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Tonnage Load Module User`s Manual

1. ZRO __ GAIN Set the ZRO GAIN switch to GAIN and use a digital voltmeter to measure the voltage across the OUT and COM terminals Record this value as the Calibration Gain Voltage OFF PRB TRK 6 PEAK ZRO GAIN CURRENT OUTPUT 20 VOLTAGE OUTPUT x x 10V Calibration Gain Voltage VIEW COMMON DC PWR IN DC COM COMMON THR OUT Figure 15 Calibration Gain Voltage Measurement DOC 17601 Page 29 qi Toledo Integrated Systems 9 Calibration complete e pocket e Set mode switches as shown OFF fe AZ OFF fe PRB TRK fe PEAK ZRO e GAIN ZT 1 User s Manual Operation Fill in the Calibration Card a sample shown below which is located in the side Model ZT 1 Serial No John Doe Calibrated By Mode Switch FillIn Switch Position Date X10 if EXT used AZ Gain PRB A1501 1 1 2015 L Shunt Ohm 3 25 wpc Sensor Config Fill In Switch Position Lg Sm FL B PEAK Toledo Transducers Inc Holland OH GAIN T Toledo Integrated Systems Madeinthe USA Figure 16 Calibration Card Sample DOC 17601 m Toledo Integrated Systems Page 30 ZT 1 User s Manual Operation gt Operation Once the ZT 1 has been calibrated it is ready for continuous use This section detai
2. SENSOR INPUT EARTH __ SHUNT V C e__ V Voltage Sensor Lg Sm fe Lg Large Signal Amplified FIL 9 No Filter SENSOR SIGNAL CONFIG Figure 9 10V out Sensor Input DOC 17601 Page 19 T Toledo Integrated Systems ZT 1 User s Manual Installation Analog Voltage Output The analog voltage output is provided on a Phoenix connector for easy access and for interfacing with other peripherals Analog Voltage Output CURRENT OUTPUT 20mA Swing between 10VDC COMMON Sessa OUT Normal Output VOLTAGE OUTPUT E REV Reverse Output COMMON Typical Connection sae TRK Track Output to PLC Analog Input card EARTH COM Analog Common PROBE DC COMMON THR OUT BOTTOM VIEW Figure 10 Analog Voltage Output Wiring Output details e OUT terminal outputs either Peak tonnage or Track tonnage depending on the TRK PEAK switch setting on the front panel e REV terminal outputs the reverse peak snap through tonnage when the front panel TRK PEAK switch is set to PEAK e TRK terminal always outputs the track tonnage regardless of the front panel TRK PEAK switch DOC 17601 Page 20 m Toledo Integrated Systems ZT 1 User s Manual Installation Analog Current Output The analog current output is provided on a Phoenix connector for easy access and for interfacing with other peripherals Analog Current Output CURRENT OUTPUT 20mA Swing between
3. Tonnage Load Module By Toledo Integrated Systems User s Manual 17617 ZT 1 Load Module User s Manual Revision A ZT 1 User s Manual Installation DOC 17601 Page 2 Toledo Integrated Systems ZT 1 User s Manual Installation Table of Contents Liiritted Warlranty u uuu u uu dd 4 Features iii 5 sessi oco ALL uk ua Lat O 7 5 mE alias 9 Mound the d T T preset o eter ae popu oes 9 DC Power Connection ii 10 Shunt Resistor Selection estar eicit ort tici ell dee 11 Tonnage Gage Sensor Connection 12 20mA out Sensor CON lOs 16 10V out Sensor Conneclion a M de 18 Analog Voltage Output a 20 Analog Output us a tot Va toc ate Uu uiu Uu 21 Triggering Internal 22 Triggering External ena i 23 M AAA AA ME 25 Sel elia 31 App I 35 A SensorInstallation 11080 ei 35 B Calibration Sheets 2 Form 1224 i 35 Table of Figures Figure 1 Mounting Dimensions ian 9 Figure 2 DC Power Wild 10 Figure 3 Built In 1M Ohm Shunt Resistor Wiring 11 Figure
4. WELD PAD METHOD FOR MOUNTING SENSORS BE SURE THE SENSOR LOCATION FOLLOWS THE BEST LOCATION DESCRIBED ON THE PREVIOUS PAGES STEP 2 3 DRILL 4 4 28 TAP ROTATE FIXTURE STEP 3 90 DEGREES f lt 4 XX I Ca Ng 4 4 28 X 1 1 4 SCREW 21 DRILL TWO SMALL CENTERED HOLES FOR ENCLOSURE STEP 4 S1 4 28 x 1 SCREWS 114 28 X 1 1 4 SCREW CA Zu A WELD EACH PAD ON THREE SIDES ONLY STEP 5 ANTI TORQUE Ze WASHERS 114 28 x 3 4 LOC WEL BOLTS PUT RAISED RIB TO PRESS Doc 11080 Rev A STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7 T400 INSTALLATION Remove all paint grease and or rust from surface to be welded Surface should be flat T I R 1 32 of an inch Drill and tap the center hole for mounting the fixture to the press member This hole should be inch deep Optional Bolt the fixture to the press member using the 4 28 by 1 inch long socket head cap screw in the center of the fixture 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 tapping these holes Optional Remove the fixture from the press member Bolt the weld pads to the fixture with 4 28 by 1 inch long socket head 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 Weld the weld pads to the press member BE SURE T
