Operating Manual

Pressing monitor EPW400

• Force/Distance Measurement

 Original operating manual

Firmware Version V1.08.88

TOX® PRESSOTECHNIK GmbH & Co. KG  Riedstraße 4  D - 88250 Weingarten

Phone +49 (0) 751/5007-0  Fax +49 (0) 751/52391  www.tox-de.com  E-Mail: [email protected]
 Introduction

This operating manual applies to devices running firmware version V1.08.81 or higher.

TOX® PRESSOTECHNIK GmbH & Co. KG  Riedstraße 4  D - 88250 Weingarten

Phone +49 (0) 751/5007-0  Fax +49 (0) 751/52391  www.tox-de.com  E-Mail: [email protected]
 Table of contents

Table of contents
1 Introduction ...................................................................................................... 9
1.1 Explanation of symbols ............................................................................. 9
2 Brief description ............................................................................................ 10
2.1 Function of the pressing monitor ............................................................. 10
2.2 Measuring Mode and Configuration ........................................................ 10
2.3 Version .22 ............................................................................................. 11
3 Technical data ................................................................................................ 12
3.1 General technical data ............................................................................ 12
3.1.1 Power supply ............................................................................... 12
3.1.2 Hardware configuration ................................................................ 12
3.1.3 Connections ................................................................................. 13
3.1.4 Digital inputs ................................................................................ 14
3.1.5 Digital outputs .............................................................................. 14
3.1.6 USB ............................................................................................. 15
3.1.7 Ethernet ....................................................................................... 16
3.1.8 Environmental conditions ............................................................. 16
3.1.9 Electromagnetic compatibility in line with EC directives................ 17
3.1.10 Sensor: analog standard signals .................................................. 18
3.1.11 Sensor: supply voltage ................................................................. 18
3.1.12 Screw sensor with standard signal output .................................... 18
3.1.13 DMS signals................................................................................. 19
3.2 Overview of built-in version ..................................................................... 20
3.2.1 Mechanical specifications ............................................................ 20
3.2.2 Dimensions of installation housing with two slots ......................... 21
3.2.3 Dimensions of installation housing with three slots....................... 21
3.2.4 Hole pattern of installation housing (rear view) ............................. 22
3.2.5 Built-in version: digital inputs I0 – I15 (37-pin connector) ............. 23
3.2.6 Built-in version: digital outputs Q0 – Q7 (37-pin connector) .......... 24
3.2.7 Built-in version: pin assignment, DMS force transducer
(channel Y) .................................................................................. 25
3.2.8 Built-in version: pin assignment, analog signals
(channel Y force / channel X distance) for analog standard
signals ......................................................................................... 26
3.2.9 Built-in version: pin assignment, analog standard signals ............ 28

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 3.3 Overview of wall-mounted version .......................................................... 30
3.3.1 Power supply ............................................................................... 30
3.3.2 Dimensions of wall-mounted version ............................................ 30
3.3.3 Wall-mounted housing: digital inputs I0-I15
(25-pin D-sub female connector) .................................................. 31
3.3.4 Wall-mounted housing: digital outputs Q0-Q7
(25-pin D-sub female connector) .................................................. 31
3.3.5 Standard wall-mounted housing: pin assignment, DMS force
transducer (channel Y)................................................................. 32
3.3.6 Wall-mounted housing: pin assignment, force transducer
(channel Y) Only hardware model EPW 400.202.1X .................. 36
3.4 Interfaces ................................................................................................ 38
3.4.1 Profibus ....................................................................................... 38
3.4.2 Fieldbus interface ........................................................................ 40
4 Transport ........................................................................................................ 43
4.1 Storage ................................................................................................... 43
4.2 Transport ................................................................................................ 43
4.3 Dispatch for repair .................................................................................. 43
5 Operating the device ..................................................................................... 44
5.1 Switching on the EPW 400 ..................................................................... 44
5.2 Operating the device via touch screen (touch-sensitive screen)............. 44
5.3 Main menu 'Measuring' ........................................................................... 45
5.3.1 Buttons (from left to right) ............................................................ 45
5.3.2 Icons ............................................................................................ 46
5.3.3 Full screen display: ...................................................................... 47
5.4 Menu 'Zoom' ........................................................................................... 48
5.4.1 Buttons (from left to right) ............................................................ 48
5.5 Menu 'Gauge curve' ................................................................................ 51
5.5.1 Buttons ........................................................................................ 51
5.6 Menu 'Windows' ...................................................................................... 52
5.6.1 Edit window type .......................................................................... 53
5.7 Menu 'Envelope curve' ............................................................................ 59
5.7.1 Text fields .................................................................................... 61

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 Table of contents

6 Configuring the EPW 400 .............................................................................. 63

6.1 Processes ............................................................................................... 63
6.1.1 Select process number (64 processes) ........................................ 64
6.1.2 Assign process name (max. 40 characters) ................................. 64
6.1.3 Copy processes ........................................................................... 65
6.1.4 Settings ........................................................................................ 66
6.1.5 Saving / restoring parameters ...................................................... 67
6.2 Configuration .......................................................................................... 68
6.2.1 Force sensor, channel Y .............................................................. 69
6.2.2 Nominal force of the force sensor (Nominal load) Version 22 ....... 69
6.2.3 Nominal force of the force sensor (Nominal load)......................... 70
6.2.4 Offset force sensor....................................................................... 70
6.2.5 Force sensor offset adjustment .................................................... 70
6.2.6 Offset limit force sensor ............................................................... 71
6.2.7 Forced offset force sensor ........................................................... 71
6.2.8 Source force sensor ..................................................................... 71
6.2.9 Nominal characteristic value of force sensor ................................ 71
6.2.10 Filter............................................................................................. 71
6.2.11 Force sensor calibration ............................................................... 72
6.2.12 Force 1 ........................................................................................ 72
6.2.13 Force 2 ........................................................................................ 73
6.2.14 Distance sensor ........................................................................... 74
6.2.15 Distance sensor Version 22 ......................................................... 74
6.2.16 Nominal distance of the distance sensor (nominal load)............... 75
6.2.17 Distance sensor offset.................................................................. 75
6.2.18 Offset adjustment of distance sensor ........................................... 75
6.2.19 Offset limit of distance sensor ...................................................... 76
6.2.20 Forced offset of distance sensor .................................................. 76
6.2.21 Filter............................................................................................. 76
6.2.22 Distance sensor calibration .......................................................... 77
6.2.23 Measuring parameters ................................................................. 79
6.2.24 Measured data acquisition (measuring parameters) ..................... 79
6.2.25 Distance rising ............................................................................. 80
6.2.26 Distance rising or falling ............................................................... 80
6.2.27 Force or distance change ............................................................. 80
6.2.28 Time-triggered ............................................................................. 80

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 6.2.29 Insert max. force at the end of the curve ...................................... 81
6.2.30 Start/stop condition ...................................................................... 81
6.2.31 Distance-triggered ....................................................................... 81
6.2.32 Force-triggered ............................................................................ 82
6.2.33 Start/stop from PLC ..................................................................... 82
6.2.34 Switching points ........................................................................... 82
6.2.35 Configuration I/O.......................................................................... 83
6.2.36 Configuring the analog outputs .................................................... 85
6.2.37 Valuation options ......................................................................... 86
6.2.38 Activate NOK buzzer (NOK buzzer) ............................................. 86
6.2.39 NOK acknowledge external (reset) .............................................. 86
6.2.40 NOK acknowledge via display (reset) .......................................... 86
6.2.41 Monitor TDC sensor ..................................................................... 86
6.2.42 Apply configuration ...................................................................... 87
6.3 Data ........................................................................................................ 88
6.3.1 Curve data ................................................................................... 88
6.3.2 Final values ................................................................................. 89
6.3.3 Settings........................................................................................ 90
6.3.4 Settings for data export to PC ...................................................... 91
6.4 Lot size ................................................................................................... 92
6.4.1 Job counter .................................................................................. 92
6.4.2 Shift counter ................................................................................ 93
6.4.3 Tool counter ................................................................................. 94
6.5 Diagram settings ..................................................................................... 95
6.6 Supplemnt .............................................................................................. 96
6.6.1 User administration ...................................................................... 97
6.6.2 Language................................................................................... 100
6.6.3 Communication parameters ....................................................... 100
6.6.4 IP address ................................................................................. 101
6.6.5 Remote access .......................................................................... 101
6.6.6 In-/Outputs ................................................................................. 102
6.6.7 Internal digital I/O ....................................................................... 103
6.6.8 Field bus parameters ................................................................. 104
6.6.9 Profibus address (only for Profibus version) ............................... 104
6.6.10 Read inputs to Anybus-S module ............................................... 105
6.6.11 Log final values on field bus ....................................................... 105

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 Table of contents

6.6.12 Write actual values ..................................................................... 105

6.6.13 Read DMC code ........................................................................ 105
6.6.14 Number of IO bytes .................................................................... 105
6.6.15 Profibus / Anybus ....................................................................... 106
6.6.16 Analog inputs ............................................................................. 107
6.6.17 Date/Time .................................................................................. 108
6.6.18 Device name .............................................................................. 109
7 PLC interface pulse diagrams ..................................................................... 110
7.1 Start/Stop.............................................................................................. 110
7.1.1 Changing the program number .................................................. 111
7.1.2 Zero point adjustment ................................................................ 111
8 Software module TOX®softWare ................................................................. 112
8.1 Networking via Ethernet ........................................................................ 112
8.2 Network server program EPW 400_Server ........................................... 112
9 Error messages ............................................................................................ 113
10 Firmware update .......................................................................................... 114
10.1 Update from version V1.08 ................................................................... 114
11 Decommissioning ........................................................................................ 116
11.1 Storage ................................................................................................. 116
11.2 Disposal ................................................................................................ 116

8 OM 100.EPW400.201810.en
 Introduction

1 Introduction

1.1 Explanation of symbols

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

Operating notes:

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

Setting
Indicates important information about setting the operating parame-
ters.

