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User Manual - PLC Products Group

1. Signals to from trok a Main Solenoid Valves ane Input 7 Input restore Air Supply Flywheel y T Main Solenoid Valves Air to clutch Resolver Press RCLS or Resolver to Monitor m to Monitor Stroke Posiion lt Stroke Position NN Crankshaft i l Crankshaft at Top Position pom Crankshaft at Bottom P osition Publication 6556 6 5 11 August 1998 Overview 1 5 Resolvers The control system requires at least one resolver and resolver input module to precisely monitor the crankshaft s rotational position for clutch brake control and PLS operation We recommend the following purchased separately resolver Rockwell Automation 846 SJDN1CG R3 resolver input module Helm HM571 RES Rotary Cam You may use a rotary cam limit switche as the redundant input to Limit Switches monitor the crankshaft s position We recommend Allen Bradley Cat No 803 P775 that you purchase separately Panel Switches The clutch brake control requires the panel and input switches listed and Input Switches below You purchase them separately Palm a lt T Lets press operators start the press Momentary pushbuttons 2 Articulated P alm 1 Buttons for GOGO Assures 2 hand operation dual contact Buttons 800P F2CA pair Run Station normally closed N C OO OO O Note Position run inch buttons at least 24
2. NOTE The press strokes continuously until you press a Stop on top button the SLC processor receives a stop on top command or a stop condition is detected Y The stroke continues until the press reaches the top Y Is the press in the near top position Yes Both processors de energize their outputs to stop the press in the near top position ATTENTION If the press coasted past the near top position while braking the brake is faulty and hazardous Repair it immediately A B abbreviations P 2 audience P 1 BCAM 3 3 3 4 block diagrams 1 2 1 4 C cables installation 3 5 link coupler W D sheet 4 C B control system control functions 1 4 installation 3 5 modes of operation 1 4 outputs 1 6 overview 1 2 response time 1 6 testing circuits 4 1 testing operation 5 1 clutch part revolution friction 1 2 connections to I O modules 3 2 3 6 3 7 continuous mode C B 1 4 A 3 counterbalance 1 0 for 3 7 D E dc version of controller 3 1 DM die monitor 1 7 modes 6 2 setting up 6 1 testing 7 1 wiring 3 7 F G H failure mode operation C B test 4 1 4 3 J 1 K inch mode C B 1 4 A 1 input switches list of 1 5 installation C B 3 2 3 5 cables 3 5 link coupler 3 5 W D sheet 4 rotary cam limit switches 3 3 3 4 IO chassis 3 2 3 3 I O wiring considerations 3 7 slot locations 3 2 kit contents of 1 1 Index
3. braking the brake is faulty and the near top position hazardous Repair it immediately Description of Operating Modes A 3 NOTE Releasing a Run button during first downstroke stops the press If the slide has not entered the upstroke zone you can resume downstroke within 5 seconds of pressing the Arm Continuous button After 5 seconds and the press is stopped you must restart continuous mode with the arming sequence Continuous Mode with Arm Continuous To run your press continuously ready the press as follows select continuous mode press the arm continuous button press both run inch buttons within 5 seconds During the first downstroke Figure A 4 releasing a run inch button stops the press Then if the press did not enter the upstroke zone TCAM still off you may resume downstroke within 5 seconds if you release and press both run inch buttons again If 5 seconds passes and the press stops you must press the arm continuous button and run inch buttons again to restart During the first upstroke Figure A 4 when TCAMs come on you may release run inch buttons and the press will continue stroking If you start the press in upstroke you must press the arm continuous button and then hold run inch buttons for a complete cycle until next upstroke Once in continuous stroking operation Figure A 5 the press stops at the next near top position whenever it receives a stop on top command However the
4. Left Right apart and the run station in accordance with ANSI B11 1 appendix A Stop on Top Stops press attop during continuous stroking Momentary pushbutton Yellow Mushroom 1 No effect in single mode single N C contact head 800T D9B E Stop Stops the press immediately Momentary pushbutton Jumbo Mushroom 1 or Note Wire switches in series as needed single N C contact head 800T FXP16RA5 more and normally open N O Mode Lets you selectthe operating mode Rotary 4 position 800T N61KF4C 1 Select Off key lockable Inch Single Continuous Arm Lets you begin a timed interval within which to omentary pushbutton Black Momentary 1 Continuous start continuous mode single N O contact Pushbutton 800T A2A Main Motor onitors whether motor forward starter is N O auxiliary contact for Motor Starter 2 Forward engaged If not it opens to prevent running the forward motor starter Auxiliary Contact 595 A Interlock press in single or continuous mode Air Pressure onitors Clutch Brake air pressure 0 single throw from Pressure Switch 1 Note Switch must be ON to engage the clutch Pressure switch 836 C 8 X321 Motion Detects if motion is stopped in single or 0 single contact 2 Detector continuous mode Interlock Control Lets you manually reset power to valve solenoids Momentary pushbutton 800T A2A 1 Reset at power up or after an E stop single N O contact Clutch Brake Lets you manually reset clutch power omentary pushbutton 800T
5. 1746 P2 1746 P2 e Resolver and resolver input module minimum e 7 slotl O Chassis B 1 1746 A7 1746 A7 of one set e 10 slotl O chassis A 1746 A10 1746 A10 e Rotary Cam Limit Switch assembly one set if e Input Module 4 1746 1A16 ac 1746 1B16 dc used e Output Module 2 1746 0A16 1746 0B16 e Solenoid Valves 4 e Relay Output Module 2 1746 0X8 1746 0X8 with Internal Fault Detection e Relays 4 700 P400A1 700DC F310724 PanelView 600 Operator Interface 6556 S PV600 A publication Mount the I O Chassis 1746 5 8 publication Install the Power Supply 1746 5 1 instructions Install the Link Coupler in LC box publication Install SLC Processors and I O Modules for Chassis A and B 1747 62 Important You must identify P rocessor A by its label and install itin the 10 slot chassis A Installing the wrong processor in chassis A or B will result in a processor fault at power up Slot Chassis A 10 slot Chassis B 7 slot SLC 5 03 Processor A 1747 L532 SLC 5 03 Processor B 1747 L532 Input Module 1746 IA16 ac or 1746 IB16 dc Input Module 1746 1A16 ac or 1746 IB16 dc Input Module 1746 IA16 ac or 1746 IB16 dc Input Module 1746 IA16 ac or 1746 IB16 dc Resolver Input Module required Resolver Input Module optional Output Module 1746 016 Output Module 1746 0B16 Isolated Relay Output Module 1746 0X8 Isolated Relay Output Module 1746 0X8 Input Module for Die Monitor 174
6. F Allen Bradley Omega Series Configurable Press Control System Cat No 6556 SCBK3 and 6556 SCBK3DC Important User Information Publication 6556 6 5 8 August 1998 Because of the variety of uses for the products described in this publication those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements including any applicable laws regulations codes and standards The illustrations charts sample programs and layout examples shown in this guide are intended solely for purposes of example Since there are many variables and requirements associated with any particular installation Allen Bradley does not assume responsibility or liability to include intellectual property liability for actual use based upon the examples shown in this publication Allen Bradley publication SGI 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control available from your local Allen Bradley office describes some important differences between solid state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication Reproduction of the contents of this copyrighted publication in whole or in part without written permission of Allen Brad
7. Response time 65 ms worst case from switched input to turned OF F output Programmable Limit Switches Number of PLS channels 8 Channel input preset range 0 359 Channel output response turn OFF based on choice of 0 359 or time ms Machine inputs top stop E stop run station 1 mode select rotary switch clutch brake air pressure motor forward interlock motion detector interelock arm for continuous on demand control reset C B power reset Environmental conditions Operating Temperature 0 to 60 C 32 to 140 F Storage Temperature 40 to 85 C 40 to 185 F Relative Humidity 5 to 95 without condensation Designed to comply with ANSI B11 1 OSHA 1910 217 CSA CAN CSA Z142 M90 NFPA No 79 Die Monitoring Number of DM channels 16 Operating Modes cyclic in position transfer static Output responses warning stop on top stop now ignore Chapter 2 Quick Start Use this chapter as an abbreviated procedure for getting setting up the clutch brake control PLS and or DM functions or as an overview if you need more information Procedure for Clutch Brake M this manual Control Verify That You have All of the Hardware Shipped in the Kit chapter 1 Hardware Included for SCBK3 for SCBK3DC Hardware That You Provide e SLC 5 03 2 1747 L532 1747 L532 e Input Switches amp Run Station Application e Link Coupler DH 45 2 1747 AIC 1747 AlC Dependent e Power Supply 2