5. BDC or 180 without the load cell or die in the press e Determine the amount of spacers needed with your load cell Cycle the press without the load cell to insure correct height DOC 17601 Page 25 m Toledo Integrated Systems ZT 1 User s Manual Operation 3 Place the load cell in the correct position in the press e The load cell should be placed so that it is centered in the press e Cyclethe press without hitting the load cell first e Place cardboard on the top and bottom of the load cell 4 Toggle the mode select switches to AZ OFF PRB OFF TRACK ZERO Also set the Gain switch to X10 to start X1 Le X10 Th H 971 e e OFF fe AZ OFF PRB TRK fe PEAK ZRO 19 GAIN 5 Balance the tonnage sensor e Adjust the ZERO pot until the Bar graph Voltmeter has only the 2 yellow 0 0V LEDs lit This indicates a balanced or zeroed state Note Using the built in bar graph voltmeter for calibration will achieve calibration accuracy of 1 of capacity If more accurate result is needed use a digital voltmeter to measure the voltage across the OUT and COM terminals see Figure 15 VOLT T Sh O o x oouooooo 6 666666666 6 66606660666 no v DOC 17601 Page 26 qi Toledo Integrated Systems ZT 1 User s Manual Operation 6 Cycle the press e Set the mode switches to AZ OFF PRB PEAK and ZERO OFF 1 AZ OFF 1 9 PRB TRK PE
6. OF LOAD CELL READOUT TONNAGE SENSORS CALIBRATION LOAD CELLS CAPACITY TONS SERIAL NO CCMOFFSET _ STI DEGREES IN CHANNEL No 1 STI REFERENCE NUMBER LOW ____ TRIGGERED FROM PROBE YES___ NO TRIPPED ALARM RELAY STOPS PRESS YES _ ALL STICKERS AND DOCUMENTS FILLED OUT YES NO IF NOT EXPLAIN WHY TFP No HIGH2 LOW 2 COMMENTS HIGH4 Show threshold value if not triggered from probe HIGH NO EXPLAIN HGH6 ___ LOW6 HIGH8 LOW8 TESTS MADE BY MAIL ADDRESS TOLEDO TRANSDUCERS INC P O BOX 10 HOLLAND OHIO 43528 TESTS ACCEPTED BY SHIPPING ADDRESS TOLEDO TRANSDUCERS INC PHONE 1 419 867 4170 6834 SPRING VALLEY DR FAX 1 419 867 4180 HOLLAND OHIO 43528
7. REFERENCE NUMBER LOW ____ TRIGGERED FROM PROBE YES___ NO TRIPPED ALARM RELAY STOPS PRESS YES _ ALL STICKERS AND DOCUMENTS FILLED OUT YES NO IF NOT EXPLAIN WHY TFP No HIGH2 LOW 2 COMMENTS HIGH4 Show threshold value if not triggered from probe HIGH NO EXPLAIN HGH6 ___ LOW6 HIGH8 LOW8 TESTS MADE BY MAIL ADDRESS TOLEDO TRANSDUCERS INC P O BOX 10 HOLLAND OHIO 43528 TESTS ACCEPTED BY SHIPPING ADDRESS TOLEDO TRANSDUCERS INC PHONE 1 419 867 4170 6834 SPRING VALLEY DR FAX 1 419 867 4180 HOLLAND OHIO 43528 TOLEDO TRANSDUCERS INC PRESS CALIBRATION TEST DATA HOLLAND OHIO U S A COMPANY DATE PRESS SERIAL No PRESS Type and amp No CONTACT PRESS CAPACITY PHONE LOAD MONITOR MODEL SERVICE ORDER CC o MONITOR SERIAL No SLIDE ADJUST INDICATOR LINEARITY PLOT USING TONS SHOWN ON TOTAL DISPLAYS TOTAL LOAD DISPLAYED ON MONITOR L J Jl ire TOTAL TONNAGE APPLIED TO LOAD CELLS ON PRESS F1224 Rev A DRAW IN e CHANNEL NUMBER e SENSOR LOCATION e MONITOR LOCATION e LOAD CELL LOCATION e DIRECTION OF MATL FLOW SHUNT RESISTORS ONE MEG YES OTHER RESISTORS CHAN 1 CHAN 2 CHAN 3 CHAN 4 TYPE OF LOAD CELLS _ MATERIAL FLOW draw arrowhead FRONT OF PRESS BED TYPE
