unidor TRsystems PKM 02 User manual

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PKM 02
TRsystems GmbH
D-75179 Pforzheim
Freiburger Straße 3
Phone: (+49) (0)7231/31520
Fax: (+49) (0)7231/315299
[email protected]
www.unidor.de | www.trsystems.de
2-channel press force measuring device

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© by TRsystems GmbH • 75179 Pforzheim • www.unidor.de • Tel.: (+49) (0)7231/3152 0
© by unidor TRsystems GmbH
D-75179 Pforzheim
Freiburger Straße 3
Phone: (+49) (0)7231/31520
Fax: (+49) (0)7231/315299
[email protected]
www.unidor.de | www.trsystems.de
Copyright protection
This manual, including the images contained therein, are protected under
copyright law. Third-party applications of this manual which violate copyright
provisions are prohibited. Reproduction, translation and electronic and
photographic archiving and alteration require written consent of the
manufacturer. Legal action will be taken against violations and corresponding
claims for damages will be asserted.
Subject to changes
Subject to changes in the interests of technical advancement.
Document information
Issue/rev. date: 00 / 13 june 2023
Document/rev. no.: 00
File name: PKM 02 Manual
Author: MP
Font types
Italic or bold font refers to the title of a document or is used to highlight text.

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Table of contents
Table of contents................................................................................................................................3
1 Change index....................................................................................................................................4
2 General.............................................................................................................................................5
2.1 Scope of application ................................................................................................................5
3 Additional safety notes....................................................................................................................6
3.1 Definition of icons and notes...................................................................................................6
3.2 Supplement notes to the intended use...................................................................................6
3.3 Organizational measures.........................................................................................................6
4 Technical data..................................................................................................................................7
5 Introduction.....................................................................................................................................7
6 Signals and connection diagram......................................................................................................8
7 View of the device ...........................................................................................................................8
7.1 Front of the device ..................................................................................................................8
7.2 Back of the device....................................................................................................................9
8 Programming the cutoff values .....................................................................................................10
8.1 Resetting faults......................................................................................................................10
8.2 Test ........................................................................................................................................10
8.3 Block diagram ........................................................................................................................10
8.3.1 View of the board..........................................................................................................11
8.3.1 View of the board..........................................................................................................12
8.4 Connections and settings on the board.................................................................................12
8.4.1 Settings for code switches.............................................................................................13
8.4.2 jumper und DIP-switch settings ....................................................................................14
8.5 Piezo sensor connection........................................................................................................15
8.6 Initiation.................................................................................................................................16
9 Dimensions ....................................................................................................................................17
10 EC Declaration of Conformity ......................................................................................................19

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1Change index
Change
Date
Index
First edition
13. june 23
00

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2General
This user manual contains the following subjects:
- Electrical specifications
- Installation
- Commissioning
- Configuration/parameterization
Since the documentation has a modular structure, this user manual is deemed a supplement to
other sources of documentation such as product data sheets, dimensional drawings, brochures and
assembly instructions.
The user manual may form part of the scope of delivery depending on customer specifications or it
may be requested separately.
These operating instructions are kept up-to-date. However, since TRsystems
GmbH/UNIDOR products are subject to continuous further development, it is
possible that short-term deviations between the device version and the
operating instructions might occur due to technical changes. Please note that
we do not assume liability for damage which might arise as a result.
2.1 Scope of application
This user manual solely applies to the following product:
PKM 02
Order number: 1050 300X 0000
The products are marked by attached nameplates and form part of a system.
Therefore, the following documentation applies:
- The system-specific operating instructions of the operator
- This user manual
- Further documents supplied together with system

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3Additional safety notes
3.1 Definition of icons and notes
means that minor physical injury or property damage may occur if
appropriate precautions are not taken.
refers to important information and/or characteristics of and application
advice for the product used.
3.2 Supplement notes to the intended use
The system is designed to be used in Ethernet networks with a maximum speed of 100 Mbs for full-
duplex operation specified in IEC 61158 as CPF2/2 (Communication Profile)
The technical directives on establishing the Ethernet network must be complied with in order to
ensure safe operation.
The intended use also includes:
observing all notes contained in this user manual,
observing the assembly instructions, in particular the chapter "Fundamental
safety notes" must be read and understood before beginning to work
3.3 Organizational measures
This user manual must always be available at the place of use of the system.
Before beginning work, the personnel assigned to perform activities on the system must have
read and understood
–the assembly instructions, in particular the chapter "Fundamental safety notes",
–and this user manual, in particular the chapter "Additional safety notes"
.
This particularly applies to temporary personnel.

