Section I
IMPORTANT
Please Read
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Before you
connect power, check connector (8) on main printed circuit board
located |
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Do not run power lines and
piezoelectric transducer wires together. Each must be |
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Before serviceman arrives
for Calibration be sure Load Monitor and Piezoelectric |
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RETURN WARRANTY CARD. |
INSTALLATION INSTRUCTIONS
The following instructions are provided in a basic sequence for simplicity in installing the piezoelectric transducers and the load monitor control box on your machines. Please select appropriate reference to your type of machine and read entire sequence before installing your IMCO system.
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1. |
Locations for mounting Piezoelectric transducers brackets. |
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2. |
Mounting of piezoelectric transducer brackets. |
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3. |
Locating and mounting Control Box or Signal Conditioning Box. |
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4. |
Attach Piezoelectric Transducers and route cable to Control Box or Signal Conditioning box. |
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5. |
Wire piezoelectric transducers into Control Box or Signal Conditioning Box. |
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6. |
Connect A/C power and clutch control into Control Box (for Control System only) |
1. LOCATIONS FOR MOUNTING TRANSDUCER
BRACKETS
OBI - C-FRAME - GAP PRESS OR PRESS BRAKE
Piezoelectric transducers are normally placed one at the back of each frame. (see Fig. No. 1-A and Fig. No. 1-B, Location A). Each is located between mounting brackets positioned approximately on a center line between the top and bottom of the gap, excluding any bolster plates. This location permits individual readout of peak load on each frame and is the preferred mounting location.
Figure No. 1-A
Figure No. 1-B
If for any reason the IMCO 112G Piezoelectric
Transducers cannot be located on the back of each frame,
then they can be mounted on the pitman using IMCO 112
Piezoelectric Transducers.
Two 112 Piezoelectric Transducers per pitman mounting connected in parallel
will provide only a single channel of readout. Make sure you have a pitman
piezoelectric transducer cable for this mounting choice. We do not
recommend mounting piezoelectric transducers on the sides of this type of press
because you will be picking up bending.
Note: If pitman mounted, mounting will be the same as straight side
press.
STRAIGHT SIDE PRESSES
Location piezoelectric transducers on theses type of machines should be on the columns front and rear ,away from the keyways. One piezoelectric transducer for each column should be mounted approximately on a center line (middle of die space)between the bottom of the ram and the top of the bed, excluding any bolster plates, to assure continued optimum output and positive response. (Fig. No. 1 Fig. No. 2
For pitman mounting attach two piezoelectric transducers per pitman located 180 degrees from each other and as close to the directional axis of rotation as possible. Wiring will be in parallel. ) Location A-1, B-1, Fig. No. 4, Fig. No. 5 and Fig. No. 6). We do not advise pitman mounting if your pitman is split or it has an adjustment mechanism in the pitman.
TYPICAL TWO POINT STRAIGHT SIDE PRESS
Column Mounting Location
Figure No. 1
Figure No. 2
TYPICAL TWO POINT STRAIGHT SIDE PRESS
Pitman Mounting Location
Figure No. 3
Figure No. 4
Figure No. 5
Figure No. 6
Note: While there are possible alternates, it is suggested that you contact the factory before selecting one.
2. MOUNTING PIEZOELECTRIC TRANSDUCER BRACKETS
Determine the piezoelectric transducer bracket locations using in accordance with the self-adhesive bracket mounting templates as supplied (see Part No. TLD-3072). 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 (see Fig. No. 3).
UNIQUE PIEZOELECTRIC TRANSDUCER
Figure No. 3
Upon completion, 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 (see Fig. No. 9). 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.
Figure No. 9
Note:
Piezoelectric transducers are measuring micro strain in frame of press and
brackets should be tightened into press frame as close
as possible to assure maximum piezoelectric signal.
3. LOCATING & MOUNTING CONTROL BOX OR SIGNAL CONDITIONING BOX
SIGNAL CONDITIONING BOX
Attach Signal Conditioning Box convenient for plug-in-working height (see Fig. No. 1) with connection for attaching portable TON-INDICATOR Amphenol connector plug, pointing toward floor. Locate and punch mark through external box mounting hole, drill and tap 1/4 inch x 20 holes in machine column frame, attach box with suitable screws.
CONTROL BOX
We recommend that you attach the Control Box and
readout dial(s) facing toward the machine operator
(see Fig. No. 6).
