The Autograph Monitor Screens Contain Most Common Information For Operator PTM LOADGARD Series Manual Rev5.9

User Manual: PTM LOADGARD Series Manual Rev5.9

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HELM INSTRUMENT CO., INC.

PTM - LOADGARD

Series

USER MANUAL

Rev. 5.9

Aug 20 2015

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 ........................................................................................................................ 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

LEARNING CYCLE ..................................................................................................................................... 21

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

DELTA TRACK EX ...................................................................................................................................... 20

PTM LOADGARD Series Operators Manual

ALARM WINDOW (ms) ............................................................................................................................... 21

(LOOK) WINDOW TIME (ms) - Only applicable to none Resolver Model .................................................. 21

ENABLING EDIT ......................................................................................................................................... 21

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

JOB RECIPE ............................................................................................................................................... 22

SAVING TO RECIPE DATABASE .............................................................................................................. 22

MAIN MENU ................................................................................................................................................ 22

Press Curve Alarm ................................................................................................................................................... 23

PTM Loadgard Press Curve Setup Procedure ........................................................................................................ 23

JOB ............................................................................................................................................................. 25

PEAK ........................................................................................................................................................... 25

HIGH CAP ................................................................................................................................................... 25

LOW CAP .................................................................................................................................................... 25

TARGET ...................................................................................................................................................... 25

SAMPLE ...................................................................................................................................................... 25

HIGH TOL ................................................................................................................................................... 25

LOW TOL .................................................................................................................................................... 25

WAVE VIEWING WINDOW ........................................................................................................................ 26

READ TONNAGE AT ANGLE .................................................................................................................... 26

ZOOM IN ..................................................................................................................................................... 27

RESET ZOOM ............................................................................................................................................ 27

TREND TYPE ............................................................................................................................................. 27

TREND ........................................................................................................................................................ 27

GRID ........................................................................................................................................................... 28

BOLD........................................................................................................................................................... 28

LEGEND ..................................................................................................................................................... 28

CHANNEL SELECT .................................................................................................................................... 28

OVERLAY ................................................................................................................................................... 28

Overlay Screens ....................................................................................................................................................... 28

SIGNATURE OVERLAY SCREEN ............................................................................................................. 29

PEAK BARS SCREEN ................................................................................................................................ 29

RECIPE MANAGER ................................................................................................................................................. 30

Recipe Main Screen ................................................................................................................................................. 30

JOB SUMMARY DISPLAY.......................................................................................................................... 30

NAVIGATION BAR ...................................................................................................................................... 30

EDIT ON ...................................................................................................................................................... 30

REMOVE ..................................................................................................................................................... 31

EDIT ............................................................................................................................................................ 31

ADD ............................................................................................................................................................. 31

COPY .......................................................................................................................................................... 31

DOWNLOAD ............................................................................................................................................... 31

MAIN MENU ................................................................................................................................................ 31

Job Setup Screen ..................................................................................................................................................... 32

JOB NAME .................................................................................................................................................. 32

HIGH CAPACITY ........................................................................................................................................ 32

LOW CAPACITY ......................................................................................................................................... 32

TARGET ...................................................................................................................................................... 32

+ TOL .......................................................................................................................................................... 33

- TOL ........................................................................................................................................................... 33

EXPAND FACTOR ...................................................................................................................................... 33

LEARNING CYCLE ..................................................................................................................................... 33

ADAPTIVE LEARNING ENABLE/DISABLE ............................................................................................... 33

ALARM WINDOW (ms) ............................................................................................................................... 34

(LOOK) WINDOW TIME (ms) - Only applicable to none Resolver Model .................................................. 34

PTM LOADGARD Series Operators Manual

PASTE......................................................................................................................................................... 34

CANCEL ...................................................................................................................................................... 34

SAVE ........................................................................................................................................................... 34

PASSWORD CHANGE ............................................................................................................................................ 35

MASTER PASSWORD ............................................................................................................................... 35

ADMINISTRATOR PASSWORD ................................................................................................................ 35

OPERATOR PASSWORD .......................................................................................................................... 35

INITIAL PASSWORD .................................................................................................................................. 35

ADTSERVER SETUP SCREEN .............................................................................................................................. 36

Monitor Screen ......................................................................................................................................................... 36

OPERATING STATUS INDICATOR ........................................................................................................... 36

OPERATING MODE INDICATOR .............................................................................................................. 36

Sensor Calibration Screen ....................................................................................................................................... 37

System Setup Screen .............................................................................................................................................. 38

WINDOW TIME (ms) - Only applicable to none Resolver Model ............................................................... 38

PEAK WINDOW (Enable/Disable) - Only applicable to none Resolver Model ........................................... 38

