PROFORCE
Installation and Operating Manual
TABLE OF CONTENTS

TABLE OF CONTENTS
INTRODUCTION
OVERVIEW
SECTION I
TRANSDUCER BRACKET DRAWING
Page 1—Transducer Bracket Template with Mounting Dimensions
Page 2—Piezo Transducer Drawing with Dimensions
Page 3—Piezo Transducer with Cable Clamp on Press Frame
SECTION II
PIEZOELECTRIC TRANSDUCER INSTALLATION
Page 1—Piezo Transducer Mounting Instructions
Page 2—Drawing for OBI, GAP, C-Frame & Press Brake
Page 3—Drawing Straight Side Press, Column Mounting 112G
Page 4—Drawing Straight Side Press, Pitman Mounting 112
Page 5—Drawing of Pitman Mounting Locations
SECTION III
TERMINAL BLOCK WIRING DESCRIPTIONS
Page 1—Terminal Block Points 1 - 4
                POINT 1 - +24 Volt D.C.
                POINT 2 - Grd. Input
                POINT 3 - Grd. Output
                POINT 4 - Analog Signature Output
Page 2—Terminal Block Points 5 - 9 TRANSDUCER INPUTS
Page 3—Piezoelectric Transducer Descriptions
Page 4—Terminal Block Points 10 - 12 CALIBRATING CAPACITORS
Page 5—Terminal Block Points 13 - 16
                POINT 13 - Grd. (output to IMCO “Read Me” device)
                POINT 14 - Peak Output
                POINT 15 - +24 Volts (output to IMCO “Read Me” device)
                POINT 16 - Cal (Calibrate)
Page 6—Terminal Block Points 17 - 19
                POINT 17 - Trim Ref (Trim Reference)
                POINT 18 - Peak Reset
                POINT 19 - Display Reset
SECTION IV
CONNECTING PROFORCE I/O MODULE TO PLC
Page 1—Determining Cable Length, Minimizing Electrical Noise Interference, Preparing The Cable
Page 2—Preparing The Cable, continued
Page 3—Wiring the Cable and Connecting to Proforce I/O Module,Minimizing Ground Loops
SECTION V
BLANKING/FORMING SWITCH
Mode of Operation - Set Position of Switch To Blanking or Forming

INTRODUCTION

Our new, low cost small size (100mm x 80mm x 25mm) Proforce Piezo I/O Module with Peak Indicating is D-Rail mounted and work in conjunction with any manufactures PLC or Industrial PC. Proforce Piezo I/O Module is used for one (1) channel of Load Monitoring. They can work with any press tonnages or press speeds.
The Proforce Piezo I/O Module offers the ability to customize Load Monitoring requirements by adapting customized software programs. They can program load trip point for both Press and Dies. Hidden menus are easily created to monitor press overload and die overloads for warranty purposes or other information that may be required.
The Analog of the Proforce Piezo I/O Module feeds directly into the PLC or Industrial PC, A to D Converter Board. The output signal is 0 - 10 Volts. - 24 Volt input.
All types of IMCO's Piezoelectric Transducers are used with the Proforce Piezo I/O Module. Column mounted, Pitman mounted and "Satellite" In-Die Transducers offer suitable mounting choices for the Proforce Piezo I/O Module. 

FEATURES

    COMPATIBLE WITH ANY MANUFACTURES PLC OR PC SIMULTANEOUSLY READS BOTH THE
        ANALOG TRACKING AND PEAK HIGH
    EACH MODULE OPERATE INDEPENDENTLY OF OTHER CHANNELS  0 - 10 VOLTS IMCO'S "ROCK
       SOLID " TECHNOLOGY FOR TEMPERATURE AND NOISE STABILITY
    D- RAIL MOUNTED
    CUSTOMIZE PRODUCTION REQUIREMENTS BY CREATING ANY LOAD MONITORING FEATURES 
    SMALL - SLEEK - COMPACT DESIGN
    LOW COST - THROW AWAY CONCEPT
    FUNCTIONAL WITH ALL TYPES OF IMCO PIEZOELECTRIC TRANSDUCERS
    CAM SELECT MODULE FOR DOUBLE ACTION PRESS - TURNS PIEZOELECTRIC TRANSDUCERS ON
        AND OFF - optional

OVERVIEW
PROFORCE
PIEZO ANALOG-DIGITAL I/0 MODULE

SECTION I    TRANSDUCER BRACKET MOUNTING
Page 1

Stick-on templates are supplied with all Proforce Piezo I/O Modules. Determine the mounting bracket locations based on the type of piezoelectric transducers to be used and the optimum output mounting location for piezoelectric transducers to be used. . Attach template to the chosen location . Drill and tape the two appropriate holes using the self-adhesive bracket mounting template (see Template No. 8010 ) to determine correct hole spacing . Make sure that in drilling the holes, the piezoelectric transducers will remain parallel to the mounting surface (Example: column or pitman's). Use regular capacity 3/8 inch or 1/2 inch power drill; we suggest, if possible, a carbide tipped drill bit, because the outer skin surface of the machine has a tendency to be tempered hardened.
Use a 1/8 IN.— 27 Inch tapered (conical) pipe tape.