8. 2 Power up 3 Reset the E Stop circuit by pressing the Control Reset button 4 Verify that the seal relay is NOT energized red plunger is not recessed PLC OK relay is energized red plunger is recessed Seal Relay Weld Fault prompt is displayed on PanelView screen 5 Shut off system power and remove the jumper 6 Restore system power 7 Reset control power by pressing the C B Power Reset button 8 Verify that CRM relay is energized red plunger is recessed there is NO fault message 9 Press and momentarily hold the C B Power Reset button 10 Verify that the seal relay is energized red plunger is recessed 11 Shut off system power Test Run Inch Buttons run station Test the wiring of Run Inch buttons by observing LEDs in slots 1 and 2 Check each OK box after verifying that the LED indication is correct Slot 1 Input LED Is Slot 2 Input LED Is OFF ON OFF ON OK For This Condition Right Run Inch button is pressed A Input 5 B Input 5 Left Run Inch button is pressed B Input 5 A Input 5 Both Run Inch buttons not pressed A amp B Input 5 A amp B Input 5 Publication 6556 6 5 11 August 1998 4 4 C B Circuit Testing Test Top Stop and Arm Continuous Buttons Test the wiring of these buttons by observing input LEDs in slot 1 Check each OK box after verifying that the LED indication is correct For This Condition Slot 1 Input LED Is OFF ON OK Top Stop not
9. 6556 2 15 Read This First complete the overall installation 6556 5 8 wire the control system 6556 6 5 11 RN1 understand the non programmable aspect of your SLC 5 03 processors mount the I O chassis Modular Chassis Install Instructions 1746 5 8 install the system power supply Power Supply Install Instructions 1746 5 1 install the isolated link coupler Link Coupler Install Instructions with coupler install digital I O modules 1 0 Module Install Instructions 1746 5 3 install the resolver with resolver install the resolver input module with module install the tonnage module optional with module install the analog I O module optional with module Only qualified installers should apply this control to a mechanical stamping press We assume that the installation team includes professional stamping press builder or re builder knowledgeable in press control and press control standards technician skilled in installing electronic control equipment The descriptions of operation of this control system and its associated resolver die monitor DM and programmable limit switch PLS functions are important to understanding how this system works We recommend that you review and understand the Overview chapter 1 before starting to install this system You may also want to browse through this manual the wiring drawings and the PanelView 600 Operating Instructions before starti
10. Code Channel mode mode Code Cydc CYC Fe mede XFR In position POS Static STC Output Response Code Warning WRN Stop on Top ST Stop Now SN Bypass BP Job Name Purpose of DM Channel Type of Switch Device Location of Switch Device Mode Output 1 2 10 11 12 13 14 15 16 Publication 6556 6 5 11 August 1998 Operation of the Programmable Limit Switch PLS Worksheet B for PLS Channels Determining Your 6 5 Allen Bradley Programmable Limit Switch software is designed to turn outputs ON and OFF at precise crankshaft positions synchronized with crankshaft rotation monitored with a resolver You can preset up to 8 ON OFF settings at angles from 0 359 You can also turn the output OFF with a timer A PLS output turns ON and OFF according to how you configure it For example Turn ON a PLS Output with a Turn OFF a PLS Output with a crankshaft ON angle that you preset crankshaft OFF angle that you preset or PLS timer that you preset 00 Near top Zone The output turns ON at a preset angle Up Down 270 stroke stroke 90 Zone Zone The output turns OFF at a preset angle or time Bottom 180 As a result you can use PLS outputs to effectively control auxiliary press machinery such as lifters grippers blow off valves and inter press automation by programming your application specif
11. A2B 1 Power Reset on power up or after E stop triple contact 1 N O and 2 N C Publication 6556 6 5 11 August 1998 1 6 Overview C B Outputs C B Response Time Publication 6556 6 5 11 August 1998 The clutch brake control has two pairs of outputs from each I O chassis chassis A and B for your clutch brake valves The control is designed to operate with valves that have internal fault detection There are no inputs for valve stem feedback The worst case time required for the clutch brake control to respond to a change of input depends on the sum of these response times Device Delay ms Input Module 1746 IA16 response time 45 Processor scan of C B code 2k words 10 Output Module 1746 0X8 switching time 10 Total worst case response time 65 The number of degrees that the shaft continues to rotate beyond the moment at which the input changes depends on the speed of rotation The greater the speed strokes per minute the further the shaft rotates before a command from the control is applied We graphed the degrees of shaft rotation vs press speed for a response time of 65 ms 80 65 ms 0 10 20 30 40 50 Degrees of Shaft Rotation Important When estimating the braking distance in degrees of rotation you must add the rotation occurring during system response time to the specified downstroke braking distance For example at 100 SPM the shaft rotates 39 during a 65 ms system response time plus the braki
12. Signal That Anti Repeat Inch or Cams open and close in upstroke Prevents a second stroke in these modes ACAM Single stroke Take over Inch or Cams open in near top zone Turns OFF triac outputs for stopping the press TCAM Single stroke attop of stroke stop on top ntinuous Cams open in near top zone after stop on top command Single stroke Cams close near bottom just Lets the press complete a single stroke or run or Continuous when or before BCAM opens continuously after run buttons are released Brake monitor Single Stroke When press stops in downstroke Indicates that braking distance is excessive BCAM orContinuous beyond BCAM closure Turns OFF solenoid outputs to prevent restart Publication 6556 6 5 11 August 1998 Installing and Wiring Set Up or Simulate Rotary Cam Limit Switches as Follows Other Conditions The software is designed to fault if when it detects a ACAM BCAM and TCAM are OFF all atthe same time b BCAM is On when ACAM is Off c ACAM does not cycle while TCAM is On during upstroke ACAM should remain On for the entire stroke except for an On Off On cycle while TCAM is On during upstroke The dual sets of contacts need not cycle at the same moment 09 Near top During downstroke BCAM must be On During upstroke TCAM must be On and BCAM must be Off During upstroke ACAM must cycle from On to Off to On while TCAM is On Near top BCAM
13. and TCAM must be Off 9704 stroke s 90 while ACAM remains On 180 Important See press manufacturer s recommendations for Near top Zone Bottom An offset of up to 1 second is acceptable On Off settings of ACAM BCAM and TCAM switches As an example we show typical ON OFF settings for rotary cam limit switches in the following table where you can write down your initial settings This Turns ON Turns OFF Typical Your RCLS ata position at a position ON OFF ON OFF BCAM e neartop beyond which the e when overlapped by TCAM in ON position 109 1909 Software detects a faulty brake TCAM e near bottom e thatlets the press stop correctly on top 1709 3509 e when or before BCAM turns OFF e before BCAM turns ON ACAM e Remains ON for entire stroke except for an Off span during upstroke see graph 290 250 Important To determine exact settings refer to recommendations provided by the press manufacturer Set the ACAM off span to the number of degrees 0 90 according to the speed of the press 0 200 strokes per minute 200 180 160 Press 140 Speed 120 pw 100 30 60 0 900 OFF Span of Anti repeat Contacts During Up Stroke Publication 6556 6 5 11 August 1998 Installing and Wiring 3 5 Install C B Input Switches Verify that your press has the following switches required inputs to and Resolver s your clutch brake control Refer to chapter 1 for switch specifications Description Ty
14. button will de energize the seal and CRM relays 1 Power up 2 Visually and with a voltmeter verify that CRMA relay is not energized outputs to all press valves are Off 3 Reset the E Stop circuit by pressing the Control Reset button 4 Visually and with a voltmeter verify that CRM relay is energized outputs to all press valves are Off Reset control power by pressing the C B Power Reset button With a voltmeter verify that power rails to C B outputs are energized Press the E Stop button oc Nl A Un Visually and with a voltmeter verify that seal relay and CRM relay are de energized Seal Relay Test circuit This test verifies that when the seal relay is off press valves are off and when the seal relay is on outputs to press valves are energized 1 Power up if not already powered up 2 Reset the E Stop circuit by pressing the Control Reset button 3 With a voltmeter verify that seal relay is not energized outputs to all press valves are Off 4 Reset control power by pressing the C B Power Reset button 5 Visually and with a voltmeter verify that seal relay is energized power rails to C B outputs are energized 6 Shut off system power C B Circuit Testing 4 3 Seal Relay Test failure mode This test verifies the correct failure mode behavior of the seal relay 1 With power off place a jumper across the wired contacts of seal relay 1031CR
