805-8 Machine

Monitor

System 5100
Installation and Operating
Manual
Doc # L-805-1091
Rev. 00

Link Electric & Safety Control Co.

444 McNally Drive
Nashville, TN 37211

Phone: (615) 833-4168

Fax: (615) 834-1984

© 2016
 Table of Contents
1 INTRODUCTION .............................................................................................................................. 4
1.1 Features ........................................................................................................................................ 4
1.2 Specifications ............................................................................................................................... 4
2 DEFINITIONS AND TERMINOLOGY ............................................................................................ 5
2.1 Stops ............................................................................................................................................. 5
2.1.1 Immediate Stop ................................................................................................................... 5
2.1.2 Top Stop .............................................................................................................................. 5
3 OPERATION ...................................................................................................................................... 6
3.1 Operator Terminal ........................................................................................................................ 6
3.1.1 ACC Softkey ....................................................................................................................... 8
3.1.2 Espanol/English Softkey ..................................................................................................... 8
3.1.3 RUN/PROG (Run/Program) Switch ................................................................................... 8
3.1.4 Automatic LCD Turn Off ................................................................................................... 8
3.2 Parameter Entry ............................................................................................................................ 9
3.2.1 Numeric Entries .................................................................................................................. 9
3.2.2 Text Entry ........................................................................................................................... 9
3.2.3 Selection from a List ......................................................................................................... 10
3.3 Access Control ........................................................................................................................... 10
3.3.1 Key Only Mode................................................................................................................. 11
3.3.2 Key or Password Mode ..................................................................................................... 11
3.3.3 Password Only Mode ........................................................................................................ 11
3.3.4 Key and Password Mode .................................................................................................. 12
3.3.5 Restricted Items ................................................................................................................ 12
3.3.6 Password System Operation ............................................................................................. 13
3.4 Main Screen................................................................................................................................ 15
3.4.1 Reason for the Last Stop ................................................................................................... 15
3.4.2 Running Status .................................................................................................................. 15
3.5 LinkNet Operator Screen ........................................................................................................... 16
3.5.1 Network Notes .................................................................................................................. 16
3.5.2 Automatic Down Time Codes .......................................................................................... 16
3.5.3 “Machine Idle” handling ................................................................................................... 16
3.6 Counters ..................................................................................................................................... 17
3.6.1 Configuring Production Counters ..................................................................................... 18
3.6.2 Production Counters.......................................................................................................... 18
3.6.3 Stroke Counter .................................................................................................................. 20
3.7 Diagnostics ................................................................................................................................. 21
3.7.1 Input Diagnostics .............................................................................................................. 21
3.7.2 Output Diagnostics............................................................................................................ 21
3.7.3 Ethernet Diagnostics ......................................................................................................... 22
3.7.4 SD Card Diagnostics ......................................................................................................... 22
3.7.5 OIT Info Screen ................................................................................................................ 22
3.7.6 Event Log .......................................................................................................................... 22
3.8 Job Setups................................................................................................................................... 22
3.8.1 Store Setup ........................................................................................................................ 23
3.8.2 Recall Setup ...................................................................................................................... 24

Doc #: L-805-1091 Page 1 Rev. 00

 3.8.3 Erase Setup........................................................................................................................ 24
4 CONFIGURATION .......................................................................................................................... 25
4.1 Main Configuration Screen ........................................................................................................ 25
4.2 Machine Parameters Configuration............................................................................................ 26
4.2.1 “Machine Running” Input ................................................................................................. 26
4.2.2 “Machine Running” Timeout ............................................................................................ 26
4.2.3 “Setup Mode” Input .......................................................................................................... 27
4.2.4 Log External Stops ............................................................................................................ 27
4.2.5 Program Mode is a STOP Condition ................................................................................ 27
4.3 Digital Input Debounce Configuration....................................................................................... 28
4.4 Operator Terminal Configuration............................................................................................... 29
4.4.1 Top Area Display .............................................................................................................. 29
4.4.2 Setting the Date and Time................................................................................................. 30
4.4.3 Access Configuration ........................................................................................................ 30
4.4.4 Configure Auxiliary Communications.............................................................................. 33
5 BACKING UP AND RESTORING THE OPERATOR TERMINAL ............................................ 34
5.1 Backup Procedure ...................................................................................................................... 34
5.2 Restore Procedure ...................................................................................................................... 35
5.3 Memory Chip Swap-out Procedure ............................................................................................ 37
6 INSTALLATION ............................................................................................................................. 38
6.1 Preliminary Installation Considerations ..................................................................................... 38
6.2 Mounting the Machine Monitor ................................................................................................. 39
6.3 System Wiring ............................................................................................................................ 41
6.3.1 Wiring Power for the System ............................................................................................ 44
6.3.2 Wiring Inputs .................................................................................................................... 45
6.3.3 Wiring Outputs.................................................................................................................. 47

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 Table of Figures
Figure 1: Operator Terminal ....................................................................................................................... 6
Figure 2: Operator Terminal Top Info Area ............................................................................................... 7
Figure 3: Example Numeric Entry Screen .................................................................................................. 9
Figure 4: Example Text Entry..................................................................................................................... 9
Figure 5: Example List Selection.............................................................................................................. 10
Figure 6: Example Password Entry Sequence .......................................................................................... 13
Figure 7: Main Screen ............................................................................................................................... 15
Figure 8: Example List Selection.............................................................................................................. 16
Figure 9: Counter Screen .......................................................................................................................... 17
Figure 10: Counter Group Screen ............................................................................................................. 17
Figure 11: Counter Configuration Screen ................................................................................................. 18
Figure 12: Main Diagnostics Screen ......................................................................................................... 21
Figure 13: Jobs Screen .............................................................................................................................. 23
Figure 14: Store Jobs Screen..................................................................................................................... 23
Figure 15: Recall Jobs Screen ................................................................................................................... 24
Figure 16: Configuration Code Entry Screen ........................................................................................... 25
Figure 17: Main Press Control Configuration Screen............................................................................... 25
Figure 18: Machine Parameters Screen .................................................................................................... 26
Figure 19: Digital Input Debounce Configuration Screen ........................................................................ 28
Figure 20: Operator Terminal Configuration Screen ................................................................................ 29
Figure 21: Date and Time Setting Screen ................................................................................................. 30
Figure 22: Access Configuration Screen .................................................................................................. 30
Figure 23: User Access Configuration Screen .......................................................................................... 31
Figure 24: Restrict/Unrestrict Screen........................................................................................................ 32
Figure 25: Set Config Code Screen .......................................................................................................... 32
Figure 26: SD Card Slot Location ............................................................................................................ 34
Figure 27: Memory Chip Location ........................................................................................................... 37
Figure 28: OIT Viewing Angles ............................................................................................................... 39
Figure 29: Panel Mounting Dimensions ................................................................................................... 39
Figure 30: Enclosure Mounting Dimensions ............................................................................................ 40
Figure 31: 805-8 Machine Monitor Connectors ....................................................................................... 42
Figure 32: Open Door View of 805-8 Machine Monitor in Enclosure..................................................... 43
Figure 33: Example Input Connections .................................................................................................... 45

Doc #: L-805-1091 Page 3 Rev. 00

1 INTRODUCTION
The 805-8 Machine Monitor board is an option board that can be used with the Link OT805 Operator
Terminal to allow the LinkNet data collection system to monitor the production statistics of a wide
variety of machinery.

It is offered in two pre-built configurations. The first is with an OT805 operator terminal intended for
panel mounting in an existing panel (model MM 805-8 PM). The second comes complete and ready to
mount with an enclosure and 24 volt power supply (model MM 805-8 ENC).

1.1 Features
• Works with any machine that can provide or can be made to provide an output indicating a cycle has
been made.
• Inputs allowing up to two part/batch/scrap counter groups to be driven by sensors for true part
counting. Part count can also be driven based on cycles.
• Input to indicate the machine is in setup or production mode. If an output is not available from the
machine, this can also be set by the operator through the screen.
• Inputs for up to 6 down time codes that can be set automatically based on status outputs from the
machine.
• Inputs for up to 6 event codes that can be sent automatically based on outputs from the machine.
• Inputs for “passing through” an existing stack light with up to 4 colors. This allows down time,
counters, and other conditions from the Machine Monitor to override which stack light color is
active based on priority.
• Outputs for driving a stack light with up to 4 colors. This can be used to indicate the running status
of the machine.
• Stop output available to inhibit machine operation when counters reach their limit or if certain inputs
are configured to generate a stop.

1.2 Specifications
Size: 6.25” wide, 7.25” high, 3” deep (Panel Mount Version)
8.3” wide, 11.5” high, 6.5” deep (Enclosure Version)

Input Power: 24VDC +/- 10%, 10 Watt (Panel Mount Version)

90-264VAC, 47-63Hz, 30 Watt (Enclosure Version)

Fuse: 5mm X 20mm, 0.5 Amp, 250 Volt, Fast Blow

Doc #: L-805-1091 Page 4 Rev. 00

2 DEFINITIONS AND TERMINOLOGY

2.1 Stops
There are two different kinds of stops that the module can generate. Some conditions always generate a
particular kind of stop, while others are programmable by the user.

2.1.1 Immediate Stop

An “Immediate Stop” sends a signal to the control to immediately stop the press, regardless of where it
is in the cycle. Note that this does NOT mean that the press will actually stop at the point where the stop
was generated, as all presses take some amount of time to drop out the clutch, apply the brake, and come
to a stop. For instance, if a decision to stop occurs at 175 degrees, the press may end up stopped at 200
degrees. The number of degrees a press requires to actually stop depends (among other things) on the
design of the press and on stroking speed. All other conditions being equal, the faster the press is
stroking, the longer it requires to stop.

2.1.2 Top Stop

A “Top Stop” sends a signal to the control to stop the press at the top of the stroke. Note that all presses
take some amount of time to stop. If the control determines that it can not stop at top in the time left
when it receives the stop command, it will make an additional stroke. Many high speed presses take
more than 1 full stroke to stop regardless of where the stop occurs.

Doc #: L-805-1091 Page 5 Rev. 00

3 OPERATION

3.1 Operator Terminal

Figure 1 shows the operator terminal front panel. This panel consists of a color LCD display with a
touch screen and RUN/PROG key switch.

OmniLink 805
OPERATOR TERMINAL
Cycle
Rate 0.0CPM Part Count
113
Espanol

Mode: Production ACC

Machine Monitor
Job: 1 LinkNet Network
JOB 1 Online
Counter Count Limit
Part 113 1200
Batch 0 Off

Reason for
the Last Stop External Stop
Running
Status All Conditions OK
Configure Toggle Diagnose
System Setup Mode

USE ONLY FINGERS TO OPERATE TOUCH SCREEN

RUN
PROG

LINK ELECTRIC & SAFETY CONTROL CO.

