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1771-6.5.18, Clutch/Brake Module, User Manual

1. For either option For optional Dump Valve For optional Micro inch Valve 1771 0D 312 1771 IA 1771 IA Module Group 4 Module Group 4 Module Group 5 Slot 0 Slot 1 Slot 0 LRA LRB LRA ire 2L1 e 6 ers att figure 6 10 Micro inch AO gt Valve Stem A e 16 DS Dump Valve 4 G e 2 S ove e Solenoids e 59 3 3I SS 4 E S i G Pressure Sw A 7 5 5I B TO 2 E Q Q 3 Md BO BO le a 2L2 foo 2L2 A Micro inch Valve Solenoids 2 ud Ux us 0 4 Chassis Switches Dump Valve Stems E 1 Micronch AS JS oN Valve Stem B I i L I 3 S S i 5 90 REN IS SIS EIN EIN 5 S S i S Pressure Sw B IS IG eS 9 Q IQ m S L I el 1 BO E ges E 212 H 2L2 12 4 ro NOTES Use this wiring with figurd 6 1 for ungrounded AC power 1 LRA and LRB load resistors for triac feedback are 2K ohm 15 watt resistors 2 Each solenoid or relay c
2. 17714A Module Group 1 Slot 1 Chassis A AS I RM 9 2 5 Top stop check TCAM 3 Q Q Cam Limit Switch Run On RCAM 510 Assembly A 10 IQ 1 Anti Repeat BC 212 2L1 Chassis B AS OS i S 2 S Top stop check TCAM 3 Q JQ S Cam Limit Switch Run On RCAM Uy Assembly B 10 si i 110 Anti Repeat ACAM S 53 211 i 1 470 ohm 50 watt 196 or 500 ohm 5 on seperate terminal strip 12278 6 21 Chapter 6 Field Wiring Arm Connections Required Hardwire Inputs Connect hardwire inputs in parallel to chassis A and B so each voting processor can monitor the following inputs in parallel Input Terminal MG Slot Figure Mode Select Switch 0 3 0 0 Main Motor Forward 4 0 0 Barrier Guard 5 0 0 Stop on top 6 0 0 Arm Continuous 7 0 0 Press Interlock 6 2 0 6 1 When connected these inputs function as follows This With PM in Input this Mode The PM module Mode Select terminals 0 3 Determines detects the selected mode the mode Main Motor Forward terminal 4 ON or OFF uses these signals to determine proper CAM action Micro inch Single stroke detects one of the permissives to start or maintain a stroke and Continuous if turned OFF immediately turns OFF solenoid
3. 17714 h 3 Modul ota s MA0 LS PLI LOB 19 ihade AS TD On A 0 IS pou Ch A i To 1 ABI 2 BIS Dp BEER OS E ChA 3 2225 EP i te Ch A 4 gt bog Right Active _ Ch B 2 IR Ch A S Frey be 18 21 Stop OnTop IY OE Seton quias E E stop dj m mT Tea EP Lo See gud 61 ios 1 E Chassis A Dummy Plug Plugin for Station Bypass EE ation 1 cette te chB 0 Left Run 1 LI Toss 0 3 Ch B 2 5 Ei 5 Ch B 3 Cd ChA 5 4 res 1 Ch 5 89 S E T ChB 3 T 1 Bese S 22 5 d Right Adive ChB 5 S i Right 2L1 211 Stop OnTop came 1 1 1 assis 1 lt 1 lt lt Eod See figure 6 10 NEC on ene j Left Right Cd E stop Inch In EE See figurd 6 1 o 6 5 poses 04 0 0 Dummy Plug Plugin 21 for Station dud Plug either the operator station Bypass m ame or dummy plug into the control panel no IMPORTANT For These Connections See Figures E STOP 6 1 STOP ON TOP 1610 6 25 Chapter 6 Field Wiring Arm Co
4. Keying ha amie eee PEE ey ES IS E PLC Ladder Programming Chapter Programming Fundamentals Configuration Matching Configuration Bits and Backplane Switches PLC Command 4 9 Summary of PLC Configuration and Command Rungs Module Group 5 Slot 0 Reserved for Micro Inch Module Groups 6 and 7 Reserved for Data Storage Monitoring Clutch Brake Controller Inputs and Outputs Report Generation Summary of Clutch Brake Controller Functions Table of Contents Voting Processor Firmware Chapter Operation of Voting Processors Emergency Shut Down Fault Monitoring Operation of Cam Limit Switches Clutch Brake Operating Modes Connections to Field Wiring Arms Chapter Installation Considerations Electrical Connections and Safety Requirements Control Power
5. Figure 4 4 Example PLC Configuration Rungs for Bits 01 thru 07 and 14 PLC 3 and PLC 5 250 Stations 3 and 4 not used 00057 00067 U U 01 01 Motion detector feedback used 00057 00067 L L 02 02 Valve stem switch feedback used i seul 03 03 Air pressure switch feedback not used 00057 00067 0 U 04 04 Ungrounded AC power 00057 00067 L L 05 05 On the hop not used 00057 00067 U U 06 06 Half stroke or Stroke and a half used 00057 00067 U U 07 07 Optional dump valve triacs used 00057 00067 L 1 14 14 NOTE Unconditionally latch or unlatch bits 0 through 7 and 14 for chassisA and as shown to use these functions Use this address format for PLC 5 250 processors 0 057 0 067 U U 01 01 4 5 Chapter 4 PC Ladder Programming Figure 4 5 Example PLC Configuration Rungs for Bits 01thru 07 and 14 PLC 5 family Stations 3 and 4 not used 0 57 Motion detector feedback used 0 57 Valve stem switch feedback used 0 57 Air pressure switch feedback not used Ungrounded AC power 0 57 On the hop not used 0 57 Stroke and a half or Half stroke used 0 57 Optional dump valve triacs used 0 57 4 6 NOTE Unconditionally latch or unlatch bits 0 through 7 and 14 for chassisA and B as shown to use these functions Chapter 4 PC Ladder Programming Matching Configuration Bits and As listed in Table
6. Select inch or micro inch mode WARNING To guard against the No possibility of personal injury install a is ih MICE EN keylock mode select switch so that only 0 MES supervisory personnel can select inch je mode Has an operator pressed No both INCH buttons a simultaneously Yes Both voting processors energize their solenoid triacs to actuate the clutch iz Has the shaft moved into its No Has an operator released No near top position either INCH button Yes es Both voting processors WARNING If the shaft de energize their solenoid triacs to stop the shaft in its near top position coasted past its near top position while braking the brake is faulty and hazardous Repair it immediately NOTE Use inch or micro inch mode to position the shaft near the top Operators may jog the shaft in either direction The shaft stops when it moves near top position or when an operator released an INCH button 12261 5 5 Chapter 5 Voting Processor Firmware 5 6 Single Stroke Mode Use single stroke mode to actuate the press through a single cycle During the downstroke Figure 5 3 releasing a RUN button stops the press if the shaft did not enter the near bottom zone you may resume the downstroke if the shaft entered the near bottom zone you must inch the press back to the near top position before restarting During the upstroke Figure 5 4 the shaft continues automa
7. E Stop Switches Seal Relays and Crowbar Relays Crowbar Test Inputs Optional Hardwire Inputs Internal External Fault Detection Optional Valve Stem Switches Motion Detectors and Air Pressure Switches Main Valve Solenoids Optional Auxiliary Valve Solenoids Optional Dump Valve 501 Optional Micro inch Valve Solenoids Electrical Noise Cam Limit Switches Required Hardwire Inputs Inch Buttons and Plug In Operator Stations Optional Binary Display Optional Indicators LAMP TOS coc donee bere XD BEY dda EOS Inputs to Chassis C Troubleshooting Chapter Troubleshooting Considerations and Requirements Troubleshooting with General Troubleshooting Procedure Troubleshooting Troubleshooting Example Display of Diagnostic Message
8. LT LT Wessweummbmni 7 T meWergweemwnnT 7 Tear essen 1101 1000 Top Triac 0 remains on after turned off Top 1101 1011 0 Triac 3 remains on after turned off 1 1101 1100 1101 1101 1101 1111 _ S frais sonia O a 1110 0011 Dump valve stem signal on when traics are off 1 T poeson OO Chapter 7 Troubleshooting diagnostic message codes are displayed by indicators connected to module group 5 slot 1 figure 6 18 or by displaying the corresponding data table word using the industrial terminal Use this table in conjunction with figurd 7 4 and figure references shown in parentheses Type of Message N Non latched L Latched T Trip Condition 1110 1000 1110 1101 1111 0000 1111 0001 1111 0100 1111 0111 1111 1000 1111 1001 1111 1010 1111 1011 Code P at Power up Alt Alternate chassis Ethr Either chassis Top Top chassis Bot Bottom chassis Diagnostic Message figure References T poems O Dump valve stem signal off when traics are on 1 T iia sina atresia 000000 T Alt Main valve stem signal remains on after triacs turn off 1 posnamem Aux valve stem signal remain on after triacs turn off 1 T presensa 0000000 Hardware or Cable Fault Chassis power tripped or chassis restarted L Lost communications between 1771 PM modules Reset latched message check cables or cycle power 3 3 t Lost comm
9. A Select inch mode and position the Yes Yes um No Y Go to Continuous Stroking Go to Stop Condition Figurd 5 6 shaft near the top NOTE Half stroke or Stroke and a half requires all operators to hold all RUN buttons until the first or second downstroke is completed Releasing a RUN button during the first upstroke requires restarting continuous mode at the arming sequence Releasing a RUN button in the first or second downstroke requires restarting as if an operator had stopped the press in the first downstroke 12266 5 12 Chapter 5 Voting Processor Firmware No Continuous Stroking From figure Both voting processors allow continuous stroking regardless of releasing RUN buttons Y Has an operator pressed a STOP ON TOP button Yes No Y Has the PLC transferred a stop on top command No Y Has a barrier guard opened Yes Y Both voting processors trip triac power to stop the shaft A trip condition message is displayed gt The stroke continues until the shaft reaches the near top position Y No Is the shaft in the near top position Yes Y Both voting processors de energize their solenoid triacs to stop the shaft in its near top position NOTE The press strokes continuously
10. Before reading this manual scan through it This will help you understand its organization Before installing your clutch brake controller read this manual thoroughly You should also read other publications that we refer While installing or troubleshooting your clutch brake controller use this manual as a reference Chapter 1 Introduction Terminology We define new terms where they first appear in this manual You should be familiar with the following terms because we use them throughout this manual press 15 a mechanical part revolution power press that is actuated by a clutch and stopped by a brake aclutch brake controller is an Allen Bradley controller which includes chassis A and B two Clutch Brake Modules cat no 1771 PM and associated I O modules a press system includes your mechanical power press clutch brake controller and all associated wiring and components a PLC is any Allen Bradley programmable controller that has 1771 remote I O operation TCAM is the acronym for Top Stop Check Cam switch ACAM is the acronym for Anti repeat Cam switch RCAM is the acronym for Run on Cam switch Firmware Revision Record The firmware has been revised as follows Firmware Revision Change in operation A B Micro inch added A C None corrected intermittent stoppage in continuous mode A D Motion detector time out increased to 4 sec A E None corrected intermittent communications proble
