Toledo Transducers MoniTTor N269 User manual



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N269 Manual
Table of Contents
I.D. Page
Warranty Page 1
Figure 1 - Enclosure Mounting Dimensions Page 2
Figure 2 - AC Power Hookup Page 4
Figure 3 - Sensor Hookup Page 5
Figure 4 - Main PC Computer Interface Wiring and Settings Page 6
Figure 5 - N269 Front Panel Page 7
Figure 6 - Keyboard Jumpers and Switches Page 8
Figure 7 - N269 Process Control Zone Chart Page 9
N269 Operators Guide Page 10
I. General Description Page 12
II. Operation Page 14
A. Using The Display and Keyboard……………………………………………………………….Page 14
1. Load Display Page 14
2. Data Display Page 14
3. Data Entry Display Page 14
4. Key Sequences Page 15
B. Using The Process Control Features……………………………………………………...……Page 15
1. The Setpoints and Zones Page 15
2. The Relays Page 16
a. Setting the Relay Timers Page 17
b. Setting the Relay Preset Counters Page 17
C. Other Setpoints…………………………………………………………………………………Page 17
1. High Setpoints Page 17
2. Low Setpoints Page 18
3. Resetting Alarms Page 19
D. Counters………………………………………………………………………………………..Page 20
1. The Stroke Counter Page 20
2. The Batch Counter Page 20
3. The Process Control Counters Page 20
4. The Alarm Counters Page 21
a. High Counters Page 21
b. Low Counters Page 22
E. Additional Operating Modes…………………………………………………………………...Page 22
1. Set-up Mode Page 22
2. Time Mode Page 22
a. Description Page 22
b. Setting the Time Value Page 23
c. The Point-In-Time Load Page 23
d. The First Level Load Page 24
e. The Second Level Load Page 24
f. The B4 Mode Page 25
3. Average Loads Page 25
4. Reverse Mode Page 26
F. Other Settings………………………………………………………………………...………...Page 26
1. The Stroke Counter Setpoints Page 26
2. Clearing the N269 Memory Page 27

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G. Other Information……………………………………………………………………...………Page 27
1. The Last Alarm Page 27
2. The Last High Alarm Page 27
3. The Last Low Alarm Page 28
4. The Highest Load Page 28
5. The Lowest Load Page 28
6. The Production Rate in Strokes per Minute Page 28
7. The Down-time (Time since the Last Stroke) Page 29
8. The Diagnostics Page 29
III. Installation Page 30
A. Mounting the Enclosure………………………………………………………………...……...Page 30
B. AC & Power Connections……………………………………………………………...………Page 30
C. Sensor Hookup………………………………………………………………………………....Page 31
D. Powering the Meter up……………………………………………………………………...….Page 31
E. Initial settings………………………………………………………………………………...…Page 32
1. Decimal Point Location Page 32
2. Press Capacity Page 32
3. Triggering the Meter Page 33
a. The Threshold Page 33
b. The Probe Input Page 33
4. The Maximum Channel Number Page 33
5. Track (calibration) Mode Page 34
6. The Calibration Shunt Page 34
7. Peak Mode Page 34
F. Calibration………………………………………………………………………………....……Page 35
1. Pre-calibrated Load Cells Page 35
2. Calculated Calibrations Page 36
3. Calibration using Reference Load Cells Page 36
G. Computer Interface Hookup……………………………………………………………………Page 37
1. RS422 Interfaces Page 37
2. RS232 Interfaces Page 37
3. Setup Parameters Page 37
IV. Troubleshooting Information Page 39
A. Using the Output Jack………………………………………………………………………….Page 39
B. Symptoms and Solutions……………………………………………………………………….Page 39
V. Serial Communications Protocol Page 40
A. The Hardware Connection……………………………………………………………………...Page 40
B. Transmission Characteristics…………………………………………………………………...Page 40
C. Record Construction……………………………………………………………………………Page 40
1. The Header Page 40
2. The Trailer Page 40
3. Data - Computer generated Page 40
a. Data Type Character Page 40
b. Command Character Page 41
c. Entry Data Page 41
d. Data Type Characters Page 41
4. Data - N269 Generated Page 44
a. Record Page 44
b. Mode Construction Page 44
c. High and Low LED Construction Page 45
d. LED Conventions Page 45
e. Numbers Page 46
f. Checksum Calculation Page 46