444 McNALLY DR. NASHVILLE, TN. 37211
PHONE (615) 833-4168

Figure 1: Operator Terminal

Doc #: L-805-1091 Page 6 Rev. 00

 359 0.0
Cycle Stroke Speed
Part Count Espanol

0
Rate CPM
Stroke Continuous 113
Mode
Mode: Production SPM ACC

a b c d e f
Figure 2: Operator Terminal Top Info Area

The top area of the operator terminal is used to display certain critical information and provide keys that
are present regardless of what screen is being displayed. The areas are (refer to Figure 2):

a) Graphical Display Rotating arrows will “spin” in the circle when the machine is running.
of Machine
Operation

b) Numeric Display This area provides a numeric readout of the Cycles per Minute at which the
of Cycles per machine is currently operating.
Minute

c) Mode The machine monitor can be configured to allow either an input or the operator
to indicate if the machine is in a production or setup mode. The current mode
is shown here.

d) Programmable This area can display a variety of information, based on user selection. Some
Display Area examples items available include running status, reason for the last stop, and
part count (shown in the example). Press inside this area to cycle to the next
available item. The operator terminal can also be configured to automatically
show a particular item when the press control mode is switched from a setup
mode to a production mode, and vice versa. See Section 4.4.1 for more
information on configuring this area and the information items available.

e) Language This key is used to switch languages used on the operator terminal see Section
Switching Key 3.1.2 for more information.

f) Quick Access Key This key displays the Quick Access screen. See section 3.1.1 for more
information.

Areas inside the white portion of the display are shown with a blue border if that area can be selected.
For example, pressing the blue bordered jobs area or the blue bordered counters area will take you to
screens related to jobs or counters, respectively. Areas usually displayed along the right side and bottom
of the display provide softkeys which may be selected by pressing the field. For example, pressing the
“LinkNet Network” bordered area in Figure 1 will select the LinkNet operation screen.

Doc #: L-805-1091 Page 7 Rev. 00

3.1.1 ACC Softkey
This is a quick access key. This key will supply direct access from any screen to the Quick Access
screen. The quick access screen contains the name of the currently logged in user, the log out softkey,
and access to auxiliary communications.

3.1.2 Espanol/English Softkey

This changes the display language from English to Spanish or Spanish to English. If the display is
currently in English, touching the Espanol softkey will change the display to Spanish. If the display is
currently in Spanish, touching the English softkey will change the display to English.

3.1.3 RUN/PROG (Run/Program) Switch

This is a keyed selector switch read directly by the operator terminal. The PROG (program) position
can be configured to causes the machine the Stop relay to drop out until the switch is returned to the
RUN position. There are several user access modes that will require the operator to turn the keyed
selector to PROG position in order to modify parameters. This switch must be in the PROG position
for Machine Monitor configuration, as described in Section 3.3 on page 10.

3.1.4 Automatic LCD Turn Off

To increase the life of the display backlight, the backlight will automatically dim ten minutes after the
machine has NOT cycled and the operator terminal detects no user activity. User activity for this
purpose is defined as pressing the touch screen or operating the RUN/PROG switch. The backlight is
turned back on and the ten minute timer is reset any time the touch screen is pressed on the operator
terminal or the RUN/PROG key is operated.

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3.2 Parameter Entry
Throughout the operator terminal, a standard form of data entry is employed. Parameters that can be
changed are indicated by a blue border surrounding the parameter. Touch inside the blue border to edit
the parameter.

3.2.1 Numeric Entries

359
A numeric parameter to be changed is selected by Stroke Speed Espanol

0 SPM
pressing the area on the screen that displays the Stroke
TOP ACC
parameter (surrounded by a blue border). This will Mode Continuous
bring up an editing screen similar to Figure 3. Access Code Needed – View Only Edit

10
Number
Job
Number Access
If the parameter contains a decimal point, it will be Code
positioned automatically by the operator terminal.
The new number is entered with the numeric
keypad.

The Clear key will clear the present number being

entered, and the Back key will go back one number.
The up and down arrow keys at the bottom right Exit
and bottom left of the numeric keypad will
Figure 3: Example Numeric Entry Screen
increment and decrement the number, respectively.

Press the Enter key to accept the new number or abort the change by pressing the Cancel softkey. The
number will not change from the previous value if the entry process is canceled.

3.2.2 Text Entry

A text parameter to be changed is selected by
359 Stroke Speed Espanol
pressing the area on the screen that displays the
parameter (surrounded by a hollow blue box). This
TOP Stroke
Mode Continuous 0 SPM ACC
Job Edit
will bring up an editing screen similar to Error! Description J o b 1 2 3 4 Text
Reference source not found..
Cancel
The editing cursor position is shown by a black
background on the character the cursor is sitting on. A B C D E F Cursor Left Cursor Right
Characters typed on the virtual keyboard will
appear at the editing cursor, and the cursor will G H I J K L Space Clear
automatically advance to the next position as
characters are “typed”. The cursor can also be M N O P Q R . & Lower Case
moved by pressing the Cursor Left and Cursor Right
S T U V W X Y Z Enter
softkeys.
Figure 4: Example Text Entry
To erase characters, position the editing cursor at
the start of the characters to erase and hit the Space softkey. Likewise, to change a character, position
that editing cursor on that character and select the new character. The Clear softkey will cause all
characters to be erased.

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Press the Lower Case softkey to display a virtual keyboard with lower case letters. The Lower Case
softkey will then change to Numbers & Misc. Pressing that key will change the virtual keyboard to one
that has numbers and other characters on it. The Numbers & Misc softkey will then change to
Upper Case. Pressing Upper Case brings the virtual keyboard back to its original configuration with
upper case letters.

Once the text is correct, press the Enter softkey to keep the changes or press the Cancel softkey to abort
the changes.

3.2.3 Selection from a List

Some parameters are not numeric or text, but
359 Stroke Speed Espanol
instead are selected from a list of options. As
usual, these parameters are displayed inside a
TOP Stroke
Mode Continuous 0 SPM ACC
Select No User Selected Select
hollow blue box. To change the parameter, press User Setting
inside the blue box to bring up a selection screen
that will be similar to that shown in Figure 5. Select Setting From the List Below
User Number 1
Note that the listed selection may all fit on one page
User Number 2
or may take several pages to display. If more than
one page is necessary to display the list, Next Page User Number 3
and Previous Page softkeys will be displayed as Setup Man Level 1
appropriate.
Setup Man Level 2 Cancel

To choose a new selection for the parameters, press Figure 5: Example List Selection
inside the blue box of the new selection. This will
cause the new parameter to take effect. Press the Cancel softkey to exit the selection screen with no
change to the parameter.

3.3 Access Control

The Machine Monitor has layers of security relative to configuration of its hardware and software and
ability to program parameters.

User (Employer) Configuration items give the user the ability to configure certain aspects of the system
to meet security, information, safety, and production requirements. One of the areas of User
Configuration relates to Access Control – a level of security that allows the person(s) the user designates
to make certain parameter settings and reset faults. See Section 4.4.3 for the configuration of the Access
Control methods discussed in this section.

The Machine Monitor has several parameters or operations that have, or can be configured to have,
limited user access, i.e., by employees specified by the user (employer). The ability to perform actions
such as job recall, job storage, or changing counter settings can be limited to certain personnel. The
control provides several means to limit access to these parameters or operations. A complete list of the
parameters and operations that can be, or are, limited as to access is listed in the Restricted Items table in
Section 3.3.5. The control has the capability to make some of these limited access items available to any

Doc #: L-805-1091 Page 10 Rev. 00

operator. Access to these items can be globally un-restricted. The items which can be un-restricted to
all users are also listed in the Restricted Items Table shown in Section 3.3.5.

Access to the User Configuration screens and their parameters is protected by the RUN/PROG key and
the User Configuration code.

The Machine Monitor employs combinations of two different means to limit access to restricted items.
These means are the RUN/PROG key switch and a user password system. The user password system
assigns names and passwords to up to sixteen users. These two means can be used alone or in
combination with each other. When a user employs the proper means to gain access control, he will
have the ability to perform the actions and change the parameters which have been designated to his
access.

There are four possible modes of operation for the access system. They are the “Key Only” mode, the
“Key or Password” mode, the “Password Only” mode, and the “Key and Password” mode. The operator
terminal can be configured to operate in any one of these four modes.

3.3.1 Key Only Mode

The “Key Only” mode is the least complex of the four modes. This mode employs the RUN/PROG key
as the means of access. Access to restricted items is granted when the RUN/PROG key is in the PROG
position.

Although the “Key Only” mode has the advantage of being easy to use, it does have a disadvantage.
This mode cannot give a particular user access to only some of the restricted items. When operating in
this mode, any user with the RUN/PROG key will have access to all of the restricted items.

3.3.2 Key or Password Mode

The key or password mode allows for either of two means to gain access to the restricted items. Access
to restricted items is granted when the RUN/PROG key is in the PROG position. In addition, a user
without the RUN/PROG key but with the correct password can access the restricted items that have been
designated for the particular user’s access only. The system allows for passwords to be assigned to
sixteen users. Each user can be assigned access to any or all of the restricted items.

The following is an example of a “Key or Password” mode operation. The RUN/PROG key is given to
the die set-up personnel. A press operator is assigned a user name and password. With the password
the operator is assigned permission to reset counters. In order to load a new job, the set-up personnel
must use the RUN/PROG key to recall a job from job storage. Once the set-up personnel sets the job
and verifies its correct operation, the operator is left to run the job.

3.3.3 Password Only Mode

The “Password Only” mode allows for sixteen users. Each user can be assigned access to some or all of
the restricted items. This mode does not use the RUN/PROG key.

The example listed above indicated that setup personnel required access to all restricted parameters. In
the “Key or Password” mode, the setup personnel used the RUN/PROG key to gain access to all of the
Doc #: L-805-1091 Page 11 Rev. 00
restricted parameters. In the “Password Only” mode, the setup personnel can still have access to all of
the restricted parameters, but the system must be configured as such. The setup personnel must be
assigned a user name and password. In addition, all restricted items would be assigned access to the
setup personnel.

Since there is no access to all restricted items with the RUN/PROG key, every restricted item must be
assigned to at least one user. If any restricted item is not assigned to at least one of the users, it cannot
be accessed. For example, if Erase Jobs is not assigned to at least one user, it will be impossible to
perform the erase job function. Access to the Erase Jobs must be assigned to at least one user, before the
erase job function can be performed.

3.3.4 Key and Password Mode

The “Key and Password” mode requires the user to have the RUN/PROG key, a user name, and a user
password. Operation is basically the same as the Password only mode, except that in addition to
entering the password the user must switch the RUN/PROG key to the PROG position.

Since there is no access to all restricted items with the RUN/PROG key only, every restricted item must
be assigned at least one user. If any restricted item is not assigned to at least one of the users, it can
never be accessed.

3.3.5 Restricted Items

The following table lists the restricted items name and function. Some items can be unrestricted. When
an item is unrestricted, it is available to any user. Unrestricted items do not require a key or password.

