Overview

The AMS 2 / Elgo sensor system by Fiessler Elektronik is a safety-critical component integrated into the AKAS Muting System for press machines. It provides safety muting signals compliant with safety class 4 and monitors the press ram's speed, traverse, and direction during closing and opening strokes to ensure safe operation.

Functionality

• Measures speed, traverse, and direction of the press ram movement.
• Performs overrun traverse control during the first stroke to verify safe operation.
• Designed for retrofitting older presses lacking work speed valves or position monitoring.
• Utilizes incremental magnetic metal tapes mounted on the moving press part, scanned by magnetic sensors.

Installation and Mounting

• AMS switchgear must be installed inside an IP54-rated switch cabinet.
• Magnetic tapes are mounted vertically on the ram or bottom platen, with length equal to maximum stroke plus 40 mm (20 mm reserve each end).
• Magnetic sensors are mounted vertically on the machine mount, directly above the tape with a maximum 2 mm gap.
• Sensors are fixed using two M3 screws in 3.4 mm clearance holes.
• Adhesive side of magnetic tape faces the ram; surfaces must be clean, dry, and contaminant-free for optimal adhesion.
• Protect magnetic tapes with covering profiles or self-adhesive steel tape to prevent mechanical damage.
• Avoid magnetic fields from clamps or permanent magnets near tapes to prevent interference.

Electrical Connection

• Sensor wiring color code: Brown = +24 V DC, White = 0 V, Green = channel A, Yellow = channel B.
• If sensor cable outlet is on the top edge, channels A and B must be swapped.
• Sensor cables must be connected to equipotential bonding with low impedance and routed separately from high-voltage lines to avoid interference.
• AMS shares the same supply voltage as the N1 K Muting switchgear and is inactive if AKAS is disconnected.
• No built-in protection against incorrect connections or short circuits; outputs are not short-circuit protected.
• Cables must be arranged to prevent mechanical damage and avoid short circuits, especially between start button wires and 5 V or 24 V lines.

Operation and Indicators

• Red LED indicates power on.
• Green LED off indicates unknown or excessive overrun traverse measurement.
• Green LED on indicates acceptable overrun traverse measurement.
• Green LED flashing (AMS2) indicates ongoing overrun traverse measurement or an error condition.
• If error persists after voltage reset, sensor connections should be checked.

Safety and Maintenance Recommendations

• Remove terminal strips during welding to prevent damage from stray currents.
• Valve spools must include spark quenching elements.
• Turn off supply voltage before disconnecting terminal strips.
• Ensure proper connection of the muting lamp (230 V AC).
• Follow recommended cable routing and separation to avoid interference and damage.

Technical Specifications

• Operating voltage: 230 V AC ±15% / +10%, 50 Hz (optional 24 V DC).
• Response time: approximately 30 ms.
• Operating temperature range: -10°C to +55°C.
• Protection rating: IP20 for AMS unit; switchgear installed in IP54 cabinet.
• Maximum stroke measurement tolerance: ±0.4 mm.
• Maximum sensor-to-tape distance: 2.0 mm.
• Surge voltage class 2 with safe separation; class 3 without safe separation.

Error Indication and Troubleshooting

• Green LED flashing signals an error; if persistent after voltage reset, verify sensor connections and check for sensor or AMS unit defects.
• If no stroke occurs after startup or overrun measurement fails, check sensor cable wiring (channels A and B may be reversed) and sensor-to-tape distance.
• Verify sensor cable voltage alternation during movement; constant 0 V indicates defective sensors.
• Avoid using sectors near the machine's speed switch-over point as upper dead center for muting to prevent errors.

Overrun Traverse Measurement Procedure

• After voltage reset, AMS performs overrun traverse control during the first press stroke.
• Stroke is stopped after 20 mm or 40 mm traverse to measure overrun.
• Allowable overrun limits: 15 mm for AKAS 1; programmable 5-14 mm for AKAS 2.
• Green LED flashes indicate measured traverse in millimeters (e.g., 8 flashes = 8 mm).
• If overrun exceeds limits, green LED remains off and test repeats on next stroke; operation is blocked until correct measurement.
• Overrun traverse control can be disabled via jumpers for machines already equipped with such control.

Operating Mode Configuration

• Operating modes are set via two DIP-switch strips behind the yellow front plate; both strips must have identical settings.
• Modes include AKAS I / LC with or without overrun traverse measuring, and AKAS II with programmable overrun limits.
• DIP-switch settings and corresponding modes are detailed on a sticker on the AMS housing.

Additional Information and Manufacturer Details

• Manufacturer: Fiessler Elektronik, Germany.
• Product certifications include TÜV Rheinland approvals for safety light curtains, mats, and other safety devices.
• Contact details and website provided for support and product information.

Critical Points and Best Practices

• Always perform overrun traverse control before operating the press with AKAS systems.
• Ensure DIP-switch settings are identical on both strips to avoid configuration errors.
• Verify sensor wiring and magnetic tape installation carefully to ensure accurate measurements.
• Do not operate the press if overrun traverse measurements are incorrect or error LEDs persist.
• Follow recommended exclusion zones near speed switch-over points for muting function to maintain safety integrity.