The Helman Group HM1525 User Manual

Page 1

Helm Instrument Company, Inc. 361 West Dussel Drive Maumee, Ohio 43537 USA 419/ 893-4356 Fax: 419/ 893-1371 www.helminstrument.com

1769 Weigh Scale

Module

Model HM1525

Instruction Manual

FEBRUARY 2004

Page 2

Solid state equipment has operational characteristics differing from those

Important User Information

of electromechanical equipment. “Safety Guidelines for the Application, 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 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:

• identify a hazard

• avoid the hazard

• recognize the consequences

ATTENTION: Please check power supply ratings before proceeding! Each tonnage module consumes (+24, 50mA +5, 66mA). 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. Weigh Scale is a registered trademark of the Helm Instrument Company, Inc.

Page 3

Table of Contents Strain Gage

Table of Contents Weigh Scale Load 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-5

Product Support....................................................P-5

Your Questions or Comments on this Manual......P-5

Overview

Getting Started

Channel Configuration, Data and Status

Chapter 1..................................................................1-1

Components..........................................................1-1

Strain Gain Transducer Operation........................1-1

Hardware Overview ..............................................1-2

Chapter 2..................................................................2-1

Getting Started......................................................2-1

Required Tools and Equipment ............................2-1

System Operation.................................................2-2

Sensor Wiring .......................................................2-2

Chapter 3..................................................................3-1

Channel Configuration, Data and Status ..............3-1

Module Addressing...............................................3-1

Module Configuration.........................................3-1

Data Table Memory Map ......................................3-1

Output Image........................................................3-1

Input Image...........................................................3-3

Integer File............................................................3-5

Page 4

Initial Setup Procedures

System TroubleShooting Guide

Table of Contents Weigh Scale Load Module User Manual

Chapter 4..................................................................4-1

Initial Setup Procedures........................................4-1

Step 1. Balance Sensor Input...............................4-1

Step 2. Set Calibration Numbers ..........................4-2

Chapter 5..................................................................5-1

HT-400 Sensor Ohm Reading ..............................5-1

Block Diagrams.....................................................5-2

Trim Jumper Setting..............................................5-2

PLC Ladder Logic.................................................5-3

Page 5

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

Who Should Use this Manual

Purpose of This Manual

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 electronic 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 Weigh Scale Module. It contains the information you need to install, wire, and use the module.

P-1

Page 6

Preface

Contents of this Manual

Chapter Title Content

Preface

1 Overview

2 Installation and Wiring

3 Channel Configuration, Data

and

Status

4 Ladder Programming Examples

5 Troubleshooting

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. Explains and illustrates the components of the system.

Provides installation information and wiring guidelines.

Examines the channel configuration and the channel status word, and explains how the module uses configuration data and generates status during operation.

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.

A Specifications

B Ladder Program

P-2

Provides physical, electrical, Environmental, and functional Specifications for the module.

Page 7

Preface

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-5

Page 10

Overview

Components

Strain Gain Transducer Operation

Chapter 1

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 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.

The Helm Weigh Scale 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 analy sis.

The Helm Weigh Scale 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.

The primary part of the load monitoring system centers around the measurement. The basic function of the Helm Strain Gain sensor is to detect the amount of 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 Weigh Scale module for processing. The Helm Strain Gage is capable of measuring either a tension or compression signal.

Page 1-1

Page 11

Hardware Overview

Chapter 1

The Weigh Scale 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 (350ohm or 700ohm).

The module can accept input from two sensors. The module has no output channels. Module configuration requires manual and user programmable setup.

The Weigh Scale 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 and application of different sensor options.

Page 1-2

Page 12

Getting Started

This chapter can help you to get started using the Helm Weigh Scale 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

Chapter 2

• 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

• Appropriate strain gage cable

• Programming equipment (All programming examples shown in this

manual demonstrate the use of Allen-Bradley’s RS Logix 500.

Page 2-1

Page 13

System Operation

Sensor Wiring

Chapter 2

The Weigh Scale module communicates to the processor through the parallel 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 Weigh Scale 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.

The sensors are wired to the modules using the rightmost bank of inputs. The pin-out is shown below.

To ensure proper operation and high immunity to 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 to two sensor inputs DO NOT attempt to parallel additional gages as you will cause damage to the module and void product warranty.

Page 2-2

Page 14

Chapter

Channel Configuration Data and Status

This chapter explains how the Weigh Scale module and the processor com m unicate through the module's input and output image.

