and outputs

System time and date of the controllerSerial number of the device hardware

SystemThe current measurement values of all connected sensors are displayed in
the ''Hardware \ System'' menu.
In the ''OUT'' or ''IN'' columns, the active inputs and outputs (green) or deactivated inputs and outputs (red) are displayed.

1Fig. 36

1
2
3
4
5

76

2

3

4

5

''Hardware \ System'' menu

ButtonFunction

SystemDigital inputs/outputs
Controller
FilterChanges to the higher menu
Opens System menu
Opens digital inputs/outputs menu
Opens Controller menu
Opens Filter menu

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Digital inputs/outputs

7

6

5

Fig. 37

4

3

2

1

''Hardware \ Digital inputs/outputs'' menu

ButtonFunction

FilterController
Digital inputs/outputs
SystemOpens Filter menu
Opens Controller menu
Opens digital inputs/outputs menu
Opens System menu
Changes to the higher menu

Designation

Description

6

Inputs7

Outputs

The status of the digital inputs is displayed.
The outputs are displayed, on which asignal is currently output.

1
2
3
4
5

The function of the occupied input and output is labeled in plain text.
üThe user is logged in with a suitable user level. The necessary write
permissions are available.

è Tap on the corresponding button of the output.
u The output is activated or deactivated.

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The system time, date as well as serial number of the device hardware isdisplayed in the ''Hardware \ Controller'' menu.

1Fig. 38

1
2
3
4
5

2

3

4

5

''Hardware \ Controller'' menu

ButtonFunction

SystemDigital inputs/outputs
Controller
FilterChanges to the higher menu
Opens System menu
Opens digital inputs/outputs menu
Opens Controller menu
Opens Filter menu

Synchronizing the system time of the controller with the system time of thepanel PCüThe user is logged in with a suitable user level. The necessary write
permissions are available.

è Tap on Update BoardTime to Systemtime button.
u The system time is synchronized.

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FilterIn the ''Hardware \ Filter'' menu, the signals can be smoothed for displaying
the curves with less low-noise. The higher the respective value is, the lower
the signal noise.

1
2

3

8

Fig. 39

1
2
3
4
5
6
7
8

ü

7

6

5

4

''Hardware \ Filter'' menu

ButtonFunction

Undo
Save
Test
FilterController
Digital inputs/outputs
SystemUndoes the entry
Saves the entry
to test the smoothing of the value
Opens Filter menu
Opens Controller menu
Opens digital inputs/outputs menu
Opens System menu
Changes to the higher menu

The user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on Filter dimension force or Filter dimension distance input field.
w The numerical keyboard opens.
2. Enter value and press the OK button to confirm.
3. Tap on Test button to test the smoothing of the value.
4. Tap on Save button to save the values.

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9.4.5

Monitoring

Zoom
The user zoom is configured in the ''Monitoring \ Zoom'' menu.
Zooming is also possible via the ''Home Screen'' menu.

1
2
3
4
5
6

10

Fig. 409

8

7''Monitoring \ Zoom'' menu

ButtonFunction

1
2
3
4

Undo

5

Zoom factor

6
7
8
9
10

Envelope curve
Windows
Zoom

Undoes the entry
Reduces zoom factor
Saves the entry
Displays the zoom area in the marked
frame
Sets the zoom factor to the value of theconfiguration for the nominal distance /nominal force
Autozoom
Opens Envelope curve menu
Opens Windows menu
Opens Zoom menu
Changes to the higher menu

Save
Zoom area

The following configuration options are available:

80Change the zoom area graphically

Change zoom area by direct entry of values

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Change the zoom area graphicallyFig. 41''Monitoring \ Zoom'' menu

Setting zoom area automaticallyü

The user is logged in with a suitable user level. The necessary write
permissions are available.

è Tap on Autozoom button.
Increasing zoom areaüThe user is logged in with a suitable user level. The necessary write
permissions are available.

è Tap on decrease zoom factor button.
- OR Tap on any spot of the diagram.

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Freely defining Zoom Areaü

The user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on zoom area in the marked frame button.
2. Define the first point of the zoom frame by tapping on the diagram.
3. Define the second opposite point of the zoom frame by tapping again
on the diagram.
w The system zooms to the size of the resulting rectangle.
4. Tap on Save button to save the values.

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Change zoom area by direct entry of values
In the ''Monitoring \ Zoom'' menu, the action window is adapted to the corresponding axes via the input fields (min/max).

Fig. 42ü''Enter zoom values'' menu

The user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on the value of the input field that has to be changed.
w The numerical keyboard opens.
2. Enter value in [mm] or [kN] and press the OK button to confirm.
3. Change additional values accordingly.
w The zoom area is adapted accordingly to the entered value.
4. Tap on Save button to save the values.

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Windows
In the ''Monitoring \ Window'' menu, evaluation windows can be created,changed or deleted.
The settings only apply for the current process.
Every window is identified by a number on the frame of the window.
1 2 3

4

15

5

14

6
13
7

12

11

Fig. 43

84

10

9

8

''Monitoring \ Window'' menu

ButtonFunction

1
2
3
4
5
6
7

Window type
Windows
Move
Undo
Save
DeleteWindow boundary

8
9
10
11
12

Envelope curve
Windows
Zoom

13
14

Left
Bottom15

Top

Edits window type
Creates a new window
Moves the windows
Undoes the entry
Saves the entry
Deletes the selected window
Selects window edge
Four text fields show the dimensions of
the selected window.
Opens Envelope curve menu
Opens Windows menu
Opens Zoom menu
Changes to the higher menu
Moves window or window side to theright
Moves window or window side to the left
Moves window or window side to the bottom
Moves window or window side to the top

Right

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Creating window

Fig. 44ü''Create Monitoring \ Window '' menu

The user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on screen at the point where the window should start.
w A red cross hair appears.
2. Tap on screen at the opposite point where the window should end.
w A second red cross-hair appears.
3. If the window does not fit: Delete the window by tapping on any pointon the screen and define a new window again (steps 1 and 2).
4. Tap on Create window button to create the window.
w The new window is outlined with a green border.
w The number of the window is displayed at the bottom left of theframe.
5. Tap on Save button to save the values.