Function
Explains the functioning of the machine or the sequence of a work-
ing process.

OM 100.EPW 400.201810.en 9
 Brief description

2 Brief description

The pressing monitor EPW ensures constant monitoring and cares for quality assur-
ance during production.

2.1 Function of the pressing monitor

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

2.2 Measuring Mode and Configuration

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

10 OM 100.EPW400.201810.en
 Brief description

2.3 Version .22

Principle display of the Pressing Monitor EPW400 as Version 22, with changeover
from channel pair A to channel pair B.
You have the option of setting channels A and B for each process independent of
force and distance.

Note
Only the one channel pair (A or B) can be used to measure and not
both simultaneously!

OM 100.EPW 400.201810.en 11
 Technical data

3 Technical data

3.1 General technical data

3.1.1 Power supply
Input voltage: 24 V / DC, ± 25% (incl. 10% residual ripple)
Current consumption: ≤1A

3.1.2 Hardware configuration

CPU ARM9 processor, frequency 200 MHz, passively
cooled
Memory storage 1 x 256 MB CompactFlash (can be expanded to 4
GB)
2 MB boot flash
64 MB SDRAM (firmware and parameters)
Data storage 1024 kB RAM, remanent, buffer battery for final
values and counter readings
Real-time clock / accuracy At 25°C ≤ ± -1 s / day,
at 10 to +70C°: ≤ + 1 s to 11 s / day
Display TFT, backlit, 5.7" graphics-capable
TFT LCD VGA (640 x 480)
Color depth: 16-bit
Backlit LED, switchable via software
Contrast 300:1
Brightness: 220 cd/m2
Viewing angle vertical 100°, horizontal 140°
Analog resistive, color depth 16-bit
Interface extensibility 1 x slot for back plane
1 x keyboard interface for max. 64 buttons with
LED
Buffer battery Lithium cell, pluggable
Battery type Li 3 V / 950 mAh CR2477N
Buffer time at 20°C typically 5 years
Battery monitoring typically 2.65 V
Buffer time for battery change min. 10 minutes
Order number: 300215

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 Technical data

Battery change
Recommendation: change battery after 2 years.
To avoid data loss while performing the battery change, turn the de-
vice on for at least 10 minutes before the change-over.
1 Disconnect the power supply
2 Discharge any electrostatic charges
3 Remove the cover from the lithium battery
4 Remove the battery. (Do not use uninsulated tools - risk of
short circuiting)
5 Insert new battery with correct polarity
6 Replace the battery cover

Correct: Incorrect:

3.1.3 Connections
• 16 digital inputs • 1 USB device
• 8 digital outputs • 1 CF memory card
• 1 Ethernet interface

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 Technical data

3.1.4 Digital inputs

16 digital inputs Isolated
Input voltage 24 V (permissible range: -30 V to +30 V)
Input current At rated voltage (24 V): 6.1 mA
Delay time of standard inputs tLOW-HIGH 3.5 ms
tHIGH-LOW 2.8 ms
Input voltage LOW level: ≤5V
HIGH level: ≥ 15 V
Input current LOW level: ≤ 1.5 mA
HIGH level: ≥ 3 mA
Input impedance 3.9 kΩ

3.1.5 Digital outputs

8 digital outputs Isolated
Load voltage Vin Rated voltage 24 V
(permissible range 18 V to 30 V)
Output voltage HIGH level min. Vin-0.64 V
LOW level max. 100 µA • RL
Output current max. 500 mA
Parallel connection of outputs possible Max. 4 outputs with Itot = 2 A
Short-circuit proof Yes, thermal overload protection
Switching frequency Resistive load 100 Hz
Inductive load 2 Hz (dependent
on inductance)
Lamp load max. 6 W
Simultaneity factor 100%

Avoid reversing current

Reversing current at the outputs may damage the output drivers.

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

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 Technical data

3.1.6 USB
Number of 2 x host (full-speed)
channels
1 x device (high-speed)
USB 2.0 According to USB device specification,
USB 2.0 compatible, type A and B
Connection to high-powered hub/host
Max. cable length 5 m

Pin MIO
1 +5V
2 Data -
3 Data +
4 GND

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

OM 100.EPW 400.201810.en 15
 Technical data

3.1.7 Ethernet

1 channel Twisted pair (10/100BASE-T),

Transmission according to IEEE/ANSI 802.3, ISO 8802-3,
IEEE 802.3u
Transmission 10/100 Mbit/s
speed
Connecting line Shielded, at 0.14 mm² Max. 300 mm
At 0.25 mm²: max. 600 mm
Length max. 100 mm
Cable Shielded, impedance 100 Ω
Connector RJ45 (modular connector)
LED status indica- Yellow: transmis- Green: ready
tor sion

3.1.8 Environmental conditions

Temperature Operation 0 to +45°C
Storage -25 to +70°C
Relative humidity without condensation (acc. to RH2) 5 to 90%
Vibrations according to 15 to 57 Hz, Amplitude 0.0375 mm,
IEC 68-2-6
occasionally 0.075 mm
57 to 150 Hz, Acceleration 0.5 g
occasionally 1.0 g

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 Technical data

3.1.9 Electromagnetic compatibility in line with EC directives

Immunity according to EN 61000-6-2 / EN 61131-2
Electrostatic discharge (EN 61000-4-2)
Contact min. 8 kV
Clearance min. 15 kV
Electromagnetic fields (EN 61000-4-3)
80 MHz – 1 GHz: 10 V/m 80% AM
(1 kHz)
900 MHz ±5 MHz: 10 V/m 50% ED
(200 Hz)
Fast transients (EN 61000-4-4)
Power supply lines 2 kV
Process digital In-output 1 kV
Process analog inputs out- 0.25 kV
puts
Communication interfaces 0.25 kV
Induced high frequency (EN 61000-4-6)
0.15 – 80 MHz 10 V 80% AM (1 kHz)
Surge voltage 1.2/50: min. 0.5 kV (measured at AC/DC converter input)
Emission interference according to EN61000-6-4 / EN61000-4-5
RFI voltage EN 55011 150 kHz – 30 (Group 1,
MHz Class A)
RFI emissions EN 50011 30 MHz – 1 GHz (Group 1,
Class A)

Compliance with the EC Directive

Compliance with EMC directives requires correct installation in ac-
cordance with the device manual.
The person marketing the complete machine is responsible for the
electromagnetic compatibility of the overall system into which the
control system is integrated.

OM 100.EPW 400.201810.en 17
 Technical data

3.1.10 Sensor: analog standard signals

Measuring is carried out by a sensor with a standardized process signal 0-10 V. The
input is selected in menu 'Configuration'.
Nominal force or nomi- Adjustable via the menu
nal distance:
A/D converter: 12 bit = 4096 steps (for EPW 400.x02.1x)
16 bit = 65536 steps (for EPW 400.x02.0x)
Nominal load of reso- Steps see A/D converter, 1 step (bit) = nominal load /
lution: steps
Accuracy of measure- 1%
ment:
Max. sampling rate: 2000 Hz (0.5 ms)

3.1.11 Sensor: supply voltage

Auxiliary voltage: 24 V ± 5%, max. 100 mA
Reference voltage: 10 V ± 1% nominal signal: 0 – 10 V

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

3.1.12 Screw sensor with standard signal output

Auxiliary voltage: 24 V ± 5%, max. 100 mA
Nominal signal: 0 – 10 V
Tare signal: 0 V = zero adjustment, > 9 V = measuring mode

Adjustment value
The entry 'Nominal force' must not be changed without the agree-
ment of the manufacturer.
Tightening torque: 14 Nm

Zero adjustment before each work cycle

With some types of force transducers or measurement amplifiers
with tare function, a decrease of the measuring accuracy is possible
after a certain period of time depending on the process. In order to
ensure repeating accuracy, a zero adjustment should be carried out
before each work cycle or at regular time intervals (e.g. for ZKN
model force transducers after approx. 10 minutes).

