Config Guide
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Configuration Guide

(How to configure a system)

Evaluate your needs for installation, number and type of sensors, PC requirements.  Click on the links for pictures and details about each product mentioned.

If you just want to get a complete turnkey system suitable for most metalforming applications you can just go to the PIP page and almost everything you need and the price is listed there.  

IF you are an engineer and want the details you can continue and see all the components that can be configured for a system by continuing to the next step:


The system starts with a signatureACE® SA2000 Processor Card (called the 'SAM"), Part /SA2 and /P.

Next, select the type of position device interface board, resolver or encoder. (More on slave /SLV later)

Best is the resolver /RSV for reliability. See the installation guide to make sure that you know the requirements for installation.  Short cuts will cost in resolution of your system.  Existing resolvers may be used with the /CNV resolver converter if the resolver is installed per our guide.

Encoders require special attention and we recommend you coordinate this with our applications engineers.

Next, select the type of I/O board you plan to add to the SA2, Part /A08, /A6D, /D16, or /A+D

/A08 is our most commonly used interface and provides for 8 high or low level analog signals.  Strain gauge signal conditioning and isolated inputs are standard.  Use this card if you plan to do mostly in-die or press frame analog sensors.  Check the data sheet for details.  You can get 4 die-protection channels without ordering a die-protection enabled interface card by using OPTO22 modules on the termination board.  These must be DC clean sensor signals if the OPTO22 is used.  The are also high speed OPTO22 modules available.

/A6D is our second most commonly used interface card since it incorporates all the signal conditioning for any type of conventional device or wire used for 4 channels of die-protection as well as the 6 analog inputs which have the same specs as the /A08.  By using this card you can monitor the force in the connections on the press with two channels, have 4 spare channels for in-die analog sensors, have 4 conventional die-protection channels (buckle, feed, eject and spare).  Also, if you have some digital on-off sensors being used for die-protection, you can add 4 OPTO22 modules to accommodate these.

/D16 accommodates 16 conventional die-protection channels.  This is available on custom order.  Most users that need this many points are using multiple SAMs and have plenty of die-protection points.

/A+D is the older version of the /A6D.  It has 8 conventional die-protection channels and 4 analog channels.  These channels have the same specifications as those above.

If your input needs are not met with these options then contact us.  If you need more channels you will need to add another SA2000 processor using a /SLV interface.  This interface synchronizes the processors on all SA2000s so equipped (up to 6 in parallel).  Our most common form of multi-SA2000 system has two /A6D interfaces cards.  Advantages to multi-SA2000 systems are:

One SA2000 is allocated to the press with force sensors on the frame and connections providing press condition monitoring and protection.  This provides a monitoring window for the full 360 degree rotation with conventional signature analysis being applied to the entire process.

The second SA2000 is allocated for in-die sensors with a much narrower monitoring window in order to maximize resolution.

Next, you need to determine what kind of computer you plan to install the signatureACE cards into or if you plan to remote the computer from the cards.  The PC will have the SAMnet card installed in it.

Most automotive or dirty environments use the /PPB Industrial Workstation mounted in the Press Control Panel.  The field terminations are brought to the Press Control Panel and terminated on a /TEB termination board connected to the SA2000 board(s) using /T04 cables.

The decision to use the /TEB or /TEC depends on total installed cost of wiring.

The /PPA modular system is used in most other applications.  It provides a nice industrial enclosure for the SA2000 and industrial PC with a remote display of your choice.  This product is also suitable for dirty environments if the enclosure is mounted inside another enclosure such as a press control cabinet.

The last option, not recommended, is to use your own PC and connect via the network to the /BOX which contains the SA2000s.  This method is not recommended since with the advent of the windows version of the software, ST limits it's responsibility for trouble shooting "strange" computers, especially "clones".

Many options exist for the PC, packaging, installation, and user interfaces.  We have probably experienced most versions.

Next, you need to decide on what software you want.  All our software falls into the SAMview™ family.