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Selecting Windowmm

Fig. 45''Monitoring \ Window'' menu

Only one window can ever be selected. The number of the selected window
is displayed in the selected window input field.
ü

The user is logged in with a suitable user level. The necessary write
permissions are available.

è Tap the window directly on the screen.
− OR −
1. Tap on Selected window input field.
w The numerical keyboard opens.
2. Enter window number and press the OK button to confirm.

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Moving window

Fig. 46''Monitoring \ Window'' menu

Move by tapping on the screenüThe user is logged in with a suitable user level. The necessary write
permissions are available.

ü

The desired window is selected.
See Selecting Window, Page 86.

1. Tap coordinate on the screen, on which the selected window should becentered.
w A red cross hair appears.
2. Tap on Move window button.
w The selected window is centered on the red cross-hair.
3. Tap on Save button to save the values.
Moving with arrow keys

üThe user is logged in with a suitable user level. The necessary write
permissions are available.

ü

The desired window is selected.
See Selecting Window, Page 86.

1. Move selected window using the arrow keys.
2. Tap on Save button to save the values.

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Changing the size of the windowmm

Fig. 47''Monitoring \ Window'' menu

Changing size of Window using Arrow Keysü

The user is logged in with a suitable user level. The necessary write
permissions are available.

ü

The desired window is selected.
See Selecting Window, Page 86.

1. Tap on Window boundary repeatedly until the size of the window to
be changed is highlighted in red on the button.
2. Move the window side with the corresponding arrow key.
3. Tap on Save button to save the values.
Changing Size of Window by entering a ValueüThe user is logged in with a suitable user level. The necessary write
permissions are available.

ü

The desired window is selected.
See Selecting Window, Page 86.

1. Tap on the input field of the window that is to be changed.
2. Enter values and press the OK button to confirm.
3. Tap on Save button to save the values.

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Changing Window Condition

mmFig. 48''Monitoring \ Window'' menu

The measuring curve must enter at the specified entry side of the windowand exit at the specified exit side.
Entry side and exit side are freely definable. The first point of intersection of
the curve with a window boundary is the entry event, the subsequent pointof intersection with a window boundary is the exit event.
Examples:Fig. 49

Examples of window boundaries

Windows

Mode
Curve entry

Curve exit

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Software

Windows

Mode
Curve entry or exit as desired

No curve entry or exit

Tab. 2Modes for window boundaries

ü

The user is logged in with a suitable user level. The necessary write
permissions are available.

ü

The desired window is selected.
See Selecting Window, Page 86.

1. Tap on Window boundary repeatedly until the size of the window to
be changed is highlighted in red on the button.
2. Tap on Modes button repeatedly until the desired mode is displayed.
3. Tap on Save button to save the values.

90

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Delete window
Windows that are no longer needed or which were created incorrectly canbe deleted.

Fig. 50''Monitoring \ Window'' menuüThe user is logged in with a suitable user level. The necessary write
permissions are available.

ü

The window which is to be moved is selected.
See Selecting Window, Page 86.

1. Tap on Delete button.
w The selected window is deleted.
2. Tap on Save button to save the values.

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Acute NOK
By activating the Acute NOK option, the <Acute NOK> output is set if thewindow is violated.

Fig. 51''Monitoring \ Window'' menuüThe user is logged in with a suitable user level. The necessary write
permissions are available.

ü

The desired window is selected.
See Selecting Window, Page 86.

1. Activate option by tapping on the checkbox.
2. Tap on Save button to save the values.

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Envelope curve
In the ''Monitoring \ Envelope curve'' menu, the envelope curve can be configured.

Fig. 52''Monitoring \ Envelope curve'' menu

The envelope curve is used wherever fast teaching-in of evaluation elements is required.
The measuring curve must run through the envelope curve and not violate
the boundary lines in the process

Switching envelope curve edit mode on/offüThe user is logged in with a suitable user level. The necessary write
permissions are available.

è Tap on On/Off button to switch the function on or off.

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Teaching-in/Activating Envelope Curve
In the <Teach-in> mode, the measured curves are recorded and the enveloping boundaries (top/bottom envelope curve) are formed.
ü

The user is logged in with a suitable user level. The necessary write
permissions are available.

ü

Edit mode is switched on.
See Switching envelope curve edit mode on/off, Page 93.

1. Tap on Teach-in button.
2. Execute work process at least 15 times.
w Several curves are recorded.
3. Tap on X Min input field to define entry coordinates of the curve.
w The numerical keyboard opens.
4. Enter value in [mm].
5. Press the OK button to confirm.
6. Tap on X Max input field to define exit coordinates of the curve.
w The numerical keyboard opens.
7. Enter value in [mm].
8. Press the OK button to confirm.
9. Enter shift of the top boundary via the top input field. The boundary lineis thereby shifted accordingly.
10. Enter shift of the bottom boundary via the bottom input field. The
boundary line is thereby shifted accordingly.
11. Tap on Save button to save the values.
12. Tap on the Evaluate button to exit teaching-in and to switch to the <Evaluate> mode.
u The envelope curve is now monitored actively.