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4Technical data
design PKM 02
display 2x pointer instrument 0-130% drag indicator
operating system 2x potentiometer 0-100% 2x reset-/2x testbutton
power supply 24V DC
power consumption ca. 150W
temperature range 0-60°C
humidity max. 95% non condensing
input impedance amplifier 1013 Ω
output signal analog 47 Ω / 0-10V DC via M12 socket 5pin
output signal digital NC contact max. 250V AC/1A
dimensions (WxHxD) 264.5x175.14x59.0mm
weight ca. 2.3 kg
5Introduction
The PKM 2000 is an analog press force measuring device with 2 channels.
The control and monitoring components installed in the device have been designed according to
state-of-the-art technology. The extension and compression of the press is measured by the piezo
sensors. The piezo sensors then convert the extension (compression), proportional to the force,
into an electric voltage. The maximum force occuring in any one cycle is saved to memory and
displayed and compared to the set value. If the set values are exceeded, the press is automatically
switched off. The values can be set to up to 130% of the press load as the tools often have an
asymmetric force distribution.
Please note: 100% for each side of the press is equal to 50% of the overall tonnage.

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6Signals and connection diagram
Inputs PKM 02
On the rear of the device there are two M12 connection sockets (X75.1 and X75.2) to connect the
piezo sensors.
Outputs and power supply PKM 02
M12 socket X01 machine - stop. The relay is linked to the stop circuit of the machine.
linked. This stops the machine immediately in the event of an error.
Analog output/reset
Channel1 and channel2 via M12 socket X74 Output voltage 0-10V DC
7View of the device
7.1 Front of the device
actual value
display, left
actual value
display, right
reset fault
"Reset" left/right
test cutoff
"Test" left/right
adjusting press
force, right
adjusting press
force, left

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7.2 Back of the device
X75.2 sensor
input channel 2
X75.1sensor
input channel 1
X74 analog
output/reset
X01 power supply
and stop output

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8Programming the cutoff values
Turn the setting dial "max. press force" to the press force you require.
Example: If you set the dial to 40%, a press with 1000 kN - i.e. 500 kN for each side - will
automatically be switched off if a press force of >200 kN is reached. The value last recorded is
saved for several seconds and can be read off the instruments.
8.1 Resetting faults
By pressing the RESET button or over X74 the fault will be reset. The display shows 0% again.
The device is ready for operation.
8.2 Test
By pressing the TEST button, the 100% display can be checked. If the limit values on the setting
dials are set to <100%, the output relay cuts off. (Checking the cutoff function).
8.3 Block diagram

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8.3.1 View of the board
poti P1-3 setting comparator stage channel 1
poti P4-6 setting of comparator stage channel 2
factory settings
jumper ME1 setting
jumper ME2 setting
jumper ME3 setting
SW402
SW401
SW202
SW201
ME1
ME2
ME3
P302
P102
SW1
P1
P4
P302 trimmpoti channel 2
P302 trimmpoti channel 2
SW402 amplifier stages channel 2
SW401 capacity levels integrator channel 2
SW202 amplifier stages channel 1
SW201 capacity levels integrator channel 1
SW1 DIP switch on and off signal- filter stages
channel 1+2

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8.3.1 View of the board
8.4 Connections and settings on the board
To adjust the capacitance and gain, the rear cover of the device must be removed.
be removed.
Warning! Before opening the device, ensure it is disconnected from the mains.
LED 6 green
+7,5V
LED 5 green -
7,5V
LED 4 green -12V
LED 3 green
+12V

