LINK Systems 1100 User Manual

SYSTEM 1100 ACCESS CODES

NORMAL ACCESS CODE: 3721

STROKE COUNTER
ACCESS CODE: 0072

SYSTEM 1100 TONNAGE MONITOR

OPERATING MANUAL

Manual LS-004

Revision 01

CONTENTS

1. Introduction ................... 1-1

1.1 System 1100 Overview . . . . . . . . . . . . 1-3

2. Operation .................... 2-1

2.1 The Operator Interface . . . . . . . . . . . 2-1

2.1.1 Tonnage Displays and Bar Graphs . . . 2-1

2.1.1.1 Display of Alarms . . . . . . . 2-1

2.1.2 Keyboard Use . . . . . . . . . . . . . 2-2

2.1.1.1 Auto Setup Key . . . . . . . . 2-2

2.1.1.2 Low Limit On/Off Key . . . . . 2-3

2.1.1.3 Down Time Code Key . . . . . . 2-3

2.1.1.4 Tonnage Forward/Reverse Key . . 2-3

2.1.1.5 Help Key . . . . . . . . . . . 2-3

2.1.1.6 Clear Key . . . . . . . . . . . 2-4

2.1.1.7 Contrast Key . . . . . . . . . 2-4

2.1.1.8 High Set and Low Set Keys . . . 2-4

2.1.2 Mode Selector Keyswitch . . . . . . . 2-4

2.2 Menu Selection . . . . . . . . . . . . . . . 2-5

2.2.1 Main Menu .............. 2-5

2.3 Tonnage Display Selection . . . . . . . . . . 2-5

2.4 Setpoints.................. 2-6

2.4.1 Editing Setpoints . . . . . . . . . . 2-7

2.4.1.1 Turning Reverse Setpts ON/OFF . 2-8

2.5 Store/Recall ................ 2-8

2.5.1 Store ................ 2-9

2.5.1.1 Enter Job Number . . . . . . . 2-9

2.5.1.2 Enter Job Description . . . . . 2-9

2.5.1.3 Store Job . . . . . . . . . . . 2-10

2.5.2 Recall................2-11

2.5.2.1 Enter Job Number . . . . . . . 2-11

2.5.2.2 Select Job . . . . . . . . . . 2-11

2.5.3 Remove................2-12

2.5.3.1 Enter Job Number . . . . . . . 2-12

2.5.3.2 Select Job . . . . . . . . . . 2-13

2.6 Counters ..................2-13

2.6.1 Part, Batch, and Quality Counters . . 2-14

2.6.2 M.R., Hi, Lo & Rev Alarms Counters . . 2-15

2.6.3 Stroke Counter . . . . . . . . . . . . 2-16

2.7 Errors ...................2-16

2.8 Configuration................2-17

2.8.1 Cal-Check . . . . . . . . . . . . . . 2-17

2.8.2 Machine Rating . . . . . . . . . . . . 2-18

2.8.3 Machine Number . . . . . . . . . . . . 2-18

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2.8.4 Threshold . . . . . . . . . . . . . . 2-19

2.8.5 Cam Zero...............2-19

2.8.6 Data Window . . . . . . . . . . . . . 2-19

2.8.7 Auto Setup..............2-20

2.8.8 Machine Speed . . . . . . . . . . . . 2-20

2.8.9 Top-Stop Timer . . . . . . . . . . . . 2-21

2.8.10 Decimal Point . . . . . . . . . . . . 2-21

2.8.11 Alarm Clear Access . . . . . . . . . 2-22

2.8.12 Memory Clear . . . . . . . . . . . . 2-22

2.8.13 Static-Cal . . . . . . . . . . . . . 2-23

3. Theory of Operation . . . . . . . . . . . . . . . . 3-1

3.1 General................... 3-1

3.2 Measurement of Load . . . . . . . . . . . . . 3-1

3.3 Summing Multiple Channels to Obtain Total Load 3-3

3.4 Limits of Measurement Accuracy . . . . . . . 3-5

3.4.1 Machine Vibration . . . . . . . . . . 3-5

3.4.2 Structural Ringing . . . . . . . . . . 3-5

3.4.3 Structural Nonlinearity

and Eccentric Loading . . . . . . . . . 3-6

3.5 Automatic Zeroing . . . . . . . . . . . . . . 3-7

3.5.1 Rate of Change Automatic Zeroing . . . 3-7

3.5.2 Automatic Zeroing by Position . . . . 3-9

3.6 Data Windows ................ 3-9

4. Applications Information . . . . . . . . . . . . . 4-1

4.1 Selection of Zeroing Method . . . . . . . . . 4-1

4.2 Strain Link Mounting Locations . . . . . . . 4-1

4.2.1 "C" Frame Machines . . . . . . . . . . 4-1

4.2.2 Straight Side Machines . . . . . . . . 4-2

4.2.3 Overdrive Double Action Machines . . . 4-6

4.2.4 Underdrive Machines . . . . . . . . . 4-7

4.2.5 High Speed Machines . . . . . . . . . 4-7

4.2.6 Other Applications . . . . . . . . . . 4-7

5. Installation ................... 5-1

5.1 Mounting the Enclosure . . . . . . . . . . . 5-1

5.2 Mounting the Strain Links . . . . . . . . . . 5-4

5.2.1 Direct Machine Mounting . . . . . . . 5-4

5.2.2 Intermediate Weld Pad Mounting . . . . 5-5

5.2.3 Intermediate Adhesive Pad Mounting . . 5-6

5.3 Conduit................... 5-7

5.4 Electrical Connections . . . . . . . . . . . 5-7

5.4.1 Connecting the Strain Links . . . . . 5-7

5.4.2 Connecting the OIT to the Logic Unit . 5-8

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CONTENTS

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5.4.3 Connecting a Zeroing Cam . . . . . . . 5-9

5.4.4 Connecting Data Window Cams . . . . . 5-9

5.4.5 Connecting a Remote Reset . . . . . . 5-10

5.4.6 Input Power & Machine Control . . . . 5-10

6. Calibration.................... 6-1

6.1 Dynamic Calibration with Load Cells . . . . . 6-2

6.2 Static Calibration with Hydraulic Jacks . . . 6-9

7. Zero Circuit Checkout after Calibration . . . . . . 7-1

8. Unbalanced Loads and Scale Factor . . . . . . . . . 8-1

9. Using System 1100 Tonnage Monitors . . . . . . . . 9-1

9.1 Machine Overload Monitoring . . . . . . . . . 9-1

9.1.1 Sample Die Setter Instructions . . . . 9-1

9.1.2 Sample Operator Instructions . . . . . 9-2

9.2 Comprehensive Load Monitoring . . . . . . . . 9-3

9.2.1 Sample Die Setter Instructions . . . . 9-6

9.2.2 Sample Operator Instructions . . . . . 9-7

9.3 Intermediate Load Monitoring . . . . . . . . 9-7

9.3.1 Sample Die Setter Instructions . . . . 9-8

9.3.2 Sample Operator Instructions . . . . . 9-8

9.4 Diagnostic Uses . . . . . . . . . . . . . . . 9-8

9.4.1 Incorrect Tie Rod Tension . . . . . . 9-9

9.4.2 Snapthrough Forces . . . . . . . . . . 9-10

9.4.3 Stop Block Forces . . . . . . . . . . 9-10

9.4.4 Scrap Choppers . . . . . . . . . . . . 9-10

10. Error Codes ...................10-1

10.1 Error Listing . . . . . . . . . . . . . . . 10-1

iii

SPECIFICATIONS

SIZE: 14½" wide, 7¼" high, 6" deep

INPUT POWER: Standard Unit

115VAC ± 15VAC, 1 ampere

Remote Display Version
Base Unit 115VAC ± 15VAC, 1 ampere
Display 115VAC ± 15VAC, 1 ampere

OUTPUT RELAY CONTACTS: 5 AMPS @ 120VAC normally open energized

closed.

DISPLAYS: One four-digit LED display for the total

peak tonnage and one four-digit LED
display for each channel peak tonnage.
One ten-segment multi-color bar graph LED
display for each channel and one 2 line
by 20 character alpha-numeric LCD
display.

INSTRUMENT ACCURACY: ± 0.1% of full scale.

ALARM REPEATABILITY: 0.1% of full scale.

GAIN RANGE: 500 to 10,000

RECORDER OUTPUT: 10 volts, full scale

SPEED: 0-2000 SPM

RESPONSE TIME: less than 15 milliseconds

OPERATING TEMPERATURE: 45°C (113°F) Maximum Ambient

iv

Section 1. Introduction

Link's System 1100 Tonnage Monitors are a family of microprocessor­based instruments that can determine, display, and compare
developed forces with preset limits for a variety of machines ­mechanical power presses, press brakes, powdered metal presses,
forging presses, die cast machines, injection molding machines,
cold headers, and similar machines - that use large forces in
production processes. System 1100 Tonnage Monitors are simple, for
ease of use in everyday production, yet sophisticated enough to be
used as analytical instruments by press and tooling engineers.
These instruments can help:

# PROTECT MACHINES from excessive bearing wear and broken frames

and load transmission components. Properly applied and used
System 1100 Tonnage Monitors provide setup personnel with
information about total and distributed machine loads (both
forward and reverse loads can be displayed). By operating
machines within capacity with a properly distributed load,
short term catastrophic machine damage due to overload or
maldistributed load, and long term fatigue of machine parts,
and wear of bearing surfaces can be reduced. The monitoring
capability of the System 1100 will help prevent continuing
overloads by stopping the machine if tonnage exceeds preset
limits during a machine cycle.

# PROTECT DIES or other tooling from production process

malfunctions that don't damage the tooling due to one out of
tolerance stroke (several bad strokes may occur on high speed
machines that can't stop in one stroke).

# ASSESS TOOLING WEAR of shear surfaces on blanking, piercing,

and trimming operations. Early indication of tooling wear can
help schedule tool repair and extend tooling life by reducing
the severity of wear before sharpening is indicated.

# CONTROL PART QUALITY by providing the load information

necessary for consistent tooling and machine setup. Out of
limit hits will stop the production process, allowing
corrections before large numbers of scrap parts are generated.

# CONSERVE ENERGY by using only the tonnage necessary to make a

part. A few thousandths of shut-height misadjustment can mean
tens of tons of unnecessary force in coining and forming
operations on larger presses. Every excess ton of force takes
energy out of the drive system with resultant increased

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INTRODUCTION

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electric bills. The System 1100 Tonnage Monitors can also
help match tooling and machines so that larger than necessary
machines aren't used in low tonnage applications, again saving
energy.

# MEET OSHA REQUIREMENTS to operate within machine capacity.

OSHA's General Industry Standards 29CFR1910.217 (f) (4)
require mechanical power presses to be operated within tonnage
rating. System 1100 Tonnage Monitors provide this information
simply and directly.

System 1100 Tonnage Monitors offer a wide range of practical
features and design parameters that make them extremely versatile
in application and use. Some of these features are:

# Layered accessibility to controls allows easy display of load,

setpoint information and alarms, but all operating mode and
setpoint selection controls require the use of a keyed
selector switch for supervisory control. Selectable keyed
reset after an alarm is standard on all units.

# Two and four channel units are available to provide versatile

and correct monitoring of a variety of machines.

# Large 4-digit LED displays continuously display forward or

reverse loads in tons for all channels and the total.

# Multi-colored LED displays graphically show the peak tonnage

relative to the high and low setpoints for each channel.

# A 2 line by 20 character LCD display and 25 key keyboard

provide easy access to all tonnage monitor functions.

# Settable tonnage limits provided are: Maximum allowable

forward tonnage (HIGH SETPOINT), minimum required forward
tonnage (LOW SETPOINT), and maximum allowable reverse tonnage
(REV SETPOINT).

# One hundred twenty-three setups containing as many as 60

setpoints can be stored in non-volatile memory and recalled by
job number or name.

# Data windows allow for close monitoring of even complex dies

by not only checking absolute peak tonnages, but also checking
up to four additional 'local peaks' created by staggered

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INTRODUCTION

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tooling. This feature requires a rotary cam switch or limit
switch for each data window used.

# Automatic Setup allows all setpoints (peak setpoints and all

data window setpoints) to be calculated and set automatically
by the System 1100.

# The number and types of alarms are automatically recorded by

the System 1100 through the alarm counters (machine rating,
high setpoint, low setpoint, and reverse setpoint alarms).

# A stroke counter, presettable batch counter, parts counter,

and quality check counter are standard.

# An RS-232 port is provided as standard equipment for

interfacing to personal computers. With optional software
package tonnage signatures captured by the System 1100 can be
displayed and stored on a personal computer.

# Signal output terminals are provided for each channel and the

total to drive a recorder or oscilloscope.

# May be calibrated either statically or dynamically.

# Operates up to 2,000 strokes per minute.

1.1 System Overview

Figures 1 and 2 show the components that are contained in the
System 1100 for the self-contained and the panel-mount versions
respectively.

The self-contained unit (Figure 1) houses all the electronics of
the System 1100 Tonnage Monitor. External connections are required
only for strain links, press control stop circuit, and optional
rotary cam switches.

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INTRODUCTION

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Figure 1. System Components of Self-contained System 1100.

The panel-mount unit (Figure 2) separates the Operator Interface
Terminal electronics from the Logic Unit electronics. This
configuration is useful when the tonnage monitor display is to be
mounted in a panel where depth is limited, or when the display is
to be mounted a long distance from the strain gauges.

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INTRODUCTION

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Figure 2. System Components for Panel-mount System 1100.

1-5

Section 2. Operation

2.1 The Operator Interface

The operator interface is the means by which the operator can
control the operation of the System 1100. The following features
of the Operator Interface will be referred to extensively in this
manual and so the operator should be familiar with them. A picture
of the Operator Interface is located on the last page of this
manual and can be folded out for viewing.

1) Tonnage Displays. The tonnage displays are large 4-digit
red LED displays used to display peak tonnage.

2) Tonnage Bar-graphs. The tonnage bar graphs are ten
segment multi-colored LED displays used to show peak
tonnage relative to the HIGH and LOW setpoints and to
indicate high and low alarms.

3) Mode Selector Keyswitch. The mode selector keyswitch is
used to control the operating mode of the System 1100 and
to gain access to tonnage setpoint limits and
configuration data.

4) Indicator LEDs. The three indicator LEDs are used to
indicate Auto Setup mode, Low Limits Off, and an active
Stop Circuit.

5) LCD Display. The 2 line by 20 character LCD display is
used to display messages and access the menus of the
System 1100.

6) Keyboard consisting of 25 keys. The keyboard is used to
enter setpoints, configuration data, clear alarms, and
for all other operator input that is required.

2.1.1 Tonnage Displays and Bar Graphs

The tonnage displays are used to display the peak forward and
reverse tonnage measured by the System 1100. Selection of forward
or reverse peak tonnage for display is discussed in the next
section.

The bar graphs are used to graphically display the measured forward
tonnage relative to the high and low setpoints. The top segment on
the bar graph represents the high setpoint, and the bottom segment

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OPERATION

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the low setpoint. The segment representing the measured tonnage
relative to the high and low setpoints is lighted each time a new
tonnage is displayed.

2.1.1.1 Display of Alarms

Alarms are generated when the System 1100 detects that the measured
tonnage has exceeded a preset value (high setpoint, reverse
setpoint, or machine rating) or in the case of low setpoints, has
not exceeded a minimum value. Alarms are indicated on the System
1100 using the tonnage displays and the bar graphs.

Machine rating alarms are generated when the measured tonnage
exceeds 125% of the channel rating, where the channel rating is the
machine rating divided by the number of channels. Machine rating
alarms are indicated by a flashing tonnage display on the channel
on which the alarm occurred.

High setpoint alarms are generated when the measured tonnage for a
channel meets or exceeds the high setpoint for that channel. High
setpoint alarms are indicated by the top red segment on the channel
bar graph flashing.

Low setpoint alarms are generated when the measured tonnage for a
channel during the stroke does not meet or exceed the low setpoint.
Low setpoint alarms are indicated by the bottom red segment on the
channel bar graph flashing.