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The user is logged in with a suitable user level. The necessary write
permissions are available.

ü

Edit mode is switched on.
See Switching envelope curve edit mode on/off, Page 93.

üTeach-in mode is activated.

1. Tap on Confirmation button.
w Recorded curve is used for teaching-in.
2. Tap on add button.
w Recorded curve is added for teaching-in.

Deleting Envelope CurveüThe user is logged in with a suitable user level. The necessary write
permissions are available.

ü

Edit mode is switched on.
See Switching envelope curve edit mode on/off, Page 93.

1. Tap on Delete button to delete the envelope curve.
2. Tap on Save button to save the values.

Supplementing Envelope CurveüThe user is logged in with a suitable user level. The necessary write
permissions are available.

ü

Edit mode is switched on.
See Switching envelope curve edit mode on/off, Page 93.

1. Tap on Evaluate button.
2. Tap on add button.
w The envelope curve is supplemented by a recorded curve outside
the boundary.

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9.4.6

Counters

12

7

Fig. 53

1
2
3
4
5
6
7

6

5

4

3

Menu ''Counter''

ButtonFunction

Reset
Save
NOK seq counter
Tool counter
Shift counter
Job counter

Resets the counter
Saves the entry
Opens NOK seq counter menu
Opens tool counter menu
Opens Shift counter menu
Opens Job counter menu
Changes to the higher menu

All counters contain the following values:

96Good parts: Value increases after each measurement completed withOK.



Bad parts: Value increases after each measurement completed withNOK.



Total parts: Value increases after each measurement and is the total ofgood parts and bad parts.

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Job Counter/Shift CounterIn the ''Counter \ Job counter'' or ''Shift counter'' menu, the respective
counter states are displayed for the current job or current shift.

1Fig. 542

3

4''Counter \ Job counter'' menu

Field

Meaning

1
2
3

Type
Counter value
Message at

4

Stop atPart type
Current value of the respective part type
Number of parts at which a message is
generated.
Number of parts at which the systemshuts down.

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Tool counterIn the ''Counter \ Tool counter'' menu, the counter value is displayed for thecurrent tool.

1

Fig. 55

98

2

3

4

''Counter \ Tool counter'' menu

Field

Meaning

1
2
3

Type
Counter value
Message at

4

Stop atPart type
Current value of the respective part type
Number of parts until a message is generated.
Number of parts when the system shuts
down.

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NOK seq counterIn the ''Counter \ NOK seq counter'' menu, the NOK components producedin succession are counted.

1Fig. 56

2

3

4''Counter \ NOK seq counter'' menu

Field

Meaning

1
2
3

Type
Counter value
Message at

4

Stop atPart type
Current value of the respective part type
Number of parts until a message is generated.
Number of parts when the system shuts
down.

Setting Message
A value can be entered for each part type via the Message at input field.
Once the counter value reaches the value, a message is issued.
The value <0> deactivates the option and no message is issued.
üThe user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on Message at input field of the corresponding part type.
2. Enter trigger value and press the OK button to confirm.
3. Tap on Save button to save the values.

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Setting Stop
A value can be entered for each part type via the Stop at input field. Oncethe counter value reaches the value, the system shuts down and a corresponding message is issued.
As soon as the counter value is reached, the <ready to measure> signal forthe following measurement is not set. A counter value message (with a red
background) is issued.
Tapping on the Reset button resets the counter. After that, the next measurement can be continued.
The value <0> deactivates the corresponding option. The system is notshut down and no message is issued.
üThe user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on Stop at input field of the corresponding part type.
2. Enter trigger value and press the OK button to confirm.
3. Tap on Save button to save the values.

Reset counter limitü

The user is logged in with a suitable user level. The necessary write
permissions are available.

è Tap on Reset button.
u The counter values are reset.

Displaying Counter in Main Screen
The corresponding counter can be displayed in the''Channel cockpit'' menu
via the optionDisplay counter in main screen.
üThe user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on Display counter in main screen input field.
w The counter is displayed in the main screen.
2. Tap on Save button to save the values.

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9.4.7

Processes
A process can either be selected by an external PLC or in the ''Processes''menu.

Processes

Fig. 57''Processes \ Processes'' menu

Selecting Processes
Selection by entering a ValueüThe user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on process number input field.
w The numerical keyboard opens.
2. Enter process number and press the OK button to confirm.
3. Tap on Save button to save the values.

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Selection by Function Buttons

üThe user is logged in with a suitable user level. The necessary write
permissions are available.

1. Select process by tapping the <-> or <+> buttons.
2. Tap on Save button to save the values.

Assigning Process Name
A name can be assigned for each process.
ü

The user is logged in with a suitable user level. The necessary write
permissions are available.

1. Select process.
2. Tap on process name input field.
w The alphanumeric keyboard opens.
3. Enter process name and press the OK button to confirm.
4. Tap on Save button to save the values.

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Copy
In the ''Process \ Copy'' menu, process parameters can be copied from asource process to several target processes.

Fig. 58

üMenu ''Process \ Copy''

The user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on source process input field.
w The numerical keyboard opens.
2. Enter source process number and press the OK button to confirm.
3. Tap on target process input field.
w The numerical keyboard opens.
4. Enter process number of the first target process.
5. Tap on target processes to input field.
w The numerical keyboard opens.
6. Enter the process number of the last target process.
7. Select the process parameters to be copied by tapping on the checkbox.
8. NOTE! Data loss! The old process settings in the target process are
overwritten by copying.
Start copying process by tapping on the Copy button.