For Straight Side mounting, the best Control Box location is usually attached to
a plate mounted on a front column facing the operator
or in a control cabinet next to the press. Whatever
location depending on the type of machine, the system is attached using (4)
four shock mounts as supplied, except when mounted in a control cabinet.
Let the system be accessible for easy use of internal
controls, yet high enough to keep clear of internal
controls and possible damage.
Refer to specific Control Box drawings and dimensions
4.
ATTACH PIEZOELECTRIC TRANSDUCER AND ROUTE CABLE TO CONTROL BOX OR
SIGNAL CONDITIONING BOX
NOTE:
DO NOT CUT CABLE UNTIL LENGTH FROM PIEZOELECTRIC TRANSDUCERS TO
CONTROL BOX IS DETERMINED
The Piezoelectric Transducers which are supplied from the factory are shipped pre-wired depending on the mounting location selected, pitman or column. As an added service to our customers are covered with rubber adhesive sealant (see Fig. No. 7). Pitman mounted piezoelectric transducers are wired in parallel with a 24 inch loop (see Fig. No. 8) and 35 feet between piezoelectric transducers for column mounted piezoelectric transducers. Do not cut any cable, until the correct cable length from piezoelectric transducers to the control box is determined.
Figure No. 7
Figure No. 8
To determine required cable length from each piezoelectric
transducer to control box, first insert the piezoelectric transducers between
the top and bottom mounting bracket (see Fig. No.
9). Tighten down the top bracket set screw, secure firmly with locknut.
Figure No. 9
Upon completing piezoelectric transducers attachment, see that cable is attached to cable clamp as close to piezoelectric transducer terminal connections as practical, to ensure relief from direct strain (see Fig No. 9).
For pitman mounting be sure that sufficient loop beyond first cable clamp is provided to allow for full rotation of pitman.
Route cable from piezoelectric transducer, using cable clamps, until reaching vicinity of control box. Then bring enough shielded cable through cable connector (customer must provide) located at top side of box and allow for sufficient cable length going through connector to ensure ease of working on each cable end for making terminal strip connections. Cut cable length and repeat for other transducers.
5. WIRE TRANSDUCERS INTO CONTROL BOX OR SIGNAL CONDITIONING BOX
NOTE:
PIEZOELECTRIC TRANSDUCERS MUST BE BROUGHT IN USING THE HOLE
AT TOP OF CONTROL BOX.
The following is an instructional sequence for preparing a piezoelectric transducer cable end for connection to terminal strip of selected control box (see Fig. No. 10).
Figure
No. 10
| A. | Slide piece of 3/8" inch wide shrinkable tubing over one end of each cable; pull over cable until approximately 4 - 5 inches in from end. (Location A). |
| B. | Strip back outer plastic case from cable approximately two and one-half (2 1/2" ) inches (Location B). DO NOT STRIP OFF METAL SHIELD. |
| C. | Make hole in metal shield at point "C" with pencil sufficient enough to fish out black and white wires. This will avoid slitting metal shield and cause fraying. (Do this step only if shield is wrapped). Twist shield so as to make third wire for grounding. |
| D. | Slide one piece of 3/19 inch shrinkable tubing over each wire and shield. Pull back to permit working on the end of wire. (Location D). |
| E. | Remove 1/8 inch from end of black and white wires: (Location E) attach open end terminal to shield (ground) and black and white wires, crimping or soldering for good connections. (Location F) |
SIGNAL CONDITIONING BOX
Attach terminal from cable running from right-hand column (or pitman) piezoelectric transducer (facing front of machine) to right-hand piezoelectric transducer input terminal block positions marked "A-S-B (see Fig. No. 11) connecting white wire to "A", black wire to "B", and shield (ground) to "S" for compression on pitman mounting. For column mounting, which puts piezoelectric in tension, reverse the wiring, put black on "A" and white on "B". Repeat procedure for left-hand column, or left side pitman, piezoelectric transducer to left-hand input terminal. Draw excess cable back through connector (customer must provide) and tighten connector for security of cable clamp.
NOTE:
If press is a single point with one (1) pitman and piezoelectric transducers
are located on pitman, being wired in parallel there will be only one
cable leading into the control box and terminal
connection hookup will be as for one side only.
