TONNAGE

TRACKER
LOAD MONITOR
Programming and Installation Manual
V1.0
 TABLE OF CONTENTS
PAGE #
2 INTRODUCTION
3 STRAIN GAUGE SENSOR INSTALLATION
4 Strain gauge placement for C FRAME press.
5 Strain gauge placement for STRAIGHT SIDE press.
6 Drill and tap method for mounting strain gauge sensors
7 Weld pad method for mounting strain gauge sensors
8 WIRING
11 TONNAGE MONITOR SETUP
12 CALIBRATION
17 Calibration #’s and Offsets
18 INITIALIZE
19 SETPOINTS
20 VIEW TONNAGE

1
 INTRODUCTION
The Tonnage Tracker will ensure a steady and consistent tonnage which can improve part quality, increase die
life, reduce press maintenance, and increase productivity. Variations in tonnage may reveal problems such as
incorrect shut height, dull tooling, unbalanced loads, incorrect die installation, variations material thickness,
broken punches, double hit, or mechanical problems with the press.

The Tonnage Tracker is designed to monitor the actual tonnage of the press and compare it to user programmed
set-points. The set-points can be programmed to monitor the tonnage required during production. If the actual
tonnage falls outside of the set-point limits a tonnage fault will occur. A tonnage fault will stop the press and
alert the operator on the screen with the fault specific message. Production of multiple bad parts and potential
damage will be avoided.

TONNAGE TRACKER SETUP

FOLLOW THE STEPS BELOW

1 First determine what type of press you have and the strain gauge placement.

2 Mount the strain gauges according to this manual.

3 Install the protective covers and run the conduit. Do not share the conduit with any other wires.

4 Wire the strain gauges to the Tonnage Tracker.

5 Enter the press capacity (max #’s)

6 LOAD CELL CALIBRATION: Calibrate the strain gauges using load cells

7 CALIBRATION NUMBERS: Record the calibration numbers and store in a safe place

8 Go to PROGRAM SETPOINTS and configure the TOLERANCE SETUP then the setpoints

2
STRAIN GAUGE
SENSOR
INSTALLATION

3
 STRAIN GAUGE PLACEMENT FOR C FRAME PRESS

Two sensors required. Sensor enclosures are included, These help protect the sensors gauges. These enclo-
sures include 1/2” knock-out holes. If conduit is used, use a 1/2” strain relief in the knock-out holes.

SENSOR PLACEMENT
Sensor location must be determined. You have two locations, front or rear of the press. (shown in the shaded
area)

Determining the best placement

Measure the rear thickness ______= Rear thickness

Multiply by three _______x 3 =

Measure the front thickness ______= Front thickness

If the front thickness is smaller than value , then mount sensors in the front. (this is the most common).

If the front thickness is larger, then place the sensor in the rear. Wire the input connections for compression
readings instead of tension.

REAR THICKNESS

Compressio
FRONT THICKNESS

Tension

4
STRAIN GAUGE PLACEMENT FOR STRAIGHT SIDE PRESS

Conduit for load sensor wires only.

CAUTION: Do not run conduit near tie rod heating openings. Crown of press

Tie rod nut

Column

Best sensor location is

in the middle 1/3 length 1/3 L
of the column on the
center line of the rod.

Load sensor
and enclosure.
The closer a sensor is
to the tie rod the better L=LENGTH
its performance will be.
of column or
1/3 L
upright

Avoid installing
sensors closer than 12”
from the top edge or 1/3 L
bottom edge of the
holes that are cut out of

Bolster/Bed

NOTE: Rule of thumb for cast frame presses or very heavy

frame presses. Position sensors in a place of least cross sec-
tion area avoiding holes as described above.

Always, if possible , avoid positioning sensors closer than (1)

column width from the crown or bolster.