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ExampleThe data from source process <0> are to be copied to the target processes<1> to <2>.
1. Enter the process number <0> in source process input field.
2. Enter the process number <1> in target process input field.
3. Enter the process number <2> in target processes to input field.
4. Select the process data to be copied.
5. Start copying process by tapping on the Copy button.

Saving/Loading
In the ''Processes \ Save/Load'' menu, process parameters can be savedon or loaded from an external data carrier (e.g. USB stick).

Fig. 59

Menu ''Processes \ Save/Load''

Copying Process ParametersüThe user is logged in with a suitable user level. The necessary write
permissions are available.

üAn external data medium is connected.

è Tap on Save parameters to USB stick button.
u All parameters and processes are saved on the connected data carrier.

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Loading Process ParametersüThe user is logged in with a suitable user level. The necessary write
permissions are available.

üAn external data carrier is connected

NOTE
Data loss!
When the data of the data carrier is loaded to the TOX®-pressing monitor,
all processes and parameters are overwritten.

1. Tap on Load parameters from USB stick button.
2. Select dataset to be loaded and press the OK button to confirm.

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9.4.8

System1
2

9

Fig. 60

1
2
3
4
5
6
7
8
9

8

7

6

5

4

3

''System \ Addition'' menu

ButtonFunction

Undo
Save
Version
Display
Date/Time
Communication
Language
Device name

Undoes the entry
Saves the entry
Opens Version menu
Opens Displaymenu
Opens Date/Time menu
Opens Communication menu
Opens Language menu
Opens Device name menu
Changes to the higher menu

Assigning Device Name
If several pressing monitors are used, it is recommendable to assign aunique name for each device. If data is saved on a USB stick, this devicename is used in the file name. This enables the imported data to be
uniquely assigned.

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Softwareü

The user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on Device name input field.
w The alphanumeric keyboard opens.
2. Enter device name and press the OK button to confirm.
3. Tap on Save button to save the values.

Changing Language

Fig. 61''System \ Language'' menu

In the ''System \ Language'' menu, you have the option to change the userinterface language.
üThe user is logged in with a suitable user level. The necessary write
permissions are available.

è Tap on the desired language to select it.
u The selected language will be available immediately

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Configuring Communication
In the ''communication'' menu, the Ethernet IP address can be configured.

Fig. 62''system \ communication \ IP address'' menu

Defining IP address via the DHCP protocolüThe user is logged in with a suitable user level. The necessary write
permissions are available.

è Tap on DHCP checkbox.
Defining IP Address by entering a ValueüThe user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on the first input field of the IP address group, enter the first three
digits of the IP address to be used and press the OK button to confirm.
w The numerical keyboard opens.
2. Repeat the procedure for all input fields in the IP address group.
3. Repeat point 2 and 3 to enter the Subnet mask and Default Gateway.
4. Tap on Save button to save the values.

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Setting Date/TimeIn the ''System \ Date/Time'' menu, the device time and device date can be
configured.

Fig. 63ü''System \ Date/Time'' menu

The user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on the Time or Date input fields.
w The numerical keyboard opens.
2. Enter values in the corresponding fields and press the OK button toconfirm.
3. Tap on Save button to save the values.

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Configuring Display
In the ''System \ Display'' menu, the settings for the display in the ''Channel
Cockpit'' menu are performed.

Fig. 64ü''System \ Display'' menu

The user is logged in with a suitable user level. The necessary write
permissions are available.

1. Select the number of curves to be displayed by tapping on the selectionlist.
2. Select whether switching points should be displayed in the diagram.
3. Tap on Save button to save the values.

Displaying Version
In the ''System \ Version'' menu, the installed SW versions are displayed.

110Operating system

Dot Net runtime environmentSoftware

Firmware

Image Version

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Fig. 65''System \ Version'' menu

Displaying/Exporting Operating Instructions
Displaying Operating Instructionsü

The user is logged in with a suitable user level. The necessary write
permissions are available.

è Tap on Display operating instructions button.
Exporting Operating Instructionsü

The user is logged in with a suitable user level. The necessary write
permissions are available.

üExternal data carrier is connected.

è Tap on Export operating instructions button
u The operating instructions are saved on an external data carrier.

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Updating Software
NOTE
Loss of data by disconnecting the device from the supply voltage!
è Do not disconnect the device from the supply voltage during the updateüThe user is logged in with a suitable user level. The necessary write
permissions are available.

ü

The device runs for at least 3 minutes.

1. Unpack ZIP file and copy "EPW500Update" folder to USB stick.
2. Connect USB stick to the device.
3. Tap on update button to update the installed software.

Updating UpdaterüThe user is logged in with a suitable user level. The necessary write
permissions are available.

è Tap on update updater button to update the software installation program.

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9.4.9

User
In the ''user'' menu, the authorizations for the respective menus are configured, e.g. whether buttons or input fields are active. After each startup, theprogram is at the lowest authorization level.
1

2
3

5

4

Fig. 661
2
3
4
5''user'' menu

ButtonFunction

Login
Undo
Save

Login for the authorizations
Undoes the entry
Saves the entry
Changes to the higher menu
Changes password

Change password

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Changing User Management/Access Authorization
The pressing monitor has an authorization management system that canlimit or enable different operating options and configuration options.