IMPORTANT:  DO NOT SUBSITTUTE A NON TAPERED TAPE

After drilling and tapping the holes, apply a light oil or grease for lubrication and insert both top and bottom brackets; top brackets have the lock nuts and should be mounted on top. Jam brackets into frame with open end wrench so as to get square part of bracket body as close as possible to column or frame of Press .  Do not remove the top bracket set screw when jamming into press frame. Make sure brackets are tight. Lock nuts should be “kissing” the frame or column.

NOTE: 
Piezoelectric transducers are measuring micro strain in frame of Press. Brackets should be tightened into Press frame as close as possible to assure maximum piezoelectric transducer signal.

        TORQUE TRANSDUCERS IN BRACKETS TO 15 INCH LBS.

SECTION I    TRANSDUCER BRACKET MOUNTING
Page 2

The IMCO Load Monitor and piezoelectric transducers are ruggedly built to withstand normal industrial environment conditions and require minimal maintenance. However, each system can benefit from careful use and maintenance. It is recommended that the following procedure be carried out at a minimum frequency of every three months. 

TRANSDUCERS  
Each piezoelectric transducer is factory pre-wired and terminal connections sealed. A visual inspection of seal and connections is all that is required. Torque piezoelectric transducers to 15 inch/lbs. at time of installation or before calibration. They should not come loose even when located on a moving connection and subjected to heavy shock. You can torque again to 15 inch/lbs., if any piezoelectric transducers screw becomes loose and the original calibration is maintained. Check to see that top locknut remains securely fastened. If loose, tighten with regular wrench. A small drop of LockTite or similar fluid should avoid future loosening of locknut.

SECTION I    TRANSDUCER BRACKET MOUNTING
Page 3

Check to see if cables are in good condition and covering remains pliable. Cracked or damaged cable can cause erratic or lack of signal from piezoelectric transducers. Activation of each piezoelectric transducer is easily checked on press by sharply squeezing top and bottom piezoelectric transducer bracket. Hold sections between thumb and forefinger simulating a quick pressure on the piezoelectric transducer as when the press member is dynamically loaded. Appropriate meter needle (digital display) should indicate a response. 

SECTION II        PIEZOELECTRIC TRANSDUCER
Page 1                          INSTALLATION

IMPORTANT
Please Read

     Do not run any other AC or DC lines with the Piezoelectric Transducer wires. Keep them separate.
     Before serviceman arrives for Calibration be sure Proforce is mounted, power connected,   
          piezoelectric transducers are mounted and connected to the Proforce I/O Module.
    Software program should be written for Press PLC or Industrial PC is the responsibility of the user.
    Record Proforce I/O Module serial number for future reference.

PIEZOELECTRIC TRANSDUCER MOUNTING INSTRUCTIONS

The following instructions are provided in a basic sequence for simplicity in installing the Piezoelectric Transducers on your machine . Please select appropriate reference to your type of machine and read entire sequence before installing your Piezoelectric Transducers. 

The IMCO piezoelectric transducers supplied from the factory for all IMCO systems are shipped pre-wired. The standard pre-wired cables are determined by the mounting location either on the columns or pitman's of the press. Standard cable lengths for column or pitman mountings are applicable to most all types presses.  Do not cut cable until length from transducers to the mounted Proforce I/O Module is determined. If the cable lengths are not long enough, custom cable lengths can be requested.

Typical mounting locations are recommended to obtain maximum output from IMCO piezoelectric transducers. While there are possible alternates, it is suggested that you contact the factory before selecting one. We do not advise pitman mounting if your pitman is split or it has an adjustment mechanism in the pitman.

The IMCO piezoelectric transducers are measuring micro strain. Brackets should be tightened and jammed into the press frame or pitman's as close as possible to assure maximum transducer signal. Make sure the brackets remain parallel to the mounting surface (i.e. columns or pitman's). Use the supplied mounting template to determine spacing distance between top and bottom mounting brackets.