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INSTRUMENT IDENTIFICATION
Name AUTOMATIC PROCESS CONTROL LOAD MONITOR
Model No. N269
Serial No.
Date Shipped
Company:
(name)
(street address)
(city - state - zip)
(telephone number)
Purchase Order No.
Invoice No.

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LIMITED WARRANTY
This unit is warranted by the manufacturer, Toledo Transducers, Inc., to be free of defects in
workmanship and material for one year from date of manufacturer’s shipment. This warranty is
limited to repairing or replacing products which manufacturer’s investigation shows were
defective at the time of shipment by the manufacturer. All products subject to this warranty
must be returned F.O.B., Toledo Transducers, Inc., 6834 Spring Valley Drive, Holland, Ohio
43528, for examination, repair, or replacement.
THE EXPRESS WARRANTY SET FORTH HEREIN IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION
ANY WARRANTIES OF MERCHANT-ABILITY OR FITNESS FOR A
PARTICULAR PURPOSE. ALL SUCH WARRANTIES ARE HEREBY
DISCLAIMED AND EXCLUDED BY THE MANUFACTURER.
Repair or replacement of defective products as provided above, is the sole and exclusive
remedy provided thereunder. The manufacturer shall not be liable for any further loss, damages,
or expenses, including incidental or consequential damages, directly or indirectly arising from the
sale or use of this product.
This warranty is subject to installation and operating conditions described in the accompanying
manual.
Any unauthorized repair voids this warranty.
There are no warranties that extend beyond those expressly set forth herein.

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3

4

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FIGURE 3 Sensor Connections – N269 (RV7)
012
L - H B G (2)
BYPASS
OFF
ANALOG TRACK OUTPUT
TOP ROW: ALL PINS = GROUND
BOTTOM ROW: ALL PINS = GROUND
LO-HI GAIN SWITCH
B = BALANCE ADJUST POT
G = GAIN ADJUST POT
1 2 3 4 L - H B G (1)
1 2 3 4 R W G B S
CHAN 1
CHAN 2
R W G B S
S = SHIELD
B = BLACK: -EXCITATION
G = GREEN: +EXCITATION
W = WHITE: +SIGNAL
R = RED: -SIGNAL

6

7

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FIGURE 6 - Keyboard Jumpers and Switches
JUMPER SETTINGS
GOOD
#1 = DOWN (CLOSED)
#3 = DOWN (CLOSED)
#2 = UP (OPEN)
A
B
J2
POS. 5 _
DOWN
UP
DOWN
UP
POS. 4 _
DOWN
DOWN
UP
UP
BAUD RATE_
76,800
9,600
1,200
300
#4 & #5 = BAUD RATE SELECT FOR I/O TO
& FROM MAIN PC
#7 = UP UNUSED KEY SWITCH
#8 = UP SETTING CAPACITY
SE
RESET DIAG
BY
P
PRE
COUNT
COUNT
TIME
PEAK HIGH
REV LOW
TRACK ENTER SHUNT
7 8 9
45 6
1 2 3
0
CLEAR
SW31
#6 = UP MASTER RESTART
A
B
J3
A
B
J5
A
B
J4
SWITCH SW31 SETTINGS
REJECT
DE.
IN.
J2 - TRANSMIT TO MAIN PC ENABLE
POS. A = RS422
POS. B = RS232
J3 - TRANSMIT TO AUX. DISPLAY ENABLE
POS. A = RS422
POS. B = RS232
J4 - RECEIVE FROM MAIN PC SELECT
POS. A = RS422
POS. B = RS232
J5 - TRANSMIT TO MAIN PC SELECT
POS. A = RS422
POS. B = RS232
1 2 3 4 5 6 7 8
(PUSH SWITCH #8 DOWN AND THEN UP BEFORE
PRESSING “ENTER” TO CHANGE CAPACITY SETTING)
+T
+T
- T
GND
RS232 OUTPUT
RS422 OUTPUT
GROUND
TO AUX. DISPLAY
KEYBOARD

