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Helm HM1520 Instruction Manual

Strain gage input module
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Strain Gage Input Module
Model HM1520
Instruction Manual
Revised : 9/21/2008

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  • Page 1 Strain Gage Input Module Model HM1520 Instruction Manual Revised : 9/21/2008...
  • Page 2 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 Instrument Company, Inc.

  • Page 3: Table Of Contents

    Table of Contents StrainGage Load Module User Manual Table of Contents Strain Gage Module User Manual Preface ....................P-1 Who Should Use this Manual............P-1 Purpose of this Manual ..............P-1 Contents of this Manual ..............P-2 Related Documentation ..............P-3 Terms and Abbreviations ..............P-4 Common Techniques Used in this Manual ........P-6 Product Support .................P-6 Your Questions or Comments on this Manual ......P-6...
  • Page 4 Table of Contents StrainGage Load Module User Manual Initial Setup Procedures Chapter 4 ....................4-1 Initial Setup Procedures..............4-1 Step 1. Set the Run mode bit to Bypass ........4-1 Step 2. Balance Sensor Input ............4-1 Step 3. Set Calibration Numbers ..........4-2 Step 4.
  • Page 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...

  • Page 6: Preface

    If you do not, contact your local Allen-Bradley representative for the proper training before using this product. Purpose of 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. This Manual...

  • Page 7: Contents Of This Manual

    Preface Contents of this Manual Chapter Title Content 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. Provides a hardware and system Overview overview.

  • Page 8: Related Documentation

    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. Read this Document Document Number An overview for the MicroLogix...

  • Page 9: Terms And Abbreviations

    Preface 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.
  • Page 10 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.

  • Page 11: Common Techniques Used In This Manual

    Bulleted lists such as this one provide information, not procedural steps. Manual • 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 •...

  • Page 12: Overview

    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 products but in the attitudes of our employees as well. We’re working together to give you the best.

  • Page 13: Hardware Overview

    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 and application of different sensor options.

  • Page 14: Hardware Features

    CAL setting. Jacks for analog or track output of sensor data. Recorder Output One jack for each channel. Can be used with chart recorders or Helm Ramcorder™ data recorder. 3. and 7. Used to zero balance the sensor during setup.

  • Page 15: Getting Started

    Chapter Getting This chapter can help you to get started using the Helm StrainGage Started 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.

  • Page 16: System Operation

    (CH2) – SIGNAL (RED) To ensure proper operation high immunity electrical noise, always use Helm strain gage cable. To limit noise, keep strain gage cable as far away as possible from power and load lines. The module can support up...

  • Page 17: Channel Configuration, Data And Status

    Chapter Channel This chapter explains how the StrainGage module and the processor communicate. Configuration For CompactLogix configuration, please refer to Appendix C – Setting Up HM1520 for Data and CompactLogix Status 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.

  • Page 18: Output Image

    Output Chapter Image (cont.) 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.

  • Page 19: Input Image

    Chapter Data Table The 8-word module input image (input from the module to the CPU) represents data words and status words. Input words (data words) hold the input data that represents Input Image 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.
  • Page 20 Chapter 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.

  • Page 21: Integer File

    Chapter 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 nteger Channel 1 Trend Deviation in percent N10:1 Integer Channel 2 Trend Deviation in percent...

  • Page 22: Step 1. Set The Run Mode Bit To Bypass

    2. Turn balance potentiometer until 0’s are all displayed. 3. If two sensors are wired, follow this procedure for both channels. ⇒ If you are using Helm Panel Software select SET CAL NO. on menu. Adjust balance pot until 0’s are displayed. Page 4-1...

  • Page 23: Step 4. Set Machine Capacity Cycle

    3. If two sensors are wired, follow this procedure for both channels. ⇒ 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.

  • Page 24: Setting Machine Capacity Scale For Multiple

    Chapter 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.

  • Page 25: Step 6. Set Minimum Low Alarm

    Chapter 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.

  • Page 26: Step 7. Set Sample Count

    Chapter 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.

  • Page 27: Step 8. Set Trend Alarms

    Chapter 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.

  • Page 28: Additional Application Notes

    Chapter Additional 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 1&2 | MODE MODULE | BUTTON...
  • Page 29 Chapter Alarm Bits - 9 bits used to determine which alarm condition is detected. High Capacity and Low Capacity Alarm bits - Channel 1 & Channel 2 Rung 3:8 | CH1 HIGH CH1 HIGH | CAPACITY CAPACITY | ALARM BIT ALARM N10:16 |----] [--------------------------------------------------------------------------------------------------------+----(L)-----+-|...