SCALE SET ................................................................................................................................................ 38

TREND ALARM .......................................................................................................................................... 38

System Setup Screen for PTM-5600P/6700P ............................................................................................ 39

SCALE SET ................................................................................................................................................ 39

System Setup Screen for PTM-4500TSM/6700TSM/6700i-TSM ............................................................................ 40

TREND WARNING OUTPUT LEVEL ......................................................................................................... 40

SAVE ........................................................................................................................................................... 40

CANCEL ...................................................................................................................................................... 40

LOOK WINDOWS ....................................................................................................................................... 40

PTM LOADGARD ADC SETUP for TSM model .................................................................................................... 41



Go To ADC Manager .......................................................................................................................... 41



ADC Manager Setup ........................................................................................................................... 41



ADC RS232 CABLE CONNECTION .................................................................................................. 43

GETTING READY FOR CALIBRATION .................................................................................................................. 44

SYSTEM SPECIFICATIONS ................................................................................................................................... 46

BYPASS OPTION FOR PTM-4500TSM Model ....................................................................................................... 47

To enable the Bypass option, please contact Helm Instrument for further instruction. ADC ASCII PROTOCOL ... 47

ADC ASCII PROTOCOL .......................................................................................................................................... 48

APPENDIX A ( PTM-4500L2 ) - 4Ch Frame with 2 Linear Transducer ................................................................. 50

APPENDIX B ( PTM-2300L ) – 2Ch Frame/Indie with 1 Linear Transducer Input ................................................ 51

APPENDIX C ( PTM-6700i ) – 6Ch In-Die Applcation ........................................................................................... 52

APPENDIX D ( PTM-5600F ) – 3Ch In-die + 2Ch Frame application .................................................................... 53

APPENDIX E ( PTM-6700TSM ) 4Ch Frame + 2Ch Indea with Resolver Input ................................................... 54

APPENDIX F ( PTM-4400i ) 4Ch In-die application ............................................................................................... 55

APPENDIX G ( PTM-4500TSM )- 4Ch Frame with Resolver Input ...................................................................... 56

APPENDIX H ( PTM-4500TSM-ASA )- 4Ch Frame + Auto Shutheight Adjust w/ Resolver Input ........................ 57

PTM LOADGARD Series Operators Manual

APPENDIX I ( PTM-5600P) - 5Ch Piezo Sensor Input .......................................................................................... 58

APPENDIX J ( PTM-4500) - 4Ch Frame with CAM input ...................................................................................... 59

APPENDIX K ( PTM-4500-ADC) - 4Ch Frame with Automatic Die Change Option .............................................. 60

APPENDIX L LINE SUPERVISOR WITH RLG CONENCTION ........................................................................... 61

APPENDIX M ( PTM-6100-SS) - 4Ch Frame, 1Ch In-Die, 1Ch Laser Sensor ....................................................... 62

APPENDIX N ( PTM-6700i-TSM) - 6Ch In-Die With Trend Warning Output .......................................................... 63

APPENDIX O PTM LOADGARD DIMEMSION (Standard Mount) ......................................................................... 64

APPENDIX P PTM LOADGARD DIMEMSION (FLANGE MOUNT)....................................................................... 65

APPENDIX P-1 PTM LOADGARD PANEL PC CONNECTIONS LAYOUT ........................................................... 66

APPENDIX Q (PTM-884TSM-SS) 4Ch Frame, 4Ch In-Die Sensors...................................................................... 67

APPENDIX R (PTM-844TSM-SS) Connection Drawing ......................................................................................... 68

APPENDIX S (PTM-1248TSM-SS) 4Ch Frame, 8Ch In-Die Sensors .................................................................... 69

APPENDIX T (PTM-1248TSM-SS) Connection Drawing ....................................................................................... 70

APPENDIX U RLG Line Supervisor Connection .................................................................................................... 71

APPENDIX V PTM-102L Connections .................................................................................................................... 72

APPENDIX W PTM-4500TSM New I/O Board Connections .................................................................................. 73

APPENDIX X PTM-6600TSM for Doule Action Connections ................................................................................ 74

APPENDIX Y PTM-8800TSM for Doule Action Connections ................................................................................. 75

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 is used during Setup or Learn mode to monitor the Trend Alarm

conditions before new Sample values are available.

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.

PTM LOADGARD Series Operators Manual

TOUCH SCREEN INTERFACE

MAIN MENU

Main menu allows you to access different area of the system. The PTM LOADGARD™

features a touch screen display for easy navigation and operation of the system. Click or

touch on the button you wish to access.

PRESS MONITOR – This is where you can monitor the peak tonnage values, tonnage

signatures, change Alarms setting, view Alarm Messages, SPC and more.

