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Summary of Contents for Helm Trend Series
- Page 1 Helm Instrument Company, Inc. 361 West Dussel Drive Maumee, Ohio 43537 USA 419/ 893-4356 Fax: 419/ 893-1371 www.helminstrument.com Trend Series TLG2300 / TLG4500 Loadgard Operating Instructions Force Measurement and Control Solutions...
- Page 2 This warranty shall extend for the one (1) year period from date of shipment from our factory or authorized dealer, provided that the product is returned, freight prepaid, to Helm within the one (1) year warranty period within specific written authorization to perform repairs.
- Page 3 OPERATING INSTRUCTIONS TREND SERIES EXPLANATION OF SYMBOLS Alternating Currrent Ω Earth (ground) TERMINAL On (Supply) Off (Supply) Caution, risk of electric shock Caution (refer to accompanying documents)
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Page 4: Table Of Contents
OPERATING INSTRUCTIONS TREND SERIES Introduction................................ 1 Trend System Operation ........................... 1 The Strain Gain Transducer Operation ......................1 Trend Loadgard Installation..........................2 Enviromental Conditions ........................... 2 Strain Gain Installation And Wiring ........................2 Sensor Wiring Connections..........................2 Instrument Power And Relay Wiring ......................... 3 Electrical Specifications............................. -
Page 5: Introduction
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. 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. -
Page 6: Trend Loadgard Installation
Refer to this manual for proper location and installation. Sensor nominal resistance values should check out in accordance with HELM drawing number T-2344-51 in Appendix A. For proper wiring, use separate conduit or sealtite for transducer cables and avoid running these cables with any press control or high power motor circuits. -
Page 7: Instrument Power And Relay Wiring
OPERATING INSTRUCTIONS TREND SERIES INSTRUMENT POWER AND RELAY WIRING Trend Loadgard supply wiring connections shall be made with 14 ga. THHN wire or equivalent. Electrical Specifications Unit marked for 120V~ operation 120V~ ±10% 50-60 Hz 500 mA Max. Unit marked for 220V~ operation 220V~ ±10%... - Page 8 OPERATING INSTRUCTIONS TREND SERIES A mechanical relay is provided to activate machine stop when an alarm condition occurs. This relay is wired “fail-safe” and will pass current through the normally closed and common contacts when the instrument is turned on and no alarms are tripped. Current rating for these contacts is 10 amps at 120VAC. Cam switch connections are supplied, if applicable.
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Page 9: Instrument Calibration
TREND SERIES INSTRUMENT CALIBRATION This section details calibration procedures. If this system has been calibrated by a HELM Field Service Engineer or by the machine manufacturer, the calibration numbers will be noted on a tag inside the instrument. Once calibrated, it is not necessary to re-calibrate unless the machine is moved, dismantled or otherwise structurally changed. -
Page 10: Preliminary Calibration Adjustment Procedures
OPERATING INSTRUCTIONS TREND SERIES PRELIMINARY CALIBRATION ADJUSTMENT PROCEDURES 1. Turn function keyswitch to SETUP position. 2. Open enclosure door, turn power on. 3. Set MONITOR/CALIBRATE switch, located on inside of door, to the CALIBRATE position. INDIVIDUAL CHANNEL ADJUSTMENTS MANUAL ZERO ADJUST 1. -
Page 11: Gain Adjust
OPERATING INSTRUCTIONS TREND SERIES GAIN ADJUST The GAIN ADJUST control is a small multi-turn control located on the extreme left of each channel board. This control is used to adjust the instrument to display the proper CAL (calibration) number on the digital meter(s). -
Page 12: Meter Calibrate Switches
OPERATING INSTRUCTIONS TREND SERIES METER CALIBRATE SWITCHES These switches, located on the microprocessor board (slot #2), are used to set meter scale based on rated machine capacity. Pull the microprocessor board out of the card rack for this adjustment. Make sure power to the instrument is OFF before pulling any boards from the rack. -
Page 13: Setting Meter Calibrate Switches On Two Channel Systems
OPERATING INSTRUCTIONS TREND SERIES METER CALIBRATE SWITCHES (cont.) SETTING METER CALIBRATE SWITCHES ON TWO CHANNEL SYSTEMS • FOR MACHINES UP TO AND INCLUDING 250 TONS TOTAL CAPACITY Put the METER RANGE selector to the LOW position. Calculate the capacity of one side by dividing the total machine capacity by the number of channels (2). -
Page 14: Alarm Set Procedures
OPERATING INSTRUCTIONS TREND SERIES INSIDE CONTROLS ALARM SET PROCEDURES Capacity and tolerance alarm adjustments are located on the inside door panel. Capacity alarms provide press overload protection. Tolerance alarms provide tooling and die protection as well as providing part quality assurance. -
Page 15: Setting Capacity Alarm
OPERATING INSTRUCTIONS TREND SERIES SETTING CAPACITY ALARM 1. Turn Function Selector to SETUP position. 2. Open enclosure door and locate slide switches on inside door. 3. Slide top switch on inner door to CALIBRATE position (right) and center switch marked CAPACITY ALARMS to the right. -
Page 16: Setting High - Low Tolerance Limits
