Helm PTM LOADGARD Series Manual de usuario

HELM INSTRUMENT CO., INC.

PTM - LOADGARD

Series

USER MANUAL

Revision 6.5

Jan 24, 2019

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, or 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

(419) 893-4356

PTM LOADGARD Series Operators Manual

EXPLANATION OF SYMBOLS

~ Alternating Current

Earth (ground) TERMINAL

On (Supply)

Off (Supply)

Caution, risk of electric shock

Caution (refer to accompanying documents)

EXPLANATION OF SYMBOLS ................................................................................................................................. ii

Introduction................................................................................................................................................................. 5

ABOUT PTM LOADGARD SERIES ........................................................................................................................... 5

Benefit ........................................................................................................................................................................ 5

PTM (Peak Tonnage Module) .................................................................................................................................... 5

Main Features ............................................................................................................................................................ 6

OPERATING MODES ................................................................................................................................... 6

LOOK WINDOW TIME (ms) - Only applicable to none Resolver Model ..................................................... 6

SAMPLING (also referred to as “Learning” or “Trending” cycles) ................................................................ 6

ALARMS ....................................................................................................................................................... 6

Other Features ........................................................................................................................................................... 7

TOUCH SCREEN INTERFACE ................................................................................................................................. 8

MAIN MENU ............................................................................................................................................................... 8

PRESS MONITOR ..................................................................................................................................................... 9

Tonnage Display Screen ............................................................................................................................................ 9

MAIN PEAK LOAD SCREEN FOR VARIATY PTM MODELS ...................................................................... 9

CURRENT JOB DISPLAY .......................................................................................................................... 12

ALARM INDICATOR & HISTORY .............................................................................................................. 12

ALARM HISTORY ....................................................................................................................................... 12

TOTAL PEAK DISAPLY FOR FRAME ....................................................................................................... 12

PEAK TONNAGE DISPLAY FOR FRAME (Ch1 – 4) ................................................................................. 12

TREND LED ................................................................................................................................................ 13

ALARM INDICATOR LED FOR FRAME CHANNEL .................................................................................. 13

PEAK DISPLAY FOR IN-DIE & ALARM INDICATOR (In-Die Screen Only) .............................................. 13

VIEWING CURRENT ALARM SETTINGS (In-Die Screen Only) ............................................................... 14

ALARM RESET ........................................................................................................................................... 14

ALARM SETUP ........................................................................................................................................... 14

OPERATING MODE ................................................................................................................................... 14

COPYING SAMPLE TO TARGET .............................................................................................................. 15

VIEW PEAK HISTORY ............................................................................................................................... 15

Peak History & SPC(Statistical Process Control) Charts ......................................................................................... 16

ZOOMED MODE ......................................................................................................................................... 16

CHANNEL SELECT BUTTONS .................................................................................................................. 16

CONFIG ...................................................................................................................................................... 16

CHANGE GRAPH RESOLUTION .............................................................................................................. 17

SCROLL ...................................................................................................................................................... 17

UNZOOM .................................................................................................................................................... 17

GRID ........................................................................................................................................................... 17

BOLD........................................................................................................................................................... 17

LEGEND ..................................................................................................................................................... 17

SPC ............................................................................................................................................................. 17

Current Alarm Setting ............................................................................................................................................... 18

Group Select ............................................................................................................................................... 19

HIGH CAPACITY ........................................................................................................................................ 19

LOW CAPACITY ......................................................................................................................................... 19

TARGET ...................................................................................................................................................... 19

+ TOL .......................................................................................................................................................... 19

- TOL ........................................................................................................................................................... 19

EXPAND FACTOR ...................................................................................................................................... 19

DELTA TRACK EX (no longer applicable) .................................................................................................. 20

LEARNING CYCLE ..................................................................................................................................... 20

ADAPTIVE LEARNING ENABLE/DISABLE ............................................................................................... 21

PTM LOADGARD Series Operators Manual

ALARM WINDOW (Degreee or ms) ............................................................................................................ 21

(LOOK) WINDOW TIME (ms) - Only applicable to some of none Resolver Model .................................... 22

ENABLING EDIT ......................................................................................................................................... 22

DOWNLOAD ............................................................................................................................................... 22

JOB RECIPE ............................................................................................................................................... 23

SAVING TO RECIPE DATABASE .............................................................................................................. 23

MAIN MENU ................................................................................................................................................ 23

Press Curve Alarm ................................................................................................................................................... 24

PTM Loadgard Press Curve Setup Procedure ........................................................................................................ 24