Figure No. 11
CONTROL BOX
Following preparation of cable ends, correctly attach terminals to respective positions. Column mounting (tension wiring) black wire to "A", white wire to "B" and shield to "S".
Pitman mounting (compression wiring) white wire to ", black wire to "shield to "S" (see Fig. No. 12 Transducer inputs and Wiring Diagram). Repeat for remainder of piezoelectric transducers.
Figure No. 12
6. CONNECT A/C
POWER AND CLUTCH CONTROL INTO CONTROL BOX
FOR CONTROL SYSTEMS
ONLY
NOTE:
THE FOLLOWING STEPS MUST BE PERFORMED BY A QUALIFIED
ELECTRICIAN. POWER MUST BE BROUGHT IN
USING THE HOLE IN BOTTOM
OF CONTROL BOX. NEVER
RUN A.C. (POWER) AND D.C. (PIEZOELECTRIC TRANSDUCERS)
TOGETHER.
For all permanently mounted control systems bring A/C voltage power line through hole in bottom of control box and make suitable power connection to terminal strip as marked. Numbers 14,15 & 16. Also for control type systems, connect the clutch control wires using emergency stop or stop on top depending on customers preference to terminal strip connections. Numbers 8 & 9 (see Fig. No. 12). Make terminal connection in accordance with wiring diagram supplied.
YOU MUST BRING IN A SEPARATE EARTH GROUND WIRE TO NUMBER 16
NOTE:
Use suitable insulated connector 1/2 inch Seal tight is suggested) to carry
wires through 7/8 inch diameter hole in bottom of box.
This final step of installation would apply if customer has purchased IMCO Calibration System .
Pre-torque each piezoelectric
transducer to 15 inch pounds, with torque wrench supplied with the IMCO
Calibration System. If calibration is to be performed by an IMCO
Service Engineer, piezoelectric transducers will be torqued at the time of
calibration.
Section II
GENERAL DESCRIPTION OF TON-LIMIT DETECTOR
INSTRUMENT PANEL
The instrument panel of your TON-LIMIT DETECTOR is illustrated in the Figure numbers provided and the function of each item is explained.
POWER ON LIGHT - (TL4001) Fig.
No. 1 and 2
Indicates when and IMCO control is activated, and should always be lit when
Press main power supply is switched on.
METER (DIGITAL) - LEFT SIDE
(TL4011, TL4000) Fig. No.1 and 2
When machine is under work load Meter (Digital) with built -in memory
circuit constantly displays peak load being applied to left side of tooling and
machine. The Meter (Digital) Control Knob is calibrated in black from 0 - 100%
in two (2) percent increments and in red from 100 - 130% to indicate overload
area.
METER (DIGITAL) - RIGHT SIDE
(TL4011, TL4000) Fig. No. 1 and 2
Same as for LEFT SIDE except displays peak load being applied on right side
of tooling and machine.
TRIMMER - ZERO [SEE BACK OF
METER (DIGITAL) ] Fig. No. 3 and 4
When needed, permits accurately positioning meter needle (digital
display) position to zero (see Maintenance Procedure). One each for left
and right side meters (digitals).
TRIMMER - GAIN [SEE BACK OF
METER (DIGITAL) ] Fig. No. 3 and 4
When needed, permits accurately positioning of meter needle (digital
display) position on 100% (see Maintenance Procedure). One each for left
and right side meters (digitals).
OVERLOAD AND UNDERLOAD
INDICATING LIGHTS - Left and Right Side (TL4002)
Fig. No. 1 and 2
These lights are individually activated when either or
both side of Press are overloaded beyond selected point on Control Monitor Knob
and/or underloaded on a Hi-Low Detector. Cancellation of their indication
is done by pressing the RESET button (TL4007).
FUSE - (TL4021) Fig. No. 5
The fuse provides a safeguard against unnatural power
conditions. It has a 1/2 amp. 250 Volt Capacity.
CONTROL MONITOR KNOB - Left Side
(TL4005) Fig. No. 1 or (TL4012) Fig. No. 2
Scale surrounding monitor knob is in black from 0 - 100% and in red from 101 -
130%. By rotating the Control Knob, white arrow can be positioned at peak
percent capacity user desires instruments to be activated for overload and/or
underload shut off for left side of machine.
CONTROL MONITOR KNOB - Right Side
(TL4005) Fig. No. 1 or (TL4012) Fig. No. 2
Same as for left side monitor except activates
overload circuit when exceeding selected peak load on right side of dies and
machine.