RECIPE MANAGER – You can create a new job, edit or delete existing jobs, and download a

job settings to the system.

PASSWORD EDIT – set or change the passwords.

ADTSERVER – helps to diagnose the system status for the trouble shooting purposes. Initial

and system setup is done here.

SHUTDOWN – prepares the system to be powered down safely. This is protected by

operator password. Use “4356123” as password to exit out to Windows Desktop screen

without shutting down the system.

Warning: We recommend to use SHUTDOWN button before powering down the system.

Improper shutting down of the system may cause an abnormal system operation.

PTM LOADGARD Series Operators Manual

PRESS MONITOR

TONNAGE DISPLAY SCREEN

PRESS MONITOR provides the screens to view peak tonnage load, Tonnage signatures, ,peak

tonnage history, and SPC charts, You can change Alarm settings and view Alarm Messages as

well.

MAIN PEAK LOAD SCREEN FOR VARIATY PTM MODELS

This screen displays peak tonnage values, alarm settings, and alarm indicators for all channels.

Alarm Setting

Display

Trend LED

Alarm Indicator LED

Peak Tonnage Display

Alarm Indicator & Alarm History

Total Peak Display

Main Tonnage screen from PTM-6700TSM

Main Tonnage screen from PTM-4500L2

PTM LOADGARD Series Operators Manual

Main Tonnage screen from PTM-4500TSM

Main Tonnage screen from PTM-5600P

Main Tonnage screen from PTM-2300PG

PTM LOADGARD Series Operators Manual

Main Tonnage screen from PTM-6600TSM-DA

Main Tonnage screen from PTM-8800TSM-DA

FOR DOUBLE ACTION PRESS MACHINES

PTM LOADGARD Series Operators Manual

CURRENT JOB DISPLAY

ALARM INDICATOR & HISTORY

ALARM HISTORY

Click on ALARM WARNING DISPLAY button to view ALARM HISTORY.

TOTAL PEAK DISAPLY FOR FRAME

PEAK TONNAGE DISPLAY FOR FRAME (Ch1 – 4)

This peak display shows the peak tonnage load of each channel within the look window from

each cycle of the press.

Shows current Job name. Job name can be edited from

RECIPE MANAGER screen

This ALARM INDICATOR button has two functions, It indicates

any alarms tonnage condition and lets you view alarm history.

When the machine is running within normal parameter, the

message on the button shows ALARM HISTORY. The message

ALARM with red color background indicates there is an alarm

condition(s). In this case, it will flash the message “Click Here

for Detail”. To view the detail message of the alarm, click on the

display to open ALARM HISTORY screen. You can click on this

display to view previous alarm messages at anytime.

You can view up to last 500 alarm

messages that have date and

time stamp. Use the scroll bar on

the right side of the list box or

arrow buttons on the bottom to

scroll up and down the history list.

Use Clear button to empty all

messages.

Note: you need administrator or

higher level of password to clear

the alarm history.

TOTAL displays the summation of the four corner peak tonnages .

This value is the actual peak tonnage load that the press is taking in

each cycle.

PTM LOADGARD Series Operators Manual

TREND LED

ALARM INDICATOR LED FOR FRAME CHANNEL

H TND (HIGH TREND ALARM)

When the peak tonnage of an individual channel reaches the high limit of the setting for Trend

Alarm, the black rectangle next to the description will turn red to indicate that a High Trend alarm

is triggered. Refer to ALARM SETUP SCREEN for details.

L TND (LOW TREND ALARM)

When the peak tonnage of an individual channel reaches the low limit of the setting for Trend

Alarm, the black rectangle next to the description will turn red to indicate that a Low Trend alarm

is triggered. Refer to ALARM SETUP SCREEN for details.

L CAP (LOW CAPACITY ALARM)

When the peak tonnage of an individual channel reaches the low limit of the setting for Capacity

alarm, the black rectangle next to the description will turn red to indicate that a Low Capacity

alarm is triggered. Refer to ALARM SETUP SCREEN for details.

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

When alarm(s) occurred, ALARM INDICATOR LED displays the cause of the

alarm.

H CAP (HIGH CAPACITY ALARM)

When the peak tonnage of an individual channel reaches the high limit of the

setting for Capacity alarm, the black rectangle next to the description will turn

red to indicate that High Capacity alarm is triggered. Refer to ALARM SETUP

SCREEN for details.

The vertical bar meter next to the peak display box is a Trend Display bar. It

shows the visual reference of a peak tonnage variation comparing to TARGET or

SAMPLE tonnage for Trend Alarm. The center green light indicates 0% variance

within the tolerance of the Trend Alarm. The green light, one above the center,

indicates 25% variance. Toward to the red light on the top, the yellow light shows

50% and 75%. Once the tonnage reaches 100% of the tolerance or beyond, all

the bars from the center to top light up and it indicates the High Trend Alarm

condition. This applies to Low Trend Alarm as well. Only difference is the

negative percentage (-25%, -50%, -75% and –100%) and opposite instead.