RESTRICTED ITEMS
NAME FUNCTION CAN BE
UNRESTICTED
Store Jobs Store jobs in memory
Recall Jobs Recall jobs from memory
Erase Jobs Erase jobs in memory
Counter Settings Change counter limits and turn counters off and on Yes

Counter Change Change counter values Yes

Counter Reset Reset counters that have reached their limit Yes

Counter Config. Configure counters Yes

Feed Settings Change feed settings

Doc #: L-805-1091 Page 12 Rev. 00

3.3.6 Password System Operation
Figure 6 displays a typical password entry sequence. This example shows the steps necessary to change
the Auto Single Stroke time. This is typical for password entry for all restricted items.

359 Stroke Speed Espanol

359 Stroke Speed Espanol
TOP Stroke
Mode Continuous 0 SPM ACC TOP Stroke
Mode Continuous 0 SPM ACC
Access Code Needed – View Only Edit Select No User Selected Select
User
10
Number Setting
Job
Number Access
Code Select Setting From the List Below
User Number 1

User Number 2

User Number 3

Setup Man Level 1

Exit Setup Man Level 2 Cancel

Step A Step B

359 Stroke Speed Espanol 359 Stroke Speed Espanol

TOP Stroke
Mode Continuous 0 SPM ACC TOP Stroke
Mode Continuous 0 SPM ACC
Edit Edit

10
Number Number
Enter Code for User Job
“User Number 1” Number Cancel
Cancel

7 8 9 Clear 7 8 9 Clear

4 5 6 Back 4 5 6 Back

1 2 3 1 2 3
0 Enter 0 Enter

Step C Step D
Figure 6: Example Password Entry Sequence

Step A: Select the restricted item. Once the parameter is selected, if restricted the display will prompt
that an access code is required. The user should press the Access Code key.

Step B: A list of users that have access to this restricted item will appear. In “Step B” of Figure 6, 5 of
the 16 possible users have access to this restricted parameter. The system may have several
more users, but the 5 users listed on the screen are the only users that have access to Auto
Single Stroke time. The user must select his user name (even if there is only one user name
displayed).

Step C: The display will show the selected user name and request the user password as shown in “Step
C” of Figure 6. The user must enter the correct password and then press the Enter key.

Doc #: L-805-1091 Page 13 Rev. 00

Step D: Upon entry of the correct password, the user will be allowed access to the restricted item. In
this example, the user will be allowed to change the Job Number parameter.

After performing the steps listed above, the user will be logged in to the password system. The user will
have access to all restricted items that have been designated for his access. This access will remain until
the user performs a log out or until the user is automatically logged out.

The user can log out by using the ACC key. This key will directly switch the display to the Quick
Access screen. The Logout soft key legend will appear along the bottom of the screen. If the operator
presses this key, he will log out. He will no longer have access to the restricted items, unless he repeats
steps A through D.

In addition to the manual log out, the system contains an automatic logout. The intent of automatic log
out is to reduce the possibility of users other than the intended user from having access to restricted
items. If there were no provisions for automatic log out and a user forgot to manually log out, all
restricted items to which the user had been designated for access would be available from the log in time
until power was removed from the operator terminal. This presents the possibility of users other than
the intended user having access to restricted items. Automatic log out is based upon both time and press
strokes. During system configuration automatic Access Timeout parameters are entered. An automatic
access timeout time and automatic access timeout strokes are entered. The time entered is the amount of
time after the last keystroke that will be allowed before the system will automatically log out the user.
For example, if the automatic access timeout is set to 60 seconds, the user will be logged out 60 seconds
after the last keystroke. If the user depresses a key before the 60 seconds have elapsed, a new 60 second
cycle will be started. The number of strokes that are entered is the number of press strokes after the last
keystroke that will be allowed before the system automatically logs out the user. For example, if the
automatic timeout is set to 10 strokes, the user will be logged out when the press completes ten strokes
after the last keystroke. If the user depresses a key before 10 strokes have been completed, a new 10
stroke cycle will be started (See Section 4.4.3.2)

Doc #: L-805-1091 Page 14 Rev. 00

3.4 Main Screen
Figure 7 shows the Main Operating Screen.
This is the screen displayed when the unit
Cycle
Rate 0.0CPM Part Count
113
Espanol
ACC
first powers up and provides an overall view Mode: Production
of the functions available along with general Machine Monitor
Job: 1 LinkNet Network
diagnostic information. From this screen the a
JOB 1 Online
operator may select Job Setups (see “a” in
Counter Count Limit
Figure 7), Counters (see “b” in Figure 7), or b Part 113 1200
the LinkNet operator screen. Touch inside Batch 0 Off
the blue bordered area of an option to go to
Reason for
that screen. the Last Stop External Stop
Running
In addition there are softkeys along the Status All Conditions OK
Configure Toggle
bottom of the screen that access the System Setup Mode
Diagnose
configuration area, diagnostics, and allow the
operator to toggle the mode of the machine Figure 7: Main Screen
between production and setup if the machine
monitor has been configured for that.

3.4.1 Reason for the Last Stop

Diagnostic information is provided to show the reason the machine stopped. Once operation is initiated,
the first stopping action is latched and displayed. This is done to capture transient conditions that may
return to their proper state after the machine stops. This information remains latched until the machine
stops again. Additional information concerning stops is stored in the Event Log (see Section 3.7.6 on
page 22). Note that most of the time this will be “External Stop”, which means the Machine Monitor
did not stop the press due to counters or some other internal reason, but that the machine stopped as part
of its own operation. This information along with the Running Status will allow the operator to
determine if and why the Machine Monitor stopped the machine, and what needs to be done to remove
the stop if generated by the Machine Monitor.

3.4.2 Running Status

Diagnostic information is provided to show any reason why operation may not be initiated. If multiple
stop conditions exist, the clearing of a displayed stop condition will result in the display of another stop
condition until no more stop conditions exist. If no stop condition exists, an All Conditions OK message
indicates that the Machine Monitor is not asserting its Stop output. Note that the machine itself may still
not be able to run due to conditions outside of the Machine Monitor.

Doc #: L-805-1091 Page 15 Rev. 00

3.5 LinkNet Operator Screen
The LinkNet screen allows operators to enter down
time codes, view machine notes, and job notes.
Cycle
Rate 0.0CPM Part Count
113
Espanol

Mode: Production ACC

Network Status: LinkNet Online
Most of the screen is given to display of the down Current DTC: 0 Production
LinkNet
time codes configured for the machine on LinkNet. DTC Description Previous Clear Down
Just to their right are buttons for navigating the 38 Bin Change Page Time Code
31 Burrs
down time codes. Note that the Previous Page and 1 Cleanup Diagnose
Next Page buttons will only appear when needed. 2 Defective Material
15 Forklift Unavailable Network
The highlight cursor (shown highlighting the Bin 19 Loading Material Select DTC Notes
Change code in the example at right) can be moved 18 Material Handling Problem
3 No Material
by the up and down arrow keys. Pressing the 7 No Operator
29 Quality Check
Select DTC softkey selects the highlighted code as 14 Scrap Removal
11 Setup Next Page Exit
the current down time code.
Figure 8: Example List Selection
To clear the down time code, press the
Clear Down Time Code softkey. This will set the Current DTC back to “Production”.

3.5.1 Network Notes

Pressing the Network Notes softkey will bring up a screen that will request the machine notes that have
been entered into LinkNet from the database. In that screen, the Job Notes softkey will request the notes
entered for the current job. Hitting that softkey again (which will have changed to Machine Notes) will
switch back to the machine notes.

3.5.2 Automatic Down Time Codes

Certain down time codes are automatic. When a new job is selected, “Job Setup” automatically
becomes the current down time code. Other codes, like “Batch Count Reached” (this occurs when the
“Batch Count” reaches its limit) or “Machine Idle” (see following section) will only become the current
down time code if there is no currently active down time code. Automatic down time codes clear
themselves the next time the machine cycles.

3.5.3 “Machine Idle” handling

If the machine does not cycle within a programmable length of time (the “Idle Time Out”, which is set
on LinkNet itself, not at the machine) AND there is no down time code currently entered, then the down
time code will automatically change to “Machine Idle”. This code will automatically clear itself when
the machine makes another cycle. The exception to this, however, is that if the setting of “Force Idle
DTC Replacement” in the LinkNet configuration screen is “Yes”, then the stop relay will be active and
the machine will not be able to cycle. To clear this condition, the operator must first select a down time
code from the list. This code will replace the time logged under “Machine Idle”. That code can then be
cleared and the machine can be cycled as usual.

This mechanism is intended to allow operators to supply a specific reason the machine has not been
running when they forget to enter a down time code at the time the machine actually stopped. While the
fact that the machine is not running is captured by “Machine Idle”, the specific reason is not.
Doc #: L-805-1091 Page 16 Rev. 00
3.6 Counters
Touch the Counter display area in the Main Screen
(see “b” in Figure 7 on page 15) to go to the
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counter screen. Mode: Production
Counter Count Limit State
3600 10000 On On /
The OT805 operator terminal can support 1 or 2 Part Off
Reset
36%
counters groups. A counter group includes a part
360 360 Trip On /
counter, a batch counter, and a scrap counter. The Batch Off
Reset
100%
first counter group also has a quality counter, which
0 100 Off On /
is intended to allow the machine to stop every so Quality Off
Reset
many cycles for a quality check.
Scrap 0 Inc. Dec. Counter
Reset Settings
Scrap Scrap
The present quantities of the part counter, batch Scrap Rate: 0.0000%
Cycle Based Job Hit Count: 509 Exit
counter, quality counter, scrap counter, and cycle Cycle Count: 783463
counter can be viewed along with the limits of
Figure 9: Counter Screen
those counters that have them.

If counters are configured for unrestricted access, anyone can change the counters and reset them. If
configured for access control (described in Section 3.3 on page 10), operators must use the selected
access control method to make changes.

If only one counter group is enabled, which is

typical, then the Counter screen shown in Figure 9
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is what will initially appear. If 2 counter groups are Mode: Production
enabled, then initially the screen shown in Figure Counter Group 1 Counter Group 2
Part: 3600 Part: Off
10 will appear. This will show an overview of the
Bin: 360 Bin: Off
status of both counter groups. Pressing anywhere
inside of the blue bordered counter group will then Scrap: 0 Scrap: 0
display the counter screen for that counter group as
shown in Figure 9.
Counter
Counters can be driven by cycles of the machine Settings
(Cycle Based counters) or by sensors tied to a
Job Hit Count: 509 Exit
hardware input (Sensor Based counters). The Cycle Count: 783463
counter drive mode is indicated in the lower left
Figure 10: Counter Group Screen
corner of the counter screen. As described in the
following section, cycle based counters can also be configured to count by a set amount every so many
cycles and each counter group can be separately configured for cycle or sensor based counting.