11. 6 9 Chapter 6 Field Wiring Arm Connections Optional Micro inch Valve Solenoids 6 10 Each dump valve solenoid should draw at least 60mA If not connect an appropriate load resistor in parallel with it For neatness and safety we recommend that you connect the load resistor only at convenient terminal strips not at the field wiring arms If you use dump valves with internal fault detection no valve stem switches but you have configured for external fault detection simulate the inputs of the dump valve stem switches Do this by jumpering the input terminals of field wiring arms for dump valve stem switches to the input terminals for the main Josh stem Mrs Jumper terminal 4 module group 4 slot 1 i urd 6 4 o 4 lor Fig Fines to terminal 0 module Group 2 slot 0 Figure 6 2 pr 2 br Figure 6 6 for zo A and B Micro inch mode lets you run your press at low speed 1 to 5 strokes per minute for setting up dies and making trial runs Micro inch mode requires that you provide a separate drive and clutch brake assembly to drive the shaft with the flywheel bypassed Micro inch mode functions only when the main clutch brake assembly is inoperative and vice versa The advantage of the micro inch mode operation is full press tonnage capacity at low press speeds Other characteristics include Micro inch motion is initiated using INCH buttons Micro inch solenoid valves function only when the mode select switch is in the MICRO
12. Yes Has each operator pressed his RUN buttons simultaneously and within 5 seconds for all stations Yes CAUTION Releasing a RUN button late in the downstroke can damage the press No NOTE Releasing a RUN button during the downstroke stops the press If the shaft does not reach the near bottom zone operators may resume the downstroke If the shaft reaches the near bottom zone an operator must inch the press back to the near top position 12262 5 7 Chapter 5 Voting Processor Firmware Both voting processors de energize their solenoid triacs to stop the shaft A stop condition mesage is displayed A Has the shaft moved into its near top position No 5 8 Figure 5 4 Operational Sequence for Upstroke in Single Mode Start upstroke From figur 5 3 Y Upstroke continues regardless of releasing RUN buttons Yes No beg ___ Y Have both voting processors detected that anti repeat cams have opened Yes Y Have all operators released all RUN buttons Yes i No Y Yes Has the shaft moved into its near top Has on the hop been enabled Yes No Y Has the shaft moved into its near top position jM ves No position Has each operator pressed his RUN buttons simultaneously and within 5
13. 201 201 make this connection when NOT using Motion Detector B B 8 Appendix B 1 0 From To Lists 1 0 From To List for Figure 6 18 Diagnostic Message Display eae B510 Output indicator for bit 10 B511 Output indicator for bit 11 B512 Output indicator for bit12 B513 Output indicator for bit 13 B514 Output indicator for bit 14 B515 Output indicator for bit 15 B516 Output indicator for bit 16 B517 Output indicator for bit 17 I O From List for Figure 6 19 Connections for Optional Indicators Pees __ B312 MICRO INCH indicator B 9 Appendix B From To Lists From To List for Figure 6 20 Connections for PC Command Switches To C213 Barrier Guard NO switch contact Reset Latched Messages NO switch C215 Stop on top NO switch contact C216 Lamp Test NO switch contact ca NOTE We have chosen rack 3 module group 2 for the address of this module in remote I O chassis C Choose your own address based on your application requirements B 10 Symbols Empty PC press 1 2 A addresses bit monitor B bottom zone 5 6 braking distance C cable connections twinaxial cam limit switches anti repeat 5 3 run on chassis A and B chassis C lamptest clutch brake controller description hardware 3 3 command rungs PC configuration Switch settings switch settings continuous mode control power crowbar
14. 080 086 08A 090 094 09A O9E 0M 085 089 08F 093 099 09D O9F 0A3 0A7 OF3 7 11 ET Clad Troubleshooting Message code Priority 7 12 Trip condition Message highest priority Trip condition messages occur anytime the PM module detects a fault condition that casts doubt on the system s ability to measure the press s shaft angle control power to the solenoid valve triacs When it detects this type of fault the PM module immediately stops press motion opens the seal relays If it detects that the seal relays did not open it blows the main power fuses with crowbar relays The trip condition fault remains until you correct the problem and press the RESET LATCHED MSG pushbutton wired to chassis C Typical fault conditions are due to system configuration feedback signals run stations or triacs After corrrecting the fault condition get back into operation with the same steps as OD Latched Message above Example If the motion detection input Figure 6 2 should turn ON while the press is operating and you did not configure for motion detection the PM module would generate the following message Error BB Hex Motion detector signal present though motion detector feedback is not configured Diagnostic diagnostic message codes are not queued When the PM module detects multiple latched or tripped message conditions it sends the highest priority message c
15. Allen Bradley Clutch Brake Module User Cat No 1771 PM M anua Table of Contents 1 Chapter Objectives Of This Manual How To Use This Manual t1 xad acus ERE RR ERIS Firmware Revision Record ra Press System Description 2 1 Chapter System Components Figure 2 1 Functional Block Diagram 22 Related Safety Documentation Clutch Brake Controller Hardware 3 1 Chapter Objectives 1 sisse m General Hardware Considerations B4 Description of your Clutch Brake Controller Twinaxial Cable Connections Multiple Clutch Brake Controllers 5 8 Panel Switches and Operator Stations B Interlock Switches Configuring Your Clutch Brake Controller B4 Rack Address of Chassis Aand B B3 Setting the Communication Rate Response Time 3 1 Module Placement
16. NC RUN button bypass is open Check wiring e T ornon T q pe ooo Inch button Figure 6 13 WD mme 7 27 ET Clad Troubleshooting Diagnostic message codes are displayed by indicators connected to module group 5 slot 1 figure 6 18 or by displaying the corresponding data table word using the industrial terminal Use this table in conjunction with figure 7 1 and figure references shown in parentheses Type of Message Code N Non latched at Power up L Latched Alt Alternate chassis T Trip Ethr Either chassis Condition Top Top chassis Bot Bottom chassis Diagnostic Message figure References Code s INCH button not released Check NO contacts Orkney EA E INCH button not released Check NC contacts ur INCH button not released Check NC contacts Alt INCH button not released Check NC contacts RIS INCH button is not released Check NO contacts Alt m qme Valve Stem Inputs Not Configured EUN URN Main valve stem input is present but not configured 6 17 5B Alt Main valve stem input is present but not configured 6 17 50 7 Auxiliary valve stem input is present but not configured 6 17 BAEZ Auxiliary valve stem input is present but not configured 6 17 Dump valve stem input is present but no configured Dump valve stem input is present but no cinfigu
17. SPM 100 90 80 70 60 50 40 30 20 10 0 0 5 10 15 20 25 12251 Degrees of Shaft Rotation Important When estimating the braking distance in degrees of rotation add the response time of the controller Figure 3 5 to the specified downstroke or upstroke braking distance of your press Locations of all clutch brake controller modules are shown in Figure 3 6 Note that some of these modules are optional AN cavtio Do not place any I O module in module groups 6 or 7 of chassis A or B These module group locations are non functional and reserved for future use If you use a slot power supply install it in module group 7 Important Use series C or later 1771 OD modules because they have improved electrical noise immunity Refer to Electrical Noise Suppression in chapter 6 for a method of suppressing surge transient noise Chapter 3 Clutch Brake Controller Hardware Figure 3 6 Module Locations Optional 1771 OA modules for display of Required 1771 IA modules for message codes brake fault run window and micro inch press inputs chassis A amp B module group 3 slot 1 chassis A module group 0 slots 0 amp 1 module group 5 slot 1 chassis A amp B module group 1 slot 1 Optional 1771 IA modules for micro inch inputs chassis A amp B module group 2 slots 0 amp 1 mdoule group 5 slot 0 ESL 1771 PM module Optional 1771 IA modules for station 3 amp 4 These slots must remain empty in chass
18. To A000 B000 8m A002 B002 A003 B003 A004 Main Motor Forward contactor A004 B004 A005 Barrier Guard switch aos BO i A006 Stop on topswihinStationa A006 B006 Arm Continuous switch in Station 1 B000 OFF position in Mode Select switch Appendix B 1 0 From To Lists From To List for Figurd 6 13 Operator Station 1 To ELE a o Left RUN button NO contact From To List for 6 14 Operator Station 2 From To A013 Left RUN button NC contact Right RUN button NO contact A015 Left Active jumper conection B013 Right RUN button NC contact Left RUN button NO contact B015 Right Active jumper conection B 7 Appendix B From To Lists JO From To List for Figurd 6 15 Operator Station 3 To A100 Left RUN button NC contact A101 Right RUN button NO contact A102 Left Active jumper conection Right Active jumper conection 1 0 From To List for Figure 6 16 Operator Station 4 From To A103 Left RUN button NC contact A104 Right RUN button NO contact 105 Left Active jumper conection B103 Right RUN button NC contact 104 Left RUN button NO contact B105 Right Active jumper conection From To List for Figure 6 17 Main and Auxiliary Valve Stem Motion Detector and Air Pressure Switches From To A200 Switch on Main Valve Stem A A201 Motion Detector A mor
19. relays 6 3 test inputs 6 4 D diagnostic display downstroke flowcharts message codes dummy plugs F fault detection solenoid valve 6 8 functions configurable Index H hardware coniderations inch mode installation considerations interlock switches K keying L lamp test load resistors 6 8 Manual how to use objectives message codes module placement switch settings module group 7 3 12 4 13 monitoring 1 0 multiple controllers N noise immunity 3 12 0 operator stations P panel switches press system components programming configuration rungs fundamentals PC command rungs Index R panel rack address 3 9 system components 2 1 report generation response time T rungs terminator resistor Terminology S top position safety triac sequential turn on 3 11 documentation troubleshooting requirements 6 1 considerations seal relay 6 3 example v 1831 procedure single mode solenoid valves auxiliary 6 9 U EST unique rack address suppression electrical noise 6 11 upstroke switch button E stop V Inch 6 24 Lamp voting processor Run switch input cam limit switches 6 20 switches wire size interlock Oe Rockwell Automation Allen Bradley a Rockwell Automation Business has been helping its customers improve pro ductivity and quality for more than 90 yea