Gag Tool Input Indicator

Trend LED

High Capacity

Alarm Indicator

High Trend Alarm

Indicator

Low Trend Alarm

Indicator

Low Capacity

Alarm Indicator

Peak Display

PTM LOADGARD Series Operators Manual

VIEWING CURRENT ALARM SETTINGS (In-Die Screen Only)

ALARM RESET

ALARM SETUP

OPERATING MODE

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

Capacity alarms and Trend alarms are available. The tolerance band for Trend alarm is

calculated by Target value + ( ±TOL x Expand Factor ). You can enable or disable the Trend

Alarm from System Setup screen.

Once the Alarm output relay is disengaged by an alarm condition(s), click on

the RESET button to clear all alarm indication and alarm relay output.

Operating mode can be switched by clicking one of the

CURRENT MODE buttons. While in LEARN mode, the

mode always changes to MONITOR mode

automatically after LEARN cycle is completed.

Click on one of the buttons to view current alarm setting values. The values will

be displayed in the Peak tonnage display boxes for 20 seconds and change back

to PEAK automatically.

The TOTAL PEAK display box shows the viewing mode currently selected.

PEAK Current peak tonnage value.

TARGET (TARG) Target tonnage value.

SAMPLE (SAMP) Sample tonnage value.

HIGH CAP (HCAP) High Capacity tonnage limit

+TOL (+TOL) High tolerance tonnage limit above the Sample or Target

value.

-TOL (-TOL) Low tolerance tonnage limit below Sample or Target

value

LOW CAP (LOW) Low capacity tonnage limit

EFACTOR (EFAC) Expanded Factor which is tolerance multiplier to

increase the tolerance band in Setup & Learn Mode

Click on ALARM SETUP button to bring up CURRENT ALARM SETTING screen

where you can set or change the current alarm settings and download the new

settings to the system to take effect. You can also stores any change you made

in this screen to Recipe database easily. Refer to CURRENT ALARM SETTING

for details.

PTM LOADGARD Series Operators Manual

Learn Mode – In LEARN mode, system averages the peak values for each channel during the

predefined learning cycle. Once the learning cycle is completed, the each average value is stored

as sample value for each channel and the operating mode automatically switches to Monitor

mode. Capacity alarms and Trend alarms are available during Learn mode. The tolerance band

for Trend alarms is calculated by Target value + ( ±TOL x Expand Factor ). You can enable or

disable the Trend Alarm from System Setup screen.

Note: you can define the number of Learn Cycle and store it as a part of job recipe item in Job

Setup screen.

Monitor Mode – In Monitor mode, you have the option to enable or disable the Adaptive

Learning feature which is part of job recipe item. When the Adaptive Learning is active, the

system continuously re-learns sample values while monitoring for any alarm condition. You can

change the number of Adaptive Learning cycle by changing the Learning Cycle from Alarm

Setup screen.

ADPT ON/OFF - This indicates whether Adaptive Learning feature is turned on or off.

Once the Adaptive Learn is active, you should see that the green LED on the mode select button

flashes.

COPYING SAMPLE TO TARGET

VIEW PEAK HISTORY

Use COPY button to replace the TARGET value with the SAMPLE value. It is

useful when you have to arbitrary set the Target value for a new job for the first

time. After the Learning procedure is completed for a new job, click on the COPY

button to update the Target values with the Sample values. When making a copy,

it prompts with a message to give you the option to update the new TARGET

values to the Recipe database for a current job.

Click this button to open PEAK TONNAGE HISTORY screen where you can view

a recorded peak tonnage graph up to previous 1000 hits in one screen. Also, you

can select the range of the peak history to display SPC (Statistical Processor

Control) charts. Refer PEAK HISTORY & SPC for details.

PTM LOADGARD Series Operators Manual

PEAK HISTORY & SPC(STATISTICAL PROCESS CONTROL) CHARTS

ZOOMED MODE

This indicates that the current history graph has been zoomed. To zoom the graph, point to the

area on the screen where you want to start zooming and drag the point down right to create a

zoom rectangle. Once the inside of the zoom rectangle covers the area where you want to zoom

in, release the point from the screen. You can repeat this to continue zooming within the area.

CHANNEL SELECT BUTTONS

Toggle the buttons to add or remove the peak graph of the channel from the history graph.

CONFIG

Channel Select

Buttons

Zoom Mode

Indicator

You can define how often the peak values need to be recorded into the

peak history. Set the Update Frequency value and click Save to take

effect the new setting.

