Tonnage Load Module User`s Manual
Contents
1. 23 Galibratlom E T 25 Front Panel u 25 Notes Bar Graph ee Pleite 25 Calibration Procedures E Pasquale ae t 26 Check 31 ST AMON EP u ei 33 Peak Mode stranded icr LO Eo tete Me EL Ma 33 Track Mode Operat O 34 13161 0151 37 Sensor Installation Doc 11080 37 Calibration sheets 2 Form 1224 37 Table of Figures Figure 1 Mounting DIITefislorts u u 9 Figure 2 DG Power Wirllg n 1 10 Figure 3 Channel 1 Built In 1M Ohm Shunt Resistor Wiring 11 Figure 4 Channel 1 External Shunt Resistor 11 Figure 5 Strain Gage Sensor Input RR bep bet RA TERRA D enna o e2. 4 1 SIDE VIEW 18 e 018 018 0118 e 018 18 18 H3 ZERO ez 22222222222222222 3 D 4 7 Figure 1 Mounting Dimensions T DOC 17495 Toledo Integrated Systems Page 9 ZT 4 User s Manual Installation DC Power Connection 24VDC power is connected to the ZT 4 as shown in Figure 2 24VDC Input DC Common Earth Chassis Ground BOTTOM VIEW Figure 2 DC Power Wiring Notes 1 The 24VDC source can be in range from 18VDC to 32VDC 2 It is 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 17495 Toledo Integrated Systems Page 10 ZT 4 User s Manual Installation Shunt Resistors Each channel comes with an 1M ohm built in shunt resistor Channel 1 is capable of utilizing either the 1M ohm built in shunt resistor or a user specified external shunt resistor Figure 3 Figure 4 Channel 1 Built In 1M Ohm Channel 1 External Shunt Shunt Resistor Wiring Resistor Installation Shunt resistor only works directly with the Wheatstone bridge type sensor It has no effect if other type of sensor is used T DOC 17495 Toledo Integrated Systems Page 11 ZT 4 User s Manual Installation
3. Shunt 2 Om if EXT used Figure 16 Calibration Card Sample T DOC 17495 Toledo Integrated Systems Page 30 ZT 4 User s Manual Calibration Check Calibration Occasionally you may need to check the unit s accuracy by verifying the Calibration gain voltage The Calibration gain voltage is recorded in the calibration card which is located in the side pocket To verify the Calibration gain voltage follow step 9 page 29 in the Calibration Procedures T DOC 17495 Toledo Integrated Systems Page 31 ZT 4 User s Manual Calibration q DOC 17495 Toledo Integrated Systems Page 32 ZT 4 User s Manual Operation gt Operation Once the ZT 4 has been calibrated it is ready for continuous use This section details the setup for Peak Mode and Track Mode operations 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 SWITCHES Y X1 9 X10 Th H e 1 L Om o OFF le AZ PRONT OFF fe PRB PEAK ZRO 0 GAIN 1 Set the Mode switches to AZ OFF PRB OFF TRK and ZRO as shown above 2 Skip this step if Auto Zero is not needed a Toggle the OFF AZ switch to AZ to start Auto Zero OFF e 1 PRB TRK fe PEAK ZRO 1 GAIN When Auto Zero is done only the 2 yellow LEDs at 0 0V lit q DOC 17495 Toledo Integrated Syst
4. 13 Figure 6 Strain Gage Sensor Cable 2 1 14 Figure 7 Strain Gage Sensor 400 15 Figure 8 20mA out Sensor Inpll aiite dee to eeeeene 17 Figure 95 30V out Sensor INPUT o ose rete E ERU de oe 19 Figure 10 Analog Voltage Output Wing eae Pe ead 20 Figure 11 Analog Current Output Wiring 21 Figure 12 Internal Threshold Wiring teet kt deter 22 Figure 13 Probe Input Wiring 23 Figure 14 Probe Timing Diagram Ee oo i 24 Figure 15 Calibration Gain Voltage Measurement 29 Figure 16 Calibration Card Samples ec ser d a ett ot ete e RE 30 1 DOC 17495 Toledo Integrated Systems Page 3 ZT 4 User s Manual 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