20. the scanner module the last chassis whether it is a clutch brake chassis or a remote I O chassis each end of the cable that connects chassis A and B at terminals 7 8 and 9 of the 1771 PM module field wiring arms For more information on how to connect remote I O channels refer to the installation publications that apply to your particular PLC Also refer to Product Data of the Remote I O Adapter Module These publications are listed in our Publications Index publication SD499 Terminator cat no 1770 Terminator cat no 1770 XT Figure 3 2 Typical Twinaxial Cable Connections Chapter 3 Clutch Brake Controller Hardware Processor Scanner S Blue S Shield Use Twinaxial P cat no 1770 CD dS Cigar for all cable connections 5 E Chassis A e Terminal Strip on 1772 SD SD2 Remote I O Scanner Blue Blue Distribution Module PLC 2 Shield Shield or Clear Clear e Terminal Block on E 1775 S4A S4B S5 EI I O Scanner Module PLC 2 JO or e Connector on PLC 5 hs i d TS Terminator P
21. you violate safety requirements discussed and referred to in this manual For AC Use This Power Mandatory That Is Figure For these Connections Ungrounded AC Power and Crowbar Test Inputs Press Interlock Switch Ungrounded Main and Auxiliary Valve Solenoids Crowbar and Seal Relays or MOV Surge Suppression Grounded AC Power and Crowbar Test Inputs Press Interlock Switch Grounded Main and Auxiliary Valve Solenoids Crowbar and Seal Relays MOV Surge Suppression 6 1 Chapter 6 Field Wiring Arm Connections Use This Mandatory Figure For These Connections 6 9 Cam Limit Switch Assemblies Main Motor Forward Barrier Guard Stop on top Arm Continuous Mode Select Switch Operator Stations 1 amp 2 Dummy Plugs Inch Pushbutton Switches WARNING To guard against injury to personnel and damage to your press connect your clutch brake controller exactly as shown in these figures The connections for optional features are shown in the following figures Use this Figure For These Optional Connections Switches on Main Valve Stems Air Pressure Sensors Motion Detector Dump and or Micro inch Valves 6 12 Operator Stations 3 amp 4 Dummy plugs Diagnostic Message Display Brake Fault Indicator Run Window Indicator Micro inch Indicator Important Use 14 AWG stranded copper wire with 3 64 inch insulation for all solenoid and relay coil connections to the 1771 OD modules We also recommend the same wire size fo
22. 4 A backplane switch positions 2 thru 8 correspond Backplane Switches with configuration bits 01 thru 07 The voting processors in your clutch brake modules allow press operation only if the set on and reset off states of configuration bits in your program correctly match the ON and OFF settings of corresponding backplane switches The voting processors check for correct configuration when you apply power to your clutch brake controller or change its mode of operation using the mode select switch Table 4 A Corresponding Backplane Switch Settings and Configuration Bits Backplane Switch Settings Configuration Backplane switch settings and configuration bits igure 3 3 Bits must be identical Pos Setting Bit Status Function 2 ON Use Stations 3 and 4 Stations 3 and 4 not used Use Motion Detector Feedback Use Valve Stem Feedback tires Petr Air Pressure Feedback not used _ NINE NN O Module Group 4 Slot 1 Chassis A amp B Set Use Dump Valve Outputs 1771 IA Module Group 4 Slot 1 Chassis A amp B Dump Valve Outputs not used is EMPTY 4 7 Chapter 4 PC Ladder Programming PLC Command Rungs 4 8 Your ladder diagram program can send four commands to the clutch brake controller by setting command bits 10 13 in the output image word for module group MG 7 Slot 1 for I O chassis A and B Command Bit Press enable 10 Stop on top 11 Reset latched messages 12 Lamp
23. 6 Example PLC Command Rungs for Bits 10 thru 13 PLC 2 Family PRESS ENABLE Switch Optional conditions 132 057 1 E L E ji L 1 E 1 L 13 n Enable Press Operation 132 067 J L d L 13 n 182 STOP ON TOP Switch 057 15 132 Command Stop on top 067 t 15 n 192 RESET Switch 057 Jo L 14 la Reset latched messages 132 067 4 L 14 e 132 LAMP TEST Switch 057 ji L 16 1a 132 Test optional indicators 067 Pu 16 5 NOTE PLC command bits 10 through 13 use conditioned logic Do not latch or unlatch instructions Corresponding switch input wiring is shown in Figure 6 15 4 9 Chapter 4 PC Ladder Programming Figure 4 7 Example PLC Command Rungs for Bits 10 thru 13 PLC 3 and PLC 5 250 PRESS ENABLE Switch Optional conditions 10032 X O0057 00067 f f E C 10 13 Enable Press Operation n 10082 STOP ON TOP Switch eod 1 15 1 11 Command Stop on top 10082 RESET Switch 00057 00067 1 j L 14 12 12 Reset latched messages 10032 LAMP TEST Switch 00057 00067 f 16 13 13 Test optional indicators NOTE PLC command bits 10 through 13 use conditioned logic Do not latch or unlatch instructions Corresponding switch input wiring is shown in Figure 6 15 Use this address format for PLC 5 250 processors 0 057 0 067 0 U 01 01 4 10 Chapter 4 PC Ladder Programming Figure 4 8 Example PL
24. AC 05 1S JS JS A HO I is 6 Motion Detector s 7 9 Switches on 6 zi B Auxiliary Valve J Stems 1 e 21 DN ne U B OO Make this connection when using Motion Detector Switch B A A 2 d Chassis B Switches on Air Pressure Switch es 211 Main Valve 211 Stems 1 r 4 Q B Sos 1 lt I 1 y o 19 Make this connection when using Remove this jumper xum Air Pressure Switch B when using Air Pressure 51 Switch B JW L I UW 1 If one or both valves have internal fault detection no valve stem switches but you B IS configured for valve stem feedback then jumper terminals 0 and 7 in chassis A and do the same in chassis B 12284 6 13 Chapter 6 Field Wiring Arm Connections Figure 6 3 Connections for Main and Auxiliary Valve Solenoids MOV Surge Suppression Crowbar and Seal Relays Ungrounded AC Power 1771 1771 0D Module Group 2 Module Group 3 Slot 1 Slot 0 Chassi
25. Action OPEN 095 LOCAL BRAKE MONITOR AND REMOTE RUN ON CAM SWITCHES BOTH OPEN 096 REMOTE BRAKE MONITOR AND LOCAL RUN ON CAM SWITCHES BOTH OPEN 097 ALT CHASSIS FOR 094 The PM is presently in the near bottom zone of the stroke run on and brake monitor cam switches on This message occurs when the PM sees an incorrect transition directly to the near top zone run on and brake monitor cam switches off without going through the upstroke 098 RUN ON CAM SWITCH OPEN SHOWING REVERSE See Standard Corrective Action Also check for proper MOTION clutch operation 099 ALT CHASSIS During single stroke or continuous mode only forward motion is allowed This message occurs when the press is in the near bottom zone and then the run on cam switch opens before the brake monitor cam opens signaling reverse motion 09A RUN ON CAM SWITCH OPEN See Standard Corrective Action 09B ALT CHASSIS The PM logic was momentarily in a zone transition state between the near bottom and up stroke zones Before being able to fully transition to the upstroke the PM saw the run on cam signal go off 7 20 Chapter 7 Troubleshooting CAM LIMIT SWITCH NEAR BOTTOM ZONE MESSAGES cont d HEX CODE 09C 09D PROBLEM CORRECTIVE ACTION BRAKE MONITOR CAM SWITCH BOUNCED OR MOTION See Standard Corrective Action Also check for proper REVERSED clutch operation ALT CHASSIS During single stroke or continuous
26. B B 3 Ap ui B4 endix B From To Lists From To List for Figurd 6 6 3L1 Power Crowbar Test and Press Interlock Inputs Grounded AC Power 3L1 Crowbar as NO contact B206 2L2 3L1 Crowbar B N contact Press Interlock Switch 2L2 From To List for Figurd 6 7 Main Solenoids Crowbar and Seal in Relays Grounded AC Power Crowbar Relay A Seal Relay A Main Valve Solenoid A Main Valve Solenoid B Crowbar Relay B Seal Relay B From To List for Figura 6 8 Auxiliary Valve Solenoids Grounded AC Power Appendix B 1 0 From To Lists From To List for Figurd 6 9 Dump Valve Solenoids Grounded AC Power B410 B411 B412 B413 Switch on Dump Valve Stem A 2L2 Switch on Dump Valve Stem B B411 2L2 Dump Valve Solenoid A B413 Dump Valve Solenoid B From TO List for Figurd 6 10 Micro Inch Valve Stem Solenoids Grounded AC Power To Micro inch Position on Selector Switch figure 12 B500 Micro inch Valve Stem Switch Micro inch Pressure Switch B406 Micro inch Valve Solenoid B B408 Micro inch Valve Solenoid B 5 Ap ui B 6 endix B From To Lists From To List for Figurel6 11 Cam Limit Switches To 117 Anti repeat Cam Limit Switch From To List for Figurd 6 12 Mode Select Switch Main Motor Forward Barrier Guard Stop on Top and Arm Continuous
27. BRAKE MONITOR CAM SWITCH OPEN AND RUN ON CAM See Standard Corrective Action Also check for proper SWITCH OPEN SHOWING REVERSE MOTION clutch operation 08F ALT CHASSIS During single stroke or continuous mode only forward motion is allowed When the press was in the downstroke the brake monitor cam and the run on cam switches were on signaling a transition from downstroke directly to the near top zone 7 19 Chapter 7 Troubleshooting CAM LIMIT SWITCH TRANSITION TO NEAR BOTTOM ZONE MESSAGES HEX CODE 090 L BRAKE MONITOR CAM SWITCH OPEN See Standard Corrective Action 091 ALT CHASSIS PROBLEM CORRECTIVE ACTION PE The PM logic was in a momentary zone transition state between downstroke and near bottom zones Before being able to fully transition into the near bottom zone the brake monitor cam turned off signaling instead a transition to the upstroke 092 L RUN ON CAM BOUNCED OR MOTION REVERSED See Standard Corrective Action Also check for proper 093 ALT CHASSIS clutch operation During single stroke or continuous mode only forward motion is allowed When the press is in the near bottom zone the brake monitor cam and the run on cam switches are closed The PM then sees the run on cams open before the brake monitor opens signaling a reverse back to the downstroke position CAM LIMIT SWITCH NEAR BOTTOM ZONE MESSAGES 094 BRAKE MONITOR AND RUN ON CAM SWITCHES BOTH See Standard Corrective