18 OM 100.EPW400.201810.en
 Technical data

3.1.13 DMS signals

Force measuring (channel Y) via DMS force transducer. The input is selected in menu
'Configuration'.
Nominal force or nomi- Adjustable in the menu
nal distance:
A/D converter: 16 bit = 65536 steps
Nominal load of reso- 65536 steps, 1 step (bit) = nominal load / 65536
lution:
Gain error: ± 0.5%
Max. sampling rate: 2000 Hz (0.5 ms)
Bridge voltage: 5V
Characteristic value: Adjustable via the menu

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

OM 100.EPW 400.201810.en 19
 Technical data

3.2 Overview of built-in version

3.2.1 Mechanical specifications

Steel panel installation housing Zinc-coated
Dimensions (W x H x D) 168 x 146 x 46 mm
Installation aperture (W x H) 175 x 150 mm
Display front panel (W x H) 210 x 185 mm
Weight approx. 1.600 kg
Plastic front panel EM-immune, conductive
Attachment method 8 x threaded bolts M4 x 10
Protection class according to DIN IP 54 (front panel)
40050 / 7.80
IP 20 (housing)
Films Polyester
Resistance according to DIN 42115
Alcohols, diluted acids and alkalis,
household cleaners

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 Technical data

3.2.2 Dimensions of installation housing with two slots

3.2.3 Dimensions of installation housing with three slots

OM 100.EPW 400.201810.en 21
 Technical data

3.2.4 Hole pattern of installation housing (rear view)

T
Top

Front view

Installation aperture
175 x 150 mm

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 Technical data

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

Pin OK Designation
1 I0 Program bit 0
2 I1 Program bit 1
3 I2 Program bit 2
4 I3 Program bit 3
5 I4 Program bit 4
6 I5 Program bit 5
7 I6 Program strobe
8 I7 Offset external
19 0V 0 V external
20 I8 Start measure-
ment
21 I9 Reserve
22 I 10 Control panel in-
terlock
23 I 11 Error reset
24 I 12 Reserve
25 I 13 Configurable input
26 I 14 Access level bit 1
27 I 15 Reserve

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

OM 100.EPW 400.201810.en 23
 Technical data

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

Pin OK Designation
19 0V 0 V external
28 Q0 OK
29 Q1 NOK
30 Q2 NOK alarm
31 Q3 Switching point
S1 1 / Enable
32 Q4 Switching point
S21 / NOK buzzer
33 Q5 Ready for meas-
urement
34 Q6 Program ACK
35 Q7 Switching point 31
/ Item quantity
warning
36 + 24 V +24 V external
37 + 24 V +24 V external

Connection example of digital inputs and outputs

1 Output function configurable

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 Technical data

3.2.7 Built-in version: pin assignment, DMS force transducer (channel Y)

Only hardware model EPW400.002.0X (with DMS subprint)
9-pin D-sub female connector DMS0 for DMS sensors
Pin DMS signal
1 Measuring signal DMS +
2 Measuring signal DMS -
3 Reserve
4 Reserve
5 Reserve
6 Supply DMS V-
7 Sensor cable DMS F-
8 Sensor cable DMS F+
9 Supply DMS V+

Note
For hardware model EPW 400.022.0X (2-channel) the second ana-
log input card is installed for channel pair 2 X/Y!
The connections are occupied the same as for the first card.

Channel Y DMS force transducer

Connection example of DMS0 without sensor cable (CKN / ZAK / ZPS)
9-pin D-sub connector
DMS0

Connection example of DMS0 with sensor cable

9-pin D-sub connector
DMS0

OM 100.EPW 400.201810.en 25
 Technical data

When connecting the DMS using the 4-conductor technique, pins 6 and 7 and pins 8
and 9 are bridged.
3.2.8 Built-in version: pin assignment, analog signals (channel Y force / channel X
distance) for analog standard signals
15-pin D-sub female connector (designation analog I/O)

Pin Type Input/Out- Analog signal

put
1 i Force signal 0 - 10 V channel Y /1
3 i Ground, force signal channel Y /1
4 i Travel signal 0 - 10 V channel X /2
6 i Ground, travel signal channel X /2
7 o Analog output 1: tare +10 V / force / distance 2
8 o Ground
13 o Analog output 2: 0 - 10 V process-bound / force / distance2
14 o Ground
15 o +10 V sensor supply

Note
For hardware model EPW 400.022.0X (2-channel) the second ana-
log input card is installed for channel pair 2 X/Y!
The connections are occupied the same as for the first card.

Channel Y force transducer, analog

Connection example of sensor with standard signal 0 - 10 V (ZKN with tare)
15-pin D-sub con-
nector, analog I/O

2 Output function configurable

26 OM 100.EPW400.201810.en
 Technical data

Channel Y oil pressure sensor

Connection example: ZDO
15-pin D-sub con-
nector, analog I/O

Channel X distance transducer

Connection example of distance potentiometer (ZWW 10 V supply voltage)
15-pin D-sub connector,
analog I/O

Connection example of distance transducer (ZKW 24 V supply voltage)

15-pin D-sub con-
nector, analog I/O

OM 100.EPW 400.201810.en 27
 Technical data

3.2.9 Built-in version: pin assignment, analog standard signals

Only hardware model EPW 400.002.1X (without DMS subprint)
Sub-D 15-pole female connector (designation analog I/O)

Pin Type Input/Out- Analog signal

put
1 i Force signal 0 - 10 V channel Y /1
3 i Ground, force signal channel Y /1
4 i Travel signal 0 - 10 V channel X /2
6 i Ground, travel signal channel X /2
7 o Analog output 1: tare +10 V
8 o Ground
13 o Analog output 2: 0 - 10 V process-bound
14 o Ground
15 o +10 V sensor supply

Note
Hardware model (2-channel) Version 22 is not provided with EPW
400.XX2.1X!

Channel Y force transducer

Connection example of sensor with standard signal 0 - 10 V (ZKN with tare)
15-pin D-sub con-
nector, analog I/O

28 OM 100.EPW400.201810.en
 Technical data

Channel Y oil pressure sensor

Connection example: ZDO
15-pin D-sub con-
nector, analog I/O

Channel X distance transducer

Connection example of distance potentiometer (ZWW 10 V supply voltage)
15-pin D-sub connector,
analog I/O

Connection example of distance transducer (ZKW 24 V supply voltage)

15-pin D-sub con-
nector, analog I/O

OM 100.EPW 400.201810.en 29
 Technical data

3.3 Overview of wall-mounted version

3.3.1 Power supply
Connection M12 connector
Pin Voltage Type Designation
1 24 V DC i 24 V supply voltage
3 0 V DC i GND supply voltage
5 PE i PE

3.3.2 Dimensions of wall-mounted version

1 Input / output 7 Supply voltage 24 V DC

2 Profibus interface (optional) 8 USB interface
3 RS232 interface (optional) 9 Ethernet interface
4 Distance transducer X1 10 Distance transducer X2 (only Ver-
sion 22)
5 Force transducer Y1 11 Force transducer Y2 (only Version
22)
6 Main switch

30 OM 100.EPW400.201810.en
 Technical data

3.3.3 Wall-mounted housing: digital inputs I0-I15 (25-pin D-sub female connector)
Pin, D-SUB OK Color code Designation
25
14 I0 White Program bit 0
15 I1 Brown Program bit 1
16 I2 Green Program bit 2
17 I3 YELLOW Program bit 3
9 I4 White-blue 3 Program bit 4
10 I5 Brown-blue3 Program bit 5
18 I6 Grey Program strobe
19 I7 White-yellow Offset external
20 I8 White-grey Start measurement
I9 Reserve
21 I10 White-pink Control panel interlock
22 I11 Brown-red3 Error reset
I12 Reserve
13 I13 White-red3 Configurable input
25 I14 3 Access level bit 1

12 0V Brown-green 0 V external (PLC)

11 0 V internal Blue 0 V internal

23 24 V inter- Pink +24 V from internal (source)
nal

3.3.4 Wall-mounted housing: digital outputs Q0-Q7 (25-pin D-sub female connector)
Pin, D-SUB OK Color code Designation
25
1 Q0 Red OK
2 Q1 Black NOK
3 Q2 Yellow- NOK alarm
brown
4 Q3 Violet Switching point S14 / Enable
5 Q4 Grey-brown Switching point S24 / NOK buzzer
6 Q5 Grey-pink Ready for measurement
7 Q6 Red-blue Program ACK
8 Q7 Pink-brown Switching point 3 4 / item quantity warning

12 0V Brown-green 0 V external (PLC)

24 24 V White-green +24 V external (PLC)

3 Must be connected later

4 Output function configurable

OM 100.EPW 400.201810.en 31
 Technical data

3.3.5 Standard wall-mounted housing: pin assignment, DMS force transducer

(channel Y)
Only hardware model EPW 400.202.0X (with DMS subprint)
Note
For hardware model EPW 400.022.0X (2-channel) the second ana-
log input card is installed for channel pair 2 X/Y!
The connections are occupied the same as for the first card.

