Strain Gage Module - Helm Instrument Company Inc.
Contents
1. Rung 3 37 CH 2 AVERAGE of SAMPLES IN TONS MOV SSS SoS 2222 La en en a li a a a ii MOVE Source I 2 6 0 Dest N10 25 0 Ladder Programming Appendix B ze Section 4 Rung 3 38 DO BIT OF PANELVIEW SAMPLE ENTRY COUNT N10 18 0 2 mee O TE E ee engeren esses 0 8 Rung 3 39 D1 BIT OF PANELVIEW SAMPLE ENTRY COUNT N10 18 0 2 RSS A E Se TS SS RT SSS ER SRR TR ORES SSS Sasso Biet 1 9 Rung 3 40 D2 BIT OF PANELVIEW SAMPLE ENTRY COUNT N10 18 0 2 2 10 Rung 3 41 D3 BIT OF PANELVIEW SAMPLE ENTRY COUNT N10 18 0 2 a Ba SR CIA ES 3 11 Rung 3 422. Incorrect y Alarm can be reset and remains cleared with press stopped Does alarm fire again gt Intermittent press with press running 1 overload condition 0 Yes Is alarm equal to 195 E of capacity alarm of gt u any channel Yes Y No Check for slug build up p Remove slug and in die run press Yes Y None Check for broken shear collar linkage or other pp Correct problem press or die damage Yes None Check press parallelism e Correct problem Out of V Parallel parallel Dial in correct calibration number Y Run press Page 5 2 System Trouble shooting Guide contd Alarm in Monitor Parts Mode Chapter 5 Alarm does not reset with press stopped Alarm does reset with press stopped Capacity alarm fired gt aq Y Tolerance alarm fired Set mode to Peak No alarm y Re sample with press running Check for slug build up p Remove slug and in die run press Yes aq y No Check for broken shear collar linkage or other p Correct problem press or die damage Yes y None Check press parallelism Correct problem Out of parallel Parallel Page
3. Channel 1 Load Value ei Integer word represents peak load on channel 1 for current machine cycle If Reverse Bit O e 0 5 is on 1 value is reverse load on channel 1 for current machine cycle Channel 2 Load Value I e 2 Integer word represents peak load on channel 2 for current machine cycle If Reverse Bit O e 0 5 is on 1 value is reverse load on channel 2 for current machine cycle Note If O e 0 1 is set to 1 then A D Value is integer word for calibration set Channel 1 Percent of Deviation I e 3 Integer word represents the percentage of change current peak load is to sample peak load Channel 2 Percent of Deviation I e 4 Integer word represents the percentage of change current peak load is to sample peak load Channel 1 Average Sample Value l e 5 Integer word represents the average of the sample load values on channel 1 in Tons Channel 2 Average Sample Value l e 6 Integer word represents the average of the sample load values on channel 2 in Tons Sample Counter l e 7 Counter used for number of Sample Count Page 3 4 Chapter 3 Using RS Logics 500 software reserve two integer file s for tonnage monitoring Reserve one counter for tonnage monitoring For illustration purposes in this manual we have reserved Integer file N10 0 N10 25 Data Description Address Integer Channel 1 Trend Deviation in percent N10 1 Integer Channel 2 Trend Deviation in percent N10 2 Integer Channel 1 Low Trend Alarm Se
4. Class 1 Division 2 Hazardous Environment Strain Gage 350 ohm 700 ohm Input Impedance 1K Display Resolution Up to 0 1 of full scale Overall Module Accuracy 1 of full scale Module Update Time 140 usec Ladder Page A 1 Appendix B Section 1 Programming Ladder Programming Summary Appendix B Section 2 ladder interface for a 2 channel tonnage system Appendix B Section 3 ladder interface for a 4 channel tonnage system Appendix B Section 4 ladder file required for every StrainGage module in your plc Ex 2 tonnage modules 2 files each with a different integer table and different UO addresses Note 1 For 2 channel system use ladder in sections 2 amp 4 2 For 4 channel system use ladder in sections 3 and have 2 files same as section 4 the file for CH S 1 amp 2 uses integer N10 and file and file for CH S 3 amp 4 uses integer N11 3 If creating a system with more than 2 StrainGage modules use Appendix B Section 3 as a reference This file has all the common integers needed for each StrainGage mod Appendix B Fe Section 1 Ladder Programming Items needed to map into program 1 Press in motion bit a If you are using Helm HR 1101 resolver for position input and are using our sample ladder Rung 2 0 helm s press in press in motion bit motion bit N12 0 N10 21 E AA AA AA AA PAA AA OS aan 4 0 b If you have your own press in
5. EE EEN MULTIPLY kota Source A N10 4 0 Source B 256 Dest N10 7 0 TREND HIGH LOW ALARM SETTING FOR CH1 ADD Spa en ag ADD Source A N10 7 0 Source B N10 3 0 Dest 0 2 6 Ladder Programming Appendix B Section 4 Rung 3 31 MUL TU MULTIPLY Source A N10 6 0 Source B 2561 Dest N10 7 0 TREND HIGH LOW ALARM SETTING FOR CH2 KADD AT EC ADD Source A N10 7 0 Source B N10 5 0 Dest OFZ TI 0 Rung 3 32 DISPLAYS PEAK TONNAGE FOR CHANNEL 1 AS LONG AS MODULE IS NOT IN SETUP MODE PANELVIEW MODE BUTTON BYPASS N10 20 MOV E Sea ee ee oe Ea AO ee SA A a a ee MOVE 3 Source 22 2 0 Dest N10 8 0 Rung 3 33 DISPLAYS CAL NUMBER FOR CHANNEL 1 ON PANELVIEW ENEE a a pa O au A ee a a EE RA O EE MOVE pE Source 132 1 0 Dest N10 22 0 Rung 3 34 DISPLAYS PEAK TONNAGE FOR CHANNEL 2 AS LONG AS MODULE IS NOT IN SETUP MODE PANELVIEW MODE BUTTON BYPASS N10 20 MOV e a Rung 3 35 DISPLAYS CAL NUMBER FOR CHANNEL 2 ON PANELVIEW MOV 4444411 MOVE Source 132221 0 Dest N10 23 0 Rung 3 36 CH 1 AVERAGE of SAMPLES IN TONS MOV aa SS O ee O Be uu O SS en SO MOVE Source 1 2 51 0 Dest N10 24 0
6. PRE all EE Rung 3 9 COPIES SCALE INFORMATION FROM CH S 1 amp 2 TONNAGE MODULE 1 INTO CH S 3 amp 4 TONNAGE MODULE 2 MONA Seo a SSS ea EEN MOVE Source N10 15 10001 Dest N11 15 10001 te pan ae een oe eee Rung 3 27 DROPS OUT RELAY WHEN THERE IS A TONNAGE FAULT CH S 1 amp 2 CH S 3 amp 4 TOP STOP MODULE MODULE RELAY OR ALARM BIT ALARM BIT E STOP RELAY N10 16 N11 16 0 7 025 2352 a E E A E SA 11 11 0 Rung 3 28 E 555555555555 555555555555 555555555555 555555555555 END Ladder Programming Appendix B Section 4 Rung 3 0 PANELVIEW CH S 1 amp 2 LOW ALARM MODULE INHIBIT LOW INDICATOR INHIBIT ALARM N10 16 0 2 oe 10 6 Rung 3 1 PANELVIEW CH S 1 amp 2 AND CH S MODULE 1 amp 2 MODULE LOOK CAM CYCLE WINDOW BIT SIGNAL N10 21 0 2 SESE E uu aa STR SRS SST aa CQ aii 0 0 Rung 3 2 PANELVIEW CH S 1 amp 2 MODE MODULE BUTTON BYPASS BIT BYPASS N10 20 0 2 SE Se AA AA ag SN ae Rs ST ae PERE RS TT SES OR ge Eee eS a OP Pee ee ee ep RR ISS ca 3 1 Rung 3 3 PANELVIEW CH S 1 amp 2 MODE MODULE BUTTON PEAK MODE PEAK BET N10 20 052 Seog Aa NA CARE 4 2 Rung 3 4 PANELVIEW MODE CH S 1 amp 2 BUTTON MODULE MONITOR MONITOR PARTS PARTS BIT N10 20 0 2 OS SAO PO A A A A gang Jess 5 3 Rung 3 5 PANELVIEW amp CH S 1862 CH S 1 amp 2 REV