JOB ............................................................................................................................................................. 26

PEAK ........................................................................................................................................................... 26

HIGH CAP ................................................................................................................................................... 26

LOW CAP .................................................................................................................................................... 26

TARGET ...................................................................................................................................................... 26

SAMPLE ...................................................................................................................................................... 26

HIGH TOL ................................................................................................................................................... 26

LOW TOL .................................................................................................................................................... 26

WAVE VIEWING WINDOW ........................................................................................................................ 27

READ TONNAGE AT ANGLE .................................................................................................................... 28

ZOOM IN ..................................................................................................................................................... 29

RESET ZOOM ............................................................................................................................................ 29

TREND TYPE ............................................................................................................................................. 29

TREND ........................................................................................................................................................ 29

GRID ........................................................................................................................................................... 30

BOLD........................................................................................................................................................... 30

LEGEND ..................................................................................................................................................... 30

CHANNEL SELECT .................................................................................................................................... 30

OVERLAY ................................................................................................................................................... 30

Overlay Screens ....................................................................................................................................................... 30

SIGNATURE OVERLAY SCREEN ............................................................................................................. 31

PEAK BARS SCREEN ................................................................................................................................ 31

RECIPE MANAGER ................................................................................................................................................. 32

Recipe Main Screen ................................................................................................................................................. 32

JOB SUMMARY DISPLAY.......................................................................................................................... 32

NAVIGATION BAR ...................................................................................................................................... 32

EDIT ON ...................................................................................................................................................... 32

REMOVE ..................................................................................................................................................... 33

EDIT ............................................................................................................................................................ 33

ADD ............................................................................................................................................................. 33

COPY .......................................................................................................................................................... 33

DOWNLOAD ............................................................................................................................................... 33

MAIN MENU ................................................................................................................................................ 33

Job Setup Screen ..................................................................................................................................................... 34

JOB NAME .................................................................................................................................................. 34

HIGH CAPACITY ........................................................................................................................................ 34

LOW CAPACITY ......................................................................................................................................... 34

TARGET ...................................................................................................................................................... 34

+ TOL .......................................................................................................................................................... 35

- TOL ........................................................................................................................................................... 35

EXPAND FACTOR ...................................................................................................................................... 35

LEARNING CYCLE ..................................................................................................................................... 35

ADAPTIVE LEARNING ENABLE/DISABLE ............................................................................................... 35

ALARM WINDOW (ms) ............................................................................................................................... 36

(LOOK) WINDOW TIME (ms) - Only applicable to none Resolver Model .................................................. 36

PTM LOADGARD Series Operators Manual

PASTE......................................................................................................................................................... 36

CANCEL ...................................................................................................................................................... 36

SAVE ........................................................................................................................................................... 36

PASSWORD CHANGE ............................................................................................................................................ 37

MASTER PASSWORD ............................................................................................................................... 37

ADMINISTRATOR PASSWORD ................................................................................................................ 37

OPERATOR PASSWORD .......................................................................................................................... 37

INITIAL PASSWORD .................................................................................................................................. 37

ADTSERVER SETUP SCREEN .............................................................................................................................. 38

Monitor Screen ......................................................................................................................................................... 38

OPERATING STATUS INDICATOR ........................................................................................................... 38

OPERATING MODE INDICATOR .............................................................................................................. 38

Sensor Calibration Screen ....................................................................................................................................... 39

System Setup Screen .............................................................................................................................................. 40

WINDOW TIME (ms) - Only applicable to none Resolver Model ............................................................... 40

PEAK WINDOW (Enable/Disable) - Only applicable to none Resolver Model ........................................... 40

SCALE SET ................................................................................................................................................ 40

TREND ALARM .......................................................................................................................................... 40

System Setup Screen for PTM-5600P/6700P ............................................................................................ 41

SCALE SET ................................................................................................................................................ 41

System Setup Screen for PTM-4500TSM/6700TSM/6700i-TSM ............................................................................ 42

TREND WARNING OUTPUT LEVEL ......................................................................................................... 42

SAVE ........................................................................................................................................................... 42

CANCEL ...................................................................................................................................................... 42

LOOK WINDOWS ....................................................................................................................................... 42

PTM LOADGARD ADC SETUP for TSM model .................................................................................................... 43

•

Go To ADC Manager .......................................................................................................................... 43

•

ADC Manager Setup ........................................................................................................................... 43

•

ADC RS232 CABLE CONNECTION .................................................................................................. 45

GETTING READY FOR CALIBRATION .................................................................................................................. 46