Reverse setpoint alarms are generated when the reverse tonnage for
a channel meets or exceeds the reverse setpoint for that channel.
Reverse setpoints alarms are indicated by a flashing reverse
tonnage (reverse tonnages are indicated by a minus sign in the
tonnage display).

2.1.2 Keyboard Use

The upper left portion of the System 1100 keyboard is the numeric
keypad. The numeric keypad is used for entering setpoints,
configuration data, and other numeric data. The remaining keys
have special functions that are explained in the remainder of this
section.

2.1.2.1 AUTO SETUP key

The AUTO SETUP key is used to access the Automatic Setup function

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OPERATION

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of the System 1100. The operator must be in the Main menu and have
the keyswitch in the PROG position to access this function.

Automatic setup stores the highest and lowest peak tonnage from
sixteen successive strokes. High setpoints are calculated as the
highest peak tonnage plus a user selected percentage of channel
rating (the auto setup tolerance), low setpoints are the lowest
peak tonnage minus the auto setup tolerance, and reverse setpoints
are the highest reverse reading plus the auto setup tolerance.
Automatic setup sets all setpoints, high, low, and reverse, for the
peak and for all data windows (if used).

When Automatic Setup is begun by the operator, the AUTO SETUP
indicator will turn on and the automatic setup screen will appear
as shown below.

AUTO SETUP TOL: 5%
STROKES NEEDED: 16

While the keyswitch is in the PROG position, the automatic setup
tolerance will flash, indicating that it can be changed. The
tolerance can be adjusted up to 30% or down to 1% using the up and
down arrow keys respectively.

The number of STROKES NEEDED will count down as the operator cycles
the machine. When all sixteen strokes have been made the System
1100 will calculate and store all setpoints. The AUTO SETUP light
will then go out, and the Main menu will again appear. The
setpoints are stored in the current setup just as if they had been
entered manually.

The automatic setup procedure can be aborted at any time before the
sixteenth stroke by pressing the CLEAR key or the EXIT key. The
previously entered setpoints will then remain in effect.

WARNING! While in Automatic Setup Mode (when AUTO SETUP light is
on) the System 1100 is effectively BYPASSED. All high, low, and
reverse alarms are turned OFF. Only machine rating alarms are
active.

2.1.2.2 LOW LIMIT ON/OFF key

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OPERATION

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The LOW LIMIT ON/OFF key is used to switch the low setpoint limits
on or off. This functions is accessible only while the keyswitch
is in the PROG position.

2.1.2.3 DOWN TIME CODE key

The DOWN TIME CODE key is for use with the Link System Tonnage
Monitor local area network system and is not used at this time.

2.1.2.4 TONNAGE FORWARD/REVERSE key

The TONNAGE FORWARD/REVERSE key is used to switch the tonnage
displays between forward and reverse tonnage. When reverse tonnage
is selected a minus sign will appear at the left of each tonnage
display, when forward tonnage is selected the minus sign will go
out.

2.1.2.5 HELP key

The operator may request a Help screen from the System 1100 by
pressing the HELP key. The Help screens are intended to aid the
operator by giving additional information and explanation of the
current stage of the program sequence. Some Help screens may be
more than two lines long. If the last character on the screen is
a down arrow, more help information is available. The operator can
press the down arrow key to view the additional lines. The
operator can terminate a help screen and return to the program at
any time by pressing the EXIT key . If no help screen is available
for the present program sequence, a message will inform the
operator that a help screen is not available.

2.1.2.6 CLEAR key

The CLEAR key is used for two main functions. The first function
is to remove any data input in progress. If the operator keys in
the wrong data but has not yet pressed the ENTER key, he may press
the CLEAR key to remove the entire data input. The correct data
may then be keyed in. The CLEAR key cannot remove any data once it
has been entered with the ENTER key.

The second function of the CLEAR key is to clear stops, alarms and
errors. If a counter reaches its programmed limit and stops the
machine, the CLEAR key can be pressed to reset the counter and
allow the machine to be restarted. If an alarm is present, such as
channel 3 high setpoint alarm, or and error is present, such as

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ERROR 40 - End Of Cycle cam failure, the CLEAR key can be pressed
to clear the alarm or error.

2.1.2.7 CONTRAST key

The CONTRAST key is used to adjust the contrast of the LCD
display. The display can be adjusted brighter or dimmer by
holding down the CONTRAST key then pressing the up or down arrow
keys respectively. If the keys are held down this function will
automatically repeat to avoid having to repeatedly press the keys
for large adjustments.

2.1.2.8 HIGH SET and LOW SET keys

The HIGH SET and LOW SET keys are used to display the high and low
setpoints on the tonnage displays. The setpoints will be displayed
as long as the key remains depressed.

2.1.3 Mode Selector Keyswitch

The Mode Selector Keyswitch is a three position keyswitch. The key
can only be removed in the RUN position.

RUN - This is the normal operating mode of the System 1100.
When the key is in this position, the operator can only view
setpoint limits, and counter information. Tonnage setpoint
limits and counter limits and count values cannot be altered
or cleared.

PROG - This is the program mode of the System 1100. When the
key is in this position, tonnage setpoint limits can be
changed or turned off, setups can be stored, recalled or
removed, and counter limits can be changed, turned off, and
count values cleared.

BYPASS - This mode is intended for use while die setting.
While in Bypass mode all high, low, and reverse setpoint
alarms are turned OFF. Only machine rating alarms are active
while in bypass mode.

2.2 Menu Selection

The LCD (Liquid crystal display, at the right-top of the operator

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interface) provides the operator with information needed to program
the System 1100. This is done by displaying a menu (list of
choices) and allowing the operator to select one of the menu items.
The blinking pointer is called the cursor and is used to identify
which item on the list is currently selected. The cursor can be
moved to a different choice on the menu using the up and down arrow
keys (see the figure on the foldout in the back of the manual).
Once the cursor is on the item desired, the operator can press the
ENTER key to get further information about that item. The operator
is not required to memorize any function names or keyboard entry
sequences.

2.2.1 Main Menu

The Main menu is the first list of options offered to the operator
during programming of the System 1100. The Main menu contains six
functions from which to choose. The Main menu is shown below.

MAIN $DISPLAY $
MENU $SETPOINTS $9

STO/RCL
COUNTERS

ERRORS
CONFIG

Only two menu options can be shown at one time on the LCD display;
the remaining options are accessible by using the up and down arrow
keys. If options are available either above or below the currently
displayed menu options, then up or down arrows will appear on the
right side of the menu indicating so.

To select an option from the menu list, move the cursor to the
desired option using the up and down arrow keys then press the
ENTER key.

Note that if data windows are disabled in the Config menu the
DISPLAY option will not appear in the Main menu.

2.3 Tonnage DISPLAY Selection

If the System 1100 has been configured for use with data windows

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OPERATION

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(section 2.8.6), the DISPLAY option will appear as the first
selection in the Main menu. The Tonnage Display menu, simply
called 'DISPLAY' in the Main menu, is used to select which tonnage
reading will appear on the tonnage displays. The Tonnage Display
menu is shown below.

TONNAGE$ PEAK $
DISPLAY$ TONNAGE $9

DATA
WINDOW 1

DATA
WINDOW 2

DATA
WINDOW 3

DATA
WINDOW 4

The up and down arrow keys are used to select the desired tonnage
for display. When the desired tonnage is shown on the menu the
corresponding tonnage readings will be displayed on the tonnage
displays.

Exiting the Tonnage Display menu automatically switches the tonnage
displays back to the peak tonnage. The Tonnage Display menu can be
exited by pressing the EXIT key or the CLEAR key.

2.4 SETPOINTS

If the System 1100 has been configured for use with data windows
(section 2.8.6), the Setpoints menu will appear when the SETPOINTS
option is selected from the Main menu, if the System 1100 has not
been configured for use with data windows, the screen shown in
section 2.4.1 will appear.

The Setpoints menu (shown below) allows the user to select a group
of setpoints for viewing or editing and to turn on or off the use
of individual data windows.

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OPERATION

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SETPTS$PEAK $
MENU $DW1 (ON) $9

DW2 (ON)
DW3 (OFF)
DW4 (OFF)

To view or edit a group of setpoints, select the desired group
using the up and down arrow keys, then press the ENTER key.
Setpoints for data windows that are turned OFF cannot be viewed or
edited until they are turned ON.

To turn on or off the use of a data window, first move the
keyswitch to the PROG position. Next, select the desired data
window using the up and down arrow keys, then press either the ON
or OFF key.

2.4.1 Editing Setpoints

The Setpoints Editing screen allow the operator to view and edit a
group of setpoints. A group of setpoints consists of a high, low,
and reverse setpoint for each channel. A typical setpoints editing
screen for a four channel System 1100 is shown below.

HI-SET LO-SET

REV-SET (ON)
CH1 22.0 18.2 96

2.0

CH2 21.7 17.9 2.1
CH3 21.9 18.1 2.0
CH4 21.1 17.3 2.2

Because of the limited size of the LCD display, not all setpoints
can be shown at one time. When additional setpoints are located
either above, below, right, or left of the displayed setpoints,
arrows indicating so will appear on the right side of the screen.

While the keyswitch is in the BYPASS or RUN positions the operator
can only view the tonnage setpoint limits. When the keyswitch is
in the PROG position the currently selected setpoint limit will
flash indicating that it can be changed. To change a setpoint,
first select it using the up, down, left, and right arrow keys,

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then enter the new setpoint over the old using the numeric keypad.
When finished entering the setpoint, press the ENTER key.

The group of setpoints shown above is for the absolute peak
tonnage. Data window setpoint groups are indicated as shown below
with the data window number appearing in the upper left corner of
the setpoints editing screen.

DW2 HI-SET LO-SET
.4

CH1 11.3 9.3 96

CH2 11.3 9.2 .4
CH3 10.9 9.1 .4
CH4 11.2 9.2 .4

The following rules apply to setpoint limits:

1) High setpoints cannot exceed 125% of channel rating.
(channel rating = machine rating/number of channels)

2) A Low setpoint must be lower than the channel's high setpoint.

3) Reverse setpoints cannot exceed 125% of channel rating.

2.4.1.1 Turning Reverse Setpoints ON/OFF

Reverse setpoints can be enabled or disabled in the setpoints
editing screen by selecting any reverse setpoint using the cursor
keys, then pressing either the ON or OFF key. This will enable or
disable ALL reverse setpoints (peak and all data windows).
Enabling and disabling of reverse setpoints can only be done while
the keyswitch is in the PROG position.

REV-SET (ON)

2.5 STO/RCL

In the System 1100, the information which includes all peak and
data window tonnage setpoint limits is called the current setup.
Since tonnage setpoints limits are set according to the tonnage
required to make a good part for a particular die, and they must
usually be changed each time the die is changed. Ordinarily this
would require either manually entering new setpoints or executing

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the automatic setup function. Manually entering large numbers of
setpoints can be tedious, and using automatic setup each time a die
is changed gives no indication of what tonnage the die operated at
the last time it was used. What is needed is a permanent record of
the required tonnage for each die. The System 1100 provides for
permanent storage of up to 123 different setups through the Sto/Rcl
menu. The Sto/Rcl menu is shown below.

STORCL$STORE $
MENU $RECALL $9

REMOVE

The Sto/Rcl menu provides the operator with the capability to store
setups to backup memory, recall setups from backup memory, and
erase setups from backup memory.

2.5.1 STORE

The Store menu allows the operator to assign a job number and
description to the current setup, and to save the current setup to
backup memory. The Store menu is shown below.

STORE $ENTER JOB# $
MENU $ENTER DESC.$9

STORE JOB

2.5.1.1 ENTER JOB#

The ENTER JOB# screen allows the operator to assign a six digit job
number to the current setup. When the ENTER JOB# screen is
entered, the job number of the current setup is displayed as shown
below.

ENTER JOB NUMBER:
000025

While the keyswitch is in the PROG position, the job number will
flash indicating that it can be changed. To change the job number

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enter the new number over the old using the numeric keypad, then
press the ENTER key.

2.5.1.2 ENTER DESC

The ENTER DESC screen allows the operator to assign a 16 character
description to the current setup. When the ENTER DESC screen is
entered, the description of the current setup is displayed as shown
below.

ENTER JOB DESC:
(LATCH01 )

While the keyswitch is in the PROG position, the description will
flash indicating that it can be changed. To change the
description, enter the new description over the old using the
numeric keypad for numbers and the up and down arrow keys for
letters. When selecting letters with the up and down arrow keys,
once the desired letter is selected use the right arrow key to move
to the next letter in the description. When finished entering the
description press the ENTER key.

2.5.1.3 STORE JOB

Once the job number and description have been set, the setup should
be stored to backup memory. When the STORE JOB option is selected
from the Store menu the screen below will be displayed.

STORE (YES/NO) ?
000025

To store the job to backup memory press the YES key, to abort this
operation press the NO key or the EXIT key. If a setup is already
stored in backup memory with the same job number, the screen below
will appear.

JOB FOUND IN MEMORY.
OVERWRITE (YES/NO) ?

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To store the current setup over the setup already in backup memory
press the YES key, otherwise press the NO key or the EXIT key.

Figure 4. Storing a Setup.

At the conclusion of a successful job storage operation, the screen
below will be displayed.

JOB STORAGE DONE.
PRESS EXIT.

NOTE: Although setups are stored in the System 1100 the
operator is encouraged to keep written records of stored
setups. These records will be useful in recovering
setups accidently lost by operator error or in the event
of memory failure within the System 1100.

2.5.2 RECALL

The Recall menu allows the user to recall previously stored setups
from backup memory into the current setup. The Recall menu is
shown below.

RECALL$ENTER JOB# $
MENU $SELECT JOB $9

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2.5.2.2 ENTER JOB#

The ENTER JOB# screen allows the operator to directly enter the
number of job to recall. The ENTER JOB# screen is shown below.

ENTER JOB NUMBER TO
RECALL: ______

The six digit job number is entered by the operator using the
numeric keypad. When the operator presses the ENTER key after
keying in the job number, the System 1100 searches the backup
memory for the requested job and recalls it if it is found. If the
requested job is not present in backup memory a message indicating
so will be displayed.

2.5.2.1 SELECT JOB

The SELECT JOB screen allows the operator to search through a list
of all jobs stored in backup memory and select from that list a job
to recall. A typical SELECT JOB screen and list of jobs is shown
below.

The operator can use the up and down arrow keys to move through the
list of jobs. When the operator presses the ENTER key the System
1100 recalls the job currently shown on the LCD display.

JOB NUMBER: 000001
(X32-0786 ) 9

JOB NUMBER: 000012
(Q45-REV01 )

JOB NUMBER: 000003
(HUB-CAP )

JOB NUMBER: 000025
(LATCH01 )

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Figure 5. Recalling a Setup.

2.5.3 REMOVE

The Remove menu allows the user to erase stored job setups from
backup memory. The Remove menu is shown below.

REMOVE$ENTER JOB# $
MENU $SELECT JOB $9

2.5.3.1 ENTER JOB#

The ENTER JOB# screen allows the operator to directly enter the
number of the job to remove from backup memory. The ENTER JOB#
screen is shown below.

ENTER JOB NUMBER TO
REMOVE: ______

The six digit job number is entered by the operator using the

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numeric keypad. When the operator presses the ENTER key the System
1100 searches backup memory for the requested job and erases it if
it is found. If the requested job is not found a message
indicating so will be displayed.

2.5.3.2 SELECT JOB

The SELECT JOB screen allows the user to search through a list of
all jobs stored in backup memory and select a job for removing. A
typical SELECT JOB screen and list of jobs is shown below.

JOB NUMBER: 000001
(X32-0786 ) 9

JOB NUMBER: 000012
(Q45-REV01 )

JOB NUMBER: 000003
(HUB-CAP )

JOB NUMBER: 000025
(LATCH01 )

The operator can use the up and down arrow keys to move through the
list of jobs. When the operator presses the ENTER key the System
1100 erases from backup memory the job currently displayed on the
LCD display.

2.6 COUNTERS

The Counters menu provides access to the eight counters of the
System 1100. The counters can be divided into three types,
counters with presettable limits, alarm counters, and the Stroke
counter. Counters with presettable limits include the Part, Batch,
and Quality counters. Alarm counters include Machine Rating
Alarms, High Setpoints Alarms, Low Setpoint Alarms, and the Reverse
Setpoint Alarms counters.