RESET - Push Button (TL4007) Fig. No. 1 and
2
In the event of an overload causing activation of one
or both protection circuits, and following correction of condition causing
overload, this button must be depressed in order to reset relay in IMCO Control
Box circuitry.
CALIBRATE - Push Button (TL4007) Fig. No. 1
and 2
This function permits check of meter (digital)
calibration (see Meter Linearity Check). When depressed both meters
(digitals) should read 100% indicating input of 4 Volts D.C. signal.
REVERSA LOAD - Push Button (See Side of Box) -
OPTIONAL
When depressed, reverses normal mode of piezoelectric
transducer activation. Provides means to indicate loads encountered from
stripping or break through force as in punching or blanking. (See full
explanation in catalog description).
Figure No. 1
Figure No. 2
Figure No. 3
Figure No. 4
GENERAL
DESCRIPTION OF METER (DIGITAL)
AND MONITOR FUNCTIONS
METER AND DIGITALS
Upon installation of an IMCO System each machine must be accurately calibrated so as to conditions self generating piezoelectric transducer outputs to within 0 - 4 Volt range representing a direct application of 0 - 100% load on machine member to which piezoelectric transducer is attached.
Therefore, with piezoelectric transducer(s) on left side machine member connected to left meter (digital) and right side meter (digital), a 100% designation on each meter (digital) indicates maximum suggested individual load permissible on each member.
To determine the total load being applied if both meter (digital) readings are identical which indicates a balanced load condition is to interpret one meter (digital) as percent of total press capacity being used.
FOR EXAMPLE:
PRESS TONNAGE: 120 Tons (60
Tons per point)
Left Meter (Digital) Reading - 40% (24 Tons)
Right Meter (Digital) Reading - 40% (24 Tons)
TONNAGE APPLIED = 40% OF 120 Tons = 48 Tons
If however, meter (digital) readings are not identical to determine total tonnage applied, add percent (tons) readouts from each meter (digital), average result by dividing by two (2) and interpret as percent of total press capacity.
FOR EXAMPLE:
PRESS TONNAGE: 120 Tons (60
Tons per point)
Left Meter (Digital) Reading - 65% (39 Tons)
Right Meter (Digital) Reading - 45% (27 Tons)
TONNAGE APPLIED = 65 + 45 = 110 divided by 2 = 55% of 120 Tons = 66 Tons
MONITOR CONTROL KNOBS
Operating independent of meter (digital) circuitry each Control Knob circuit provides the means to select the point between 0 - 100% at which the overload relay is triggered thereby signaling for drive disengagement. The user can then determine the most suitable tonnage required for the press and/ or to make a quality part by first observing the meter (digital) readouts and then setting each Control Knob at the peak load limit (and/or low limits). If limits are exceeded, individually or together, one or both Control Knobs automatically signal for drive disengagement.
Selection of the percent over the actual load required to perform work is at the discretion of the customer and normally determined by past or new found experience in using IMCO Load Monitors. While Control Knobs will also function between 100 - 130% and is entirely the customer's choice, we strongly recommend that no press be operated with any Control Knob set beyond the 100% point.
OPERATING INSTRUCTIONS
Obtaining the most effective use of the IMCO Load Monitor the following is a suggested operational procedure that can be followed when making each new die set-up.