8. tension The ZT 1 will compensate for the slight change It will readjust the zero base line This zero base line is the no load value of the press With a consistent zero value the tonnage output readings should remain accurate When the probe turns on the ZT 1 opens the window to read a load signal In peak mode the load level rises to the highest value When the probe turns off the peak level is held at its high level and the auto zeroing function is resumed Notice the dotted line below The peak level is reset the next time the probe transitions from off to on The timing of the probe should be such that it turns on just before the machine begins generating a load 140 and remains on until the load is removed 240 Peak Reset Load Signal Probe Closed Trigger 400 240 140 page rope Open Probe ZT 1 Auto Zeroing Figure 14 Probe Timing Diagram DOC 17601 Page 24 a Toledo Integrated Systems ZT 1 User s Manual Operation gt Calibration Refer to the diagram below for control locations 1 X10 GAIN SWITCH MODE SELECT SWITCHES BAR GRAPH VOLTMETER ADJUSTMENT CONTROLS 1 With the sensor placed in the best possible location see appendix A torque the sensor down to 150 in lbs on the sensor bolts Do not put the sensor enclosure cover on yet You will need to test the sensor location 2 Find the shut height of the press e Jogthe press until the ram is at bottom dead center
9. 080 Rev A RUN SENSOR CABLE THROUGH CONDUIT PLACE SENSOR ON MOUNTING HOLES PLACE ANTI TORQUE WASHERS OVER SENSOR HOLES SCREW IN SENSORS BOLTS 4 EACH FINGER TIGHT USE ONLY THE 1 4 28 x 3 4 LOC WEL BOLTS THAT ARE IN THE SENSOR PACKAGE TORQUE EACH 1 4 28 x 3 4 SCREW TO 150 LB IN OR 12 5LB FT ASSEMBLE BOX COVER d A LOAD Mx MODEL T400 SIN x 7 T400 INSTALLATION CONDUIT PAGE 7 TOLEDO TRANSDUCERS INC PRESS CALIBRATION TEST DATA HOLLAND OHIO U S A COMPANY DATE PRESS SERIAL No PRESS Type and amp No CONTACT PRESS CAPACITY PHONE LOAD MONITOR MODEL SERVICE ORDER CC o MONITOR SERIAL No SLIDE ADJUST INDICATOR LINEARITY PLOT USING TONS SHOWN ON TOTAL DISPLAYS TOTAL LOAD DISPLAYED ON MONITOR L J Jl ire TOTAL TONNAGE APPLIED TO LOAD CELLS ON PRESS F1224 Rev A DRAW IN e CHANNEL NUMBER e SENSOR LOCATION e MONITOR LOCATION e LOAD CELL LOCATION e DIRECTION OF MATL FLOW SHUNT RESISTORS ONE MEG YES OTHER RESISTORS CHAN 1 CHAN 2 CHAN 3 CHAN 4 TYPE OF LOAD CELLS _ MATERIAL FLOW draw arrowhead FRONT OF PRESS BED TYPE OF LOAD CELL READOUT TONNAGE SENSORS CALIBRATION LOAD CELLS CAPACITY TONS SERIAL NO CCMOFFSET _ STI DEGREES IN CHANNEL No 1 STI
10. 1 User s Manual Installation Full bridge 120 to 1000 ohms Built in 10VDC at 250mA max 1mV V of sensor imbalance Low range x50 to x550 adjustable High range x500 to x5 500 adjustable Built in 1 mega ohm 1 or external custom shunt Normal Peak and Reverse Peak 0 to 10VDC Track output 10 to 10VDC Normal Peak and Reverse Peak 0 to 20mA Track output 20 to 20mA 1 of full scale max 02 of full scale max Time constant 10 seconds DIP switch selectable DC to 5 000 Hz 2000 SPM max when triggered by External Probe 500 SPM max when triggered by Internal Threshold 4 to 158 degree F or 20 to 70 degree C LED bar graph voltmeter for setup and diagnostic Internal Threshold 35V 70V or External Probe NPN PNP proximity probes solid state or dry contact relays Built in 24VDC at 80mA max supplies power to the probe 24VDC at 300mA max Automatic resettable fuse 0 9 W x 4 1 H x 4 7 D Standard DIN Rail mount Page 7 m Toledo Integrated Systems ZT 1 User s Manual Installation DOC 17601 Page 8 m Toledo Integrated Systems ZT 1 User s Manual Installation gt Installation Mounting the ZT 1 The ZT 1 is designed to clip onto standard top hat DIN rail TH 35 7 5 or TH 35 15 12288822202 SIDE VIEW T L a PRB PWR ZERO
11. 20mA het OUT_C Normal Output VOLTAGE OUTPUT REV_C Reverse Output COMMON Typical Connection to PLC Analog Input card TRK_C Track Output DC PWR IN DC COM EARTH COM Analog Common PROBE DC COMMON THR OUT BOTTOM VIEW Figure 11 Analog Current Output Wiring Output details e OUT C terminal outputs either Peak tonnage or Track tonnage depending on the TRK PEAK switch setting on the front panel e REV C terminal outputs the reverse peak snap through tonnage when the front panel TRK PEAK switch is set to PEAK e C terminal always outputs the track tonnage regardless of the front panel TRK PEAK switch DOC 17601 Page 21 Toledo Integrated Systems ZT 1 User s Manual Installation Triggering Internal Threshold The ZT 1 can be triggered by an internal threshold value When this triggering method is used the ZT 1 begins monitoring when the load rises above the level determined by the front panel s Th H L switch Refer to Figure 12 below to configure the ZT 1 for threshold triggering CURRENT OUTPUT 20mA VOLTAGE OUTPUT 10V H High Threshold 0 8V L Low Threshold 0 4V COMMON DC PWR IN INTERNAL THRESHOLD DC COM O _ EARTH SI 24V out PROBE DC FO PNP pa EJ COM COMMON FO THRES THR OUT ON PROBE THRESH ON OFF PROBE THRESH OFF FRONT