When the Rate of Change automatic zeroing method is used (section

3.5.1) spurious counts can be produced if clutch or brake

engagement produces forces in the machine frame greater than the

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zeroing threshold. The most accurate counts can be obtained when
the System 1100 is used with the optional zeroing cam (sections

2.8.5 and 3.5.2).

The Counters menu is shown below.

CNTRS $PART $
MENU $BATCH $9

QUALITY

M.R. ALARM
HIGH ALARM
LOW ALARM
REV. ALARM
STROKE

2.6.1 PART, BATCH, and QUALITY COUNTERS

The Part, Batch, and Quality counters have presettable limits.
These counters can be programmed to stop the production process
after a specified number of parts have been made. Only good parts
are counted, that is, parts whose forward tonnage is between the
high and low setpoints, and whose reverse tonnage is less than the
reverse setpoint. These counters operate in this way regardless of
BYPASS mode, or low or reverse limits being turned off.

For installations where the System 1100 stop circuit is connected
to the emergency stop of the press control, the System 1100
provides a top-stop delay timer (section 2.8.9). This timer is
capable of providing delays from 0 to 1 seconds to stop the machine
with the ram at the top of the stroke when a counter limit is
reached.

The Part counter is intended to count the total number of parts in
a run. The Batch counter is intended to count the number of parts
per batch. This counter is useful if part bins must be changed
several times during a part run. The Quality counter is used to
stop the production process at regular intervals for the operator
to perform part quality inspections.

The Part, Batch, and Quality counters all operate similarly and so
the examples discussed below apply to all of these counters. An
example Batch counter screen is shown below.

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BATCH CNT: 0012934
(ON) LIMIT: 0123000

While the keyswitch is in the PROG position, the counter limit will
flash, indicating that it can be changed. This is done by entering
the new limit over the old using the numeric keypad, and then
pressing the ENTER key. The counter can be turned on or off while
in PROG mode by pressing the ON or OFF keys respectively. The
count value can be reset to zero while in PROG mode by pressing the
CLEAR key. The screen below will then appear.

CLEAR COUNTER?
(YES/NO)

Pressing the NO key will leave the count value in tact, while
pressing the YES key will reset the counter to zero. The example
counter screen is shown below after the counter has been cleared.

BATCH CNT: 0000000
(ON) LIMIT: 0123000

2.6.2 MACHINE RATING, HIGH, LOW and REVERSE ALARMS COUNTERS

The MACHINE RATING, HIGH, LOW, and REVERSE alarms counters count
the number of occurrences of each type of alarm. These counters do
not have limits, but should be checked regularly for excessive
numbers of alarms. All alarm counters operate similarly and so the
following discussion applies to all the alarm counters. An example
HIGH alarms counter screen is shown below.

HIGH-SET ALARMS:
0000027

While the keyswitch is in the PROG position alarm counters can be
reset to zero by pressing the CLEAR key. The screen below will
then prompt the operator for the access code.

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ENTER ACCESS CODE:
____

The access code is entered by using the numeric keypad, then
pressing the ENTER key. If the correct access code is entered, the
screen below will then appear.

CLEAR COUNTER?
(YES/NO)

Pressing the NO or EXIT keys will leave the alarm counter value in
tact, while pressing the YES key will reset the alarm counter to
zero. The alarm counter screen below is shown after the counter
has been cleared.

HIGH-SET ALARMS:
0000000

2.6.3 STROKE COUNTER

The stroke counter is used to record the total number of machine
stokes since the System 1100 was installed on the machine. The
stroke counter screen is shown below.

STROKE COUNT:
0000145267

The stroke counter can be cleared by pressing the CLEAR key and
then entering a special access code. The stroke counter can be
cleared only while the keyswitch is in the PROG position. Since
the stroke counter is meant to count the total number of strokes
for the machine, it should never be cleared except in the case of
moving the System 1100 to a different machine.

2.7 ERRORS

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The Errors menu provides the operator with the capability to view
a list of the currently active errors. Error codes are provided
with a short plain English explanation of error.

An example list of errors is shown below.

ERROR 05 - Channel
1 above threshold.9

ERROR 01 - Channel
1 will not zero.

ERROR 40 - End Of
Cycle cam failure.

ERROR 48 - Chan 1
high set too high.

Only one error is displayed at a time, with other errors available
by pressing the up and down arrow keys as indicated by the arrows
appearing at the right of the error screen. Errors can be cleared
by pressing the CLEAR key.

2.8 CONFIG

The Config menu allows the operator to program important
information about the machine on which the System 1100 is
installed, and on how the System 1100 will operate.

When the CONFIG option is selected from the Main menu the operator
will be prompted with the access code screen seen below.

ENTER ACCESS CODE:
____

The access code is entered by using the numeric keypad, then
pressing the ENTER key. If the correct access code is entered, the
Config menu will appear as shown below.

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CONFIG$CAL-CHECK $
MENU $MACH RATING$9

MACH NUMBER
THRESHOLD
CAM ZERO
DATA WINDOW
AUTO SETUP
MACH SPEED
TOPSTOP TMR
DECIMAL PT.
ALARM CLR
MEMORY CLR
STATIC-CAL

2.8.1 CAL-CHECK

The CAL-CHECK option is used to view the System 1100 calibration
numbers. When the operator selects the CAL-CHECK option from the
Config menu the screen below will appear and the calibration
numbers for each channel will appear in the tonnage displays. If
the number in the tonnage display varies, take the mean value of
the numbers that appear as the calibration number.

** CAL-CHECK MODE **
PRESS EXIT TO END

Always stop the machine from stroking before selecting the CAL­CHECK option. Calibration numbers are most accurately read when
the main machine drive system, including flywheels, is at a
standstill. Pressing the EXIT key will return the operator to the
Config menu.

2.8.2 MACH RATING

The machine rating number is a scale factor that is programmed into
the System 1100 during initial calibration. The machine rating
should never be changed after calibration unless a memory failure
causes the loss of the proper setting.

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When the operator selects the MACH RATING option from the Config
menu the machine rating screen will appear. An example machine
rating screen for a 100 ton machine is shown below.

MACHINE RATING:

100.0

A decimal point will automatically appear if the decimal point has
been turned on (section 2.8.10). For machines with capacities of
less than 500 tons, the decimal point should be turned on.

While the keyswitch is in the PROG position the machine rating will
flash, indicating that it can be changed. The machine rating is
entered directly by using the numeric keypad and then pressing the
ENTER key. The machine rating should be set equal to the rated
tonnage capacity of the machine on which the System 1100 is
installed.

2.8.3 MACH NUMBER

The MACH NUMBER screen allows the operator to assign a four digit
number to the machine. This number is used for machine
identification by the Link Systems Tonnage Monitor local area
network and Signature Analysis software.

When the MACH NUMBER option is selected from the Config menu, the
MACH NUMBER screen will appear as shown below.

MACHINE NUMBER:
1234

While the keyswitch is in the PROG position the machine number will
flash, indicating that it can be changed. The machine number is
entered by using the numeric keypad, and then pressing the ENTER
key.

2.8.4 THRESHOLD

The zeroing THRESHOLD is the minimum tonnage on any channel that is
required to produce a tonnage reading. Normally the zeroing

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threshold will be set at 5% of channel rating. However, on some
machines clutch and brake engagement can cause forces in the
machine frame greater than this threshold, resulting in nuisance
tonnage readings. For this reason the threshold can be adjusted up
to 10% in the THRESHOLD screen as shown below.

THRESHOLD: 5%
(USE 89 TO CHANGE)

While the keyswitch is in the PROG position the threshold will
flash, indicating that it can be changed. To increase or decrease
the threshold press the up or down arrow keys respectively.

2.8.5 CAM ZERO

CAM ZERO (zeroing by position) enables an external rotary cam
switch or limit switch to control the System 1100 zero circuits.
When CAM ZERO is enabled, the zero circuits are no longer
controlled by the zeroing threshold but instead by the closure of
the external cam switch. The CAM ZERO screen is shown below.

CAM ZERO MODE: ON
(ON/OFF TO CHANGE)

While the keyswitch is in the PROG position the ON or OFF indicator
will flash, indicating that it can be changed. To enable or
disable the use of the external zeroing cam, press the ON or OFF
keys respectively.

2.8.6 DATA WINDOW

The DATA WINDOW option in the Config menu allows the user to
completely disable the use of data windows. If data windows will
never be used, it is recommended that they be disabled in this way.

Disabling data windows simplifies some menu operations. In
particular, disabling data windows eliminates the DISPLAY option in
the Main menu. Also, when the SETPOINTS option is selected in the
Main menu, the operator is immediately shown the peak setpoints
instead of having to select from a list of the peak and data window
1, 2, 3, and 4 setpoints.

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The DATA WINDOW screen is shown below.

DATA WINDOWS: OFF
(ON/OFF TO CHANGE)

While the keyswitch is in the PROG position the ON or OFF indicator
will flash, indicating that it can be changed. To enable or
disable the use of the data windows, press the ON or OFF keys
respectively.

2.8.7 AUTO SETUP

The AUTO SETUP option in the Config menu allows the operator to set
the automatic setup tolerance. While the automatic setup tolerance
can be adjusted during auto setup process, this screen is useful
for initial machine configuration. The auto setup configuration
screen is shown below.

AUTO SETUP TOL: 5%
(USE 89 TO CHANGE)

While the keyswitch is in the PROG position the automatic setup
tolerance will flash, indicating that it can be changed. The
tolerance can be adjusted up to 30% and down to 1% using the up and
down arrow keys respectively.

2.8.8 MACH SPEED

The MACH SPEED option in the Config menu allows the operator to
configure the operating speed for the machine on which the System
1100 is installed. For variable speed machines, the speed range
should be select for the maximum operating speed of the machine.
The machine speed screen is shown below.

SPEED: 61-120 SPM
(USE 89 TO CHANGE)

While the keyswitch is in the PROG position the speed range will

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flash, indicating that it can be changed. The operator can adjust
the speed range from 'OVER 600 SPM' to '0-60 SPM' using the up and
down arrow keys respectively. Correct setting the machine speed is
necessary for the proper operation of the System 1100.

Note! For machines running over 500 strokes per minute a zeroing
cam should be installed (section 3.5.2).

2.8.9 TOPSTOP TMR

For installations where the System 1100 stop circuit relay is
connected to the press control emergency stop, the top-stop delay
timer can be used to delay the activation of the stop circuit relay
until the press ram is at the top of the stroke. The top-stop
delay timer only affects stops caused by the PART, BATCH, and
QUALITY counters. The top-stop delay timer screen is shown below.

TOP-STOP DELAY TIMER
000 ms

While the keyswitch is in the PROG position the delay time will
flash, indicating that it can be changed. The operator can program
a new delay time by entering the new time over the old using the
numeric keypad, and then pressing the ENTER key. The top-stop
delay timer can be set from 0 to 1 second with one millisecond
resolution.

For installations where the System 1100 stop circuit relay is
connected to the press control top-stop circuit, the top-stop delay
timer should be set to 000 milliseconds.

2.8.10 DECIMAL PT

The DECIMAL PT screen allows the operator to turn on or off the
decimal point in the System 1100 tonnage displays. For machines
with capacities of less than 500 tons, the decimal point should be
turned on. The decimal point screen is shown below.

DECIMAL POINT: ON
(ON/OFF TO CHANGE)

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While the keyswitch is in the PROG position the on/off indicator
will flash, indicating that it can be changed. The operator can
turn the decimal point on or off by pressing the ON or OFF keys
respectively.

When the decimal point has been turned on, a decimal point will
automatically appear in all setpoint programming screens and the
machine rating screen.

2.8.11 ALARM CLR

The ALARM CLR screen allows the operator to enable/disable
restrictions on the use of the CLEAR key for clearing alarms and
errors. The alarm clear configuration screen is shown below.

ALARM CLEAR ACCESS:
BYPASS/RUN/PROG

The sample alarm clear screen shown above indicates that the CLEAR
key can be used for clearing tonnage setpoint alarms and errors
while the keyswitch is in any position (BYPASS, RUN, or PROG).

ALARM CLEAR ACCESS:
PROG

The sample alarm clear screen shown here indicates that the use of
the CLEAR key for clearing alarms and errors has been restricted to
use only while the keyswitch is in the PROG position.

While the keyswitch is in the PROG position the alarm clear access
will flash, indicating that it can be changed. The operator can
toggle between the two alarm clear access settings by pressing the
ENTER key.

2.8.12 MEMORY CLR

The MEMORY CLR function is used to erase the current job setup in
the event of a failure of the non-volatile memory. If the System

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1100 detects that the current setup has inadvertently been
corrupted, ERROR 45 (Current job setup corrupt) will result.

Two options are available for correcting this situation, the
operator can recall a previously stored setup, or can erase the
current setup using the MEMORY CLR function. If the entire non­volatile memory has been corrupted, recalling a previously stored
setup will not be possible, and so the MEMORY CLR function would be
necessary.

When the MEMORY CLR option is selected from the Config menu, the
operator is prompted with the screen below. Pressing the YES key
will erase the current setup, while pressing the NO key will return
the operator to the Config menu.

CLEAR CURRENT JOB
SETUP (YES/NO) ?

After the MEMORY CLR function has been executed all setpoints, peak
and all data windows, will be set to zero tons. Stroking the
machine with these setpoints will immediately cause setpoint
alarms. The operator should either manually enter proper operating
setpoints (section 2.4.1), or begin the automatic setup function
(section 2.1.2.1) before stroking the machine.

2.8.13 STATIC-CAL

The STATIC-CAL screen is used for static calibration of the System
1100 using hydraulic jacks. When the STATIC-CAL option is selected
from the config menu the screen below is displayed.

* STATIC-CAL MODE *
PRESS EXIT TO END

While in the STATIC-CAL screen, the System 1100 keeps the zero
circuits turned off, and continuously updates the tonnage displays
with the current tonnage seen by the strain gages. This allows
static loads, created using hydraulic jacks, to be used for
calibration. For more information on static calibration see
section 6.2.

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Section 3. Theory of Operation

3.1 General

Load bearing structural members of machines are elastic bodies -­stretching, compressing, bending, and/or twisting depending on
applied forces. Externally applied forces or moments (torsion)
applied to a solid body cause internal stresses (forces per unit
area) in that body, resulting in dimensional changes of the body.
Such force induced dimensional changes are referred to as strain,
and are expressed as changes in length per unit length.

The strain induced in a metal structural member depends on the
externally applied force, the physical properties of the particular
metal used, and the geometry of the structural member. As long as
stresses within a structural member are less than a certain value,
(dependent on type of material) called the limit of
proportionality, strain is proportional to stress, and for a given
geometric shape and material, to the size, direction, and point of
application of externally applied force. Within this "elastic
region" of the material, the structural member will return to its
original dimensions when an externally applied force is removed.

External forces of such magnitude as to induce stresses in the
material somewhat above the limit of proportionality will cause the
material of the structural member to reach the yield point, causing
permanent distortion of the structural body when the force is
removed. Still greater applied forces will cause the material to
reach the point of fracture, breaking the structural member.

Long term fatigue of structural members is also related to force
induced stress levels and the number of stress cycles (applications
and removals of force on the structural member). Lifetime of
structural members operated well within the elastic region of the
structural material (at low stress levels relative to the limit of
proportionality) is extremely long in terms of stress cycles (and
hence machine cycles). Lifetime is significantly reduced as
structural member stresses near the limit of proportionality.

Structural members of machines that use force in production
processes normally are designed so that induced stresses at rated
load are well below the limit of proportionality, avoiding
stretched, bent or "sprung" machine components and short machine
cycle lifetimes. Thus, the machine operates in the elastic region
of its structural members, with stresses and strains that are
related to applied loads. The stretch or compression of certain

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THEORY OF OPERATION

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machine structural members can indicate the force applied by the
machine (machine load) as well as the load distribution to
structural members in production processes.

