Helm Trend Series User manual

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

OPERATING INSTRUCTIONS TREND SERIES

LIMITED WARRANTY

Helm Instrument Co., Inc. (”HELM”) hereby warrants that the instruments and

sensors (collectively the ”Product”) manufactured by it and sold to customer, are

free from defects in material and/or workmanship under normal use subject to the

following conditions. This warranty shall not apply to any Product which has been

subjected to improper installation, misuse, negligence, accident, alteration, where

service has been performed by other than an authorized Helm serviceman, o

where the serial number has been defaced or altered. 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. Helm’s obligations and the exclusive remedy of customer under this

warranty are limited to repairing or replacing any defective Product at no

additional charge and returning Product to customer freight paid. Repair parts

and replacement Products shall be furnished on an exchange basis and shall be

either new or reconditioned. All replaced parts and Products shall become the

property of Helm.

EXCEPT AS SPECIFICALLY STATED HEREIN, HELM MAKES NO

WARRANTIES EXPRESSED OF IMPLIED, OF THIS PRODUCT INCLUDING

BUT NO LIMITED TO WARRANTIES OF MERCHANTABILITY OR FITNESS

FOR A PARTICULAR PURPOSE, OR AS TO THE QUALITY, UTILITY OR

PERFORMANCE, ALL QF WHICH ARE HEREBY EXPRESSLY EXCLUDED. IN

NO EVENT SHALL THE LIABILITY OF HELM EXCEED THE PURCHASE

PRICE OF THIS PRODUCT. NOR SHALL HELM BE LIABLE FOR ANY

DAMAGES WHATSOEVER, INCLUDING BUT NOT LIMITED TO SPECIAL,

INDIRECT, INCIDENTAL OR CONSEQUENTIAL CHARGES, EXPENSE OR

DAMAGES, ARISING OUT OF THE USE OR INABILITY TO USE THIS

PRODUCT OR FOR ANY CLAIM BY ANY OTHER PARTY.

Should you have any questions concerning this Warranty, you may contact Helm

by writing or calling:

HELM INSTRUMENT COMPANY, INC.

CUSTOMER SERVICE

361 WEST DUSSEL DRIVE

MAUMEE, OHIO 43537

(41 9) 893-4356

OPERATING INSTRUCTIONS TREND SERIES

EXPLANATION OF SYMBOLS

Ω

Alternating Currrent

Earth (ground) TERMINAL

On (Supply)

Off (Supply)

Caution, risk of electric shock

Caution (refer to accompanying

documents)

iii

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..................................................................................................................................... 3

Replacement Fuses .......................................................................................................................................... 3

Instrument Calibration ....................................................................................................................................... 5

Preliminary Calibration Adjustment Procedures ............................................................................................... 6

Individual Channel Adjustments........................................................................................................................ 6

Manual Zero Adjust ........................................................................................................................................... 6

Gain Adjust........................................................................................................................................................ 7

Meter Calibrate Switches .................................................................................................................................. 8

Setting Meter Calibrate Switches On Two Channel Systems ........................................................................... 9

Alarm Set Procedures ..................................................................................................................................... 10

Setting Capacity Alarm.................................................................................................................................... 11

Setting High - Low Tolerance Limits ............................................................................................................... 12

Establishing Optimum Tolerance Settings ...................................................................................................... 12

Job Data Control (Jdc) .................................................................................................................................... 13

Initial Storing Of Capacity And Tolerance Settings ......................................................................................... 13

Storing Of Target Loads .................................................................................................................................. 13

Testing For Open Job Number........................................................................................................................ 14

Calling Stored Job Data For Die Setup ........................................................................................................... 14

Front Panel Controls - Operating Instructions................................................................................................. 15

Three Position Function Selector .................................................................................................................... 15

Setup (Clear) Keyswitch Position.................................................................................................................... 15

Monitor Parts Keyswitch Positions .................................................................................................................. 16

Alarm Set Status ............................................................................................................................................. 17

Digital Meter Display ....................................................................................................................................... 17

Trend Display-Quality Window........................................................................................................................ 18

Recorder Output Jacks.................................................................................................................................... 19

Front Panel Push Buttons ............................................................................................................................... 20

Alarm Reset ................................................................................................................................................. 20

Capacity Alarms........................................................................................................................................... 20

Strokes Per Minute ...................................................................................................................................... 20

Tolerance Alarms......................................................................................................................................... 20

Reverse Load .............................................................................................................................................. 20

Target Load ................................................................................................................................................. 20

Cleaning .......................................................................................................................................................... 21

Computer Interface And Filter Card Wiring .......................................................................................Appendix A

OPERATING INSTRUCTIONS TREND SERIES

INTRODUCTION

You have just purchased the most advanced load monitoring system available. In addition to this system,

HELM INSTRUMENT CO., INC. manufactures a complete line of load monitoring control systems for use

on metal stamping, forging, compaction and assembly presses; cold forming, cold heading, injection molding

and die cast machines.

Standard or custom transducers and load cells are available for in-die monitoring or transfer or progressive

tooling. Easy to use software systems designed for your specific plantwide SPC programs are also

available.

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.

TREND SYSTEM OPERATION

The HELM TREND LOADGARD control system provides protection for the die, the product and the machine

with minimal operator involvement. The Loadgard takes a sample of the forming force of an ideal part,

stores this level in memory and compares each subsequent force level against the ideal.

In addition to capacity alarms for overload protection, the TREND Loadgard features high and low tolerance

limits, set automatically for each channel based on a pre-established setting.