  • Page 30: Trend High And Low Alarm Bits

    Chapter Trend High and Low Alarm bits Rung 3:12 | CH1 HIGH CH1 HIGH | TREND TREND | ALARM BIT ALARM N10:16 |----] [--------------------------------------------------------------------------------------------------------+----(L)-----+-| | CH'S 1&2 | MODULE | ALARM BIT N10:16 +----(L)-----+ | Rung 3:13 | CH1 LOW CH1 LOW | TREND TREND...

  • Page 31: Machine \ Top Stop Bit

    Chapter 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&2 E-STOP OR | MODULE TOP STOP | ALARM BIT | RELAY N10:16 |----]/[---------------------------------------------------------------------------------------------------------------( )-----| NOTE: Customer mapped in output module.

  • Page 32: Low Alarm Inhibit

    | LOW ALARM | INHIBIT | INDICATOR N10:16 +----(L)-----+ | 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&2 MODULE...

  • Page 33: Peak Look Window

    Chapter 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&2 MODULE | CAM CYCLE | +LIM---------------+ N10:21 |-+LIMIT TEST +-------------------------------------------------------------------------------------------------( )-----| | |Low Lim | |Test N153:0| | |High Lim...
  • Page 34 Chapter System 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 .
  • Page 35 System Chapter Trouble- shooting Guide (contd.) Alarm in Peak Mode Alarm does not reset Alarm can be reset or remain reset w/ and remains cleared press stopped with press stopped Check zero balance Does alarm fire again Intermittent press on all channels with press running overload condition Not able to...
  • Page 36 System Chapter Trouble- shooting Guide (contd.) Alarm in Monitor Parts Mode Capacity alarm fired Alarm does not reset Alarm does reset with press stopped with press stopped Tolerance alarm fired Check for slug build-up Remove slug and Set mode to Peak in die run press No alarm...
  • Page 37 Chapter System Trouble- shooting Guide (contd.) Press not stopped during an alarm condition Is relay jumped out Run press Remove jumper at press controls Relay should be energized and contacts closed during a "no alarm" condition. Contacts open during power down of unit Replace relay Page 5-4...
  • Page 38 Chapter System Trouble- shooting Guide (contd.) Uneven load distribution Tonnage readings HIGH Tonnage readings HIGH Tonnage readings HIGH on diagonal corners on adjacent corners on one corner Broken Out of Replace Check for broken or Correct Check the parallelism Remove slug Check for slug build-up wear collar deformed shear collar...
  • Page 39 Chapter System Trouble- shooting Guide (contd.) Erratic readings Check for die Correct problem problem None Check for variation Correct problem in stock None Check for press Correct problem problem Page 5-6...
  • Page 40 LED Indicators 6 LED’s for alarm status Physical Specifications: Module ID Code 3535 Recommended Cable Strain Gage Cable (Helm part number 6117) Terminal Strip 8-pin removable Operating Temperature 0°C to 60°C (32°F to 140°F) Environmental Specifications: Hazardous Environment...
  • Page 41 Appendix B Ladder Page A-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.
  • Page 42 Appendix B 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...
  • Page 43 Ladder Appendix B Programming 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 | ch's 1&2 | cam input | cam bit N10:21 |----] [---------------------------------------------------------------( )-----|...
  • Page 44 Ladder Programming Appendix B Rung 2:0 | PRESS IN | MOTION BIT N10:21 C5:5 |----]/[--------------------------------------------------------------------------------------------------------+--(RES)-----+-| | PANELVIEW | LOW ALARM | INHIBIT | INDICATOR N10:16 +----(L)-----+ | Rung 2:1 | PANELVIEW | AND CH'S | 1&2 MODULE LOW ALARM | CAM CYCLE INHIBIT | BIT COUNTER...
  • Page 45 Ladder Programming Appendix B Rung 3:0 | press in | motion bit N10:21 C5:5 |----]/[--------------------------------------------------------------------------------------------------------+--(RES)-----+-| | PANELVIEW | LOW ALARM | INHIBIT | INDICATOR N10:16 +----(L)-----+ | Rung 3:1 | PANELVIEW | AND CH'S | 1&2 MODULE LOW ALARM | CAM CYCLE INHIBIT | BIT COUNTER...