3.2 Measurement of Load

System 1100 Tonnage Monitors use strain gauge transducers (strain
links) mounted to appropriate load bearing structural members of
power presses and other machines to measure load. These strain
links, consisting of a Wheatstone bridge arrangement of strain
gauges attached to an intermediate fixture, provide electrical
signals proportional to the amount the intermediate fixture is
stretched or compressed. When mounted to a machine structural
member, the intermediate fixture follows dimensional changes of the
machine structure, stretching and compressing with the section of
machine structure between fixture mounting points.

A very stable voltage is used to excite the strain gauges on the
intermediate fixture. When the fixture is stretched or compressed,
the strain gauges change resistance with dimensional change,
increasing or decreasing resistance due to tension or compression,
respectively. A change in output voltage proportional to this
resistance change and the excitation voltage is generated,
providing a signal to the tonnage monitor that can be used to
determine machine load.

The dimensional changes of machine structure between strain link
mounting points are usually in the microinch range, with
corresponding strain link signal outputs of millivolts. The strain
links are connected to the tonnage monitor with shielded wire. The
strain link signals are amplified by the System 1100 channel cards
to larger voltage levels and the maximum (peak) signal is stored in
a peak hold circuit each cycle until read by the microprocessor and
displayed on the digital readouts as tonnage. Calibration of the
tonnage monitor occurs when electrical signals from all strain
links due to known load are amplified to a voltage level that
causes the known load to be displayed on the digital readouts.

The selection of machine structural members whose strain is to be
measured depends on machine structural configuration and load
information desired. For example, on a single point gap or OBI
power press, the total tonnage exerted by the press passes through
the single connection from crankshaft to slide (ram). Therefore,
a single strain link mounted on this connection can be used to

3-2

THEORY OF OPERATION

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monitor total machine tonnage.

This monitoring method, however, does not determine load
distribution to the two sides of the machine frame due to off
center die forces. Since press manufacturers rate machines with a
uniformly distributed central load, the two "C" shaped side members
of the machine are designed to carry one-half the total machine
load rating (usually a generous overdesign allowance is provided
for short-term overloads). Tooling forces that act to the left or
right of the front vertical centerline of a gap or OBI press
distribute a larger proportion of the load to the left or right
side of the frame, respectively. Thus, it is possible to use dies
that exert forces within the machine rating and still overstress
one side of the machine frame due to off center loading.

Using two strain links, one on each sideframe member of a gap OBI
press, and using a two channel tonnage monitor gives the
distribution of tonnage to each side of the machine frame. Alarm
limits may be set for both sides of the frame to prevent
overloading due to off center loads. The total peak tonnage
exerted by the press is obtained for display by continuously
summing the two channel outputs and storing the maximum value of
the sum each machine cycle.

Similarly, machines with straight side frame configurations (four
corner post or modified four post construction) can be monitored as
to load distribution and total load by using a four channel tonnage
monitor with strain links on each upright between bed and crown.
Such monitoring indicates both eccentric loading from front to back
as well as left to right. A two channel tonnage monitor with
strain links mounted on the two connections of a two point straight
side press can measure left and right load distribution and total
load, but not front to back off center loading.

3.3 Summing Multiple Channel Outputs to Obtain Total Load

When multiple strain links are used to measure load distribution to
machine frame members, the outputs of tonnage monitor channels
associated with each transducer must be added to obtain the total
tonnage exerted by the machine in the production process. Strain
links should be mounted on geometrically symmetrical frame members
that share equal proportions of a centrally located machine load;
i.e., the two side frames on "C" frame machines, uprights on

3-3

THEORY OF OPERATION

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straight side machines, or, in certain applications, on the
multiple connections between crankshaft and slide on machines that
develop slide motion mechanically. Under these conditions of
geometric symmetry, a central machine load should be divided
equally to each strain link. Each channel of a two channel tonnage
monitor should read 1/2 and each channel of a four channel unit
should read 1/4 of a central load.

To obtain the peak total tonnage exerted by complex tooling in a
machine cycle with staggered forces that are not centrally located,
System 1100 tonnage monitors do not add the peak tonnages on each
channel. Rather, the instantaneous sum of all channel outputs is
taken, and a separate peak hold circuit stores the peak total
signal for display. On complex tooling, the total peak tonnage is
not usually the sum of the displayed tonnages on each channel! To
illustrate this principle, consider a die with two staggered
punches of equal cross-sectional area and that are equally sharp.
The longer punch is located on the left side of the die, and the
shorter punch is on the right side of the die as shown in Figure 5.

Assume the die is located in the
center of an OBI press bed and
that two holes are to be pierced
in a sheet metal blank. A two
channel tonnage monitor is used
with strain gauge transducers
located on both sides of the
press frame, and the load signal
for both left and right channels
is observed on an oscilloscope
to be that shown in Figure 6.

The oscilloscope trace shows
that the longer left punch
contacts the blank first and
exerts a peak total force of 100
tons at time t1, with 60 tons distributed to the left side of the
frame (since the punch exerts its force to the left of the press
centerline) and 40 tons distributed to the right side of the frame.
A moment after the left punch breaks through the blank, the right
punch contacts the blank and builds up to a total peak tonnage of
100 tons at time t2, with 60 tons distributed to the right side and
40 tons to the left side of the press frame.

Figure 6.

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Figure 7.

The peak tonnage on the left side of the press was 60 tons at time
t1. The peak tonnage on the right side of the press was 60 tons
at time t2. But the peak total tonnage never exceeded 100 tons.
Thus, the correct readings on the tonnage monitor display are 60
tons on the left channel, 60 tons on the right channel, and 100
tons for the total peak tonnage.

3.4 Limits of Measurement Accuracy

Several factors influence the absolute accuracy of tonnage
measurements on machines that use forces in production processes.
Although inherent instrument accuracy can be within 1% of total
machine rating, there are machine and load dependent factors which
can affect tonnage readings.

3.4.1 Machine Vibration

On mechanically driven machines with flywheels and crankshafts,
harmonic vibratory forces induce low level tensile and compressive
stresses and strains in the machine frame. The induced strain on
large machines, and particularly large gear driven machines with
clutch engaged, can be as large as a few percent of strains induced
in the frame due to loading the machine to rated tonnage. This
results in a "wiggly" baseline electrical signal from strain gauge

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THEORY OF OPERATION

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transducers when no load forces are being developed in the machine,
and may cause a small variation in displayed tonnage from stroke to
stroke for each channel as harmonic strain is added to load strain.
It should be noted, however, that the effects of harmonic vibration
are generally reduced when the machine actually exerts force in the
production process. Figure 7 illustrates harmonic "mechanical
noise" in a strip chart recording of a tonnage monitor output
signal.

Figure 8. Harmonic Noise.

3.4.2 Structural "Ringing"

Any elastic body has a natural response which dies out with time if
energy is suddenly applied to or removed from the body. Just as
a diving board vibrates back and forth in dying oscillations until
it is again stationary when suddenly relieved of a person's weight,
a machine structure "rings" when load is suddenly released by
material breakthrough in blanking and piercing operations. Figure
8 illustrates a typical ringing at the end of a blanking operation
in a tonnage monitor signal.

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Figure 9. Structural Ringing.

The positive going signal is generated by machine frame stretch as
the tooling builds up force on the material. The signal increases
until the tooling breaks through the partly sheared material,
suddenly releasing the machine load to zero. The sudden release of
load causes the machine structure to rebound, creating the dying
oscillations (ringing) in the machine structure after material
breakthrough. The first negative peak of the oscillation is the
largest strain caused in the machine frame due to ringing, and is
often referred to as the "snapthrough" force. In effect, the
energy stored in the machine's frame under load creates a reverse
load on the machine when suddenly released.

Depending on structural mass and stiffness, ringing generally dies
out in a few milliseconds to a few hundredths of a second. This
short response normally has no effect on tonnage monitor accuracy
as long as machine speeds are less than 600 strokes per minute. At
speeds greater than 600 strokes per minute, the ringing may not die
out between load signals, and can cause a small offset in tonnage
monitor readings because the continuous ringing between load
signals interferes slightly with automatic zeroing circuits.

Ringing normally doesn't occur in forming, coining, forging, or
powdered metal compacting operations. The load on these operations
is released slowly by the machine ram or slide in the upstroke.

3.4.3 Structural Nonlinearity and Eccentric Loading

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THEORY OF OPERATION

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Although stress and strain at a given location on a machine load
bearing structural member is proportional to the load force
transmitted to that location, certain conditions of eccentric
loading can induce signals that are not equal to the actual force
exerted by tooling.

Tonnage monitors on Gap, OBI, and other "C" frame power presses and
other machines calibrated with a load centered under pitmans (or
cylinder rod connections on hydraulic machines), will indicate a
tonnage greater than that actually exerted by dies when tooling is
moved forward of center under the ram or slide. When the same
force is applied forward of slide center, it acts through a longer
lever arm on the "C" frame, stretching (straining) the front of
the frame and compressing the rear of the frame more than when
centrally located. The larger strains act on the tonnage monitor
strain links to indicate tonnages that are larger than actually
exerted by tooling. It should be noted that the forward located
tooling produces the same stress and fatigue of the frame as a
centrally located tonnage seen by the frame. In addition, the
forward load tries to cock the slide and introduces lateral forces
in gibs in ways that accelerate wear.

On straight side presses and other machines of similar design,
eccentric loading that is not supported by connections to the ram
or slide can cock the slide or ram and introduce bending moments
into uprights through gibbing that causes strain links to be
stretched more than by vertical forces alone. Again, however, the
effect on the machine is equivalent to a central load of the
tonnage indicated by the tonnage monitor.

As long as bearing and gib clearances are within recommended
tolerances, the tooling forces will be accurately indicated by a
tonnage monitor on two point machines, if the load is applied
beneath the connections or near the straight line between
connections. On a four point machine, accurate tooling forces are
indicated as long as loads are applied in the rectangular area
within the four connections to the slide or ram.

3.5 Automatic Zeroing

Temperature changes cause expansion or contraction of machine
structural members, introducing strains in typical steel or cast
iron machine frames of 6 to 7 microinches/inch per degree
Fahrenheit. The strains induced by temperature must be

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THEORY OF OPERATION

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distinguished from the strains induced by machine loads and be
compensated if tonnage monitors are to provide accurate reading.
The temperature induced strains are sensed by tonnage monitor
strain links and will shift the "zero" signal (baseline) level from
which strains induced by loads are measured unless automatic
zeroing of the baseline is provided.

3.5.1 Rate of Change Automatic Zeroing

Two alternative methods of automatic zeroing are provided with
System 1100 Tonnage Monitors. The first method distinguishes
between thermal and load induced signals by the rate of change of
sensed strain. Temperature induced strains occur extremely slowly,
while load induced strains occur extremely rapidly (in a few
milliseconds). The slow changes are "zeroed out" of the system by
a special circuit. Load signals reach a threshold level before the
special zero circuit can react and turn off the zero circuit for
the relatively brief time that the signal is above the threshold
level.

After the primary load signal falls below the threshold level, an
internal timer delays turn on of the automatic zero circuit for up
to 200 milliseconds to allow peak circuits to capture reverse loads
due to snapthrough or stripping forces and to avoid integrating
snapthrough forces into the baseline.

The threshold level and internal delay timer associated with rate
of change zeroing are also used to determine when a completed
signal is displayed on the tonnage displays. A load signal is
displayed only after the signal has decreased below the threshold
level and remained below the threshold for the internal delay time.
This allows the highest peak only of several that might result in
a single stroke from progressive or staggered tooling to be
displayed, instead of the last peak. This is illustrated in Figure

9. The amount of delay time is set according to the machine speed
setting located in the Config menu (section 2.8.8). For proper
operation of the System 1100 the machine speed must be set
correctly.

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THEORY OF OPERATION

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Figure 10.

Without the delay time, the tonnage display would be updated three
times in a single stroke, retaining only the last (40 ton) peak for
a time long enough to be read. Each time the signal goes above the
threshold the timer is reset.

The threshold level to which a signal has to rise to turn off the
automatic zero circuit is about 5% of rated channel tonnage. On
some machines, particularly larger geared machines, clutch
engagement or braking can introduce torques that strain the machine
frame as much or more as load signals equal to 5% of rated channel
tonnage. These extraneous signals will produce nuisance readings
on the tonnage displays.

The threshold level can be changed to 10% of rated channel tonnage
in the THRESHOLD screen located in the Config menu (section 2.8.4).
This is only recommended for machines that don't perform draw
operations or other operations using air cushions or nitrogen
cylinders for material clamping. Air cushions or nitrogen
cylinders may exert forces too low to reach the 10% threshold
during the first part of tooling contact. The automatic zero
circuit will then continue to operate until the tooling closes
enough to exert forces that cross the 10% threshold, shifting the
baseline by a few percent of rated tonnage and introducing errors
of a few percent of rated tonnage into the peak tonnage indicated.

When clutch and brake engagement cause nuisance readings, the
recommended procedure is to employ automatic zeroing by position,
as discussed next in this manual.

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THEORY OF OPERATION

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3.5.2 Automatic Zeroing by Position

The second method of automatic zeroing provided on a System 1100
Tonnage Monitor is zeroing by position (cam zeroing). A cam switch
or limit switch adjusted to be closed when the machine ram or slide
is in a region where no force is generated by tooling "tells" the
automatic zero circuit when no load is on the machine, allowing the
circuit to be activated. The cam or limit switch opens before the
tooling closes in the downstroke to turn off the zero circuit and
capture the peak load signal. The cam or limit switches close
again on the upstroke after tooling and stripper forces are over to
resume zeroing.

3.6 Data Windows

Peak tonnage monitors capture the maximum tonnage seen by each
strain gauge. This maximum tonnage is used for comparison to
setpoints in determining if an alarm should be generated to stop
the production process. While this is adequate for most
applications, complex tooling can produce multiple peaks resulting
in only the greatest peak being checked against setpoints. Where
closer monitoring is desired in these applications, System 1100
Tonnage Monitors provide four Data Windows to monitor up to four
additional peaks other than the absolute maximum peak tonnage.
These additional peaks are referred to as 'local' peaks. The
position of the local peaks is determined by external cam switches
connected to the System 1100 data window inputs, labeled DW1, DW2,
DW3, and DW4.

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THEORY OF OPERATION

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Figure 11. Use of a Data Window.

The tonnage verses time graph in Figure 10A is for a two station
die. The first station stamps a logo onto the part (absolute peak)
and the second station cuts out the part (local peak).

Since the absolute peak tonnage is created by the coining of the
logo, the local peak is not checked using a normal peak tonnage
monitor. The local peak could completely disappear as shown in
Figure 10B and a normal peak tonnage monitor would not detect any
anomaly in the process. This is exactly what would happen if the
material did not feed between strokes. Using a single data window,
however, places a high, low, and reverse tonnage setpoint on the
local peak.

Data window cams should be set to turn on before the local peak and
turn off after the local peak. When a data window input is active
(cam closed), the corresponding data window setpoints become
active. When no data window inputs are active (all open) the
absolute peak setpoints are active. This is illustrated in Figure
10 with the active setpoints shown as horizontal dashed lines.

In the maximum configuration the System 1100 can use five groups of
setpoints (peak & 4 data windows). On a four channel unit using

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THEORY OF OPERATION

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all three types of setpoints (high, low, and reverse) this yields
a total of 60 setpoints (5 x 4 x 3 = 60), which is a lot of
setpoints to key in by hand! The System 1100 Auto Setup function
makes entering these setpoints unnecessary, by automatically
calculating and storing all of these setpoints.

3-13

Section 4. Applications Information

4.1 Selection of Automatic Zeroing Method

As explained in the Section 3 of this manual, two methods of
automatic zeroing are possible with a System 1100 Tonnage Monitor.
The rate of change method of automatic zeroing requires less
hardware (no cam switch or limit switch) and less installation
wiring and is excellent for most non-geared mechanical power
presses, hydraulic presses, and similar machines. Each System
1100 shipped from the factory is set up for standard rate of change
zeroing.