5
 DRILL AND TAP METHOD FOR MOUNTING SENSORS
TOP
STEP 2
BE SURE THE SENSOR LOCATION FOLLOWS THE BEST LOCATION
DESCRIBED ON THE PREVIOUS PAGES.
#3 Drill
(5MM

1/4-28 tap
(Metric 6-1)

STEP 1 Remove all paint and grease from sensor mount area. IF the machine
surface is flat (total indicated reading of .002”) and smooth (125u in.)
the load sensor can be bolted directly to the surface.
STEP 3-4
#3 Drill
TOP (5MM STEP 2 Drill and tap the center hole for mounting the fixture to the press
member. This hole should be 1/2” (13mm) deep.

1/4-28 x 1-1/4 STEP 3 Bolt the fixture to the press member using the 1/4-28 by 1-1/4”
screw
Drill through
(M6-1 x 35) long socket head cap screw in the center of the fixture.
four

STEP 4 Insert the number 3 drill (5mm) into the smaller corner hole and drill out
all four holes to a depth of 3/4 of an inch (19mm).

STEP 5 Loosen the fixture. Rotate the fixture 90 degrees clockwise. Tighten the
center screw of the fixture. Insert the number 21 drill into the small
Rotate fixture centered hole and drill out both holes to a depth of 3/8 of an inch. These
Drill through the two 90 degrees
small centered holes. holes are for mounting the sensor enclosure. A the fixture does not al-
low for tapping these holes.
TOP

#21 Drill STEP 6 Loosen the fixture. Rotate the fixture another 90 degrees clockwise such
that the larger corner holes line up with the holes drilled in Step 4. Insert
STEP 5 a tap to be sure the holes line up. Lock the fixture in place by tightening
the center screw.

STEP 7 Insert the tap into the larger tap guide holes and tap each hole.
Rotate fixture
90 degrees BE SURE TO USE PLENTY OF TAPPING FLUID.

1/4-28 tap STEP 8 Remove the fixture and repeat Steps 1-7 for each additional sensor
(Metric 6-1)
mounting position.

STEP 9 Mount the sensor with the raised rib to the press. The anti-torque
washers should go between the screw and the sensor body. Torque each
Tap through four 1/4-28 x 3/4” long socket head cap screw to 150 LB-IN or 12.5 LB-FT.
large holes
TOP

STEP 6–7

Anti-Torque
washers

STEP 9 CIECO
1/4-28x3/4
LOC-WELL bolts

Put raised rib to press

6
 STEP 2
WELD PAD METHOD FOR MOUNTING SENSORS
TOP

BE SURE THE SENSOR LOCATION FOLLOWS THE BEST LOCATION

DESCRIBED ON THE PREVIOUS PAGES.
#3 Drill
(5MM

1/4-28 tap
(Metric 6-1)
STEP 1 Remove all paint ,grease and or rust from surface to be welded.
(Surface should be flat T.I.R 1/32 of an inch)
STEP 3 STEP 2 Drill and tap the center hole for mounting the fixture to the press
Rotate fixture
1/4-28 x 1-1/4
90 degrees member. This hole should be 1/2” (13mm) deep.
screw
STEP 3 Bolt the fixture to the press member using the 1/4-28 by 1-1/4”
(M6-1 x 35) long socket head cap screw in the center of the fixture.
TOP

#21 Drill
Orient the fixture as shown and drill out the #21 holes to a depth of
3/8 of an inch for the enclosure mounting. The fixture is not used for
Drill through the two
small centered holes. tapping these holes.

STEP 4 Remove the fixture from the press member. Bolt the weld pads to the
fixture with 1/4-28 by 1 inch long socket heat cap screws provided.
Reattach the fixture with the weld pads bolted on using the center hole
as in Step 3. Orient the fixture as shown.

STEP 5 Weld the weld pads to the press member. (BE SURE TO ONLY
WELD THE WELD PADS ON THREE SIDES AS SHOWN.) a
1/4-28 x 1 screw single pass is sufficient. Do not remove the fixture until slag is re-
STEP 4 moved and or assembly has cooled. When welding cast iron, use a dry nickel
TOP rod such as: Lincoln electric “Soft Weld”, Hobart “NI Cast 99”, or
MB Weld Prod. “MG 210“. Strike arc on steel then puddle into the cast
iron.