Fig. 67''User Login'' dialog

Authorization

Description

Password

Level 1
Level 2
Level 3

Configuration
Configuration (system, settings)
Configuration (Service)

TOX1
TOX2
TOX3

1. Tap on login button.
w The ''User Login'' dialog opens.
2. Tap on user name selection field and select authorization level.
w The description and user group is displayed in the corresponding
fields.
3. Tap on password input field.
w The alphanumeric keyboard opens.
4. Enter password of the authorization level and press the OK button toconfirm.
u If the password was entered correctly, the selected authorization levelis active.
- OR If the password was entered incorrectly, a message will appear and thelogin procedure will be canceled.

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9.4.10

Data

Final values
In the ''Data \ Final values'' menu, the final imported values of a measurement in the internal memory are listed.

1

6

Fig. 68

5

4

3

2

''Data \ Final values'' menu

ButtonFunction

1

Save

2
3
4
5
6

MemorySettings
Curve data
Final values

Saves the recorded data to an external
data carrierOpens Memory menu
Opens Settings menu
Opens Curve data menu
Opens Final values menu
Changes to the higher menu

After each measurement, a final value dataset is saved in the internal memory. This dataset includes the following information:
Parameters

Description

No.

Number of the measurement.
1000 final values are stored in a circular buffer, i.e. with each newmeasurement, the oldest dataset (= no. 999) is discarded and thenewest is added (last measurement = no. 0).
Identification Number
Each measurement is indicated with a unique consecutive number.
Program used

ID
Prg.

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Parameters

Description

StatusMeasurement OK (green)
Measurement NOK. (red)maximum force
maximum distance
Date (dd/mm/yyyy) and time (hh:mm:ss)

Max. force
Max. distancemeasurementtimeüThe user is logged in with a suitable user level. The necessary write
permissions are available.

1. Connect external data carrier.
2. Tap on Export button.
u The data is copied to the connected data carrier.

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Curve data
In the ''Data \ Curve data'' menu, the curve data can be saved. This window
contains a list of the value pairs recorded in the internal memory(distance/
force) of the last measuring curve.

1
2

7

Fig. 69

6

5

4

3

''Data \ Curve data'' menu

ButtonFunction

1

Save

2

Save

3
4
5
6
7

MemorySettings
Curve data
Final values

Saves the recorded data to an external
data carrier
Saves the selected curve data to an external data carrierOpens Memory menu
Opens Settings menu
Opens Curve data menu
Opens Final values menu
Changes to the higher menu

After each measurement, the curve data is saved in the internal memory.
This dataset includes the following information:
Parameters

Description

No.

Number of the measurement.
100 curve data are stored in a circular buffer, i.e. with each newmeasurement, the oldest dataset (= no. 99) is discarded and thenewest is added (last measurement = no. 0).
Identification Number
Each measurement is indicated with a unique consecutive number.
Program used
Measurement OK (green)
Measurement NOK. (red)ID
Prg.
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Parameters

Description

Max. force
Max. distance
Measure Timemaximum force
Maximum distance
Date (dd/mm/yyyy) and time (hh:mm:ss)ü

The user is logged in with a suitable user level. The necessary write
permissions are available.

üIn the ''Data \ Settings'' menu, the storage of the curve data is activated.

üExternal data carrier is connected.

è Tap on Export button.
− OR −
tap on Single Export button.
u The recorded curve data is saved on an external data carrier.

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Settings
In the ''Data \ Settings'' menu, you can configure whether data should besaved on an external data carrier or network drive during the export andwhich data (none, all data, NOK data or OK data).
After the export, the data is available as a CSV file in the corresponding directories.

1
2

7

Fig. 70

1
2
3
4
5
6
7

6

5

4

3

''Data \ Settings'' menu

ButtonFunction

Undo
Save
MemorySettings
Curve data
Final values

Undoes the entry
Saves the entry
Opens Memory menu
Opens Settings menu
Opens Curve data menu
Opens Final values menu
Changes to the higher menu

The following values can be selected:


None



Only OK

Only NOKall

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Selecting Valuesü

The user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on the corresponding selection field and select the desired value.
2. Tap on Save button to save the values.

Selecting CSV SeparatorüThe user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on CSV separator selection list and select the desired separator.
2. Tap on Save button to save the values.

Selecting Decimal SeparatorüThe user is logged in with a suitable user level. The necessary write
permissions are available.

1. Tap on Decimal separator selection list and select the desired separator.
2. Tap on Save button to save the values.

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Network Drive/USB StickAll data (final values/curve data) can be retrieved via a network drive or
saved to a USB stick.
During high production frequency, the memory expansion should be used
as memory location.
The local network and security guidelines must be configured in such a
way that communication is not impaired.
Data of the last 10 days are stored in a ring memory in the corresponding
folders.
Folder

MemoryDescription

EPWCurveExp

Internal

EPWCurveExt

External

EPWFinValExp

Internal

EPWFinValExt

External

Temp

External

A folder with a corresponding date is created per working day.
A folder with corresponding names is created below the day folder for each hour.
Each stored curve is filed there as a CSV
file with a corresponding date/time.
The folder can contain a maximum of1000 files. If more than 1000 data setsare created, these data sets are written in
a new folder.
A folder with a corresponding date is created per working day.
A folder with corresponding names is created below the day folder for each hour.
Each stored curve is filed there as a CSV
file with a corresponding date/time.
The folder can contain a maximum of1000 files. If more than 1000 data setsare created, these data sets are written in
a new folder.
A CSV file with a corresponding date is
created per working day. All final values
together with a corresponding identification are stored in this file
A CSV file with a corresponding date is
created per working day. All final values
together with a corresponding identification are stored in this file
Temporary folder