(12-pin round socket)

The force measurement on channel Y is optionally carried out using a DMS force
transducer or a measuring sensor with standardized process signal 0 - 10 V.
Standardized measuring sensor
Auxiliary voltage: 24 V ± 5%, max. 100 mA (x = 100 mA, y = 100 mA)
Signal: 0 – 10 V

Pin assignment force signal (channel Y)

12-pin round socket

Pin Signal name Type Input/Out- Notes

put
C V+ o Supply DMS V+
B V- o Supply DMS V-
f S- DMS i Measuring signal DMS -
G S+ DMS i Measuring signal DMS +
e F- DMS o Sensor cable DMS -
d F+ DMS o Sensor cable DMS+
j Shield o Shield

k 24 V DC o Auxiliary power for external measuring sen-

sor 24 V
a 0 V DC o Earth external
L Signal + i Input standardized measuring signal
m Signal - o Measuring signal earth
h Tare Signal tare

32 OM 100.EPW400.201810.en
 Technical data

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

Connection example of DMS with sensor cable

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

24 V supply voltage

OM 100.EPW 400.201810.en 33
 Technical data

Connection example: ZDO

Pin assignment distance signal (channel X)

The pin assignment is identical in hardware models EPW400.202.0X and
EPW400.202.1X.

Note
For hardware model EPW 400.022.0X (2-channel) the second ana-
log input card is installed for channel pair 2 X/Y!
The connections are occupied the same as for the first card.

12-pin round socket

Pin Signal name Type Input/Out- Notes
put
C 10 V+ o Auxiliary power for external measuring sen-
sor 10 V
k 24 V DC o Auxiliary power for external measuring sen-
sor 24 V
m 0 V DC o Earth external

G Signal + i Input standardized measuring signal

a Signal - i Measuring signal earth

j Shield o Shield
h Analog o Analog output 0 - 10 V process-bound
e 0 V DC o Earth analog output

34 OM 100.EPW400.201810.en
 Technical data

Connection example of distance transducer potentiometer (ZWW 10 V supply volt-

age)

Connection example: distance transducer (ZKW)

OM 100.EPW 400.201810.en 35
 Technical data

3.3.6 Wall-mounted housing: pin assignment, force transducer (channel Y)

Only hardware model EPW 400.202.1X

Note
Hardware model (2-channel) Version 22 is not provided with EPW
400.XX2.1X!

(12-pin round socket)

The force measurement on channel Y is optionally carried out using a DMS force
transducer or a measuring sensor with standardized process signal 0 - 10 V.
Standardized measuring sensor
Auxiliary voltage: 24 V ± 5%, max. 100 mA (x = 100 mA, y = 100 mA)
Signal: 0 – 10 V

Pin assignment force signal (channel Y)

12-pin round socket

Pin Signal name Type Input/Out- Notes

put
C
B
f
G
e

j Shield o Shield

k 24 V DC o Auxiliary power for external measuring sen-

sor 24 V
a 0 V DC o Earth external
L Signal + i Input standardized measuring signal
m Signal - o Measuring signal earth
h Tare Signal tare

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

36 OM 100.EPW400.201810.en
 Technical data

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

24 V supply voltage

Connection example: ZDO

OM 100.EPW 400.201810.en 37
 Technical data

3.4 Interfaces

3.4.1 Profibus
According to ISO/DIS 11898, isolated
Min. max.
Output differential voltage ± 1.5 V ±5V
Input differential voltage ± 0.2 V ±5V
Input offset voltage - 7 V/+ 12 V (to GND)
Output drive current ± 55 mA (Udiff = ± 1.5 V)

Transmission speed Up to 100 m cable max. 12000 kbit

length
Up to 200 m cable max. 1500 kbit
length
Up to 400 m cable max. 500 kbit
length
Up to 1000 m cable max. 187.5 kbit
length
Up to 1200 m cable max. 93.75 kbit
length
Number of subscribers per Without repeater max. 32
segment
With repeater Max. 126 (every repeater
used reduces the max.
number of subscribers)
Connecting line Shielded, twisted Wire cross-section
Min. 0.34 mm²
Wire diameter 0.64 mm
Wave impedance 135 to 165 Ω
Capacitance per unit length < 30 pf/m
Loop resistance 110 Ω/km
Recommended cables For fixed installation of UNITRONIC® BUS L2/FIP
or
UNITRONIC® BUS L2/FIP 7-wire
For flexible installation of UNITRONIC® BUS FD P
L2/FIP
Node addresses 3 to 124

38 OM 100.EPW400.201810.en
 Technical data

Pin Profibus
3 RXD/TXD-P
4 CNTR-P (RTS)
5 0V
6 +5V
8 RXD/TXD-N

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

OM 100.EPW 400.201810.en 39
 Technical data

3.4.2 Fieldbus interface

Data length: Byte 0-2

Inputs I0-I15 Designation Field bus byte Field bus bit

I0 Program bit 0 0 0
I1 Program bit 1 0 1
I2 Program bit 2 0 2
I3 Program bit 3 0 3
I4 Program bit 4 0 4
I5 Program bit 5 0 5
I6 Program strobe 0 6
I7 Offset external 0 7
I8 Start measurement 1 0
I9 Reserve 1 1
I 10 Control panel inter- 1 2
lock
I 11 Error reserve 1 3
I 12 Reserve 1 4
I 13 Configurable input 1 5
I 14 Access level bit 1 1 6
I 15 Reserve 1 7

Outputs Q0-Q7 Designation Field bus byte Field bus bit

Q0 OK 0 0
Q1 NOK 0 1
Q2 NOK alarm 0 2
Q3 Switching point S1 5 0 3
Q4 Switching point S25 0 4
Q5 Ready for measure- 0 5
ment
Q6 Program ACK 0 6
Q7 Switching point S35 0 7

5
Output function options:
Switching point S1 / Enable
Switching point S2 / Buzzer
Switching point S3 / Warning piece counter

40 OM 100.EPW400.201810.en
 Technical data

Format of final values via fild bus (bytes 3 – 63):

The end values are written on bytes 3 to 55 on the field bus (if this function is acti-
vated).
• Byte X (structure):
7 6 5 4 3 2 1 0 Byte X
Byte 3: Status (Status 2 = OK / Status 3 = NOK)
Byte 4, 5, 6, 7: Running number
Byte 8: Program
Byte 9: Reserve
Byte 10, 11: Max. force [kN] * 100
Byte 12, 13: Max. distance [mm] * 100
Byte 14: Second
Byte 15: Minute
Byte 16: Hour
Byte 17: Day
Byte 18: Month
Byte 19: Year

Byte 20, 21: Window 1, actual force [kN] * 100 (for actual distance [mm])
Byte 22, 23: Window 1, force upper limit [kN] * 100
Byte 24, 25: Window 1, force lower limit [kN] * 100
Byte 26, 27: Window 1, actual distance [mm] * 100
Byte 28, 29: Window 1, distance upper limit [mm] * 100
Byte 30, 31: Window 1, distance lower limit [mm] * 100

Byte 32, 33: Window 2, actual force [kN] * 100 (for actual distance [mm])
Byte 35, 35: Window 2, force upper limit [kN] * 100
Byte 36, 37: Window 2, force lower limit [kN] * 100
Byte 38, 39: Window 2, actual distance [mm] * 100
Byte 40, 41: Window 2, distance upper limit [mm] * 100
Byte 42, 43: Window 2, distance lower limit [mm] * 100

Byte 44, 45: Window 3, actual force [kN] * 100 (for actual distance [mm])
Byte 46, 47: Window 3, force upper limit [kN] * 100
Byte 48, 49: Window 3, force lower limit [kN] * 100
Byte 50, 51: Window 3, actual distance [mm] * 100
Byte 52, 53: Window 3, distance upper limit [mm] * 100
Byte 54, 55: Window 3, distance lower limit [mm] * 100

Byte 56, 57: Actual value force [kN] * 100

Byte 58, 59: Actual value distance [mm] * 100
Byte 60 - 63: Reserve

OM 100.EPW 400.201810.en 41
 Technical data

The actual distance [mm] of the respective window is determined as follows:

The actual distance [mm] is exactly in the centre of the window in X-direction.
Example:
The window extends from 8.00 mm to 11.60 mm => actual distance [mm] = 9.80 mm.
The actual force [kN] is the point where the measurement curve intersects the actual
distance [mm].