STEP 6 Remove the weld fixture. DO NOT WELD AFTER FIXTURE IS RE

STEP 5 MOVED. The 4 screws holding the pads to the fixture and the 1 center
screw may be discarded. DO NOT USE THE FOUR 1 INCH LONG
SCREWS TO ASSEMBLE SENSOR. The sensor kit contains four
1/4-28 x 1-1/4
3/4” long screws for assembling the sensor to the press member. Weld
pad surface must be clean – no weld bumps, scratches, etc. Be sure the
weld pad tapped holes are clean and bottom of holes are free of weld
flash.
TOP Weld each pad on
three sides only STEP 7 Mount the sensor with the raised rib to the press. The anti torque
washers should go between the screw and the sensor body. Torque
each 1/4-28 x 3/4” long socket head screw to 150 LB-IN or
12.5 LB-FT.
Anti-Torque
washers

STEP 7
1/4-28x3/4
LOC-WELL bolts

Put raised rib to press

7
 Tonnage Tracker wiring
Strain gauge wiring

COMPRESSION WIRING

GND
Swap RED and WHITE

RX
TX
wires shown above
3 2 1 TONNAGE
RS232 TRACKER
4 SETUP DISABLE

5 REMOTE RESET
1
LOAD WINDOW
6

JP18
LIMIT SWITCH REMOTE

7 GND
3

8 ANALOG OUTPUT
Jumper pins 1 & 2 to require faults to
be cleared by a remote reset button or
momentary keyswitch.
9 +V

10 -V
LOAD1

11 +S

12 -S

13 SH

14 +V

15 -V
LOAD2

16 +S

17 -S

18 SH

19 +V

20 -V
LOAD3

21 +S
CONTRAST

22 -S

23 SH

GREEN 24 + EXCITATION

BLACK 25 - EXCITATION
LOAD4

WHITE 26 +SIGNAL

RED 27 - SIGNAL
TENSION
SHIELD 28 SHIELD
WIRING

8
Tonnage Tracker wiring continued

NOTE:
Always start with input one. Leave unused inputs
open. Remember to program any unused input MAX
number to zero.

UNUSED STRAIN GAUGE INPUTS

MUST BE JUMPED AS SHOWN!
Shield preparation
Proper shield preparation is manda- SH 23
tory. Improperly prepared shield wire -S 22
will result in significant electrical
noise and incorrect tonnage readings. +S 21
Loosen the braided shield so that the
individual strands can be twisted
-V 20
together to make a shield wire. +V 19
Connect the twisted shield wire into
the SH terminal for that sensor.
Make sure to follow these instruc-
tions or noise problems will occur.
Loosen shield braid with a
small screw driver. Do not
cut the braid.

Twist the shield strands

together to form a shield wire.

Set the cam for the Load Window to start just prior to generating a load and end just after the generated
load has completed. E.g. 120 degrees to 240 degrees.

LOAD WINDOW: The load window is an area in the press stroke where the tonnage will be monitored
and compared with the programmed set-points. Outside the window the load sensors are
ignored and the inputs are zeroed.

ANALOG OUT: Programs which input will output to the analog output terminal. This output is a real time
output only when the position of the press is within the programmed LOAD WINDOW.
Use the up/down arrows to select either input 1,2,3 or 4.

9
Tonnage Tracker wiring continued

10
 TONNAGE MONITOR SETUP
FUNCTIONS

Toggle the MENU key.