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Network Drive/USB Stick Data AccessIf the option save final values on network drive or save curve data on
network drive was selected in the ''Data\ Settings'' menu, the data can beaccessed as follows.
ü

The user is logged in with a suitable user level. The necessary write
permissions are available.
®

è Open Windows -Explorer, enter the IP address of the device and press
the Enter button to confirm.
u All corresponding folders will be displayed

Fig. 71

122

Network drive folder

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MemoryIn the ''Data\ Memory'' menu, an external memory expansion (USB stick)can be initialized and selected.
During high production frequency, the memory expansion should be used
as memory location.
See "Data \ Memory, Page 123" menu
The local network and security guidelines must be configured in such a
way that communication is not impaired.

Selecting Memory Location for Usage Data

1
2

7

Fig. 72

1
2
3
4
5
6
7

6

5

4

3

''Data \Memory'' menu

ButtonFunction

Save
Undo
MemorySettings
Curve data
Final values

Saves the entry
Undoes the entry
Opens Memory menu
Opens Settings menu
Opens Curve data menu
Opens Final values menu
Changes to the higher menu

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Softwareü

The user is logged in with a suitable user level. The necessary write
permissions are available.

üUSB stick is inserted.

1. Tap on Initialize memory expansion to enable external memory expansion.
2. Tap on memory location for usage data selection list and select ''internal memory'' or ''memory expansion'' memory location.
3. Tap on storage interval for counter selection list and select time interval.
4. Tap on Save button to save the values.
u Memory expansion is activated after restarting.

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Troubleshooting

10 Troubleshooting
10.1

Detecting faults
Faults are displayed as alarms on the pressing monitor. Depending on thetype of fault, the alarms are displayed as errors or warnings.
Alarm
Type

Display

Meaning

Warning

Text with an orange background in
the information and status display ofthe device.
Text with a red background in the information and status display of thedevice.

--Fault

10.1.1

The next measurement is disabled and must be eliminatedand acknowledged.

Acknowledging Messages
1. Tap on error symbol.
w The dialog with all error messages opens.
2. Tap on Ackn all button to acknowledge the pending error messages.
- OR tap on Cancel button to close the dialog without acknowledging the error messages.

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Troubleshooting

10.1.2

126

Error messages
Fault

Cause

Measure0001(HMI RTC time invalid)
0001(HMI RTC time invalid)
0002(Controller RTC
time invalid)
0002(Controller RTC
time invalid)
0002(Controller RTC
time invalid)Time (panel PC) incorrect

Correct the time (panel PC) in the settings.

Buffer battery(panel PC) is fullydischarged

For spontaneous further operation correct PC time synchronization in Settings.
Replace the buffer battery (panel PC)
Synchronize time (hardware) with PC
time.

Time (hardware) is
incorrect
Time (PC) is incorrect

Correct the time of the PC in the settings.

Buffer battery(hardware) is fullydischarged

Buffer battery (replace the hardware).

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Maintenance

11 Maintenance
11.1

Maintenance and repair
The recommended time intervals for inspection work and maintenancework must be observed.
The correct and proper repair of the TOX® PRESSOTECHNIK product can
only be assured by appropriately trained specialists. The operating company or the personnel in charge of the repair must ensure that the repair
personnel are properly trained in the repair of the product.
The repairers themselves are always responsible for the work safety.

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Maintenance

11.2

Safety during maintenance
The following applies:

Observe maintenance intervals if present and stipulated.



Maintenance intervals may vary from the stipulated maintenance intervals.
The maintenance intervals may have to be verified with the manufacturer if necessary.

11.3



Perform only maintenance work that is described in this manual.



Inform operating personnel before starting repair work.

Appoint a supervisor.

Maintenance schedule
The operating company is responsible for compliance with the maintenanceschedules and documentation of maintenance.
1. Ensure that all maintenance work is performed at the intervals specified
in the maintenance schedule.
2. Records of completed maintenance work must be kept.
At the end of the chapter is the maintenance table with the maintenancecycles.

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Maintenance

11.4

Controller Battery Change
TOX® PRESSOTECHNIK recommends a battery change after 10 years at
the latest.
ü

Device is de-energized.

üPerson is electrostatically discharged.

üElectrically non conductive tool for removing the battery.

1
3

Fig. 73

Cheese head screw
Battery2
4

Housing
Panel PC

Opened housing

1. Loosen and remove cheese-head screws.
2. Remove panel PC from the housing.
3. NOTE! equipment damage due to short-circuit!
Remove lithium battery using an electricallynon conductive tool.
4. Install new lithium battery in the correct polarity.
5. Reinsert panel PC into the housing and assemble using the cheesehead screws.

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Maintenance

11.5

Panel PC Battery Change
TOX® PRESSOTECHNIK recommends a battery change after 10 years at
the latest.
ü

Device is de-energized.

üPerson is electrostatically discharged.

üElectrically non conductive tool for removing the battery.

ü

A scratch-free base for placing the screen onto.

1
3

Fig. 74

Cheese head screw
Panel PC

2

Housing

Opened housing

1. Loosen and remove cheese-head screws.
2. Remove panel PC from the housing and place it onto a scratch-freesurface with the screen facing downwards.
3. Remove screws and threaded bolts.

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1
3

Screw
Threaded bolt

Fig. 75

Open panel PC

2

Cover

4. NOTE! Equipment damage due to short-circuit!
Remove cover and lithium battery using an electricallynon conductive
tool.