28. Example configuration rungs are shown in Figurd 4 3 through Figure 4 5 Program your configuration rungs according to the requirements of your press system Be sure to set or reset each configuration bit 01 thru 07 and 14 with unconditioned rungs They contain only output instructions such as latch unlatch or output energize Bits set by these rungs do not change during press operation The latching or unlatching of these bits must correspond with backplane switch settings covered in chapter 3 Figure 4 2 Bit addresses of Output Image Table Word for Module Group 7 of Chassis A amp B PLC 2 20 PLC 2 30 Oy7 xx PLC 3 PLC 5 250 PLC 5 O y7 xx where yy rack address per Figurd 3 4 Xx bit number 00 17 Important Do not use bits 00 and 15 17 for any purpose 4 3 Chapter 4 PC Ladder Programming Figure 4 3 Example PLC Configuration Rungs for Bits 01 thru 07 and 14 PLC 2 Family 057 Stations 3 and 4 not used 01 067 01 057 Motion detector feedback used 02 067 02 057 Valve stem switch feedback used 03 067 03 057 Air pressure switch feedback not used 04 067 04 057 Ungrounded AC power 05 067 05 057 On the hop not used 06 067 Stroke and a half used 06 057 VS 07 067 07 057 Optional dump valve triacs used 14 067 4 4 14 Chapter 4 PC Ladder Programming
29. INCH position Diagnostic codes for micro inch mode are listed in the look up table They are 9 bit binary 3 digit hex as compared with 8 bit binary 2 digit hex for all other diagnostic codes Voting processors inhibit main valve auxiliary valve and dump valve solenoids whenever you use micro inch Voting processors monitor these outputs in micro inch mode to verify they are not on or shorted Connect valve solenoids A and B for micro inch mode as shown in Figurd 6 4 for ungrounded solenoids and Figurd 6 8 for grounded solenoids If you do not use micro inch no connections are needed Figurd 6 4 Figurd 6 8 also show connections for feedback from micro inch valve solenoid triacs that allows both voting processors to monitor the on or off state for each triac check for shorted or open triacs and shorted or open solenoids of the micro inch valves load resistors LRA and LRB for triac feedback from micro inch valve solenoids switch inputs for the mode select switch valve stem switches and pressure switch for micro inch circuits Electrical Noise Suppression Chapter 6 Field Wiring Arm Connections Each solenoid valve should draw at least 60mA If not connect an appropriate load resistor in parallel with it For neatness and safety we recommend that you connect feedback and load resistors only at convenient terminal strips not at the field wiring arms Select the same type of solenoid valve for micro in
30. additional valve stem requirements see section title Internal External Fault Detection 6 5 Chapter 6 Field Wiring Arm Connections Internal External Fault Detection 6 6 When PM modules command triacs ON or OFF they check that feedback signals triac valve stem air pressure and motion detector have turned ON or OFF in the order shown and within the times shown If and when a PM module detects that a triac or feedback signal has not turned ON or OFF within the times shown it trips seal relay output to remove power from the wiring arms of 1771 OD output modules Be sure that you configure your clutch brake controller accordingly by setting your backplane switches chapter 3 and programming your configuration bits chapter 4 Connect either one or both motion detector switches and either one or both pressure switches if so configured If your main valves have external fault detection switches and you configured for valve stem feedback all other clutch brake solenoid valves must have external valve stem feedback If auxiliary valve solenoids have internal fault detection do not have valve stem switches jumper terminal 7 to terminal 0 Module group 2 slot 0 Figurel6 2 bro chassis A and B There are two general types of solenoid valves those with external fault detection and those with internal fault detection Solenoid valves with external fault detection have switches on the valve stems which you use to feed b
31. configured to start the press in continuous mode Thereafter the press runs until stopped by a stop on top command or when a fault is detected This command from a switch wired to the clutch brake controller or from the PLC stops the press at a predetermined point Releasing and pressing both RUN buttons during a specific portion of the upstroke causes the press to continue running onto the next stroke without stopping This is a configurable option The operator must press both RUN buttons for 1 2 or 1 1 2 press cycles before the press can run on its own This is a configurable option Run buttons must be held until Run on take over Cams are made 1 Cam limit switches must indicate that the press is in the near top position before motion can start in single or continuous mode Chapter 4 PC Ladder Programming Interrupted stroke Continuous If an operator releases a RUN button during a down stroke the press stops immediately If within five seconds of stopping an operator releases both RUN buttons and presses them again the press continues the downstroke If more than five seconds elapses the operator must inch the press to top select continuous mode and follow the first Continuous procedure above Interrupted stroke Single stroke Same as Continuous mode except there is no time limit on re applying the RUN button Anti tie down The press will not start if you tie down one or more RUN buttons After all RUN button
32. examine on instruction and one output energize instruction he examine on instruction monitors input image bit 03 for module group 0 chassis A or B the output energize instruction controls the CONTINUOUS indicator Important Do not store data in unused data table addresses for chassis A and B These are reserved for future enhancements for the clutch brake controller Your PLC ladder program can monitor clutch brake controller functions for report generation This allows you to display through an RS 232 C peripheral device any of the following Operator instructions fault correction procedures status reports diagnostic message codes The clutch brake module generates diagnostic message codes presented in tabla 7 C Use them to generate messages that you have stored in PLC memory These messages can be troubleshooting instructions to your press operators For detailed descriptions of report generation see the following publications For PLC 2 family processors PLC 2 Family Report Generation Module cat no 1770 RG User s Manual publication 170 815 For PLC 3 processors I O Scanner Message Handling Module cat no 1775 S4B User s Manual publication 1775 6 5 3 Peripheral Communications Module cat no 1775 GA User s Manual publication 1775 6 5 4 For PLC 5 family processors BASIC Module cat no 1771 DB User s Manual publication 1771 6 5 34 Summary of Clutch Brake Controller Fu
33. other I O chassis independent of the Clutch Brake Controller Chapter 3 Clutch Brake Controller Hardware Table 3 A Required and Optional Hardware Quantity Function Important You must use 8 point modules with 2 slot addressing Required Hardware 2 Clutch Brake Module 1771 PM X Monitors and controls the press 2 Wiring Arm 1771 WB Connections to 1771 PM 2 Chassis 1771 A2B Contains the modules 10 120V AC Input Modules 1771 IA Monitors press inputs 2 120V AC Isolated Output Modules Series C 1771 OD Controls press outputs Optional Hardware 2 120V AC Output Modules 1771 OA Display of diagnostic messages 1 120AC Output Module 1771 OA Controls optional indicators 2 120V AC Input Modules 1771 IA Dump valve circuit 2 120V AC Isolated Output Modules Series C 1771 OD Dump valve and or micro inch circuit 2 I O chassis 1771 A4B Substitute chassis when using the optional dump valve circuit 1 120V AC Output Module 1771 OA Micro inch indicator 2 120V AC Input Modules 1771 IA Micro inch circuit 2 120V AC Input Modules 1771 IA Additional operator stations Clutch brake modules operate in parallel to monitor and control your press Clutch brake modules are also called voting processors because they must always have a consensus Unless both voting processors constantly agree that they sense identical conditions in your
34. outputs after motion has started Barrier Guard terminal 5 prevents press from starting or stops it immediately Arm Continuous terminal 7 Continuous momentary Each ON OFF transition starts a 5 sec period in which you must only less than 3 sec press all active RUN buttons to start continuous stroking Pressing Arm Continuous again within 5 seconds starts another 5 sec period Press Interlock terminal 6 ON detects one of the permissives to start or maintain a stroke after chassis A amp B MG 2 Slot 0 transition if turned OFF immediately stops the press or prevents it from starting WARNING To guard against injury to personnel wire you barrier guard switch exactly as shown in Figurd 6 10 Conform to all requirements for safeguarding the point of operation of your press as detailed in OSHA Regulations Title 29 Labor Chapter XVII Section 1910 217 6 22 Chapter 6 Field Wiring Arm Connections If you have more than one operator station connect the STOP ON TOP buttons in series Figure 6 10 Connections for Main Motor Forward Barrier Guard Stop on Top Arm Continuous and Mode Select Switches 1771 1 Module Group 0 Slot 0 ChassisA A Main Motor Forward 5 1 Barrier Guard l E e 4 5 Station 1 Station 2
35. test 13 These commands can be issued manually by an operator pushing a switch or automatically by a switch closure in your machinery They function as follows Output Status Condition Controlled by PM Module Press Enable mustbe ON enable motion in any mode Bit 10 OFF Immediately turns OFF triac outputs Stop on top off to on Turns OFF solenoid outputs the next time the Continuous mode only transition run on cam switches open Bit 11 mustbe OFF To start or maintain continuous stroking Reset Latched Message off to on Clears any latched or tripped message code Bit 12 transition shown in MG 5 Slot 1 as long as the condition that caused the message no longer exists Lamp Test ON Turns ON all these outputs Bit 13 Brake Fault Run Window Micro inch Message and other diagnostic message lamps OFF Turns OFF these outputs El Holding this bit ON may inhibit the capture of subsequent Lor t messages Bit addresses for these command bits are shown in Figurq 4 2 Example PLC command rungs are shown in Figurd 4 6 hrough Figure To enable these commands write ladder program rungs that are conditioned with examine on examine off instructions to monitor corresponding switch inputs wired to I O chassis C You can use any available discrete module terminals excluding those in chassis A or B for these inputs Figure 6 15 For additional information refer to chapter 6 Inputs to Chassis Chapter 4 PC Ladder Programming Figure 4