15. cycle at same moment Important See press manufacturer s recommendations An offset of up to 1 second is acceptable for on off settings of ACAM BCAM and TCAM switches Connect the Cables this manual chapter 3 You must make the cable that connects the two link couplers See the Installation Instructions that accompanied the link coupler for the terminations The cable uses a pair of 6 pin phoenix connectors Use this cable to connect notes that you make between link couplers in chassis A and B see coupler installation instructions 1747 C11 Link coupler to the SLC processor came with the link coupler two required E chapter 3 and Wire the I O Modules RCLS and Input Switches Wiring Dwgs For wiring instructions refer to chapter 3 and Wiring Drawings publication 6556 2 15 Publication 6556 6 5 11 August 1998 Quick Start 2 3 E 0 Test Clutch Brake Circuits chapter 4 ATTENTION Be sure that all C B hardware is installed before starting this step E i Test Clutch Brake Operation chapters 5 Procedures for Setting Up PLS and DM Channels LA Familiarize yourself with PLS and DM operation Chapters 1 amp 6 2 ii using DM determine your DM requirements Chapter 6 Determine the quantity of DM input channels their modes types of input switches and their locations We provide worksheet A for your convenience Wire DM input switches to the 1746 ITV16 input module in chassis A slot 6 3 ii using
16. forthe cycle next window goes ON You can use a DM input to monitor anindividual station for a part in correct position in position mode asequence of stations for the progression of a part transfer mode The software provides up to 16 DM selectable input channels You connect DM inputs to the 1746 ITV input module in chassis A slot 6 The optional tonnage monitor lets you view either two or four tonnage points upon each closure of the die The PanelView 600 Operator Interface displays a set of tonnage screens that lets you setup and calibrate tonnage channels view absolute tonnage and deviation from benchmark tonnage with each closure of the die setalarms to indicate when detected tonnage exceeds upper or lower limits We recommend the following tonnage monitor purchased separately e tonnage input module Helm HM604 TSM tonnage sensors and secondary calibration standard also from Helm Related Safety Information Overview 1 9 You are responsible for the safety of the installed press control and for meeting all applicable laws codes and safety requirements This control deals only with electrical control portions of the C B mechanism ANSI B11 1 regarding mechanical power presses OSHA 1910 217 and other applicable standards pertaining to safety recommendations related to ATTENTION The installer of this control must follow machine construction general electrical machine guarding a po
17. pressed Top Stop pressed Arm Continuous not pressed Arm Continuous pressed Test Mode Selector Switch Test the wiring of this switch by observing input LEDs in slot 1 Check each OK box after verifying that the LED indication is correct For This Mode select Position EX Input LEDs Are OFF sio Input LED Is ON ok Inch input2 A K B Inputs 2 3 4 except A amp B for the selected input only the selected input Single input 3 Continuous input 4 Test Rotary Cam Limit Switches Test the wiring of the RCLSs by observing input LEDs in slots 1 and 2 Check each OK box after verifying that the LED indication is correct Slot 1 Input LED Is OFF ON OK For This Condition ACAM BCAM TCAM atrest B Inputs 13 14 B Input 15 ACAM BCAM TCAM actuated B Inputs 13 14 B Input 15 Test Resolver s and Resolver Input Module s Test the wiring of the resolver s according to instructions from the manufacturer Publication 6556 6 5 11 August 1998 Chapter 5 Testing C B Operation Chapter Objective Once you have checked the wiring of your clutch brake control use this chapter to test its operation Tests include troubleshoot the setup of your RCLS assemblies 1 tests the operating modes e test the switches Trou bleshooting the Setup We recommend that you test the rotary cam limit switches RCLS in of Your RCLS Assemblies Inch mode The processor monitors RCLS signals to ensure that the mo
18. 5 11 August 1998 3 2 Installing and Wiring Install SLC Processors Install the SLC processors and I O modules in designated slots of each and 1 0 Modules I O chassis A and B Important You must insert the SLC processor labeled A into the 10 slot chassis A and the processor labeled B into the 7 slot chassis B If reversed the processors will fault at power up amp OCSS NS WOW WS SN NN eS Self locking tabs secure the module A in the chassis La E Door panel label a identifies terminal block connections Removable barrier type terminal block is color coded to the module for quick identification Chassis A Slot Description of Module Slot Description of Module 0 Processor A 1747 L532 SLC 5 03 Isolated Relay Output Module 1746 0X8 1 _ Input Module 1746 1416 ac or 1746 1B16 dc 6 Input Module 1746 ITV16 2 Input Module 1746 IA16 ac or 1746 IB16 dc 7 Tonnage Module optional Helm HM579 TSM 3 Resolver Input Module Helm HM571 RES 8 Tonnage Module optional Helm HM579 TSM 4 Output Module 1746 0A16 or 1746 0B16 dc 9 Spare Slot 0 Slotl Slot2 Slot3 Slot4 Slot5 Slot6 Slot Slot8 Slot9 SLC 5 03 1A16 IA16 Resolver OA16 0X8 ITV16 Tonnage Tonnage Spare Ss ey ee ee ee p 1 1 1 oo ooon Gagaga GGG 20 oooo aa oo 0000 0000 2000 00 e aa oo000 0000 oooo oo oo 0000 0000 roo oo 0000 o
19. 6 ITV 16 optional I O Module 1746 NIO4V for S auto counterbalance variable speed press drive optional Tonnage Module Helm HM579 TSM shut height adjustment optional Tonnage Module Helm HM579 TSM 0 ex m ZE wo WE E e ET E NE Publication 6556 6 5 11 August 1998 2 2 Quick Start Install C B Input Switches and the Resolver You wire them in step 9 n a Description run station inch run palm button Esp mode selection psp arm continuous E stopreset ClBpowerrest main motor forward N O single contact motion detector arprssue Tesolvers orresolver amp RCLS See chapter T m this manual Set Up if used or Simulate Rotary Cam Limit Switches chapter 1 00 Set Up or Simulate Rotary Cam Limit Switches as Follows During downstroke BCAM must be On 8 During upstroke TCAM must be On and BCAM must be Off During upstroke ACAM must cycle from On to Off to On while TCAM is On D Near top BCAM and TCAM must be Off Near top while ACAM remains On 270 90 Other Conditions The software is designed to fault if when it detects a ACAM BCAM and TCAM are OFF all at the same time b BCAM is On when ACAM is Off c ACAM does not cycle while TCAM is On during upstroke ACAM should remain On for the entire stroke except for an On Off On cycle while TCAM is On during upstroke 1800 Dual sets of contacts need not
20. PLS determine your PLS requirements Chapter 6 Determine the quantity of PLS channels turn ON presets and turn OFF angle or time We provide worksheet B for your convenience Wire PLS outputs from the 16 point output module in chassis A slot 4 pts 8 15 4 Use the PanelView 600 Operator Interface to set up system configuration DM and Operating Instr PLS channels the resolver passwords and variable speed compensation 6556 5 8 Refer to the referenced publication for System DM and PLS setup procedures They include System Configuration Active PLS DM setups on line Recipe PLS DM setups offline System Monitoring Mm Test DM and PLS channels Chapter 7 Use procedures in chapter 7 and screens described in the PanelView 600 Operating Instructions to test DM and PLS channels resolver inputs transfer mode channels Publication 6556 6 5 11 August 1998 2 4 Quick Start Notes Publication 6556 6 5 11 August 1998 Chapter Objective If Using the DC Version Check Hardware Mount the I O Chassis Install the Power Supply Install the Isolated Link Coupler Chapter 3 Installing and Wiring In this chapter we help you install the C B control with these steps e if using the dc version 1 check hardware e mount the I O chassis install the power supply install the isolated link coupler install SLC processors and I O modules setup rotary cam limit switches e install C B input swit
21. aft The logic is designed to detect the absence mis alignment or unwanted presence of material moving through an automated stamping process Crankshaft positions are monitored by a resolver See chapter 3 for wiring DM inputs You enter setups with the Panel View PV600 Operator Interface The software and associated hardware monitor a variety of logical inputs to detect deviant conditions seta fault upon detection of a deviant condition You select whether the fault automatically initiates a warning stop on top stop now condition or whether the fault is ignored Publication 6556 6 5 11 August 1998 1 8 Overview Cyclic Mode Transition Diag Tonnage Monitoring Publication 6556 6 5 11 August 1998 Expected Transition Occurs Within Window Sensor turns ON then OFF within window a b Pulse type signal How a DM Channel Works You select one of several operational modes for a DM input such as cyclic in position e transfer e static As long as the logic detects expected conditions no action is taken When the logic detects a deviant condition it sets a fault For example in cyclic mode an input switch is expected to close within a preset zone of rotation that we call a window Which Results in a Fault SIGNAL Sent After window goes OFF Input is NOT ALLOWED When Sensor 1 stays ON beyond the window 2 turns ON outside the window sensor turns ON 3 remains OFF