Although rate of change zeroing often works well on some large gear
driven machines, a significant number of such machines experience
strains in the machine frame large enough to induce small load
readings on the System 1100 tonnage display due to forces
introduced by gear slap, clutch engagement, and/or brake engagement
acceleration characteristics. It is recommended that zeroing by
position (cam zeroing) be used on large gear driven machines. Some
smaller non-geared machines with high clutch or brake torque may
also significantly strain the machine frame and produce unwanted
tonnage readings due to clutch or brake engagement.

If rate-of-change zeroing is used, follow the checkout procedures
outlined in Section 7 to confirm that no nuisance readings due to
mechanical "noise" interfere with desired tonnage readings.

4.2 Strain Link Mounting Locations

4.2.1 "C" Frame Machines

Machines with "C" frame configurations, such as OBI and GAP frame
presses, OBS hydraulic presses, etc., are best monitored with two
strain links input to a two channel System 1100 Tonnage Monitor.
One strain link should be mounted on each sideframe member.

This monitoring method indicates total tonnage as well as load
distribution to both sides of the machine frame. It also indicates
when excessive stress is placed on the machine by tooling that is
located forward of the pitman(s) or other connection(s) to the
machine slide. Choices of strain link mounting locations are
illustrated in Figure 11.

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APPLICATIONS INFORMATION

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Figure 12. "C" Frame Machine.

The preferred mounting locations are near the middle of the front
of the "C" frame. The forces that occur at the front of the
machine frame are tensile forces. The compression forces that
occur at the "acceptable" locations at the rear of the "C" frame
can be accompanied by nonlinear buckling (bending) on thin web
sideframes of some machines.

Do not mount strain links near the curves at the front of the "C"
frame. The curvature of the frame produces nonlinear strain
signals. Also, on presses with increased cross sections near the
front of the frame, avoid mounting sensors next to the change of
cross section to avoid nonlinear strain signals. The center
portion of the front face of the "C" frame is an excellent sensing
location, but sensors are highly susceptible to damage from die
setting operations.

4.2.2 Straight Side Machines

Straight side presses and other machines of four "corner post" or
modified four "corner post" construction are best monitored by four
strain links that input to a four channel System 1100 Tonnage
Monitor. On machines with tie rod through hollow upright (column)
construction, strain links may be mounted on either the tie rods
or the uprights, although ease of installation usually dictates

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APPLICATIONS INFORMATION

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mounting the strain links on uprights. On solid frame straight
side machines, the uprights are also the best strain link
locations.

Mounting strain links on each upright gives load distribution to
each upright as well as total load. This method helps indicate
optimum tooling location to minimize load and machine deflection.

The best strain link locations are below gibs and at least 12
inches above where the upright joins the machine bed. Locating the
strain links in the gib region can cause excessive bending moments
to be translated through the gibs into the upright as the slide
tries to "cock" for some conditions of eccentric loading.
Locations too near the bottom of the upright may produce a
nonuniform strain field. Do not mount strain links on any side of
an upright that has a tie rod access opening. When holes are
present in the desired upright mounting location, avoid mounting
strain links any closer than three diameters of the hole directly
above or below the hole or any closer than one diameter of the hole
to the side of the hole. Don't mount strain links in recessed
panel areas in uprights.

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APPLICATIONS INFORMATION

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Figure 13. Straight Side Machine.

Stay away from corners of uprights as strain link mounting
locations. The best locations on the upright for strain links on
machines of tie rod construction are generally on the centerline of
the tie rod. Avoid any mounting locations where uprights have
internal reinforcements or other change of section. Insofar as
possible, strain links should be mounted in conditions of geometric
symmetry on uprights and at the same vertical height on each
upright. Figure 12 illustrates mounting locations for straight
side machines of tie rod construction.

Figure 13 shows areas to avoid on uprights of straight side
machines of tie rod construction. The cross-hatched areas should
be avoided.

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APPLICATIONS INFORMATION

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Figure 14.

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APPLICATIONS INFORMATION

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On solid frame straight side machines, the preferred strain link
mounting location is inside the "windows" under the ends of the
crankshaft. A strain link should be mounted on the inside face of
each column forming the "windows" as shown in Figure 14.

Figure 15.

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APPLICATIONS INFORMATION

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4.2.3 Overdrive Double Action Presses

Overdrive double action presses have an inner and an outer slide
that are driven by connections from crankshafts located in the
crown (top) of the press structure.

If the strain links are installed on the uprights of the press
(double action presses are usually straight side structures) the
peak tonnage displayed will be the sum of the outer slide and the
inner slide tonnages. Additionally, One data window can be used to
measure the tonnage of the outer slide alone. The data window cam
should be set to close before the outer slide reaches the bottom of
the stroke then open before the inner slide contacts the material
to be formed.

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APPLICATIONS INFORMATION

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Figure 16. Overdriven Double Action Press.

If both inner and outer slide tonnage readings are desired, the
most accurate measurement is obtained by using strain links on each
connection to the outer slide as inputs to one System 1100 Tonnage
Monitor, and strain links on each connection to the inner slide as
inputs to a second System 1100 Tonnage Monitor. This is
illustrated in Figure 15.

4.2.4 Underdrive Machines

Machines that have underdrive action with connecting rods that pull
the slide(s) down from a drive system located in the bed of the
machine must be monitored by strain links mounted on each
connecting rod to the slide(s). On underdriven double action
presses, two separate tonnage monitors should be used to monitor

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APPLICATIONS INFORMATION

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tonnage of the inner and outer slide.

4.2.5 High Speed Machines

The fast response of the System 1100 peak hold circuits and the
total logic cycle time make it possible to monitor tonnage on
machines that run continuously at speeds in excess of 2000 strokes
per minute (spm). When such machines are operated at speeds in
excess of 1000 spm at loads only a fraction of rated machine
capacity, the mechanical "noise" introduced by harmonic motion and
"ringing" of the frame may produce strains in the machine frame
that are significant relative to the load signal. If so, the load
indications of any tonnage monitor will exhibit significant
variations from stroke to stroke.

Depending on machine construction and application, however, many
high speed operations can be successfully monitored for load. The
System 1100 has superior design characteristics for these
applications. Strain Link mounting locations for "C" frame and
straight side high speed machines are the same as for slower
machines of similar frame construction.

4.2.6 Other Applications

System 1100 Tonnage Monitors can also be used on other machines
that use force in production processes. These include upsetters,
injection molding machines, cold headers, etc. Information
concerning strain link mounting locations can be supplied by your
Link representative.

4-9

Section 5. Installation

5.1 Mounting the Enclosure

System 1100 Tonnage Monitors are available in two mounting
configurations, the self-contained unit, and the panel mount unit.

The self-contained unit (Figure 1, page 1-3) houses all System 1100
electronics in one enclosure. Mounting dimensions for the self­contained unit enclosure are shown in Figure 16.

The panel-mount unit (Figure 2, page 1-4) separates the Operator
Interface Terminal (OIT) electronics from the Logic Unit
electronics. This configuration is useful when the tonnage monitor
display is to be mounted in a panel where depth is limited, or when
the display is to be mounted a long distance from the strain
gauges. Mounting dimensions for the OIT and the Logic unit
enclosure are shown in Figures 17 and 16 respectively.

For either configuration the Operator Interface Terminal (OIT) or
self-contained unit enclosure should be mounted in a position that
permits operator observation of the tonnage displays and
accessibility to persons designated to adjust setpoints. When the
unit is mounted on the machine, always mount the enclosure on the
shock mounts provided.

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INSTALLATION

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Figure 17. System 1100 Mounting Dimensions.

5-2

INSTALLATION

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Figure 18. System 1100 Remote OIT Mounting Dimensions.

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INSTALLATION

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5.2 Mounting the Strain Links

Strain links may be bolted directly to the machine or bolted to
intermediate pads welded or adhered to the machine.

5.2.1 Direct Machine Mounting

1) Select the desired mounting locations for the strain links
(section 4.2).

2) Remove paint, oil, grease, etc., to obtain a bare metal
surface slightly larger than the LST-1000 strain link. The
metal surface must be flat and smooth so that the strain link
is not warped and contacts the surface area evenly when
mounted. A mounting surface that is flat within .0025 inches
and with a 250 microinch or less finish will give best
results. Grind the surface if necessary.

3) Scribe a line on the metal surface on which the strain link is
to be mounted in the direction of tension or compression of
the structural member. This will be a vertical line on
columns or ties rods of straight side presses and OBI and
other "C" frame machines that are not inclined. On inclined
OBI presses and other machines, the scribe marks should follow
the inclined angle.

4) Place the hardened drill
fixture provided with the
direct mounting strain
link kit in position
adjacent to the scribed
line and use a no. 3 drill
to drill a 5/8" deep hole
through the center hole
position of the drill
fixture. Tap the hole for
a 1/4 x 28 thread. Bolt
the drill fixture securely
to the mounting area, as
shown in Figure 18.

Figure 19. Drill Fixture.

5) Use a no. 3 drill to drill 5/8" deep holes in the mounting
surface through the remaining four holes in the drill fixture.
Tap the holes for a 1/4 x 28 thread after removing the drill

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INSTALLATION

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fixture.

Note! Do not attempt to locate and drill mounting holes
without using the drill fixture. The hole pattern must be
precise.

6) Deburr the mounting holes and wipe the mounting area with a
clean rag.

7) Mount the strain link as
shown in Figure 19. Make
certain that the washers
provided with the strain link
kit are placed over the
strain links. Torque the 1/4
x 28 bolts to 150 in-lbs. A
calibrated torque wrench is
the preferred tool to torque
the bolts.

8) Mount the protective cover
box provided in the strain
link kit, if used, centrally
over the strain link. It is
important to mount the cover box before calibration begins.
The cover box mounting holes may slightly change the strain
sensed by the strain links.

5.2.2 Intermediate Weld Pad Mounting

1) Select the desired machine
mounting locations for the
strain links (section 4.2).

2) Remove paint, oil, grease,
etc., to obtain a bare metal
surface slightly larger than
the LST-1000 strain link.

3) Clean the mounting surface
with a solvent, removing all
grease, oil, and other
contaminants.

Figure 20. LST-1000 Strain
Link.

Figure 21. Alignment Fixture.

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INSTALLATION

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4) Assemble the intermediate pads to the alignment/clamping
fixture using the 1/4 x 28 bolts provided, as shown in Figure

20.

5) Hold the alignment/clamping
fixture firmly on the
mounting area in the
direction of tension or
compression of the structural
member or, alternatively,
drill a 5/8 inch deep hole
through the center hole of
the alignment/clamping
fixture, tap for 1/4 x 28
threads, and bolt the
alignment/clamping fixture to the mounting area through the
center hole. Tack weld both sides of each intermediate pad to
the mounting surface first, then continuously weld the out
ends and sides of the intermediate pads to the mounting
surface as shown in Figure 21.

Figure 22. LST-1000 Weld
Pads.

6) Remove the alignment/clamping fixture and bolt the LST-1000
strain link to the pre-tapped holes in the intermediate pads.
Make certain that the washers provided with the strain link
kit are placed over the strain links. Torque the 1/4 x 28
bolts to 150 in-lbs. A calibrated torque wrench is the
preferred tool to torque the bolts.

7) Mount the protective cover box provided in the strain link
kit, if used, centrally over the strain link. It is important
to mount the cover box before calibration begins. The cover
box mounting holes may slightly change the strain sensed by
the strain links.

5.2.3 Intermediate Adhesive Pad Mounting

1) Repeat steps 1-4 of the procedure for Intermediate Weld Pad
Mounting.

2) Thoroughly clean the mounting surface and intermediate pads
with a solvent such a perchloroethylene or triclorethylene,
etc.. It is important to remove all grease or oil from the
surfaces to be bonded.

3) Mix the epoxy cement provided with the intermediate adhesive

5-6

INSTALLATION

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pad strain link kit thoroughly.

4) Apply an even coat 1/16" deep on the bottom of the
intermediate pads.

5) Clamp the alignment/intermediate pad assembly firmly to the
mounting area for at least 24 hours. The press must not be
operated during the curing of the epoxy.

6) After the epoxy has cured for 24 hours, remove the
alignment/clamping fixture from the intermediate pads and bolt
the LST-1000 strain link to the pre-tapped 1/4 x 28 holes in
the intermediate pads. Make certain that the washers provided
with the strain links are placed over the strain links.
Torque the 1/4 x 28 bolts to 150 in-lbs. A calibrated torque
wrench is the preferred tool to torque the bolts.

7) Mount the protective cover box provided in the strain link
kit, if used, centrally over the strain link. It is important
to mount the cover box before calibration begins. The cover
box mounting holes may slightly change the strain sensed by
the strain links.

Four channel System 1100 units are shipped with stick-on
labels designated CH1, CH2, CH3, and CH4. the labels should
be applied to each strain link cover box so that the channel
that the strain link is attached to is clearly identified.

5.3 Conduit

1) Run flexible or rigid conduit from the strain link protective
boxes to the knockout holes in the bottom of the System 1100
enclosure. Open the door of the enclosure and place the
retaining nut(s) on the conduit connector(s).

2) If optional cams or other limit switches are used for
automatic zeroing and/or data windows, run conduit from one of
the knockout holes to the rotary cam switch or other switch.

3) Run conduit from a knockout hole in the bottom of the System
1100 enclosure to the main machine control enclosure. Open
the front door of the enclosure and place a retaining nut on
the conduit connector.

5-7

INSTALLATION

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5.4 Electrical Connections

5.4.1 Connecting the Strain Links

1) Pull the strain link cables through the conduit from strain
link locations to the System 1100 enclosure (to the Logic Unit
for panel-mount versions of the System 1100).

2) Cut excess cable lengths off, leaving about 12 inches of
length between the entrance of the cable into the enclosure
and the end of the cable. Strip about 2 1/2 inches of the
cable insulation off of the braided wire shield. Remove the
four conductor wires from the shield, taking care to leave the
shield wire length connected to the cable.

3) The terminals for the strain links are shown in Figure 25.
The conductor of the strain link cables are to be connected to
the channel terminals. The connections of the strain link
cables to the channel terminals should be:

Strain Link in Tension
When Machine is Loaded

Green Wire ------------- REF
White Wire ------------- SIG+
Red Wire --------------- SIG­Black Wire & Shield ---- GND

Strain Link in Compression

When Machine is Loaded

Green Wire ------------- REF
Red Wire --------------- SIG+
White Wire ------------- SIG­Black Wire & Shield ---- GND

For a two channel System 1100, connect the strain link mounted
on the LEFT side of the machine to the Channel 1 terminals,
and the strain link mounted on the RIGHT side of the machine

5-8

INSTALLATION

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to the Channel 2 terminals.

For a four channel System 1100, connect the strain link
designated to be CHANNEL 1 to the Channel 1 terminals, and the
strain links designated to be connected to channels 2, 3, and
4, respectively to the Channel 2, 3, and 4 terminals.

5.4.2 Connecting the OIT to the Logic Unit (panel-mount units)

For the panel-mount System 1100 (units in which the operator
interface electronics is housed in a separate enclosure from the
logic electronics) the Operator Interface Terminal (OIT) must be
wired to the Logic Unit. This connection is made through a four
conductor (2 twisted pairs) shielded cable. Connections should be
made as shown in Figure 22.

Figure 23. Connection of the OIT to the Logic Unit.

Connect the red wire to the KEYBOARD A terminal, the black wire to
the KEYBOARD B terminal, and the green wire to the KEYBOARD C
terminal at both the OIT and the Logic Unit. The white wire is not
used and should be cut off at both ends of the cable. The two
shield wires (each twisted pair is shielded) should be connected
with the green wire to the KEYBOARD C terminal at the Logic Unit.
The shield wires are not connected at the OIT end of the cable and
should be cut off.

5.4.3 Connecting the Optional Cam Switch for Zeroing

1) The terminal for the End Of Cycle cam switch is shown in
Figure 25. To install the zeroing cam switch, connect a wire
from the EOC terminal (End Of Cycle) on the Logic board to one
side of the cam switch contact. If the System 1100 is
grounded to the machine ground, the second side of the cam

5-9

INSTALLATION

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switch contact can be connected to the machine for grounding.

2) If an ungrounded machine control system is present, run a wire
from the second side of the cam switch back to the GND
terminal adjacent to the EOC terminal on the Logic board.