36. 00 Brake monitor and run on cam switches both open E ereas annona o e eos m ereas oan e 1001 1000 t Run on cam switch open showing reverse motion 1001 1001 Run on cam switch open showing reverse motion 7 31 ET Clad Troubleshooting diagnostic message codes are displayed by indicators connected to module group 5 slot 1 figure 6 18 or by displaying the corresponding data table word using the industrial terminal Use this table in conjunction with figurd 7 1 figure references shown in parentheses ne of Message Code Non latched P at Power up Latched Alt Alternate chassis T Trip Condition Ethr Either chassis Top Top chassis Bot Bottom chassis Diagnostic Message figure References Transition to Upstroke Figureg 5 1 6 11 1001 1010 t Run on cam switch open 1001 1011 Run on cam switch open 1001 1100 MEE Brake monitor cam switch bounced or motion reversed 1001 1101 EMEN Brake monitor cam switch bounced or motion reversed Upstroke Figures 5 1 6 11 1001 1110 EMEN Brake monitor closed when run on cam switch opened 1001 1111 Brake monitor for this chassis closed when run on cam switch for the other chassis is open ee ILI DE pero E frereana Transition 0 Near Top Zone Figured 5 1 6 11 1010 0100 t Brake monitor cam switch closed 1010 0101 Brake monitor cam switch closed 1010 0110 A6 L Run on cam switch bounced or mot
37. 1011 0100 Valve stem switch configuration bit and backplance switch mismatched 1011 0101 1011 0110 Ungrounded grounded AC power configuration bit and backplane switch mismatched 1011 0111 On the hop configuration bit and backplane switch mismatched 1011 1000 PN Stroke and a half configuration bit and backplane switch mismatched N 1011 1001 B9 Dump valve configuration bit disagrees with corresponding I O modules in chassis 1011 1010 BA ND I O input module is missing 7 38 Chapter 7 Troubleshooting Diagnostic message codes are displayed by indicators connected to module group 5 slot 1 figure 6 18 or by displaying the corresponding data table word using the industrial terminal Use this table in conjunction with figurd 7 1 figure references shown in parentheses Type of Message Code N Non latched P at Power up L Latched Alt Alternate chassis T Trip Condition Ethr Either chassis Top Top chassis Bot Bottom chassis Diagnostic Message figure References Motion Detector and Pressure Switch Faults 3 1011 1100 Air pressure signal present though air pressure feedback is not configured 7 39 Appendix Bit Monitoring Addresses Use the addresses in the following tables to monitor press operation Address digits a b and c are rack address digits Assign them as required by your application For PLC 2 20 2 30 processors rack addresses are 1 thru 7 For P
38. 2 or 6 6 For this wiring And this feature Follow these instructions Single switch Motion detector Connect the jumper between terminal 1 chassis A and terminal 1 chassis B Air pressure Connect the jumper between terminal 2 chassis A and terminal 2 chassis B either of above Omit dotted line wiring for redundant switch circuits Redundant switch Motion detector Remove the jumper between terminal 1 chassis A and terminal 1 chassis B Air pressure Remove the jumper between terminal 1 chassis A and terminal 1 chassis B either of above Add dotted line wiring for redundant switch circuits for motion detector and or air pressure Main Valve Solenoids A and B Connect main valve solenoids A and B as shown in Figure 6 3 Or Figurd 6 7 with these connections feedback from main valve solenoid triacs that allows both voting processors to monitor the on or off state of each triac and check for shorted or open triacs and open or shorted main valve solenoids load resistors LRA and LRB for triac feedback from main valve solenoids A and B crowbar relay coils and seal relay coils If your main valves use valve stem switches for external fault detection you must configure for valve stem fault detection by setting backplane switches chapter 3 and programming configuration bits chapte Then your optional auxiliary and or dump valves must also use valve stem switches If not you must simulate their inputs by jumpering th
39. 2284 6 17 Chapter 6 Field Wiring Arm Connections Figure 6 7 Connections for Main and Auxiliary Valve Solenoids Crowbar and Seal Relays and MOV Surge Suppression Grounded AC Power 1771 1771 0D Module Group 2 Module Group 3 Slot 1 Slot 0 Chassis A Chassis A AlN 1 5 e 3L1 o I t S US IOJ mS 15 T 3 5 e JO E CIR I I 3 c 6 E Crowbar Rela IS LRA LRB LRA 18 PO e AN y B 1 212 11 S 3 L r Seal Relay 3L2 e e e 3L2 B Chassis B Chassis B 3 a Main e 5 Valve AC WS Solenoids 1 3 S a x E D I I E ey SI Crowbar Rel T 7 JS owbar Relay A A As gt n s e 2 f 25 Z 3 5 BE NOTES Use this wiring with 6 5 for grounded AC power 1 LRA and LRB load resistors for triac feedback are 2K ohm 15 watt resistors e e e q auxiliary solenoids are not used replace with 2K ohm 15 watt resistors 312 Auxiliary Valve Soleno
40. 6 GJ O 7 Stop on top B Station 3 Station 4 dj 22 OLO OLO Arm Continuous Station PE 2L1 MICRO4NCH figures 6 4 6 8 Ott Chassis B 3 A Mode 0 Select Inch 1 2 Single Stroke 3 4 211 Continuous 5 6 7 mei 212 lI This normally open limit switch must be closed for continous operation 12279 6 23 Chapter 6 Field Wiring Arm Connections Inch Buttons and Plug In Operator Stations Connect the NC and NO contacts of each INCH button to opposite chassis exactly as shown in Figure 6 11 This allows both voting processors to monitor and cross check both INCH buttons for correct operation You may locate the INCH buttons at an operator control panel However they are not part of any plug in operator station Wire them directly as shown in Figure 6 11 Plug in operator stations 1 thru 4 and dummy plugs that you may use to bypass these stations are shown in Figure 6 11 hind Figurel 6 12 You may alter this configuration according to the number of bypassable stations that you need for your press system If all run stations are bypassed you may still operate in inch or micro inch mode using INCH buttons For example if you have only one operator station you may wire station 1 as shown in Figure 6 11 using direct wiring instead of operator station plug connections However you must also bypass station 2 using direct wiring instead of dummy plug connections In other wor
41. 6 12 This chassis is optional because you can omit redundant functions use alternatives for the non redundant functions As alternatives you can program the PLC to transfer the message reset bit bit 14 and or the lamp test bit bit 16 to the clutch brake modules to provide those functions If already using A B s PanelView 9 use that operator interface to implement these functions If you use chassis C follow these steps 1 Wire PLC command switches as shown in Figure 2 Include command rungs Figure 4 6 4 7 or4 8 3 Set the backplane switches of chassis C to a valid rack address for your PLC and clutch brake system 6 31 Chapter 6 Field Wiring Arm Connections Chassis C can be any remote or local I O chassis connected to your PC Refer to sections titled Panel Switches and Operator Stations in chapter 3 ind Configuration Rungs in chapter 4 for additional information Figure 6 15 Connections for Optional PLC Command Switches 2L1 Chassis C Remote I O Chassis Customer Interlock 1771 A AC Input Module e Rack 3 Module Group 2 Bits 10 thru 17 Barrier Guard Bit 13 Bi 3 Q it 14 S Reset Latched Messages Bit 15 SI ao Bit 16 S 9 Stop On Top LL IS IS H Lamp Test EM 212 To write the ladder p agram to imple
42. Address Switch Setting on 1771 PM Module SW 1 2 Always ON starting Module Group 0 Always OFF Always ON 57 6K baud Rack Addresses Switch Assembly SW 1 Position E PLC 2 30 PLC 3 PLC 5 25 PLC 5 250 2 3 4 5 Chassis 00 on on on on on on B 01 22072200122 00122 22 0022 22 U0 22 22 U0 22 U0 22 00 22 00 77 NOTE Chassis A and B must have consecutive rack addresses 12250 3 10 Setting the Communication Rate Response Time Chapter 3 Clutch Brake Controller Hardware For example if you choose rack address 2 for chassis A you must choose rack address 1 or 3 for chassis B Set the rack address in each clutch brake module Place a label on each clutch brake module to identify in which chassis A or B it belongs Important Chassis A and B rack addresses must be unique No I O chassis can have the same rack address as either chassis A or B This restriction prohibits using the rack address of either chassis A or B for any complementary I O chassis a chassis with the same module addresses but having input modules where chassis A and B have output modules and output modules where chassis A and B have input modules This restriction also prohibits using the rack address of either chassis A or B for any partial remote I O chassis a chassis that starts with module group 2 4 or 6 Refer to chapter 4 Module Group 7 PLC Command Rungs
43. C Command Rungs for Bits 10 thru 13 PLC 5 PRESS ENABLE Switch VA Optional conditions 1032 X 0 57 E lt 13 Enable Press Operation m Ld 032 STOP ON TOP Switch a 11 0 67 tli mm 15 Command Stop on top 11 0 57 1032 RESET Switch 1 JE 14 Reset latched messages 0 67 12 57 1032 LAMP TEST Switch t Test optional indicators 0 67 13 NOTE PLC command bits 10 through 13 use conditioned logic Do not latch or unlatch instructions Corresponding switch input wiring is shown in Figure 6 15 4 11 Chapter 4 PC Ladder Programming Summary of PLC Configuration We summarize the bits in module group 7 used for determining and Command Rungs configuration requirements and enabling operator commands Figure 4 9 Figure 4 9 Functions of PLC Configuration and Command Bits PLC Configuration Bits f 17 16 15 14 13 12 11 10 07 06 05 04 03 02 01 00 Output image table word Module Group 7 Chassis _ amp PLC Command Bits Bit Bit Status Type of No Function Set Reset Rung 01 Stations 3 and 4 Used Not Used Unconditioned 02 Motion Detector Feedback Used Not Used Unconditioned 03 Valve Stem Feedback Used Not Used Unconditioned 04 Air Pressure Feedback Used Not Used Unconditioned 05 AC Power Configuration Ungrounded Grounded Unconditioned 06 On The H
44. Codes Types of Diagnostic Message Codes Message code Priority Processing Diagnostic Message Codes eret e E 8 DARE I J 1 Is es s f Diagnostic Message Codes Table 7 C Complete Listing of diagnostic message codes Summary Diagnostic diagnostic message codes in Table 7 C Bit Monitoring Addresses I O FROM TO LISTS Table of Contents Chapter Objectives Objectives Of This Manual How To Use This Manual Introduction This chapter will help you become familiar with the Objectives of this manual procedure for using this manual We have written this manual to help an electrical engineering technician or any person with a similar background design a clutch brake controller for a mechanical power press using the 1771 PM clutch brake module install the clutch brake controller troubleshoot the clutch brake controller The overall safety of your mechanical power press rests upon your knowledge of this manual and other referenced documents Moreover the ease with which you can understand each chapter rests upon your knowledge of previous chapters To simplify your installation and maintenance tasks we recommend that you become familiar with this entire manual before installing your clutch brake controller The following suggestions should help you use this manual
