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Preface

Terms and
Abbrevia-
tions
(continued)

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 Load -

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 force 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.

P-5

Содержание HM1520

Страница 1: ...Strain Gage Input Module Model HM1520 Instruction Manual Revised 9 21 2008...

Страница 2: ...ibility 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 eq...

Страница 3: ...r Questions or Comments on this Manual P 6 Chapter 1 1 1 Trend Components 1 1 Strain Gain Transducer Operation 1 1 Features 1 1 Hardware Overview 1 2 Hardware Features 1 3 Chapter 2 2 1 Getting Starte...

Страница 4: ...annel systems 4 3 Step 5 Set Capacity Alarms 4 3 Step 6 Set Minimum Low Alarm 4 4 Step 7 Set Sample Count 4 5 Step 8 Set Trend Alarms 4 6 Set High and Low Trend Alarm Channel 1 4 6 Set High and Low Tr...

Страница 5: ...Table of Contents StrainGage Load Module User Manual Appendix Specifications Appendix A Ladder Program Appendix B Setting Up HM1520 Module for CompactLogix Appendix C...

Страница 6: ...ation control system that used Allen Bradley small logic controllers You should have a basic understanding of SLC 500 products You should understand electronic process control and be able to interpret...

Страница 7: ...mines the channel configuration and the channel status word and explains how the module uses configuration data and generates status during operation 4 Ladder Programming Examples Gives an example of...

Страница 8: ...icroLogix 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...

Страница 9: ...n 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 Amplification of an input sig...

Страница 10: ...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...

Страница 11: ...ts provide sequential steps or hierarchical information Product Support Contact your Helm representative or call Helm direct at 419 893 4356 sales and order support product technical training warranty...

Страница 12: ...ule 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 Transducer Opera...

Страница 13: ...requires 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 fr...

Страница 14: ...n turns Auto Zero off 1 and 5 Channel Gain Potentiometer Used to set calibration numbers Set three position switch to CAL setting 4 Recorder Output Jacks for analog or track output of sensor data One...

Страница 15: ...ach 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 unfamilia...

Страница 16: ...channel on the module can receive input signals from strain gage based sensors The module converts the analog values directly into digital values Sensor Wiring The sensors are wired to the modules usi...

Страница 17: ...ode CH 1 2 O e 0 1 Bit Peak Mode CH 1 2 O e 0 2 Bit Monitor Parts Mode Bit O e 0 3 Bit Alarm Reset CH 1 2 O e 0 4 Bit Reverse Load CH 1 2 O e 0 5 Bit Low Alarm Inhibit CH 1 2 O e 0 6 Bit Reserved O e...

Страница 18: ...r 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 settin...

Страница 19: ...Bit I e 0 5 Bit Channel 2 Trend High Alarm Bit I e 0 6 Bit Channel 2 Trend Low Alarm Bit I e 0 7 Bit Learn Cycle Indicator Bit I e 0 9 Integer Channel 1 Load Value I e 1 Integer Channel 2 Load Value I...

Страница 20: ...t of deviation of sample is stored at integer word I e 6 Channel 1 Load Value I e 1 Integer word represents peak load on channel 1 for current machine cycle If Reverse Bit O e 0 5 is on 1 value is rev...

Страница 21: ...tting 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 A...

Страница 22: ...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...

Страница 23: ...tion 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 2...

Страница 24: ...68 300 75 350 87 400 100 450 112 500 125 800 200 1000 250 1200 300 Chapter 4 Step 5 Set Capacity Alarms This value is a discrete load tonnage value not a percentage NOTE Although the range of values...

Страница 25: ...e 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 al...

Страница 26: ...arts 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 f...

Страница 27: ...es 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 f...

Страница 28: ...ly during machine setup operations Rung 3 3 PANELVIEW CH S 1 2 MODE MODULE BUTTON PEAK MODE PEAK BIT N10 20 O 4 4 2 Monitor Parts Mode When Monitor Parts Mode bit is turned ON the sample is calculated...