3) Adjust the zeroing cam switch as
shown in Figure 23. The cam
switch must be set to open
before the machine tooling
exerts force on the downstroke,
and close after all tooling and
stripper forces are relieved on
the upstroke.

4) On machines that are not
crankshaft driven, such as
hydraulic power presses, a limit
switch that is held closed when
the slide is in the upper
section of the stroke can be
used instead of a cam switch.
Always run cam switch or limit
switch wires in separate conduit
from 115VAC or higher voltage
conductors.

Figure 24. Setting of
Optional Zeroing Cam
Switch.

5.4.4 Connecting Optional Data Window Cam Switches

1) Data windows are used to display and place setpoints on
tonnage other than the absolute peak tonnage. The data window
cam switches should be setup as discussed in section 3.6.
When data windows are to be used, connect a wire from one
contact of each data window cam switch to the System 1100 data
window terminals located on the Logic board is the Logic Unit.
The four data window terminals are labeled DW1, DW2, DW3 and
DW4. If the System 1100 is grounded to the machine ground the
other contact of all the data window cam switches can be
connected to the machine for ground.

2) If an ungrounded machine control system is present, wire the
other data window cam contacts to the GND terminal adjacent to
the data window terminals on the System 1100 Logic board.

3) Always run data window can switch wires in separate conduit

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INSTALLATION

___________________________________________________________________

from 115VAC or higher voltage conductor.

5.4.5 Connecting an Optional Remote Reset

A remote reset pushbutton can be wired into the System 1100
allowing alarms and errors to be reset from a remote location. To
install the remote reset button, connect one side of a normally
open pushbutton to the RST terminal on the System 1100 Logic board.
Connect the other side of the pushbutton to the GND terminal
adjacent to the RST terminal.

Note that the remote reset button is pressed, the System 1100 drops
out the stop circuit relay during the reset sequence. Care should
be taken in placement of the remote reset pushbutton to avoid
nuisance stops due to unintentional pressing during production.

5.4.6 Input Power and Machine Control Connections

The terminals for connecting 115VAC
power to the System 1100 and connecting
the System 1100 output relay contacts
into the machine control system are
located on the power supply module on
the left side of the interior of the
System 1100 enclosure (Logic Unit
enclosure for panel-mount units).

The 115VAC power supply wires and
output wires should be connected as
shown in Figure 24, and run in a
separate conduit from the low voltage
d.c. wires connected to the Logic board
and Channel cards.

Connect the normally open contact (held
closed during normal operation) on the
power supply terminal strip into the
machine top stop circuit.
Alternatively, The System 1100 can be
connected to machine emergency stop.
Connecting the System 1100 output relay contact in the emergency
stop circuit may or may not enhance die and machine overload
protection by reducing the machine clutch torque before an overload
reaches its maximum value. The pneumatic reaction time of the

Figure 25. Power Supply
Connections.

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INSTALLATION

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clutch mechanism, the point in the stroke where the overload
occurs, and the machine speed determine whether the machine can
stop quickly enough after an overload is sensed to avoid the peak
overload. One consequence of connecting the System 1100 into the
emergency stop circuit can be sticking the machine on bottom when
an overload occurs.

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INSTALLATION

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Figure 26. System 1100 Logic Unit Electrical Connections.

5-13

Section 6. Calibration

Calibration of a System 1100 Tonnage Monitor consists of achieving
a known load on the machine and adjusting the installed monitor so
that the known load is displayed by the monitor. The known load
used during calibration should be at least 50% of rated machine
load and preferably 100% of rated machine load. On straight side
machine frame configurations of tie rod construction, it is always
advisable to use loads of 100% of machine rating in calibration
when strain links are mounted on uprights compressed by the tie
rods. False load readings can be generated if a tie rod looses
enough tension that the upright is released from compression before
full load is reached. This condition can be detected during
calibration if 100% of machine rating load is used.

Either static or dynamic calibration techniques can be used to
calibrate System 1100 Tonnage Monitors. Load cell(s) are used to
provide the known load in dynamic calibration. The load cell(s)
are placed in the machine point of operation (normally with
tooling absent) and a combination of shimming and machine shut
height adjustment is used to generate the desired load to be used
for calibration. The machine must be cycled, so that the slide
strikes the load cells at the bottom of the stroke to generate the
load. The load cells must be electrically connected to a tonnage
monitor to indicate the maximum force (tonnage) exerted by the
machine in a stroke. Each load cell has a pre-determined
relationship between applied force and its electrical output signal
to the tonnage monitor. This makes it possible to specify the
calibration number to which a Link System 1100 Tonnage Monitor
should be adjusted for use with that load cell to indicate the
tonnage applied to the load cell.

Hydraulic jacks are used in static calibration of System 1100
Tonnage Monitors. The machine slide is placed in the bottom of
stroke position, and, if necessary, the hydraulic jack(s) are
placed upon plates or shims in the point of operation so that they
can exert force between slide and bolster. A large pressure gauge
is used to indicate the pressure of the hydraulic fluid as the jack
is pumped up. The force exerted by the jack is equal to the fluid
pressure times the area of the jack cylinder. Thus, the pressure
required to exert a given force (tonnage) can be determined and
adjusted to that value.

Single or multiple load cells or jacks can be used to load the
machine to the value used for calibration. When a single load
cell or jack is used for calibration, it should be centrally

6-1

CALIBRATION

___________________________________________________________________

located under the machine slide. Where multiple load cells or
jacks are employed for calibration, they should be located in a
geometrically symmetrical pattern with respect to the center of the
machine slide. The preferred procedure is to place a single load
cell or jack directly under each connection to the slide from
crankshaft, hydraulic cylinder, etc., on overdriven machines.

When multiple load cells are used, each load cell should be of the
same physical dimensions and load rating. The load cells must be
shimmed as necessary to provide equal loads on each cell. The
combination of geometrically symmetrical location and equal loading
for load cells will produce a total machine load equal to the sum
of the loads on each individual load cell and will simulate a
single central load.

Note! Incorrect gib adjustments, and/or severe bearing wear in the
slide drive system can cause the slide to cock and generate
significant forces against linear guides or gibs. These
non-symmetrical forces can void the assumption of central loading
and introduce some error in the calibration procedure.

CAUTION! Extreme care should be used in calibration procedures for
tonnage monitors. Severe damage to the machine being calibrated or
the calibration equipment can result from incorrect shut height
adjustments, etc., on machines driven by rotary crankshafts, or
from any action that causes a machine to develop excessive forces.
Injury to personnel calibrating the machine or to others in the
machine area can result from poorly implemented load cell or
hydraulic jack stacks that fly out of the machine under load.
NEVER place hands between load cell or hydraulic jack stacks and
the machine slide! Link Systems provides calibration services at
a reasonable charge. These services should be used if there is
doubt that customer employees can correctly and safely calibrate a
machine.

6.1 Dynamic Calibration with Load Cells

1) Check to see that the System 1100 Tonnage Monitor for
permanent use on the machine is installed as per the
installation instructions of this manual.

2) Turn on the power to the System 1100 Tonnage Monitor. Observe
that the System 1100 tonnage displays zero. If the tonnage
displays fail to zero within 40 seconds or an error occurs,

6-2

CALIBRATION

___________________________________________________________________

check that the strain links are wired correctly into the
Channel cards and refer to error code charts in this manual.

3) Before calibration can proceed, the proper Machine Rating,
Machine Speed, and Decimal Point settings must be programmed
in the Configuration menu of the System 1100. If these
parameters have already been programmed, verify their proper
setting in Configuration menu (sections 2.8.2, 2.8.8 and

2.8.10).

Other settings and options affecting the operation of the
System 1100 are also programmed in the Configuration menu and
should be properly programmed before proceeding.

Note that setting the machine rating into the System 1100 is
a calibration procedure only. Changing the machine rating
number after calibration will result in erroneous tonnage
readings.

If error codes relating to setpoint limits occur, complete
step 4 of these instructions and push the CLEAR key to clear
the errors.

4) Follow the procedures in section 2.4.1 of this manual to set
the high setpoint for each channel of the installed System
1100 Tonnage Monitor to about 10% greater than the tonnage
expected on each channel when the machine is loaded at rated
tonnage. The expected tonnage for a two channel System 1100
at full load is one-half (1/2) the rated tonnage of the
machine. For a four channel System 1100, the expected tonnage
for each channel is one-fourth (1/4) the rated tonnage of the
machine.

Example: A machine is rated at 200 tons. The high setpoint
limits for each channel should be set to 110 tons (10% over
1/2 of 200 tons) if a two channel System 1100 is used; or to
55 tons (10% over 1/4 of 200 tons) if a four channel System
1100 is used to monitor tonnage.

5) Follow the procedures in section 2.4.1 of this manual to set
the low setpoints for each channel of the installed System
1100 to Zero (0).

6) Bring the machine slide or ram to the bottom of stroke

6-3

CALIBRATION

___________________________________________________________________

position and turn off power to the machine. Place the load
cell(s) to be used for calibration into position in the
machine. Load cell(s) of similar capacity and dimension are
preferably centered under each drive connection (pitman,
cylinder rod, etc.) to the slide or ram of the machine. Also
place any parallels or similar thickness plates on or under
the load cells necessary to reduce the gap between slide and
bolster (etc.) so that the "stack" of load cells and parallels
can be contacted at the bottom of the machine stroke.

It is recommended that steel plates at least one inch thick
and of at least 2 inches greater lateral dimension than load
cell contact surfaces be placed both under and over the load
cell to help distribute load and avoid load cell impressions
in slide or bolster material. All plates or parallels should
be symmetrically placed relative to the centerline of the load
cells, and plates and parallels used for each load cell stack
should be similar in dimension to those used in other stacks.

On mechanical power presses and other machines with shut
height adjustments, the stack height should be greater than
the minimum shut height, and the machine shut height must be
adjusted so that clearance between the machine slide and the
load cell stack(s) is provided.

Caution! If the load cell(s) stack height is greater than the
machine shut height, as adjusted, cycling the machine may
result in severe damage to the machine and to load cells!

7) Connect the load cell electrical cable(s) to the load cell(s).
Plug connectors are provided for this purpose.

8) A second System 1100 Tonnage Monitor should be used as a
"portable" unit in conjunction with the load cell(s) for the
purpose of calibration. Connect the wire end of the load cell
cable(s) to the channel terminals of the "portable" System
1100 unit. These terminals are accessible through the front
door of the System 1100 enclosure.

Only one load cell per System 1100 channel may be used. A two
channel System 1100 used as a portable unit can provide for
either single or double load cell calibration. A four channel
System 1100 used as a portable unit can be used for
calibrations that employ two, three, or four load cells.

6-4

CALIBRATION

___________________________________________________________________

The relationship of which load cell is connected to which
channel is important. Load cells must be shimmed to carry
equal loads in a subsequent step of this calibration procedure
and the force generated by the machine on the load cell is
indicated by the channel of the "portable" System 1100 to
which the load cell is connected. A simple method of
establishing the relationship between load cells and System
1100 channels is to label the load cell connected to Channel
1 as Load Cell 1, etc.

Figure 27. Portable Unit Load Cell & Unused Channel
Connection.

The cable used to connect the load cell to a System 1100
channel termination has four conductors and a shield. The
connections should be accomplished as shown in Figure 26.
Power to the unit should be turned off before making these
connections.

If the "portable" System 1100 unit has channels to which no
load cells are to be connected, the terminals for these
channels must be terminated by connecting the SIG+ and SIG­inputs to GND as shown in figure 26.

9) Supply power to the "portable" System 1100 tonnage monitor by
connecting terminals L1, L2, an GND on the power supply module
to a line cord an plugging into a 115VAC source. The power

6-5

CALIBRATION

___________________________________________________________________

supply module is located on the left side of the enclosure.
(Note: The GND connection is important to avert possible
electrical shock.)

10) Determine the machine rating number that must be programmed
into the "portable" System 1100 connected to the load cells as
follows:

If a two channel System 1100 is used as the "portable"
calibration unit, the machine rating number is twice (2X) the
tonnage capacity of the load cell(s) used; i.e., if either one
or two 100 ton load cells are used to load the machine, the
correct machine rating number is 2 X 100 tons = 200.0 tons.

If a four channel System 1100 is used as the "portable"
calibration unit, the machine rating number is our times (4X)
the tonnage capacity of the load cell(s) used; i.e., if one,
two, three, or four 100 ton load cells are used to load the
machine, the correct machine rating number is 4 X 100 tons =

400.0 tons.

11) Set the machine rating number into the "portable" System 1100
unit by using the MACH RATING option in the Config menu
(section 2.8.2).

Note that, when a System 1100 is used as a calibration unit in
conjunction with load cells, the machine rating number is a
scale factor dependent on the rated tonnage capacity of the
load cell(s) used in calibration and is not determined by the
tonnage capacity of the machine being calibrated.

If error codes relating to setpoint limits occur, follow step
12 of this procedure then press the CLEAR key clear the
errors.

12) Follow the procedures in the section 2.4.1 of this manual to
set the high setpoint for each channel of the "portable"
System 1100 unit used for calibration to about 10% greater
than the rated tonnage of the load cell(s) used in
calibration. For example, if one or more 100 ton load cells
are used to calibrate a machine, each channel high setpoint
limit should be set to 110.0 tons (10% more than 100 tons)
regardless of whether a two channel, or four channel System

6-6

CALIBRATION

___________________________________________________________________

1100 is used as a "portable" calibration unit.

Follow the procedures in section 2.4.1 of this manual to set
the low setpoints for each channel of the "portable" System
1100 to zero (0).

13) Set the calibration number for each channel of the "portable"
System 1100 unit to the specified value labelled on the load
cell connected as an input to the respective channel. To set
the calibration number of a channel, select the CAL-CHECK
option in the Config menu. Press the YES key when prompted
with "ESTOP WILL ACTIVE! BEGIN CAL-CHECK (Y/N)?". The
calibration number of each channel will then appear in each
tonnage display.

Adjust the GAIN ADJUST on the Channel card till the number on
the channel's tonnage display is equal to the calibration
number designated on the load cell.

Clockwise rotation of the channel gain adjustment results in
increasing numbers on the tonnage display.

No calibration number can be displayed for unused channels on
the "portable" System 1100 unit. However, GAIN ADJUST
potentiometers for unused channels to which no load cell is
connected should be turned fully counterclockwise.

14) Check to assure that load cell stacks are correctly located
and that machine shut height of other bottom of stroke
adjustment provides clearance between ram or slide and load
cell stack(s) as per the instructions of step 4 of this
calibration procedure.

Turn on the power to the machine and the installed (permanent)
System 1100 Tonnage Monitor and return the slide to the top of
stroke position.

15) Make single strokes of the machine, adjusting the shut height
or other bottom of stroke adjustments downward to lower the
machine slide or ram from 0.002" to 0.004" between successive
strokes until the "portable" System 1100 tonnage displays give
a reading, indicating that contact is being made with one or
more load cell stacks.

6-7

CALIBRATION

___________________________________________________________________

16) If a single load cell is used for calibration, continue to
single stroke the machine and adjust shut height or other
bottom of stroke adjustment until the rated capacity of the
load cell or the machine, whichever is less, is reached on the
CHANNEL of the "portable" unit to which the load cell is
input.

The rated tonnage capacity of the load cell should be at least
50% of the rated tonnage capacity of the machine being
calibrated. Adjustment distance should be restricted to less
than 0.001" between strokes as rated machine tonnage is
approached.

If two or more load cells are used for calibration, adjust the
shut height or other bottom of stroke adjustment until about
20% of rated machine tonnage capacity is displayed on the
"portable" unit TOTAL display. The tonnage exerted on each
load cell is displayed on the channel tonnage displays to
which each is input. If load cell tonnages are not equal, add
shim stock to the stack of load cells with lower readings.
Make a single stroke of the machine and observe the new
tonnage readings of each load cell channel. Repeat this
process until all load cell readings are equal to within 2%.