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FIGURE 7 - N269 Process Control Zone Chart
This meter is designed to determine the peak load on each cycle of the press and respond to
the load by operating the appropriate relays. The 4 variable setpoints establish the 5 zones
shown on the sketch. For resolution and accuracy a 4 digit display shows the load.
DEcrease Zone Relay
Acts in response to loads
greater than setpoint #4
|//////|******| Relay has a timer and a
|//////|******| 1-9 preset counter
|/ RE /|******|
|//////|******|
HIGH SETPOINT #3-----------------|******|------|
|******|::::::|
|* DE *|::::::| GOod Part Zone Relay
|******|::::::| Relay operates each
HIGH SETPOINT #4------------------------|::::::| time the load is
|::::::| greater than set-
|: GO :| point #6 and less
|::::::| than setpoint #3
LOW SETPOINT #5------------------------|::::::| Relay has a timer
|++++++|::::::|
|+ IN +|::::::|
|++++++|::::::|
LOW SETPOINT #6-----------------|++++++|------|
|//////|++++++|
|/ RE /|++++++| INcrease Zone Relay
|//////|++++++| Acts in response to loads
|//////|++++++| less than setpoint #5
REject Zone Relay has a timer and a
Two relays - both act in 1-9 preset counter
response to loads greater
than setpoint #6 or less
than setpoint #3. REject Relay has a timer
SHUTdown Relay has a 1-9 preset counter
The meter has 5 relays - 2 for the REject zone and 1 for each of the DEcrease, INcrease, and
GOod part zones. One or two process control relays may operate at once depending on the
load and preset counter values.
Three of the relays have their own 1-9 preset counters. For one of these relays to operate, the
consecutive number of loads set on the preset counter must occur in its load zone. A number
less than this will cause the count to start over. Thus, if the DEcrease zone preset counter is set
to 3, the DEcrease relay would operate after 3 loads in a row above the #4 high setpoint.
Four of the relays have their own separate timers that control the length of time the relay remains
operated. Thus, if the INcrease zone relay timer is set for .8 seconds and the INcrease relay
operates it will remain operating for .8 seconds. These timers may be set to any time between 0
and 99.99 seconds.