12. 335 ONIGNL NOSAL ZSZ 0FZ HIHSVM FOVIdIY ANY 318VI 3n0HOL FONIYIAHNNIYIO ALISOddO 533530 08 31001 SHOSN3S OML HOSN3S AVO1 0071 KINO 393H H3HSVM 3010801 318VO PAGE 4 T400 INSTALLATION Doc 11080 Rev A USING THE T400 SENSOR INSTALLATION FIXTURE KIT No 1977 749 METRIC INSTALLATION FIXTURE KIT No 1974 749 DRILL AND TAP METHOD FOR MOUNTING SENSORS BE SURE THE SENSOR LOCATION FOLLOWS THE BEST LOCATION DESCRIBED ON THE PREVIOUS PAGES 3 DRILL STEP 2 Uk gt 2 1 4 28 TAP METRIC 6 1 3 DRILL 5mm X CN DRILL THROUGH FOUR SMALL HOLES STEPS 34 1 4 28 X 1 1 4 SCREW METRIC 6 1 X 35 ROTATE FIXTURE 90 DEGREES 2041 STEP 5 O 4 SS 21 DRILL 8 lt DRILL THROUGH THE TWO SMALL CENTERED HOLES ROTATE FIXTURE 90 DEGREES 1 4 28 TAP STEPS 6 7 METRIC 6 1 TAP THROUGH FOUR LARGE HOLES _ ANTI TORQUE lt WASHERS STEP 9 1 4 28 x 3 4 LOC WEL BOLTS PUT RAISED RIB TO PRESS Doc 11080 Rev A STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 STEP 6 STEP 7 STEP 8 STEP 9 T400 INSTALLATION Remove all paint and grease from sensor mount area If the machine surface is flat total indicated reading of 002 and smooth 125 u in the load sensor can be bolted directly to the surface Drill and tap the center hol
13. 4 External Shunt Resistor Installation 11 Figure 5 Strain Gage Sensor INput ii 13 Figure 6 Strain Gage Sensor Cable 14 Figure 7 Strain Gage A a aio 15 Figure 8 20mA out Sensor Input 17 Figure 9 10V out Sensor alia alati 19 Figure 10 Analog Voltage Output Wiring a 20 Figure 11 Analog Current Output Wiring a 21 Figure 12 Internal Threshold Wiring occi o o n tte ote ut OQ t 22 Figure 13 Probe Input Wiring alano 23 Figure 14 Probe Timing 24 Figure 15 Calibration Gain Voltage 29 Figure 16 Calibration Card 30 DOC 17601 Page 3 q Toledo Integrated Systems ZT 1 User s Manual Installation Limited Warranty This unit is warranted by the manufacturer Toledo Transducers Inc to be free of defects in workmanship and materials for one year from date of manufacturer s shipment This warranty is limited to repairing or replacing products which manufacturer s investigation shows were defective at the time of shipment by the manufacturer All products subject to this warranty must be returned for examination r
14. A HO SISSIHA 3I VH LSVO dO JINN agg 315709 953 AHL NI LNO LNO JHAY 1WH1 S310H 3 dO 3903 NOLLOA HO 3903 dOL JHL NOYH NVHL 35 19 SHOSN3S ONITIVLSNI GIOAV SSI8d INVHH TIVM V SI LI dI TIVM 9938 3GISNI SHL NO SHOSN3S TIVLSNI 318ISSOd dI 18 1 LHOlddN YO 38 TIM 3 81314 JO SLI 931139 3H1 COM 311 HISN31 1 OL SI HOSN3S V H3SO IO JHL 1e L qou 311 3H1 dO ANIM Y431N39 AHL NO LHOIYdN I NAN109 dO H19N31 L AHL NI SI NOLIVOO I HOSNIS 1539 LHOIYdN NANTOD SSIYd dO gt s LL SYNSOTONA HOSN3S dVO1 S NIN3dO ONILVIH COY 311 YVAN LINGNOO NNY LON OQ NOILOVO AINO S38IM YOSNIS QVO LINONOO LAN qQOt PAGE 3 T400 INSTALLATION Rev A Doc 11080 SHOSN3S HLO8 MOHS OL MIA ONISNOH LN3ALLSRfGV JANS WVH 3Qri ONIAOW 3HL dO LNO NAHL Waal 1 LXAN OL LINONO9 E 2 INSWLLSNrav adris OL ANd SIAON AHL N3HM Q3Q33N MOVIS d 18V9 SI d001 AHL ALON lt A y 81 HO ALLA NI 87 051 OL 1108 YOSNIS x 8Z Y 1 HOV3 INDUOL HINOLSNI XO8 NOILWNINYAL SEN 9 90 8 3d LAN HLIM HOLO3NNOO 43 7138 NIVHIS 88 51 8 ALON