For CompactLogix / RSLogix™ 5000 setup, please refer to Appendix A

With RS Logix500 software, verify the module ID code.

Expansion General Configuration

Weigh Scale Module ID Code = 1

Series/Major Rev/Minor Rev = D

Vendor ID = 3

Product Type = 9

Product Code = 1

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.

The 8 word output image (output from the CPU to the module) contains

Output Image

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 Reserved O:e.0/0

Bit Reserved O:e.0/1

Bit Reserved O:e.0/2

Bit Zero Stabilize 0=Off 1=On O:e.0/3

Bit LSD Flicker 0=Off 1=On O:e.0/4 Bit Vibration Filter 0=Off 1=On O:e.0/5 Bit Channel 2 Trim O:e.0/6 Bit Coarse Zero Up Adjust O:e.0/7

Bit Channel 1 Trim O:e.0/8

Bit Reserved O:e.0/9

Bit Reserved O:e.0/10

Bit Reserved O:e.0/11

Bit Coarse Zero Down Adjust O:e.0/12

Bit Clear Tare O:e.0/13

Bit Tare O:e.0/14

Bit Channel Toggle 0=CH1 1=CH2 O:e.0/15

Integer Channel 1 Scale value O:e.1

Integer Channel 1 mV/V Setting O:e.2

Integer Channel 1 A/D Trim Setting O:e.3

Integer Channel 2 mV/V Setting O:e.4

Integer Channel 2 A/D Trim Setting O:e.5

Integer A/D Samples Setting O:e.6

Integer Channel 2 Scale value O:e.7

Page 3-1

Page 15

Output Image (cont.)

Zero Stabilize Bit (O:e/3)

Enables module feature to display “0” when Weigh scale is empty.

0 = Disable 1 = Enable

Least Significant Bit (LSD) Flicker Bit (O:e/4)

LSD of weigh value. Does not change when load is applied or if load is constant.

Vibration Filter Bit (O:e/5)

Enables vibration filter to cancel out load variation due to vibration of product weighed. 0 = Disable 1 = Enable

Channel 2 Trim Bit (O:e/6)

Factory set bit to load Channel 2 trim value into module (Not for end user)

Coarse Zero Up Adjust Bit (O:e/7)

Used to increase offset of amplifier to set to range of A/D.

Channel 1 Trim Bit (O:e/8)

Factory set bit to load Channel 1 trim value into module (Not for end user)

Coarse Zero Down Adjust Bit (O:e/12)

Used to decrease offset of amplifier to set to range of A/D.

Clear Tare Bit (O:e/13)

Resets or removes tare value from module. (Used to initially setup module)

Tare Bit (O:e/14)

Sets weigh value to zero.

Channel Toggle Bit (O:e/15)

Used to switch from Channel 1 to Channel 2 when setting up channels.

Channel 1 Scale Value (Integer Word O:e.1)

Value of scale from capacity of load cell for Channel 1.

Channel 1 mV/V Setting (Integer Word O:e.2)

4 digit mV/V setting from load cell mV/V specification.

Channel 1 A/D Trim Setting (Integer Word O:e.3) Factory set trim value for Channel 1. (Not for end user)

Channel 2 mV/V Setting (Integer Word O:e.4) 4 digit mV/V setting from load cell mV/V specification.

Channel 2 A/D Trim Setting (Integer Word O:e.5)

Factory set trim value for Channel 2. (Not for end user) A/D Samples Setting (Integer Word O:e.6)

Sets number of samples (for averaging) of weigh value. (0-1000)

Channel 2 Scale Value (Integer Word O:e.7) Value of scale from capacity of load cell for Channel 2.

Page 3-2

Chapter

Page 16

Data Table Input Image

Chapter

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 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.

(I =file type : =element delimiter 2 =slot . =word delimiter 0 =word / 2 =bit)

Bit Trim Mode I:e.0/1 Bit Reserved I:e.0/2 Bit Reserved I:e.0/3 Bit Reserved I:e.0/4 Bit Reserved I:e.0/5 Bit Reserved I:e.0/6 Bit Channel 1 Sign Bit I:e.0/14

Integer Channel 1 Weigh Value I:e.1

Bit Reserved I:e.0/0

Bit Channel 2 Sign Bit I:e.0/15

Integer Channel 2 Weigh Value I:e.2 Integer Channel 1 A/D Trim Value I:e.3

Integer Reserved I:e.4 Integer Channel 2 A/D Trim Value I:e.5 Integer Communication Fault Counter I:e.6 Integer Reserved I:e.7

Calibrate Mode Bit (I:e/1)

If set, module is in trim mode. Bit should always be clear.