7. Parts Mode Bit O e 0 3 Bit Alarm Reset CH 1 amp 2 O e 0 4 Bit Reverse Load CH 1 amp 2 O e 0 5 Bit Low Alarm Inhibit CH 1 amp 2 O e 0 6 Bit Reserved O e 0 7 Bit DO Bit of Sample Count O e 0 8 Bit D1 Bit of Sample Count O e 0 9 Bit D2 Bit of Sample Count O e 0 10 Bit D3 Bit of Sample Count O e 0 11 Bit D4 Bit of Sample Count O e 0 12 Bit Reserved O e 0 13 Bit Reserved O e 0 14 Bit Reserved O e 0 15 Integer Scale Value O e 1 Integer Capacity Low Alarm Setting Channel 1 O e 2 Integer Capacity High Alarm Setting Channel 1 O e 3 Integer Capacity Low Alarm Setting Channel 2 O e 4 Integer Capacity High Alarm Setting Channel 2 O e 5 Integer Trend High Low Alarm Setting Channel 1 O e 6 Integer Trend High Low Alarm Setting Channel 2 O e 7 Page 3 1 Output Image cont Chapter 3 Peak Look Window Bit 0 O 2 0 When set on 1 the look window is active When set off 0 the look window is inactive The module will process data while look window is active Bypass Mode Bit O 2 When set on 1 module is in calibration mode Channels are disabled No alarms are active Only occurs when in Tonnage Calibration Screen Peak Mode Bit O 2 2 When set on 1 module is in setup peak only monitoring mode Capacity alarms are active Alarm Reset Bit O 2 4 When set on 1 alarm reset occurs Alarm condition must be cleared Reverse Load Bit O 2 5 When set on 1 reverse load values are stored l e 1 I e 2 Low Alarm Inhibit Bit 0
8. StrainGage module for processing The Helm Strain Gage is capable of measuring either a tension or compression signal e Sample and Compare Logic processor memorizes the sample or benchmark load StrainGage and compares each machine cycle against this sample Module Features e User programmable Sample Count selectable number of machine cycles on which to base the sample e High and Low Capacity Alarm Sets a discrete load limit for a maximum allowable load and a minimum allowable load e High and Low Trend Alarm Sets set as a percentage of load change on an established sample e Low Alarm Inhibit User programmable option to disable low alarm during process start up Page 1 1 Hardware Overview Chapter 1 The StrainGage module can be attached to the controller or to an adjacent I O module before or after din rail mounting It is a Class 1 module uses eight input words and eight output words It interfaces to strain gage based transducers 3500hm or 700ohm The module can accept input from two sensors The module has no output channels Module configuration reguires manual and user programmable setup The StrainGage module receives and stores digitally converted analog data into its image table for retrieval by processor The module supports connections from any combination of up to two strain gage sensors Any combination of Helm Strain Gage sensors can be used Contact Helm for additional information on the type
9. and application of different sensor options The Helm module reguires 1 input from a cam switch or a proximity sensor for establishing the peak look window Page 1 2 Chapter 1 Hardware Alarm Status Display Fault Status High and Low Door Label Channel 1 Channel 2 calibrate switch Wiring diagram for 2 sensor inputs 2 and 6 Three position switch used for setup Channel Calibrate Switch AZ Auto Zero ON position is the normal run position CAL position calibrate is used with Gain pot to set calibration numbers OFF position is used with Balance pot to zero sensor OFF position turns Auto Zero off 1 and 5 Used to set calibration numbers Set three Channel Gain Potentiometer position switch to CAL setting 4 Jacks for analog or track output of sensor data Recorder Output One jack for each channel Can be jused with chart recorders or Helm Ramcorder data recorder 3 and 7 Used to zero balance the sensor during setup Channel Balance Potentiometer Set three position switch to OFF position Gain Selector ME Used to amplify the sensor input High and Low Cam Jumper Setting Located at Bottom Left Corner of This switch is factory set at high range Under normal operating conditions the setting should not BAER be changed Personnel responsible for the calibration of the Helm StrainGage module Black Jumper
10. for broken or Replace 4 Check for broken or amp run press in die wear collar deformed shear collar wear collar deformed shear collar Page 5 5 Chapter 5 System Trouble shooting Guide contd Erratic readings Yes Check for die Correct problem 4 problem None Yes Check for variation Correct problem lt in stock V None Yes Check for press Correct problem lt problem Page 5 6 Electrical Specifications cal fications nmental fications fications Backplane Current Consumption Appendix A Backplane Power Consumption 10W Number of Channels 2 isolated I O Chassis Location Any I O module slot except 0 A D Conversion Method Successive Approximation 12 bit Normal Mode Rejection between input and input 50 db at 2000 gain AMP roll off frequency 650 Hz at 3000 Gain Calibration Manual Calibration Isolation LED Indicators 500 VDC continuous between inputs and chassis ground and between inputs and backplane 6 LED s for alarm status Module ID Code 3535 Recommended Cable Strain Gage Cable Helm part number 6117 Terminal Strip Operating Temperature 8 pin removable 0 to 60 C 32 F to 140 F Hazardous Environment Classification Type of Input
11. make the determination of the range setting during the calibration process Page 1 3 Getting Started Chapter 2 This chapter can help you to get started using the Helm StrainGage module The procedures included here assume that you have a basic understanding of PLC products You should understand electronic process control and be able to interpret the ladder logic instructions required to generate the electronic signals that control your application Because it is a start up guide this chapter does not contain detailed explanations about the procedures listed It does however reference other chapters in this book where you can get more information about applying the procedures described in each step It also references other SLC documentation that may be helpful if you are unfamiliar with programming techniques or system installation requirements If you have any questions or are unfamiliar with the terms used or concepts presented in the procedural steps always read the referenced chapters and other recommended documentation before trying to apply the information This chapter will tell you what equipment you need explain how to install and wire the module show you how to set channels for the sensor input Required Tools and Equipment Have the following tools and equipment ready small blade screwdriver potentiometer trimmer tweeker appropriate strain gage cable programming equipment All programming examples
12. motion bit Rung 2 1 customer press in press in motion bit motion bit N7 0 N10 21 aaa NA ea aa RS A A RR TE Eege 0 0 2 Resolver or a rotary cam or prox probe a If using resolver map the angle value into N153 0 Rung 2 3 SETS UP CAM WINDOW FOR TONNAGE MODULE PANELVIEW AND CH S 1 amp 2 MODULE CAM CYCLE BIT LIM N10 21 LIMIT TEST 4444444444444 o Low Lim 6001 0 Test N153 0 0 High Lim 2830 Note Centers Signature in look window Ladder Programming Appendix B Section 1 b If using rotary cam or prox probe and it a 1 2 CH system modify rung 2 3 Appendix B Section 2 Rung 2 7 prox probe or rotary cam input 2 4CH system modify rung 3 3 Appendix B Section 3 Rung 2 4 prox probe or rotary cam input des ch s 1 amp 2 ch s 344 cam bit N11 21 NOTE Make sure prox probe or rotary cam is on between 90 to 220 3 Top Stop or E Stop a 2 CH system modify rung 2 13 Appendix B Section 2 for where your top stop or e stop relay is connected Rung 2 5 ch s 1 amp 2 top stop module or e stop alarm bit relay N10 16 0 7 SS aa Ee E 11 0 NOTE Whenever output module is located b 4 CH system modify rung 3 27 Appendix B Section 3 Rung 2 6 ch s 182 ch s 3 amp 4 module Imodule alarm bit alarm bit relay N10 1