PTM LOADGARD Series Operators Manual

CHANGE GRAPH RESOLUTION

SCROLL

UNZOOM

GRID

BOLD

LEGEND

SPC

Click this toggle button to make the width of the peak graph line bold.

Click this button to show or hide the legend of the graphs displayed on the screen.

Click this button to reset the zoomed graph and return to original size.

The Peak history records up to 10,000 previous peak values. You can

change the number of viewable peak points on a graph by choosing

one of the options

100pt – to display 100 peak points at a time

500pt – to display 500 peak points at a time

1000pt – to display 1000 peak points at a time

Click this button to show or hide vertical and horizontal grid lines on Peak Graph

screen.

These buttons let you scroll left or right to view rest of the peak points outside

the graph. Click left arrow button to scroll left, right arrow button to scroll right.

Click this button to generate SPC charts within the peak data displayed on the history

graph. Use Zoom or Scroll to select the range of the peak history to generate SPC

chart you want to see.

If more than one channel is displayed in the history graph, SPC averages them to

generate the charts.

PTM LOADGARD Series Operators Manual

CURRENT ALARM SETTING

In CURRENT ALARM SETTING, you can view / edit the current alarm settings and also save the

change to current job database and download the change to ADTServer.

Resolver TSM model: PTM 2300/4500/6600DA/6700TSM

None Resolver model: PTM-4500

PTM LOADGARD Series Operators Manual

Group Select

Select Group Select option if you want all channels to have same settings.

HIGH CAPACITY

HIGH CAPACITY is the limit for the maximum peak tonnage allowed to operate the machine.

Normally the value is set at or below the scale value which is the capacity of the machine

divided by the number of frame sensor channels. HIGH CAPACITY alarm is available in all

modes.

Note: You need to enable the Edit mode by using Administrator or higher level of password in

order to make any changes from this screen.

LOW CAPACITY

LOW CAPACITY is the limit of the minimum peak tonnage allowed to operate the machine.

Normally the value is set for 0 (disabled) unless there is a special need. LOW CAPACITY

alarm is available in all modes.

TARGET

The concept of TARGET is to provide a Trend alarm protection for SETUP and LEARN

modes. Normally, Trend Alarm requires a sample tonnage to compare the current peak

tonnage to monitor the alarm condition. However, the Sample value is only available when

the system has completed its Learning cycle and the operating mode has been changed to

Monitor mode. In typical load monitoring system, the Trend alarm is not available during

Setup and Learn mode. In this system, the TARGET feature is to gives you the full protection

of Trend Alarm by letting you manually enter the expected tonnage value for the job before

running the press. Once the machine has started and acquired new Sample values by

Learning procedure, you can update the Target values with them by clicking the Target

COPY button in the main Tonnage screen. In case that you try to run a new job and are not

sure where the Targets need to be set at, you can set each Target value to zero. This will

disable the Trend Alarm on a channel by channel basis. After system learns the new sample

values, you can use the Target Copy command to update the Target values.

Note: While the system is in Setup or Learn mode, adjust Expand Factor to increase the

tolerance band to avoid unnecessary Trend alarm warning. Refer to Expand Factor for

details.

+ TOL

This is the upper tolerance tonnage limit for a High Trend alarm of each channel. This limit

prevents the current peak tonnage load from exceeding the +TOL tonnage setting above the

Target (In Setup or Learn mode) or Sample (In Monitor mode) value.

Note: Depending on EXPAND FACTOR value, actual tolerance may differ from the value that

was set while the system is in Setup or Learn mode. Refer to EXPAND FACTOR for detail.

- TOL

This is the lower tolerance tonnage limit for a Low Trend alarm of each channel. This limit

prevents the current peak tonnage from exceeding the -TOL tonnage setting below the

Target (In Setup or Learn mode) or Sample (In Monitor mode) value.

Note: Depending on EXPAND FACTOR value, actual tolerance may differ from the value that

was set while the system is in Setup or Learn mode. Refer to EXPAND FACTOR for detail.

EXPAND FACTOR

These are the multipliers for the + and -TOL values to increase the range of the tolerance

bands so that the system has less chance to fire Trend alarms while the press is running in

SETUP or LEARN mode. Once the system is in Monitor mode, This EXPAND FACTOR does

not affect the tolerance for Trend and Tracking alarm band in PLM model. However, in TSM

PTM LOADGARD Series Operators Manual

model(with Resolver), this expand factor still applies to the Tolerance setting for Trend alarm,

but not Tracking alarm.