5. tw ta OFF sm AZ OFF ma PRI Mr PT d VOLT gt gt lt liz o CAIN PRB 8 4 ZERO NT Sb Tonnage Load Module By Toledo Integrated Systems User s Manual 17618 ZT 4 Load Module User s Manual Revision A ZT 4 User s Manual T DOC 17495 Toledo Integrated Systems Page 2 ZT 4 User s Manual Table of Contents Limited Warranty AUS 4 Features OVervi W O 5 arti fef 7 eU 9 Mounting Ines Te ed edad ep 9 DG Power csi itm Pase 10 Shunt Resistors 5 seta tiet vue tours tob 11 Tonnage Gage Sensor Connection 12 20mA out Sensor Conneclion a a ee ee 16 10V out Sensor Connection Eee eee ee ee aod 18 Analog Voltage Output e ttr e libe 20 Analog Current Outil M ERa iiag 21 Triggering Internal TSS ON ni epat 22
6. T400 INSTALLATION Doc 11080 Rev A USING THE 400 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 QM i 4 1 4 28 METRIC 6 1 3 DRILL 5mm X DRILL THROUGH FOUR SMALL HOLES STEPS 3 4 1 4 28 X 1 1 4 SCREW METRIC 6 1 X 35 ROTATE FIXTURE 90 DEGREES 7041 STEP 5 O 4 21 DRILL G lt DRILL THROUGH THE TWO SMALL CENTERED HOLES ROTATE FIXTURE 90 DEGREES S1 4 28 STEPS 6 7 6 1 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 in the load sensor can be bolted directly to the surface Drill and tap the center hole 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 4 inch M6 1 x 35 long socket head cap screw in the center of the fixture Insert the number 3 dril
7. 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 CH1 3 or from the bottom of the unit CH4 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 for the corresponding channel to V position for voltage sensor Strain Gage sensor outputs voltage signal 2 Set the Lg Sm dip switch for the corresponding channel to Sm position for small signal Strain Gage sensor outputs un amplified signal small signal 3 Set FIL dip switch for the corresponding channel to No filter position Apply this filter only when electrical noise becomes a problem at the analog output Note There are four sets of Sensor Signal Configuration dip switches Each set is for the corresponding channel mq DOC 17495 Toledo Integrated Systems Page 12 DOC 17495 ZT 4 User s Manual Installation Shield Excitation Black CH4 CH2 4 Excitation Green INPUT Signal White lt Signal Red COMMON a CH2 C
8. 1 NPN COM THRES out ON PROBE THRESH ON OFF PROBE THRESH OFF FRONT VIEW BOTTOM VIEW Figure 12 Internal Threshold Wiring The probe PRB indicators should turn on when the Channel 1 load rises above the threshold value and turn off when the load falls back below the threshold value DOC 17495 Toledo Integrated Systems Page 22 ZT 4 User s Manual Installation Triggering External Probe The ZT 4 can be triggered by an external probe signal If an external probe is used the probe supply voltage 4 24 VDO is provided by the ZT 4 The figure below illustrates the wiring for a variety of sensing devices SINKING PROBE NPN N O BRN 24V out PNP NPN COM THRES out SOURCING PROBE PNP N O 24V out PNP NPN COM THRES out DRY CONTACTS m 24V out Sy PNP NPN c COM FRONT THRES out VIEW BOTTOM VIEW Figure 13 Probe Input Wiring The probe PRB indicators should turn on when the probe turns on and turn off when the probe turns off T DOC 17495 Toledo Integrated Systems Page 23 ZT 4 User s Manual Installation If the front panel Auto Zero switch is enabled the ZT 4 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 tension The ZT
9. 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 cc m E TAP THESE HOLES WITH 10 32 5 Uem Sue 22 22 10 32 x 3 8 PAN HEAD MACHINE SCREW 1 4 28 x 3 4 SOC HD SCREW SENSOR ENCLOSURE 11080 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
