Burster ForceMaster 9110 User manual

OPERATING MANUAL
ForceMaster 9110
©2013 burster
präzisionsmesstechnik gmbh & co kg
All rights reserved
Manufacturer:
burster präzisionsmesstechnik gmbh & co kg
Talstraße 1 – 5
76593 Gernsbach
Germany
P.O.Box 1432
76587 Gernsbach
Germany
Valid from:
08.10.2013
Tel.:
(+49) 07224 / 6450
Fax.:
(+49) 07224 / 64588
E-Mail:
[e-mail]
www.burster.de
1378-BA9110EN-5170-101523

Warranty - exclusion of liability
All information in the present documentation was prepared and compiled with great care and reproduced
subject to effective control measures. No warranty is provided for freedom from errors. We reserve the
right to make technical changes. The present information as well as the corresponding technical data can
change without notice. Reproduction of any part of this documentation or its processing or revision using
electronic systems is prohibited without the manufacturer's prior written approval.
Components, devices and measured value sensors made by burster präzisionsmesstechnik (hereinafter
referred to as "product") are the results of targeted development and meticulous research. As of the date
of delivery, burster provides a warranty for the proper condition and functioning of these products covering
material and production defects for the period specified in the warranty document accompanying the
product. However, burster excludes guarantee or warranty obligations, as well as any liability beyond that,
for consequential damages caused by improper use of the product, in particular the implied warranty of
success in the market as well as the suitability of the product for a particular purpose. Furthermore,
burster assumes no liability for direct, indirect or incidental damages as well as consequential or other
damages arising from the provision and use of the present documentation.

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Contents
1. For your safety ...................................................................................................................................................9
2. Introduction ......................................................................................................................................................10
2.1 Intended use......................................................................................................................................10
2.2 Ambient conditions ............................................................................................................................10
2.2.1 Storage conditions ............................................................................................................10
2.2.2 Conditions of use ..............................................................................................................10
2.3 Personnel ..........................................................................................................................................11
2.4 Scope of supply.................................................................................................................................11
2.5 Conversions and modifications .........................................................................................................11
3. Device concept.................................................................................................................................................12
3.1 Range of functions ............................................................................................................................12
3.2 Simple operation................................................................................................................................12
3.3 Autoconfiguration ..............................................................................................................................12
3.4 Counter..............................................................................................................................................12
3.5 Documentation of measuring operations ..........................................................................................12
3.6 Languages.........................................................................................................................................13
3.7 Support for automation ......................................................................................................................13
3.8 Front view of the ForceMaster 9110 .................................................................................................14
3.9 Rear view of the ForceMaster 9110 ..................................................................................................15
3.10 Menu structure of the ForceMaster 9110 .......................................................................................16
3.10.1 Operating example (extract from the menu).....................................................................19
3.10.2 Aids to orientation for operation........................................................................................19
3.10.3 Display and operating concept .........................................................................................20
3.10.4 Entering text and numbers................................................................................................21
3.11 Autoconfiguration ..............................................................................................................................22
3.11.1 "Autoconfig" menu ............................................................................................................22
3.11.2 "Step 1: teach-in" ..............................................................................................................23
3.11.3 "Step 2: Set Modes"..........................................................................................................23
3.11.4 "Step 3: Set values" ..........................................................................................................25
3.11.5 Finish autoconfiguration....................................................................................................27
3.12 Card reader .......................................................................................................................................28
3.12.1 MasterCard .......................................................................................................................28
3.12.2 ToolCard ...........................................................................................................................28
3.12.3 PLCCard ...........................................................................................................................28
3.13 "PLC & IO" menu...............................................................................................................................29
3.13.1 List of possible conditions.................................................................................................32