Force [kN]
8.00 mm
11.60

Actual force
[mm]

Actual distance [mm] Distance

[mm]

42 OM 100.EPW400.201810.en
 Transport

4 Transport

4.1 Storage
• Cover the electrical connections to protect them from dust, e.g. with adhesive tape.
• Protect the display against sharp-edged objects. If necessary, attach a suitable
protective cover (e.g. made of cardboard or hard foam).
• Use a dry, ventilated room for storage.
• Enwrap the device (e.g. with a plastic bag).
• In case of high humidity: add a drying agent to the packaging (e.g. silica gel).
4.2 Transport
• Protective measures: as described in chapter Storage.
• Packaging:
− Use a stable transport container for dispatch that has all-round interior pad-
ding.
− Ensure that there is sufficient distance to the walls of the transport container.
− Fix the device securely inside the transport container.
• Accompanying documents (see chapter Dispatch for repair, p. 43)
4.3 Dispatch for repair
If you send the device for repair to the manufacturer's works or to an appropriate
technical service provider, please include the following notes so that we can return
the device to you as quickly as possible:
• A detailed, precise description of the fault (however, while keywords are sufficient,
the brief note 'device is defective' helps very little); if the malfunction is unclear,
include also a brief description of the operating conditions and installations (up-
stream devices, etc.).
• The name of our employee who is informed about the defect or with whom you
have agreed to send the device to the manufacturer.
• The name of the contact person in your company for possible queries.
Please also include information even if the matter has already been discussed in detail
with one of our employees.

OM 100.EPW 400.201810.en 43
 Operating the device

5 Operating the device

5.1 Switching on the EPW 400

After it has been switched on, the device displays the start screen:

Once Windows CE and the necessary applications have loaded, the device will show
the main menu (graphical display of measured values).

5.2 Operating the device via touch screen

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

44 OM 100.EPW400.201810.en
 Operating the device

5.3 Main menu 'Measuring'

During measuring operation, the measuring display appears. The measurement

curve, the configured windows and the envelopes are displayed in graph form. The
selected zoom area displays the plotted force/travel area.
In the upper status bar, the current process number is faded in. The second line dis-
plays the Wnumber assigned to the process and the EPW 400 process name. The
third status bar provides an additional numerical display of the measured values for
max. force [kN] and max. distance [mm].
An error is indicated by a red bar, a message by a yellow bar.
5.3.1 Buttons (from left to right)
Zoom Changes the display detail

Measure curves Accessories for curve measuring

Edit windows Opens the menu 'Edit window'

Edit envelope Opens the menu 'Edit envelope curve'

OM 100.EPW 400.201810.en 45
 Operating the device

Menu Opens the 'Maintenance' menu

Error reset Resets an error. This button appears only in

case of an error.

Firmware version Reads the firmware version.

5.3.2 Icons
Measure OK The last measurement was OK

Measurement NOK Last measurement was not OK. At least one

evaluation criterion was violated (envelope /
window)
Measure active Measurement is running, values are being rec-
orded.

Measurement Measurement stopped by clicking on symbol

stopped manually 'Measurement OK', 'Measurement NOK', or
'Measurement running'. Enable the measure-
ment by clicking on symbol 'Measurement
stopped'.
Device ready to EPW 400 is ready to start a measurement.
measure

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

measure

Fault Device signals an error. The exact cause of the

error is highlighted in red at the top of the
screen.
Ethernet interface Connection via Ethernet to a PC not yet possi-
not initialized ble.

Ethernet interface ini- Connection via Ethernet to a PC realized

tialized

No USB stick in- No USB stick found

serted

USB stick inserted USB stick detected

46 OM 100.EPW400.201810.en
 Operating the device

5.3.3 Full screen display:

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

OM 100.EPW 400.201810.en 47
 Operating the device

5.4 Menu 'Zoom'

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

5.4.1 Buttons (from left to right)

Save user zoom Saves the current setting as a user zoom

Restore user zoom Opens the saved user zoom

Cancel zoom Sets the maximum zoom area (fixed by the

nominal load of the sensors)

Enter Takes over the set zoom area and returns to the
main menu

Undo Goes back to the previous zoom view; this but-

ton appears when a change is made to the
zoom setting.

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

48 OM 100.EPW400.201810.en
 Operating the device

A window with a numerical tap field will be displayed:

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

OM 100.EPW 400.201810.en 49
 Operating the device

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

As soon as a purple frame becomes visible,

the <Zoom in frame> button appears for zooming in the selected frame;

When a change is made to the zoom setting, an 'Undo' button appears,

which will take you back to the previous zoom view.

50 OM 100.EPW400.201810.en
 Operating the device

5.5 Menu 'Gauge curve'

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

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

OM 100.EPW 400.201810.en 51
 Operating the device

5.6 Menu 'Windows'

The evaluation windows are changed, created or deleted in this menu.
The settings in this menu apply to the currently selected process (e.g.,
process 3).

The process can be changed either by means of an external PLC or in the "Processes"
menu (see page 63). A process may include up to 10 windows, with window 0 always
being an online window; this window is monitored during measuring. As soon as a
violation is identified, a signal is forwarded to the PLC in real time so that action can
be taken
(e.g. if a press comes down at an angle or there is a premature step-up in force, it will
be opened immediately).
Only one window is selected each time and is recognizable by 'Text field selected
window' or by the yellow window number. A window is selected by tapping on 'Text
field selected window' followed by the input of the window number or by tapping the
window to be selected in the diagram. Four text fields show the dimensions of the
selected window.

52 OM 100.EPW400.201810.en
 Operating the device

5.6.1 Edit window type

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

Online window Window '0'

Three window types are available for online window Window '0' which cannot be
changed:
• Online Window TYPE A:

• Online Window TYPE B:

• Online Window TYPE C:

OM 100.EPW 400.201810.en 53
 Operating the device

Window '1' to Window '10':

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

Absolute The selected window remains in the absolute position

Max. X The selected window is positioned with reference to the maximum
value reached (max. X)
Mean value The selected window is positioned with reference to the last speci-
X fied OK curves stored (mean value X)

54 OM 100.EPW400.201810.en
 Operating the device

Window 'Max. X'

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

OM 100.EPW 400.201810.en 55
 Operating the device

Window 'Mean value X'

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

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

56 OM 100.EPW400.201810.en
 Operating the device

The 'Dustbin' button deletes the selected window.

You can change the size of a window

− By entering the required values in the text fields or

− By marking one side and tapping on the 'arrow buttons'
Arrow buttons

Move the highlighted side Move the highlighted side

to the left or the right up or down

Move window button

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

OM 100.EPW 400.201810.en 57
 Operating the device

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

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

'Accept window' button

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

58 OM 100.EPW400.201810.en
 Operating the device

5.7 Menu 'Envelope curve'

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

Copy envelope Copies the lower entered envelope curve pa-

curve parameters rameters to the upper ones or the upper ones
to the lower ones. Depending on what was
taught first.
Change mode Switches the envelope mode between 'Evalu-
ation', 'Teach' and 'Teach new'

Teach-in on request Specifies whether a curve is taught after con-

firmation by the user or automatically after
each measurement.

Switch envelope Switches the monitoring system on or off via

function on/off the envelope. The set envelope parameters
remain unchanged.

Teach additional Here a NOK curve can be taught. This button

curve only appears after a NOK evaluation of the
last curve and a violation of the envelope.
Apply inputs, return The inputs are adopted and the main menu is
to main menu called up.

OM 100.EPW 400.201810.en 59
 Operating the device

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

Upper envelope

Lower envelope

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

60 OM 100.EPW400.201810.en
 Operating the device

5.7.1 Text fields

SY: Force value by which the selected envelope (upper or lower) is
moved vertically in relation to the corresponding envelope
curve.
End Y: Upper limit of the envelope.
Begin Y: Lower limit of the envelope.
Upper / lower: Choice of whether the parameter applies to the upper or lower
envelope.
SX: Distance value by which the selected envelope (upper or lower)
is moved horizontally in relation to the corresponding envelope
curve.
Begin X: Left-hand limit of the envelope.
End X: Right-hand limit of the envelope.

SX

SY

To teach an envelope, proceed as follows:

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

OM 100.EPW 400.201810.en 61
 Operating the device

 Tap on 'Begin Y' to set the value to '0'.

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

62 OM 100.EPW400.201810.en
 Configuring the EPW 400

6 Configuring the EPW 400

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

6.1 Processes
− Select process number (e.g. 5)
− Allocate a name to the process (40 characters max., e.g. process
5)
− Copy processes

Wnumber

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

OM 100.EPW 400.201810.en 63
 Configuring the EPW 400

6.1.1 Select process number (64 processes)

− The process number can be selected using the arrows  and .
− The process number can be accessed by numerical input:
Tap the Process No. input field.
A window containing a numerical keypad will open.
 Enter the required process number and confirm this value with the 'Enter' button.
6.1.2 Assign process name (max. 40 characters)
You can assign a name to each process. Tap on Process Name, and a window will
open with an alphanumeric keypad for entering the name:

By pressing the shift key  you can switch to

− capital letters
− lowercase letters
− numbers and special characters
 The entry is adopted using the 'Enter' button.
 You can also enter a number containing up to ten digits for each process (T num-
ber). Tap on the number and a window will open with a numerical keypad, which
can be used to enter the number.