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8.4.1 Settings for code switches
*setting not permitted
Codeswitches SW201(401) capacity (nF)
0
71,8
1
65,0
2
61,8
3
55,0
4
49,8
5
43,0
6
39,8
7
33,0
8
38,8
9
32,0
A
28,8
B
22,0
C
16,8
D
10,0
E
6,8
F*
0,0
Codeswitches SW202(402) amplification
0
11,12
1
11,08
2
11,03
3
10,96
4
10,93
5
10,84
6
10,76
7
10,64
8
10,48
9
10,27
A
10,07
B
9,67
C
9,51
D
8,80
E
7,90
F
5,27
SW402
SW401
SW202
SW201

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8.4.2 jumper und DIP-switch settings
jumper ME1-ME3
ME1+2 sampling latch channel 1+2: jumper left 2.2µF/right 10 µF
ME3 reference voltage: jumper left Uref = 7.06V/right Uref = 6.79V
DIP-switch SW1
switch 1-4 filter setting channel 1
either turn on only 1 or 2, or turn on none*
F limit = 1KHz (33nF) (default 1+2= OFF)
1 F limit = 100Hz (220nF II 33nF) (1=ON, 2=OFF)
2 F limit = 355Hz (47nF II 33nF) (2=ON, 1=OFF)
either turn on only 3 or 4, or turn on none*
3 with filter (default 3=ON, 4=OFF)
4 without filter (4=ON, 3=OFF)
switch 5-8 filter setting channel 2
either only 5 or 6, or turn on none*
5 with filter (default 5=ON, 6=OFF)
6 without filter (6=ON, 5=OFF)
either only 7 or 8, or turn none on*
F limit = 1KHz (33nF) (default 7+8= OFF)
7 F limit = 100Hz (220nF II 33nF) (7=ON, 8=OFF)
8 F limit = 355Hz (47nF II 33nF) (8=ON, 7=OFF)
*never both at the same time, otherwise this can lead to malfunctions or damage to the electronics!
ME1
ME2
ME3
on
off

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8.5 Piezo sensor connection
The piezo sensors delivered with the device are mounted to the press either on the pressing or
drawing side (see diagram below). In order to protect the sensors, please place the protective caps
over the sensors once the latter have been mounted and calibrated. The cables that connect the
sensors to the device should not be disconnected or extended with either connectors or terminals
(charge loss).
Assignment sensor JZT 127
Press pull
channel 1+ channel 1 -
black red
red black
Channel 2+ Channel 2 -
black red
red black

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8.6 Initiation
• wire up the sensors and connecting cables
•connect the distribution voltage
• connect the press stop output to the press control
• set the amplifier to basic position 3 using the code switch SW202 (SW402)
• set the maximum performance of the object to be measured (e.g. max. press force)
• keep pressing the code switch SW201 (SW401) until the required output voltage is shown on
the display (max. 10 V)
• using the code switch SW202 (SW402) you are also able to compensate the differing sensitivity
of the sensors, for those devices with several channels
• if the board is replaced (service), please ensure that the code switches are set to the same
values as before, otherwise there could be a danger of overloading. It may also be necessary to
recalibrate the device.

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9Dimensions

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10 EC Declaration of Conformity
Manufacturer: TRsystems GmbH, System department Unidor
Factory: Unidor, Freiburger Straße 3, D-75179 Pforzheim
hereby confirm for the
Product: PKM 02
Device type: Press Force Measuring Device
Model name: PKM 02
compliance with the EC Directive 89/392/EEC and the following standards:
EN 60204.1, Electrical Equipment for Industrial Machines
Electromagnetic Compatibility 89/336/EEC IEC 801 Parts 1, 2, 4
EN 55011 Radio Interference Voltage
EN 55022 Noise Radiation
VDE 0100, VDE 0113, EN 60204
Issued by: TRsystems GmbH, System department Unidor
Date: 13 june 2023
Place: Pforzheim, Germany