22. ake control C B air pressure motion detector main motor forward Publication 6556 6 5 11 August 1998 5 4 Testing C B Operation Publication 6556 6 5 11 August 1998 C B Air Pressure Switch Ln RO N N Remove the C B air pressure switch input from chassis A at slot 1 terminal 12 Place the mode selector switch in single stroke mode Attempt to start the press and observe that it does not start Reconnect the air pressure switch input to chassis A step 1 Remove the switch input from chassis B slot 1 terminal 12 to repeat the test Attempt to start the press and observe that it does not start Reconnect the air pressure switch input to chassis B step 5 Motion Detector Switch Remove the motion detector switch input from chassis B at slot 2 terminal 0 Place the mode selector switch in single stroke mode Start the press and observe that it stops before reaching bottom If the press reaches bottom the circuit is not functioning correctly Reconnect the motion detector switch input to chassis B Main Motor Forward Switch 1 an ROC N Remove the main motor forward switch input from chassis A at slot 1 terminal 11 Place the mode selector switch in single stroke mode Attempt to start the press and observe that it does not start Reconnect the main motor forward switch input Remove the switch input from chassis B slot 1 terminal 11 to r
23. are cleared Active PLS screen all PLS channels are OFF 1 From the Active PLS screen cursor to PLS channel 1 ATTENTION Before going to step 2 be aware that when you turn ON a PLS channel the PLS output may turn on immediately 2 Turn on PLS channel 1 with an up down arrow key plus return key 3 At the output module observe that the LED indicator for PLS channel 1 turned on or that the output device turned on If the output LED for the channel did not turn on or the output device did not turn on check for errors in wiring of your output device chapter 3 4 Turn off the PLS channel with an up down arrow key plus return key 5 Cursor to the next channel and repeat steps 1 4 until you have tested all PLS channels wired into your system Publication 6556 6 5 11 August 1998 7 4 Testing DM and PLS Channels Notes Publication 6556 6 5 11 August 1998 Clutch Brake Operating Modes Appendix A Description of Operating Modes You can select any one of the following operating modes with the mode selector switch Off Inch Single stroke Continuous stroking Off When an operator selects OFF the control system is designed to e turn off all outputs to press valves reset faults Inch Mode Before entering single or continuous mode use inch mode to jog the press to the near top position to set up the machine The press stops when it moves into the near top position or when you release a run inch
24. at if one processor detects a condition different from that detected by the other its control logic is designed to declare a fault and turn off all outputs to press valves The other processor is designed to follow suit Link couplers cat no 1747 AIC provide communication between processors in chassis A and B They also provide communication between the PanelView 600 Operator Interface and both processors For additional information refer to wiring drawings sheet 4 and the instructions that accompanied the link couplers The logic of this control is pre programmed and burned into processor memory at the factory It cannot be changed except by return to Allen Bradley You cannot program these clutch brake processors Publication 6556 6 5 11 August 1998 1 4 Overview Modes of C B Operation An operator can select the mode of clutch brake operation with a selector switch located on a control panel In accordance with ANSI B11 1 Section 4 12 4 1 the selection of operating mode must be lockable This Mode Lets the Operator Disable operation of the clutch brake control when the press is not in operation J og the press through through successive B ofthe cycle by pressing and releasing the pair of run inch buttons If the buttons are held the press will stop at the top of its stroke Single stroke Run the press through one complete cycle by holding both run inch buttons until completion of the down stroke Continuous Run the pr
25. blication 6556 6 5 11 August 1998 Transition Diagram X Transition Diagram Definition of Window and Description of Modes Window Input signals for Cyclic CYC and In position POS modes are synchronized with the rotation of the crankshaft and must be detected within a zone of crankshaft rotation We call this zone a window For example a part detect signal could be expected within a window of 80 110 to indicate that a part was inside a die before it was hit by a stroke When the software detects input signals that are different from those described here the software generates a fault signal We graphically define these window inputs as follows angle R OFF ON OFF _ ea S P cuntur Input rotation transition Cyclic CYC Use this mode to verify that a pulse from the sensor OFF ON OFP occurred within the window once each stroke For example use it to detect that a part moved past a monitor Which Results in a Fault Signal Sent After window goes OFF Input is NOT ALLOWED When Sensor For These Expected Transitions Sensor turns ON then OFF within window 1 stays ON beyond window 2 turns ON outside window sensor turns ON 3 remains OFF for the cycle next window goes ON In position POS Use this mode to verify that the sensor signal remained ON within the entire window once each stroke The signal must cycle OFF outside the window Use it to detect if ejector and other auto
26. button Figure A 1 Figure A 1 Typical Operational Sequence for Inch Mode Select inch mode Y ATTENTION To guard against the possibility of personal injury install a keylock mode select Switch so that mode selection can be supervised Have you released both Inch U buttons Yes No Have you pressed both Inch buttons concurrently iQ Y Yes Both processors energize their outputs to actuate the clutch iM No Yes Has the press moved into the No Have you released near top position either Inch button Yes je Both processors de energze 4 their outputs to stop the press ATTENTION If the press coasted past the near top position while braking the brake is faulty and hazardous Repair it immediately 12261 Publication 6556 6 5 11 August 1998 A 2 Description of Operating Modes Single Stroke Mode Single stroke mode is designed to stroke the press once from top to bottom to top with the concurrent use of the run inch buttons Once the press reaches the takeover cam TCAM the operator can release the run inch buttons without stopping the press It continues to the near top position In downstroke releasing a run inch button stops the press Figure A 2 Then if the press did not enter the upstroke zone TCAM On you may resume downstroke by again pressing run inch butt
27. ces use this chapter to check circuit wiring A ATTENTION Before starting this chapter be sure that e all clutch brake control hardware is installed e clutch brake wiring is complete the control is in compliance with all applicable standards Otherwise personal injury or property damage could result This section describes the following tests e PLC OK failure mode CRM Relay e Seal Relay circuit e Seal Relay failure mode e Run inch Buttons Arm Continuous Button Mode Selector Switch 1 2 2 3 3 e Stop on top Button 4 4 4 e Rotary Cam Limit Switches 4 4 e Resolver s and Resolver Input Modules PLC OK Test failure mode This test verifies the correct failure mode operation of the PLC OK relay for chassis A You will repeat this procedure for chassis B 1 With power off jumper the wired contacts of PLC OK relay 1010CR Power up 2 3 Press the C B Control Reset button to energize the CRM relay 4 Press and momentarily hold the C B Power Reset button 5 Verify that the PLC OK relay is NOT energized red plunger is not recessed PLC OK Check Failed prompt is displayed on Panel View screen 6 Shut off system power 7 Remove the jumper 8 Repeat steps 1 7 for chassis B PLC OK relay 1033CR Publication 6556 6 5 11 August 1998 4 2 C B Circuit Testing Publication 6556 6 5 11 August 1998 CRM Relay Test circuit This test verifies that pressing the E stop
28. ches and resolver s connect chassis cables wire your C B control ND t ta WN RR Re wiring considerations We provide wiring drawings publication 6556 2 15 for two versions grounded ac drawing set 6556503 and dc drawing set 6556503DC The dc version has these changes in respect to the ac version replace input module 1746 IA16 with 1746 IB16 in slots 1 and 2 e replace output module 1746 OA16 with 1746 OB16 in slot 4 replace wiring drawing set 6556503 with 6556503DC To check the contents of the kit refer to Contents of Kit in chapter 1 If items are missing contact your local salesperson or distributor To mount the 7 slot and 10 slot I O chassis Cat No 1746 A7 and 1746 A10 refer to publication 1746 5 8 SLC 500 Modular Chassis Installation Instructions Look for this publication in the product box To install the power supply Cat No 1746 P2 refer to publication 1746 5 1 SLC 500 Power Supplies Installation Instructions Look for this publication in the box that contained the power supply The power supply slides into card guides on the left side of the I O chassis To install the link coupler Cat No 1747 AIC refer to publication Installation Instructions for the SLC500 Isolated Link Coupler shipped with it Mount the coupler adjacent to the power supply on the panel holding the I O chassis Keep the instruction sheet handy because you will use it to fabricate and connect cables Publication 6556 6