OPERATING INSTRUCTIONS TREND SERIES SETTING HIGH - LOW TOLERANCE LIMITS Every TREND system features tolerance alarms which are used to establish a “quality window” that the process will operate within. These alarms are set as a percentage of the forming force and automatically adjusted each time a sample is taken or a new job is started. -
Page 17: Job Data Control (Jdc)
OPERATING INSTRUCTIONS TREND SERIES JOB DATA CONTROL (JDC) The JED feature provides memory storage of up to 100 different job numbers per LOADGARD. The following data is stored for each job: • Capacity alarm settings • Tolerance alarm settings •... -
Page 18: Testing For Open Job Number
OPERATING INSTRUCTIONS TREND SERIES JOB DATA CONTROL (cont.) TESTING FOR OPEN JOB NUMBER 1. Put JDC switch in AUTO mode. 2. Select job number. 3. Yellow LED will flash if job number is available. CALLING STORED JOB DATA FOR DIE SETUP 1. -
Page 19: Front Panel Controls - Operating Instructions
OPERATING INSTRUCTIONS TREND SERIES FRONT PANEL CONTROLS - OPERATING INSTRUCTIONS THREE POSITION FUNCTION SELECTOR • A position marked SETUP (Clear) • A monitoring position marked MONITOR PARTS (RESET BUTTON NOT ACTIVE) • A monitoring position marked MONITOR PARTS (RESET BUTTON ACTIVE) SETUP (CLEAR) KEYSWITCH POSITION Use this position for machine and die set up. -
Page 20: Monitor Parts Keyswitch Positions
OPERATING INSTRUCTIONS TREND SERIES MONITOR PARTS KEYSWITCH POSITIONS During production, the keyswitch should be in one of these MONITOR PARTS positions. Once the machine is set up and producing good parts, turn the switch to one of these positions. The instrument will take a sample of the forming loads and store this sample in memory. -
Page 21: Alarm Set Status
OPERATING INSTRUCTIONS TREND SERIES ALARM SET STATUS LED's located on front panel indicate status of instrument capacity and tolerance alarm settings as follows: • MANUAL JDC and Computer controls are inactive. Alarm limits adjusted based on switch settings inside door. -
Page 22: Trend Display-Quality Window
OPERATING INSTRUCTIONS TREND SERIES TREND DISPLAY-QUALITY WINDOW Each vertical TREND column represents one channel of monitoring. The TREND portion of the instrument works on the “benchmark” principle. The instrument will take a sample of the forming loads at each channel and automatically establish the high and low alarm limits. -
Page 23: Recorder Output Jacks
OPERATING INSTRUCTIONS TREND SERIES RECORDER OUTPUT JACKS Each TREND instrument has one or two dual circuit jacks for use with HELM Ramcorder or for output to a strip chart recorder. Corner or Side Capacity level 2 Channel systems: Ring = Left Tip = Right at each jack is 2.66 volts... -
Page 24: Front Panel Push Buttons
OPERATING INSTRUCTIONS TREND SERIES FRONT PANEL PUSH BUTTONS ALARM RESET Pressing this switch initiates a Peak reset for any alarm condition. This switch is only active when keyswitch is in SETUP or MONITOR PARTS RESET ACTIVE position. CAPACITY ALARMS Press the CAPACITY ALARMS button to any operating mode to display the capacity alarm setting on each channel. -
Page 25: Cleaning
OPERATING INSTRUCTIONS TREND SERIES CLEANING External cleaning to this unit is to be with a clean cloth moistened with warm water and mild detergent only. The unit should be wiped dry then allowed to air dry before returning to service. - Page 26 OPERATING INSTRUCTIONS TREND SERIES...
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Page 30: Computer Interface And Filter Card Wiring
OPERATING INSTRUCTIONS TREND SERIES COMPUTER INTERFACE AND FILTER CARD WIRING The computer interface card Model EIC plugs into Slot #1 of the card rack. Mount the filter board on the inside panel marked “DO NOT REMOVE”. Use existing thumbwheel screws on left side of panel. - Page 31 OPERATING INSTRUCTIONS TREND SERIES DESCRIPTION OF MULTI I/O FILTER CARD Computer or PLC can be either 422 or 232 communications. Connections for 422 communications: J22 on filter card should be jumpered across pins 2 and 3. The cable coming from the EIC card plugs into J2 and J3 on the filter card.
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- Page 34 OPERATING INSTRUCTIONS TREND SERIES Model TLG-8000 This appendix describes additional operating instructions for the standard TLG-8000 and TLG-8000DP with Cam Limit Switch. Refer to drawings T-2435-42 and T-2435-41 following is appendix.
- Page 35 OPERATING INSTRUCTIONS TREND SERIES Appendix C: TLG-8000 Operation Guidelines...
- Page 36 OPERATING INSTRUCTIONS TREND SERIES Appendix C: TLG-8000 Operation Guidelines...
- Page 37 OPERATING INSTRUCTIONS TREND SERIES TLG System Troubleshooting Guide The following system set-up conditions should be verified prior to proceeding to block diagrams. See pages listed below, in parenthesis, in this manual for switch location in instrument. Unit powered up. 110V power supplied to unit (page 3).
- Page 38 OPERATING INSTRUCTIONS TREND SERIES TLG Unit Voltage Checks -9 pin connector located under “Do Not Remove” plate, upper LH Corner Satisfactory Voltage Range Brown -3.8 to -4.2 volts -3.8 to -4.2 volts Orange +3.8 to +4.2 volts Yellow -11.5 to -12.5 volts Green +11.5 to +12.5 volts...
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- Page 45 OPERATING INSTRUCTIONS TREND SERIES PROBLEM POSSIBLE CAUSE REMEDY No front panel indications Fuse blown. Replace fuse. Power source. Check power. Display flashes zeroes. Instrument turned off/on with function Reset instrument by turning function switch in Monitor Parts position. selector to Standby/Clear.
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