45. IDII og vooo Micro Inch I PA I i fr 22 Chassis B 211 IQ I Micro nch 21 S A x 3I 19 SIS S s JS 212 12286 6 30 Lamp Test Inputs to Chassis C Chapter 6 Field Wiring Arm Connections When you configure the lamp test feature you can check that all indicators are working by pressing the LAMP TEST switch connected to chassis C The clutch brake controller energizes the outputs to the following indicators while the lamp test input is on Module Group 5 Slot 1 Chassis A and B for the diagnostic display Module Group 3 Slot 1 Chassis A and B for BRAKE FAULT RUN WINDOW and MICRO INCH indicators Since hex hexadecimal numbers are easier than binary for people to read you may want to display hex message codes You may provide a device to convert the eight digit binary outputs of chassis A and B module group 2 slot 1 to two digit hex displays Select output modules that provide proper voltage to the device For assistance contact your local Allen Bradley sales engineer or distributor In chapter 7 we describe other methods of displaying hex message codes Chassis C provides for these functions reset latched messages lamp test customer interlock redundant to Figure 6 1 or 6 5 barrier guard redundant to Figure 6 10 Stop on top redundant to Figures 6 11
46. LC 3 processors rack addresses 00 thru 77 Refer to Rack Addresses of Chassis A and B 3 10 further information A 1 Appendix A Bit Monitoring Address Module Group 0 Function PLC 2 30 PLC 3 Chassis Chassis A B B 0 Selector switch OFF position 1a0 00 1b0 00 10ab0 00 10ac0 00 EN Selector switch INCH position 1 0 01 160 01 10ab0 01 10ac0 01 Selector switch SINGLE position 1a0 02 1b0 02 10ab0 02 10ac0 02 4 Main motor forward NO contactor 1a0 04 1b0 04 10ab0 04 10ac0 04 Slot 1 1771 1 Figurd 6 11 Term PLC 2 30 PLC 3 Chassis Chassis B A gt Slot 0 1771 1A Figurd 6 10 Station 1 left RUN NC contacts 1a0 10 10ab0 10 right RUN NC contacts 1b0 10 10ac0 10 Station 1 right RUN NO contacts 1 0 11 10ab0 11 left RUN NO contacts 1b0 11 10ac0 11 2 Station 1 left Active 1a0 12 10ab0 12 right Active 1b0 12 10ac0 12 Station 2 left RUN NC contacts 1 0 13 10ab0 13 right RUN NC contacts 1b0 13 10ac0 13 Station 2 right RUN NO contacts 1a0 14 10ab0 14 left RUN NO contacts 1b0 14 10ac0 14 5 Station 2 left Active 1a0 15 10ab0 15 right Active 1b0 15 10ac0 15 Left INCH NC contacts 1a0 16 10ab0 16 Right INCH NC contacts 1b0 16 10ac0 16 7 Right INCH NO contacts 1a0 17 10ab0 17 Left INCH NO contacts 1b0 17 10ac0 17 A 2 Appendix A Bit Monitoring Address Module Group 1 Slot 0 1771 14 6 12 Addresses Term PLC 2 30 PLC 3 Cha
47. Module Group 5 Slot 0 Reserved for Micro inch Important Your PLC ladder program must include unconditioned configuration rungs that set or reset configuration bits to match the settings of backplane switches Refer to chapter 4 Establish the address of chassis A and B in each clutch brake module so the PLC can communicate with it Use valid rack addresses as determined by your PLC Switch assembly SW 1 determines the rack address It is located under a sliding cover plate on the left side of the clutch brake module near the top Loosen the two screws holding the cover plate and slide it open Locate switch assembly SW 1 at the top of the printed circuit board as shown in Figurd 3 4 Using switch assembly SW 1 designate chassis A and B as follows Chassis A any rack address having position 6 OFF Chassis B next consecutive upper or lower rack address Important If your ladder program monitors rack adapter fault bits for each chassis containing a clutch brake module the fault bits will indicate a faulted rack whenever the module trips power to I O swingarms This is because clutch brake modules stop all communciation with the PLC until they verify that swingarm power has been disconnected Important Always configure I O racks assigned to clutch brake controllers as full racks so the PLC can write configuration bits to each PM chassis in Module Group 7 3 9 Chapter 3 Clutch Brake Controller Hardware Figure 3 4 Rack
48. Module group Slot Rare 22 Module group Slot Figure 0 0 3 0 e o ea O 12273 6 16 Chapter 6 Field Wiring Arm Connections Figure 6 6 Connections for Optional Switches on Main Valve Stems Air Pressure Sensors and Motion Detectors Grounded AC Power 1771 1 Module Group 2 Slot 0 Chassis A Remove this jumper when using Motion AG Detector Switch B E 5 1S JS JS A HO I is 6 Motion Detector s 19 Switches on 6 zi S Auxiliary Valve Stems 1 21 DN Dh Op pe rea EE OO Make this connection when using Motion Detector Switch B A A O Nu M AT Chassis B Switches on Air Pressure Switch es 21 I Main Valve 211 Stems 1 B 4 S B US i eee 4 ME eee ee eee Steere aE LET EE I 3 Remove this jumper PA Make this connection when using when using Air Pressure gt Air Pressure Switch B Switch B 516 610 7I SN 1 one or both valves have internal fault detection no valve stem switches but you B configured for valve stem feedback then jumper terminals 0 and 7 in chassis A and do H the same in chassis B 1
49. T The main motor forward input needs to be on in order to enter single or continuous modes Once in single or continuous mode the press will stop if that input goes off ACAM OPEN PREVENTING ENTRY INTO SINGLE OR CONTINUOUS MODE AWAITING RELEASE OF ALL STOP ON TOP BUTTONS FOR ENTERING CONTINUOUS MODE You must release STOP ON TOP buttons of all active stations before the PM can switch to another mode of press operation AWAITING RELEASE OF ARM CONTINUOUS BUTTON FOR ENTERING CONTINUOUS MODE You must release the ARM CONTINUOUS button and press the RUN buttons of all active stations before the PM can switch to continuous mode BARRIER GUARD DROPOUT OR ABSENT Press stops operation CORRECTIVE ACTION Check selector switch wiring in figure Ohne operation JO Check wiring to swing arm Check I O module for correct operation Check station wiring in ice EE a E Check swing arm wiring and I O module for proper operation Check for proper cam settings in figurd 5 1 Check for proper cam wiring in figure 6 9 Inch press to the top position Release all run buttons Check for proper operation of all buttons Check button wiring in figured 6 1 and 6 12 Check feedback contact and wiring in figure 6 10 Check swing arm wiring and I O module for proper operation Check wiring of in figure 6 9 and check position in figurd 5 1 Check RUN button wiring figures and 6 12 Check ARM CONTINUOUS butto
50. T FAULT Problem Correction Intermittent electrical noise faulty 1771 PM Cycle power module or shorted I O chassis backplane Replace 1771 PM module Replace each I O module one at a time Replace I O chassis Intermittent electrical noise or faulty 1771 PM Cycle power module Replace 1771 PM module Figure 7 2 Troubleshooting Flowchart for Module Indicators Press will not run Is a diagnostic Yes message displayed Goto table 7 C Y Is the mode select switch off Yes Select proper Does the Yes Resume mode press run normal No Are all status indicators for Yes All bower is ofi inputs to the 1771 IA module a urd off See Figurd 7 1 See figurd 6 1 pr 6 5 No No operation Y Check the 1771 PM module indicators See figur 7 1 Press should run Refer to press Y Yes Are rack addresses rack Yes Are both ACTIVE indicators on gt size 1 and or baud rate builder s documentation set correctly No m Yes Is either ACTIVE indicator blinking 7a Go to tabl 7 A No Y Is either I O RACK FAULT indicator E No o Go to tabld7 B Y Is either CBM FAULT indicator on Yes No Y Replace the 1771 PM module whose ACTIVE indicator is off or check the chassis power supply 1 Th
51. These messages are typically related to a wiring error or equipment malfunction Example A broken or loose wire on the active line of Run Station 1 Figure 6 13 could cause the PM module to generate the following message code Error 10 Hex Check RUN button signals Activate or bypass the station 7 9 ET Clad Troubleshooting Latched Messages medium priority Latched messages occur when the PM module detects error conditions while the press is running clutch brake solenoids are ON The module Stops press motion immediately latches ON a diagnostic message turns OFF solenoid valve triacs seal relays remain closed The latched message condition remains until you correct the problem and press the RESET LATCHED MSG pushbutton wired to chassis C Typical error conditions are equipment failures or improper mechanical adjustments Example If the barrier guard switch should open while the press is running in continuous mode the PM module would immediately turn OFF the solenoid valve triacs and generate the following message code Error 09 Hex Barrier guard dropout or absent Latched Messages Followed by OD corrective intervention Whenever a diagnostic message code is followed by the 0D message code the maintenance technician must reset the PM system by removing control power and then re applying power This forces the technician to correct the problem before press operation can continue Stand
52. You must interpret from there Assume that your press is running normally then stops suddenly For this example we will follow the general troubleshooting procedure 1 2 Examine Figure 7 2 and Figurel7 3 The first question asked in both figures is whether a diagnostic message is displayed For this example we assume that chassis A and B are displaying these diagnostic messages chassis A 0010 1001 hex 29 chassis B is displaying 0010 1000 hex 28 Because your answer is yes see Table 7 D fo define the problem In Tabld 7 D you find that Binary 0010 1001 hex 29 is a T type trip condition message that tells us Station 1 active connection is open for alternate chassis Check wiring figure 6 11 Since chassis is displaying this message the alternate chassis is chassis B Binary 0010 1000 hex 28 is the same message It is for the chassis displaying the message chassis B in this case Chapter 7 Troubleshooting In Table 7 C the numbers in parentheses are figure references In this example both messages refer to Figura 6 11 Therefore place a bookmark at Table 7 D hind go to that figure Figure 6 11 shows station 2 active connections for both chassis Left Active connects to terminal 5 of field wiring arm for module group 0 slot 1 in chassis A Right Active connects to terminal 5 of field wiring arm for module group 0 slot 1 in chassis B Since you learned in step 3 that