29. control Wire your I O modules and ac or dc power distribution according to those drawings Inputs and outputs by I O module and chassis slot are as follows For In I O Chassis See Sheet Power distribution Cabling for Link Coupler and P rocessor Inputs to 1746 IA16 1746 IB16 e CRM relay e main motor forward reverse C B mode select Run Inch buttons clutch valve 1 feedback top stop arm continuous fault reset Seal relay C B air pressure main motor start stop and reverse feedback e ACAM BCAM TCAM chassis B only if used Inputs to 1746 IA16 1746 IB 16 for I O cross checking A and B 7 of 14 e feedback from various relays slot 2 e feedback from RCLS e heartbeat Helm HM571 RES resolver input module s Slot 3 8 of 14 required for chassis A optional for chassis B 1746 0A16 terminals 0 7 for I O cross checking e seal relay e BCD mode e ACAM BCAM TCAM clutch output ON heartbeat 1746 0A16 pts 8 15 for PLS outputs chassis A only 1746 0A16 pts 8 9 for optional counterbalance outputs chassis B only 1746 0X8 Outputs A and B 10 of 14 e clutch valve outputs and feedback slot 5 e PLC OK relay and feedback e main motor forward reverse outputs e indicator outputs 9 of 14 1746 ITV16 for DM Inputs chassis A slot6 11 of 14 1746 NIO4V optional I O module for counterbalance chassis B slot 6 pressure shut height position and variable speed drive Helm HM604 TSM tonnage module optiona
30. correct state when the window is ON It monitors the up stream station 1 and station 2 as a pair Then it monitors consecutive pairs of stations stations 2 amp 3 3 amp 4 etc Stroke n Stroken 1 Stroke n 2 Stroke n 3 Partin the die Partin transfer Partin the die Mol sw lana Up stream l Station2 f Station 3 Station4 XFR mode input XFR mode Input XFR mode Input XFR mode Input Outputbypassed Select desired output response for channels 2 4 Static Mode STC Use this mode to detect that an event occurred independent of the press stroke When a static mode input turns Off the programmed output is turned On For example use it to detect end of stock When the software detects a channel fault it displays the channel number and type of fault on a PanelView screen The software also sets a fault response that you select from the following warning PanelView 600 displays alarm banner on the active screen a Stop on top stop now output by passed no fault response for XFR mode up stream station or channels not used Use this worksheet to identify your DM channels Write down these items in the space provided a Purpose of DM channel a Mode of DM channel by code a Type of input switch s Location of input switch Output response by code Publication 6556 6 5 11 August 1998 6 4 Determining Your We repeat the codes for channel mode and output response Channel Mode
31. e 1 1746 TV16 1746 TV16 with Internal Fault Detection Output Module 2 1746 0A16 1746 0B16 Operator Interface 1 Relay Output Module 2 1746 OX8 1746 0X8 PanelView 600 6556 SP V600 Relays 4 700 P400A1 700DC F310224 Tonnage Module optional 2 max Analog I O Module 1 optional Important The purchase of this kit includes the license to use this control on one stamping press Publication 6556 6 5 11 August 1998 1 2 Overview About This This is a pre programmed SLC based control system that provides for Control System Clutch brake Control for controlling a mechanical stamping press designed for use only with mechanical stamping presses ATTENTION The clutch brake control system is having a part revolution friction clutch and or brake Applying this control to any other type of press could result in personal injury and or damage to equipment Die Monitoring permissives designed to monitor the proper progression of the part and to prevent the die from closing upon detecting a part mis alignment or mal function of part transfers Programmable Limit Switches that you use to turn outputs on or off at precise crankshaft positions synchronized with crankshaft rotation monitored by a resolver Tonnage Monitoring optional modules to accept strain gage inputs to monitor the pressure generated on the stamped part Other features diagnostics for SLC based troubleshooting recipe mana
32. e eben 7 3 Appendix A Clutch Brake Operating Modes 0 0 cece cece eee nee A 1 Index AL ea e ae aS EAEE Aan E E aie E EAE E AE A E E EE I 1 Chapter 1 Overview Chapter Objective The purpose of this chapter is to acquaint you with your Allen Bradley Clutch Brake Control cat no 6556 SCBK3 or SCBK3DC Topics include Contents of the kit About this control system Control by redundant processors Link couplers Protected memory in SLC 5 03 processors Modes of C B operation C B control functions e Functional block diagram Resolvers Rotary cam limit switches e Panel switches and input switches C B Outputs C B Response time Programmable Limit Switches PLS Die Monitor DM Tonnage monitoring O 00 10 OQ GO Un Lh tn FS A PW Ut F2 e Related safety documentation e Specifications of the C B control PLS and DM 10 Contents of the Kit Clutch brake control kit cat no 6556 SCBK3 or SCBK3DC includes Hardware Included for SCBK3 Hardware That You Provide SLC 5 03 2 1747 L532 1747 L532 Input Switches and Run Stations Link Coupler DH 45 2 1747 AIC 1747 AlC application dependent Power Supply 2 1746 P2 1746 P2 Rotary Cam Limit Switche 1 if used 7 slot I O Chassis 1 1746 A7 1746 A7 Resolver minimum of 1 10 slot 1 0 Chassis 1 1746 A10 1746 A10 Resolver Input Module minimum of 1 Input Module 4 1746 1A16 ac 1746 1B16 dc Solenoid Valves 4 Input Modul
33. ee eee 1 2 Control by Redundant Processors 0 0 00 0 ce eee eee nee 1 3 Link Couplers 2 dci e Lee e See e qe et PN EE 1 3 Protected Memory in SLC 5 03 Processors lesse 1 3 Modes of C B Operation cs ss S R R 0 R R RR R R RR RR ee 1 4 Functional Block Diagram 0 0 00 erarnan eian e ee 1 4 C B Control Functions 0 0 0 eee eee eh 1 4 hugo Mc 1 5 Rotary Cam limit Switches 5 1 5 Panel Switches and Input Switches 0 0 00 000005 1 5 C B Outputs iz cce RR ches RE e ER Shae Hee eee ru 1 6 C B Response Time 0 0 eee cece eh 1 6 Programmable Limit Switches PLS 0 000000 000005 1 6 Die Monitor DM 0 eee e 1 7 Tonnage Monintor eaS 0 0 0 0 0 R ddt riadit TR regret 1 8 Related Safety Information 0 0 e eee eee eee 1 9 Specifications of the C B Control PLS and DM 1 10 Chapter 2 Procedure for the Clutch Brake Control 2 1 Procedures for Setting Up PLS and DM Channels 2 3 Chapter 3 Chapter Objectives 06 04 6 0 666 0 9 REA II 3 1 If Using the DC Version sag 0 R Rg 0 R RR RR eee nee 3 1 Che ck the Hardware TTT 3 1 Mount the I O Chassis 3 1 Install the Power Supply 0 0 cece eee eee nee 3 1 Install the Isolated Link Couplers 0 000000 eee ee 3 1 Install the SLC Processors and I O Modules Lese 3 2 Set Up Rotary Cam Limit Switches 00000 3 3 Install C B Input Sw
34. epeat the test Repeat steps 3 and 4 Objectives Operation of DM Modes When Input Signals Are Synchronized with crankshaft rotation and detected within a zone or rotation window Chapter 6 Determining Your DM and PLS Requirements This chapter helps you select DM operating modes apply DM windows select DM output responses use DM worksheet select PLS operating modes use PLS worksheet Uu tun Uc wn Important For instructions on using PanelView 600 screens to configure DM and PLS channels refer to the panel View 600 Operating Instructions publication 6556 5 8 The purpose of DM channels is to verify that predictable conditions in your press operation take place When the software detects a fault condition it sets a selected output response You select the type of mode for each channel from the following cyclic in position e transfer e static Use the following table to help you select the types of channel modes required for your application We Call This Mode Used For Example To detect parts in position Cyclic or In position arpa ecd S ynchronized with crankshaft rotation as parts Transfer verify the progression of the part from are moved through multiple transfer locations one transfer location to the next Independent of press stroke Static detect the end of stock Publication 6556 6 5 11 August 1998 6 2 Determining Your Pu
35. ess continuously until stopped by a stop on top command or until a fault is detected To startthe press you press the ARM CONTINUOUS switch and then press the pair of run inch buttons within five seconds C B Control Functions Clutch brake control functions are summarized in the following table Stop on top Continuous Lets the operator stop the press attop of stroke cycle stop Interrupted stroke Single or Continuous Lets the operator stop the press by releasing a run inch button during downstroke Anti tie down Prevents the press from starting a new stroke if the control detects that an operator has tied down the run inch buttons After run inch buttons are released the operator must press both buttons atthe same time Anti repeat Single stroke Limits press operation to a single stroke even if the operator continues to press or Inch both run inch buttons The operator must release and press them again to start the next stroke Motion detector Single or Continuous Detects press motion from a hardware or software input Brake Monitor Prevents restarting the press when the control detects an over travel condition Functional Block Diag ram The functional block diagram in shows the relationships between mechanical components of a stamping press and the C B control Run Station 1 pair of buttons for run and inch SLC Processor pe n SLC Processor in Chassis A in Chassis B
36. gement for storing up to 20 setups production monitor for indicating progress during a production run lube for automatic or manual lubrication of the press This SLC based control system consists of A resolver provides precise rotational inputs to monitor press stroke Multiple switches provide inputs o e Pe to monitor correct part movement synchronized with the press stroke Eora Link Coupler to provide for two SLC 5 03 processors with factory installed control software two I O chassis with input and output modules two link couplers for inter processor communication Panel View Operator Interface Terminal PanelView terminal lets you enter setpoints ba and I O chassis holds modules that process 1 0 store setup files for use later e Te amine PON Pan is __ Power SLC processor with pre programmed software monitors inputs and controls the clutch brake communication between processors mechanism and other press control functions Publication 6556 6 5 11 August 1998 Control by Redundant Processors Link Couplers Protected Memory in SLC 5 03 Processors Overview 1 3 This clutch brake control uses two independent SLC 5 03 processors one in chassis A and the other in chassis B Both processors monitor all clutch brake I O and exchange information about machine status They are linked by hardwired I O and a pair of Link Couplers 1747 AIC so th