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N269 OPERATORS GUIDE
TURN ON POWER - The first time power is applied all values are set to 0.0 except for the
following:
CAPACITY = 100.0 each chan THRESHOLD = 6.3 chan 0
HIGH SETPOINT = 100.0 each chan DIFFERENCE SET = 100.0 chan 0
LOWEST LOAD = 100.0 each chan COUNT HIGH SET = 100.0 chan 0
OPERATING MODE = PEAK mode PRESET COUNTERS = 1
ENTERING DECIMAL POINT and CAPACITY (Only necessary at 1st power-up)
Press HIGH HIGH HIGH pt. (0-3) ENTER (0-2) (value) ENTER
CHECKING CALIBRATION NUMBERS - (Sensor or cell must be connected)
1. press TRACK (Track LED comes on, peak LED goes off)
2. Zero each channel (0,1,2) by adjusting BALANCE pot (chans. 1,2)
3. press SHUNT (S appears in ch. 0, cal nos. appear in chans. 0-2)
4. Adjust GAIN pot chs. 1&2 to get proper cal nos. if not correct.
If the number will not go high enough switch to HIGH GAIN.
5. press SHUNT (S gone, ch. 0-2 = 0. If not=0, repeat steps 2-5)
OPERATING MODES - press PEAK (Peak LED comes on, track LED goes off)
SETUP MODE - press SETUP - LED toggles on/off - if on, in SETUP mode
REVERSE MODE - press REV - LED toggles on/off - if on, in REVERSE mode
AVERAGE TONNAGE DISPLAY - press LOW COUNT 0 or 1 ENTER
0 = no averaging, 1= average of 16 hits (L displayed in chan 0)
IME MODES - press TIME TIME - LED toggles on/off - LED on=TIME mode
to change the TIME mode press TIME (0-3) ENTER
0 = B4, 1 = FIRST LEVEL, 2 = SECOND LEVEL, 3 = POINT-IN-TIME
SETPOINT DATA To display press: To change press:
HIGH SETPOINTS RESET HIGH CHAN # (value) ENTER
LOW SETPOINTS RESET LOW CHAN # (value) ENTER
TIME VALUE RESET TIME 0 (value) ENTER
BATCH COUNTER RESET PRECOUNT (value) ENTER
THRESHOLD LOW LOW LOW 0 (value) ENTER
COUNT HI SETPOINT HIGH COUNT 0 (value) ENTER
COUNT LO SETPOINT LOW COUNT 0 (value) ENTER
COUNT & TIME DATA To display press:
COUNT RESET COUNT
HI COUNTS COUNT HIGH
LO COUNTS COUNT LOW
RATE in SPM COUNT TIME
DOWNTIME TIME COUNT
TONNAGE DATA To display press:
LAST ALARM HIGH LOW
LAST HI ALARM HIGH TIME
LAST LO ALARM LOW TIME
HIGHEST LOAD RESET HIGH HIGH
LOWEST LOAD RESET LOW LOW
RELAY TIMERS To display press: To change press:

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GOOD PART RELAY TIME GOOD 0 (value) ENTER
REJECT RELAY TIME REJECT 0 (value) ENTER
DECREASE RELAY TIME DE 0 (value) ENTER
INCREASE RELAY TIME IN 0 (value) ENTER
PRESET COUNTERS To display press: To change press:
SHUTDOWN RELAY TIME REJECT . (0-9) ENTER
DECREASE RELAY TIME DE . (0-9) ENTER
INCREASE RELAY TIME IN . (0-9) ENTER
ZONE COUNTERS To display press:
REJECT HI ZONE COUNT REJECT HI
REJECT LO ZONE COUNT REJECT LO
DECREASE GOOD ZONE COUNT GOOD DE
INCREASE GOOD ZONE COUNT GOOD IN
OK ZONE COUNT GOOD GOOD
DECREASE ZONE COUNT COUNT DE DE
RELAY COUNTERS To display press:
GOOD PART COUNT GOOD
REJECT COUNT REJECT
DECREASE COUNT DE
INCREASE COUNT IN
INCREASE ZONE COUNT COUNT IN IN
CHANGE FROM 0 TO 2 CHANS & BACK: LOW LOW LOW . 0 or 2 ENTER
RESETTING ALARMS: RESET RESET RESET
CLEARING ANY DATA: CLEAR - clears display to zero
CLEAR MEMORY: press and hold CLEAR - then press RESET RESET RESET
DIAGNOSTICS: each time DIAG is pressed new diagnostic info is shown when #=1, battery
voltage is displayed
I. GENERAL DESCRIPTION - Refer to figure 7