Doc #: L-805-1091 Page 17 Rev. 00

3.6.1 Configuring Production Counters
Up to 2 counter groups can be enabled on a job by
job basis. In other words, one job can have one
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Mode: Production ACC

counter group enabled, while a second job can have
2 counter groups enabled. Cycle based counter Counter Stroke Based Configure Counters
Group 1
groups can also be set to increment by a particular Counter Configure
Sensor Based
value every so many cycles rather than Group 2 System
incrementing by 1. To configure the counters,
press the Counter Settings softkey in the counter
screen of Figure 9.

A screen similar to Figure 11 will appear and Job Hit

Count 509
allows each counter group to be set to cycle based
Exit
counting, sensor based counting, or not used.
Hitting the Configure System softkey in this screen Figure 11: Counter Configuration Screen
will bring up a screen with only two settings –
“Maximum Number of Counter Groups” and “Enable True (Sensor Based) Part Counters”. These
settings apply to the system as a whole instead of to a job. The maximum number of counter groups can
be set to 1 to 2 and will affect how many counter groups are shown in the screen of Figure 11. If
“Enable True (Sensor Based) Part Counters” is set to “No”, then “Sensor Based” will not be available to
choose as counter group type. Both of these settings are present to allow a reduction in the number of
settings presented to operators for features that are not used.

Counter groups that are set to “Cycle Based” also have a Configure button shown to the right of the
group (as seen in Figure 11 for Counter Group 1). When pressed, a screen will appear that allows the
“Counter Increment” and “Counter Frequency” to be set. The “Counter Increment” is how much the
counter will be increased when a count occurs. For instance, a job producing two parts per cycle would
count by 2 every 1 cycle. The “Counter Frequency” is how often the counter should count. A
lamination die might produce a part every 10 cycles. If a lamination die with 10 laminations was also a
2 out die, the “Counter Frequency” would be set to 10, and the “Counter Increment” would be set to 2.
The counter would then count by 2 every 10 cycles. For typical one-out jobs, both of these values
would be 1, which would count by 1 every 1 cycle.

If a counter group is set to “Sensor Based” then it is driven by its corresponding hardware inputs,
PCNT1 (part count 1) and SCNT1 (scrap count 1) for counter group 1, or PCNT2 (part count 2) and
SCNT2 (scrap count 2) for counter group 2. See Section 6.3.2 for how to use these inputs.

3.6.2 Production Counters

The three production counters provided are Part, Batch and Quality. All production counters that are
turned “On” will increment as the press strokes, when the press is operating in a production mode.

NOTE: Cycle based Part, Batch, and Quality counters only count when not in setup
mode and only if turned “On”. The cycle counter always counts regardless of
mode. Sensor based counters count whenever their senor detects a part.

Doc #: L-805-1091 Page 18 Rev. 00

When the current count reaches the programmed limit, a top stop will be issued. This stop will remain
active until the counter is reset or is turned off.

The Part counter usually records the total parts made for a given process setup. The Batch counter
usually records a small group of a process run, such as the number of parts that can be put into one
container. The Quality counter is typically used to record the number of parts that can be made between
quality inspections.

Below each production counter is a bar graph that visually indicates the progress made toward that
counters limit. When the count reaches the limit, the bar graph will change from blue to red. The
percentage completion for each counter is shown to the right of the bar graph.

3.6.2.1 Turning Production Counters On or Off

Production counters can be turned “On” or turned “Off”. When a counter is turned “Off”, it does not
increase and cannot issue a stop to the press control. A production counter is toggled “On” or “Off” by
pressing the On / Off softkey for that counter and will be shown in the “State” column. If an access
control mode (see Section 3.3 on page 10) is being used that requires a password, a user must be
configured to have the “Counter Settings” permission to change this parameter.

3.6.2.2 Changing the Limit for Production Counters

Each production counter has a limit setting. When this limit is reached, a top stop will be issued. The
slide will stop at the top of the stroke and further stroking will be prevented until the counter is reset or
until the counter is turned off. If an access control mode (see Section 3.3 on page 10) is being used that
requires a password, a user must be configured to have the “Counter Settings” permission to change this
parameter.

3.6.2.3 Resetting Production Counters

A counter reset will set a production counter’s current count to zero. If an access control mode (see
Section 3.3 on page 10) is being used that requires a password, a user must be configured to have the
“Counter Reset” permission to change this parameter.

Resetting the Part counter will also reset the Batch and Quality counters.

To reset a production counter, touch the Reset softkey to right of the counter to reset. The operator
terminal will ask for verification before actually resetting the counter.

3.6.2.4 Scrap Counter

The scrap counter can be set, incremented, and decremented manually. If the Inc. Scrap key is pressed,
then 1 is added to the scrap count and 1 is subtracted from the part and bin counters. Likewise, if the
Dec. Scrap key is pressed, then 1 is subtracted from the scrap count and 1 is added to the part and bin
count. If the scrap count value is edited by pressing inside the blue bordered box showing the count,
then the part and bin count is not affected. When the counter group is “Sensor Based”, then the scrap
count is incremented each time the SCNT1 or SCNT2 (depending on counter group) hardware input is
triggered without affecting the part or bin count.

Doc #: L-805-1091 Page 19 Rev. 00

3.6.2.5 Changing the Count for Production Counters

The current count value of a production counter can be changed. If an access control mode (see Section
3.3 on page 10) is being used that requires a password, a user must be configured to have the “Counter
Change” permission to change this parameter.

The current count is changed by touching the counter field of the desired counter and entering the new
value. The numeric entry screen provides softkeys to increment or decrement the counter or a new
number can be entered.

3.6.3 Stroke Counter

The stroke counter increments anytime the crankshaft travels from the top of the stroke to the bottom of
the stroke. Contact Link Systems service department to reset the stroke counter.

Doc #: L-805-1091 Page 20 Rev. 00

3.7 Diagnostics
Pressing the Diagnose softkey in the main screen
will display the screen shown in Figure 12. Most
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of the information in this screen is used by Link Mode: Production
DP Chan 1 A2D Reading: 943 OIT
personnel for telephone troubleshooting, but the DP Chan 2 A2D Reading: 945 Diagnostics
following items are of general interest: DP Chan 3 A2D Reading: 943
DP Chan 4 A2D Reading: 944
Run/Program Key: Run
Run/Program Key – Show the position of the SD Card Detected: No Input
RUN/PROG key on the front of the operator SD Card OK: No Diagnostics
Screen Cal Switch: No
terminal. Use this to verify that the key switch is Battery Voltage: 3.02
Output
Diagnostics
operating correctly.
Ethernet
Diagnostics
SD Card Detected and SD Card OK – These two OIT SD Card Event Exit
lines show whether an SD Card is inserted into the Info Diagnostics Log
SD Card slot of the operator terminal and, if Figure 12: Main Diagnostics Screen
inserted, whether the card has been successfully
read.

Battery Voltage – The 805 operator terminal uses one CR2032 coin cell battery to maintain its
calendar/time functions and a small amount of battery backed memory. This voltage of a new battery
should be slightly more than 3 volts. This value will be shown in yellow when the voltage drops below
2.4 volts and in red when it drops below 2.19 volts. Most settings are stored in flash memory and are
not lost when the battery fails, but some things that are updated very rapidly (like the current counter
values) are written into battery backed RAM. If, after powering down and back up, the counter values
are 0, then check this readout and replace the battery if needed.

3.7.1 Input Diagnostics

Pressing the Input Diagnostics softkey in the screen of Figure 12 will bring up a screen that shows each
of the hardware inputs on the 805-8 machine monitor board. To the right of each input is the “On” or
“Off” state of the input as sensed by the system, and the “On Count” of the input. The “On Count” I
simply the number of times the input has turned from off to on. While not normally needed, each input
has separate On and Off debounce times (see Section 4.3) and this diagnostic can be used to set those
correctly when necessary.

3.7.2 Output Diagnostics

Pressing the Output Diagnostics softkey in the screen of Figure 12 will bring up a screen that shows each
of the hardware outputs on the 805-8 machine monitor board. To the right of each of the output names
is the On or Off state of that output. In addition, there is an Enter Test Mode softkey on this screen. To
enter test mode, press this softkey and enter the configuration code when prompted. All outputs will
turn off and a Toggle softkey will appear to the right of each output. Pressing the Toggle key for an
output will toggle it between off and on. This will allow testing the connection or operation of whatever
the output is tied to.

Once test mode is exited (by pressing the Exit Test Mode softkey or simply exiting the screen), the
outputs will return to their normal function.
Doc #: L-805-1091 Page 21 Rev. 00
 WARNING: The configuration code is required before entering test mode to prevent
accidental or unauthorized operation of the outputs. Before toggling
outputs make sure to understand the effects of turning that output off
or on for the machine to which it is connected. Outputs may cause
machine operations to occur or voltages to appear that are hazardous to
personnel.

3.7.3 Ethernet Diagnostics

Pressing the Ethernet Diagnostics softkey in the screen of Figure 12 will bring up a screen that shows
information about the current state of the Ethernet connection. The information near the top of the
screen shows the Host Name of the operator terminal and whether or not there is an active Ethernet
connection. An active connection is when there is an Ethernet cable plugged into the Ethernet jack
AND the other end of the cable is connected to an active hub or switch. Most of the other information
shown on this screen are standard Ethernet settings that can be used by information technology
personnel to verify proper operation on the company network. In particular, the IP Address is often
necessary to know to make connections to the operator terminal from things such as Modbus masters
and from LinkNet data collectors.

3.7.4 SD Card Diagnostics

Pressing the SD Card Diagnostics softkey in the screen of Figure 12 will bring up a screen that shows
information about any SD Card that is inserted in the SD Card connector, if any. For the most part the
information displayed here is useful for Link personnel to use when troubleshooting over the telephone.
The exception to this is the Backup / Restore softkey. See Section 5 for information on backing up and
restoring the terminal.

3.7.5 OIT Info Screen

Pressing the OIT Info softkey in the screen of Figure 12 will bring up a screen that shows information
about the operator terminal hardware, and its software version.

3.7.6 Event Log

Pressing the Event Log softkey in the screen of Figure 12 will bring up a screen that shows timestamped
events, primarily information about why the operator terminal generated a stop. In the case of the
machine monitor this will usually be counter stops.

3.8 Job Setups

In the Link operator terminal, all pertinent information for the current job such as counter settings and
others can be stored for later use as a block of information called a "job setup". Since this programmed
data may change from job to job as different tools or fixtures for the machine are changed, saving a job
setup prevents the operator from having to manually change all this information. The operator can
Doc #: L-805-1091 Page 22 Rev. 00
simply recall the appropriate job setup which was previously stored and the machine is ready to run.
The OT805 operator terminal can store 100 different job setups.