15. AK ZRO 6 GAIN e Further adjust the shut height so that the press impacts the load cell and generates a load at 100 of press capacity See warning below WARNING Depending on the press capacity and the size of the load cells being used loading the press at capacity with load cells could indent the ram or bolster If this is a concern you may choose to calibrate the press only up to 80 of capacity DOC 17601 Page 27 Toledo Integrated Systems ZT 1 User s Manual Operation 7 Adjust the gain Run the press for 2 cycles at capacity Compare the voltage level on the Bar graph Voltmeter with the load cell s display Adjust the GAIN pot Repeat until the desired voltage LED just turns on For example 6 0V at 100 0 tons Note Use the 6 0 VOLT LED in the built in bar graph voltmeter as an example When this LED is on it could mean a voltage anywhere from 6 0 volt to 6 9 volt But when this LED just changes state from off to on it indicates an accurate reading of 6 0 volt This characteristic applies to all LED s in this built in bar graph voltmeter 6 666666666 PR UJ U WR If less gain is needed change the Gain switch to X1 then repeat from Step 4 DOC 17601 Page 28 Toledo Integrated Systems ZT 1 User s Manual Operation 8 Record the Calibration Gain Voltage e Set the mode switches to AZ OFF PRB OFF TRACK and ZERO as shown and verify that the sensor is at zero
16. ET e IGNAL WIRES BRAIDSHIELD Figure 6 Strain Gage Sensor Cable Stripping 2 Strip approximately 14 of insulation from each of the four signal conductors Note If your sensor cable is not double shielded with both foil and a braid electrical noise may affect your output readings DOC 17601 Page 14 a Toledo Integrated Systems ZT 1 User s Manual Installation Illustration B Sensors Connection The ZT 1 accepts the signals from Toledo Transducers T 400 sensors as well as other strain gage sensors Figure 7 illustrates the sensor connections T400 Sensor T400 Sensor O t Tension Force Compression Force 0 O SENSOR CONNECTION Tension connection SHIELD shown For compression SHL connections switch the E B red and white wires E G S W S R Figure 7 Strain Gage Sensor Wiring DOC 17601 Page 15 m Toledo Integrated Systems ZT 1 User s Manual Installation 20mA out Sensor Connection The 20mA out Sensor applies to sensors with output up to 20mA including the 4 20mA output sensor Refer to Figure 8 for the procedures below Connection 1 Remove the Phoenix plug from its socket on the top of the unit and wire the sensor cable as shown 2 The Phoenix plug can then be inserted back into its socket Configuration 1 Set the V C dip switch to C position for current output sensor 20mA out sensor outputs current signal 2 Se
17. GAIN 2000200000000000000 Sg e a D 4 7 W 0 9 Figure 1 Mounting Dimensions DOC 17601 T Page 9 I Toledo Integrated Systems ZT 1 User s Manual Installation DC Power Connection 24VDC power is connected to the ZT 1 as shown in Figure 2 CURRENT OUTPUT 20 COMMON VOLTAGE OUTPUT 10V COMMON DC PWR IN DCCOM EARTH PROBE DC 24VDC Input DC Common Earth Chassis Ground COMMON THR OUT BOTTOM VIEW Figure 2 DC Power Wiring Notes 1 The 24VDC source can be in range from 18VDC to 32VDC 2 ltis important to connect an Earth Ground to the GND terminal 3 Do not apply power until all the wirings in this Installation Section are done DOC 17601 Page 10 qi Toledo Integrated Systems ZT 1 User s Manual Installation Shunt Resistor Selection Strain Gage Sensor only Skip this section if you are not using a strain gage sensor Shunt resistor only works directly with the Wheatstone bridge type sensor The ZT 1 is capable of utilizing either a standard 1M ohm built in shunt resistor or a user specified external shunt resistor SENSOR SENSOR INPUT INPUT EARTH __ EARTH __ SHUNT OR SHUNT 1M _ pm SHU in SENSOR SENSOR SIGNAL SIGNAL CONFIG CONFIG TOP TOP VIEW VIEW Figure 3 Figure 4 Built In 1M Ohm Shunt External Shunt Resistor Wiring Resistor Installation DOC 17601 Page 11 m Toledo Integrated Systems ZT 1 User s Manual Inst