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1. |
Check POWER ON light of Control Box is activated. |
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2. |
Set each CONTROL KNOB to 100%. |
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3. |
Place dies in press while checking for any incorrect wear or damage as per normal procedure. |
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4. |
Manually position dies in press and secure per normal procedure. |
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5. |
Start press by single stroking, gradually adjusting press shut height to ensure suitable die clearances, etc. but avoid applying any heavy load. |
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6. |
Check LEFT and RIGHT meter (digital) readouts to help in setting dies for best load distributed load condition. |
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7. |
Slowly adjust press shut height downward in approximate .005 increments until acceptable part is obtained with minimum pressure. |
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8. |
When acceptable part is obtained, note percent (tons) readout on each meter (digital) and set each overload CONTROL KNOB to desired peak load position, plus additional percent for minor variation in stock, tool wear, etc. |
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9. |
Log information of meter (digital) readings and CONTROL KNOB settings (see example of typical log sheet ). This will help in future set up of dies as well as indicate at a later check any subsequent wear or change in conditions of tools or press. |
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10. |
Run press as for normal operating conditions. |
NOTE:
We strongly urge that press is not run with any CONTROL KNOB set beyond 100%
designation. We recommend that in the event set-up readings are
beyond 100% on either or both meters (digitals) that a recheck of set-up
be made to determine:
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(a.) |
Dies are not hitting unnecessarily hard because of incorrect die positioning or ram setting. |
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(b.) |
Overlooked damaged or worn die sections are not causing excess load. (Check die stations by individually loading and reading meters (digitals) to determine a high loading point |
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(c.) |
Whether scrap has become stuck inside die stations. Particularly prevalent on blanking and piercing dies. |
OPERATING OUR DIGITAL SYSTEMS
IMCO’S New Digital System provides limits in both Percent and Tons. The control knobs are in percent, the displays are in direct tons. You press a center button "DISPLAY TONS" and it shows the percent limits on the digital display in tons. It displays each tonnage increment on the digital displays as you turn the control knob which is in percent scales.
It is not necessary to know the tonnage of the press to use our New Digital System. You can adjust the correct tonnage by moving a jumper on the back of each digital display. Detailed instructions come for adjusting the correct tonnage comes with each system.
System can be purchased for stock without having to the know the tonnage of the Press it will be mounted on.
MAINTENANCE
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. Piezoelectric transducers are pre-torqued at time of calibration to 15 inch/lbs. They should not come loose even when located on a moving connection and subjected to heavy shock. If any piezoelectric transducer screw does become loose it can be re-torqued to 15 inch/lbs. and 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.
TRANSDUCER CABLES
Check to see if cables are in good condition and covering remains pliable. Cracked or damaged cable can cause erratic or lack of signal form 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.
All internal control circuitry is of latest solid state design and does not require a normal maintenance schedule. For general maintenance, swing open inner panel door by removing large round head screw in center and at right of door. DISENGAGE ALL POWER and check the piezoelectric transducer inputs and capacitance terminals for loose connections (right side of circuit board - see Fig. No. 12) Power input and control function terminals should also be checked for secure connections (bottom, center of box - see Fig. No. 12).
DO NOT TAMPER WITH CIRCUIT BOARD. IN THE EVENT OF ANY MALFUNCTION THE IMCO FACTORY OR REPRESENTATIVE SHOULD BE CONSULTED PRIOR TO ANY CORRECTION.
METER LINEARITY CHECK
When meters (digitals) are at
reset, both meter needles (digital displays) positions should be
registering zero (0%). If either are out of position, insert a small
screwdriver into Zero trimmer located behind meters (digitals), (see Fig. No. 4
& 5) and rotate trimmer screw in appropriate direction until meter needle
(digital display) position is correctly registering zero(0%) percent.
To check each meter needle (digital display) position at 100%, press does not have to be activated. Set both Control Knobs to position between 110 - 130%. Depress Calibrate push button and hold in. Each meter needle (digital display) should register 100%.
If either needle (display) does not register 100%, continue to depress Calibrate push button, insert a small screwdriver into Gain trimmer screw located behind meters (digitals) and rotate in appropriate direction until one or both meter needles (digital displays) are accurately positioned on100%. When 0% and 100% needle (digital) on meters (digitals) are correctly established, meter (digital) linearity is correct.
MONITOR LINEARITY CHECK
Control knob circuitry function is independent of meter (digital) circuitry, and require their own check. Test left side Control Knob first, then repeat for right side.
TRIGGERING TEST AT 100%
Rotate Control Knob clockwise until reaching
approximate 40%. Then slowly turn Control Knob anti-clockwise toward zero
(0) percent. When arrow points to zero (o) percent, appropriate
overload light should be activated. NOTE: Permissible triggering is +2%
per channel.
TRIGGERING TEST AT 0%
Rotate Control Knob clockwise until reaching
approximately 120%, then depress and hold in Calibrate push button. Rotate
Control Knob slowly anti-clockwise toward 100%. When arrow points to 100%,
appropriate overload light should be activated. NOTE: Permissible
triggering accuracy is +2% per channel.
Triggering linearity is normally factory preset and will not drift beyond +2% range. If triggering points 0% and 100% are out of reasonable tolerance, special triggering information can be found on the TWEAK IN page.