When load cell tonnages are equalized, again repeat the cycle
of single stroking the machine with shut height or other
bottom of stroke adjustment between strokes and continue to
observe the tonnage on each load cell channel of the
"portable" System 1100. It may be necessary to re-shim
certain load cell stacks to equalize tonnage on all load cells
as rated tonnage capacity of the machine is neared. Rated
machine capacity of the machine is reached when individual
tonnage on load cells equals the rated machine tonnage divided
by the number of load cells used to calibrate the machine.
For example, if four (4) load cells are used to calibrate a
200 ton mechanical power press, the press is loaded to
capacity when each of the four load cells is loaded to 50
tons. When rated machine tonnage, or a lesser tonnage at
which the machine is to be calibrated is reached, lock shut
height adjustments, etc., and proceed to step 17.

Do not exceed rated tonnage capacity of the machine or load
cells during the calibration process by more than five or ten
percent. If the tonnage exerted on any channel of the
"portable" System 1100 unit exceeds the High Setpoint limit,

6-8

CALIBRATION

___________________________________________________________________

the CLEAR key must be pushed to obtain further readings.

Vibratory motion in the machine often introduces stroke to
stroke variations of one or two percent in the load cell
tonnage readings. When this happens it is impractical to try
to refine the load on the machine any closer than within one
or two percent of rated tonnage.

17) After loading the machine to the tonnage at which it is to be
calibrated as per step 16 of this calibration procedure, check
that the installed (permanent) System 1100 is set to display
FORWARD tonnage (no minus sign in the tonnage displays). Also
check that installed System 1100 is not in CAL-CHECK mode and
press the EXIT key to end CAL-CHECK if it is.

For a two channel installed System 1100 unit, make single
strokes of the machine and perform gain adjustments for both
channels between strokes until channel 1 and channel 2
tonnages of the installed System 1100 unit are within one or
two percent of one-half (1/2) the sum of the load cell
tonnages indicated by the channels of the "portable" System
1100 unit.

For a four channel installed System 1100 unit, make single
strokes of the machine and perform gain adjustments on the
four channels between strokes until all four channel tonnages
are within one or two percent of one-fourth (1/4) the sum of
the load cell tonnages indicated by the channels of the
"portable" System 1100 unit.

18) Turn the machine motor(s) off and wait for any flywheel
motion, etc. to stop. Leave power on the installed System
1100 Tonnage Monitor. (On mechanical power presses it may be
necessary to turn the press control system to the "Inch" mode
to retain power to the System 1100 with the main drive motor
off). Select the CAL-CHECK option in the Config menu to
display calibration numbers. Press the YES key when prompted
with "ESTOP WILL ACTIVE! BEGIN CAL-CHECK (Y/N)?". The
calibration number of each channel will then appear in each
tonnage display. These are the calibration numbers for the
System 1100 as installed on the machine. It is IMPORTANT to
retain these numbers so that periodic checks for calibration
can be made. It is suggested that a copy of these numbers be
retained inside the System 1100 cabinet and that a second copy

6-9

CALIBRATION

___________________________________________________________________

be kept in files.

If the calibration numbers displayed on the tonnage displays
for a particular channel vary, take the median value of the
numbers displayed as the calibration number.

19) Press the EXIT key to end CAL-CHECK mode.

20) Remove the load cells and associated "stack" elements from the
machine and disconnect the cables from the load cells and the
"portable" System 1100 unit.

Calibration is complete.

6.2 Static Calibration with Hydraulic Jacks

1) Follow procedures 1-5 under the Dynamic Calibration with Load
Cells section of this manual.

6) Turn on power to the machine and place the machine ram or
slide at the bottom of stroke position.

7) Turn off machine drive motors or hydraulic pumps, etc., and
place the jack(s) to be used in calibration under the machine
ram or slide.

If a single jack is used, directly center the jack under the
ram or slide.

If multiple jacks are used, the jacks should be placed in a
geometrically symmetrical pattern relative to the center of
the ram or slide. On machines with multiple connections to
the slide, it is preferable to use a jack directly under each
connection.

Also place any plates or parallels under the jack necessary to
reduce the gap between jack and slide at this time. Plates
used to elevate the jack should have greater lateral
dimensions than the jack and should extend beyond the jack on
all sides.

8) Select the CAL-CHECK option in the Config menu to display
calibration numbers. Press the YES key when prompted with
"ESTOP WILL ACTIVE! BEGIN CAL-CHECK (Y/N)?". The calibration

6-10

CALIBRATION

___________________________________________________________________

number of each channel will then appear in each tonnage
display.

For a two channel System 1100 unit, adjust the GAIN ADJUST
potentiometer for CHANNEL 1 (left strain gauge) until the
number 400 appears on the channel 1 tonnage display. Adjust
the GAIN ADJUST potentiometer for CHANNEL 2 (right strain
gauge) until the number 400 appears on the channel 2 tonnage
display.

For a four channel System 1100 unit, adjust the GAIN ADJUST
potentiometer for CHANNEL 1 until the number 400 appears on
the channel 1 tonnage display. Repeat this procedure for
CHANNEL 2, CHANNEL 3, and CHANNEL 4 until the number 400
appears in each channel tonnage display.

9) Press the EXIT key to end CAL-CHECK mode. Select the STATIC­CAL option in the Config menu. Press the YES key when
prompted with "BEGIN STATIC-CAL (YES/NO)?".

For a four channel System 1100 unit, adjust ZERO ADJUST
potentiometer until the number that appears in the channel 1
tonnage display reads between ±1% of rated tonnage of the
machine to be calibrated. Repeat the zero adjustment
procedure using the ZERO ADJUST for the respective channels
until all channels are zeroed within ±1% of rated machine
tonnage.

Do NOT exit the STATIC-CAL mode.

10) Use the hydraulic jack(s) equipped with suitable pressure
gauge(s) to exert the tonnage at which the machine is to be
calibrated, preferably rated tonnage of the machine but a
tonnage of at least 50% of rated machine tonnage.

When more than one jack is used for calibration, each jack
pressure should be adjusted to exert equal forces (±1%) on the
ram or slide of the machine.

11) For a two channel System 1100 unit, rotate the GAIN ADJUST for
CHANNEL 1 until the number appearing on the channel 1 tonnage
display reads within ±1% of one-half (1/2) of the sum of the
tonnages exerted by the jack(s).

6-11

CALIBRATION

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For a four channel System 1100 unit, rotate the GAIN ADJUST
for CHANNEL 1 until the number appearing on the channel 1
tonnage display reads within ±1% of one-fourth (1/4) of the
sum of the tonnages exerted by the jack(s). Repeat this
procedure for channels 2, 3, and 4.

12) Release the pressure of the jack(s) and remove the jack(s) and
associated stack materials from the machine.

13) Press the EXIT key to end STATIC-CAL mode. Select the CAL­CHECK option in the Config menu to display calibration
numbers. Press the YES key when prompted with "ESTOP WILL
ACTIVE! BEGIN CAL-CHECK (Y/N)?". The calibration number of
each channel will then appear in each tonnage display. These
are the calibration numbers for the System 1100 as installed
on the machine. It is IMPORTANT to retain these numbers so
that periodic checks for calibration can be made. It is
suggested that a copy of these numbers be kept inside the
System 1100 cabinet and that a second copy be kept in files.

If the calibration numbers displayed on the tonnage displays
vary, take the median value of the numbers displayed as the
calibration number.

14) Press the EXIT key to end CAL-CHECK mode.

Calibration is complete.

6-12

Section 7. Zero Circuit Checkout After Calibration

If the "rate of change" automatic zeroing method (no cam switch
used for zeroing) is used, it is necessary to verify that strains
induced in the machine frame due to mechanical noise, such as
engagement of clutches or brakes or gear "slap" do not exceed the
factory set zeroing threshold of 5% of rated channel tonnage.

1) Select a die from the group of dies used in the machine with
one of the heaviest upper die weights. Install the die in the
machine and adjust the machine shut height so that the dies
don't close at the bottom of the stroke. The purpose of
installing this die is to make sure that acceleration and
deceleration forces when a stroke begins and ends will produce
the maximum strains in the machine frame that will be
experienced in actual production operations. The heavier the
upper die, or other tooling attached to the slide, the greater
the acceleration and deceleration forces due to clutch or
brake engagement or gear slap.

2) Set the low setpoint limits of the System 1100 to zero (0).
The high setpoint limits should be set to at least 50% of
rated machine tonnage capacity.

3) Make single strokes of the machine and observe the System 1100
tonnage displays. The tonnage displays will constantly read
zero if acceleration and deceleration forces at the beginning
and end of the stroke do not strain the machine frame enough
to exceed the 5% zeroing threshold.

If the tonnage displays remain zero throughout several single
strokes, proceed to step 5 of this procedure.

If the tonnage displays change from zero to indicate a number
other than zero at the start of the stroke only, and retains
this same number at the completion of the stroke, the
acceleration forces at the beginning of the stroke are
straining the frame enough that the 5% zeroing threshold is
exceeded. In actual production operations the tooling force
at the bottom of the stroke will replace the reading caused by
acceleration forces and retain the actual tooling tonnage at
the end of the stroke. Proceed to step 5 of these procedures.

If the tonnage displays change to indicate a number at the end
of the stroke, deceleration forces caused by braking are
causing strains in the machine frame that exceed the 5%

7-1

ZERO CIRCUIT CHECKOUT

)))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))))

zeroing threshold. Proceed to step 4 of this procedure.

4) Mechanical noise due to deceleration forces as the machine
slide stops at the end of a stroke that exceed the 5% zeroing
threshold will displace the tonnage display readings obtained
due to tooling forces at the bottom of the stroke. To prevent
this nuisance loss of actual tonnage readings, the zeroing
threshold must be changed to a larger percentage of rated
channel tonnage capacity, or the cam zero (zeroing by
position) option must be used.

The preferred method is to install a cam switch or other limit
switch to determine when the System 1100 zeroes, following the
procedures in section 5.4.3 of this manual.

Alternatively, the zero threshold can be set to 10% of rated
channel tonnage capacity and may eliminate the need for cam
zeroing by elevating the threshold above the mechanical noise
level. This is described in section 2.8.4 of this manual.

After setting the zeroing threshold to 10%, repeat step 3 of
this procedure. If the tonnage displays still change at the
end of the stroke, the cam zeroing option is required. If the
tonnage displays do not change at the end of the stroke,
proceed to step 5 of this procedure.

5) When rate of change zeroing (non-cam zeroing) is used, the
Machine Speed setting in the Config menu must be set
accurately for proper operation of the System 1100 (see
section 2.8.8).

7-2

Section 8. Unbalanced Loads and Scale Factor

Most machines that use force in production processes are designed
for distributed central loads at rated tonnage and lesser non­central (eccentric) loads. However, some forging presses and other
machines are designed to permit operation at full tonnage with
either central loads or, within specified limits of offset from
center, non-central loads.

The procedures in Section 6 "Calibration" of this manual are
written for machines designed for rated tonnage only with
distributed central loads. Since a central load will be
distributed equally to each side of a "C" frame machine or to each
column of a straight side machine, a two channel tonnage monitor
expects 1/2 of rated machine tonnage to appear on each channel when
the machine is operated at rated capacity. A four channel tonnage
expects 1/4 of rated machine tonnage to appear on each channel when
the machine is operated at rated capacity. The machine rating
alarms for any channel are tripped any time, the tonnage of the
channel exceeds 125% of the tonnage expected at full load, as
explained in the following examples.

Example 1. A 100 ton OBI press is equipped with a two channel
System 1100 Tonnage Monitor, with strain links mounted on each side
frame member. A central load at rated tonnage will register 50
tons on channel 1 and 50 tons on channel 2 when a machine rating of
100 tons is programmed into the unit and the calibration
instructions of this manual are followed. Programming the machine
rating at 100 tons automatically sets the machine rating alarms at

62.5 tons (125% of 50 tons) on both channel 1 and 2. No tooling

can be run in the machine that produces more than 62.5 tons on
either side of the frame.

Example 2. A 100 ton straight side press is equipped with a four
channel System 1100 Tonnage Monitor. A central load of 100 tons
will register 25 tons on each of the four channels. When a machine
rating of 100 tons is programmed into the unit, and the calibration
instructions of this manual are followed, the System 1100
automatically sets the machine rating alarms at 31.25 tons (125% of
25 tons) for each channel. No tooling can be run in the machine
that produces more than 31.25 tons on any column.

The machine rating number that must be programmed into the System
1100 is simply a scale factor. For machines that are designed to
operate at full rated tonnage with an off center load, a machine
rating alarm fixed at 125% of expected channel tonnage at full load

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may prevent the machine from operating with acceptable non-central
loads. This can be rectified by a simple procedure involving
changing both the machine rating number (scale factor) and the
channel calibration numbers.

After a System 1100 is calibrated using the standard procedures in
the Section 6 of this manual, the allowable tonnage per channel,
as set by machine rating alarms can be increased while maintaining
calibrated tonnage readings by the following procedures.

For a two channel System 1100, the machine rating number which
should be programmed to shift the machine rating alarms to a
desired tonnage is determined by dividing the desired allowable
tonnage per channel by 0.625. To keep the System 1100 correctly
calibrated, it is then necessary to change each calibration number
for both channels of the two channel unit to the new calibration
numbers.

ORIGINAL MACHINE RATING

C' = ------------------------- * C

N1 N1

NEW MACHINE RATING

and,

ORIGINAL MACHINE RATING

C' = ------------------------- * C

N2 N2

NEW MACHINE RATING

where,

C' = New calibration number for channel 1

N1

C = Original calibration number for channel 1

N1

C' = New calibration number for channel 2

N2

C = Original calibration number for channel 2

N2

For a four channel System 1100, the machine rating number which
should be programmed to shift the machine rating alarms to a
desired tonnage is determined by dividing the desired allowable
tonnage per channel by 0.3125. To keep the System 1100 correctly
calibrated after changing the machine rating number, it is
necessary to change each calibration number for each channel of the
four channel unit to the new calibration numbers,

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UNBALANCED LOADS AND SCALE FACTOR

___________________________________________________________________

ORIGINAL MACHINE RATING

C' = ------------------------- * C

N1 N1

NEW MACHINE RATING

ORIGINAL MACHINE RATING

C' = ------------------------- * C

N2 N2

NEW MACHINE RATING

ORIGINAL MACHINE RATING

C' = ------------------------- * C

N3 N3

NEW MACHINE RATING

and

ORIGINAL MACHINE RATING

C' = ------------------------- * C

N4 N4

NEW MACHINE RATING

where C' , C' , C' , C' , are the new calibration numbers to which
channels 1 through 4 should be adjusted, respectively. C , C ,
C , C , are the original calibration numbers for channels 1 through

N3 N4

N1 N2 N3 N4

N1 N2

4, which were determined by the procedures followed in the Section
6 of this manual.

The following examples illustrate how the System 1100 Tonnage
Monitors on the machines of Examples 1 and 2 of this section can be
set up to permit more tonnage on each channel while retaining
calibration.

Example 3. Following the instructions in the Section 6 of this
manual for the two channel System 1100 unit on the machine of
Example 1 resulted in a machine rating number of 100.0 tons being
programmed into the unit. The calibration numbers were found to be
144 for channel 1 and 148 for channel 2. It is desired to shift
the machine rating alarms on each channel from 62.5 tons (125% of
50 tons for each side) to 70 tons for each channel. To do this,
calculate the new machine rating number (scale factor). The
required number is:

70 tons

MACHINE RATING NUMBER = --------- = 112 tons

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UNBALANCED LOADS AND SCALE FACTOR

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0.635

Reprogram the machine rating number from the original 100 ton value
programmed during calibration to 112 tons.

Next calculate the new calibration numbers required to remain
calibrated with the new machine rating number. These are:

100

C' = ----- * 144 . 129

N1

112

100

C' = ----- * 148 . 132

N2

112

Round off calibration numbers calculated as above to the nearest
whole number. Adjust the calibration numbers to the new values
calculated as above, i.e., 129 for channel 1 and 132 for channel 2
in this example.