Страница 29: ...N10 16 L 0 0 CH S 1 2 MODULE ALARM BIT N10 16 L 11 Rung 3 9 CH1 LOW CH1 LOW CAPACITY CAPACITY ALARM BIT ALARM I 4 N10 16 L 1 1 CH S 1 2 MODULE ALARM BIT N10 16 L 11 Rung 3 10 CH2 HIGH CH2 HIGH CAPACI...

Страница 30: ...6 L 11 Rung 3 13 CH1 LOW CH1 LOW TREND TREND ALARM BIT ALARM I 4 N10 16 L 5 5 CH S 1 2 MODULE ALARM BIT N10 16 L 11 Rung 3 14 CH2 HIGH CH2 HIGH TREND TREND ALARM BIT ALARM I 4 N10 16 L 6 6 CH S 1 2 MO...

Страница 31: ...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 2 E STOP OR MODULE TOP STOP ALARM BIT RELAY N10 16 O 2 11 0 NOTE Customer mapped in outpu...

Страница 32: ...NHIBIT INDICATOR N10 16 L NOTE Use N10 21 8 when using Helm s resolver module and Helm s press in motion ladder logic 10 or use customer s own press in motion bit Rung 2 1 PANELVIEW AND CH S 1 2 MODUL...

Страница 33: ...0 High Lim 220 OR Rung 2 7 prox probe or rotary ch s 1 2 cam input cam bit I 4 N10 21 0 0 Note Customer mapped in input Input for the Look Window can be obtained from a rotary cam limit switch proxim...

Страница 34: ...e 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 350 ohms All other color combinations 266 ohms All colors to Grou...

Страница 35: ...move slug and cable short Intermittent sensor overload condition Intermittent press parallelism Check press press or die damage collar linkage or other Check for broken shear in die Check for slug bui...

Страница 36: ...ce alarm fired No alarm None No Yes Yes Correct problem run press Remove slug and press or die damage collar linkage or other Check for broken shear in die Check for slug build up Alarm does reset wit...

Страница 37: ...of unit Contacts open during power Yes Remove jumper Run press a no alarm condition and contacts closed during Relay should be energized No No No Is relay jumped out at press controls Replace relay du...

Страница 38: ...Out of problem Correct deformed shear collar Check for broken or Broken wear collar Replace deformed shear collar Check for broken or Broken wear collar Replace Tonnage readings HIGH on adjacent corne...

Страница 39: ...5 System Trouble shooting Guide contd None Check for press problem Yes Correct problem Correct problem Correct problem Yes None Yes in stock Check for variation problem Check for die Erratic readings...

Страница 40: ...tion 500 VDC continuous between inputs and chassis ground and between inputs and backplane LED Indicators 6 LED s for alarm status Module ID Code 3535 Recommended Cable Strain Gage Cable Helm part num...

Страница 41: ...Ex 2 tonnage modules 2 files each with a different integer table and different I O addresses Note 1 For 2 channel system use ladder in sections 2 4 2 For 4 channel system use ladder in sections 3 and...

Страница 42: ...on bit N12 0 N10 21 4 0 b If you have your own press in motion bit Rung 2 1 customer press in press in motion bit motion bit N7 0 N10 21 0 0 2 Resolver or a rotary cam or prox probe a If using resolve...

Страница 43: ...4 cam bit N11 21 0 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...

Страница 44: ...21 C5 5 N10 10 U 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 Low Lim 600 0 Test N153 0 0 NOTE CENTERS SIGNITURE IN LOOKWIN...

Страница 45: ...5 DN Preset 4 Accum 1 Rung 3 2 PANELVIEW LOW ALARM press in INHIBIT motion bit INDICATOR N10 21 C5 5 N10 16 U 0 DN 10 Rung 3 3 SETS UP CAM WINDOW FOR TONNAGE MODULE PANELVIEW AND CH S 1 2 MODULE CAM...