13. permission of the Allen Bradley Company and Helm Instrument Company is prohibited Throughout this manual we use note to make you aware of safety considerations ATTENTION Identifies information about practices or circumstances that can lead to property damage Identifies information that is especially important for successful application and understanding of the product Attentions help you e identify a hazard e avoid the hazard e recognize the consequences ATTENTION Please check power supply ratings before proceeding Each tonnage module consumes 24 65 mA 5 150mA Be sure to not overload the power supply PLC PLC2 PLC3 and PLC5 are registered trademarks of the Allen Bradley Company Inc SLC SLC500 PanelView RediPANEL Dataliner are trademarks of Allen Bradley Company Inc IBM is a registered trademark of International Business Machines Incorporated StrainGage is a registered trademark of the Helm In Table of Contents StrainGage Load Module User Manual Table of Contents Strain Gage Module User Manual Eege EE ee Be a A ee ei P 1 Who Should Use this Manual P 1 Purpose of this Manual P 1 Contents of this Manual ooooo oom P 2 Related Documentation sesseeseeeseeeeeeereerreerieerirerrnerrnerrerrrerrenee P 3 Terms and Abbreviatons P 4 Common Techniques Used in this Manual ooooooo P 6 Product SUppont ee NN aan aah P 6 Your Questions or Comments on t
14. 2 14 E gEE ENDF SF 3452 FF FH Ladder Programming Appendix B ES Section 3 Rung 3 0 press in motion bit N10 21 c5 5 222 Paes SS soa SS SSS SRS Sa SSSR SSS SS SSR SSS SS SS ee RES 0 PANELVIEW LOW ALARM INHIBIT INDICATOR N10 16 FF 0 10 Rung 3 1 PANELVIEW AND CH S 1 amp 2 MODULE LOW ALARM CAM CYCLE INHIBIT BET COUNTER N10 21 C5 5 CTU I COUNT UP CU 0 DN Counter C5 5 DN Preset 4 Accum dl Rung 3 2 PANELVIEW LOW ALARM press in INHIBIT motion bit INDICATOR N10 21 C535 N10 16 See a Cams AE AA AA EE 803 kaan 0 DN 10 Rung 3 3 SETS UP CAM WINDOW FOR TONNAGE MODULE PANELVIEW AND CH S 1 2 MODULE CAM CYCLE BIT LIM N10 21 LIMIT TEST SS SSS SSS A FRI TE TI O O a Haan Iran Low Lim 600 0 Test N153 0 124 High Lim 28301 NOTE CENTERS SIGNITURE IN LOOKWINDOW CH S 3 amp 4 MODULE CAM CYCLE BIT N11 21 0 Rung 3 4 PANELVIEW LOW ALARM CH S 3 amp 4 INHIBIT LOW ALARM INDICATOR INHIBIT MAP IN N10 16 0 2 aa AA Ban an aa e e 10 4 Ladder Programming Appendix B Section 3 Rung 3 7 MOVES LOW INHIBIT COUNTS THAT IS ENTERED FROM PANELVIEW INTO PRESET OF THE LOW ALARM INHIBIT COUNTER MOV 5555 2 2 MOVE Source N10 17 all Dest C5 5
15. 2 6 When set on 1 low alarming is disabled for duration Duration set in ladder counter file Machine Capacity Scale Setting Integer Word O 2 1 Represents the total load rating of each load cell The Range of the cells being used are 20 Ton A value must be present to enable module functionality Minimum Load Alarm Setting Channel 1 Integer Word O e 2 Integer value of low capacity alarm setting Range 0 to 9999 A value of O disables alarm Capacity Load Alarm Setting Channel 1 Integer Word O e 3 Integer value of high capacity alarm setting Range 0 to 9999 A value of 0 disables alarm Minimum Load Alarm Setting Channel 2 Integer Word O e 4 Integer value of low capacity alarm setting Range 0 to 9999 A value of O disables alarm Capacity Alarm High Setting Channel 2 Integer Word O e 5 Integer value of low capacity alarm setting Range 0 to 9999 Trend Alarm Channel 1 High and Low Integer Word O e 6 Integer values of high and low trend alarm settings Values are set in percent and represent The maximum and minimum percent of change off the sample value Range 0to 99 A value of 2520 represents a 25 high alarm and a 20 low alarm A value of 0 disables alarm Trend Alarm Channel 2 High and Low Integer Word O e 7 Integer values of high and low trend alarm settings Values are set in percent and represent The maximum and minimum percent of change off the sample value Range 0to 99 A value of 2520 repres
16. 5 3 Chapter 5 System Trouble shooting Guide contd Press not stopped during an alarm condition No ls Is relay jumped out Run press lt q Remove jumper lt q at press controls En Relay should be energized and contacts closed during a no alarm condition Contacts open during power down of unit Y No Replace relay Page 5 4 Chapter 5 System Trouble shooting Guide contd Uneven load distribution WE 3 gt N CH Be KA va Pas oA A A A A S e SC si Es NI Da Tonnage readings HIGH Tonnage readings HIGH Tonnage readings HIGH on diagonal corners on adjacent corners on one corner Broken Out of f Yes 1 Replace 4 Check for broken or Correct a Check the parallelism Remove slug 4 Check for slug build up wear collar deformed shear collar problem parallel of press amp run press in die OK Y Parallel y None Outof Yes Out of Correct 4 Check the parallelism Remove slug 4 Check for slug build up Correct a Check the parallelism problem parallel of press amp run press in die problem parallel of press 1 Parallel Y None Parallel Yes Broken Broken Remove slug 4 Check for slug build up Replace 4 Check
17. 6 N11 16 0 7 153221402522252 ME AA 11 11 NOTE Wherever output module is located top stop or e stop Ladder Programming Appendix B Section 2 Rung 2 0 PRESS IN MOTION BIT N10 21 c5 5 SES E TT EE EE TS EE aa POSO SS EE EE RES 0 PANELVIEW LOW ALARM INHIBIT INDICATOR N10 16 t L 10 Rung 2 1 PANELVIEW AND CH S 1 amp 2 MODULE LOW ALARM CAM CYCLE INHIBIT BIT COUNTER N10 21 C5i5 CTU Sees 1 4 1 gt 5535 55227555542397 59775 COUNT UP CU 0 DN Counter C5 5 DN Preset 4 Accum 1 dee Rung 2 2 PRESS IN PANELVIEW MOTION BIT LOW ALARM INHIBIT INDICATOR N10 21 C5 5 N10 10 Seca 125 Ye ae a er A aa SES aa ON SES 0 DN 10 Rung 2 3 SETS UP CAM WINDOW FOR TONNAGE MODULE PANELVIEW AND CH S 1 2 MODULE CAM CYCLE BIT LIM N10 21 LIMIT TEST a ii di EE EE SE Low Lim 600 0 Test N153 0 ol NOTE CENTERS SIGNITURE IN LOOKWINDOW High Lim 28301 ELECT E Rung 2 4 MOVES LOW ALARM INHIBIT COUNTS ENTERED FROM PANELVIEW INTO THE PRESET OF THE LOW ALARM INHIBIT COUNTER MOV SSS SSeS aS Se Bere me nee nee me ee a eee MOVE Source N10 17 01 Dest C5 5 PRE 4 4 4 Rung 2 13 CAUSES EITHER E STOP OR TOP STOP RELAY TO DROP OUT WHEN THERE IS A TONNAGE FAULT CH S 1 amp 2 E STOP OR MODULE TOP STOP ALARM BIT RELAY N10 16 0 7 Sl re CIR 2 11 0 Rung