Channel 1 Sign Bit (I:e/14)

If Channel 1 signal is positive value, Bit = 0 and negative value Bit = 1.

Channel 2 Sign Bit (I:e/15)

If Channel 2 signal is positive value, Bit = 0 and negative value Bit = 1.

Page 3-3

Page 17

Input Image (cont.)

Channel 1 Weigh Value (I:e.1)

Weigh value for Channel 1

Channel 2 Weigh Value (I:e.2)

Weigh value for Channel 2.

Channel 1 A/D Trim Value (I:e.3)

Value stored in module for Channel 1. Value should match value on sticker.

Channel 2 A/D Trim Value (I:e.5)

Value stored in module for Channel 2. Value should match value on sticker.

Communication Fault Counter (I:e.6)

Used to troubleshoot noise or ground loops. Associated with module faults to PLC. Counter value should always be zero.

Page 3-4

Chapter

Page 18

Integer File

Using RS Logix500 software, reserve an integer file for Weigh Module monitoring. For illustration purposes in this manual, we have reserved Integer file N10:0 - N10:16.

Data Description Address

Bit Channel 2 Sign Bit N10:0/3 Integer Channel 1 A/D Trim N10:5 Integer Channel 1 Weigh Value N10:8 Bit Up Button N10:16/1

Bit Channel 2 A/D Trim Set Bit N10:16/2 Bit Down Button N10:16/3

Bit Reset Zero N10:16/9 Bit Tare/Zero Button N10:16/12 Bit Channel Toggle Bit 0=CH1 1=CH2 N10:16/13

Bit Channel 1 Sign Bit N10:0/2 Integer Faults N10:2 Integer Channel 2 A/D Trim N10:6 Integer Channel 2 Weigh Value N10:9

Bit Channel 1 A/D Trim Set Bit N10:16/4

Page 3-5

Chapter 3

Page 19

Setup Procedure

A complete 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:

•

Balance sensor input(s)

•

Set Calibration numbers

Step 1. Balance Sensor Input.

1. Set mV/V to 2000.

2. Set Scale to 10000.

Chapter

3. Press Clear Tare pushbutton.

4. Use Up and Down buttons to set amplifier to low range of A/D (20,000 counts)

5. Press Zero/Tare pushbutton.

Step 2. Set Calibration Numbers

1. Set Scale to capacity of load cell.

2. Set mV/V to load cell specification.

3. Example: 100 ton load cell, 2.025 mV/V For scale set, enter 100 For mV/V set, enter 2025

Page 4-1

Page 20

System Troubleshooting Guide

HT-400 Sensor Ohm Readings

Green-Black 350 ohms Red-White 350 ohms

All other color combinations 266 ohms All colors to Ground open Shield to Ground open

Electrical Specifications:

Type of input Strain Gage (350 ohm, 700 ohm) Input Impedance 10k Display Resolution Up to .0025% of full scale Overall Module Accuracy .01% of full scale Module Update Time 10 µsec Number of Channels 2 (isolated) A/D Conversion Method Successive Approximation - 16 bit Normal Mode Rejection: (between +/- input) 116DB CMRR Amplifier Bandwidth 200 kHz Calibration Software Selectable Isolation: 500 VDC continuous between inputs and chassis ground, and between input and backplane LED indicators 2 LED's for Power and Alarm Recommended Cable Strain Gage Cable (Helm part number 6117) Terminal Strip 16-pin removable Operating Temperatures 0°C to 60°C (32°F to 140°F) Hazardous Environment Classification Class 1 Division 2 Hazardous Environment

Trim Jumper

Located at Bottom Left Corner of Module

Black Jumper

Factory Jumper. Removing this Jumper will cause module to Become unstable.