LOAD1 SETPOINTS > Press ENTER ^ LOAD1 > 089.0 (less then or equal to Max #)
HIGH

Press ^ ^ LOAD1 > 000.0 (less then HIGH)

Low

Press ^ ^ LOAD1 > 045.0 (equal to of less then 1/2 Max#)

REV

Press ^ ^ LOAD1 > 0099 (1-1000, no decimal)

MAX

Enter the press capacity divided Press > LOAD1 > 0090 (use the arrow keys to enter the Max#)
by the number of inputs into MAX
each inputs MAX.
e.g. 100 ton press, using 4 in- Press ENTER (saves the new Max#)
puts, each MAX = 25 tons.

Make sure all other settings are Press ^ ^ LOAD1 > 001.5 (if level must be greater than low setting)
set near their maximums to TOL + (if repeatability, 1- Max#)
eliminate faults during calibra- Press ^
tion. This is normally done auto- ^ LOAD1 > 001.5 (if level, less then High setting)
matically when the Max# is en- TOL - (if repeatability, 1 - Max#)
tered.

Repeat above steps for all inputs.

NOTE: Always start with input #1. All unused inputs must have a programmed MAX LOAD # of
zero. Max numbers can effect setpoints. Do not change the max numbers unless you are pre-
pared to calibrate.

11
 LOAD CELL CALIBRATION
SETTING UP FOR LOAD CELL CALIBRATION

1. Place the load cells as shown on the following page

2. Adjust the shut height appropriately so that a load is generated Use shims on the load cells to get a uni-
form load reading on each load cell.
Do not exceed the maximum load rating of the load cells.

3. Calculate the required load for each load cell using the formula below.

M x 0.75
=L
N

N = # OF LOAD CELLS USED

L = TONNAGE READING FOR EACH LOAD CELL @ 75%
M = MAXIMUM TONNAGE CAPACITY OF PRESS
Caution: Do not exceed the maximum load cell rating

4. Stroke the press so that L is displayed on each of the load cells.

NOTE: The number of load cells used should be equal to or less than the number of inputs used.

5. Once L is displayed on each of the load cells go to the following pages for calibration.

12
LOAD CELL CALIBRATION PROGRAMMING continued

Load cells must be used to calibrate

the Tonnage Tracker. Place the load
cells as shown below. Adjust the shut
height to generate a load when the
press is stroked. Use shims on the load
cells to get a uniform load
reading on each load cell.
DO NOT EXCEED THE MAXI- Left Rear
Input #___ Right Rear Right Front
MUM LOAD RATING OF THE Input #___ Input #___
LOAD CELLS. Left Front
Input #___ 888
8
888
8

LOAD CELL PLACEMENT

BED TOP VIEW

TWO LOAD CELLS

LOAD LOAD
CELL CELL CL For 2 or 4 inputs
If 4 inputs are used, divide the
CL load cell readings by 2

LOAD CELL PLACEMENT

LOAD LOAD
CELL BED TOP VIEW CELL

FOUR LOAD CELLS

CL For 4 inputs

LOAD LOAD
CELL CL CELL

13
LOAD CELL CALIBRATION PROGRAMMING

With the press at the top of the stroke (no load applied, load limit switch off), press MENU key to :

LOADCELL CALI. > Press ENTER ^ LdCell 1 > 000.0 (Stroke the press, adjusting the shut ht. and/or shimming
ActualTons=000.0 to attain a load of 75% of press capacity on the load
cells)

^ LdCell 1 > 000.0 (The displayed Actual Tons is an arbitrary number at

ActualTons=023.1 this point)

If using two load cells with four Press > LdCell 1 > 038.6 (use the arrow keys to enter the reading from the load
inputs, divide the load cell read- ActualTons=023.1 cell into LdCell 1)
ings by 2.

The LdCell 1 display will imme- Press ENTER LdCell 1 > 000.0 (Stroke the press. Read the actual tons. If the
diately revert back to 000.0 when ActualTons=038.2 ActualTons display matches the load cell reading,
you press enter then procede to input 2. If not reenter the load cell #
into LdCell 1 and repeat until they closely match)

Repeat above steps until all inputs are calibrated.