SECTION II         OBI - GAP - C-FRAME - PRESS BRAKES
Page 2

SECTION II              STRAIGHT SIDE PRESS
Page 3                                                               
                                                                                Column Mounting
                                                                     112G Piezoelectric Transducers

112 IDS In-Die Satellite Piezoelectric Transducer
112IDS are mounted in the hardened die plate under a section of die that has a critical load to be monitored. Multiply 112IDS transducers may be connected in parallel to increase signal strength and average the load from a wider area in the die. 112IDS transducers are wired for compression with Teflon cable, which is impervious to oil and maintains its flexibility. (wiring diagram “Terminal Block Points 5 through 9”, separate sheet)

112 Pitman Mounted Piezoelectric Transducer
112 are used on the connecting rods or pitman's of the press, because the stresses on the pitman's are greater than on the columns. The lower output 112 transducer is suitable for pitman mounting. Two (2) 112 transducers are pre-wired in parallel and mounted on each pitman or connecting rod. One (1) 112 transducer is mounted on the front of the pitman and the other is mounted on the back of the pitman, 180 degrees apart in the direction of the rotation compensating for bending of the pitman. Even though the 112 transducer is ideally suited for pitman mounting with its lower output, it does not limit its mounting use in other areas. 112 transducers are wired for compression with Teflon cable, which is impervious to oil and maintains its flexibility. (wiring diagram “Terminal Block Points 5 through 9”, separate sheet.)

112G Column Mounted Piezoelectric Transducer
112G transducers are used for column mounting in Single Point Straight Side Press (one pitman), Two Point Straight Side Press (two pitman’s) , Four Point Straight Side Press (four pitman’s) and the back of GAP, C-Frame, OBI, Press brakes. 112G transducers have three (3) times the output of the 112 transducer. When mounted on the columns of Presses the 112G transducers are wired for tension, When mounted on the back of GAP,C-Frame, OBI and Press Brakes the 112G transducer is wired for compression. The optimum way to monitor a Straight Side Presses is to use one (1) 112G transducer on each Press column and use one (1) Proforce Piezo I/O Module for each column being measured. IMCO recommends mounting 112G transducers on the front and back of the Press column halfway between the bed of the press and the top of the ram. We do not recommend mounting on the sides of the Press columns in order to reduce the chance of measuring bending which can occur on the side of some Presses. (wiring diagram “Terminal Block Points 5 through 9”, separate sheet).

112G Column Mounted Transducer wired in parallel (2nd Parallel Sensor)
Two 112G transducers wired in parallel can be used on Two Point Straight Side Presses (two Pitman’s) using one (1) Proforce Piezo I/O Module and two (2)112G transducers wired in parallel to be mounted on the left front Press column and the left rear column. Then the same on the right front and right rear Press column ending up with a Proforce Piezo I/O Module for the (LS) left side and one for the (RS) right side of the Press, instead of one 112G transducer and one (1) Proforce Piezo I/O Module for each column of the Press. (wiring diagram “Terminal Block Points 5 through 9”, separate sheet).

DETERMINING CABLE LENGTH
When you determine the length of cable required to connect Proforce I/O Module, remember to include additional length to route the drain wire and foil shield to earth ground. Route cable long enough to avoid signal attenuation.

MINIMIZING ELECTRICAL NOISE INTERFERENCE
High speed analog signals are particularly vulnerable to electrical noise. Take precautions when routing signal cables. To help reduce the effects of electrical noise on analog signals, we recommend that you:

       Install the PLC AND Proforce I/O Module in a NEMA rated enclosure.
       Make sure that the PLC and Proforce I/O Module is properly grounded.
       Use Belden cable # 1503A, # 8451 or #8761 (or equivalent) for signal wiring.    
       Ground the cable properly.
       Route signal cables away from other wiring or in grounded conduit.
       Group Proforce I/O Modules away from AC or high-voltage DC modules.

We recommend re-checking Proforce I/O modules operation after installing new machinery or
other sources of electrical noise near the I/O Modules.                      
                           




ATTENTION:
Before wiring a Proforce I/O Module, disconnect Power from the I/O Module and from any Power other Power source to the Module.

PREPARING THE CABLE

1. At each end of the cable, strip about 3 inches ( 76.19 mm) of casing to expose the wires.
2. At the ground end of the cable (Figure 1), twist the drain wire and the foil shield            
    together and bend them away from the cable. Using a hot air blower, apply shrink wrap
    where wires leave the casing.
3. At the other end of the cable, cut off the drain wire and foil shield. Apply shrink wrap to
    the junction where wires leave casing.
4. Trim the signal wires to 2 inch (50.8 mm) lengths. Strip about 3/16 inch (4.76 mm) of
    insulation away to expose the copper strands for connections.
5. Decide where you will connect the cable to earth ground, and ground it. Refer to
    GROUNDING THE CABLE.
6. Connect signal wire (black and white) to terminal block and to input or output device.
    (see separate sheets for Wiring Terminal Block Points 1 through 19).