SYSTEM SPECIFICATIONS ................................................................................................................................... 49

BYPASS & REMOTE ALARM RESET .................................................................................................................... 50

OPTION FOR PTM-4500TSM Model ...................................................................................................................... 50

To Enable the BYPASS OPTION ............................................................................................................................ 50

APPENDIX A ( PTM-4500L2 ) - 4Ch Frame with 2 Linear Transducer ................................................................. 53

APPENDIX B ( PTM-2300L ) – 2Ch Frame/Indie with 1 Linear Transducer Input ................................................ 54

APPENDIX C ( PTM-6700i ) – 6Ch In-Die Applcation ........................................................................................... 55

APPENDIX D ( PTM-5600F ) – 3Ch In-die + 2Ch Frame application .................................................................... 56

APPENDIX E ( PTM-6700TSM ) 4Ch Frame + 2Ch Indea with Resolver Input ................................................... 57

APPENDIX F ( PTM-4400i ) 4Ch In-die application ............................................................................................... 58

APPENDIX G ( PTM-4500TSM )- 4Ch Frame with Resolver Input ...................................................................... 59

PTM LOADGARD Series Operators Manual

APPENDIX H ( PTM-4500TSM-ASA )- 4Ch Frame + Auto Shutheight Adjust w/ Resolver Input ........................ 60

APPENDIX I ( PTM-5600P) - 5Ch Piezo Sensor Input .......................................................................................... 61

APPENDIX J ( PTM-4500) - 4Ch Frame with CAM input ...................................................................................... 62

APPENDIX K ( PTM-4500-ADC) - 4Ch Frame with Automatic Die Change Option .............................................. 63

APPENDIX L LINE SUPERVISOR WITH RLG CONENCTION ........................................................................... 64

APPENDIX M ( PTM-6100-SS) - 4Ch Frame, 1Ch In-Die, 1Ch Laser Sensor ....................................................... 65

APPENDIX N ( PTM-6700i-TSM) - 6Ch In-Die With Trend Warning Output .......................................................... 66

APPENDIX O PTM LOADGARD DIMEMSION (Standard Mount) ......................................................................... 67

APPENDIX P PTM LOADGARD DIMEMSION (FLANGE MOUNT)....................................................................... 68

APPENDIX P-1 PTM LOADGARD PANEL PC CONNECTIONS LAYOUT ........................................................... 69

APPENDIX Q (PTM-884TSM-SS) 4Ch Frame, 4Ch In-Die Sensors...................................................................... 70

APPENDIX R (PTM-844TSM-SS) Connection Drawing ......................................................................................... 71

APPENDIX S (PTM-1248TSM-SS) 4Ch Frame, 8Ch In-Die Sensors .................................................................... 72

APPENDIX T (PTM-1248TSM-SS) Connection Drawing ....................................................................................... 73

APPENDIX U RLG Line Supervisor Connection .................................................................................................... 74

APPENDIX V PTM-102L Connections .................................................................................................................... 75

APPENDIX W PTM-4500TSM New I/O Board Connections .................................................................................. 76

APPENDIX X PTM-6600TSM for Doule Action Connections ................................................................................ 77

APPENDIX Y PTM-8800TSM for Doule Action Connections ................................................................................. 78

APPENDIX Z PTM-2300D-TSM with Diverter Output ............................................................................................ 79

APPENDIX A1 PRofinet Add-On Kit Connection .................................................................................................... 80

APPENDIX B1 PTM-2300-TSM-RD (Remote Display) ......................................................................................... 82

APPENDIX C1 PTM-2100-SS Laser Sensor Input with Cutter Control ................................................................ 83

PTM LOADGARD Series Operators Manual

INTRODUCTION

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 and 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.

ABOUT PTM LOADGARD SERIES

PTM LOADGARD series is one of the most advanced load monitoring systems Helm can offer.

Sophisticated features such as smart sampling, adaptive learning, SPC(Statistical Process Control)

Charts, etc. help monitoring the operation of your machine and protect them from faulty operation.

BENEFIT

• Press Protection – protect press components, including dies, from costly damage

• Parts Quality Control – ensure parts are being made (stamped) as specified

Variations in the mechanical press and the part making process have the costly potential of press

damage, waste of material, and downtime. The PTM LOADGARD uses force monitoring for both

press protection and parts quality control. If an excessive force that could potentially damage the

press machine or a variation in force occurs during the part making process are detected, the PTM

LOADGARD triggers an “alarm” and stops the press. This allows the press operator to correct the

potential problem ahead.