18. O ONLY WELD THE WELD PADS ON THREE SIDES AS SHOWN A single pass is sufficient Do not remove the fixture until slag is removed and or assembly has cooled When welding cast iron use a dry nickel 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 Remove the weld fixture DO NOT WELD AFTER FIXTURE IS REMOVED 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 inch 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 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 4 28 x in long socket head screw to 150 LB IN or 12 5 LB FT PAGE 6 SENSOR ENCLOSURE MOUNTING USE 10 32 TAP IN THE TWO 3 8 DEEP HOLES THAT WERE DRILLED WITH THE FIXTURE IN THE PREVIOUS INSTRUCTIONS MOUNT THE ENCLOSURE TO THE PRESS MEMBER AND RUN 1 2 INCH CONDUIT TO THE LOAD MONITOR ENCLOSURE gem m a E TAP THESE HOLES WITH 10 32 TAP lt ni Sue 10 32 x 3 8 PAN HEAD MACHINE SCREW 1 4 28 x 3 4 SOC HD SCREW SENSOR ENCLOSURE 24 Doc 11
19. PRB TRK fe PEAK ZRO GAIN b When Auto Zero is done only the 2 yellow LEDs at 0 0V are lit DOC 17601 Page 33 Toledo Integrated Systems ZT 1 User s Manual Operation 3 Set the OFF PRB switch to PRB OFF el AZ OFF 1 9 PRB TRK fe PEAK ZRO GAIN DOC 17601 Page 34 qi Toledo Integrated Systems ZT 1 User s Manual Appendix Appendix A Sensor Installation Doc 11080 B Calibration Sheets 2 Form 1224 DOC 17601 Page 35 m Toledo Integrated Systems ZT 1 User s Manual Appendix DOC 17601 Page 36 m Toledo Integrated Systems INSTALLING T400 LOAD SENSORS FIVE HOLES DRILLED AND TAPPED IN PRESS MEMBER 400 LOAD SENSOR TWO ANTI TORQUE WASHERS FOUR LOC WEL BOLTS 3 4 INCH LONG TORQUE EACH 1 4 28 x 3 4 IN LONG SOCKET HEAD SCREW TO 150 LB IN OR 12 5 LB FT WELD PADS ARE WELDED ON THREE SIDES ONLY T400 LOAD SENSOR TWO ANTI TORQUE WASHERS FOUR LOC WEL BOLTS 3 4 INCH LONG TORQUE EACH 1 4 28 x 3 4 IN LONG SOCKET HEAD SCREW TO 150 LB IN OR 12 5 LB FT The above illustrations represent the proper arrangement of Model T400 Load Sensor kit parts using either the Drill and Tap method or the Weld method A proper installation is necessary to produce good results Before installing the sensors please read the appropriate instructions listed below Sensor Placement Page 2 Press Frame Page 3 Pitman Mount Page 4 Drill a
20. VIEW BOTTOM VIEW Figure 12 Internal Threshold Wiring The probe PRB indicator should turn on when the load rises above the threshold value and turn off when the load falls back below the threshold value DOC 17601 Page 22 Toledo Integrated Systems ZT 1 User s Manual Installation Triggering External Probe The ZT 1 can be triggered by an external probe signal If an external probe is used the probe supply voltage 24VDC is provided by the ZT 1 The figure below illustrates the wiring for a variety of sensing devices SINKING PROBE NPN N O BRN 24V out SOURCING PROBE PNP N O 24V out PNP NPN COM THRES ON OFF PROBE THRESH OFF PROBE THRESH ON DRY CONTACTS n fo Figure 13 24V out PNP NPN COM THRES Probe Input Wiring The probe PRB indicator should turn on when the probe turns on and turn off when the probe turns off DOC 17601 m Toledo Integrated Systems BOTTOM VIEW CURRENT OUTPUT 20mA VOLTAGE OUTPUT 10V COMMON DC PWR IN DC COM COMMON THR OUT ZT 1 User s Manual Installation If the front panel Auto Zero switch is enabled the ZT 1 will remain in the auto zeroing mode of operation until an external probe is applied The auto zero feature is important for accurate readings Over time the press frame will slightly change in its structure This may be due to temperature or press frame
21. allation Strain Gage Sensor Connection Refer to Figure 5 for the procedures below Connection 1 Prepare the sensor cable for termination as described in Illustration A on page 14 2 Remove the Phoenix plug from its socket on the top of the unit and wire the sensor cable as described in Illustration B on page 15 3 The Phoenix plug can then be inserted back into its socket Configuration 1 Set the V C dip switch to V position for voltage sensor Strain Gage sensor outputs voltage signal 2 Set the Lg Sm dip switch to Sm position for small signal Strain Gage sensor outputs un amplified signal small signal 3 Set FIL dip switch to No filter position Apply this filter only when electrical noise becomes a problem at the ZT 1 analog outputs DOC 17601 Page 12 Toledo Integrated Systems ZT 1 User s Manual Installation Shield Excitation Black SENSOR Excitation Green INPUT Signal White Signal Red EARTH __ SHUNT 1 ETE SHU in V Voltage for Tonnage Sensors Sm Small Signal Un amplified No Filter SENSOR SIGNAL CONFIG Figure 5 Strain Gage Sensor Input DOC 17601 Page 13 qi Toledo Integrated Systems ZT 1 User s Manual Installation Illustration A Sensor Cable Termination 1 Strip the sensor cable as shown in Figure 6 below Be sure not to knick any of the signal conductors or cut the braid shield m approx 2 inches A CABLE JACK