Touch the current Job display area in the Main

Screen (see “a” in Figure 7 on page 15) to select the
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Job Setups screen shown in Figure 13. Mode: Production
Job Description Job
1232 Upper Bracket Setups
The jobs can be arranged on the display in either 1233 Lower Bracket Sort By
alphabetical order by their description or in 1376 A-8236-KJ Upper Arm Descrip.
1377 A-8354-LO Lower Arm
numerical order by job number by touching the 2445 Z-6353-AA Frame Recall
Sort By Number / Sort By Descrip. softkey (this 2478 B-8736-ZS Brake Shoe Setup
3633 C-8362-HY S. Bracket
softkey toggles between the two descriptions). 17854 C-3873-JF S. Pan Store Setup
25435 C-3763-UF S. Back
192827 C-5733-YF S. Latch Erase
This screen has softkeys to Recall a job setup, Store 289373 F-8367-TD LF Pan Next
Page Setup
289450 F-8546-GD RF Pan
a job setup, or Erase a job setup as described in the
Current 1233 Exit
following sections. Job Lower Bracket
Figure 13: Jobs Screen
3.8.1 Store Setup
From the Jobs screen shown in Figure 13, touch the
Store Setup softkey to display the screen shown in
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Figure 14. The Store Setup screen allows the user Mode: Production
Job Store
to place all settings for the job currently in use into Number
1233
Setup
the internal file storage area. Job
Description Lower Bracket Store Setup
WARNING!
The user must have access control to change the Incorrect setups may cause damage and/or injury.
parameters on this screen or store the job. Access To store a job setup:
control is described in Section 3.3 on page 10. If 1) Program and verify all settings for this job setup.
2) Enter the job number for this setup.
an access control mode is being used that requires a 3) Enter a job description for this setup.
password, a user must be configured to have the
Press “Store Setup” when ready.
“Store Jobs” permission to store a job.
Exit

The screen shown in Figure 14 allows the user to Figure 14: Store Jobs Screen
enter a new number under which the job will be
stored by selecting the “Job Number” field. This number must be unique to store to a new job. Entering
a number already in use allows the current settings to replace the previous ones for that job number.
After entering a job number, the “Job Description” field can be selected to enter an alphanumeric
description. Press the Store Setup softkey in order to save the current job information in the internal file
system under the job number and job description displayed. The operator terminal automatically returns
to the Job Setups screen.

Doc #: L-805-1091 Page 23 Rev. 00

 NOTE: The “Current Job” is actually a separate job in the operator terminal. Changes
made to the current job are NOT automatically made to the stored job. The
user must intentionally store the new settings over the old job number if those
settings are to be saved permanently under that job number. The “Current
Job” does keep the changes that are made until a new job is recalled over it.
This allows the stored job to keep a set of baseline parameters that may need
minor tweaks (for material thickness variation, for example).

3.8.2 Recall Setup

From the Job Setups screen shown in Figure 13,
touch the Recall Setup softkey to display the Recall
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Setup screen shown in Figure 15. If enough jobs Mode: Production
Job Description Recall
are stored to take more than one page to display 1232 Upper Bracket Setup
then Next Page and Previous Page softkeys will 1233 Lower Bracket Recall
allow additional pages of jobs to be displayed to 1376 A-8236-KJ Upper Arm Selected
1377 A-8354-LO Lower Arm
locate the page that the job is on. 2445 Z-6353-AA Frame Recall By
2478 B-8736-ZS Brake Shoe Job Num.
3633 C-8362-HY S. Bracket
Use the up and down arrow keys to move the 17854 C-3873-JF S. Pan
highlight cursor to the desired job and then touch 25435 C-3763-UF S. Back
192827 C-5733-YF S. Latch Next
the Recall Selected softkey to recall the job. 289373 F-8367-TD LF Pan Page
289450 F-8546-GD RF Pan
Select job and press “Recall Selected” or press “Recall Exit
If the job number to recall is already known, the By Job Num.” and enter number.
Recall By Job Num softkey allows the user to enter Figure 15: Recall Jobs Screen
the desired job number directly into the operator
terminal, which automatically searches the file system and, if located, retrieves the job.

For either recall method described above, the operator terminal will ask for confirmation from the user
before actually recalling the job.

The user must have access control to perform a job recall. Access control is described in Section 3.3 on
page 10. If an access control mode is being used that requires a password, a user must be configured to
have the “Recall Jobs” permission to recall a job.

3.8.3 Erase Setup

From the Jobs screen shown in Figure 13, touch the Erase Setup softkey to display the Erase Jobs
screen. The Erase Jobs screen allows the user to select the job with arrow keys or enter the job number
that is to be erased in the same manner as the Job Recall screen does (with Erase Selected and
Erase By Job Num. softkeys).

The operator terminal will ask for confirmation from the user before actually erasing the job.

The user must have access control to perform a job erase. Access control is described in Section 3.3 on
page 10. If an access control mode is being used that requires a password, a user must be configured to
have the “Erase Jobs” permission to erase a job.

Doc #: L-805-1091 Page 24 Rev. 00

4 CONFIGURATION

4.1 Main Configuration Screen

The 805-8 Machine Monitor has multiple layers of security relative to configuration of its hardware and
software and the ability to program parameters.

The main level of security are User (Employer)

Configuration items that give the user the ability to
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configure certain aspects of the system to meet the Mode: Production
security, information, and production requirements Edit
Number
or preferences for the machine on which the Enter Configuration
Code Cancel
monitor is used. The configuration screens are
accessible only from the Main screen shown
previously in Figure 7 on page 15. The
7 8 9 Clear

Configure System softkey only appears on the Main 4 5 6 Back

screen when the RUN/PROG switch is in the
PROG position and, when touched, the display will 1 2 3
ask for the Configuration code as shown in Figure
16. This Configuration code is user programmable. 0 Enter

The original code is sent from the factory to a

designated person when the control is ordered. The Figure 16: Configuration Code Entry Screen
user has the option of keeping the original code or changing to another. The user must record and
protect the current code. This code should only be provided to qualified personnel with knowledge of
any requirements for items to be configured.

If the User Configuration code is entered correctly,

the selection softkeys shown in Figure 17 are
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presented. Touching a softkey will result in the Mode: Production
Configure System
display of the associated configuration screen.
Machine Parameters
Once access to the configuration screen has been
Digital Input
granted, the RUN/PROG switch may be switched Debounce
back and forth between PROG and RUN.
Downtime Code
Switching to RUN will not kick the user out of the Inputs
configuration area, but most parameters cannot be
changed unless the key is placed in the PROG Operator Terminal
position. Pressing the Exit softkey will return the
Exit
display to the Main screen.
Figure 17: Main Press Control Configuration
Screen

Doc #: L-805-1091 Page 25 Rev. 00

4.2 Machine Parameters Configuration
The Machine Parameters screen is accessed by
touching the Machine Parameters softkey in the
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Mode: Production ACC

Main Configuration screen (see Figure 17 on page
“Machine CYCLE Input Machine
25). Running” Input Parameters
“Machine 500 ms
The parameters shown in Figure 18 are User “Running” Timeout
“Setup Operator Selected
Configuration parameters typically set when the Mode” Input
Machine Monitor is installed. Log External Off
Stops
Program Mode is
4.2.1 “Machine Running” Input A STOP Condition
Yes

This parameter controls which input will be used to

indicate the machine is actively running. While Exit
“Running”, the circular indicator at the upper left Figure 18: Machine Parameters Screen
corner of the screen will display rotating arrows.
Some machines may have outputs that indicate when they are actively running, while others may only
indicate they have made a cycle. The choices for this setting are:

CYCLE Input - In this mode, as soon as the CYCLE input turns On, the machine is considered to
be running. It will be considered “running” for the “Machine Running” Timeout time. If
the machine usually runs at 60 cycles per minute, then each cycle should last 1 second (or
1000 milliseconds). Setting the “Machine Running” Timeout to a little longer than that,
perhaps 1200 milliseconds, would cause the machine monitor to consider the machine to
be “running” continuously because the cycle input would retrigger the timeout once a
second. When the machine goes longer than 1200 milliseconds without a CYCLE input,
then the machine is no longer “running”. Use this mode when the machine does not have
an output that stays On while it is running.

RUN Input - In this mode, the machine is “running” as long as the RUN input is On. Like the case
when using the CYCLE input, the “Machine Running” Timeout is also used with this
input. The timeout can be used to allow an output that pulses when the machine is
running to act as if it stays on.

4.2.2 “Machine Running” Timeout

As described in the previous section, this setting works in conjunction with the “Machine Running”
Input parameter to allow intermittent inputs to be treated as a continuous input to indicate the machine is
“running”.

Doc #: L-805-1091 Page 26 Rev. 00

4.2.3 “Setup Mode” Input
This parameter controls how, or if, the machine monitor is told that the machine is in a setup mode,
rather than a production mode. The choices are:

Not Used - Indicated the machine does not have, or does not use a setup mode. This might be the
case with certain single-use machines that are dedicated to a particular purpose.

SETUP Input - Uses the SETUP hardware input to indicate the machine is in setup mode. Use
this when a hardware output is available from the machine.

Operator Selected - When no output from the machine is available to drive the SETUP hardware
input, then the operator can indicate the current mode (setup or production) by using a
Toggle Setup Mode softkey on the main screen of the operator terminal as shown in
Figure 7. The current mode (Setup or Production) is displayed in the upper left corner of
the operator terminal (see “c” in Figure 2).

4.2.4 Log External Stops

The event log records a timestamped reason each time the machine stops. In the case of the Machine
Monitor most of these stops will likely originate from the machine and not from the monitor. In these
cases, the machine monitor only knows that it did not generate the stop and records those as “External
Stop”. Since the simple fact that the machine stopped may not be diagnostically useful, if you set this
parameter to “No” then only stops actually generated from the Machine Monitor (such as counters
reaching their limit) will be recorded in the event log. If this is set to “Yes” then “External Stop” will
also be logged.

4.2.5 Program Mode is a STOP Condition

If set to “Yes”, then when the Machine Monitor RUN/PROG switch is in the PROG position, then the
Machine Monitors STOP output relay will open up, preventing the machine from running or stopping
the current cycle – assuming the STOP relay is properly tied into the machine circuit.

Doc #: L-805-1091 Page 27 Rev. 00

4.3 Digital Input Debounce Configuration
The Digital Input Debounce screen is accessed by Input “On” Input “Off” Espanol
touching the Digital Input Debounce softkey in the Debounce Time Debounce Time
Cycle 10 ms ACC
Main Configuration screen (see Figure 17 on page 2 ms
(CYCLE)
25). In this screen the debounce characteristics of Setup Mode
2 ms 10 ms Configure
(SETUP)
each input can be set. Running
2 ms 10 ms
(RUN)
On the screen each input is briefly described Part Count 10 ms
2 ms
1 (PCNT1)
followed by how it’s labeled on the board itself in Scrap Count
2 ms 10 ms
parentheses. Press the Next Page and 1 (SCNT1)
Part Count
Previous Page softkeys to see all the inputs 2 (PCNT2)
2 ms 10 ms
Scrap Count Next Page
2 ms 10 ms
2 (SCNT2)
The Input “On” Debounce Time is the amount of Part Count
2 ms 10 ms Exit
time in milliseconds that the input must be Aux (PCAUX)
continuously on before the Machine Monitor will Figure 19: Digital Input Debounce Configuration
treat it as “On”. Screen

Likewise, once the input is considered to be “On”, the Input “Off” Debounce Time is the amount of time
in milliseconds that the input must be continuously “Off” before the Machine Monitor will treat it as
“Off”.