64 OM 100.EPW400.201810.en
 Configuring the EPW 400

6.1.3 Copy processes

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

By tapping the input fields behind 'from process' and 'to process', the input window
with the numerical keypad will be opened for the direct input of the numbers of the
processes.
You can specify which process parameters to copy from the current process. Tapping
the input fields next to the parameter designations selects (marked by "X") or dese-
lects (empty field) the individual parameters.
In order to copy the selected parameters to one or to several consecutive processes,
tap on the input field behind 'from process'. This opens the input window with the
numerical keypad. Enter the number of the first process and confirm by pressing
'Enter'. Then tap on the input field behind 'until process'. In the input window with the
numerical keypad, enter the number of the last process. A sequence in which process
0 follows process 63 is not allowed.

Attention
When copying data to all or some processes, the previous settings
for these processes will be lost!

 Tap on 'Copy' to start the copying process. Tapping on the "Cancel" button will
cancel the process.

OM 100.EPW 400.201810.en 65
 Configuring the EPW 400

6.1.4 Settings
Here the settings for the processes can be made.

When the "Increment process number after measurement' field is acti-

vated, the process number is increased by one (authorization level 1
only). This means that the process is changed over to the next process.

By tapping the input fields behind 'Pmin' and 'Pmax', the input window with the nu-
merical keypad will be opened.
1 In field 'Pmin' enter the start process number the counter is to adopt as starting
point.
2 In field 'Pmax' enter the end process number up to which the counter is to increase
the process number.
When the "Increment P-number after measurement' field is activated,
the Wnumber is increased by one (authorization level 1 only).

By tapping the input field in front of 'Password level to switch processes', the input
window with the numerical keypad will be opened. Here the authorization level can be
set that is necessary for the process changeover (authorization level 3 only).

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6.1.5 Saving / restoring parameters

Actuating button 'Save / restore parameters', opens the submenu for
copying all parameters and processes from the USB stick.

Copy parameters to USB stick

Tapping on the 'Save Parameters on USB Stick' copies all parameters
and processes to the USB stick.

Load parameters from USB stick

Tapping on 'Load Parameters from USB Stick' copies all parameters
and processes from the USB stick.

Data will be overwritten

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

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

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6.2.1 Force sensor, channel Y

In the opened window it is possible to fix the parameters of the force sensor separately
for each process. The setting of the current process can be copied to other processes.
EPW 400.X02.X EPW 400.X02.0: DMS hardware version

6.2.2 Nominal force of the force sensor (Nominal load) Version 22

In the opened window it is possible to select the parameters of the force sensor sep-
arately for each channel pair (measuring board). The setting of the current process
can be copied to other processes.
EPW 400.X02.X EPW 400.X02.0: DMS hardware version

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6.2.3 Nominal force of the force sensor (Nominal load)

In this line, you can set the nominal force of the used force sensor. The nominal force
is specified in kN. The nominal force is achieved at the max. measuring signal of the
force transducer. For a standard signal of 0-10 V, the nominal force is 10 V.
 Tap on the input field after 'Nominal force'. The input window containing the nu-
merical keypad appears.
 Enter the nominal force using the numerical keypad (enter a point before decimal
places; if no decimal places are entered, then the display shows two decimal
places '.00').
 Confirm the entry with the 'ENTER' button.
 By tapping on the measurement unit, a window with an alphanumerical keypad
appears. You may enter four characters for the measurement unit.
6.2.4 Offset force sensor
In this line you can enter the offset value of the measuring signal in kN.
The 'Offset' parameter adjusts a possible zero point displacement of the analog meas-
urement signal of the sensor.
 Tap on the input field behind 'Offset'. The input window containing the numerical
keypad appears.
 Enter the offset value using the numerical keypad (enter a point before decimal
places; if no decimal places are entered, then the display shows two decimal
places '.00').
 Confirm the entry with the 'ENTER' button.
6.2.5 Force sensor offset adjustment
By tapping on the 'offset adjustment' button, the actual analog measur-
ing signal of the transmitter is taken as offset.

An offset adjustment is always necessary after changing or adding a force transducer.

Make sure the force transducer is not loaded during the adjustment.

Note
Generally, an offset adjustment should be carried out at least once a
day or after about 1000 measurements

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6.2.6 Offset limit force sensor

The offset limit is used set the maximum tolerated offset to 10%, 20% or 100% of the
nominal force.
Offset adjustment for sensor with normal signal output:

− TOX® standard sensor: 10% (20% possible for compensation)

 By tapping on the input field behind 'Offset limit', the value of the offset limit can
be changed between '10', '20' and '100'. The value displayed last will be adopted.
6.2.7 Forced offset force sensor
If the 'Forced offset' function is activated, the EPW 400 carries out an offset adjust-
ment for the respective channel automatically every time it is switched on. If this func-
tion is not activated, the EPW 400 is ready to measure as soon as it is switched on.
 Tap on the input field next to 'Forced offset' to switch the forced offset on or off.
The last setting displayed will be adopted.
6.2.8 Source force sensor
By tapping on the input field behind 'Source', you can switch between normal signal
and DMS. The last source displayed will be adopted.
If DMS is activated, an additional parameter 'Character number' is displayed.
6.2.9 Nominal characteristic value of force sensor
The characteristic for the DMS force transducer is entered using the 'Characteristic
number' parameter.
Value range: 0.1 – 8 mV/V
 Tap on the input field next to 'Characteristic number'. The input window containing
the numerical keypad appears.
 Enter the characteristic number using the numerical keypad (enter a point before
decimal places; if no decimal places are entered, then the display shows two dec-
imal places '.00').
 Confirm the entry with the 'ENTER' button.

Bridge supply voltage

The bridge supply voltage is 5 V.

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

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6.2.11 Force sensor calibration

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

6.2.12 Force 1
To teach, click on button 'Teach'.
Read in the current electric measuring signal.

Tap on the 'Force 1' input field.

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

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6.2.13 Force 2
To teach, click on button 'Teach'.
Read in the current electric measuring signal.

Tap on the 'Force 2' input field.

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

Accept calibration

Close the window 'Enter nominal force' by tapping on button 'Accept

calibration'. The configuration will be adopted.

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6.2.14 Distance sensor

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

6.2.15 Distance sensor Version 22

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

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6.2.16 Nominal distance of the distance sensor (nominal load)

In this line you can set the nominal distance for the distance transducer used. The
nominal distance is specified in mm. The nominal distance is achieved at the maxi-
mum measuring signal (10 V) of the distance transducer. In the above example, the
sensor has an output voltage of 10 V for a distance of 50 mm.
 Tap on the input field behind 'Nominal distance'. The input window containing the
numerical keypad appears.
 Enter the nominal distance using the numerical keypad (enter a point before dec-
imal places; if no decimal places are entered, then the display shows two decimal
places '.00').
 Confirm the entry with the 'ENTER' button.
 By tapping on the measurement unit, a window with an alphanumerical keypad
appears. You may enter 4 characters for the measurement unit.
 When using a resistance potentiometer, you must enter the potentiometer re-
sistance in kΩ (as per data sheet) in order to optimize the linearity of the measuring
chain.
6.2.17 Distance sensor offset
In this line the offset value of the measurement signal is entered in mm.
The 'Offset' parameter adjusts a possible zero point displacement of the analog meas-
urement signal of the sensor.
 Tap on the input field behind 'Offset'. The input window containing the numerical
keypad appears.
 Enter the offset value using the numerical keypad (enter a point before decimal
places; if no decimal places are entered, then the display shows two decimal
places '.00').
 Confirm the entry with the 'ENTER' button.
6.2.18 Offset adjustment of distance sensor
By tapping on the 'offset adjustment' button, the actual analog measur-
ing signal of the transmitter is taken as offset.

An offset adjustment is always necessary after changing or adding a distance trans-

ducer. Make sure the distance transducer is not loaded during the alignment.

Note
Generally, an offset adjustment should be carried out at least once a
day or after about 1000 measurements

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6.2.19 Offset limit of distance sensor

The offset limit is used set the maximum tolerated offset to 10%, 20% or 100% of the
nominal distance.
Offset adjustment for sensor with normal signal output:
TOX® standard sensor: 10% (20% possible for compensation)
 By tapping on the input field behind 'Offset limit', the value of the offset limit can
be changed between '10', '20' and '100'. The value displayed last will be adopted.