22. e for mounting the fixture to the press member This hole should be 1 2 inch 13mm deep Bolt the fixture to the press member using the 4 28 by 1 inch M6 1 x 35 long socket head cap screw in the center of the fixture Insert the number 3 drill Smm into the smaller corner hole and drill out all four holes to a depth of 4 of an inch 19mm Loosen the fixture Rotate the fixture 90 degrees clockwise Tighten the center screw of the fixture Insert the number 21 drill into the small centered hole and drill out both holes to a depth of 3 8 of an inch These holes are for mounting the sensor enclosure The fixture does not allow for tapping these holes They are tapped without the fixture Enclosure mounting is not done in metric 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 a tap to be sure the holes line up Lock the fixture in place by tightening the center screw Insert the tap into the larger tap guide holes and tap each hole BE SURE TO USE PLENTY OF TAPPING FLUID Remove the fixture and repeat Steps 1 7 for each additional sensor mounting position 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 4 28 x in long socket head cap screw to 150 LB IN or 12 5 LB FT PAGE 5 USING THE T400 SENSOR INSTALLATION FIXTURE KIT No 1977 749
23. epair or replacement F O B to Toledo Transducers Inc 6834 Spring Valley Drive Holland Ohio 43528 The express warranty set forth herein is in lieu of all other warranties expressed or implied including without limitation any warranties of merchant ability or fitness for a particular purpose All such warranties are hereby disclaimed and excluded by the manufacturer Repair or replacement of defective products as provided above is the sole and exclusive remedy provided thereunder The manufacturer shall not be liable for any further loss damages or expenses including incidental or consequential damages directly or indirectly arising from the sale or use of this product Any unauthorized repair voids this warranty There are no warranties that extend beyond those expressly set forth herein DOC 17601 Page 4 m Toledo Integrated Systems ZT 1 User s Manual Installation Features Overview e Designed to work with strain gage sensors and load cells The ZT 1 can also accept input from 4 20mA current output sensors or voltage output sensors e Simultaneously provides normal peak reverse peak and track voltage outputs Also simultaneously provides the associated 0 20mA current outputs e Built in threshold trigger simplifies installation External probe trigger can also be used when situation required e LED bar graph voltmeter for easy setup and diagnostic e Built in 1 Mega Ohm calibration shunt resistor User se
24. lected external shunt resistor can be used for load cell applications e 1 and x10 amplifier gain ranges to work with either strong or weak signal from the load sensor e Auto Zero can be selected using dip switches to compensate for zeroing errors caused by environmental changes such as temperature humidity and etc e Electrical noise rejection filter can be enabled when situation required e Plug in connectors for easy wiring and installation e Standard DIN Rail mount simplifies systems integration e Modular with common bus design allows future upgrade and expansion The ZT 1 tonnage load module is designed for critical force measurement applications where accuracy extreme stability and dependable noise rejection is essential It is equipped with an LED bar graph voltmeter for easy setup and diagnostic The ZT 1 is DIN rail mountable and is designed to interface with a PLC analog card and to display output through a human machine interface HMI DOC 17601 Page 5 m Toledo Integrated Systems ZT 1 User s Manual Installation DOC 17601 Page 6 m Toledo Integrated Systems Specifications Transducers Sensor Excitation Balance Range Gain Ranges Calibration Shunt Output Range Voltage Output Range Current Circuit Inaccuracy Circuit Non linearity Auto Zero Frequency Response Speed Limit Operating Temperature Display Trigger Probe Input Input Power Dimensions Mounting DOC 17601 ZT