Example: Target = 60 , Sample = 64, +Tol = 10, -Tol =15, Exp Factor = 2.0

In Setup or Learn mode

Actual High Trend limit = 60 + (10 * 2.0) = 80

Actual Low Trend limit = 60 - (15 * 2.0) = 30

In Monitor mode

Actual High Trend limit = 60 + 10 = 70

Actual Low Trend limit = 60 - 15 = 45

DELTA TRACK EX

Delta Track feature pertains to the filtering of tracking alarms, and help avoid “nuisance” type

alarms. The filtering occurs during sudden force change through the press stroke. Delta

Track filtering can be seen in the signature screen, where high slopes area of the sample

signature (along with the tracking bands) are filtered out during relatively small portion of the

stroke.

Filter level can be adjusted. Enter a value between 1 and 99 to determine how much of the

slope rate area to be filtered. 99 filter the least and 1 will filter the most out of the slope area.

Enter ‘0’ to disable Delta Track filtering.

Enter “100” to enable Perpendicular Tolerance(PT) tracking bands.

PT Tracking generates the tracking bands that envelop around the sample signatures evenly

throughout the alarm window area. This Tacking gives you the ability to monitor tracking

alarm in very tight tolerance setting without cause “nuisance” alarm by any minimal horizontal

shiftiness of the force signature.

Standard Tracking at 15% Tolerance

Delta Track Enabled & set at 80

P.T. Tracking at 3% Tolerance

PTM LOADGARD Series Operators Manual

LEARNING CYCLE

Enter the number of cycles to take to learn new Sample values in LEARN mode. In

MONITOR mode, Adaptive Learning feature uses this cycle to learn new Samples when it is

enabled. In TSM Model, enter 0 to use Target values as Sample for Trend alarm in Monitor

mode without going through learning process for new sample. Note that Learn Cycle set to

“0” disables Tracking alarm.

ADAPTIVE LEARNING ENABLE/DISABLE

You can enable or disable Adaptive Learning feature in MONITOR mode. By enabling the

Adaptive Learning, the system continuously learns new sample values while it is in Monitor

mode and applies the new Sample values to monitor Trend alarm conditions as soon as

available. This will allow the system to adapt any small gradual variances of the tonnage

load through the time which are caused by environmental change such as temperature. If

any tonnage load that causes an alarm, the reading is excluded from Adaptive Learning

process.

ALARM WINDOW (ms)

Set alarm window to adjust the area of the force signature to monitor for tracking alarm. If

PEAK WINDOW is enabled, this ALARM WINDOW determined the area of the signature to

capture the peak tonnage instead of from entire signature. Enter start and stop Alarm

Window times in msec within Window Time.

Note: In Resolver model, enter the range of the angle value instead of time.

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

Look Window Time is the duration of time when the force signature and peak tonnage is

captured. The WINDOW TIME need to be adjusted based on the speed of the machine to

capture optimal force signature.

ENABLING EDIT

Before you are able to make any changes on the settings in this screen, you

have to enable Edit mode first. To do so, click on Edit button and enter a

password to enable the Edit mode. Depending on the password clearance

level, restrictions will apply.

Default Password:

Operator password = “123”

Administrator Password = “123456”

Master Password = “1968”

PTM LOADGARD Series Operators Manual

Here is the table for editable contents based on the password type.

Functions

Operator

Password

Administrator

Password

Master

Password

Scale Value change

High/Low Capacity Setting

Window Time Setting

Tracking Threshold Set

High/Low Tolerance Setting

Target/ EXP Factor

Tracking On/Off

Learn Cycle Count

Alarm Window Setting

RECIPE Job Download

RECIPE Job Add/Edit/Delete

DOWNLOAD

JOB RECIPE

SAVING TO RECIPE DATABASE

MAIN MENU

Click this button to download new alarm settings to system. Downloading

is only allowed in Setup mode. If the system is currently in LEARN or

AUTOMATIC mode, it will prompt with a message that will ask if you want

to switch back to SETUP mode.

Note: Any change of settings you make in this screen will take effect after

Download is completed.

Click this button to go to RECIPE MANAGER screen.

Click this button to update current job stored in Recipe database with the

new settings made from this screen.

Click this button to return to main tonnage screen

PTM LOADGARD Series Operators Manual

PRESS CURVE ALARM

The resolver based PTM Loadgard system allows the operator to enter the specified 36

press curve points in the Press Curve Data Setup screen for Press Curve Alarm.

Multiple press curve data can be saved. Select a press curve data file and click download to

active it.

PTM LOADGARD PRESS CURVE SETUP PROCEDURE

A. How to edit existing Press Curve data file

1. Select the file you created from the list then click

Edit button to enter date points

2. Edit the value in 36 points to match Press Curve

data. starting 0 degree in degree, enter data every

10 degree. The data is a percent value x 10 of total

capacity of the machine.