10. that each sensor is at zero see notes on page 25 ZRO _ GAIN Setthe ZRO GAIN switch to GAIN and use a digital voltmeter to measure the voltage across the OUT1 and COM terminals Record this value as the Calibration gain voltage for Channel 1 Then do the same for Channel 2 3 and 4 OFF fe PRB TRK ZRO GAIN Channel Calibration Gain Channel 2 Calibration Gain Voltage 9111113110 Voltage Channel 3 Calibration Gain Voltage Common 9 Channel 4 Calibration Gain Voltage BOTTOM VIEW Figure 15 Calibration Gain Voltage Measurement T DOC 17495 Toledo Integrated Systems Page 29 ZT 4 User s Manual Calibration 10 Documentation e Fill in the Calibration Card a sample shown below which is located in the side pocket e Set Mode switches as shown Calibration is now complete ZRO 0 1 GAIN Model ZT 4 Serial No 1501 Calibrated By John Doe Date 1 1 2015 Channel Gain Range Gain Sensor Mode Switch Number Switches DC Volts Location Fill In Switch Position 4X io 3 25 LR 4X 40 3 20 RR 1 x10 3 28 LF 4X 4 3 32 RF T Toledo Integrated Systems Holland OH Made in the USA Toledo Transducers Inc Sensor Signal Configuration Fill n Switch Position
11. 28 3 4 SCREW TO 150 LB IN OR 12 5LB FT ASSEMBLE BOX COVER d KU NIRE gt LOAD MODEL 400 5 7 gt 400 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 ____ MONITOR SERIAL No SLIDE ADJUST INDICATOR LINEARITY PLOT USING TONS SHOWN ON TOTAL DISPLAYS TOTAL LOAD DISPLAYED ON MONITOR L _ Jl i 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 NO OTHER RESISTORS CHAN 1 CHAN 2 CHAN 3 4 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 REFERENCE NUMBER LOW TRIGGERED FROM PROBE YES NO TRIPPED ALARM RELAY STOPS PRESS YES ALL STICKERS AND DOCUMENTS FILLED OUT YES IF NOT EXPLAIN WHY __ HIGH2 LOW 2 COMMEN
12. 4 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 4 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 402 240 140 page rope Open Probe ZT 4 Auto Zeroing Figure 14 Probe Timing Diagram DOC 17495 Toledo Integrated Systems Page 24 ZT 4 User s Manual Calibration Calibration Front Panel Controls Refer to the diagram below for control locations X1 X10 GAIN SWITCH FOR CHANNEL 2 X1 X10 GAIN SWITCH FOR CHANNEL 3 X1 X10 GAIN SWITCH FOR CHANNEL 4 1 X10 GAIN SWITCH FOR CHANNEL 1 MODE SWITCHES DISPLAY CHANNEL SELECTOR BAR GRAPH CHANNEL 2 ADJUSTMENT VOLTMETER CONTROLS CHANNEL 3 ADJUSTMENT CONTROLS CHANNEL 1 ADJUSTMENT CONTROLS CHANNEL 4 ADJUSTMENT CONTROLS Notes Bar Graph Voltmeter Normally a dig
13. COM 311 OL SI HOSN3S V H3SO IO JHL qou 311 31 dO ANIM 31 33 AHL NO LH9IHdfl dO H19N31 L AHL NI SI NOLIVOO I YOSNAS 1538 LH IYdN 5 dO 2 LL SYNSOTONA 5 5 S NIN3dO ONILVAH CO 211 YVAN LINGNOO LON OQ NOILOVO AINO S38IM YOSNAS QVO LINGNOOD LAN qQOt JIL PAGE 3 T400 INSTALLATION Rev A Doc 11080 SHOSN3S 108 MOHS OL MIIA ONISNOH LNAWLSArdV JANS WVH 30119 dO LNO NAHL Waal 1 LXAN OL LINANOO E INSWLLSNrav 30118 OL ANd SSAOW AHL N3HM Q3Q33N MOVIS d 18V9 SI dOO1 38 41 AHL ALON lt A y 14819580 lt lt 2 11 08 OL 1108 HOSNAS vIe X HOV3 1 3 18 5 XO8 NOILWNINYAL 38 1 29 90 8 3d LAN HLIM 1 431139 NIVHIS C88 SLYC H ALON 335 ONIGNL NOSAL 29 0 28 3 8 30801 3 3 ANY ANY 318VO 3n0HOL NO ALISOddO 8338 30 08 31001 39 3 SHOSN3S OML HOSN3S AYOT 00 1 KINO 33H 3 8 3010801 318VO TA PAGE 4
14. EL No 1 STI REFERENCE NUMBER LOW TRIGGERED FROM PROBE YES NO TRIPPED ALARM RELAY STOPS PRESS YES ALL STICKERS AND DOCUMENTS FILLED OUT YES IF NOT EXPLAIN WHY __ HIGH2 LOW 2 COMMENTS HIGH4 10 4 _ Show threshold value if not triggered from probe HIGH NO EXPLAIN HIGH6 LOW6 HIGH8 LOW 8 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