18. E PRESS SWITCH PRESS SWITCH CAPACITY SETTING CAPACITY SETTING CAPACITY SETTING If 2 sensors are installed in the tooling rather than on the press structure set the Machine Capacity Scale to the highest load tonnage of one sensor Page 4 2 Chapter 4 Setting Machine Capacity Scale for multiple channel systems Divide the Machine capacity by the number of sensors and set Machine Capacity Scale on all modules to the result Example If 2 load modules are used for monitoring a straight side press with 4 sensors mounted on the press columns set the Machine Capacity Scale on both modules to the highest load tonnage of one sensor Use the following table as a reference for setting the Machine Capacity Scale for a system comprised of 2 force modules and 4 sensors PRESS SWITCH PRESS SWITCH PRESS SWITCH CAPACITY SETTING CAPACITY SETTING CAPACITY SETTING same on all same on all same on all modules modules modules 100 25 125 150 37 175 43 200 250 62 275 68 300 350 87 400 100 450 500 125 800 200 1000 1200 300 Step 5 Set Capacity Alarms This value is a discrete load tonnage value not a percentage NOTE Although the range of values for capacity alarm settings is 0 to 9999 it is recommended that you do not enter values that exceed the capacity rating of the machine press A value of 0 disables capacity alarm set To determine the maximum rating for each channel divide the total machine press capacity by the numb
19. END ALARM N10 16 CH2 HIGH CH2 LOW CH1 HIGH TREND 4 CH1 LOW TREND ALARM N10 16 CH2 HIGH TREND ALARM N10 16 CH2 LOW TREND ALARM N10 16 Ladder Programming Rung 3 20 PANELVIEW TONNAGE FAULT RESET BUTTON N10 21 Rung 3 21 PANELVIEW TONNAGE FAULT RESET BUTTON Rung 3 22 PANELVIEW ALARM RESET BUTTON Rung 3 23 Rung 3 24 Rung 3 25 Appendix B TA Section 4 CH1 HIGH CAPACITY CH1 LOW CAPACITY ALARM N10 16 CH2 HIGH CAPACITY ALARM N10 16 CH2 LOW CAPACITY ALARM N10 16 CH S 1 amp 2 MODULE ALARM RESET BIT 0 2 CH S 1 amp 2 SCALE INFO Source N10 15 01 Dest 0 32 11 01 CH1 LOW CAPACITY ALARM SETTING Source N10 12 01 Dest 022 2 01 CH1 HIGH CAPACITY ALARM SETTING Source N10 11 01 Dest 0 23 01 Ladder Programming esate B Section 4 Rung 3 26 CH2 LOW CAPACITY ALARM SETTING HMONG SSS aaa SS a a 03995797979 MOVE Source N10 14 0 Dest 0 2 4 0 Rung 3 27 CH2 HIGH CAPACITY ALARM SETTING MOVE AR Sn ii E BF FE eS as Se een an MOVE Source N10 13 0 Dest 02 5 0 Rung 3 28 CH 1 TREND DEVIATION IN PERCENT EM SATA te Eeer Eed dee ee ee eebe e ee eegend e ee dee MOVE Source 1 20 31 0 Dest N10 1 0 Rung 3 29 CH 2 TREND DEVIATION IN PERCENT Rung 3 30 MUGS TES Se
20. ERSE MODULE LOAD REV LOAD BUTTON BIT N10 21 0 2 Sera RSS Re SSR aS Se aa TIERES HERE RSS In aa E ente 6 5 Rung 3 6 SAMPLE SETTING MONG EE ER sa ESA EA SA a EI 7 MOVE KS Source N10 18 0 Dest C5 0 PRE 0 do iaeiei Rung 3 7 MODULE 1 PANELVIEW SAMPLE CYCLE MODE COUNTER BIT BUTTON MONITOR PARTS N10 21 N10 20 KAREN RO COUNT DOWN CD 0 5 Counter C5 0 DN Preset OI Accum OI Rung 3 8 PANELVIEW SAMPLE MODE COUNTER BUTTON PEAK N10 20 c5 0 Rung 3 11 CH1 HIGH CAPACITY ALARM BIT T2 Rung 3 12 CH1 LOW CAPACITY ALARM BIT T32 Rung 3 13 CH2 HIGH CAPACITY ALARM BIT LES Rung 3 14 CH2 LOW CAPACITY ALARM BIT I 2 Ladder Programming CURRENT SAMPLE COUNT z O lt i H 1 I H 1 H I H 1 H I I MOVE Source C5 0 ACC 01 Dest N10 19 01 PANELVIEW LEARN CYCLE INDICATOR CHl HIGH CAPACITY ALARM CH1 LOW CAPACITY CH2 HIGH CAPACITY CH2 LOW CAPACITY ALARM Appendix B T Section 4 Ladder Programming Rung 3 15 CH1 HIGH TREND ALARM BIT E32 Rung 3 16 CH1 LOW TREND ALARM BIT 1 2 Rung 3 17 CH2 HIGH TREND ALARM BIT T32 Rung 3 18 CH2 LOW TREND ALARM BIT 132 Rung 3 19 PANELVIEW TONNAGE FAULT RESET BUTTON N10 21 7 4 4 U Appendix B Section 4 CH1 HIGH CH1 LOW TR
21. EW MODE CH S 1 amp 2 BUTTON MODULE MONITOR MONITOR PARTS PARTS BIT N10 20 0 4 eech a ES PS AN ee Se PA An SA Aa TA SA PA AAA SEA SE SAE O Lenka 5 3 The panel function switch in these 3 rungs need to be a button on your operator interface multistate pushbutton with 3 states that writes 3 different values to tag N7 6 1st state 8 bypass 2nd state 16 peak 3rd state 32 monitor parts Page 4 7 Alarm Bits 9 bits used to determine which alarm condition is detected High Capacity and Low Capacity Alarm bits Channel 1 amp Channel 2 Rung 3 8 CH1 HIGH CH1 HIGH CAPACITY CAPACITY ALARM BIT ALARM 1 4 N10 16 o a a a ii sn ee ee aii o 5 1 0 0 CH S 182 MODULE ALARM BIT N10 16 L 11 Rung 3 9 CH1 LOW CH1 LOW CAPACITY CAPACITY ALARM BIT ALARM I 4 N10 16 Sone AA IT hy SS 1 1 CH S 1 amp 2 MODULE ALARM BIT N10 16 L 11 Rung 3 10 CH2 HIGH CH2 HIGH CAPACITY CAPACITY ALARM BIT ALARM 1 4 N10 16 Sena E SRR SS RRS RSS SH SSS HH SH HH 4237 hiss 2 2 CH S 1 amp 2 MODULE ALARM BIT N10 16 PEEL 11 Rung 3 11 CH2 LOW CH2 LOW CAPACITY CAPACITY ALARM BIT ALARM 1 4 N10 16 Se a ia as acia L ES 3 3 CH S 1 amp 2 MODULE ALARM BIT N10 16 L 11 Page 4 8 Chapter 4 Trend High and
22. GAN GREEN BOTH GAN BLACK CH2 SIGNAL WHITE The module can support up to two sensor inputs DO ei e gi 3 NOT attempt to parallel che zen ED L E additional gages as you will cause damage to the module and void product warranty E ae Page 2 2 Chapter 3 Channel This chapter explains how the StrainGage module and the processor communicate Configuration Through the module s input and output image It lists the preliminary setup and operation Data and required before the module can function Status With RS Logic 500 software verify the module ID code Product ID Code 1 Expansion General Configuration Vendor ID 3 Product Type 9 Product Code 1 Series Major Rev Minor Rev B No special I O configuration SPIO CONFIG information is required The module ID code automatically assigns the correct number of input and output words The following memory map shows how the output and input image tables are defined Output Image The 8 word output image output from the CPU to the module contains Information that you configure to define the way a specific channel will work Example If you want to configure channel 2 on the module located in slot 4 in the SLC chassis your address would be O 4 2 o file type element delimiter 4 slot word delimiter 2 word Bit Look Window Signal CH 1 amp 2 O e 0 0 Bit Bypass Mode CH 182 O e 0 1 Bit Peak Mode CH 1 amp 2 O e 0 2 Bit Monitor
23. Low Alarm bits Rung 3 12 CH1 HIGH CHl HIGH TREND TREND ALARM BIT ALARM 1 4 N10 16 a il L 4 4 CH S 1 amp 2 MODULE ALARM BIT N10 16 L 11 Rung 3 13 CH1 LOW CH1 LOW TREND TREND ALARM BIT ALARM I 4 N10 16 a ME AEEA ii L 5 5 CH S 1 amp 2 MODULE ALARM BIT N10 16 Rung 3 14 CH2 HIGH CH2 HIGH TREND TREND ALARM BIT ALARM 1 4 N10 16 Bese a E SSS SS eae IRRE 2 Tah SS te 6 6 CH S 1 amp 2 MODULE ALARM BIT N10 16 11 gt 11 Rung 3 15 CH2 LOW CH2 LOW TREND TREND ALARM BIT ALARM I 4 N10 16 za PES SRS AA SERASA ET ATA AA AA AAA eg RA Aa ai ne ESS ER Sen eee en L 7 7 CH S 1 amp 2 MODULE ALARM BIT N10 16 L 11 Page 4 9 Chapter 4 Machine Top Stop bit Rung 2 13 CAUSES EITHER E STOP OR TOP STOP RELAY TO DROP OUT WHEN THERE IS A TONNAGE FAULT CH S 1 amp 2 E STOP OR MODULE TOP STOP ALARM BIT RELAY N10 16 0 2 EE in TI 0 NOTE Customer mapped in output module Page 4 10 Chapter 4 Low Alarm Inhibit In some processes it may be necessary to inhibit the Low Capacity alarm during machine ramp up Use the following example to set the low alarm inhibit bit based on a counter Rung 3 0 PANELVIEW CH S 1 amp 2 LOW ALARM MODULE INHIBIT LOW INDICATOR INHIBIT ALARM N10 16 0 4 SP Fear aa IT 10 6