The default values will normally work just fine, but in certain cases they may need to be adjusted. For
example, if an output is available on a machine that is subject to interference or for some reason flickers
“On” (It is common for electromechanical relays contacts to “bounce” when they turn “On” or “Off”),
you may want to increase the Input “On” Debounce Time so that the Machine Monitor doesn’t detect
the input until it has been “On” for 20 milliseconds. This would prevent the example bouncy relay
output from being sensed as turning “On” multiple times. The Input diagnostic screen is handy for
detecting these kinds of conditions and testing the settings here. The “State” and “On Count” in that
screen can be used to make sure no false “On” is detected.

In an opposite example, it may be that a sensor used to detect something flickers “Off” due to machine
vibration or some other condition. The Input “Off” Debounce time could be set so that the input has to
“Off” continuously for 500 milliseconds before it is treated as “Off”.

NOTE: Debounce values will affect the maximum rate at which things can be
detected. For instance, if a part count input is set up with a 250ms “On”
debounce and a 750ms “Off” debounce, then at most 60 parts per minute can
be detected (250ms on plus 750ms off = 1000ms or 1 second for the input to
turn on and then off).

Doc #: L-805-1091 Page 28 Rev. 00

4.4 Operator Terminal Configuration
The Operator Terminal configuration screen is
accessed by touching the Operator Terminal softkey
Cycle
Rate 0.0CPM Part Count
3600
Espanol

Mode: Production ACC

in the Main Configuration screen (see Figure 17 on
Setup Mode Top Operator
page 25). Area Display
Part Count
Terminal
Production Mode
Part Count
Top Area Display
The screen shown in Figure 20 can be used to
configure the operator terminal to display specific
Date: 06/23/2009 Set Date and
default information in the “top info area” that Time: 10:40:35 AM Time
appears in all operator screens. Access
Config
Auxiliary
The operator can select any of the “Top Area Comm Setup
Display” items by pressing the top info area, but the Display 70% Exit
selection made here will be the default at power up. Brightness
This screen can also be used to set the real time Figure 20: Operator Terminal Configuration
clock if necessary. Screen

4.4.1 Top Area Display

The center section of the top display area can be configured to show the following items:

• Part Count
• Current Status
• Reason for Last Stop

The displayed item can change when the stroking mode is changed. The user can chose the item that is
to be displayed in Setup mode and the item that is to be displayed in Production mode.

Note also that touching the “top info area” in any screen will cycle through the available information
items that are not currently shown. This allows the operator to conveniently see any of the items without
having to change them in this screen. The next time the mode is changed, however, the item will be
shown as configured here again.

Doc #: L-805-1091 Page 29 Rev. 00

4.4.2 Setting the Date and Time
The operator terminal contains a real time clock.
To set the time and date, press the
Cycle
Rate 0.0CPM Part Count
3600
Espanol
ACC
Set Date and Time softkey shown in Figure 20. The Mode: Production
Operator
screen of Figure 21 will be displayed. Set the date After the Date and Time are set, press “Enter” to update Terminal
and time to the desired values and then press the the clock or “Cancel” to exit this screen without changing
the clock.
Enter softkey to keep the changes. Note that the
date and time change only occur at the time the
Enter softkey is actually pressed. Press the Cancel Month Day Year
softkey to abandon any changes and keep the 7 / 15 / 2009 Enter
current date and time.
Hour Minute Second
12 : 35 : 17 PM Cancel

Figure 21: Date and Time Setting Screen

4.4.3 Access Configuration

As described in Section 3.3 on page 10 the user
must gain Access Control in order to perform
Cycle
Rate 0.0CPM Part Count
3600
Espanol

Mode: Production ACC

certain operations and change certain parameters.
Access Store Access
This access control can be obtained by two means, Mode
Key OR Code
Job Code
0
Config
RUN/PROG key or a user password system. These Access
30 sec
Access
5 Set Config
Timeout Strokes
two means can be used alone or in combination Code
with each other. Num User Description Used Restrict /
Unrestrict
1 User 1 Yes Edit
Press the Access Config softkey from the Operator
2 User 2 No Edit
Terminal Configuration screen (see Figure 20) will
display the Access Configuration screen shown in 3 User 3 No Next Page
Edit
Figure 22. 4 User 4 No Edit Exit

In addition to some basic parameters that determine Figure 22: Access Configuration Screen
how access control will work, this screen lists the
“Users” that can operate the system. Note that “Users” are ignored if the “Access Mode” is set to “Key
Only”. The Next Page and Previous Page softkeys are used to page through up to 16 possible “Users”.

The following sections discuss the parameters and features of this screen.

4.4.3.1 Access Mode Configuration

There are four access modes. These are “Key and Code”, “Code Only”, ” Key or Code”, and “Key
Only”. These modes are explained in Section 3.3 on page 10.

Doc #: L-805-1091 Page 30 Rev. 00

4.4.3.2 Access Timeout and Access Strokes

When users gain access by using a password, they remain logged in until they manually log out or are
automatically logged out. See Section 3.3.6 on page 13. Automatic log out can be either time based or
stroke based.

The timed log out is based upon the time between keyboard activity. If the user does not press any key
on the operator terminal within the time programmed, the control will automatically log out the user.
The “Access Timeout” parameter sets this time. A time of 0 seconds turns off the timed log out and the
system will not automatically log out a user based on time (but manually logging out or stroke based
automatic logout will still function).

The “Access Strokes” parameter sets the number of press strokes between keyboard activity that the
system will allow before automatically logging out the user. A value of 0 strokes turns off the stroke
based automatic log out (but manually logging out or timed based automatic logout will still function).

4.4.3.3 Store Job Code

The “Store Job Code” is an optional access code that can be required before an operator is allowed to
store a job and is used ONLY when “Access Mode” is “Key Only”. This allows only trusted operators
to overwrite a job setup while still allowing other operators to recall job setups and perform other
operations. Since the purpose of this code is primarily the protection of known good job setups, it also
applies to job erase operations. A setting of “0” will disable this function, and anyone with the
RUN/PROG key will be able to store and erase job setups.

4.4.3.4 Edit User

The control allows for up to sixteen users to have

the ability to gain access control. Each user is
Cycle
Rate 0.0CPM Part Count
3600
Espanol
ACC
assigned a name, a password, and various Mode: Production
User Access
permissions. Touch the Edit softkey to the right of Description
User 1
Config
a user in the Access Configuration screen (shown in User
1 Used Yes
Figure 22) to display the User Configuration screen Code
Items in RED are unrestricted
shown in Figure 23. Permissions
Store Counter
Yes Yes
This display provides the following information: Jobs Change
Recall Counter
Yes Yes
Jobs Reset
• User name/description Erase
No
Counter
No
Jobs Config
• User’s current password Counter Feed
Yes Yes Exit
• Whether or not the User is “Used” Settings Settings
• A listing of permissions for this user. Figure 23: User Access Configuration Screen

The user can be enabled or disabled. When a user

is enabled (“Used” set to “Yes”), the user’s name will appear on a list of possible users that may obtain
access control. When a user is disabled (“Used” set to “No”), the user’s name will not appear on a list
of possible users that may obtain access control.

Doc #: L-805-1091 Page 31 Rev. 00

Each user can be granted permission to access certain restricted items. A list of these items is shown in
Section 3.3.5 on page 12. If a restricted item is configured with a “Yes”, the user can obtain access to
that item. If the restricted item is configured with a “No”, the user cannot obtain access to that item.

4.4.3.5 Restrict/Un-Restrict Access

In addition to the user access system, certain items

can be made available to any operator as shown in
Cycle
Rate 0.0CPM Part Count
3600
Espanol
ACC
Figure 24. An example of this would be to allow Mode: Production
These permissions can be set to allow anyone access to Access
any operator to reset the production counters. Any the actions listed at any time. If “Yes” appears after the Config
item marked as “Yes” can be changed by an listed action then NO PROGRAM KEY OR CODE WILL BE
REQUIRED to perform the action! User permissions will
operator without the RUN/PROG key or an access Be overridden by these settings.
code. Note that this is true even if the “Access Actions That Require No Key or Code
Mode” is in one of the modes that require a code Counter
Yes
Settings
and the user permission for the same setting is
Counter
marked to deny access. These settings will override No
Change
any other restriction. Counter
Yes
Reset
Counter Exit
No
Config
Figure 24: Restrict/Unrestrict Screen
4.4.3.6 Setting the Configuration Code

Selecting the Set Config Code softkey in the Access

Configuration screen, will display the
Cycle
Rate 0.0CPM Part Count
3600
Espanol
ACC
Configuration Code screen shown in Figure 25. Mode: Production
This code is used to gain access to the user Access
This screen allows the Configuration Code to be configuration screens for both standard and optional Config
changed. This is the configuration code that features of the control. This code should ONLY be
known to persons who have the technical knowledge and
protects Top Stop Calibration, Machine Parameters, the authorization of the employer to configure the
Lubrication Systems Configuration, Operator control.
Terminal Configuration, Restricted Programmable CAUTION! Some settings affect safety considerations.
Others can affect whether production systems are
Limit Switch Setting, Names and Messages, properly controlled or monitored.
Counter Configuration, Tonnage Monitor Make sure you record and keep this code in a secure
Configuration, Die Protection Configuration, and place. If it lost, you will have to contact Link Systems
to restore access to the configuration screens.
Auto Setups Configuration. It is imperative that
Configuration Exit
this code be given only to authorized personnel Code
999
who are familiar with the control and with the
Figure 25: Set Config Code Screen
consequences of incorrect parameter settings.

The configuration code is set at the factory. It is suggested that this code not be changed unless the
security of the configuration code has been jeopardized. If a configuration code has been obtained by
personnel who do not require access to the configuration parameters, it must be changed. When this
code is changed, the previous code will no longer be valid. The value of the new code should be
documented and stored in a secure place.

If a current code value is lost, the factory must be consulted for a recovery procedure.

Doc #: L-805-1091 Page 32 Rev. 00

4.4.4 Configure Auxiliary Communications
The Auxiliary Comm Setup softkey provides access to the configuration screens for the communication
options These options include serial communication ports for interfacing to electronic servo feeds,
auxiliary equipment (such as PLCs), a laptop interface for downloading messages, and a network
interface. See the manual pertaining to the particular device that is connected for communication.

Doc #: L-805-1091 Page 33 Rev. 00

5 BACKING UP AND RESTORING THE OPERATOR TERMINAL
The OmniLink 805 Operator Terminal (OIT) stores most of the settings of the system to which it is
attached in its internal storage. This section is intended to give maintenance personnel the necessary
procedures to back up and restore the memory from an OIT to a secure digital card. Backup that are
created can be used to restore the settings stored in the backup to the same OIT, or to a different OIT in
cases where the original OIT must be replaced due to damage.