DO NOT remove the load cells. Use the chart on the following page to graph the linearity of the tonnage moni-
tor. The linearity is a result of proper installation and the condition of the frame of the press.

14
LOAD CELL CALIBRATION PROGRAMMING continued

EXAMPLE:
100 ton press with 2 sensors and 2 load cells.
(input #1 sensor mounted to left side and input #2 sensor to right side of the press)

-Adjust the shut height until a reading of (100 x 0.75) ÷ 2 = 37.5 tons on each load cell

-Actual readings of:

Left load cell reading of 37.5 tons
Right load cell reading of 37.0 tons

-Enter the data

Enter 037.5 into LdCell 1
Enter 037.0 into LdCell 2
NOTE: If using four inputs with two load cells, divide the left load cell by two for the
left side and the right load cell reading by two for the right side.

EXAMPLE:
200 ton press with 4 sensors and 2 load cells.
(input #1 left front, input #3 left back, input #2 right front, input #4 right back )

-Adjust the shut height until a reading of (200 x 0.75) ÷ 2 = 75 tons on each load cell

-Actual readings of:

Left load cell reading of 74.5 tons
Right load cell reading of 75.0 tons

-Two load cell with four sensors requires the following.

Divide the left load cell reading by two for inputs 1 & 3 (74.5 / 2 = 37.3)
Divide the right load cell reading by two for inputs 2 & 4 (75.0 / 2 =37.5)

-Enter the data

Enter 037.3 into LdCell 1
Enter 037.3 into LdCell 3
Enter 037.5 into LdCell 2
Enter 037.5 into LdCell 4

15
 LOAD CELL CALIBRATION LINEARITY PLOT

Adjust the shut height to decrease the tonnage. Repeat this process and record the total added reading from the load cells and the total
tonnage displayed on the control (see VIEW TONNAGE to see total tons). Once a sufficient amount of data is recorded , use the
graph below to plot a line. The graph will represent the linearity of the installation.

LOAD CELL TOTAL TONNAGE MONITOR TOTAL

1 1
2 2
3 3
4 4
5 5
6 6
7 7
8 8
9 9

75% max IDEAL LINEARITY

“TOTAL”
Tons displayed
on screen

0
75% max
“TOTAL” tons displayed on load cells.
16 E.g. If using two load cells add the two readings to get the total.
 CALIBRATION NUMBERS
RECORD THE CALIBRATION NUMBERS IN THE AREA BELOW FOR FUTURE USE
AND FACTORY TROUBLE-SHOOTING.

CALIBRATION #s > Press ENTER ^ LOAD1 > 16777450

CAL#

Press ^ ^ LOAD2 > 16777450

CAL#

Press ^ ^ LOAD3 > 16777450

CAL#

Press ^ ^ LOAD4 > 16777450

CAL#

CAL NUMBER 1
If the calibration is corrupted
CAL NUMBER 2 ENTER the calibration num-
bers to recalibrate without hav-
CAL NUMBER 3 ing to use load cells.
CAL NUMBER 4

Record the Factory Info numbers before calling in for technical support

FACTORY INFO. > Press ENTER ^ ZERO1 > 00065532

OFFSET1 = 00002108

Press ^ ^ ZERO1 > 00065532

OFFSET1 = 00002108

Press ^ ^ ZERO1 > 00065532

OFFSET1 = 00002108

Press ^ ^ ZERO1 > 00065532

OFFSET1 = 00002108

ZERO1 OFFSET1

ZERO2 OFFSET2

ZERO3 OFFSET3

ZERO4 OFFSET4

17
 INITIALIZE
Toggle MENU to:

INITIAL > Press ENTER ^ JOB # > 0001 (Shows the current Job #. 1-1000)

Press ^ ^ TOOL# > 84756453 (displays the Tool # for the current Job#)

Press ^ ^ PROGRAM > 0000 (supervisory code = 1478)

ENABLED

Press ^ ^ ANALOG > 3 (selected sensor to output to a chart recorder. 1-4)

OUTPUT

Use arrow keys to change values. Press ENTER to save new values. The Tool# and all Setpoints are stored under the currently
selected Job#.