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3.13.2 List of possible commands ...............................................................................................33
3.14 "Cam" menu ......................................................................................................................................33
3.15 Measuring and adjusting ...................................................................................................................35
3.16 Force alarms......................................................................................................................................35
3.16.1 Force alarm 1....................................................................................................................35
3.16.2 Force alarm 2....................................................................................................................35
3.17 Step chain controller (option) ............................................................................................................36
3.18 Cam switching mechanism................................................................................................................37
3.19 I/O interface .......................................................................................................................................38
3.19.1 Connector pin assignments ..............................................................................................38
3.19.2 I/O signal combinations ....................................................................................................39
3.20 Switching on procedure .....................................................................................................................40
4. Initial commissioning ......................................................................................................................................41
4.1 Fitting the load cell to the manual press............................................................................................41
4.2 Fitting the displacement measurement system (DMS) to the manual press ....................................42
4.3 Setting up the measurement chain on the ForceMaster 9110 ..........................................................44
5. Measurement ....................................................................................................................................................46
6. Configuring the ForceMaster 9110 settings..................................................................................................49
6.1 "Counter" menu .................................................................................................................................50
6.2 USB stick (option)..............................................................................................................................52
6.2.1 Operation with a USB stick ...............................................................................................52
6.2.2 "USB stick" menu..............................................................................................................53
6.2.3 Data storage example.......................................................................................................57
6.3 "PLC & IO" menu...............................................................................................................................58
6.3.1 List of possible conditions.................................................................................................61
6.3.2 List of possible commands ...............................................................................................62
6.4 "Cam" menu ......................................................................................................................................62
6.5 "CARD" menu....................................................................................................................................64
6.6 "Manual settings"" menu. ..................................................................................................................67
6.7 "Error signals" menu..........................................................................................................................69
6.8 "Order data" menu.............................................................................................................................72
6.9 "Statistics" menu................................................................................................................................74
6.10 "Manual and internal settings" menu.................................................................................................75
6.11 "Date & time" menu ...........................................................................................................................80
6.12 "Status" menu....................................................................................................................................81
6.13 "Languages" menu ............................................................................................................................81

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7. Force-displacement curves ............................................................................................................................82
8. Technical data ..................................................................................................................................................89
9. Configuration notes.........................................................................................................................................90
9.1 Choosing the right load cell ...............................................................................................................90
9.2 Choosing the right displacement sensor ...........................................................................................91
9.3 Advice................................................................................................................................................91
10. Available accessories......................................................................................................................................92
11. Ordering example ............................................................................................................................................93
12. Index..................................................................................................................................................................94

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For your safety
1. For your safety
The following symbols on the device and in this manual warn of hazards:
Symbols in the manual
Warning
Death or serious injury
can
occur if no appropriate precautions are taken.
Caution
Damage to property can occur if no appropriate precautions are taken.
Note
It is important to heed these safety notices in order to ensure correct handling of the
instrument.
Symbols on the device
Observe the text on the device
Observe the text next to/underneath the warning sign:
"Unplug the mains before opening! - Observe safety instruction - Servicing only by trained
technicians"

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Intended use
2. Introduction
2.1 Intended use
The ForceMaster 9110 is a device for monitoring repetitive production processes. Its particular
purpose is the recording and evaluation of process signals, where the curve of the force has a
defined relationship with displacement or time. The result of the analysis is classified as either
ACCEPTABLE (OK) or is NOT acceptable (NOK). Visual and acoustic signals are given, and
made available at various interfaces.
The device is not a replacement for safety equipment, such as for the emergency shutdown of a
press if the pressing force exceeds a limit value.
2.2 Ambient conditions
2.2.1 Storage conditions
•clean packaging
•dry
•no condensation
•temperature between 0 °C and +60 °C
2.2.2 Conditions of use
•indoors
•maximum altitude: 2000 m above sea level
•operating temperature: between +5 °C and +40 °C
•humidity: 80% up to 31 °C, decreasing linearly above that temperature to 50%
at Tmax, no condensation
•protection class:1
•transient excess voltage: according to Category 2
•potential to ground: ≤12 V DC between analog ground and ground
•supply voltage: 90 to 264 Veff, 47 to 63 Hz

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Introduction
2.3 Personnel
The operating personnel must be familiar with the respectively applicable regulations. They must
follow these regulations.
2.4 Scope of supply
•ForceMaster 9110
•Operating manual
•1 x mains cable
•PC software
•MasterCard 9110-Z001
2.5 Conversions and modifications
If you open up the ForceMaster 9110 or dismantle it during the warranty period, the warranty will
be immediately voided.
The ForceMaster 9110 may only be opened by our technical personnel.
It is forbidden to make any modification to the ForceMaster 9110 without our written permission.
In that case we can accept no liability.