24. Rung 2 0 PRESS IN MOTION BIT N10 21 c5 5 22 PSSS 377 IE SEITE SEES IDEE SEHR a Hanser sass SSE RES gt 8 PANELVIEW LOW ALARM INHIBIT INDICATOR N10 16 L 10 NOTE Use N10 21 8 when using Helm s resolver module and Helm s press in motion ladder logic or use customer s own press in motion bit Rung 2 1 PANELVIEW AND CH S 1 amp 2 MODULE LOW ALARM CAM CYCLE INHIBIT BIT COUNTER N10 21 C5 5 KETUA SS Veh aa EE COUNT UP CU 8 DN Counter C5 5 DN Preset 4 Accum 1 Rung 2 2 PRESS IN PANELVIEW MOTION BIT LOW ALARM INHIBIT INDICATOR N10 21 C5 5 N10 16 Saari 555555 LE RRR SRE ESAS SEARS EHE EE EE ee EEE TE Hoana 8 DN 10 Rung 2 4 MOVES LOW ALARM INHIBIT COUNTS ENTERED FROM PANELVIEW INTO THE PRESET OF THE LOW ALARM INHIBIT COUNTER MOV SPSS et SPS Se I EGA ASIA e ee ene oe is ia le AA MOVE Source N10 17 01 Dest C5 5 PRE 4 Fressen Page 4 11 Chapter 4 Peak Look Window The following example details the peak look window requirement Rung 2 3 SETS UP CAM WINDOW FOR TONNAGE MODULE PANELVIEW AND CH S 1 amp 2 MODULE CAM CYCLE BIT FADE ME SSS SAS N10 21 LIMIT TEST Ei ee Fe ee a ae E Ee EP ee Wiesen Low Lim 90 0 Test N153 0 01 High Lim 2201 4 OR Rung 2 7 prox probe or rotary ch s 1 amp 2 cam input c
25. Strain Gage Module Model HM1520 Instruction Manual DECEMBER 2001 Solid state equipment has operational characteristics differing from those Important User of electromechanical equipment Safety Guidelines for the Application Information Installation and Maintenance of Solid State Controls Allen Bradley Publication SGI 1 1 describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will the Allen Bradley Company or Helm Instrument Company be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation the Allen Bradley Company or Helm Instrument Company cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Allen Bradley Company or Helm Instrument Company with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written
26. ad Measurement of negative load force being exerted on machine following the break through of material Also referred to as snap through Sample Load force values established from a series of machine cycles Also defined as benchmark Sample Count User input value used to specify how many machine cycles to base the sample on Sampling time The time required by the A D converter to sample an input channel Scale Value used to describe the press machine overall tonnage Set for maximum value of one channel For example settings for a 150 ton press 75 Setup Mode Status condition of monitor typically enables during die setup Machine capacity alarms are enabled On resolver based systems press curve alarm can be enabled This mode is also used during machine and resolver calibrations Status Word Contains status information about the channel s current configuration and operational state You can use this information in your ladder program to determine whether the channel data word is valid Target Load A reference load established by the user Used primarily during setup to improve setup time Tolerance Trend Alarm User defined upper and lower control limits established during the sample and compare process These limits are established on the peak load and will activate the machine stop relay when exceeded Tracking Alarm Requires resolver input The sample and compare process is applied to the entire forming for
27. am bit 1 4 N10 21 a THE A AA in 0 0 Note Customer mapped in input Input for the Look Window can be obtained from a rotary cam limit switch proximity probe or position resolver N10 21 1 Indicates the machine stop and start status on the Panel This bit is setto 1 ON when a module alarm occurs N10 21 0 Set bit to 1 ON during peak window time clear at other times Page 4 12 System Chapter 5 Trouble shooting Guide Make sure three position switch is in top ON position See diagram page 1 3 HT 400 Sensor Ohm Readings Green Black 350 ohms Red White o o 350 ohms All other color combinations 266 ohms All colors to Ground open Shield to Ground n a aa anaana open Page 5 1 System Trouble shootin Guide contd g Chapter 5 Alarm in Peak Mode Alarm does not reset or remain reset w press stopped 4 Y A Disconnected Check zero balance on all channels Not able to V balance channel s Connect sensor lt Bad readings Broken sensor cable or sensor bad d Check sensor connections at terminal strip y Connected Disconnect sensors and take ohm readings V Good readings Reconnect sensors Channel s balance OK Y Check calibration numbers
28. anelview Screens Shows Panelview Screens and explain their various functions Preface Related Documentation The following documents contain information that may be helpful to you as you use Allen Bradley SLC products To obtain a copy of any of the Allen Bradley documents listed contact your local Allen Bradley office or distributor For Read this Document Document Number An overview for the MicroLogix Programmable Controllers MicroLogix 1500 Programmable Controllers 1764 UM001A US P A description on how to install and use your MicroLogix Programmable Controller MicroLogix 1500 Programmable Controller Base Units Installation Instructions and Wiring Diagrams 1764 INOOTA ML P A description on how to install the processor into the MicroLogix 1500 Base unit MicroLogix 1500 Processor Installation Instructions 1764 IN002A ML P Selecting Discrete Input Output Modules Compact Discrete Input Output Modules Technical Data 1769 2 1 View power usage of expansion modules to determine power supply requirements Expansion Modules System Qualifier RA Website Download End Cap Installation Compact I O End Caps Terminators 1769 5 16 Installation Instructions A complete listing of current Automation Automation Group Publication Index SD499 Group documentation including ordering instructions Also indicates whether the documents are available on CD ROM or in multi languages A gloss
29. ary of industrial automation terms Allen Bradley Industrial Automation ICCG 7 1 and abbreviations Glossary An article on wire sizes and types for grounding electrical equipment National Electrical Code P 3 Published by the National Fire Protection Association of Boston MA Terms and Abbrevia tions The following terms and abbreviations are used throughout this manual For definitions of terms not listed here refer to Allen Bradley s Industrial Automation Glossary Publication ICCG 7 1 Calibration Procedure performed by trained personnel where machine or press is dynamically loaded to impact on load cells A process of linearity measuring to determine the loading capacity of the machine Calibration Number Amplification values established during machine calibration or pre assigned on force load cells Channel Refers to one of two strain gage inputs available on the modules terminal block Chassis A hardware assembly that houses devices such as I O modules adapter modules processor modules and power supplies Configuration Word Contains the channel configuration information needed by the module to configure and operate each channel Information is written to the configuration word through the logic supplied in your ladder program Data Word A 16 bit integer that represent the value of the analog input channel The channel data word is valid only when the channel is enabled Gain Ampli