37. ic output responses The output of each PLS channel is directed to the 1746 OA16 module in chassis A slot 4 points 8 15 for PLS channels 1 8 Use this worksheet to identify your PLS channels Write down these items in the space provided a Name of the PLS controlled function a Preset angle to turn ON a Preset time or angle to turn OFF Output point to control the function 1746 OA16 points 8 15 in chassis A slot 4 Publication 6556 6 5 11 August 1998 6 6 Determining Your Job Name slot 4 Output Pt 8 PLS controlled Function Preset ON Angle 0 359 Preset OFF Angle or Time ms 9 10 11 12 13 14 15 Publication 6556 6 5 11 August 1998 Objectives Testing a DM Channel Chapter 7 Testing DM and PLS Channels This chapter gives you procedures for testing the following e Data monitor DM channel 1 e DM transfer mode channel 2 Resolver inputs 3 Programmable limit switch PLS channel 3 In this procedure you test one channel at a time to verify signal thru put is correct from the input switch into the data table that the software detects and indicates a channel fault that the software and wiring are set up to reset a fault Use these screens Active DM screen to enter values and Status screen for fault prompts Observe or set up the following initial conditions before starting regardless of how you intend to use each channel late
38. int of operation guards light curtain gates 2 hand switches In addition to local codes and laws you are responsible for the safety recommendations detailed in all applicable codes and standards including e OSHA Regulations Title 29 Labor Chapter XVII Section 1910 217 Mechanical Power Presses e ANSI B11 1 American National Standard for Machine Tools Mechanical Power Presses Construction Care and Use available from American National Standards Institute 1430 Broadway NY NY 10018 3363 e NFPA No 79 Electrical Standard for Metalworking Machine Tools e CAN CSA Z142 M90 Code for Punch Press and Brake Press Operation Health Safety and Guarding Requirements Canadian Standards Assoc 178 Rexdale Blvd Rexdale Toronto Ontario Canada M9W 1R3 Also refer to Important User Information inside the front cover Publication 6556 6 5 11 August 1998 1 10 Overview Specifications for the Clutch Brake Control Specifications for Programmable Limit Switches and Die Monitoring Publication 6556 6 5 11 August 1998 Type of processors pair of SLC 5 03 processors preprogrammed non programmable Type of power grounded ac 6556 SCBK3 dc 6556 SCBK3DC C B mode selections off inch single stroke continuous Valve outputs two clutch brake valves Type of valves internal fault detection Position monitoring inputs at least one resolver input and one additional resolver or one additional rotary cam limit switch assembly
39. ion buttons near top zone the part of the press cycle when the press is atthe top of its stroke PLS programmable limit switch a switch synchronized with the rotary position of a crankshaft to cycle an output on off at precise positions RCLS rotary cam limit switch a switch that rides a rotating cam to provide information on the position of the press crankshaft resolver an electro mechanical device that precisely monitors the angular position of a rotating shaft run station a press operator s point of operation that typically contains a pair off pushbuttons to start or stop the press single stroke mode a mode that allows the operator to run one complete press stroke usually started atthe top SLC small logic controller a Rockwell Automation Allen Bradley programmable controller solenoid valve an on off electrically driven valve TCAM takeover RCLS a device designed to allow upstroke without the operator holding the run inch buttons top stop a command designed to stop the press at the top of its stroke upstroke zone the part of the press cycle when the press travels from the end of downstroke to the near top position Publication 6556 6 5 11 August 1998 Overview Quick Start Installing and Wiring Testing C B Circuits Table of Contents Chapter 1 Chapter Objective 0 N satu e Re ERE ps EX se ba ex 1 1 Contents of tlie Kit iss oad ced pk RE ERG eho RA URS EE ENS 1 1 About This Control System 0 0 0 0 Kn R Ra
40. itches and Resolver s lsleeeeeesse 3 5 Connect Chassis Cables llle 3 5 Wire Youf C B Control cce e Rena Rd RR RR UR ee 3 6 Wiring Considerations sss ss g R RRR RR R 0 RR R RRR ee 3 7 Chapter 4 Chapter Objective cles RR eee tit bes ened C IER God cee 4 1 Testing Circuits and Failure mode Operation 4 1 Publication 6556 6 5 11 August 1998 P 2 Testing C B Operation Determining Your DM and PLS Requirements Testing DM and PLS Channels Description of Operating Modes Index Publication 6556 6 5 11 August 1998 Chapter 5 Chapter Objective 0 0 0 0 eee III 5 1 Troubleshooting the Setup of Your RCLS Assemblies 5 1 Test the Operating Modes 0 R R ris erer TRT RT eee eee 5 2 Test the Switches 22 5 eI ceed ceed RRR eka nea Seas ee 5 3 Chapter 6 Chapter Objective is ccc seve cet RRR RR cee ewe REEL RT ES 6 1 Operation of DM Input Modes 0 0 0 cece eee eee 6 1 Output Responses for DM Channels 0 000000 000s 6 3 Worksheet for DM Input Channels ss sss sa r esee 6 4 Operation of the PLS sceso eect ce eee Ree RD E 6 5 Worksheet for PLS Output Channels nusnasauaruan arrua 6 6 Chapter 7 Chapter Objectives sss a Ra KR eee III 7 1 Testing a DM Channel e ge rR ctes R RRR I 7 1 Testing DM Transfer mode Channels 0 000000 000005 7 2 Testing the Resolver Input 0 0 0 0 eee eee ee eee 7 3 Testing a PLS Channel 4 006 052 ccs dee em
41. l chassis A 12 and 13 slots 7 8 of 14 Spare chassis A slot9 14 of 14 Wire power supplies and other electrical devices according to instructions that accompanied them Wiring Considerations DM Inputs Installing and Wiring 3 7 Wire die monitor DM inputs to the 1746 ITV16 input module in chassis A slot 6 This module sources current the load is a sink Connect 2 wire or 3 wire input switches as follows Sourcing sink load DC OO INO S gt IN 1 DC VDC PLS Outputs Wire PLS outputs to a 1746 OW 16 relay contact output module in chassis A slot 4 terminals 8 15 as follows Relay Output DC DC L1 for ac L2 for ac I O for Automatic Counterbalance and Variable speed Press Drive and Shut height Adjustment Wire these optional features to the 1746 NIO4V module in chassis B slot 6 Wire its I O as shown above Module characteristics include Inputs Input Specs 0 to 10 V dc 10 to 10V dc 20 to 20 mA 16 bit resolution 16 384 counts 60 ms response 10Hz input filter Outputs Output Range 0 to 10V dc 14 bit resolution Publication 6556 6 5 11 August 1998 3 8 Installing and Wiring Notes Publication 6556 6 5 11 August 1998 Chapter Objective Testing Circuits and Failure mode Operation Chapter Al C B Circuit Testing Once you have completed the installation of your clutch brake control and wired your I O devi
42. ley Company Inc is prohibited Throughout this manual we use notes to make you aware of safety considerations ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attention statements help you to e identify a hazard avoid the hazard recognize the consequences Important Identifies information that is critical for successful application and understanding of the product PanelView and SLC are trademarks of Allen Bradley Company Inc Manual Objectives Other Required Publications Qualifications for Applying this Product Recommendation to Help You Install the System Preface Using This Manual This manual describes how to apply the 6556 SCBK3 or 6556 SCBK3DC Clutch Brake C B Control Kit including Programmable Limit Switch PLS and Die Monitor DM functions to your mechanical stamping press The manual helps you install test and operate the control To complete the installation of this clutch brake control system you will need to use these publications some of which accompany other Rockwell Automation products in the system To Do This Use this Publication Pub Omega Series Configurable Press l Control System this manual 6556 6 5 11 use PanelView 600 Operator Interface Clutch Brake PanelView 600 to set up and operate the system Operating Instructions ac or dc Wiring Drawings 6556503 and 6556503DC
43. license software 1 1 link coupler 1747 AIC 1 3 3 1 cable fabrication W D sheet 4 modes of operation C B 1 4 A 1 DM 6 1 0 outputs C B 1 6 overview of C B control 1 1 P Q panel switches 1 5 PLS programmable limit switch 1 7 setting up 6 1 6 5 testing 7 3 wiring 3 7 processors SLC 5 04 1747 L532 1 3 publications related P 1 quickstart 2 1 R resolvers 1 5 3 3 7 3 response time of C B control 1 6 rotary cam limit switches 803 P 775 1 5 setting up and testing 3 4 3 5 5 1 S safety information 1 9 shut height adjustment 1 0 for 3 7 single stroke mode C B 1 4 A 2 Specifications C B DM PLS 1 10 Switches list of panel and input 1 5 TU V terms and abbreviations P 2 1 4 testing C B circuits and failure modes 4 1 4 3 C B operating modes amp switches 5 1 5 3 DM and PLS channels 7 1 7 3 RCLS operation 5 1 resolver operation 7 3 transfer mode DM 6 2 7 2 variable speed drive I O for 3 7 W Z wiring 3 1 3 6 3 7 W D pub 6556 2 15 Publication 6556 6 5 11 August 1998 Index Publication 6556 6 5 11 August 1998 Notes ZR Rockwell Automation Allen Bradley a Rockwell Automation Business has been helping its customers improve productivity and quality for more than 90 years We design manufacture and support a broad Allen Bradley range of automation products worldwide They include logic processors power and motion control devices o