6.2.20 Forced offset of distance sensor

If the "Forced offset" function is activated, the EPW 400 carries out an offset adjust-
ment for the respective channel automatically every time it is switched on. If this func-
tion is not activated, the EPW 400 is ready to measure as soon as it is switched on.
 Tap on the input field next to 'Forced offset' to switch the forced offset on or off.
The last setting displayed will be adopted.
6.2.21 Filter
With the parameter 'Filter' the cutoff frequency of the measuring channel can be set.
Value range: 5 Hz - 1000 Hz

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6.2.22 Distance sensor calibration

Calibration:
This function is used to specify the allocation of the electric measuring
signal and of the measuring variable to be displayed. This is a pure two-
point calibration.

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

 Tap on the 'Distance 1' input field.

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

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

 Tap on the 'Distance 2' input field.

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

Accept calibration

Close the window 'Enter nominal force' by tapping on button 'Accept

calibration'. The configuration will be adopted.

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6.2.23 Measuring parameters

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

6.2.24 Measured data acquisition (measuring parameters)

The mode for measuring data acquisition is always set for the process currently acti-
vated only. For opening the submenu 'Measuring data acquisition' tap on button
'Meas. parameters':

In the top line, you can switch between the following four options by tapping on the
text:

− Distance rising
− Distance rising or falling
− Force or distance change
− Time-triggered

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6.2.25 Distance rising

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

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6.2.29 Insert max. force at the end of the curve

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

Maximum sampling rate

The maximum sampling rate is usually 2000 Hz.

6.2.30 Start/stop condition

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

In the top line you may select among the following options by tapping on the entry:

− Distance-triggered
− Force-triggered
− Start/stop from PLC
6.2.31 Distance-triggered
A measurement is started as soon as the distance set at 'Start' is exceeded, and
stopped as soon as the distance set at 'Stop' is not reached. With option 'Set force to
zero at start' it is enforced that at the moment of exceeding the start threshold, the
actual force is used as offset for measurement.

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

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

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Note: Firmware version EPW 400

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

6.2.35 Configuration I/O

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

Selection Function
Output 3: Switching point 1 Refer to switching points
Release Change condition at NOK or reset
Output 4: Switching point 2 Refer to switching points
NOK buzzer Change switching state if NOK,
For activation see 'Evaluation options'
Output 7: Switching point 3 Refer to switching points
Warning piece Change of the switching condition when
counter reaching the taught-in number in the order
counter, view counter or tool counter.
Input 13: TDC sensor For activation see 'Evaluation options'
Authorization bit 0 After activation, the user level can be se-
lected from a control system.
Reset For activation see 'Evaluation options'

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

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

Close the window 'Configuration I/O' by tapping on the button 'Accept'.

The configuration will be adopted.

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6.2.36 Configuring the analog outputs

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

here.

Selection Function
Output 0: Actual distance Outputs the actual value of the distance
value [V] sensor
Actual force value Outputs the actual value of the force sen-
[V] sor
Tare signal Outputs a tare signal
Deactivated Output 0 is deactivated
Output 1: Actual distance Outputs the actual value of the distance
value [V] sensor
Actual force value Outputs the actual value of the force sen-
[V] sor
Process-dependent Outputs a predefined voltage which is set
value in the 'Switching points' menu
Deactivated Output 1 is deactivated

Close the 'Configure analog outputs' window by tapping on the "Accept"

button. The configuration will be adopted.

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6.2.37 Valuation options

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

The corresponding function is activated (X) or deactivated by tapping on the input

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

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6.2.42 Apply configuration

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

 Tap on the corresponding button in order to adopt the entry for the activated pro-
cess, for all 64 processes or for several consecutive processes.

Attention:
When copying data to all or some processes, the previous settings
for these processes will be lost!

To copy the values to several consecutive processes, tap on the input field behind
'from process'. The input window containing the numerical keypad appears. Enter the
number of the first process and confirm by pressing 'Enter'. Then tap on the input field
behind 'until process'. In the input window with the numerical keypad, enter the num-
ber of the last process and confirm by pressing "Enter".

Attention:
A sequence in which process 0 follows process 63 is not allowed.

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

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

6.3.1 Curve data

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

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

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

This button saves the recorded curves to a connected USB stick as a

CSV file. Depending on the size of the recorded curves, up to 100
curves are saved and copied on the USB stick. The name of the EPW
400 device as well as date and time will be used as name of the data
file. The data can be found on the USB stick in the "Tox\Archive" folder.

Close the 'Curve data' menu by tapping on 'Exit'.

6.3.2 Final values

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

After each measurement, a dataset of final values is stored. This dataset includes the
following information:
No. Number of the measurement. 1000 final values are stored in a circu-
lar buffer, i.e. with each new measurement, the oldest dataset (= no.
999) is discarded and the newest is added (last measurement = no.
0)
Run. no. Indicates a unique running number that increases by one after each
measurement
Prog. Assignment of the measurement to a program
Status State no. '2': Measurement OK (green background)
State no. '3': Measurement NOK (red background)
State no. – 4 = error number (see chapter 9 'Error messages')
Example: state no. '9': 9 – 4 = 5 => online window violated
Force maximum force
Distance Maximum distance
Date Date of measurement (dd.mm.yy)
Time Time of measurement (hh:mm:ss)
W1 F_in Force entry in window 1

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W1 D_in Distance entry in window 1

W1 F_out Force exit in window 1
W1 D_out Distance exit in window 1
W1 F_mid Force average in window 1
You can scroll upwards, downwards, right and left using the arrow keys , ,  and
.
Close the 'Curve data' menu by tapping on 'Exit'.

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

Additional display of sampling rate and valuation time in ms (authoriza-

tion level 3 only).

This button saves the recorded curves to a connected USB stick as a

CSV file. The last 1000 end value data sets will be saved and then cop-
ied to the USB stick. The name of the EPW 400 device as well as date
and time will be used as name of the data file. The data can be found
on the USB stick in the "Tox\Archive" folder.

6.3.3 Settings

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

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6.3.4 Settings for data export to PC

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

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6.4 Lot size

Three independent counters are available in the EPW 400:

Job counter Counts the OK/total parts of an order in progress

Shift counter Counts the OK/total parts of a shift
Tool counter Counts the total parts that have been processed with the cur-
rent tool set.

6.4.1 Job counter

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

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

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Close the 'Job counter' window by tapping on the 'Accept' button. The
displayed values will be adopted.

6.4.2 Shift counter

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

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

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6.4.3 Tool counter

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

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

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 Configuring the EPW 400

6.5 Diagram settings

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

The number of last curves that can be displayed on the touch screen is increased or
decreased using the  und  arrows.
The corresponding function is activated (X) or deactivated by tapping on the checkbox
(up to the last nine curves can be displayed):
• Redraw view after changing process:
After a process change (program change) the measuring display will be newly drawn,
e.g. process-depending Zoom settings become active.
The 'Redraw view after changing process' function will briefly interrupt the machine's
readiness to measure, until the display is updated (approx. 100 ms). If the measure-
ment shall be started immediately after the program change, this function must be
deactivated. The display will then be updated after the measurement.
If the Function 'draw curve online while measurement is running' is activated, a meas-
urement must not be started before the display is updated completely. That is why the
PLC has to request the signal 'Acknowledge process change'.
• Draw curve online while measurement is in progress:
If the curve is drawn on the measurement display during measurement, the optimum
sampling rate will be reduced to approx. 200 Hz because of the system load.
This function may be used for set-up operations or for lever presses.
Close the 'Diagram settings' window by tapping the 'Accept' button. The
number of curves displayed on the input field will be adopted.

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 Configuring the EPW 400

6.6 Supplemnt
In this menu you reach the following submenus by tapping on the corre-
sponding entry:

User administration Manage authorization levels / password

Language Change the language version
Communication parame- PC interface, field bus parameters
ters
In-/Outputs Current status of digital inputs/outputs
Date/Time Display of current time and date
Device name Enter a designation for the EPW 400

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 Configuring the EPW 400

6.6.1 User administration

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

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

 Press the 'Log on' button in the icon bar.

 In the 'Log on' dialog box, enter the password for the highest access level available
to you:

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 Configuring the EPW 400

Default setting: Authorization level 1: TOX

Authorization level 2: TOX2
Authorization level 3: TOX3
Note: the system is case-sensitive!
 Confirm the password with the 'Enter' button.

Log off when inactive

Log off takes place automatically after 10 minutes of inactivity.

Close the 'User administration' menu by tapping on button 'Exit'. The

level selected last will be adopted.

Change password
Pay attention to the authorization level
The change of password will take effect only in the authorization
level in which you are logged on. To change the passwords of the
other authorization levels you have to log on to those levels and
change the password there.

 Tap in menu 'User administration' on item 'change password'.

 First enter the correct combination of figures from the former password with the
help of the keypad window and confirm the entry with 'OK'.
Incorrect entry of a password is indicated by a corresponding message; press the
'Cancel' button to return to the "Extras" menu.
If the input of the password is correct, the window 'New password:' appears
 Use the keypad window to enter the new password and confirm by pressing "OK".
 In the next window, you will need to re-enter the new password as a check. To
apply the new password, close this dialog box by pressing 'OK'.
The message 'Password changed' is displayed.