Страница 46: ...ource N10 17 4 Dest C5 5 PRE 4 Rung 3 9 COPIES SCALE INFORMATION FROM CH S 1 2 TONNAGE MODULE 1 INTO CH S 3 4 TONNAGE MODULE 2 MOV MOVE Source N10 15 1000 Dest N11 15 1000 Rung 3 27 DROPS OUT RELAY WH...

Страница 47: ...1 2 MODE MODULE BUTTON PEAK MODE PEAK BIT N10 20 O 2 4 2 Rung 3 4 PANELVIEW MODE CH S 1 2 BUTTON MODULE MONITOR MONITOR PARTS PARTS BIT N10 20 O 2 5 3 Rung 3 5 PANELVIEW CH S 1 2 CH S 1 2 REVERSE MOD...

Страница 48: ...BIT ALARM I 2 N10 16 L 0 0 CH S 1 2 MODULE ALARM BIT N10 16 L 11 Rung 3 12 CH1 LOW CH1 LOW CAPACITY CAPACITY ALARM BIT ALARM I 2 N10 16 L 1 1 CH S 1 2 MODULE ALARM BIT N10 16 L 11 Rung 3 13 CH2 HIGH C...

Страница 49: ...E ALARM BIT N10 16 L 11 Rung 3 17 CH2 HIGH CH2 HIGH TREND TREND ALARM BIT ALARM I 2 N10 16 L 6 6 CH S 1 2 MODULE ALARM BIT N10 16 L 11 Rung 3 18 CH2 LOW CH2 LOW TREND TREND ALARM BIT ALARM I 2 N10 16...

Страница 50: ...N10 16 U 3 Rung 3 21 PANELVIEW TONNAGE CH S 1 2 FAULT MODULE RESET ALARM BUTTON RESET BIT N10 21 O 2 7 4 Rung 3 22 PANELVIEW ALARM RESET MODULE 1 BUTTON ALARM BIT N10 21 N10 16 c U 7 11 Rung 3 23 CH S...

Страница 51: ...OV MOVE Source N10 13 0 Dest O 2 5 0 Rung 3 28 CH 1 TREND DEVIATION IN PERCENT MOV MOVE Source I 2 3 0 Dest N10 1 0 Rung 3 29 CH 2 TREND DEVIATION IN PERCENT MOV MOVE Source I 2 4 0 Dest N10 2 0 Rung...

Страница 52: ...2 1 0 Dest N10 8 0 Rung 3 33 DISPLAYS CAL NUMBER FOR CHANNEL 1 ON PANELVIEW MOV MOVE Source I 2 1 0 Dest N10 22 0 Rung 3 34 DISPLAYS PEAK TONNAGE FOR CHANNEL 2 AS LONG AS MODULE IS NOT IN SETUP MODE P...

Страница 53: ...ANELVIEW SAMPLE ENTRY COUNT N10 18 O 2 0 8 Rung 3 39 D1 BIT OF PANELVIEW SAMPLE ENTRY COUNT N10 18 O 2 1 9 Rung 3 40 D2 BIT OF PANELVIEW SAMPLE ENTRY COUNT N10 18 O 2 2 10 Rung 3 41 D3 BIT OF PANELVIE...

Страница 54: ...Tags for RSLogix 5000 INPUT IMAGE DATA TAGS Data Tags Local x I Data Type Bit Description Data 0 BIT 0 1 2 3 4 5 6 7 8 9 Channel 1 High Capacity Alarm Indication Bit Channel 1 Low Capacity Alarm Indi...

Страница 55: ...Count D1 Bit Sample Count D2 Bit Sample Count D3 Bit Sample Count D4 Bit Data 1 INT Set Scale Value Data 2 INT Set Channel 1 Low Capacity Alarm Value Data 3 INT Set Channel 1 High Capacity Alarm Valu...

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