30. c process control and be able to interpret the ladder logic instructions required to generate the electronic signals that control your application If you do not contact your local Allen Bradley representative for the proper training before using this product This manual is a learning and reference guide for the Helm StrainGage Module It contains the information you need to install wire and use the module P 1 Preface Contents of this Manual Preface Describes the purpose background and scope of this manual Also specifies the audience for whom this manual is intended and defines key terms and abbreviations used throughout this book 1 Overview Provides a hardware and system overview Explains and illustrates the components of the system 2 Installation and Wiring Provides installation information and wiring guidelines Channel Configuration Data Examines the channel configuration and and the channel status word and Status explains how the module uses configuration data and generates status during operation 4 Ladder Programming Examples Gives an example of the ladder logic required to define the channel for operation Also includes representative examples for unique requirements such as sample count trend calculation etc Explains how to interpret and correct problems that occur while using the load module Provides physical electrical Environmental and functional Specifications for the module P
31. ce based on user selected upper and lower control limits Trend Deviation Percent of change high and low from sample value to current value Update Time The time required for the module to sample and convert the input signals of all enables input channels and make the resulting data values available to the SLC processor Preface Common Techniques The following conventions are used throughout this manual Used in this AG Manual e Bulleted lists such as this one provide information not procedural steps Numbered lists provide sequential steps or hierarchical information Product Contact your Helm representative or call Helm direct at 419 893 4356 Support sales and order support product technical training warranty support support service agreements Your Questions or Comments on this Manual If you have any suggestions for how this manual could be made more useful to you please send us your ideas P 6 Chapter 1 Overview You have just purchased the most advanced load monitoring solution available HELM INSTRUMENT COMPANY INC manufactures a complete line of load monitoring control solutions for use on metal stamping forging compaction and assembly presses cold forming cold heating injection molding and die cast machines Standard or custom transducers and load cells are available for in die monitoring of transfer or progressive tooling At HELM quality is inherent not only in the design of our prod
32. e listing of a sample ladder logic program is included at the back of this manual Examples shown here are for reference All values are 0 default on initial start up This means that all alarms are disabled You must make the following adjustments for proper operation set calibration numbers set meter scale set capacity maximum load alarms set minimum load alarms set sample count set trend alarms Steps 2 and 3 require adjustment to the three position toggle switch on the inside panel of the module Step 1 Set the Run mode bit to Bypass From your operator interface put the tonnage module into bypass mode Both the setup and run lights on the tonnage module should be off Rung 3 2 PANELVIEW CH S 1 amp 2 MODE MODULE BUTTON BYPASS BIT BYPASS N10 20 0 4 hmm Lon E E 3 1 NOTE Make sure that only 1 bit is set at any time for Panel Mode integer N10 20 Step 2 Balance Sensor Input 1 Set three position switch to OFF center position 2 Turn balance potentiometer until 0 s are all displayed 3 If two sensors are wired follow this procedure for both channels gt If you are using Helm Panel Software select SET CAL NO on menu Adjust balance pot until O s are displayed Page 4 1 Chapter 4 Step 3 Set Calibration Numbers 1 Set three position switch to calibrate down position 2 Turn Gain Potentiometer to dial in calibration numbers 3 If two sensors a
33. ents a 25 high alarm and a 20 low alarm A value of 0 disables alarm Page 3 2 Chapter 3 Data Table The 8 word module input image input from the module to the CPU represents data Input Image words and status words Input words data words hold the input data that represents the values of the sensor inputs Input words status bits contain the various status conditions and reflect the configuration settings you have entered into the output configuration words To obtain the status of Channel 2 Capacity Alarm Bit of the module located in slot 2 of the rack use address 1 2 I filetype element delimiter 2 slot word delimiter 0 word 2 bit Bit Channel 1 High Capacity Alarm Bit l e 0 0 Bit Channel 1 Low Capacity Alarm Bit l e 0 1 Bit Channel 2 High Capacity Alarm Bit l e 0 2 Bit Channel 2 Low Capacity Alarm Bit l e 0 3 Bit Channel 1 Trend High Alarm Bit l e 0 4 Bit Channel 1 Trend Low Alarm Bit l e 0 5 Bit Channel 2 Trend High Alarm Bit l e 0 6 Bit Channel 2 Trend Low Alarm Bit 1 e 0 7 Bit Learn Cycle Indicator Bit l e 0 9 Integer Channel 1 Load Value Lei Integer Channel 2 Load Value l e 2 Integer Channel 1 Deviation value in Percent l e 3 Integer Channel 2 Deviation value in Percent l e 4 Integer Channel 1 Sample value in Ton l e 5 Integer Channel 2 Sample value in Ton l e 6 Integer Sample Count l e 7 Channel 1 High Capacity Alarm Bit When on 1 channel 1 load has met or exceeded the high alarm limit Load values are st
34. er of sensor inputs EXAMPLE A press or slide rated at 100 tons with a 2 channel force module would have a capacity alarm setting of 50 tons per sensor input This setting differs from the Scale setting as it can be adjusted up or down depending on the nature of the process The recommended maximum value is 195 of Machine Capacity Scale Rung 3 23 CH1 HIGH CAPACITY ALARM SETTING MOM TETE Se ne AE ii me een een RSS AA se MOVE Source N10 11 01 Dest 0 4 3 01 Page 4 3 Chapter 4 Step 6 Set Minimum Low Alarm This value is a discrete load tonnage value not a percentage The range of this value is 0 to 9999 A value of 0 disables Minimum Low Alarm Use a value here that represents a minimum load tonnage that is acceptable for the process Use this alarm setting when running in Peak Mode to alarm against low load tonnage hits Rung 3 22 CH1 LOW CAPACITY ALARM SETTING FMOVS 222 OSOS lia MOVE Source N10 13 01 Dest 0 4 2 01 Page 4 4 Chapter 4 Step 7 Set Sample Count The sample count is a user programmable parameter that tells the processor how many machine strokes are required to establish sample or benchmark load values The value can range from 0 to 16 A value of 0 invalidates the Monitor Parts mode You should set Sample Count to a minimum of 1 to enable Monitor Parts mode Note Each time you change Monit
