X-SENSORS X-302 User manual

Operating Manual
Measuring System X-302/Wireless
for Tie Bar Strain Measurement

Version 4 (January 2021) EN 2
Content
Introduction and Description..................................................................................................... 3
Installation and Operation ......................................................................................................... 4
Help! ........................................................................................................................................... 9
Safety instructions................................................................................................................... 10
Disposal.................................................................................................................................... 12
Technical Data ......................................................................................................................... 12
Order information..................................................................................................................... 13
X-Sensors AG
Landenbergerstrasse 13
CH-8253 Diessenhofen
[email protected]
[phone]
www.x-sensors.com

Version 4 (January 2021) EN 3
Introduction and Description
The X-102 Sensors measure the strain of tie bars in an injection- or pressure-molding ma-
chine, such that the relationship between position and pressure can be captured.
The strain, measured in units of microstrain, is directly proportional to the force and may
easily be calculated:
F = µε xA xEMod x10-6
[Force in kN = Strain in µε x csa in mm² x Young’s modulus in kN/ mm² x 10-6]
The digital displays in the X-318 display values in µε, kN, and other units. Force is calculated
using the strain along with the given parameters of tie bar diameter and Young’s modulus.
The displays can show up to four individual sensors, as well as the average of strain or the
total pressure from all connected sensors.

Version 4 (January 2021) EN 4
Installation and Operation
In order to compensate properly for bending, the sensors are to be mounted at 180° on the
tie bar, meaning that they are mounted precisely opposite each other.
Preparation
•The Sensors must be spaced at least two tie bar diameters away from the tie bar
clamps.
•Choose a mounting location which meets this requirement and clean it of all forms
of surface contamination. Hard contaminants should be removed with a wire brush
until the shiny bare metal is visible.
•Mount the sensors to the tie bar. Take care that the measuring element is properly
aligned, because when first mounted it is likely to be crooked. Pull lightly on the ca-
ble entry side until the alignment is correct. Now the sensor can be tightened down
and will be ready for use.
•Now connect the sensors through the junction box to the display unit and plug that
into the power line. Turn on the display unit, enter the desired measuring setup, and
then press the button ZERO.
•Run the machine through three complete opening and closing cycles. This serves to
null all the internal settings.
Measuring procedure
1. Open the mold and set the digital display to zero using the ZERO button.
2. Close the mold with the pressure which is to be measured.
3. The display shows the strain in the tie bar as well as the average of all four sensors.
4. Open the mold again. The display should return to zero.
5. If the display does not read zero, set it back to zero.
6. Repeat this operation two more times and note the average of all the sensors. This
will provide the best accuracy.
Once you have done this preliminary setup will know the closing pressure for each tie bar
and the variation in closing pressure between them. By adjusting the parallel alignment of
the mold faces you can then produce the same pressure from all the tie bars.

Version 4 (January 2021) EN 5
The X-102 sensors are equipped with very strong magnets. Do not let
the sensors get close to each other because they will immediately
snap together and can only be separated using a great deal of force.
Mounting a single sensor.
The cable is secured to the T-piece. The
two inputs are internally wired in parallel.
Mounting two sensors and connect the
cables to the T-piece. In this arrangement
the dual-compensated output is the aver-
age of the two sensors.
Take care not to mount the sensor too close to the
clamp location. The clearance must be at least
twice the diameter of the tie bar.
Bad example –the sensor is too
close to the clamp.
min. 2 x Holm 
X

Version 4 (January 2021) EN 6
During mounting the sensor must be
aligned to the tie bar
Bad example –the sensor is sitting at an
angle to the tie bar.
When measuring with two sensors on a sin-
gle tie bar they must also be aligned with
each other.
Bad example –the sensors are not at
180° to each other.
When setting up the sensor the magnetic foot with its spindle and
adjusting nut must be positioned in the middle of the sensor body.

Version 4 (January 2021) EN 7
When setting up the sensor, both little wheels
must be in contact with the surface of the tie
bar.
(Tip: If the hardened wheels become blunt,
they can be rotated up to 30 degrees.)
To be sure the measuring blade is
straight before making a measurement,
you should raise the blade slightly and re-
position it.
Check that all 4 wheels are in contact
with the surface of the tie bar.
If the sensor is not stable on the tie bar during machine cycles,
the contact pressure can be increased by screwing in the knurled nut.