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The N269 process control load meter is used to control the variable material fill of a press on the
basis of the peak load. System input can be from one or two strain gage bridge type sensors. In a
single channel system the input is usually a load cell. Systems with two channels generally use
two press frame mounted load sensors. When two sensor inputs are used, the side to side load as
well as the total load is displayed by the N269. The peak load displayed in channel 0 is used to
perform the process control functions. Five relays are used: four control the process and a fifth
can shutdown the machine.
The N269 divides the range of loads into five zones using four process control setpoints. These
setpoints, form the highest to the lowest, are labeled 3, 4, 5 & 6. All loads above #3 are
considered high rejects and all loads below #6 are low rejects. A load value between #3 and #6 is
considered a good part. Setpoint #4 must be set below #3 and above #6. Setpoint #5 is between
#4 and #6. Any load above #4 is in the decrease zone and any load below #5 is in the increase
zone. A load which falls between #4 and #5 is in the OK zone where no adjustment is made.
Any load in the reject zone (low or high) causes the REject relay to operate. Any load in the good
zone (between #3 and #6) causes the GOod relay to operate. The INcrease and DEcrease relays
have preset counters associated with each relay. In order for the DEcrease relay to operate the
load must be in the decrease zone a number of times in a row determined by the setting of the
decrease preset counter. The INcrease relay will operate only when the load has been in the
increase zone the same number of times in a row as is set on the increase preset counter.
The REject relay has a preset counter as well. However, this counter determines the number of
consecutive rejects which must occur before the machine is shutdown using the shutdown relay.
Each process control relay (RE, DE, IN, GO) has a timer which determines the length of time for
which the relay stays on. These timers may be set from 0 to 99.99 seconds in increments of .01
sec.
The machine can also be shutdown immediately in the event of a high load on either sensor input
(channels 1 or 2 if more than one sensor input is used) or the total load (channel 0). The setpoints
which determine the high shutdown load are the high setpoints #0, #1 and #2. When two sensor
inputs are used, another setpoint is used to shutdown the machine if the difference in load between
channels 1 and 2 exceeds this "difference" setpoint. This setpoint is the channel 0 low setpoint.
The N269 keeps track of many counts. Each of the five zones has an 8 digit counter. Each relay
has an 8 digit counter which increments when the relay operates. All loads above setpoint #4 are
counted (decrease zone) as well as all loads below #5 (increase zone) by 8 digit counters. Each
high alarm setpoint and the difference setpoint has a 4 digit counter which counts these
shutdowns. A stroke counter counts every press stroke (8 digits). Finally there is a
predetermined counter (8 digit batch) which can be set to shutdown the press at the end of a
certain number of parts.
Whenever a shutdown occurs, the channel 4 display shows the word "STOP" and the channel 5

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display goes blank.
Several operating modes can be selected in addition to the normal peak mode. Setup mode
disables all relays. Reverse mode shows any reverse loading taking place. A time delay starting
at the beginning of the load cycle can be set to use the load at a particular point the stroke. First
level mode is the peak load up to the time point. Second level mode is the peak load after the time
point. The B4 mode combines first level and normal peak mode. In addition, the average load for
the previous 16 strokes may be used for the process control. Finally, calibration is done in the
track mode.
The N269 contains numerous additional features. Normally a threshold is used to sense the
beginning of a cycle. Alternately a probe may be used. Another probe may be used to select a
point in the stroke rather than the time delay described above. The N269 can display strokes per
minute, the accumulated downtime (time since the last stroke), and the last alarm load value. The
highest load and the lowest load is also stored in the memory.
All setup parameters and counts are stored in a battery backed up memory which will hold the
data for years. A diagnostic routine indicates when the battery needs to be replaced. The
diagnostics also indicate probe and relay status in addition to the software version number.
The N269 also has a built in high speed computer interface. RS232 or RS422/RS485 can be
chosen with selectable speeds of from 300 to 76,800 baud. When using the RS422/RS485
interface up to 32 meters may be daisy chained on the same twisted pair cable. In this
configuration each meter has a unique address which the computer uses to poll it in turn. The
computer has all the capability that an operator has at the N269 keyboard. Information can be
fully up or down loaded to and from the computer.
II. OPERATION
A. USING THE DISPLAY AND KEYBOARD - Refer to figure 5
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