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 Configuring the EPW 400

6.6.1.2 Access administration via digital inputs

The access level can also be pre-selected via the digital inputs.
For this purpose, Input 13 must be set to 'Authorization Bit 0' (see chapter Configura-
tion I/O, p. 83)
The access level is then pre-selected with inputs 13 and 14.

Input Status Input Status Access level

I13 1 I14 0 Level 1
I13 0 I14 1 Level 2
I13 1 I14 1 Level 3

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 Configuring the EPW 400

6.6.2 Language
In this submenu, you can change the current language. Select your preferred lan-
guage.
To open this window, tap on the 'Language' button in the 'Supplement'
menu.
Tap on the appropriate button to switch to the new language.

Close this window by tapping on the 'Accept' button. The language se-
lected last will be adopted.
6.6.3 Communication parameters
In this menu, the settings for the PC interface (field bus, Ethernet) are
made

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

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 Configuring the EPW 400

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

Restart required following the change

After changing the IP address, you must restart the device!

Tap the desired input field to enter an address using the numerical keypad. The entry
is adopted using the 'Enter' button.
IP address will be automatically obtained from a DHCP server (requires
access level 2).

Close this window by tapping on the 'Accept' button. The displayed pa-
rameters will be adopted.

6.6.5 Remote access

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

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 Configuring the EPW 400

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

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

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 Configuring the EPW 400

6.6.7 Internal digital I/O

An activated input/output is marked by a green rectangle, a deselected input/output
is marked by a red rectangle. The function of the occupied inputs and outputs is de-
scribed in clear text.

Inputs: The status of the digital inputs on the EPW 400 is displayed.
Outputs: The outputs to which a signal is currently being emitted by the
EPW 400 are displayed.

 By tipping on the button of the corresponding output, the output is activated or

deactivated. The color of the rectangle will correspondingly change.
Changes are applied without further confirmation. The changes remain effective until
the 'Inputs/outputs' submenu is exited.
Using the arrow keys you may change between byte 0 and
byte 1.

To close the window, tap the 'Exit' button.

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 Configuring the EPW 400

6.6.8 Field bus parameters

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

6.6.9 Profibus address (only for Profibus version)

 The arrows  and  can be used to decrease or increase the Profibus address
by a value of 1 each time.
 When tapping on the input field between the arrows, you can change the number
of the Profibus address with the help of the numerical keypad.

Note:
After changing the Profibus address, a new start of the device is re-
quired!

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 Configuring the EPW 400

6.6.10 Read inputs to Anybus-S module

Activation of the device via field bus

Activation of the device via digital inputs/outputs.

 For changeover, tap on the input field next to 'read inputs from anybus module'.

6.6.11 Log final values on field bus

The final values will be output to the field bus interface

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

6.6.12 Write actual values

When this checkbox is activated, the measured values of force and distance are con-
tinuously output on the field bus.
6.6.13 Read DMC code
This field can be used to specify that the data matrix code is to be read via field bus.
The data matrix code is a piece part designation with a max. of 56 characters.
The character 0 (0x00) applies as the end of the string for less than 56 char-
acters.
There are options that the string is read with the start of measurement, here it
must be applied to the bus before the start of measurement, or at the end of
measurement, here it must be applied before the end of measurement.
6.6.14 Number of IO bytes
With this field the number of I/O bytes configured on the bus are specified. A maximum
of 64 bytes for inputs and outputs is possible.
The value refers each to the inputs and outputs, while the number of inputs and out-
puts is always equal. The value 16 would therefore activate 16 input bytes and 16
output bytes on the bus. The functions on input and output bytes 17 - 63 could there-
fore not be reached.

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 Configuring the EPW 400

6.6.15 Profibus / Anybus

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

Inputs: The status of the field bus inputs on the EPW 400 is displayed. A
change of the inputs is only possible via field bus.
Outputs: The field bus outputs to which a signal is currently being emitted
by the EPW 400 are displayed.

 By tapping on the button of the corresponding output, the output is activated or

deactivated. The color of the rectangle will correspondingly change.
Changes are applied without further confirmation. The changes remain effective until
the 'Inputs/outputs' submenu is exited.
To close the window, tap the 'Exit' button.

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 Configuring the EPW 400

6.6.16 Analog inputs

In this window the analog measured values are displayed.

Version 22:
The corresponding value is displayed here depending on which
measuring board is selected or set.

To close the window, tap the 'Exit' button.

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 Configuring the EPW 400

6.6.17 Date/Time
In this menu the current time as well as the date are displayed.

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

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 Configuring the EPW 400

6.6.18 Device name

Here a name for the EPW 400 can be allocated.

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

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 PLC interface pulse diagrams

7 PLC interface pulse diagrams

7.1 Start/Stop
OK
NOK
NOK alarm
Switching
point SP1
Switching
point SP2
Ready for
measurement
Start meas-
urement

1
Output OK or NOK is set dependent on the measured result.
Delay time after start = 0 - 10 ms
2
Output NOK_alarm is set dependent on the measured result in the online win-
dow.
3
Start of measuring operation with start signal and any additional start/stop
condition
X History of last measurement

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

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 PLC interface pulse diagrams

7.1.1 Changing the program number

Program bit 0-5
Program strobe
Program ACK

1
Delay time Strobe / Ack: min 10 ms, max. 20 ms
2
New program number applied and data read, max. 100 ms

X History

I5 I4 I3 I2 I1 I0 Program
0 0 0 0 0 0 0
0 0 0 0 0 1 1
0 0 0 0 1 0 2
0 0 0 0 1 1 3
0 0 0 1 0 0 4

1 1 1 1 0 0 60
1 1 1 1 0 1 61
1 1 1 1 1 0 62
1 1 1 1 1 1 63

7.1.2 Zero point adjustment

Program bit 01 Channel X = 0 / Channel Y = 1
Offset external
Program strobe1
Program ACK2
Ready for meas-
urement

1
Delay time Strobe / Ack: min 10 ms, max. 20 ms
2
Duration of zero point adjustment: max. 4 sec
 Program bit0 = Zero point adjustment either for channel X or channel Y
Program bit0 = 0: X-channel
Program bit0 = 1: Y-channel
 Program bit1: If program bit 1 is set, zero point adjustment will take place simulta-
neously for channel X and channel Y

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 Software module TOX®softWare

8 Software module TOX®softWare

• Display and filing of measuring values

• Processing and filing of device configurations
• Offline - setup of device configurations
Please observe the comprehensive separate operating manuals for TOX®softWare
WORX and the EPW 400 software module.

8.1 Networking via Ethernet

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

8.2 Network server program EPW 400_Server

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

112 OM 100.EPW400.201810.en
 Error messages

9 Error messages

Error number Error message

0 No error
4 Started, not ready to measure
5 Online window violated
6 OK job counter limit reached
7 Total job counter limit reached
8 OK shift counter limit reached
9 Total shift counter limit reached
10 Tool counter limit reached
11 Error transmit online window
12 piece part NOK
13 TDC sensor not left
14 No measurement started
22 Measuring buffer full
23 Offset limit force sensor exceeded
24 Offset limit distance exceeded

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 Firmware update

10 Firmware update

10.1 Update from version V1.08

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

Example: LW 'USB_128k (D:) Tox

 Unzip the files you have received from TOX® PRESSOTECHNIK into the 'TOX'
folder.
 Connect the USB stick to the EPW 400
The 'USB stick' icon should now be highlighted in green
(within about 5 s).
This icon appears in the main menu (see chapter 5.3 'Main menu 'Meas-
uring'')

In the main menu, click on the button with the version number.

Click on button 'firmware update'

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 Firmware update

 Click on button 'Yes' to install the update. After the update, the following message
will appear:

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 Decommissioning

11 Decommissioning

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

Environmental protection
When disposing of the battery, the worn and spare parts, and the
pressing monitor and its accessories, the national regulations on
environmental protection currently in force must be observed.

 The batteries and accumulators must not be disposed of in the

normal household waste.
 The batteries and accumulators must only be disposed of at an
approved collection site.

Disposal
Dispose of the packaging sorted according to type.
Use the local options for the collection of paper and cardboard.

Disposal
Old electronic devices must not be disposed of in the household
waste.
Dispose of the old pressing monitor at the nearest electronic dis-
posal site or contact TOX® PRESSOTECHNIK.

The labels on the product, accessories and in the associated documentation specify
that the product and accessories (e.g. power supply units, USB cables) must not be
disposed of in the normal household waste at the end of their service life. Please
dispose of this device and its accessories separated from other waste, to prevent the
environment and human health from being damaged due to the uncontrolled disposal
of waste.
With recycling, the re-use of materials, or other forms of recycling of old devices and
accumulators, you make an important contribution to the protection of the environ-
ment.

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