44. mation parts are retracted to home position Input is NOT ALLOWED When the Sensor Signal 1 turns OFF before window goes OFF 2 does not turn OFF outside window 3 remains OFF for the cycle Which Results in a Fault signal Sent After sensor turns OFF next window goes ON next window goes OFF For These Expected Transitions Sensor turns ON before and OFF after window Transfer Mode XFR Use transfer mode to monitor the transfer of a part in a transfer press from one transfer location to the next for each stroke of the press Typically each transfer location has an in position sensor The logic of transfer mode is similar to that of a first in first out FIFO shift register It monitors sensor stations in sequence a pair at a time Important When setting up XFR mode channels you must 1 Assign consecutive channels to consecutive sensor stations in the sequence 2 Configure the first input in the transfer mode sequence upstream input as the first channel in the sequence with its output bypassed 3 Configure remaining channel outputs for the desired fault response Output Responses for DM Channels Worksheet A for DM Channels Station po at at x 120V ac or 24V dcO Channel Setup Channel 1 channel 2 channel 3 channel 4 Determining Your 6 3 In the following 4 station example the software looks for signals from in position switches to be in
45. n top Release the run inch buttons and press again for 1 2 seconds aA 5 a fF amp NY m Observe that the press cycles until you release a button then stops Test the Switches Testing C B Operation 5 3 Single stroke Mode Place the mode selector switch in single stroke mode Press and hold run inch buttons for more than 1 2 stroke Observe that the press cycles and stops on top Release run inch buttons and press again Then release in downstroke 1 2 3 4 5 6 7 8 Observe that the press stops immediately Bring the press to top by pressing run inch buttons and release in upstroke Repeat steps 2 and 3 This time hold run inch buttons for the entire cycle Observe that the press runs through one stroke and stops at the top Continuous Mode with Arm Continuous Place the mode selector switch in continuous mode Press the Arm Continuous button Immediately press run inch buttons and release after downstroke 1 2 3 4 5 6 7 Observe that the press continues to cycle Press the Stop on top button Observe that the press completes the cycle and stops on top Return to step 2 and press the Arm continuous button This time wait for 5 seconds or until the Arm continuous timer has timed out before pressing run inch buttons 8 Observe that the press does not start Repeat steps 2 through 6 for a final verification Test the following switches with an operating clutch br
46. ng distance Programmable Limit Switch PLS Die Monitoring DM Overview 1 7 The Allen Bradley Programmable Limit Switch is factory programmed ladder logic that lets you time or sequence outputs according to precise and repeatable positions of a crankshaft Crankshaft positions are monitored by a resolver You can use PLS outputs to integrate auxiliary press machinery such as lifters grippers blow off valves and inter press automation into your stamping press control system See chapter 3 for wiring PLS outputs How a PLS Channel Works Using the Panel View 600 Operator Interface you preset the rotational position preset angle at which you want the PLS output to turn ON You also select how you want the PLS output to turn OFF by preset angle or preset time The output module in chassis A slot 4 controls the outputs to your application 09 Near top Zone Angular preset to turn output ON Up Down 270 stroke stroke 90 Zone Zone Angular or time preset to turn output OFF Bottom 1809 Then you can select your application specific PLS output to trigger part movement between presses in a transfer line die automation devices such as grippers and lifters monitoring correct part movement with a DM track function Allen Bradley Die Automation Monitoring is factory programmed ladder logic designed to let you monitor a variety of conditions synchronized with the rotation of a stamping press cranksh
47. ng this project Publication 6556 6 5 11 J uly 1998 P 2 Terms and Abbreviations You should become familiar with these abbreviated terms For complete definitions of clutch brake terms refer to ANSI B11 1 1988 section 3 Term Definition ACAM anti repeat RCLS a device designed to limit press operation to a single cycle if the actuating means is held actuated bottom position the part of the press cycle where the dies are closed BCAM brake monitor RCLS a device designed to prevent the next stroke if stopping time or distance exceeds a preset buttons palm type pushbutton switches used by an operator for starting and stopping the press clutch brake valve the main valve that controls the flow of air to the clutch brake mechanism continuous mode the mode where the control maintains continuous stroking after an operator starts the press a combination of switches and logic used to protect automation machinery and stamping dies from damage if when a part deviates from its intended path thru a sequence of progressive dies the part of the press cycle when the press travels from near top zone through bottom to the upstroke zone DM die monitor downstroke zone fault detection for valves internal valve is designed to turn itself off when it faults grounded ac power ac power distribution where the L2 side of the ac line is grounded inch mode a mode that lets an operator move the press incrementally by pressing and releasing run stat
48. o 1747 AIC Resolve Link Input Coupler Module Publication 6556 6 5 11 August 1998 Set Up Rotary Cam Limit Switches Installing and Wiring 3 3 Chassis B Slot Description of Module Slot Description of Module Processor B 1747 L532 SLC 5 03 L4 Output Module 1746 0A16 or 1746 0B16 Input Module 1746 IA16 ac or 1746 1B16 dc Isolated Relay Output Module 1746 0X8 Input Module 1746 IA16 ac or 1746 1B16 dc I O Module 1746 NIO4I optional Resolver Input Module optional Helm HM571 RES Slot 0 Slotl Slot2 Slot3 Slot4 Slot5 Slot SLC 5 03 A16 IA16 Resolver OA16 0X8 NIO4I ooo00 0000 Oooo 0000 o000 0000 Eo 0000 oo oo oo W 1747 AIC j Link Coupler Input Module To set up or simulate with a resolver rotary cam limit switches set up the cam angles for each switch assembly as described below and according to the press manufacturer s installation instructions Important Mount these assemblies on opposite ends of the crankshaft so a mismatch fault will occur if the crankshaft breaks brake monitor BCAM contacts close at a point that lets the system detect an increase in braking distance e take over TCAM contacts close at bottom to let the press complete a stroke and open during upstroke to let the press stop at the top anti repeat ACAM contacts limit press operation to a single stroke in single stroke mode This Cam In this Mode With these Conditions Provides a
49. ons Once the press reaches the takeover cam TCAM the press continues automatically through the upstroke Figure A 3 Figure A 2 Typical Operational Sequence for Downstroke in Single Mode Select single mode Y Y No Is the motor running forward Yes Y No y Have you released both Run buttons since the previous stroke Yes v No Have you pressed both Run buttons concurrently m Yes y Y No Both processors energize Have you released a their outputs to actuate the gt Run button clutch for downstroke V Yes Y Both i processors de energze 1 Is the press into the No their outputs to stop the press upstroke zone Yes y Have you released then No Goto RI pressed both Run buttons Figure A 3 concurrently y Yes Both processors de energize their outputs to stop the press Yes Has either processor Publication 6556 6 5 11 August 1998 Figure A 3 Typical Operational Sequence for Upstroke in Single Mode Upstroke continues regardless of releasing Run buttons Y detected a critical fault No Has the press moved into the near top position Yes Y ATTENTION If the press coasted Both processors de energize past the near top position while their outputs to stop the press in
50. pe run station inch run palm button E stop mode selection rotary key lockable top stop push button arm continuous E stop reset C B power reset main motor forward N O single contact motion detector air pressure position monitor two resolvers or one resolver and one RCLS assembly Follow manufacturer recommendations when installing the resolver s Mount position monitors at opposite ends of the crank shaft axis Connect them as follows resolver input modules in chassis A and B resolver to chassis A RCLS assembly to chassis B If using a pair of resolvers one resolver and one RCLS assembly Connect Chassis Cables Connect cables as shown You must make the cable that connects between the two link couplers See the Installation Instructions that accompanied the link coupler for the terminations The cable uses a pair of 6 pin phoenix connectors 1747 C11 Link coupler to the SLC processor came with link coupler 2 required 1747 C20 PanelView 600 to Link Coupler came with PanelView 600 that between link couplers see coupler installation you make in chassis A and B instructions PS 1747 C1L jel Chassis B Publication 6556 6 5 11 August 1998 To PanelView 600 1747 C20 cable that you make 3 6 Installing and Wiring Wire Your C B Control Publication 6556 6 5 11 August 1998 We provide wiring drawings publication 6556 2 15 for the ac 6556503 and dc 6556503DC versions of this