1

Fig. 76

Battery

Replace lithium battery

5. Install new lithium battery in the correct polarity.
6. Install cover and fasten using the screws and threaded bolts.
7. Reinsert panel PC into the housing and assemble using the cheesehead screws.

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Maintenance132

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Maintenance table

Maintenance table
The specified intervals are only approximate values. Depending on the areaof application, the actual values may differ from the guide values. The actual intervals can be found in the system control.
Maintenance cycle

Additional information

10 years

11.4
11.5

Controller Battery Change
Panel PC Battery Change

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Maintenance table

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Repairs

12 Repairs
12.1

Repair work
No repair work is necessary.

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Repairs

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Disassembly and Disposal

13 Disassembly and Disposal
13.1

Safety requirements for disassemblyè Have the disassembly carried out by qualified personnel.

13.2

Disassembly
1. Shut down system or component.
2. Disconnect system or component from the supply voltage.
3. Remove all connected sensors, actuators or components.
4. Disassemble system or component.

13.3

Disposal
When disposing of packaging, consumables and spare parts, including themachine and its accessories, the relevant national environmental
protection regulations must be complied with.

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Appendices

14 Appendices14.1

Declaration of conformity

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Appendices

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Index

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Index

Index
AC

accessNetwork drive .......................................... 122
USB stick ................................................ 122
access authorization
Change ................................................... 114
Adjustment
Distance sensor offset .............................. 55
Force sensor ............................................. 55
Analog Out .................................................... 25
authorization
Change ................................................... 114

calibration
Sensors..................................................... 56
Checkboxes................................................... 45
Commissioning .............................................. 39
communication
Configure ................................................ 108
Define IP address ................................... 108
configuration .................................................. 19
Display .................................................... 110
DMS Characteristic Value......................... 58
Input.......................................................... 57
Output ....................................................... 57
Sensors..................................................... 53
Switching points........................................ 73
Contact .......................................................... 11
Control elements ........................................... 44
controller
Change battery ....................................... 129
Counter
Display in main screen............................ 100
Reset counter value................................ 100
Set message............................................. 99
Set stop................................................... 100
CPU module .................................................. 22

B
Basic safety requirements ............................. 13
battery change
Controller ................................................ 129
Panel PC................................................. 130
buttons
Function buttons ....................................... 44

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IndexDE

date
Set .......................................................... 109
Declaration of conformity............................. 139
description
Function .................................................... 19
device name
Assign ..................................................... 106
dialogKeyboard .................................................. 46
Save changes ........................................... 48
Digital ............................................................ 27
Input.......................................................... 27
Output ....................................................... 27
Digital IN triggered......................................... 71
Dimensions.................................................... 21
Disassembly ................................................ 137
Safety...................................................... 137
Dispatch
Repair ....................................................... 35
display
Configur .................................................. 110
Operating instructions............................. 111
Software version ..................................... 110
Disposal....................................................... 137
distance
Change ..................................................... 65
Rising .................................................. 59, 63
Rising or falling ......................................... 61
Distance sensor............................................. 25
Adjust offset .............................................. 55
Distance-triggered ......................................... 69
DMS............................................................... 23
DMS Characteristic Value
Configure .................................................. 58
DMS signals .................................................. 33
Document
additional .................................................... 8
Validity ........................................................ 8

envelop curve
Teach-in .................................................... 94
envelope curve
Delete ....................................................... 95
Supplement............................................... 95
Switch off .................................................. 93
Switch on .................................................. 93
Environmental conditions .............................. 32
Error message ............................................. 126
Ethernet RJ45 ............................................... 29
Exclusion of liability ......................................... 7
export
CSV separator ........................................ 120
Decimal separator................................... 120
Network drive .......................................... 121
Operating instructions............................. 111
Settings................................................... 119
USB stick ................................................ 121
Values..................................................... 120

Ffaults
Detect ..................................................... 125
force
Change ..................................................... 65
Rising ........................................................ 63
force sensor
Adjust offset .............................................. 55
DMS .......................................................... 23
Standard input ......................................... 24
Force-triggered .............................................. 70
function
Software.................................................... 43
Function buttons ............................................ 44
Function description ...................................... 19

G
Gender note .................................................... 8

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IndexH

L

HazardElectrical ................................................... 16
Hazard potential ............................................ 16
Holding bracket
Installation................................................. 37

language
Change ................................................... 107
Legal note........................................................ 7
Liability .......................................................... 18
list
Selection ................................................... 45
lowercase
Permanent ................................................ 46

I
Icons .............................................................. 49
Identification
Product ..................................................... 18
ImagesHighlighting ............................................... 10
Important information ...................................... 7
Information
Important..................................................... 7
Information bar .............................................. 44
input
Configure .................................................. 57
Digital ........................................................ 27
Force sensor ............................................. 24
Input field ....................................................... 45
Installation ..................................................... 37
Holding bracket......................................... 37
Intended use.................................................. 17
interface
Software.................................................... 43
USB .......................................................... 28
Interfaces....................................................... 23

J
Job counter
Display in main screen............................ 100
Reset counter value................................ 100
Set message............................................. 99
Set Stop .................................................. 100