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Range of functions
3. Device concept
3.1 Range of functions
The ForceMaster 9110 is a measuring instrument that monitors production operations at manual
presses by measuring the applied force and the distance travelled by the punch.
The design includes mechanisms that make sure that reported errors cannot be ignored.
3.2 Simple operation
Bei der Entwicklung des ForceMaster 9110 wurde auf einfache Bedienung großer Wert gelegt. Es
gibt nur einen Bedienknopf, der genügt, um durch das Menü zu navigieren.
3.3 Autoconfiguration
The work required to set up the ForceMaster 9110 has been simplified through the introduction of
an autoconfiguration system. You carry out the pressing of a part as an example, and the
ForceMaster 9110 records the pressing forces and the distance.
This makes all settings automatically. Whether the sensors are of F or F/s type is also detected.
The measuring mode is set automatically. Units such as newtons (N), kilonewtons (kN) or
displacement (mm) are set automatically.
3.4 Counter
The ForceMaster 9110 counts the number of parts that have been checked, recording both the
total number of parts as well as how many were assessed as OK and how many were NOK (not
OK). In practice, the number of parts that are assessed as NOK must be the same as the number
of parts in the scrap box at the manufacturing station. In this way you can also check whether the
worker has correctly sorted out the scrap parts.
3.5 Documentation of measuring operations
The ForceMaster 9110 offers several options for documenting production quality. You are also
able to write up to 50 manufacturing jobs into a job memory, transfer this to an Excel table, and
store it on a USB stick.
It must be possible to trace the documentation back to the individual manufacturer part. This is
only possible if a large amount of memory is available and if the data can be handled easily.
These facilities are provided by a USB stick.

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Device concept
Two recording modes are available to you. A CSV file is generated in both cases. Many
statistical programs (e.g. Excel, Access) can process this format.
•A job file records the data measured for each part, including what force was
reached, and whether the part was OK.
•A menu allows you to choose whether the entire pressing curve is to be stored.
Because a pressing curve contains a relatively large amount of data, the
storage process takes up to 3 seconds. In addition, this data record takes a
correspondingly large amount of storage on the stick.
It is possible to collect the accumulated data daily, and to use another stick for the following day.
The data that has been collected can then be saved on a PC or a server.
The large amount of storage available on a USB stick makes it possible to store the
documentation over a longer period of time. You should, however, evaluate the data regularly, so
that anything learnt from it can promptly be used to modify the production process.
3.6 Languages
The ForceMaster 9110 can be set for operation in a number of languages. See Section 6.15 for
the available languages.
3.7 Support for automation
The ForceMaster 9110 has a simple, freely programmable step chain controller, is supported in
addition by a cam switching mechanism. This allows simple, small-scale automation to be
implemented. There are 6 cams. Control signals can be triggered by these cams. Each cam can
be programmed in a variety of ways. The cam signals can exclusively be used through the
optional step chain controller.

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Support for automation
3.8 Front view of the ForceMaster 9110
Key
Explanation
1 Card reader
2 Two-line display
3 Folding feet
4
Operating knob
5
Red indicator lamp NOK
6
Green indicator lamp OK
7
Loudspeaker

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Device concept
3.9 Rear view of the ForceMaster 9110
Key
Explanation
8 Mains connection
9
Mains switch
10
Fuse
11
Connection for USB stick (optional)
12
Connection for load cell
13 Connection for displacement sensor
14 RS232 interface
15 I/O interface
16
USB connection for PC

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Menu structure of the ForceMaster 9110
3.10 Menu structure of the ForceMaster 9110

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Device concept

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Menu structure of the ForceMaster 9110

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Device concept
3.10.1 Operating example (extract from the menu)
Extract from the setting menu
The menu structure of the ForceMaster 9110 has been kept simple.
Like PC applications, there is a main menu. When you select a menu item, you are taken to a
sub-menu.
3.10.2 Aids to orientation for operation
Arrows that indicate the possible directions of rotation are provided on the lower right of the
display, immediately next to the rotary knob, for better orientation in the menu.
If the arrow points to the left (<) or to the right (>) you can turn the operating knob to the left or
right in order to reach a menu item.
Man. Einstell.
Fehlersignale
Fehlersignal
Fehl.sig.lautst.
Fehler quit
Beep aus
Beep bei BK
Beep VST
^^^^^
Unter-
funktion
Auftragsdaten

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Menu structure of the ForceMaster 9110
Note
There are menu functions that can be switched on or off.
An asterisk (*) appears at the end of the line if the function is switched on, so that
you can see the status straightaway.
3.10.3 Display and operating concept
A single knob, which you can turn and press, serves as the operating element.
When you have found the menu item where you want to change something, press the operating
knob. This takes you to a sub-menu. By turning the operating knob, you can navigate through the
sub-menu. When you have found the function you want, press the knob in order to select it.
1 Turn the operating knob until the menu item you want appears on the
display.
2 Press the operating knob in order to select the menu item.
To return from a sub-menu back to the main menu, turn the operating knob to the last menu item,
represented by arrows (^^^^^), and select it.
1 Turn the operating knob until the row of arrows (^^^^^) appears on the
display.
2 Press the operating knob to go to the main menu.