51. perator interfaces sensors and a variety of software Rockwell is one of the world s leading technology companies Worldwide representation mH SS Argentina e Australia e Austria e Bahrain e Belgium e Brazil e Bulgaria e Canada e Chile e China PRC e Colombia e Costa Rica e Croatia e Cyprus e Czech Republic e Denmark e Ecuador e Egypt e El Salvador e Finland e France e Germany e Greece e Guatemala e Honduras e Hong Kong s Hungary e Iceland e India e Indonesia e Ireland e Israel e Italy eJ amaica eJ apan eJ ordan e Korea e Kuwait e Lebanon e Malaysia e Mexico e Netherlands e New Zealand e Norway e Pakistan e Peru e Philippines e Poland e Portugal e Puerto Rico e Qatar e Romania e Russia CIS e Saudi Arabia e Singapore e Slovakia e Slovenia e South Africa Republic e Spain e Sweden e Switzerland e Taiwan e Thailand e Turkey e United Arab Emirates e United Kingdom e United States e Uruguay e Venezuela e Yugoslavia Allen Bradley Headquarters 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Publication 6556 6 5 11 August 1998 PN955133 08 Copyright 1998 Allen Bradley Company Inc Printed in USA
52. press stops immediately whenever either processor detects a trip or stop condition or a required condition is removed Figure A 4 Typical Operational Sequence to Start Continuous Mode e Y Select continuous mode Y Yes Y No Is the motor running forward y Yes Y No Have you released the Top Stop button Yes Y y No Have you released both Run buttons ne Yes t No Have you pressed the s Arm Continuous button y Yes Y No Have you pressed Has the Arm Continuous timer Yes both Run buttons No timed out m y Yes Both processors energized their outputs i No Has the press reached the Have you released a Run button upstroke zone No 7 or has a stop condition occurred y Yes y Yes Ce Both processors de energize their Figure A 5 outputs to stop the press Y R Publication 6556 6 5 11 August 1998 A 4 Description of Operating Modes Publication 6556 6 5 11 August 1998 Figure A 5 Typical Operational Sequence for Continuous Stroking R3 Both processors allow continuous stroking regardless of releasing Run buttons Have you pressed Yes a Top stop button y No Has the PLC received Yes a Top stop command No 0 E Has a stop condition been detected Yes Both processors de energize outputs to stop the press
53. r all DM channels are set for by pass mode Active DM screen all DM channel outputs are set for by pass mode Active DM screen the fault prompt states Channels 1 16 Cleared Status screen Important Your SLC processor must be programmed and in Run mode Start with channel 1 1 Close the input switch 2 From the Active DM screen select channel mode static channel output 2 warning 3 Go to the Status screen 4 Open the input switch 5 Observe the fault prompt Channel 1 Warning If you do not see a warning on the Status screen check for errors in input switch wiring chapter 3 6 Close the input switch 7 Press the fault reset pushbutton 8 Observe that the fault prompt returns to Channels 1 16 Cleared Important Repeat this procedure for each operational DM channel Publication 6556 6 5 11 August 1998 7 2 Testing DM and PLS Channels Testing DM Transfer mode Test the series of channels that you assigned as transfer mode to Channels verify that you have correctly set them up Before you begin be sure that Important you tested all your DM channels as described above to verify DM channel mapping and wiring the entry station is set up correctly with a bypassed output its channel number is the first in the series of XFR mode channels its output mode is set to by passed its window is set correctly A part must be in position throughout the window you
54. set up your sequence of XFR mode channels with consecutive uninterrupted channel numbers window On Off setpoints A part must be in position throughout the window channel mode transfer mode output mode stop now top stop or warning channel switches are actuated in the same order as their channel numbers ie channel switch first channel 2 switch second etc Follow this procedure 1 With the press in motion transfer a part through the first two stations channel 1 with bypassed output amp channel 2 2 Stop the press If the part transfers correctly the software should not indicate a fault If it does check that the window turn On and Off settings are correct 3 Restart the press and transfer the part to the next station either stopping at each station or completing the series of stations The software should not indicate a fault If it does check that the window turn On and Off settings are correct 4 As appropriate stop the press and safely remove a part 5 Restart the press and machinery When the crankshaft position reaches the next window the software should indicate a fault at the next station because the part is missing Observe fault prompt on Status screen 6 To resume transfer mode operation Press the Resume Operation pushbutton This pushbutton resets the logic of the remaining transfer mode channels according to the status of the errant part you can remove it or place i
55. t back in position to resume operation Press the fault reset pushbutton Restart the press If the software faults check wiring of the Resume Operation pushbutton chapter 3 Publication 6556 6 5 11 August 1998 Testing the Resolver Input Testing a PLS Channel Testing DM and PLS Channels 7 3 In this procedure you observe that the angular position of the crankshaft matches the observed die position of the stamping press Use these screens Active PLS DM menu to read indicated crankshaft position 1 Jog the press through one stroke 2 Observe that reported position matches the crankshaft position Top dead center and bottom are the best positions to observe If the press position is not reported refer to the manufacturer s troubleshooting information for your resolver and resolver input module Also check for errors in resolver input wiring chapter 3 If the reported press position shows rotation in a direction opposite to the crankshaft reverse the resolver input wires Test one channel at a time to verify signal thru put from the data table to the output module or output device Use these screens Active PLS to turn On each channel You also observe the channel LED indicator to verify that the output turned ON You may also observe the output device that you wired to the output terminal for each channel Observe or set up the following initial conditions before starting e all PLS channel setpoints
56. tion progresses through the correct sequence of e downstroke upstroke top zone During each stroke rotary cam limit switches must cycle through these zones near bottom Top Zone Downstroke Upstroke BCAM Of On TCAM Off On ACAM nS a uS BCAM and TCAM can transition within the Same scan or overlap their On states Important The software reads the zones according to the on off status of ACAM BCAM and TCAM switches that you set mechanically When the software detects any one of the following fault conditions it is designed to turn outputs off and set the corresponding Panel View messages for detected fault conditions Use the following look up table to take corrective action Publication 6556 6 5 11 August 1998 Testing C B Operation Msg PanelView Message Processor Faults Cause of Fault Effect of Fault How to Correct the Fault 026 027 028 029 033 034 041 042 043 044 046 llegal RCLS Combination Forward Transition from Top Forward Transition from Downstroke Forward Transition from Upstroke Forward Shaft Position Transition Faults ACAM Upstroke BCAM Mismatch Between Processors TCAM Mismatch Between Processors ACAM Mismatch Between Processors Cam Mismatch Faults Brake Monitor Fault S oftware hardware cams produced inv S oftware hardware cams did not go from near top to downstroke S oftware hardware cams did not enter upstroke S of
57. tware hardware cams did not enter near top zone ACAM did not cycle in upstroke One processor sees the BCAM On On alid combination Press will stop or notrunin Check software cam logic or single or continuous mode hardware cams for proper operation or settings y of 027 029 detected ile the other does not e processor sees the TCAM ile the other does not e processor sees the ACAM ile the other does not y of 041 043 detected On a top stop command the press Press cannot operate in Check the brake and slid onto BCAM before stopping single or continuous mode brake monitor cam settings To clear this latched fault bit you must enable the fault reset bit or turn the mode select switch to OFF Test the Operating Modes Publication 6556 6 5 11 August 1998 Here are procedures to test dynamic operation of the press in these modes inch e single stroke continuous with the arm continuous method to start this mode Important If the press control faults or does not operate as expected read the fault or prompt message and see Appendix B for e faults for troubleshooting prompts for operating the press Inch Mode Place the mode selector switch in inch mode Power up by pressing the Control Rest and C B Power Reset buttons Verify that seal relays and CRM relays are energized Concurrently press and hold both run inch buttons Observe that the press cycles and stops o

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