25. ls the setup for Peak Mode and Track Mode operations I Peak Mode operation In Peak Mode the output will increase to the highest load level and remain at that voltage until the probe transitions from off to on again MODE SELECT SWITCHES x1 STI X10 ThH 9 1 OFF 83 AZ OFF e PRB HEY TRK e PEAK ZRO fel GAIN 1 Set the Mode Select Switches to AZ OFF PRB OFF TRK and ZRO as shown above DOC 17601 Page 31 Toledo Integrated Systems ZT 1 User s Manual Operation 2 Skip this step if Auto Zero is not needed a Toggle the OFF AZ switch to AZ to start Auto Zero OFF PRB TRK PEAK ZRO __ GAIN b When Auto Zero is done only the 2 yellow LEDs at 0 0V are lit 3 Set the OFF PRB switch to PRB and set the TRK PEAK switch to PEAK OFF AZ OFF PRB TRK PEAK ZRO GAIN DOC 17601 Page 32 m Toledo Integrated Systems ZT 1 User s Manual Operation Il Track Mode operation In Track Mode output will follow the loading on the sensor as the load on the machine increases and decreases MODE SELECT SWITCHES v x1 BA Th H Ie TL Om OFF fen AZ OFF e PRB AEN TRK fen PEAK ZRO fel GAIN 1 Set the Mode Select Switches to AZ OFF PRB OFF TRK and ZRO as shown above If Auto Zero is not needed it is done Skip the following steps 2 If Auto Zero is needed then a Toggle the OFF AZ switch to AZ to start Auto Zero OFF fe
26. nd Tap Method of Installing Sensors Page 5 Weld Method of Installing Sensors Page 6 T400 Enclosure Mounting Details Page 7 Doc 11080 Rev A T400 INSTALLATION PAGE 1 NOISNIL SSANMOIHL LNO J NOISS3HdlNOO SSANMOIHL YVAN 3 Uoisue Jo pe su sBuipeaJ uoisseJduuoo JO uonoeuuoo jndui au es ay ul Josues eu si SSAUYOIU JUOI OU JI sow SI siu ay ui sjosues yUNOW Us uey SI sseuyoly 110 eui yl INOHJ SSANMOIHL AHL 33 SV3IN X AAYHL AP AIdILININ SSANMOIHL 3 AYNSVAW x NOILVIO1 1539 3 ANIWYALAG OL MOH ease pepeus au Ul UMOUS sseJd eu JO JESI ay JO UOJ SY 1 OM peuiuuejep eq jsnu uoneoo JOSUSS IN3IN3OV ld YOSNAS S310H LNO MOONM JHL NI SJ3IT3M NIVYLS 2 1 9NISN LS3SSnS 3M aasn SI LINONO9 dl S3 10H LNO ADONA uZIL FANTONI SAYNSOTONA 3S3HL SIONVIO YOSNAS 0071 IHL 193108d SSSHL SIYNSOTINI HOSN3S 2 z qaasinoas SHOSNGS 2 L SALON PAGE 2 T400 INSTALLATION Rev A Doc 11080 315108 YO JHL NOY4 H LGIM 1 NVH L H39S019 SHOSN3S ONILY901 3181SSOd dl S3SVO 11 NI 3AO8V CIgdIHISAA SV Sd OH GIOAV 9385 SSOHI 1SVI1 40 VIYV NV NI SHOSN3S TIVLSNI S3SSJeYd AAV3H AI
27. t the Lg Sm dip switch to Lg position for large signal 20mA out sensor outputs amplified signal large signal 3 Set FIL dip switch to No filter position Apply this filter only when electrical noise becomes a problem at the ZT 1 analog outputs DOC 17601 Page 16 m Toledo Integrated Systems ZT 1 User s Manual Installation SENSOR INPUT EARTH __ SHUNT Current Sensor Lg Sm 6_ Lg Large Signal Amplified FIL gt 67 No Filter SENSOR SIGNAL CONFIG Figure 8 20mA out Sensor Input DOC 17601 Page 17 T Toledo Integrated Systems ZT 1 User s Manual Installation 10V out Sensor Connection The 10V out Sensor applies to sensors with output up to 10V Refer to Figure 9 for the procedures below Connection 1 Remove the Phoenix plug from its socket on the top of the unit and wire the sensor cable as shown 2 The Phoenix plug can then be inserted back into its socket Configuration 1 SettheV C dip switch to V position for voltage sensor 10V out sensor outputs voltage signal 2 Set the Lg Sm dip switch to Lg position for large signal 10V out sensor outputs amplified signal large signal 3 Set FIL dip switch to No filter position Apply this filter only when electrical noise becomes a problem at the ZT 1 analog outputs DOC 17601 Page 18 m Toledo Integrated Systems ZT 1 User s Manual Installation 10V out sensor

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