35. esrnesrnerrnnennnennsrnnsrnne 4 3 Step 6 Set Minimum Low Alarm oo WWW 4 4 Step 7 Set Sample Count AE 4 5 Step 8 Set Trend Alarms ooooooooWoooWo oo Woman 4 6 e Set High and Low Trend Alarm Channel 1 4 6 e Set High and Low Trend Alarm Channel 2 4 7 Additional Application Notes AA 4 8 Mode Status cunda 4 8 Bypass MOde ha an maa nia an nan inn 4 8 Peak Mode sai sentuh Laba Besa nanas 4 8 Monitor Parts Mode o Woman 4 8 High Capacity and Low Minimum Alarm bits Channel 1 amp 2 4 10 Trend High and Low Alarm bits ooooooooa 4 11 Machine Top Stop bit oooroo oo 4 12 Low Alarm INhibit anna anakan 4 13 Peak Look Window er 4 14 System Chapter de ia 5 1 Trouble Shooting HT 400 Sensor Ohm Reading oooooooooo 5 1 Guide Block Diagrams cuota ld 5 2 Preface Who Should Use this Manual Purpose of This Manual Preface Read this preface to familiarize yourself with the rest of this manual This preface covers the following topics who should use this manual the purpose of this manual terms and abbreviations conventions used in this manual Allen Bradley support Use this manual if you are responsible for the design installation programming or maintenance of an automation control system that used Allen Bradley small logic controllers You should have a basic understanding of SLC 500 products You should understand electroni
36. fication of an input signal Load Force Measurement of impact during a machine cycle Sensors provide the input for this measurement Look Window Resolver or cam activated window which allows specific degrees in a machine cycle to be processed Low Alarm Inhibit Number of consecutive machine cycles where low alarm is inhibited Used in a process where machine cycles several times before running speed is established LSB Least Significant Bit Refers to a data increment defined as the full scale range divided by the resolution The bit that represents the smallest value within a string of bits Monitor Parts Mode Status condition used during production run Sample and compare logic is enabled On resolver based systems tracking alarm limits can be enabled Multiplexer A switching system that allows several input signals to share a common A D converter Remote Configuration A control system where the chassis can be located several thousand feet from the processor chassis Terms and Abbrevia tions continued Preface Resolution The smallest detectable change in a measurement typically expressed in engineering units e g 0 15C or as a number of bits For example a 12 bit system has 4 096 possible output states It can therefore measure 1 part in 4096 Resolver Sometimes called encoder Device attached on a machine to determine stroke position Sine cosine based resolver required for Helm systems Reverse Lo
37. his Manual P 6 Overview A an nana 1 1 Trend Components u s 1 1 Strain Gain Transducer Operation oooooooWo 1 1 PERU nn nev es ee e 1 1 Hardware Overview oooooo Woo oo Woman 1 2 Hardware Features ooWo o Wo momen 1 3 Getting Started Chapter ain an aa ena aah 2 1 Geting Sa Ce EE 2 1 Required Tools and Equipment ooooooWoooo 2 1 System Operation 4 na daan an an naa inai 2 2 Sensor WING ade catatan aa uan 2 2 Chapter 3 Sioa a IR aa 3 1 Channel Channel Configuration Data and Status ooo 3 1 Configuration Module Addressing oooWoo omoW oma 3 1 Data and Status Module Configuration oooo o oo 3 1 Data Table Memory Map ooooo Woo oom oom 3 1 Output Image aiii adas 3 1 Input Image aa Aa ma ana an 3 3 a 3 5 Table of Contents StrainGage Load Module User Manual Initial Setup Chapter A 4 1 Procedures E Initial Setup Procedures AAA 4 1 Step 1 Set the Run mode bit to Bypass o ooooo 4 1 Step 2 Balance Sensor Input 4 1 Step 3 Set Calibration Numbers ooooooc 4 2 Step 4 Set Machine Capacity Cycle ooooo 4 2 e Setting Machine Capacity Scale using 1 two Channel force module sssesseeeeseeeseereeerreerieerrerrieernees 4 2 e Setting Machine Capacity Scale for multiple channel svsiems 4 3 Step 5 Set Capacity Alamms sssesseeseessnesrnesrr
38. nel A sample of 30 tons is calculated for channel 1 and a sample of 40 tons is calculated for channel 2 If any succeeding machine stroke develops tonnage of 33 10 of 30 3 tons or higher on channel 1 the High Trend Alarm is reached and the alarm bit is turned ON If tonnage falls to 27 the Low Trend Alarm set is reached and the alarm bit is turned ON You have completed the basic setup and the module is operational Page 4 6 Additi Chapter 4 onal Application Notes Mode Status The three modes are Bypass Peak Monitor Parts Bypass Mode Used for module setup and at the time of calibration All alarms are disabled in bypass mode Rung 3 2 PANELVIEW CH S 182 MODE MODULE BUTTON BYPASS BIT BYPASS N10 20 0 4 Il Der A S TC js 3 1 Peak Mode In Peak Mode operation the high capacity alarms and the low minimum alarms are active There is no sample calculation and high and low Trend alarms are inactive This mode is used primarily during machine setup operations Rung 3 3 PANELVIEW CH S 162 MODE MODULE BUTTON PEAK MODE PEAK BIT N10 20 0 4 Karel ass ET ee EE Fe A AA ANA E urn Bene 4 2 Monitor Parts Mode When Monitor Parts Mode bit is turned ON the sample is calculated based on the number of sample counts and the high and low Trend alarms are activated The High Capacity and Low Minimum Alarms remain active Rung 3 4 PANELVI
39. or Parts mode bit from ON to OFF the sample value is cleared During normal operations Monitor Parts mode is enabled when beginning a process run If the process varies due to change in material thickness for example it may be necessary to take a new sample Rung 3 34 DO BIT OF PANELVIEW SAMPLE ENTRY COUNT N10 18 0 4 Seas Weer a Sm ae EE EE IRE 0 8 Rung 3 35 D1 BIT OF PANELVIEW SAMPLE ENTRY COUNT N10 18 0 4 PRR Rane ssa a AA an SS TS SSS STR nennen ne KE Zo 1 9 Rung 3 36 D2 BIT OF PANELVIEW SAMPLE ENTRY COUNT N10 18 0 4 ee A aa NGA Ser 2 10 Rung 3 37 D3 BIT OF PANELVIEW SAMPLE ENTRY COUNT N10 18 0 4 seem aa a E RS PS 3 11 Rung 3 38 D4 BIT OF PANELVIEW SAMPLE ENTRY COUNT N10 18 0 4 Era e EE EE S 4 12 Page 4 5 Chapter 4 Step 8 Set Trend Alarms The Trend Alarm settings are established as a percentage of allowable change in load These percentages are applied to the sample load values There is a High Trend Alarm set and a Low Trend Alarm set for each channel The limits can range from 0 to 99 A setting of 0 disables the alarm These alarms are active when the Monitor Parts Mode bit is ON When monitor parts mode is enabled the sample process takes place Example Monitor Parts mode is enabled with a sample count of 4 and high and low Trend Alarms set at 10 The load generated on the next 4 machine cycles is averaged to obtain the sample value for each chan