3. For example, if the press capacity is 500t and the

press is rated as 250t at 90 degree crank angle

according to the press curve chart, then enter 500

(50% x 10 = 500) for 9th data entry point. The

formula is:

Press Curve Data Value = (Capacity @ angle / Press Capacity) * 1000

( 250 / 500 ) x 1000 = 500

Active Press Curve

data in the Loadgard

System.

Turn Edit On to make

changes

When new data has

been downloaded,

click Refresh to

update the screen

with new data

Press Curve data

files stored in

memory

Data from the

selected file

stored in

memory.

To edit the data

in the selected

file. This will

lead to PRESS

CURVE DATA

entry screen

To create a new

press curve data file.

Download a selected

Press Curve data file

to be active data

PRESS CURVE DATA ENTRY

SCREEN

Copy all data points from a

selected file and paste the

same data into a different file

selected

PTM LOADGARD Series Operators Manual

B. How to Create a new Press Curve data file.

1. First you need 36 data points from Angle vs. Tonnage capacity graph.

2. Turn Edit On.

3. Click Create button and name your data file using the pop-up keyboard.

4. Select the file you created from the list then click Edit button to enter date points

5. Enter 36 points for Press Curve date. starting 10th degree, enter data every 10 degree.

The data is a percent value x 10 of total capacity of the machine.

Please refer to the table below for example how to calculate the data points for each degree.

Press Capacity: 500t

Crank Angle

(Degree)

Capacity@Angle

(t)

Press Curve Data

(% x 10)

100

200

110

220

120

240

140

280

180

360

200

400

225

450

Press Curve Data Value = (Capacity @ angle / Press Capacity) * 1000

For example, if the press capacity is 500t and the press is rated as 250t at 90 degree crank angle

according to the press curve chart, then enter 500 (50% x 10 = 500) for 9th data entry point.

( 250 / 500 ) x 1000 = 500

C. How to Download A Press Curve Data File to be Active .

1. Select a Press Curve data file

created in PRESS CURVE DATA

FILES list and click DOWNLOAD

button.

2. Click Refresh button to update the

CURRENT DATA list screen with

the recently downloaded data.

3. Click Return to go back to Alarm

Setup screen and enable Press

Curve feature for each Channel.

PTM LOADGARD Series Operators Manual

Signature (Wave) Display Screen

The Signature Display screen displays real-time force signatures for individual channels. The

overlaying with other signatures or graphs help you to monitor the operating status of the

machine or verify the alarm conditions easier.

JOB

This is the current job name downloaded from RECIPE MANAGER.

PEAK

Current peak tonnage value for the channel currently displayed.

HIGH CAP

High Capacity Alarm setting value in tons for the channel currently displayed.

LOW CAP

Low Capacity Alarm setting value in tons for the channel currently displayed.

TARGET

TARGET setting value in tons for the channel currently displayed.

SAMPLE

SAMPLE value in tons for the channel currently displayed.

HIGH TOL

+ TOLERANCE setting value in tons for the channel currently displayed.

LOW TOL

- TOLERANCE setting value in tons for the channel currently displayed.

PTM LOADGARD Series Operators Manual

WAVE VIEWING WINDOW

ZOOM INDICATOR: This message indicates that the graph is currently zoomed.

HIGH CAPACITY: High Capacity limit

HIGH TREND: Upper limit of trend alarm band

LOW TREND: Lower limit of trend alarm band

SAMPLE/TARGET: In SETUP and LEARN mode, it displays the Target line.

In AUTOMATIC mode, it displays the Sample line.

LOW CAPACITY: Low Capacity limit

CURRENT WAVE: Current tonnage signature read from sensor.

READ TONNAGE AT ANGLE

To delete last reading on the

screen

Click on this button to enable the Read

Tonnage at Angle feature. To view the

tonnage at angle, click on the

coordination you want to read from the

signature screen. You can view up to

20 readings on a screen

simultaneously. Use Back or Clear

button at the top-right corner to delete

unwanted readings.

HIGH CAPACITY

CURRENT

CHANNEL

NUMBER

LEGEND

HIGH TREND

LOW TREND

SAMPLE/

TARGET

LOW CAPACITY

CURRENT WAVE

To clear all readings on the

screen

ZOOM

INDICATOR

READ TONNAGE

@ ANGLE

PTM LOADGARD Series Operators Manual

ZOOM IN

RESET ZOOM

TREND TYPE

TREND

The Zoom feature allows the user to “zoom in” on a selected area of the signature

for analysis at a higher resolution. Click this button to put the signature screen in

zoom mode.

Note: Once the wave is zoomed, a message “ZOOMED” shows up on the top-left

corner of the Signature View Window to indicate that signature is currently in

zoomed mode.