K
Keyboard ....................................................... 46

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IndexM
Main menus ................................................... 50
maintenance ................................................ 127
Maintenance schedule............................ 128
Safety...................................................... 128
Measures
Organizational........................................... 14
Measuring mode............................................ 19
Measuring parameters
Distance rising .......................................... 59
Distance rising or falling............................ 61
Force or distance change ......................... 65
Force or distance rising ............................ 63
Time-triggered .......................................... 67
Memory extension ....................................... 123
memory location
For usage data........................................ 123
men
Data ........................................................ 115
Menu
Channel cockpit ........................................ 50
Communication ....................................... 108
Configuration ............................................ 53
Controller .................................................. 78
Copy ....................................................... 103
Counter ..................................................... 96
Curve data .............................................. 117
Date/Time ............................................... 109
Digital inputs/outputs ................................ 77
Display .................................................... 110
Envelope curve ......................................... 93
Filter .......................................................... 79
Final values............................................. 115
Full-screen display .................................... 51
Hardware .................................................. 76
IO Config................................................... 57
Job counter ............................................... 97
Language ............................................... 107
Measuring parameters.............................. 58
Memory ................................................... 123
Monitoring ................................................. 80
NOK seq counter ...................................... 99
Processes ............................................... 101
Save/Load............................................... 104
Sensors..................................................... 53
Settings................................................... 119
Shift counter.............................................. 97

146

Start/Stop.................................................. 68
Switching points........................................ 73
System .............................................. 76, 106
Tool counter.............................................. 98
User ........................................................ 113
Version.................................................... 110
Window ..................................................... 84
Zoom......................................................... 80
messageAcknowledge .......................................... 125
Error ........................................................ 126
Misuse ........................................................... 17
monitoring
Operation .................................................. 41
Process ..................................................... 19N
NOK options .................................................. 74
Nominal DistanceSet ............................................................ 54
Nominal Force
Set ............................................................ 54
Note
Gender........................................................ 8
General ..................................................... 10
Legal ........................................................... 7
Warning signs ............................................. 9O
operating instructions
Display .................................................... 111
Export ..................................................... 111
operation ....................................................... 41
Monitoring ................................................. 41
Safe .......................................................... 17
Organizational measures .............................. 14
outputConfigure .................................................. 57
Digital ........................................................ 27

TOX_Manual_Process-monitoring-unit_EPW500FP_en-US

IndexP

S

Panel PC
Change battery ....................................... 130
preparation
System ...................................................... 39
process ........................................................ 101
Assign name ........................................... 102
Copy parameters .................................... 104
Load parameters..................................... 105
Select ...................................................... 101
Process monitoring system ........................... 19
Product Identification ..................................... 18
pulse diagrams
PLC interface ............................................ 30

Safety ............................................................ 13
Maintenance ........................................... 128
safety requirements
Basic ......................................................... 13
Operating company .................................. 14
Selection
Personnel.................................................. 15
Selection lists ................................................ 45
Selection of personnel ................................... 15
sensorAdjust offset .............................................. 55
Analog standard signals ........................... 32
Calibrate ................................................... 56
Distance sensor ........................................ 25
DMS force sensor ..................................... 23
Force sensor standard input .................... 24
Standard signal output.............................. 32
Supply voltage .......................................... 32
Sensors
Configuration ............................................ 53
Setting
Date ........................................................ 109
Nominal Distance...................................... 54
Nominal Force .......................................... 54
Time ........................................................ 109
Shift counter
Display in main screen............................ 100
Reset counter value................................ 100
Set message............................................. 99
Set Stop .................................................. 100
software ......................................................... 43
Function .................................................... 43
Interface.................................................... 43
Update .................................................... 112
software version
Display .................................................... 110
Source of supply............................................ 11
Special characters ......................................... 47
Other ......................................................... 47
Permanent ................................................ 47
Start/Stop
Digital IN triggered .................................... 71
Distance-triggered .................................... 69
Force-triggered ......................................... 70
Time-triggered .......................................... 72
starting

Q
Qualifications ................................................. 15

R
Repair
Dispatch .................................................... 35
Repairs ................................................ 127, 135

TOX_Manual_Process-monitoring-unit_EPW500FP_en-US147

Index

System ...................................................... 39
Status bar ...................................................... 44
Status window ............................................... 52
Storage .......................................................... 35
Temporary storages.................................. 35
Supply voltage ............................................... 28
switching points
Configure .................................................. 73
systemPreparing .................................................. 39
Starting ..................................................... 39

T
Target group .................................................... 8
Technical data ............................................... 21
CPU module ............................................. 22
Dimensions ............................................... 21
DMS signals.............................................. 33
Environmental conditions.......................... 32
Pulse diagrams ......................................... 30
Sensor ...................................................... 32
Standard signal output sensor .................. 32
Weight....................................................... 21
Texts
Highlighting ............................................... 10
time
Set .......................................................... 109
Time-triggered ......................................... 67, 72
Transport ....................................................... 35
Troubleshooting........................................... 125
Type plate...................................................... 18

V
Validity
Document ................................................... 8W
Warning signs.................................................. 9
Warranty ........................................................ 18
Weight ........................................................... 21
window
Activate acute NOK .................................. 92
Change condition...................................... 89
Change size.............................................. 88
Create ....................................................... 85
Delete ....................................................... 91
Move ......................................................... 87
Select ........................................................ 86
Status window........................................... 52

Z
Zoom area
Change ............................................... 81, 83

UupdateSoftware.................................................. 112
Updater ................................................... 112
updater
Update .................................................... 112
uppercase...................................................... 47
Permanent ................................................ 47
usage data
select memory location ........................... 123
USB interface ................................................ 28
Use
Intended.................................................... 17
User administration ..................................... 114

148

TOX_Manual_Process-monitoring-unit_EPW500FP_en-US