  • Page 46 Ladder Programming Appendix B Rung 3:7 MOVES LOW INHIBIT COUNTS THAT IS ENTERED FROM PANELVIEW INTO PRESET OF THE LOW ALARM INHIBIT COUNTER +MOV---------------+ | |---------------------------------------------------------------------------------------------------------+MOVE |Source 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---------------+ |...
  • Page 47 Ladder Programming Appendix B Rung 3:0 | PANELVIEW | CH'S 1&2 | LOW ALARM | MODULE | INHIBIT | INDICATOR | INHIBIT ALARM N10:16 |----] [---------------------------------------------------------------------------------------------------------------( )-----| Rung 3:1 | PANELVIEW | CH'S 1&2 | AND CH'S MODULE | 1&2 MODULE| LOOK | CAM CYCLE | WINDOW...
  • Page 48 Ladder Programming Appendix B Rung 3:9 CURRENT SAMPLE COUNT +MOV---------------+ | |--------------------------------------------------------------------------------------------------------+MOVE |Source C5:0.ACC| | 0| | |Dest N10:19| | 0| | +------------------+ | Rung 3:10 PANELVIEW LEARN CYCLE INDICATOR C5:0 N10:16 |----] [---------------------------------------------------------------------------------------------------------------( )-----| Rung 3:11 | CH1 HIGH CH1 HIGH | CAPACITY CAPACITY...
  • Page 49 Ladder Programming Appendix B Rung 3:15 | CH1 HIGH CH1 HIGH | TREND TREND | ALARM BIT ALARM N10:16 |----] [--------------------------------------------------------------------------------------------------------+----(L)-----+-| | CH'S 1&2 | MODULE | ALARM BIT N10:16 +----(L)-----+ | Rung 3:16 | CH1 LOW CH1 LOW | TREND TREND | ALARM BIT ALARM...
  • Page 50 Ladder Programming Appendix B Rung 3:20 | PANELVIEW | TONNAGE | FAULT CH1 HIGH | RESET CAPACITY | BUTTON ALARM N10:21 N10:16 |----] [--------------------------------------------------------------------------------------------------------+----(U)-----+-| | CH1 LOW | CAPACITY | ALARM N10:16 +----(U)-----+ | | CH2 HIGH | CAPACITY | ALARM N10:16 +----(U)-----+ | | CH2 LOW...
  • Page 51 Ladder Programming Appendix B Rung 3:26 CH2 LOW CAPACITY ALARM SETTING +MOV---------------+ | |---------------------------------------------------------------------------------------------------------+MOVE |Source N10:14| | 0| | |Dest O:2.4| | 0| | +------------------+ | Rung 3:27 CH2 HIGH CAPACITY ALARM SETTING +MOV---------------+ | |---------------------------------------------------------------------------------------------------------+MOVE |Source N10:13| | 0| | |Dest O:2.5| | 0| |...
  • Page 52 Ladder Programming Appendix B Rung 3:31 +MUL---------------+ |-----------------------------------------------------------------------------------------------------+-+MULTIPLY +-+-| | |Source A N10:6| | | 0| | | | |Source B 256| | | | | | | |Dest N10:7| | | 0| | | | +------------------+ | | TREND HIGH\LOW ALARM SETTING...
  • Page 53 Ladder Programming Appendix B Rung 3:38 D0 BIT OF | PANELVIEW | SAMPLE | ENTRY COUNT N10:18 |----] [---------------------------------------------------------------------------------------------------------------( )-----| Rung 3:39 D1 BIT OF | PANELVIEW | SAMPLE | ENTRY COUNT N10:18 |----] [---------------------------------------------------------------------------------------------------------------( )-----| Rung 3:40 D2 BIT OF | PANELVIEW | SAMPLE | ENTRY...
  • Page 54 Select New Module Select 1769 MODULE – Generic 1769 Module Click OK Module Properties: Enter Module name (must begin with a letter) example) HELM HM1520 Enter Module description Enter Slot location Select Comm Format. Must be Data – INT Connection Parameters...
  • Page 55 Appendix C OUTPUT IMAGE TAGS Data Tags Data Description Local:x.O Type .Data[0] Look Window Signal Input Bit Set Bypass Mode Bit Set Peak Mode Bit Set Monitor Parts Mode Bit Alarm Reset Bit Reverse Load Enable Bit Low Alarm Inhibit Enable Bit Reserved Sample Count D0 Bit Sample Count D1 Bit...

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