Page 5-1

Chapter

Page 21

Page 22

Page 23

Page 24

APPENDIX A – Module Properties RSLogix™5000

Page 25

WEIGH_MODULE - Ladder Diagram Page 1

WEIGH_1525:MainTask:MainProgram 2/27/2008 3:01:17 PM Total number of rungs in routine: 7 C:\Jobs\Helm\Module_Logic\COMPACTLOGIX_HM1525.ACD

MOVE SAMPLE SETPOINT FROM MMI SCREEN TO MODULE

MOVE SCALE SETPOINTS FROM MMI SCREEN TO MODULE

WEIGH MODULE A/D

SAMPLES SETTING

MOV Move Source

Dest

WEIGH MODULE CHANNEL

Move Source

Dest

WEIGH MODULE CHANNEL

Move Source

Dest

HM1525_CONTROL[1]

Local:1:O.Data[6]

1 SCALE

MOV

HM1525_CONTROL[2]

10000

Local:1:O.Data[1]

10000

2 SCALE

MOV

HM1525_CONTROL[3]

10000

Local:1:O.Data[7]

10000

1 1

MOVE MV/V SETPOINTS FROM MMI SCREEN TO MODULE

WEIGH MODULE CHANNEL

1 MV/V SETTING

MOV

Move Source

Dest

WEIGH MODULE CHANNEL

Move Source

Dest

HM1525_CONTROL[4]

Local:1:O.Data[2]

2 MV/V SETTING

MOV

HM1525_CONTROL[5]

Local:1:O.Data[4]

2000 2000

RSLogix 5000

Page 26

WEIGH_MODULE - Ladder Diagram Page 2

WEIGH_1525:MainTask:MainProgram 2/27/2008 3:01:17 PM Total number of rungs in routine: 7 C:\Jobs\Helm\Module_Logic\COMPACTLOGIX_HM1525.ACD

TOGGLE VIBRATION FILTER, ZERO STABILIZE, FLICKER OFF/ON CONTROL FROM MMI SCREEN TO MODULE

VIBRATION FILTER

OFF/ON TOGGLE

HM1525_CONTROL[0].0

ZERO STABLE OFF/ON

TOGGLE

HM1525_CONTROL[0].1

WEIGH MODULE

VIBRATION FILTER

OFF/ON

Local:1:O.Data[0].5

WEIGH MODULE ZERO

STABLE OFF/ON

Local:1:O.Data[0].3

LSD FLICKER OFF/ON

TOGGLE

HM1525_CONTROL[0].2

COURSE ZERO UP, COURSE ZERO DOWN, CLEAR TARE, TARE, CHANNELS 1/2 PUSHBUTTONS FROM MMI

SCREEN TO MODULE

COURSE ZERO UP

PUSHBUTTON

HM1525_CONTROL[0].3

COURSE ZERO DOWN

PUSHBUTTON

HM1525_CONTROL[0].4

CLEAR TARE

PUSHBUTTON

HM1525_CONTROL[0].5

TARE PUSHBUTTON

HM1525_CONTROL[0].6

CHANNELS 1/2 TOGGLE

BIT

HM1525_CONTROL[0].7

ONE_SHOTS.0

ONS

ONE_SHOTS.1

ONS

WEIGH MODULE LSD

FLICKER OFF/ON

Local:1:O.Data[0].4

WEIGH MODULE COURSE

ZERO UP ADJUST Local:1:O.Data[0].7

WEIGH MODULE COURSE

ZERO DOWN ADJUST

Local:1:O.Data[0].12

WEIGH MODULE CLEAR

TARE

Local:1:O.Data[0].13

WEIGH MODULE TARE

Local:1:O.Data[0].14

WEIGH MODULE

CHANNELS 1/2 TOGGLE

0=CH1 1=CH2

Local:1:O.Data[0].15

CHANNELS 1 AND 2 DATA SIGN BITS FROM MODULE TO MMI SCREEN

WEIGH MODULE CHANNEL

1 SIGN BIT

Local:1:I.Data[0].14

WEIGH MODULE CHANNEL

2 SIGN BIT

Local:1:I.Data[0].15

MMI CHANNEL 1 SIGN

BIT STATUS

HM1525_STATUS[0].0

MMI CHANNEL 2 SIGN

BIT STATUS

HM1525_STATUS[0].1

RSLogix 5000

Page 27

WEIGH_MODULE - Ladder Diagram Page 3

WEIGH_1525:MainTask:MainProgram 2/27/2008 3:01:17 PM Total number of rungs in routine: 7 C:\Jobs\Helm\Module_Logic\COMPACTLOGIX_HM1525.ACD

CHANNELS 1 AND 2 WEIGH VALUES FROM MODULE TO MMI SCREEN

MMI WEIGH MODULE

CHANNEL 1 WEIGH

VALUE

MOV Move Source

Dest

MMI WEIGH MODULE

CHANNEL 2 WEIGH

Move Source

Dest

Local:1:I.Data[1]

HM1525_STATUS[1]

VALUE

MOV

Local:1:I.Data[2]

HM1525_STATUS[2]

207 207

207 206

(End)

RSLogix 5000