15. H3 OUTPUT INPUT 10V COMMON ee CH3 imam ib SENSOR2 v c V Voltage for Tonnage Sensors Em Lg Sm e Sm Small Signal Un amplified CH4 SOM T OUTPUT SENSOR 3 FIL gt No Filter zn SIGNAL CONFIG SENSOR 4 SIGNAL CONFIG BOTTOM TOP VIEW VIEW Figure 5 Strain Gage Sensor Input d Toledo Integrated Systems Page 13 ZT 4 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 1 CABLE JACKET b IGNAL WIRES BRAIDSHIELD 00 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 T DOC 17495 Toledo Integrated Systems Page 14 ZT 4 User s Manual Installation Illustration B Sensors Connection The ZT 4 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 SENSOR CONNECTION Tension connection SHIELD shown For compression SHL connections switch the E B red and white wires E G S W S R Fig
16. MON CH3 OUTPUT SENSOR 2 dd SIGNAL rossi CONFIG CH4 OUTPUT SENSOR SIGNAL ae CONFIG 3 SENSOR 4 SIGNAL CONFIG BOTTOM VIEW Figure 9 T Toledo Integrated Systems 10V out Sensor Input 10V out sensor V C fe 1 V Voltage Sensor Lg Sm 9 Lg Large Signal Amplified Page 19 ZT 4 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 Swing between 10VDC OUTO Normal Output Average Total Channel OUT1 4 Normal Output Channel 1 to 4 Channel Typical Connectio 1 to PLC Analog ZONON REV1 4 Reverse Output Input card perm Channel 1 to 4 TRK1 4 Track Output Channel 1 to 4 COM Analog Common BOTTOM VIEW Figure 10 Analog Voltage Output Wiring Output details e OUT terminals output either Peak tonnage or Track tonnage depending on the TRK PEAK switch setting on the front panel REV terminals output the reverse peak snap through tonnage when the front panel TRK PEAK switch is set to PEAK TRK terminals always output the track tonnage regardless of the front panel TRK PEAK switch q DOC 17495 Toledo Integrated Systems Page 20 Analog Current Output ZT 4 User s Manual Installation The analog current output is available in Channel 1 only It is provided on a Phoenix con
17. T DOC 17495 Toledo Integrated Systems Page 38 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 and 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 NOISN3 L SSANMOIHL LNO J NOISS3HdlNOO SSANMOIHL Uoisue jo pe su sBuipeaJ uoisseJduuoo JO uonoeuuoo jndui y 4884 y u Josues eu si SSAUYOIU OU JI sow y SI 6141 0 eui ui sjosues Us uey s ss uy
18. TS HIGH4 10 4 _ Show threshold value if not triggered from probe HIGH NO EXPLAIN HIGH6 LOW6 HIGH8 LOW 8 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 ____ MONITOR SERIAL No SLIDE ADJUST INDICATOR LINEARITY PLOT USING TONS SHOWN ON TOTAL DISPLAYS TOTAL LOAD DISPLAYED ON MONITOR L _ Jl i 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 NO OTHER RESISTORS CHAN 1 CHAN 2 CHAN 3 4 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 CHANN
19. W 21 DRILL TWO SMALL CENTERED HOLES FOR ENCLOSURE STEP 4 4 4 28 x 1 SCREWS 114 28 X 1 1 4 SCREW Ta Zu SS WELD EACH PAD ON THREE SIDES ONLY STEP 5 ANTI TORQUE 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 4 inch long socket head cap screw in the center of the fixture Orient the fixture as shown and drill out the 721 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 TO 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
20. ZRO 1 GAIN e Further adjust the shut height so that the press impacts the load cells and generates a load at 10096 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 17495 Toledo Integrated Systems Page 27 ZT 4 User s Manual Calibration 8 Adjust the gain Set the Display channel selector to 1 for Channel 1 e Run the press for 2 cycles at capacity e Compare the voltage level on the bar graph with the load cell that corresponds to Channel 1 e Adjust the Channel 1 GAIN pot e Repeat until the desired voltage LED just turns on see notes on page 25 For example 6 0V at 100 0 tons VOLT gt 4 2 2 66666 6 666666666 UJ 70 WR f less gain is needed change the Channel 1 Gain switch to X1 then repeat from Step 4 for this channel only e Repeat this step for Channels 2 3 and 4 DOC 17495 Toledo Integrated Systems Page 28 ZT 4 User s Manual Calibration 9 Record the Calibration Gain Voltage e Set the Mode switches to AZ OFF PRB OFF TRACK and ZERO as shown Use the Display channel selector and the Bar graph voltmeter to verify