A “secure digital” (SD) flash card is used to store

the backup data. This type of flash card is
commonly available from stores such as Radio
Shack, Best Buy, Wal-Mart, Target, etc. Since a
single backup for an 805 operator terminal will take
up less than 64KB of space, even the smallest
capacity SD cards will have more than enough
space for backups. The location of the SD card slot
on the back of the OIT is shown below in Figure 26.

5.1 Backup Procedure

To back up the OIT, first go to the backup / restore
screen. To get there:
• From the main screen (the screen shown
when the operator terminal is first turned
on), press the Diagnose softkey.
• Press the SD Card Diagnostics softkey.
• Press the Backup / Restore softkey. Note
that this key will not appear unless the
RUN/PROG key is in the PROG position.
• The operator terminal will ask for the SD
Configuration Code. Enter the code and the CARD
Backup/Restore screen will be shown.
Figure 26: SD Card Slot Location
The screen will indicate whether an SD card is present and, if so, whether there are any backup files on
it.

To make a backup file:

• Press the Backup OIT softkey. Note that this key will only be present if the RUN/PROG key is in
the PROG position AND an SD Card is inserted in the SD Card slot of the OIT.
• A new screen will appear that will allow a short description of the backup to be entered. In
addition to this, the serial number of the OIT and the date and time (according to the OIT clock)
will automatically be stored with the backup.

Doc #: L-805-1091 Page 34 Rev. 00

 • This screen will also show a warning if a backup file for this OIT is already present. Multiple
OITs can be backed up on one SD Card, but only one backup file from each OIT can be stored
on a given card.
• After a description has been entered, press the Execute Backup softkey to start the backup.
• A progress bar at the bottom of the screen will indicate the status of the backup, and after
completion a message will appear indicating the success or failure of the operation.
• Hit Exit to go back to the main backup / restore screen.

The main backup / restore should now indicate that is has found a backup file for this OIT.

NOTE: One SD Card can store backup files from many different OT805 operator
terminals, but only one backup file from each individual OT805 can be stored
on a card. To make multiple backups of a single OT805, use a different card
for each backup.

5.2 Restore Procedure

WARNING: Unlike backups, which make no changes, a restore of a backup file will
completely replace the settings and information contained in the
operator terminal. Make absolutely sure you restore the intended
backup file!

To restore the OIT, first go to the backup / restore screen. To get there:
• From the main screen (the screen shown when the operator terminal is first turned on), press the
Diagnose softkey.
• Press the SD Card Diagnostics softkey.
• Press the Backup / Restore softkey. Note that this key will not appear unless the RUN/PROG
key is in the PROG position.
• The operator terminal will ask for the Configuration Code. Enter the code and the
Backup/Restore screen will be shown.

The screen will indicate whether an SD card is present and, if so, whether there are any backup files on
it. The screen will also indicate whether there is a backup file that was originally made from the same
operator terminal and/or whether backup files exist that were made from different operator terminals.

Backups made from the same operator terminal show up in the main backup / restore screen. The user
entered description is shown along with the date and time that the backup was made. To restore a
backup file to the same operator terminal that made it:
• From the main backup / restore screen press the Execute Restore softkey. Note that this key will
not appear unless the RUN/PROG key is in the PROG position and an SD Card is inserted that
has a backup file that was created from the same operator terminal.

Doc #: L-805-1091 Page 35 Rev. 00

 • A warning screen will appear that explains the original information in the operator terminal will
not be recoverable after the restore is started. Press the Execute Restore softkey in this screen
and a progress bar at the bottom of the screen will show the progress of the operation. Do not
remove power from the unit until the operation is finished.
• Press the Exit softkey and the operator terminal will reboot with the new settings.

Sometimes, such as when the original operator terminal has been damaged, it may be necessary to
restore a backup file made from a different operator terminal. To do this:
• From the main backup / restore screen press the View Other Backups softkey. Note that this key
will not appear unless the RUN/PROG key is in the PROG position and an SD Card is inserted
that has a one or more backup files that were created from different operator terminals.
• A screen will appear with the backup files available to choose from. These files are listed with
the serial number of the operator terminal that made them, the date and time they were made, and
the user entered description of the backup. Select a file from this screen by pressing the name of
the file to restore.
• A warning screen will appear that explains the original information in the operator terminal will
not be recoverable after the restore is started. Press the Execute Restore softkey in this screen
and a progress bar at the bottom of the screen will show the progress of the operation. Do not
remove power from the unit until the operation is finished.
• Press the Exit softkey and the operator terminal will reboot with the new settings.

Doc #: L-805-1091 Page 36 Rev. 00

5.3 Memory Chip Swap-out Procedure
In cases where an operator
terminal is being swapped out with
another, but there is no backup file
available or the only one available
is badly out of date, the memory
chip that contains the information
stored on the operator terminal Memory
may be moved to new terminal. Chip
Figure 27 shows the location of the
memory chip. Note that it will be
necessary to remove the 805-8
board to get access to the chip.

Before starting this procedure,

make sure all power is removed
from both operator terminals.

Carefully remove the chip from its

socket in the operator terminal
being replaced. If using a small
screwdriver to assist in the
removal, be careful to place the
screwdriver between the chip and
Figure 27: Memory Chip Location
the socket rather than the socket
and the circuit board.

In the same manner, remove the chip in the new operator terminal. Now place the chip from the original
operator terminal into the socket of the new operator terminal. Pay careful attention to the notch on one
side of the chip. It should match the notch in the socket. With the circuit board oriented as shown in
Figure 27, the notch in the chip should point down. Also make sure not to bend the leads of the chip
under or out as it is being inserted into the socket.

After the memory chip is installed, power up the new operator terminal and verify that the settings are
correct.

Doc #: L-805-1091 Page 37 Rev. 00

6 INSTALLATION

NOTE: Before you begin installation, you should read this entire manual carefully.
This will help you to understand system functions and plan the installation
to save time and the necessity to rework portions of the installation.

6.1 Preliminary Installation Considerations

The 805-8 Machine Monitor comes in two configurations: panel mount for situations where there is
available panel space in an existing enclosure, or in a complete enclosure. In either case, try to locate
the machine monitor close to the machine control for easy access, keeping in mind that the operator will
need to interact with the screen from time to time.

The wiring instructions for installation contained in this manual are necessarily generic since the
Machine Monitor may be interfaced with a wide variety of machinery using multiple relay and
electronic components. If the installer has questions related to the proper installation of the system,
contact the service personnel at Link Systems. Always test each component of the system installation
to see that proper function is obtained.

WARNING: Improper system installation or improper interface from the Machine

Monitor to the machine control may result in damage to the machine or
other equipment and increase the possibility of injury to operators and
others. Use qualified installers.

Installation of this system should be done in accordance with OSHA’s lockout/tagout regulations (see
CFR 1910.147). You will be mounting Machine Monitor components on or near the machine, and may
be exposed to mechanical hazards if machine movement should occur during mounting activities.
Depending on the configuration of Machine Monitor purchased and interface requirements to the
machine control, you may also be wiring electrical circuits that will use 115VAC or 230VAC voltages.
Unless these circuits are de-energized during wiring activities, a serious or even fatal shock may occur.
Remove hazardous energy during system installation.

WARNING: Failure to comply with CFR 1910.147 regulations and remove

hazardous energy during installation of the Machine Monitor may
result in serious injury or death! Use only qualified installers trained in
lockout procedures for installation.

Doc #: L-805-1091 Page 38 Rev. 00

6.2 Mounting the Machine Monitor
The Machine Monitor is usually delivered pre-mounted in an enclosure
Display
ready to bolt on to the machine. It is also available without the enclosure, Surface
when there is panel space available in an existing enclosure.

In either case, consideration should be given to the viewing angle of the

operator. Figure 28 shows the most usable viewing angles for the LCD 30°
display used in the Link OIT - about 30 degrees “above” to 45 degrees
below is preferable. Going further in either direction by about 20 degrees
is possible, if absolutely necessary. Viewing the operator terminal from 45°
slightly “below” it generally results in the best display quality.

The panel mount version of the machine monitor requires the panel cutouts
and holes shown in Figure 29.

In selecting the mounting location, note not only the panel space required,
but also the depth clearance needed for the unit, which is needed to allow
Figure 28: OIT Viewing
for wiring to exit the back. There is also a 1.2” (30mm) clearance needed Angles
for wiring and SD Card insertion space at the bottom of the operator
terminal

panel 0.2”
(5.1) 5.875” (149.2)
3.0” (76.2)
min clearance

Cutout
3.375”
(85.7)
0.16” (4.1) 6.35”
diameter (161.3)
6 places
CL

Values in parentheses
are in millimeters
OIT 3.375”
face 5.5” (139.7) (85.7)
plate

1.2” (30)
min clearance 0.19”
(4.8) Required front panel space
6.25” X 7.25” (158.8 X 184.2)

Figure 29: Panel Mounting Dimensions

Doc #: L-805-1091 Page 39 Rev. 00

Figure 30 shows the mounting dimensions of the Machine Monitor that is already in an enclosure.
When selecting the mounting location, allow for room to open the door of the enclosure (it swings to the
left) and for conduit and/or cable entry to the enclosure. In addition, if the mounting location is subject
to heavy vibration, then the enclosure should be mounted using shock mounts.

8.3” (211)
7.9” (201) 7.0” (178)
6.5” (165) 6.0” (152.4)

OIT
face
Hinge plate

11.5” 10.75”
(292) (273)
Values in parentheses 10.3”
are in millimeters (262)

RUN
PROG

Door Latches
(2 places)

0.31” (7.9)
diameter
Door (4 places)

Figure 30: Enclosure Mounting Dimensions

Doc #: L-805-1091 Page 40 Rev. 00

6.3 System Wiring
Wiring between the Machine Monitor enclosure (or the enclosure the panel mount version in mounted
in) and the machine should be run in conduit. The use of flexible liquid tight conduit with ground is
suggested, but hard conduit can also be used.

The conduit runs that may be needed, depending on the configuration of the Machine Monitor and the
features used are:
• Conduit for 115VAC or 230VAC connections between the Machine Monitor enclosure and the
machine control.
• Conduit for low voltage connections between the Machine Monitor enclosure and the machine
control.
• Conduit for sensors on the machine running back to the Machine Monitor.
• Conduit from the Machine Monitor to a stack light.
• Conduit for the Ethernet cable from its drop to the Machine Monitor.

NOTE: If you have both 115VAC circuits and low voltage circuits, run them in separate
conduits. You can run the Ethernet cable with the low voltage wiring if needed.

The 805-8 Machine Monitor itself operates on +24 VDC and requires up to 400 milliamps (or about 10
watts). The version of the Machine Monitor that comes in an enclosure is supplied with a 30 watt +24
VDC power supply that accepts 90 to 264 VAC, 47 to 63 Hz. The extra capacity of this supply can be
used to power sensors (for cycle or part detection, for instance) or indicators (like stack lights) if needed.