53. ack the status of valve stems to your clutch brake controller The firmware in your clutch brake module performs the fault detection A valve with external fault detection Figures 6 2 orle 6 provides an external signal of its valve position When the valve is energized the external signal is Interfacing this type of valve to the clutch brake system requires enabling valve stem feedback with backplane switches Figure 3 3 enabling valve stem feedback in PC configuration rungs Figure If you configure for valve stem feedback all valves must have valve stem feedback or simulate it have their respective terminals jumpered to the input terminals of the main valve stem switches for simulated inputs Chapter 6 Field Wiring Arm Connections Solenoid valves with internal fault detection close automatically when the valves detect a mechanical fault They have no valve stem switches When using this type of solenoid valve do not configure your clutch brake controller for valve stem fault detection A valve with internal fault detection mechanically assures that both solenoids energize in unison before the valve passes air Should a fault occur and only one side energizes the valve will not pass air Some valves of this type have a poppet valve which blows and vents to the atmosphere The poppet valve must be manually reset Optional All switches shown in Figure 6 2 pr Figurd 6 6 hre optional Decide Valve Stem Switch
54. and press the ARM CONTINUOUS button in order to restart press operation During the first upstroke without stroke and a half Figure 5 7 releasing a RUN button does not stop the press opening a barrier guard stops the press if the shaft did not stop in the near top position inch it there and repeat the procedure from the beginning If you configured for half stroke or stroke and a half requirement continue holding the RUN buttons until the shaft runs through the first or second downstroke and first or second near bottom position releasing a RUN button stops the press and first downstroke conditions apply Once in continuous operation NO TAG the press stops whenever you press stop on top the PLC transfers a stop on top command a barrier guard opens either voting processor detects a trip or stop condition 5 9 Chapter 5 Voting Processor Firmware Figure 5 5 Operational Sequence for Starting Continuous Mode Select continuous mode PER No Is the barrier guard closed Yes y Is the shaft in the near top No Select inch mode and position the position shaft to the near top position Yes y Y Main Motor Forward Yes Have all operators released all STOP ON TOP buttons Yes Y No Have all operators released all RUN buttons Yes Has an o
55. anti repeat cam is on the brake monitor cam is on and the run on cam is off This message will occur if the PM sees the anti repeat cam signal go off during downstroke UPSTROKE MESSAGES 6 RUN ON CAM OPENED BEFORE SEEING THE See Standard Corrective Action 069 ALT ANTI REPEAT CAM TRANSITION OT OFF Once the press is in the near bottom zone the PM needs to see a off on transition of the anti repeat cam signal during the up stroke If the run on cam opens before this transition this message will occur 0 RUN BUTTON RELEASED DURING FIRST UPSTROKE IN This message appears when you select stroke and a half CONTINUOUS MODE INCH TO TOP for entering continuous mode you release one or both RUN buttons during the first upstroke i 7 You must enter INCH mode and inch the press to the top to continue normal press operation 7 SHAFT NEAR TOP INCH TO TOP You cannot enter single or continuous mode unless the press is at proper near top starting position figurd 5 1 Check CAM switch wiring figure 6 9 BRAKE OR MOTION DETECTOR MESSAGES 72 BRAKE OVERRUN Check alignment of the run on and brake monitor cams to 73 BRAKE OVERRUN INCH BACK TO TOP conform to fig 5 1 in the PM manual and to assure adequate and safe stopping distance before reaching the If the press has not stopped within the open window of the near brake monitor cam Check the condition of the brake top position this indicates that the pre
56. ard Corrective Action Because the 0D message code accompanies a variety of other diagnostic message codes we recommend a standard corrective action Use it when correcting faults for OD diagnostic message codes presented in Table Check for proper cam setting and operation Refer to Figure n this manual Check for bad or frozen cam contacts f more than one cam assembly is used for multi speed press operation check switching of these cams Check for proper wiring of cam switches Check for proper wiring of I O module swing arms 7 10 Re starting the Press Chapter 7 Troubleshooting You re start the press with this procedure E relays When the OD message is displayed press ESTOP to drop the seal Message code 50 is displayed swingarm power dropout 2 Press the START button 3 Press the RESET LATCHED MSG button 4 Select INCH mode if not already selected 5 Inch the press to the near top position Types of OD Diagnostic Message Codes The OD diagnostic message code accompanies the following type of Hex Code 066 067 diagnostic messages Type of Message Downstroke Upstroke Brake or Motion Detector Cam Limit Switch Near Top Position Transition to Downstroke Downstroke Transition to Near Bottom Zone Near Bottom Zone Transition to Upstroke Upstroke Transition to Near Top Position Hardware or Cable 068 069 072 079 07A OF1
57. at cam switch closed continuously 6 11 Run on cam switch opened too soon or anti repeat cam switch closed continuously 6 11 PN Awaiting release of all RUN button 6 13 thru 6 16 PN y Awaiting release of all RUN button 6 13lthru 6 16 Fault in Set up for Continuous Mode O remesan o o Continuous cycle not armed Awaiting PC to inhibit stop on top signal 4 5 4 7 DW pna Ps NOLO MN Sd L Motion detector signal missing at start of downstroke 6 17 Motion detector signal missing during upstroke 5 1 6 17 7 29 ET Clad Troubleshooting diagnostic message codes are displayed by indicators connected to module group 5 slot 1 figure 6 18 or by displaying the corresponding data table word using the industrial terminal Use this table in conjunction with figura 7 1 and figure references shown in parentheses Type of Message Code N Non latched P at Power up L Latched Alt Alternate chassis T Trip Condition Ethr Either chassis Top Top chassis Bot Bottom chassis Binary Hex Type Code Diagnostic Message figure References pe Motion detector signal missing during on the hop downstroke 5 1 6 17 LC emissis 0111 1000 Motion detector signal missing during continuous cycle 5 16 17 LC p tors T D uemeesswiemesWismerse m LT jmemwiiwwsmsewsm B 0111 1101 Faulty Cam Limit Switch Near To
58. ately commands its seal relay to remain de energized If either voting processor detects that 3L1 is still on after commanding its seal relay to de energize it energizes its crowbar relay This shorts 3L1 to 3L2 which blows the 3L1 and 3L2 line fuse or fuses Crowbar tests inputs shown in Figure 6 1 Jor Figure 6 5 allow the voting processors to test their crowbar relays without blowing the 3L1 and 3L2 line fuse or fuses This test occurs while you push the START button shown in Figurd 6 1 or Figure 6 5 To allow for the crowbar test you should press the START button break before make pushbutton switch for more than one half second As you begin pressing the START button its two sets of N C normally closed contacts open first isolating crowbar A and B relay contacts from 3L2 As you press the START button all the way in its N O normally open contacts close applying 3L1 power to module group 3 slot 0 Before you release the START button each voting processor briefly energizes its crowbar relay and checks through its crowbar test input that the relay turns on then off Each voting processor energizes its seal relay only after its crowbar relay is tested as working correctly At any time after you release the START button either crowbar relay can blow the 3L1 and 312 line fuse or fuses shown in Figure 6 5 Chapter 6 Field Wiring Arm Connections Optional Hardwire Inputs Connect optional hardwire inputs a
59. ation rungs and backplane switch settings relationships between configuration rungs and voting processor firmware the option of monitoring the press through your PLC ladder program the option of using PLC report generation to display messages that you have stored Your PLC ladder program is composed of instructions that you enter into PLC memory These instructions are organized into rungs They typically monitor inputs and control outputs Your PLC ladder program does not control your clutch brake controller but it does configure and enable it Although your ladder program cannot control any clutch brake controller outputs it controls output image table bits to configure and enable the voting processors Your ladder program may examine input image table bits to monitor clutch brake controller functions as we will explain later This chapter concentrates on PLC ladder programming that relates to your clutch brake controller For more details on ladder programming refer to the programming manual that applies to your PLC processor These publications are listed in our Systems Division Publication Index publication SD499 PLC ladder programming is described in this chapter as it relates to clutch brake controller hardware and voting processor firmware Figurd 4 1 4 1 Chapter 4 PC Ladder Programming Figure 4 1 Overview of Clutch Brake Controller m PM Chassis oting A A B Programmabl
60. ator Figurd7 B How to read the PM Module s I O RACK FAULT and CBM FAULT indiators Figure 7 2 How to troubleshoot with LED indicators 7 1 ET Clad Troubleshooting Figure 7 1 Module Indicators for Chassis A or B Input Module Indicators Input status indicators are clear On input One indicator per terminal PM Module Indicators ACTIVE green Output Module Indicators Output status CBM m indicators are red FAULT On output red E RACK j Blown fuse FAULT indicators are clear red On blown fuse Refer to tables E 4 1 1771 Module 17714A Modules 1771 OD Module 12292 Table 7 A ACTIVE Indicator If the ACTIVE indicator is blinking identify the problem by the number of blinks There are 2 sets of blinks first set of blinks short pause gt second set of blinks long pause E 4 repeat continuously lt Number of Blinks of Blinks Problem Faulty RAM Replace 1771 PM module rr 5 ea e ee Illegal interrupt Cycle power Replace 1771 PM module Firmware faut fault Replace 1771 PM module 1771 PM module Lol E communications between 1771 PM modules Lol o MEN connections between 1771 PM modules or or watchdog timed out Replace 1771 PM module 7 2 Chapter 7 Troubleshooting Table 7 B 1 0 RACK FAULT CBM FAULT Indicators 1 0 RACK CBM FAUL
