Helm Instrument Company, Inc. 361 West Dussel Drive Maumee, Ohio 43537 USA 419/ 893-4356 Fax: 419/ 893-1371 www.helminstrument.
Important User Information Solid state equipment has operational characteristics differing from those 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.
Table of Contents Strain Gage Module 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 ......................................
Table of Contents Weigh Scale Load Module User Manual Initial Setup Procedures 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 System TroubleShooting Guide HT-400 Sensor Ohm Reading .................
Preface Preface Read this preface to familiarize yourself with the rest of this manual. preface covers the following topics: • • • • • Who Should Use this Manual This 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.
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. 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.
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.
Preface Terms and Abbreviations 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.
Preface Common Techniques The following conventions are used throughout this manual: Used in this • Bulleted lists such as this one provide information, not procedural steps. Manual • Numbered lists provide sequential steps or hierarchical information.
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.
Chapter 1 Hardware Overview 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.
Chapter 2 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.
Chapter 2 System Operation 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.
Chapter 3 Channel Configuration Data and Status This chapter explains how the Weigh Scale module and the processor communicate 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 Vendor ID = 3 Product Type = 9 Product Code = 1 Series/Major Rev/Minor Rev = D Weigh Scale Module ID Code = 1 No special I/O configuration (SPIO CONFIG) information is required.
Chapter 3 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.
Chapter 3 Data Table Input Image 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 Reserved I:e.
Chapter 3 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.
Chapter 3 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.
Chapter 4 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. 3. Press Clear Tare pushbutton. 4.
Chapter 5 System Troubleshooting Guide HT-400 Sensor Ohm Readings Green-Black Red-White All other color combinations All colors to Ground Shield to Ground 350 ohms 350 ohms 266 ohms open open Electrical Specifications: Type of input Input Impedance Display Resolution Overall Module Accuracy Module Update Time Number of Channels A/D Conversion Method Normal Mode Rejection: (between +/- input) Amplifier Bandwidth Calibration Isolation: LED indicators Recommended Cable Terminal Strip Operating Temperatures
APPENDIX A – Module Properties RSLogix™5000
WEIGH_MODULE - Ladder Diagram WEIGH_1525:MainTask:MainProgram Total number of rungs in routine: 7 Page 1 2/27/2008 3:01:17 PM C:\Jobs\Helm\Module_Logic\COMPACTLOGIX_HM1525.ACD 0 MOVE SAMPLE SETPOINT FROM MMI SCREEN TO MODULE WEIGH MODULE A/D SAMPLES SETTING MOV Move Source HM1525_CONTROL[1] 1 Dest Local:1:O.Data[6] 1 1 MOVE SCALE SETPOINTS FROM MMI SCREEN TO MODULE WEIGH MODULE CHANNEL 1 SCALE MOV Move Source HM1525_CONTROL[2] 10000 Dest Local:1:O.
WEIGH_MODULE - Ladder Diagram WEIGH_1525:MainTask:MainProgram Total number of rungs in routine: 7 Page 2 2/27/2008 3:01:17 PM C:\Jobs\Helm\Module_Logic\COMPACTLOGIX_HM1525.ACD TOGGLE VIBRATION FILTER, ZERO STABILIZE, FLICKER OFF/ON CONTROL FROM MMI SCREEN TO MODULE WEIGH MODULE VIBRATION FILTER VIBRATION FILTER OFF/ON OFF/ON TOGGLE Local:1:O.Data[0].5 HM1525_CONTROL[0].0 3 4 ZERO STABLE OFF/ON TOGGLE HM1525_CONTROL[0].1 WEIGH MODULE ZERO STABLE OFF/ON Local:1:O.Data[0].
WEIGH_MODULE - Ladder Diagram WEIGH_1525:MainTask:MainProgram Total number of rungs in routine: 7 6 Page 3 2/27/2008 3:01:17 PM 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 Local:1:I.Data[1] 207 Dest HM1525_STATUS[1] 207 MMI WEIGH MODULE CHANNEL 2 WEIGH VALUE MOV Move Source Local:1:I.