To select an area to zoom in: Press

touch screen (and keep pressed) at

top left area of desired part of wave

to zoom in, and drag finger at a

diagonal down and to the right. A box

will be drawn and finger followed as

the touch screen is pressed. Release

touch screen to draw zoomed-in part

of the wave.

Repeat Zooming is permitted to

continuously zoom in on a particular

area of a signature.

Click this button to return full view(unzoom)

Click this button to open the SELECT TREND GRAPH TO SHOW screen where you

can

select which Trend graphs to be displayed when TREND button is activeted.

You can add/remove different types of

trend graphs you desire to overlay on the

signature screen. To add, click on the

button you want to view. When the button

is pushed in, the option for the graph is

added. Click again to remove it.

Note: This option only works with TREND

button.

Toggle this button to show or hide the trend graphs selected from TREND TYPE

option. This will give the visual references of the alarm settings and forming force

related to the Sample.

PTM LOADGARD Series Operators Manual

Thru

GRID

BOLD

LEGEND

CHANNEL SELECT

OVERLAY

OVERLAY SCREENS

Click this button to show or hide vertical and horizontal grid lines on the wave

screen.

Click this toggle button to make the current signature graph line bold.

Click this button to show or hide the legend of the graphs displayed on the screen.

Select a button to display the corresponding channel signature on

the screen.

Click this button to view the overlay of multiple channels of current signatures. Also,

you can select the option to view multi-channel peak bar graph from here. Refer to

OVERLAY SCREEN for details

Note: You cannot view Trend graphs while Overlay screen is on. All other features are

still available.

You can add/remove multiple channels

of signatures to overlay on one screen

by clicking the channel buttons from

Select Channels To Overlay screen.

Choose the channel(s) you wish to

view and click Show button to view

Signature Overlay.

Select SHOW AS BAR to view Peak

Bars instead.

PTM LOADGARD Series Operators Manual

SIGNATURE OVERLAY SCREEN

PEAK BARS SCREEN

High Capacity limit

Peak Tonnage

reading

Color coded Alarm

Indication

Trend alarm

Tolerance range

bar

Peak Tonnage Bar

PTM LOADGARD Series Operators Manual

RECIPE MANAGER

RECIPE MAIN SCREEN

Recipe Manager is where you can create and store new jobs, edit or delete existing jobs, and

download the job you want to set the system for. You can store virtually unlimited number of

jobs.

JOB SUMMARY DISPLAY

Job Summary Display shows a list of all stored jobs that have been created and saved into a

job database. Each job is listed with job name and note. By clicking on one of the jobs from

the list, it will highlight the job and make it as an active job. The active job can only be

Edited, Removed or Downloaded. You can use navigation bar on the right side of the list box

to change the active job.

NAVIGATION BAR

You can select an active job by using navigation buttons. It will help you to navigate through

the Job Summary Display to select the job you want by using touch of buttons instead of

dragging small scroll bar.

EDIT ON

In order to Add, Edit, Delete, or Download an active job, The Edit button on the bottom-left of

the screen must be turned on. This enables Edit, Add, Remove, and/or Download buttons

depending on which level of password is entered. Download requires either the Operator

level or higher password. Edit, Add and Remove require Administrator level or higher

password.

JOB SUMMARY

DISPLAY

NAVIGATION

BAR

CURRENT

ACTIVE JOB

PTM LOADGARD Series Operators Manual

REMOVE

EDIT

ADD

COPY

DOWNLOAD

MAIN MENU

REMOVE button deletes a current active job from the Job Summary Display.

Select the job you wish to delete and click on REMOVE button.

EDIT button will lead you to JOB SETUP screen where you can make changes

of current active job settings such as Job name, alarm settings, etc. In order to

edit a job, select the job you wish to edit from Job Summary Display and click

on EDIT button.

Click Add button to bring up JOB SETUP screen. All parameters for alarm

settings will be blank except the High Capacity alarm. The High Capacity alarm

is predefined by previous job.

When you create a new job, you can also copy the settings from an existing job

from the Job Summary List and paste them into a new job or the existing job.

To copy a job, select the job you want to copy and click on COPY button. Once

you go to JOB SETUP screen to add or edit a job, you will see that PASTE

button is enabled. Click on the PASTE button to paste the settings, you copied,

into the alarm settings for the job.

Click DOWNLOAD button to download the current active job to ADTServer to

take effect of the new settings. The operation mode has to be in SETUP mode to

download the job.

Click this button to return to Main menu.

PTM LOADGARD Series Operators Manual

JOB SETUP SCREEN

This is where you can edit or enter new settings for the job you created.

JOB NAME

Enter a job name for the job you created. This will identify each job in the Job database. You

can enter any character up to 20 characters.