Version 4 (January 2021) EN 8
Connections and Commissioning
Attach all the sensors with the USB cables to the Display unit X-318. Up to four terminal
boxes can be connected to inputs CH1…CH4.
Connect USB power using the USB cable, for charge the device.
View of Display unit X-318
•On power-up the Display by pressing the button for min. 3 seconds.
•Start the browser and connect to www.x-sensors.iot/ for measurement.

Version 4 (January 2021) EN 9
Help!
•What do I do when the zero reading is unstable ?
Because the measurement is very sensitive to shock and vibration, you can improve
it as follows:
1. Reduce the closing speed, making the closure softer.
2. Clean the tie bar surface better at the measuring location, using a wire brush
if necessary.
3. Adjust the setting of the knurled screw on the Sensor X-102. Do not set it too
high.
4. As an alternative to measuring the tie bar strain during closing, the strain can
also be measured when the mold opens. Experience shows that there is less
vibration on opening. Press the ZERO button when the mold is closed, and keep
it closed for about 20 seconds. When the mold opens the display will show a
negative pressure. Ignore the minus sign. Do this two more times, then read the
average value.
•Following some disturbance in an industrial environment it may happen that the display
shows a positive or negative zero.
You can press the ZERO button at any time before starting a measurement,
to provide a better zero.
•What can I do if the display does not indicate zero but a reading during a measurement ?
Vibration in the machine can sometimes cause the measuring blade to slip.
If the offset is not too large, i.e. not more than ±10 µε, you can just subtract it from
the result.

Version 4 (January 2021) EN 10
Safety instructions
It is assumed that installation, calibration, and operation of the equipment
will be performed by suitably qualified personnel.
Read through this document carefully and make yourself familiar with the
operation of the product before starting to use it. Keep this document on
hand, so it can be referred to as needed.
Failure to observe these safety recommendations can lead to property damage and
bodily injury!
The tie bar strain measuring system may not be used in life-support
or life-saving applications!
The measuring system is not suitable for safety-related applications!
Take care when handling the sensor magnets and replacing them in
their carrying case. Parts of the body can get trapped due to the
strong magnetic attractive force!!
Be aware that the measuring blades and friction wheels have func-
tional sharp edges which can cause cuts!
Dress the long connecting and power cables carefully to avoid any
risk of tripping and falling!

Version 4 (January 2021) EN 11
Transport and Storage
A transport case with a custom foam insert is provided for transport and storage. The sen-
sors, junction boxes, cables and display unit should be stored and transported in this case
to avoid possible damage or loss.
View contents of measuring case X-302-04/Wireless
View contents of measuring case X-302-08/Wireless

Version 4 (January 2021) EN 12
Servicing and Repair
The components of the measuring system should be returned annually for recalibration.
This will ensure many years of trouble-free operation.
Repairs can only be carried out by the manufacturer.
Disposal
Disposal of the packaging and the equipment the responsibility of the
owner who must observe all relevant national and regional laws, or, at the
end of its useful life, send it back to the manufacturer.
Technical Data
Display unit X-318 power input
5 VDC (USB Type-C)
Sampling rate
100 Hz
Tare range
± 3.5 mV/V
Sensor power from the Display unit X-318
3 VDC
Bridge resistance of Sensor X-102
350 Ω
Accuracy of the complete measuring chain
± 2% of readout or ±3µε
Operating temperature range
+10 ... +40 °C
Storage and transport temperature range
-20 … +70 °C
Dimensions of the transport case
430 x 310 x 130 mm³ (X-302-04/Wireless)
500 x 400 x 180 mm³ (X-302-08/Wireless)
Material transport case
Polypropylene
Weight transport case
approx. 4 kg (X-302-04/Wireless)
approx. 6 kg (X-302-08/Wireless)

Version 4 (January 2021) EN 13
Order information
Sensor
X-102/USB
Extensometer with magnetic foot
Display unit 4 Channel
X-318/IoT
Universal Display unit for Connection up to 4
Sensors
Measuring System for Tie
Bar Strain Measurement
with 4 Sensors
X-302-04/
Wireless
Measuring case consisting of
4x Sensor X-102
1x Display unit X-318 incl. USB charger/cable
4 x USB -connection cable length 5m
1 x Transport case
Measuring System for Tie
Bar Strain Measurement
with 8 Sensors
X-302-08/
Wireless
Measuring case consisting of
8x Sensor X-102
1x Display unit X-318 incl. USB charger/cable
4 x USB -connection cable length 5m
4 x T-piece to connect 2 sensors
1 x Transport case
Notes:
This product conforms to all the requirements of directive 2006/42/EG.