Toggle MENU to:

TOL. INITIAL > Press ENTER ^ TOLRNCE > RPTBL (RPTBL or LEVEL)
TYPE
Press ^
^ TOLRNCE > 0039 ( # of successive tolerance faults to initiate a stop)
Press ^ COUNT 0005 (counts remaining till fault)

Use arrow keys to change values. Press ENTER to save new values. The Tolerance Type is universal to all Jobs and the Tolerance
Count is stored under the currently selected Job#.

TOLERANCE TYPE: There are two types of tolerance settings, LEVEL and REPEATABILITY.

LEVEL – will set a fixed tolerance window according to the ± TOLERANCE settings.
Set the ± TOLERANCE to the actual tonnage limits that are required. If the actual peak tonnage falls outside
of the tolerance settings a fault will occur after the tolerance count has expired. (see below for the fault sequence)

REPEATABILITY – allows for a floating window based on the last peak tonnage reading. Each peak
tonnage will be compared to the last peak tonnage. If the difference is greater than allowed by the
± TOLERANCE settings a fault will occur after the tolerance count has expired. (see below for the fault sequence)

TOLERANCE COUNT: The amount of strokes in a row a tolerance fault can occur before a stop will occur. If
the peak tonnage falls back into the allowable tolerance, the counter will reset and a stop will not occur.

18
 TONNAGE SETPOINTS
Toggle the MENU key.

LOAD1 SETPOINTS > Press ENTER ^ LOAD1 > 089.0 (less then or equal to Max #)
HIGH

Press ^ ^ LOAD1 > 000.0 (less then HIGH)

Low

Press ^ ^ LOAD1 > 045.0 (equal to of less then 1/2 Max#)

REV

Press ^ ^ LOAD1 > 0099 (1-1000, no decimal)

MAX

Press ^ ^ LOAD1 > 001.5 (if level must be greater than low setting)
TOL + (if repeatability, 1- Max#)

Press ^ ^ LOAD1 > 001.5 (if level, less then High setting)
TOL - (if repeatability, 1 - Max#)

Each input has its own set-point screen. Program each

one according to the requirements of the die you are
currently using. The setpoints will be saved under the
current job number. When this job is used again the set-
points will be recalled from memory.

SET UP DISABLE input to the Tonnage Tracker will

disable the LOW tonnage faults. This is useful during
setup to eliminate nuisance faults.

Each parameter is applied to the input number only. They are saved under the current job number and are
recalled when that job number is used.

HIGH TONS: Maximum allowable tonnage per stroke. A tonnage above this value while in the tonnage
window will cause a fault.

LOW TONS: Minimum allowable tonnage per stroke. If the peak tonnage does not exceed this value while
in the tonnage window a fault will occur.

REVERSE TONS: Maximum allowable reverse tonnage per stroke. A reverse tonnage above this value
while in the tonnage window will cause a fault.

± TOLERANCE: The allowable variation from the optimum tonnage. See “Tolerance Setup” on the previ-
ous page for more details on the tolerance function.

Wire fault output to stop circuit.

19
 VIEW TONNAGE

Toggle the MENU key.

VIEW TONNAGE > Press ENTER ^ 036.7 + 032.5 (shows the positive peak tonnage for each input)
035.1 034.0 (total display shows positive peak total of all the inputs)

Press ^ ^ 016.3 - 014.2 (shows the reverse peak tonnage for each input)
015.5 015.9 (total display shows reverse peak total of all the inputs
with a minus sign)

[order of displayed inputs]

Input1 Input2
Input3 Input4

Power up and RESETs revert to the VIEW TONNAGE screen. If Max#’s for all inputs are not equal, no total is displayed. [- - - -]
When there is a fault, the total screen flashes on and off.

20