21. ems Page 33 ZT 4 User s Manual Operation 3 Set the OFF PRB switch to PRB and set the TRK PEAK switch to PEAK The unit is now ready to run in Peak mode OFF AZ OFF PRB TRK PEAK ZRO GAIN Track Mode Operation In Track mode output will follow the loading on the sensors as the load on the machine increases and decreases MODE SWITCHES Y X1 __ X10 Th H e 1 L Om e OFF 1A7 FRONT OFF fe PRB TRK fe PEAK ZRO fe GAIN 1 Set the Mode switches to AZ OFF PRB OFF TRK and ZRO as shown above If Auto Zero is not needed skip the following steps The unit is now ready to run in Track mode q DOC 17495 Toledo Integrated Systems Page 34 ZT 4 User s Manual Operation 2 If Auto Zero is needed then a Toggle the OFF AZ switch to AZ to start Auto Zero OFF 29 AZ OFF 9 PRB 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 The unit is now ready to run in Track mode OFF L 91 AZ OFF 9 PRB TRK fe PEAK ZRO 1 GAIN 1 DOC 17495 Toledo Integrated Systems Page 35 ZT 4 User s Manual Operation T DOC 17495 Toledo Integrated Systems Page 36 2 4 User s Manual Appendix Appendix A Sensor Installation Doc 11080 B Calibration Sheets 2 Form 1224 T DOC 17495 Toledo Integrated Systems Page 37 2 4 User s Manual Appendix
22. in 1 Mega Ohm calibration shunt resistor Channel 1 accepts user selected external shunt resistor 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 4 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 4 is DIN rail mountable and is designed to interface with a PLC analog card and to display output through a human machine interface HMI T DOC 17495 Toledo Integrated Systems Page 5 ZT 4 User s Manual T DOC 17495 Toledo Integrated Systems Page 6 Specifications Channels Transducers Sensor Excitation Balance Range Gain Ranges Calibration Shunt Output Range Circuit Inaccuracy Circuit Non linearity Auto Zero Frequency Response Speed Limit Operating Temperature Display Trigger Probe Input Input Power Dimensions Mounting DOC 17495 ZT 4 Use
23. ital voltmeter is used to check the sensor balance and output voltage during a calibration The digital voltmeter is connected to the OUTx and COM terminals see Figure 15 If calibration accuracy of 1 of capacity is acceptable the built in Bar graph voltmeter can be used for calibration Let us use the 6 0 VOLT LED in the built in Bar graph voltmeter as an example here When this LED is on it could mean a voltage anywhere from 6 00 volt to 6 99 volt But when this LED just changes state from off to on it indicates an accurate reading of 6 00 volt This characteristic is useful when you dial the gain pot to adjust the output voltage This characteristic applies to all LED s in this Bar graph voltmeter In case you need to set the output voltage to 5 50 volt the Bar graph voltmeter will not work accurately You will need to use a digital voltmeter for cases like this T DOC 17495 Toledo Integrated Systems Page 25 ZT 4 User s Manual Calibration Calibration Procedures 1 Before calibrating the unit verify each hardware mentioned in the Installation Section is connected and set up properly With the sensors placed in the best possible location see appendix A torque the sensors down to 150 in lbs on the sensor bolts Do not put the sensor enclosure covers on yet You will need to test each sensor location Find the shut height of the press Jog the press until the ram is at bottom dead center BDC o