Example 4. Following the instructions in Section 6 of this manual
for the four channel System 1100 unit on the machine of Example 2
resulted in a machine rating number of 100.0 tons being programmed
into the unit. The calibration numbers were found to be 526 for
channel 1, 532 for channel 2, 535 for channel 3, and 524 for
channel 4. It is desired to shift the machine rating alarms from

31.2 tons for each channel to 40 tons. To do this, calculate the

new machine rating number (scale factor). The required number is:

40 tons

MACHINE RATING NUMBER = --------- = 128 tons

0.3125

Reprogram the machine rating number from the original 100 ton value
to 128 tons.

Next, calculate the new calibration numbers for each channel.
These are:

100

C' = ----- * 526 . 411

N1

128

100

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UNBALANCED LOADS AND SCALE FACTOR

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C' = ----- * 532 . 416

N2

128

100

C' = ----- * 535 . 418

N3

128

100

C' = ----- * 524 . 409

N4

128

Adjust the calibration numbers to the new values, i.e., 411 for
channel 1, 416 for channel 2, 418 for channel 3, and 409 for
channel 4.

8-5

Section 9. Using System 1100 Tonnage Monitors

There are several possible levels of utilization of System 1100
Tonnage Monitors in everyday production operations. In addition,
there are several special purpose and diagnostic uses that a System
1100 can perform. This section of the manual gives suggestions for
using the System 1100. The information provided should be
considered as guidance. As the operator gains familiarity with the
System 1100, he should develop tonnage monitoring programs that
best fit his needs.

9.1 Machine Overload Monitoring

The least complex use of a System 1100 Tonnage Monitor is as a
monitor for machine overload. Many mechanical power presses and
other machines are chronically operated in severely overloaded
conditions because of improper matching of tooling to machine
capacity, because tooling wear increases the tonnage required to
produce a part, because of improper shut height adjustment, or
because tooling is improperly positioned in the machine.
Overloading drastically increases bearing wear, deflection, and
breaking of load bearing structures on machine tools.

When used as a machine overload monitor, the high setpoint limits
for each channel of the System 1100 are chosen and set so that any
load which exceeds rated machine tonnage capacity, or, at the
employer's discretion, up to 125% of rated capacity, will cause the
System 1100 to generate a high setpoint alarm and prevent another
stroke until the System 1100 alarm is cleared. This prevents
operation of the machine when die setting procedures, tooling wear,
improper location of dies etc., cause the machine to be overloaded.

Using the System 1100 only as a machine overload monitor requires
the lowest level of operator and die setter involvement with the
tonnage monitor. High setpoint limits, once chosen, are not reset
and low setpoint limits can be turned off or set to zero.

During die setting, the die setter must interact with the tonnage
monitor only if the dies, as set, produce an overload. During
production operation, an overload alarm alerts the operator to
determine and remove the cause of the overload.

9.1.1 Sample Die Setting Instructions

1) Follow normal die setting procedures, setting dies and making
trial strokes with material in place while slowly decreasing
shut height on mechanically driven (crankshaft) machines or

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USING SYSTEM 1100 TONNAGE MONITORS

___________________________________________________________________

increasing pressure on hydraulic machines.

2) If no alarms are tripped on the System 1100 during trial
strokes, including several trial strokes after the final
adjustment that produces a satisfactory part, the machine may
be turned over to production.

4) If a two channel System 1100 is used on the machine and a
channel 1 high setpoint and/or machine rating alarm indicates
an overload on the left side of the machine when making a
trial stroke, shift the dies to the right in the machine bed
till trial strokes indicate that the channel 1 and 2 tonnages
are approximately the same to reduce the left overload.
Similarly, tooling should be shifted left in the bed if a
channel 2 high setpoint and/or machine rating alarm indicates
an overload on the right side of the machine.

If both channel 1 and channel 2 high setpoint and/or machine
rating alarms are tripped on a trial stroke, check to see if
a correct part can be made after reducing the tonnage by shut
height adjustment, etc. Also, on "C" frame machines such as
OBI, OBS, and gap presses, check to that dies are centered
front to back under the connecting rods that drive the slide.
Dies located too far forward under the slide of such machines
cause greater strains on the machine frame.

If a correct part cannot be made without tripping one or more
high setpoint alarms and/or machine rating alarms, the die
should be placed in a machine of larger capacity or reworked
to require less tonnage to make the part.

5) If a four channel System 1100 is used on a straight side
machine, and one of the four channel high setpoint and/or
machine rating alarms is tripped during trial strokes, shift
the tooling away from the corner of the machine monitored by
the channel indicating the alarm. When possible, tooling
should be located so that approximately equal tonnage readings
are obtained on the tonnage displays for all four channels.

If, under approximately balanced load conditions, high
setpoint and/or machine rating alarms are tripped, reduce
tonnage by shut height adjustment or other tonnage adjustment
and see if a correct part can be made with less tonnage. The
tooling should be placed in a machine of greater rated tonnage
capacity or reworked to require less tonnage if a correct part

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USING SYSTEM 1100 TONNAGE MONITORS

___________________________________________________________________

cannot be produced without overloading the machine.

9.1.2 Sample Operator Instructions

1) Each time power is first turned on to the machine, observe
that the System 1100 tonnage displays go to zero (0) before
attempting to cycle the machine.

2) Observe that a reading appears on the tonnage displays after
the first machine stroke that produced a part.

3) An overload on any channel will be indicated by a flashing
light and/or flashing tonnage reading and will prevent another
stroke. The supervisor should be called and the condition
that caused the overload cleared before pushing the CLEAR key
on the System 1100 and proceeding with production.

4) If the press will not stroke and an error occurs (indicated by
a flashing STOP CIRCUIT indicator light) call the supervisor.

9.2 Comprehensive Load Monitoring

Although monitoring only for machine overload provides great
benefits in machine maintenance and repair costs, using the System
1100 in a more comprehensive load monitoring scheme that
establishes standards and monitors production tonnages more closely
can greatly expand benefits to the user. Both machine and tooling
life can be extended, energy can be conserved, fewer scrap parts
generated, and part quality can be made more consistent by using
the System 1100 to determine and optimize tooling location and
required tonnage in die setting; and by selecting high, low, and
reverse setpoint limits so that changes in tonnage greater than
those due to normal variations in the production process will trip
an alarm and stop the machine from cycling.

A comprehensive load monitoring program requires more knowledge and
interaction with the System 1100 by die setters and operators than
a simple machine overload monitoring program. The following
procedures and information can be useful in establishing a
comprehensive load monitoring program. Of course, the user may
choose to modify or add to the described procedures to suit his
particular needs.

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USING SYSTEM 1100 TONNAGE MONITORS

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1) Initially determine and record the optimum location and
minimum required tonnage for each set of tools used in a
machine. Any tooling that requires more tonnage to produce a
correct part than the rated tonnage capacity of the machine,
or, at management's discretion, some selected percentage over
rated machine capacity should be moved to a machine with
higher rated tonnage, or the tooling should be reworked to
require tonnage below rated machine capacity.

2) Although not always practical because of other production
considerations such as feeding, part transfer, part removal,
or tooling design, the optimum die location on "C" frame
machines such as OBI, OBS, and Gap presses is generally with
tooling centered from front to back under the connection(s)
that drive the slide (ram), and at a left to right location in
the machine bed that produces approximately equal tonnage
readings on the left and right channels of a System 1100
Tonnage Monitor. On a straight side frame machine, the
optimum tooling location in the machine bed is generally that
location that produces approximately equal tonnages on each
channel of a four channel System 1100 Tonnage Monitor.
Equalizing the load in the machine usually produces less
deflection between lower and upper dies, reduces bearing and
gib wear, and fatigues structural members of the machine less.

Using the System 1100 to determine the minimum tonnage
necessary for tooling to produce correct parts develops an
initial die setting standard for more consistent setups that
will conserve energy, extend machine and tooling life, and
achieve more consistent parts from different production runs.
The initial determination of minimum tonnage to make the part
also provides a standard by which tooling wear may be judged
and scheduled for rework when wear increases, or, in some
instances, decrease the tonnage necessary to make a correct
part.

Note! Tool and die makers calculate the approximate tonnage
required to produce a part. These calculations, in some
instances, can be substantially overstated or understated.
With the System 1100, the actual tonnage required to produce
a part can be determined as well the normal variations in
tonnage due to inconsistency of material thickness, material
physical properties, parts lubrication, etc.

During the initial use of the System 1100 to determine optimum

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USING SYSTEM 1100 TONNAGE MONITORS

___________________________________________________________________

die location and tonnage, the location and required tonnage is
ideally recorded and attached to the die set as a reference
for future setup and for determining die wear.

The high and low setpoint limits should then be determined for
each channel. The high setpoints for each channel should be
set far enough above each channel tonnage that normal
variations in tonnage don't trip the high setpoint alarms.
The low setpoint alarms should be set far enough below each
channel tonnage that normal variations in production tonnage
don't trip the low alarms. The combination of the high and
low setpoint alarms provides a tonnage "tolerance", helping to
assure parts quality. Out of tolerance hits warn of problems
in the production process. A good starting point in the
determination of high and low setpoint limits for a channel is
about 10% above the average tonnage displayed by the System
1100 for that channel over several strokes for the high
setpoint, and about 10% below the average tonnage for the low
setpoint.

High and low setpoints should be set symmetrically above and
below the operating tonnage respectively. The tonnage bar
graphs should then light the middle GREEN bar graph segments
on all channels. This symmetrical setting of setpoints can be
performed automatically by the System 1100 through the use of
the Auto Setup function. The Auto Setup function sets the
high, low and reverse setpoint limits to a preset tolerance

9-5

USING SYSTEM 1100 TONNAGE MONITORS

___________________________________________________________________

around the measured tonnage.

The Auto Setup tolerance can be increased and the Auto Setup
function executed again if nuisance stops due to normal
variations in production tonnage occur.

Once established, the initial setpoint tonnages for each
channel of the System 1100 should be recorded on the label
that contains initial optimum location and tonnage records for
reference in future setups. The record should be kept on a
separate label from the original die maker's specifications.
The die maker's specifications should be left on the die! The
tonnage setpoint limits should also be stored in the permanent
memory of the System 1100 (section 2.5) for recall when the
die is used in the future. The System 1100 provides storage
for up to 123 setups.

2) Each time the tooling is used, the die setter should reference
the initially determined optimum tooling location, minimum
required tonnage, and should recall the tonnage setpoint
limits for that die from permanent memory. Of course die wear
and differences in material may require some changes in setup
tonnages and setpoints from the initial reference values.

By comparing the progressive variation in minimum tonnage
required to make a correct part with the initial values, die
rework can be scheduled. After a die is reworked or repaired,
reference location and minimum tonnage and setpoint limits for
each System 1100 channel should again be determined and
recorded.

3) During production, the System 1100 will generate an alarm,
stop the machine, and prevent further strokes until the alarm
is cleared if tonnage falls below a low setpoint or rises
above a high setpoint. When this occurs the operator should
clear the condition, or call the supervisor to clear the
condition, before the alarm is reset and production resumed.
High and low setpoint alarms may have to be changed where
alarms are tripped due to greater than expected variation in
material or tooling wear that occurs over longer runs.

On high speed machines, dies in rapid operation may heat
enough that die expansion causes tonnage to progressively
increase toward some equilibrium tonnage after stroking
begins. Setpoint limit tolerances will have to be increased

9-6

USING SYSTEM 1100 TONNAGE MONITORS

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to allow this variation or, alternatively, the operator may
reset setpoints during operation after equilibrium is reached
as indicated by readings on the System 1100 tonnage displays.

9.2.1 Sample Die Setting Instructions

1) Locate dies in the previously determined optimum location that
provides approximately equal tonnage readings on each System
1100 channel, or as near to equal readings as possible when
feeding, part removal, part transfer, die design, or other
considerations prevent the die from being located in the
machine so that approximately equal tonnage readings are
obtained on each channel.

Recall the setup from permanent memory then move the keyswitch
to the BYPASS position to bypass all high, low and reverse
setpoint alarms.

3) Follow normal die setting tryout procedures, making trial
strokes with material in place and adjusting tonnage slowly
upwards by shut height adjustment of mechanically driven
machines or hydraulic pressure on hydraulic machines. When
the TOTAL tonnage displayed on the System 1100 tonnage
displays is approximately equal to the previously determined
reference value recorded on the die, check to see if a correct
part is being made. Compare the tonnage on each channel of
the System 1100 with the previously determined reference
tonnages for each channel to see if any significant changes in
load distribution have occurred. Ideally the GREEN segments
of each channel bar graph will light indicating that the
measured tonnage falls directly between the high and low
setpoint limits that were previously determined for the die.

If a correct part can be produced with the TOTAL TONNAGE set
at a value near the reference tonnage, and if load
distribution has not significantly changed, proceed to step 4
of this procedure. If load distribution is significantly
changed, relocating the die from the reference location to a
location that gives approximately equal tonnages on all System
1100 channels, if possible, is recommended only after checking
to see that excessive die wear has not caused the change in
tonnage distribution. Other causes of changing load

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USING SYSTEM 1100 TONNAGE MONITORS

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distribution can be use of different shims or parallels on
dies or different location of shims or parallels from setup to
setup.

If, when the TOTAL tonnage is adjusted to the initial
reference value recorded on the die, a correct part can't be
made, adjust the tonnage slowly upward till a correct part is
produced. Remember, differences in material thickness and
hardness can cause more or less tonnage to be required. A
TOTAL tonnage required to produce a correct part that is
significantly greater than the reference tonnage recorded on
the die may indicate die wear severe enough that die rework
should be scheduled.

Proceed to step four of this procedure after final die
location and tonnage have been set.

4) Note the tonnage readings on each channel of the System 1100
Tonnage Monitor after making a trial stroke under final setup
conditions. If the tonnages on each channel of the System
1100 fall approximately between the previously determined high
and low setpoint limits, then move the keyswitch from the
BYPASS position to the RUN position for production.

If the tonnage on one or more channel(s) is different than the
reference tonnage recorded on the die for that/those
channel(s), set the high and low setpoints for each channel at
about the same percentage above and below the actual tonnage
readings of each channel as the previously stored setpoints.
The System 1100 can do this automatically through the Auto
Setup function. The keyswitch should be returned to the RUN
position for production.

9.2.2 Sample Operator Instructions

1) Each time power is first turned on to the machine, observe
that the System 1100 tonnage displays go to zero (0) before
attempting to cycle the machine.

2) After the first machine stroke, observe that a reading appears
on the tonnage displays.

3) In the event that a high or low alarm on one or more channels
of the System 1100 stops the machine and prevents another
stroke, the supervisor should be called and the condition that

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USING SYSTEM 1100 TONNAGE MONITORS

___________________________________________________________________

caused the alarm cleared before pushing the CLEAR key on the
System 1100 and proceeding with production.

4) If high or low alarms trip frequently in the production
process and no apparent cause is found, nuisance alarms may be
taking place because normal variations in the production
process occasionally cause tonnage to fall somewhat below low
setpoint limits or somewhat above high setpoints on any
channel showing the high or low setpoint alarm with the actual
tonnage reading for the channel and reset the low or high
setpoint if necessary.

5) If the press will not stroke and an error occurs (indicated by
a flashing STOP CIRCUIT indicator light) on the System 1100,
call the supervisor.

9.3 Intermediate Load Monitoring

An intermediate load monitoring program that is somewhat more
complex than simple overload monitoring but doesn't require the
record keeping suggested in the comprehensive load monitoring
program can provide many of the benefits of comprehensive load
monitoring. The lack of recorded reference values to tonnage and
die location primarily makes it more difficult to assess tooling
wear, but in some instances the die setter's memory may compensate
for lack of records.

9.3.1 Sample Die Setter Instructions

1) Move the keyswitch to the BYPASS position to turn off all
high, low and reverse setpoint limits.

2) Follow normal die setting procedures, making trial strokes
with material in place and adjusting tonnage slowly upwards by
shut height adjustment of mechanically driven machines or
hydraulic pressure on hydraulic machines. After each trial
stroke, observe the tonnage on each channel of the System 1100
Tonnage Monitor. Shift the die location to obtain
approximately equal tonnages on each channel, or as near to
equal tonnages on each channel as possible when feeding, part
removal, part transfer, or die design prevents the obtaining
of approximately equal tonnage on each channel.

Use the TOTAL tonnage reading on the System 1100 to set the

9-9