PTM (PEAK TONNAGE MODULE)

• PTM is a single channel strain gage sensor input module to process the signal of the strain

gage to analog output.

• PTM provides Auto-Zero® feature (patented by Helm Instrument Co., Inc.). The Auto-Zero®

feature automatically keeps the zero balance of the load signal between every load cycles to

compensate the tonnage variation affected by any environmental conditions changes such as

temperature.

PTM LOADGARD Series Operators Manual

MAIN FEATURES

OPERATING MODES

PTM LOADGARD Series has three function modes controlled by an operator.

• Setup Mode – Used for system setup, Job setup or new job download.

Capacity alarms are active. Trend Alarms are active if the Trend Alarm in

Setup option is enabled from Server Setup screen. Target value is used

for monitoring the Trend alarm conditions as a reference point.

• Learn Mode – Learns new sample value.

Capacity alarms are active. Trend alarms are active if the Trend Alarm in

Setup option is enabled from Server Setup screen. Target value is used

for monitoring the Trend alarm conditions as a reference point.

• Monitor Mode – Adaptive learning can be active in this mode.

Capacity alarms are active. Trend alarms are active. Sample value is

used for monitoring the Trend alarm conditions as a reference point.

LOOK WINDOW TIME (ms) - Only applicable to none Resolver Model

PTM LOADGARD monitors tonnages between the “critical” time of the press stroke called the look

window. 224 points (tonnage readings) per channel are recorded during the look window time from

the look window start trigger point. These points are displayed as a “wave” or “signature” in the

Signature Analysis screen.

SAMPLING (also referred to as “Learning” or “Trending” cycles)

Samples for pre-determined number of press strokes, defined as sample counts in Alarm Setup

screen.

When the sampling is completed, PTM LOADGARD takes an average peak tonnage and / or

tonnage signature per channel (while sampling), and stores as a Sample peak value and/or Sample

Signature per channel and uses it as a reference point for Trend / Tracking Alarm conditions.

• Sample – Sample is the value learned automatically from Learn mode or Monitor mode by

adaptive learn feature. The Sample value is used to calculate the Trend and Tracking

Alarm condition in Monitor mode.

• Target – When you create a new job, Target values need to be entered manually. These

values can be copied from the Sample values when Leaning process is completed for the

job. The Target can be used during Setup or Learn mode to monitor the Trend Alarm

conditions before new Sample values are available or just can be used as visual reference

for each Job.

ALARMS

In normal operation, the Alarm relay is closed for fail safe. When the tonnage alarm(s) condition

is detected, the system opens the TOP STOP relay

• High/Low Capacity – Normally set at machine capacity. This provides the protection for

the Machine. This alarm is active in all modes.

• High/Low Trend – creates high and low tolerance for peak load based on Target or

Sample tonnage. The tolerance values are the allowable tonnage deviation above and

below Sample or Target tonnage. This provides the means to maintain the quality of the

part making. Trend alarms are available in all modes. There is an option to disable the

Trend alarm during Setup or Learn mode.

PTM LOADGARD Series Operators Manual

• High/Low Tacking – creates high and low tolerance bands around the sample tonnage

signature for monitoring the alarm condition through out the stroke. Tracking alarm is only

available in Monitor mode

• Press Curve (only available for Resolver based model) – Since a press may have

different force capacities at different angles, the press manufacture may provide a

“through the stroke press-curve and motion curve” set of data points. This alarm is valid

in both setup and Monitor mode.

OTHER FEATURES

• Signature Analysis – Displays the forming force signature for each channel. You can

zoom, read the tonnage value at angle, overlay multiple channels, view multiple peak

tonnage value in bar graph, and more to help you analyzing the force signature.

• Alarm History – You can view last 500 alarm messages with time stamped.

• Peaks History – You can view a peak tonnage history graph of last 10000 strokes.

• SPC (Statistical Process Control) – You can view statistical charts of peak tonnage

variation from selected peak history. Avail SPC charts are Individual & Moving Range,

*Average & Range, *Median & Range, *Average & Std. Deviation, and Histogram

• Jobs Recipe – You create alarm settings per job base and store to Job Recipe for later

quick download to setup the system.

• Adaptive learning – While the system is in Monitor mode, you can enable an Adaptive

Learning option to continuously learn new sample tonnage while monitoring. This will allow

the system to adapt any small gradual variances of the tonnage through time when requires

• Multi-Level Password Protection – you can restrict certain functions or screens of the

system from being accessed by unauthorized personnel or prevent from unauthorized

changes of the system settings. Different level of passwords gives more secure and

effective protection for the system.

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