24. l 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 400 SENSOR INSTALLATION FIXTURE KIT No 1977 749 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 54 XX CU Nag 4 4 28 X 1 1 4 SCRE
25. mA out Sensor Input T Toledo Integrated Systems 4 20 sensor BLU vr P IS C Current Sensor Lg Large Signal Amplified No Filter Page 17 ZT 4 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 CH1 3 or from the bottom of the unit CH4 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 for the corresponding channel to V position for voltage sensor 10V out sensor outputs voltage signal bs Set the Lg Sm dip switch for the corresponding channel to Lg position for large signal 10V out sensor outputs amplified signal large signal 3 Set FIL dip switch for the corresponding channel to filter position Apply this filter only when electrical noise becomes a problem at the analog output Note There are four sets of Sensor Signal Configuration dip switches Each set is for the corresponding channel mq DOC 17495 Toledo Integrated Systems Page 18 c DOC 17495 ZT 4 User s Manual Installation BLU CH2 INPUT INPUT COMMON aco CH2 CH3 OUTPUT INPUT 10V COM
26. nector for easy access and for interfacing with other peripherals Typical Connection to PLC Analog Input card OUT 1 REV 1 TRK 1 COM COM 24V in OV in GND 24V out THRES out Tm VIEW 24V out S R 8 W E G E B SHL lilii 11 Output details Analog Current Output Channel 1 only Swing between 20mA OUT C1 Normal Output REV C1 Reverse Output TRK C1 Track Output COM Analog Common Analog Current Output Wiring OUT C1 terminal outputs either Peak tonnage or Track tonnage depending on the TRK PEAK switch setting on the front panel REV C1 terminal outputs the reverse peak snap through tonnage when the front panel TRK PEAK switch is set to PEAK TRK C1 terminal always outputs the track tonnage regardless of the front panel TRK PEAK switch DOC 17495 mq Toledo Integrated Systems Page 21 ZT 4 User s Manual Installation Triggering Internal Threshold The ZT 4 can be triggered by an internal threshold value When this triggering method is used the ZT 4 begins monitoring when the Channel 1 load rises above the level determined by the front panel s Th H L switch Refer to Figure 12 below to configure the unit for threshold triggering High Threshold 0 70V L Low Threshold 0 35V INTERNAL THRESHOLD pe 24V out 031 PNP
27. o u 1 0 4 eui 4 INOHJ SSANMOIHL LNO4 AHL 33 SV3IN gt X 1 AP SSANMOIHL AHL AYNSVAW 15448 AHL ANIWYALAG OL MOH ease pepeus au Ul UMOUS sseJd eu JO JeeJ y JO y suoneoo peuiuuejep eq jsnuJ uoneoo Josuegs IN3IN3OV ld YOSNAS S310H LNO MOONM 381 NI SJ3IT3M NIVMLIS 2 1 9NISn LS3SSnS 3M aasn SI LINGNOO dl S3 LNO MOON 83 8 3S3HL 935 5 5 00 1 IHL 1O31OMd SSSHL SAYNSOTONA HOSN3S 2 2 qaasinoas sHOSN3S 2 L SALON PAGE 2 T400 INSTALLATION Rev A Doc 11080 74116108 HO NMOSWO JHL H LGIM NWN109 1 NVH L H39S019 SHOSN3S SNI1VOO1 3181SSOd 41 S3SVO NI 8 Qdardosad SV Sd NOILOAS 88093 15 1 40 NV NI SHOSN3S TIVLSNI 83893 4 HO 953 4 LSVO EWNHL dO JINN 038 18 08 1 988384 AHL NI LNO LNO JHAY JVH L S31OH dO 3903 WOLLOS 3904 dOl JHL INO Z NVHL 50 3 SHOSN3S ONITIVLSNI GIOAV 55 dive TIVM 1 V SI LI TIVM SS3ud 3GISNI 3H 1 NO SHOSN3S TIVLSNI 318ISSOd 4l LHOlddN 38 NIAN YTIOO AO SLI 831138