NOTE: Even though the Machine Monitor that is supplied in an enclosure has a +24
VDC supply, it is not a requirement to use that supply. If the machine the
monitor is installed on has 400 milliamps of available capacity on its own
+24 VDC supply (about 10 watts) and does not have conveniently available
AC power, then the machines supply can be used to power the Machine
Monitor in the same way as the panel mounted version.

WARNING! ALWAYS remove the AC power from the unit before servicing and/or
wiring the Monitor. Lethal voltages are present in the enclosure
when the unit is powered!

WARNING! Make sure you completely wire the AC power connections (paying
particular attention to making sure the enclosure is grounded) before
applying power to the Machine Monitor. Lethal voltages are present
in the enclosure when the unit is powered!

Doc #: L-805-1091 Page 41 Rev. 00

Figure 31 is a view of the back of the operator terminal showing the location and pinout of the
connectors used to interface the Machine Monitor to the machine. Figure 32, next page, shows a view
of the version of Machine Monitor that is already in an enclosure.

DTC1
DTC2
DTC3
DTC4
DTC5
DTC6

COM
EV1
EV2
EV3
EV4
EV5
EV6
Stop CON6
Relay

805-8 Machine Monitor

Option Board

CON4 CON5
SLO_Y
SLO_R
SLO_A

AO1
AO2
AO3
+24
SLO_G

+24

STOP NO STOP NC
(5A 250VAC 30VDC)
ETHERNET

PCAUX

CYCLE
SETUP
PCNT1
SCNT1
PCNT2
SCNT2

SLI_G

SLI_R
SLI_A
SLI_Y

COM

COM
COM

RUN
CON1 CON2 CON3
PORT 1 805 Operator
Terminal Board
TX
RX
GND

FUSE FUSE 5X20

0.5A 240V
FAST BLO
SD CARD POW / DP
USB

PUSH TO INSERT
USB

PUSH TO EJECT
DP1
DP2
DP3
DP4
+OT
COT
SHLD
GND
CANH
CANL

Figure 31: 805-8 Machine Monitor Connectors

Doc #: L-805-1091 Page 42 Rev. 00

Doc #: L-805-1091
OPTO 22
AC or DC

DTC1
DTC2
DTC3
DTC4
DTC5
DTC6
EV1
EV2
EV3
EV4
EV5
EV6
COM
Stop CON6
Relay OPTO 22
AC or DC
805-8 Machine Monitor

CON9
CON10

Option Board OPTO 22

1 2 3 4 5
AC or DC
1 2 3 4 5 6 7 8

CON4 CON5
OPTO 22
AC or DC

+24

+24
AO1
AO2
AO3
STOP NO STOP NC 802-5B Solid State Output Board
(5A 250VAC 30VDC)

SLO_Y
SLO_R
SLO_A

SLO_G
Optional Extra DIN Rail
Solid State for Terminals

SLI_G
SLI_Y
SLI_R
SLI_A
COM
CYCLE
SETUP
RUN
COM

PCNT1
SCNT1
PCNT2
SCNT2
PCAUX
COM

ETHERNET
CON1 CON2 CON3
Relay Board

Page 43
PORT 1 805 Operator
Terminal Board
+24 VDC

TX
RX
FUSE 5X20

GND
FUSE Power Supply
0.5A 240V
FAST BLO
SD CARD POW / DP Ground
PUSH TO INSERT

USB
PUSH TO EJECT

USB
DP1
DP2
DP3
DP4

+OT
COT
Lug

+OT
COT
N

GND
SHLD
CANL
CANH
L

DSP
30-24

- -
Vout ADJ.
DC OK
DC LO

Back Side of
+ +

Operator Terminal

Figure 32: Open Door View of 805-8 Machine Monitor in Enclosure

Rev. 00
6.3.1 Wiring Power for the System

WARNING: National Codes and standard (NEC, VDE, BSI, etc.) and local codes
outline provisions for safely installing electrical equipment.
Installation must comply with specifications regarding wire types,
conductor sizes, branch circuit protection, and disconnect devices.
Failure to do so may result in personal injury and/or equipment
damage.

Pull wires with the appropriate color code in conduit between the Machine Monitor enclosure (if used)
and the machine control. Remember to run high voltage wiring in one conduit and low voltage wiring,
if any, in a separate conduit.

The Machine Monitor itself, whether the panel “POW / DP” Connections on 805
mounted version or the enclosure version, operates Operator Terminal
on +24 VDC and requires up to 400 milliamps (or +OT +24 VDC Input Power
about 10 watts). The power connection is made on (0.4 Amps )
the “POW / DP” connector (see Figure 31on page
COT Ground - +24VDC Return
42) as shown in the table at right.

For the panel mounted version, use at least 18AWG wire to connect the +24 VDC power and ground as
shown in the table above.

The version of the Machine Monitor that comes in Power Supply Connections on
an enclosure is supplied with a 30 watt +24 VDC Enclosure +24 VDC Supply
power supply that accepts 90 to 264 VAC, 47 to 63 L 90 – 264 VAC Line
Hz. The +24 VDC output is already wired to the 37 VA (0.8 Amp)
Machine Monitor as shown in Figure 32. Use
N 90 – 264 VAC Neutral
16AWG wire to connect the supply as shown in the
Ground Connect protective earth to the
table at right. Note that the power supply itself is
Lug ground lug on the enclosure (see
double insulated and does not require a separate
Figure 32)
ground, but that ground (protective earth or PE)
must still be connected to the “Ground Lug” in the enclosure (see Figure 32).

Doc #: L-805-1091 Page 44 Rev. 00

6.3.2 Wiring Inputs
The Machine Monitor has several input
CYCLE
connectors to allow the machine to indicate
certain conditions or events, such as making a SETUP
cycle. Each input connector has a “COM”
RUN +24 VDC
terminal, which is the common for that connector
(see Figure 31, CON1, CON2, CON3, and COM GROUND
CON6).

The inputs on the connectors mentioned above are CON3 Connector

optically coupled, isolated inputs and so can be 805-8 Board
driven from different supplies than are powering
the Machine Monitor. Note that you can use the
CYCLE
same supply that is powering the Machine
Monitor, but if you are coming off a PLC output SETUP
from the machine it may be more convenient not
RUN +24 VDC
to.
COM GROUND
The COM terminal on each input connector must
be tied to either ground or +24VDC from the
device that is driving it. If the “COM” terminal CON3 Connector
for a connector is tied to ground, then +24 VDC 805-8 Board
on an input on that connector will turn that input Figure 33: Example Input Connections
“On”. Likewise if the “COM” terminal is tied to
+24 VDC, then grounding the input will turn it “On”. Figure 33 shows an example of the CON3
connector wired up in each of these configurations.

While Figure 33 is showing relay contact driving the inputs, anything that can switch between ground
and +24 VDC will work. For instance, when the “COM” terminal is tied to +24 VDC, then an NPN
proc sensor could drive the input. If the “COM” terminal is tied to ground, then a PNP proc sensor
could drive the input.

NOTE: Remember that each of the CON1, CON2, CON3, and CON6 connectors
has its own independent “COM” terminal that must be tied to either ground
or +24 VDC but they do not have to be the same across all connectors.

Use the input diagnostic screen (see Section 3.7.1on page 21) to verify that the input is turning “On” and
“Off” as expected.

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The inputs (see Figure 31 on page 42 for locations) and their functions are:

CON1 This input increments Part Count 1 and Bin Count 1 when it switched from “Off”
PCNT1 to “On”. This is used when counters are being driven by sensors actually
detecting parts as they come off the machine. This is especially useful when the
number of cycles do not match up with the number of parts (2 parts per cycle, 10
cycles per part, etc.). It’s also useful when the machine or process does its own
part validation and can reject a part, which can be counted as scrap by the SCNT1
input. If not used, the Machine Monitor can drive its counters from the CYCLE
input.

CON1 This input increments Scrap Count 1 when it switched from “Off” to “On”. This
SCNT1 is especially useful when the machine or process does its own part validation and
can reject a part. If not used, the operator can manually indicate when scrap is
made.

CON1 This input increments Part Count 1 and Bin Count 1 when it switched from “Off”
PCNT2 to “On”. See the explanation under PCNT1 for more information.

CON1 This input increments Scrap Count 1 when it switched from “Off” to “On”. See
SCNT2 the explanation under SCNT1 for more information.

CON1 Not used at this time.

PCAUX

CON2 When “On”, indicates the machine wants the green stack light to be lit. This can
SLI_G be used to optionally integrate the Machine Monitor into an existing stack light
that is already being used by the machine.

CON2 When “On”, indicates the machine wants the yellow stack light to be lit. This can
SLI_Y be used to optionally integrate the Machine Monitor into an existing stack light
that is already being used by the machine.

CON2 When “On”, indicates the machine wants the red stack light to be lit. This can be
SLI_R used to optionally integrate the Machine Monitor into an existing stack light that is
already being used by the machine.

CON2 When “On”, indicates the machine wants the auxiliary (could be any color –
SLI_A basically a fourth light on the stack) stack light to be lit. This can be used to
optionally integrate the Machine Monitor into an existing stack light that is
already being used by the machine.

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 CON3 When the CYCLE input switched from “Off” to “On”, it indicates that the
CYCLE machine has just made a cycle. This input is the only input that is actually
required to be connected. If the part and scrap count inputs are not used, then this
input can also be used to drive the counters.

CON3 When “On”, this input indicates the machine is in “Setup” mode, rather than
SETUP “Production” mode. If this input is not used then the system can be configured to
allow the operator to manually indicate the mode.

CON3 When “On”, this input indicates the machine is “Running”. If this input is not
RUN used then the CYCLE input in combination with a timeout can be used to indicate
the machine is running (see Section 4.2.1).

CON6 When “On”, these inputs indicate that a down time condition is in effect. This will
DTC1 to cause, if configured for it, a particular down time code to become active. If
DTC6 multiple inputs are on at the same time, then priority will be given to the lower
input number. For example, if DTC1 and DTC3 are both on, then DTC1 will
“win”.

CON6 When these inputs switch from “Off” to “On”, then, when configured for it, an
EV1 to EV6 event code associated with the input will be logged to the network.

6.3.3 Wiring Outputs

The primary output on the Machine Monitor is a Stop relay that can be used to stop the machine when,
for instance, a counter limit is reached or if you want to force the operator to enter a down time code
after the machine has gone idle. CON5 (see Figure 31 on page 42) has the following terminals:

CON5 These two terminals are the normally open contact of the stop relay and are the
STOP NO ones that would typically be wired into the machine stop circuit. During normal
operation when no Stop is being asserted, these contacts are closed. If a Stop from
the Machine Monitor is active, or if the Machine Monitor loses power, this contact
will open up. While not required,

CON5 These two terminals are the normally closed contact of the stop relay and will be
STOP NC the opposite of the normally open contact described above. This contact is
provided for the rare case where some auxiliary indication is needed, but is
typically not used.

CON5 Reserved for future use.

AO1 to A03

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 CON5 Reserved for future use.
+24

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