Digital meters display load, machine speed, alarm settings and capacity alarms. Machine stop is initiated

when an off tolerance part is produced.

THE STRAIN GAIN TRANSDUCER OPERATION

The basic function of the HT-400 Strain Gain is to detect the amount of the deflection imposed on the press

as parts are being formed. All Strain Gain sensors are matched to within 1% and therefore can be replaced

without re-calibration of the machine.

The HT-400 Strain Gain sensors are mounted to strategic high stress areas of the machine frame. Signals

from these sensors are routed to the TREND Loadgard for processing. The HT-400 is capable of measuring

either a tension or compression signal.

OPERATING INSTRUCTIONS TREND SERIES

INSTALLATION GUIDELINES

TREND LOADGARD INSTALLATION

WARNING

If this unit is modified in a manner not specified by the manufacturer, protection provided may be impaired.

Repair or calibration of this equipment is to be done by authorized personnel only. This unit contains no

serviceable parts other than those outlined in this manual. Return unit to manufacturer for repair.

For purposes of safety, this unit is to be permanently installed. Electrical lines will be housed in conduit so

that wiring is not subject to mechanical stress. A means of electrical disconnect (switch or circuit breaker)

shall be included in the permanent power installation. This disconnect device will be in close proximity to the

equipment and within easy reach of the operator. The device will be clearly marked as the disconnect for

the equipment (ref. Drawing T-2227 Appendix A).

For best results, mount the TREND Loadgard at eye level and within operators' reach. Use the supplied

rubber shock mounts to isolate the unit from vibration. Care should be taken to insure that the instrument

chassis ground Ωis the same potential as the machine ground. See Mounting Detail Illustration in

Appendix A.

ENVIROMENTAL CONDITIONS

This unit is designed for indoor use only. Operating temperature range is from 5ºC up to 55ºC.

STRAIN GAIN INSTALLATION AND WIRING

Specific sensor location and mounting instructions are described in the “Installing Strain Gain Transducers”

manual. 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. Transducer cables should never be run near high voltage (220VAC, 440VAC)

circuits.

SENSOR WIRING CONNECTIONS

The Sensor Terminal Strips are located inside the box, above the circuit board card rack.

NOTE: Always route power and sensor cables through proper holes as designated inside the

LOADGARD enclosure.

TENSION COMPRESSION

+G (gage positive) green black

-G (gage negative) black green

-S (signal negative) red red

(shield) shield shield

+S (signal positive) white white

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%

50-60 Hz 250 mA Max.

Installation Class III

Replacement Fuses

Replace fuses with main power OFF! (o)

Replace fuses with "TT" time delay fuses of specified rating only!

TLG-4500 models marked for 120V~ operation require a .5A 20mm x 5mm type TT fuse.

TLG-4500 models marked for 220V~ operation require a .25A 20mm x 5mm type TT fuse.

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.

CARD RACK - Channel Boards

The steel cabinet (card rack) inside the instrument holds all the circuit boards. Slot #1 is reserved for the

optional computer interface card. Slot #2 contains the microprocessor board that controls all instrument

logic. Slot #3 is open.

Slots #4 through 7 are reserved for channel boards. Refer to the illustrations below for the proper location of

each channel board in your instrument(s).

Channel boards are interchangeable. Use the jumper plugs on the individual

channel boards for setting the proper channel board number.

NOTE: Jumpers are factory set prior to shipment. Adjust this jumper only if

you switch channel board locations.

OPERATING INSTRUCTIONS 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. If you have any questions or need a HELM Field Engineer for calibration,

please contact our Field Service Department at 419-893-4356.

The illustration below details the locations of switches and potentiometers used during calibration.

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. Push AUTO ZERO switch to the OFF

(back) position.

2. Pull CALIBRATION switch to the OFF

(forward) position.

3. Adjust the ZERO BALANCE

The zero balance (BALANCE ADJUST) controls are the small

multi-turn potentiometers at the extreme right of each channel

board.

Watch the outside meter and turn the BALANCE ADJUST

control of the first channel board until the meter displays all

zeros. Repeat for all channels.

NOTE: On models TLG-4100 & TLG-2100, push LEFT or RIGHT DISPLAY button to display individual

channel readings.

This manual suits for next models

Table of contents

Other Helm Control System manuals

Helm

Helm PTM LOADGARD Series User manual

Popular Control System manuals by other brands

Pentair Pool Products

Pentair Pool Products Compool Installation and user guide

ComfortNET

ComfortNET CTK04 manual

Fireye

Fireye InSight II 95DSS3 manual

CAME

CAME G3000 installation manual

Idemia

Idemia MorphoAccess VP MD installation guide

Axis

Axis P1445-LE-3 user manual

HEIDENHAIN

HEIDENHAIN TNC 150 B manual

CNC-Step

CNC-Step High-Z T-Series operating instructions

Doosan

Doosan DVF Series Operation user's manual

Honeywell

Honeywell KAP 140 Maintenance manual

Honeywell

Honeywell vk41 series Handbook

AirBench

AirBench FPW Operation and maintenance

Cypress

Cypress HHR-3160 product manual

CAME

CAME GLT40AOS installation manual

Zonex

Zonex GEN II -VVT Installation and application manual

Altronics

Altronics K 9650 quick start guide

micro-trak

micro-trak RoadMaster Reference manual

micro-trak

micro-trak Calc-An-Acre II Reference manual