28. r s Manual One to four channels Full bridge 120 to 1000 ohms Maximum of 2 350 ohm sensors paralleled per channel 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 Channel 1 accepts custom shunt Normal Peak and Reverse Peak 0 to 10VDC Track output 10 to 10VDC Channel 1 also provides current outputs 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 LED bar graph voltmeter for setup and diagnostic Internal Threshold 35V 70V base on Channel 1 signal 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 0 5A max Automatic resettable fuse 1 9 W x 4 1 H x 4 7 Standard DIN Rail mount T Toledo Integrated Systems Page 7 ZT 4 User s Manual T DOC 17495 Toledo Integrated Systems Page 8 ZT 4 User s Manual Installation Installation Mounting the 2 4 The ZT 4 is designed to clip onto standard top hat DIN rail TH 35 7 5 or TH 35 15 5 22222222 222
29. r 180 without the load cells or die in the press e Determine the amount of spacers needed with your load cell Cycle the press without load cells to insure correct height Place the load cells in the correct position in the press All load cells should be equal distance from the sides and front and rear For example 12 from the sides 10 from front and rear Load cells are typically placed at each corner of the press s bed e Cycle the press without hitting the load cells first Place cardboard on the top and bottom of the load cells Toggle the Mode switches to AZ OFF PRB OFF TRACK ZERO Also set all Gain switches to X10 to start CH2 X10 X1 X10 9 J L OFF je 1 AZ OFF PRB TRK PEAK ZRO 0 GAIN T DOC 17495 Toledo Integrated Systems Page 26 ZT 4 User s Manual Calibration 6 Balance the tonnage sensors e Setthe Display channel selector to 1 for Channel 1 The Bar graph voltmeter now shows the balance of Channel 1 Adjust the Channel 1 ZERO pot until the bar graph has only the 2 yellow 0 0V LEDs lit This indicates a balanced or zeroed state see notes on page 25 VOLT T 623 4 gt 6 666666666 6 666666666 UJ U WR Repeat this step for Channels 2 3 4 7 Cycle the press e Set the Mode switches to AZ OFF PRB and ZERO OFF Le PRB TRK PEAK
30. repair 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 17495 Toledo Integrated Systems Page 4 ZT 4 User s Manual Features Overview e Designed to work with strain gage sensors and load cells The ZT 4 can also accept input from 4 20mA current output sensors or voltage output sensors e Four independent channels for accommodating up to eight sensors e Simultaneously provides normal peak reverse peak and track voltage outputs Channel 1 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 Built
31. ure 7 Strain Gage Sensor Wiring T DOC 17495 Toledo Integrated Systems Page 15 ZT 4 User s Manual Installation 20mA out Sensor Connection The 20mA out Sensor applies to sensors with output up to 20 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 CH1 3 or from the bottom of the unit CH4 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 for the corresponding channel to C position for current output sensor 20mA out sensor outputs current signal 2 Set the Lg Sm dip switch for the corresponding channel to Lg position for large signal 20mA out sensor outputs amplified signal large signal 3 Set FIL dip switch for the corresponding channel to No filter position Apply this filter only when electrical noise becomes a problem at the analog output Note There are four sets of Sensor Signal Configuration dip switches Each set is for the corresponding channel mq DOC 17495 Toledo Integrated Systems Page 16 DOC 17495 BOTTOM VIEW Figure 8 CH2 INPUT SENSOR 2 SIGNAL CONFIG SENSOR 3 SIGNAL CONFIG SENSOR 4 SIGNAL CONFIG ZT 4 User s Manual Installation BRN 20
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