40. ored at integer word l e 1 Channel 1 Low Capacity Alarm Bit When on 1 channel 1 load has met or dropped below the low alarm limit Load values are stored at integer word l e 1 Channel 2 High Capacity Alarm Bit When on 1 channel 2 load has met or exceeded the high alarm limit Load value is stored at integer word I e 2 Channel 2 Low Capacity Alarm Bit When on 1 channel 2 load has met or dropped below the low alarm limit Load value is stored at integer word I e 2 Page 3 3 Chapter 3 Channel 1 High Trend Alarm Bit When on 1 channel 1 load has met or exceeded the high alarm percentage of sample Load values are stored at integer word I e 1 Percent of deviation of sample is stored at integer word I e 5 Percent of deviation of sample is stored at integer word I e 5 Channel 1 Low Trend Alarm Bit When on 1 channel 1 load has met or dropped below the low alarm percentage of sample Load values are stored at integer word I e 1 Percent of deviation of sample is stored at integer word I e 5 Channel 2 High Trend Alarm Bit When on 1 channel 2 load has met or exceeded the high alarm limit Load value is stored at integer word I e 2 Percent of deviation of sample is stored at integer word I e 6 Channel 2 Low Trend Alarm Bit When on 1 channel 2 load has met or dropped below the low alarm percentage of sample Load value is stored at integer word I e 2 Percent of deviation of sample is stored at integer word I e 6
41. re wired follow this procedure for both channels gt If you are using Helm Panel Software select the SET CAL NO Menu Adjust gain balance pot until calibration numbers are correct for channel 1 and channel 2 Always make sure that the three position switch is in ON top position for Normal operation The remaining setup procedures can be accomplished with the Run Mode bit in either Bypass Peak or Monitor Parts Mode However the Bypass Mode should only be used when setting calibration values or zero balancing the sensor input Step 4 Set Machine Capacity Scale The three position switch should be placed in the ON top position This setting is based off of one channel It represents the maximum allowable load or tonnage from one sensor location Integer N10 14 should be set from your operator interface Rung 3 21 CH S 1 amp 2 SCALE INFO MOV 22 MOVE DEI Source N10 15 O Dest 0 4 1 Oli PS DA AA Ea Setting Machine Capacity Scale using 1 two channel force module If 2 sensors are installed on the left and right sides of a 60 ton press set the Scale to 30 maximum capacity of one sensor Use the following table as a reference for setting the Machine Capacity Scale for a single force module installation with two sensors Divide the press machine capacity by the number of sensors 2 and set Scale to the result PRESS SCAL
42. shown in this manual demonstrate the use of Allen Bradley s RS Logix 500 Page 2 1 Chapter 2 System The StrainGage module communicates to the processor through the parallel Operation backplane interface and receives 5Vdc and 24Vdc power from the power supply through the backplane No external power supply is required The MicroLogix and CompactLogix platforms can support up to 8 I O modules You may install up to 3 StrainGage modules using the base power supply An additional power supply can be added to support more than 3 modules Refer to publication 17864 UM100A US P for information on expansion power supply systems Each individual channel on the module can receive input signals from strain gage based sensors The module converts the analog values directly into digital values Sensor The sensors are wired to the modules using the rightmost bank of inputs Wiring The pin out is shown below CH 1 SIGNAL WHITE CH 1 NOISE DRAIN SHIELD CH 1 SIGNAL RED BOTH GAGE BLACK BOTH GAGE GREEN CH 2 SIGNAL WHITE CH 2 NOISE DRAIN SHIELD CH2 SIGNAL RED 2220000 To ensure proper operation and high immunity to electrical noise always use Helm strain gage cable POWER O ALARM O TONNAGE To limit noise keep strain gage cable as INPUT MODULE far away as possible from power and load lines CHI SIGNAL CH SHIELD CHI SIGNAL RED BOTH
43. tting N10 3 Integer Channel 1 High Trend Alarm Setting N10 4 Integer Channel 2 Low Trend Alarm Setting N10 5 Integer Channel 2 High Trend Alarm Setting N10 6 Integer 256 Multiply register N10 7 Integer Channel 1 Peak Value in Tons N10 8 Integer Channel 2 Peak Value in Tons N10 9 Integer Channel 1 High Capacity Alarm Setting N10 11 Integer Channel 1 Low Capacity Alarm Setting N10 12 Integer Channel 2 High Capacity Alarm Setting N10 13 Integer Channel 2 Low Capacity Alarm Setting N10 14 Integer Scale N10 15 Bit Channel 1 High Capacity Alarm N10 16 0 Bit Channel 1 Low Capacity Alarm N10 16 1 Bit Channel 2 High Capacity Alarm N10 16 2 Bit Channel 2 Low Capacity Alarm N10 16 3 Bit Channel 1 High Trend Alarm N10 16 4 Bit Channel 1 Low Trend Alarm N10 16 5 Bit Channel 2 High Trend Alarm N10 16 6 Bit Channel 2 Low Trend Alarm N10 16 7 Bit Learn Cycle Bit N10 16 9 Bit Low Alarm Inhibit Bit N10 16 10 Bit Alarm Indication Bit Module Alarm Bit N10 16 11 Integer Low Alarm Inhibit Cycle Count N10 17 Integer Samples set from 1 to 16 N10 18 Integer Current Running Sample Counter N10 19 Integer Mode Status Value N10 20 Bit Cam Cycle Bit N10 21 0 Bit Start Stop Indicator Bit N10 21 1 Bit Reverse Load Bit N10 21 6 Bit Alarm Reset Bit N10 21 7 Integer Channel 1 Calibration Value N10 22 Integer Channel 2 Calibration Value N10 23 Integer Channel 1 Sample Peak in Tons N10 24 Integer Channel 2 Sample Peak in Tons N10 25 Page 3 5 Chapter 4 A complet
44. ucts but in the attitudes of our employees as well We re working together to give you the best After all that s what our business is all about providing innovative instrumentation to help make your manufacturing process more productive and your operation more effective The Helm StrainGage combines machine and tooling monitoring with programmable limit switch function User programmable high and low limits protect the machine and tooling to ensure part quality Critical setup information can be stored and uploaded as part of a die recipe program An optional resolver input module is used to compare machine press tonnage to crank angle for real time signature analysis Components The Helm StrainGage module is attached to the controller or to an adjacent I O module on the din rail The system is comprised of two parts the input module and two Helm Strain gage based sensors Strain Gain The primary part of the load monitoring system centers around the measurement Transducer The basic function of the Helm Strain Gain sensor is to detect the amount of Operation deflection imposed on the press or die as parts are being formed All Strain Gain sensors are matched to within 1 and therefore can be replaced without recalibration of the machine The Helm Strain Gain sensors can be mounted to strategic high stress areas of the machine frame or strategically located in tooling or applied to stop blocks Signals from these sensors are routed to the
Download Pdf Manuals
Related Search