Currently, but soon to be changed with the windows release, all systems must have the following foundation software:

/CCM press critical curve and tonnage monitoring software.  This provides conventional peak and angle tonnage monitoring with protection of the press through the entire load curve provided by the manufacturer...the only real form of press load protection.  Peak tonnage does not really protect most presses!  Press curves are easily installed by the user without any charges typical for this service using any text processor.

/DIE die setup facility.  This provides a complete data base for tools, sensors, additional presses on the same network, and alarm event logging.  Each tool has a unique die setup signature and tool note file which is used to assure consistent setups by providing the setup information and then confirmation by comparison of the setup with the master signature.

/SAM is the signature-based process control software which assure consistent parts by comparing each part made with the master signature or prior selected run signature.  It has event logging, save signatures by fault type, provides user comments on each saved signature for later use or for assistance in using the optional software products.

Our most powerful tool, usually purchased in addition to the above by all existing users, is SPCview, part /SPC.

SPCview, as a minimum established a complete SPC system for tracking specific features of the signature which represent critical process data.

The most powerful part of this package is it's ability to provide the process engineer with a tool to apply to existing bad signatures in order to look for the same bad features in the future and then when discovered to display the actual problem to the operator with a text message instead of requiring the operator to understand the signature.  It is a knowledge base tool that stores information about problems and then automatically displays this information when the system see the same problem.

Our most advanced process software is FeatureView, part number /FEX.

This product provides sophisticated process analysis tools for measuring work done tools or sections of tools.

It provides tool condition monitoring.

It provides the ability to implement solution of formulas in real-time while the process is running.

It has been applied to a Ford patent, solely licensed by ST, which monitors the thickness, hardness and work hardening coefficient during deep draw operations.

This product is never purchased without ST involvement in the application.

Next you need to determine what firmware options, if any, you desire

There are many firmware options.  They include remote pushbutton operator support, part-tracking through the die, automatic limit setting based upon process trending (usually used on high speed presses), servo output control, light stack interfacing, and many more.

Next you need to determine the position transducer you plan to use.

This matches your selection of the interface card above.

ST sells a resolver which connects using a cable or we can supply the connector.  See /RSV.

ST does not stock any encoders but can assist in selection.  Most encoders are only applied in linear applications such as hydraulic presses or assembly systems.

If you have an existing resolver you can use a /CNV converter as noted above.

Next you need to select the cable lengths required for your installation.

The SAMnet cable length needs to be specified...the distance from the PC to the SA2000 card(s).  This can be any distance but we supply standard lengths of 1 foot (/S01), 30 foot (/S30), and custom (/SXX).

The termination cable from the SA2000 to the /TEC or /TEB.  The /T04 is four feet and is used internal to enclosures.  Other sizes are 10 foot (/T10), 30 foot (/T30), 50 foot (/T50), and custom (/TXX)

You now need to select the length of cable needed for your position transducer.

For resolvers we supply 30 foot (/R30), 50 foot (/R50), 75 foot (/R75), custom (/RXX), and we provide just the connector (/RSC)

For the /CNV converter we supply a 2 foot cable for the input side with the /CNV.  This must not be changed.  We also supply the output cables in 30 foot (/C30), 50 foot (/C50), 75 foot (/C75), custom (/CXX)

We do not supply cables for encoders except under custom order.

Next you need to select the sensors you plan to use.  This is usually known by the customer.  The variety is so larger that we do not stock in-die traditional sensors.  We do stock special in-die and press force sensors.  Do not attempt to use force sensors for in the die that do not have at least 500% over-range protection or you will incur high sensor replacement and downtime costs.

Our sensors for the press frame or connections are the /400 Insitu sensors.  They come with cable lengths of 1 foot (/400-01), 35 foot (/400-35), 50 foot (/400-50), 75 foot (/400-75), and, custom (/400-XX)

Our in-die sensors come in many sizes and types.  We custom make many sensors to suit the specific application.  Some stock sensors:

In-die rugged zed /CSL featuring high over-range protection and sealed.

Ball-lock sensors /BL

Finally you need to determine if you need our assistance in installation or training.  We offer both services either at our factory or on site.  Please contact us for specifics.

Hopefully this guide give one the overview of all the components in a typical system.





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