61. b2 01 1b2 02 1b2 03 1b2 04 PLC 3 Chassis A 10ab2 00 10ac2 00 10ab2 01 10ac2 01 10ab2 02 10ac2 02 10ab2 03 10ac1 03 10ab2 04 10ac2 04 Feedback from Press Interlock Switch 1a2 06 1b2 06 10ab2 06 10ac 06 7 Input from Aux Valve Stem NO Switch A 1a2 07 1b2 07 10ab2 07 10ac 07 Switch B Optional Slot 1 1771 1A Figur 6 3 of 6 7 Addresses PLC 2 30 Chassis 0 Feedback input from Triac 0 Chassis A 1a2 10 Feedback input from Triac 0 Chassis 1a2 11 Feedback input from Triac 1 Chassis A 1a2 12 A4 B 1b2 10 1b1 11 1b2 12 1b2 13 1b2 14 1b2 15 1b2 16 1b2 17 PLC 3 Chassis A 10ab2 12 10ac2 12 Appendix A Bit Monitoring Address Module Group 3 Slot 0 1771 00 Figurd 6 3 of 6 7 Addresses PLC 2 30 PLC 3 Chassis Chassis A B A B Triac 1 for Main Solenoid B 183 01 1b3 01 10ab3 01 10ac3 01 9 amp 10 Triac 4 for Crowbar Relay A 183 04 1b3 04 10ab3 04 10ac3 04 Relay B Term Function 11 amp 12 Triac 5 for Seal Relay A 1a3 05 1b3 05 1023 05 10 3 05 Relay Slot 1 1771 OA Figurd 6 14 Addresses PLC 2 30 PLC 3 Chassis Chassis B A B 8 7 BRAKE FAULT Indicator 1a3 10 10ab3 10 EBEN RUN WINDOW Indicator 1 3 11 10ab3 11 2 MICRO INCH Indicator 13 12 1b3 12 10ab3 12 10ac3 1 5 Appendix A Bit Monitoring Address Module Group 4 S
62. button bypass is open Check wiring pronao NO RUN button bypass is open Check wiring Not Used Station 3 mh 0 ria O ER pne e e pane a O Rains Cesk AN NN E NC RUN button is open Check button or wiring e T eron aoon m T rerio 3B Alt T NC RUN button bypass is open Check wiring T NO RUN button bypass is open Check wiring 7 26 Chapter 7 Troubleshooting Diagnostic message codes are displayed by indicators connected to module group 5 slot 1 figure 6 18 or by displaying the corresponding data table word using the industrial terminal Use this table in conjunction with figure 7 1 figure references shown in parentheses Type of Message Code N Non latched at Power up L Latched Alt Alternate chassis T Trip Ethr Either chassis Condition Top Top chassis Bot Bottom chassis Diagnostic Message figure References Code NO RUN button bypass is open Check wiring Station signals present though not configured Station signals present though not configured Figure 6 16 oT eros Wiese me ___ roa Roos RUN button not released Check NC contacts CC JOELLE e ona e M NN P orsa a e T pen a ar T eeno T
63. caps against accidental breakage STOP ON TOP FAULT tells an operator that the brake is faulty If the shaft overshoots the near top position in inch single or continuous mode both voting processors prohibit clutch actuation and turn on this indicator See TablelS a pnd Figure 6 14 RUN WINDOW turns on when starting the press in these modes single stroke When both RUN buttons have been pressed at one station other active stations have 5 seconds to press their RUN buttons as shown by this indicator 6 27 Chapter 6 Field Wiring Arm Connections 6 28 continuous Each ON OFF transition of the ARM CONTINUOUS button starts a 5 second period in which you must press all active RUN buttons to start continuous stroking as shown by this indicator Pressing the ARM CONTINUOUS button again within 5 seconds after the transition starts another Important Press the momentary ARM CONTINUOUS button less than 3 seconds Pressing it for a longer time may inhibit its function and require you to release and press it again MICRO INCH turns on when voting processors detect an error in micro inch mode and display a diagnostic message code which is displayed by means of the diagnostic message display Use look up table 7 C fo determine the fault or error You can use the micro inch output in two ways to turn on the MICRO INCH indicator tosetthe most significant bit in 9 bit binary output Diagnostic codes for micro i
64. ch as you select for main and auxiliary solenoid valves internal or external fault detection Use series C or later 1771 OD output modules because they have improved electrical noise immunity To provide additional immunity against surge transient noise we recommend that you connect metal oxide varistors MOVs to the triac outputs of your 1771 OD modules for main and auxiliary valve solenoids and dump valve solenoids if used Typical connections are shown for auxiliary valve solenoids for ungrounded AC power Figure 6 4 and grounded AC power Figurel6 8 Connect the MOVs as close to the field wiring arm terminals as possible In the grounded AC power configuration make connections to 3L2 not located on the field wiring arm as short as possible 6 11 Chapter 6 Field Wiring Arm Connections Figure 6 1 Ungrounded AC Power Connections Crowbar Test Inputs and Press Interlock Switch H H4 uf Isolation Step Down Transformer Incoming L 4 Lo ibs AC Disconnect E E Ococm e Ground Fault Lamps and Text Switches 17 217 A D 2 e
65. clutch brake press system either or both voting processors stop press motion or prevent it from starting Your clutch brake controller monitors and controls your press Although your PLC does not control your press it does configure and enable the clutch brake controller Your PLC ladder program can monitor inputs to and the status of your clutch brake controller This allows your PLC to control other indicators machines or processes related to your press system 3 3 Chapter 3 Clutch Brake Controller Hardware Twinaxial Cable Connections 3 4 In addition to chassis A and B you must connect your PLC to at least one local or remote I O chassis chassis C You need two three or four inputs at a local or remote I O chassis Important You must use 2 slot addressing and 8 point single density I O modules Typical twinaxial cable connections of your clutch brake controller are shown in Figure 3 2 Connect your clutch brake controller to your PLC as part of its remote I O distribution network Use Twinaxial Cable cat no 1770 CD and Terminators cat no 1770 XT Connect chassis A next to chassis B in the serial chain as shown in Figure 3 2 You may connect one or more remote I O chassis in the same serial chain Also you may connect remote I O chassis to other distribution channels at the I O scanner module of your PLC Connect four Terminator Resistors cat No 1770 XT as shown in Figure 3 2 Connect one at
66. cs were es A de energized No No Have all operators released all lt RUN buttons A Yes Has each operator pressed his No RUN buttons simultaneously and within 5 seconds for all stations Yes NOTE Releasing a RUN button during the first downstroke stops the press If the shaft has not entered the near bottom zone operators can resume the downstroke within 5 seconds of releasing a RUN button After 5 seconds operators must restart continuous mode by means of the arming sequence 12265 5 11 Chapter 5 Voting Processor Firmware First Upstroke From figurd 5 6 No Has 1 2 or 1 1 2 stroke been configured Yes Both voting processors continue actuating the clutch for the first upstroke Y Has an operator released a RUN button or has the barrier guard opened Figure 5 7 Operational Sequence for First Upstroke and Second Downstroke in Continuous Mode Yes No Y Is the shaft in the near top position Yes Both voting processors continue actuating the clutch for the second downstroke Has an operator released a RUN button or has a barrier guard opened Both voting processors de energized their solenoid triacs to stop the press Did the shaft stop in the near bottom position No A Go to Figure 55 Select Continuous Mode
67. ct processor fault Switch to RUN mode PC processor is not in RUN mode probably due toa processor fault OF PRESS INTERLOCK DROPOUT OR ABSENT Check wiring of press interlock switch in 6 1 0 6 5 10 CHECK RUN BUTTON SIGNALS MAKE STATION ACTIVE OR The cactive station input is absent but the PM module is BYPASSED detecting a change of state of operator RUN buttons Check station 1 figurd 6 11 15 MAKE LEFT AND RIGHT ACTIVE CONNECTIONS IDENTICAL Check station 1 figur 6 11 7 15 ET Clad Troubleshooting 7 16 STATION MESSAGES HEX CODE 6A 6B 6C 6D 6E 6F PROBLEM AWAITING RELEASE OF ALL ACTIVE RUN BUTTONS OCCURS UNDER THE FOLLOWING CONDITIONS 1 If after pressing 1 active run button and then not pressing all active run buttons within 5 seconds After an additional 5 2 seconds the message will occur During single stroke mode and at the end of a normal stroke the PM is looking for all active run buttons to be released within 1 second of de energizing clutch valve outputs 3 After the arm continuous button is released if all active station run buttons are not released within 0 1 second IN GENERAL THESE MESSAGES OCCUR TO PREVENT THE FOLLOWING 1 2 ANTI TIE DOWN The PM requires that both buttons be released if both were pressed and then one has been released There is no time delay for this condition to cause a trip message The PM al
68. d be designated A3112 From TO List for Figurd 6 1 3L1 Power Crowbar Test and press Interlock Inputs 3L1 Crowbar as NO contact B206 2L2 3L1 Crowbar B N contact Press Interlock Switch 212 From To List for Figurd 6 2 Main Solenoids Crowbar and Seal In Relays Ungrounded AC Power Main Valve Soelnoid A LRB Main Valve SOlenoid B Crowbar Relay A Seal Relay A Main Valve Solenoid A Main Valve Solenoid B Crowbar Relay B Seal Relay B B 1 Appendix B From To Lists From To List for Figurd 6 3 Auxiliary Valve Solenoids Ungrounded AC Power Auxiliary Valve Solenoid A A309 LRB Auxilialry Valve Solenoid B A3011 B304 B306 Auxiliary Valve SOlenoid A B308 Auxiliary Valve SOlenoid B 3L2 B3011 3L1 From To List for Figura 6 4 Dump Valve Solenoids Ungrounded AC Power B410 B411 Dump Valve Solenoid A B412 A410 B413 LRA Dump Valve Solenoid B Switch on Dump Valve Stem A 412 212 LRB Switch on Dump Valve Stem B Dump Valve Solenoid A 2L2 Dump Valve Solenoid B B413 3L2 B 2 Appendix B 1 0 From To Lists From To List for Figurd 6 5 Micro Inch Valve Solenoids Ungrounded AC Power Micro inch Position on Selector Switch figure Micro inch Valve Stem Switch A406 Micro inch Valve B507 Solenoid A A506 212 LRB BENE Solenoid B 2L2 B405 Micro inch Valve Solenoid A B407 Micro inch Valve Solenoid
69. ds to bypass station 2 you may simply connect terminals 3 and 4 of each field wiring arm to 211 For another example if you have three operator stations and only station 2 will be in constant use build and wire plug in stations 1 and 3 as shown in Figure 6 11 and Figure 6 12 Directly wire station 2 according to Figurg 6 11 Directly wire station 4 bypass according to Figur 6 12 You must also build and wire the dummy plugs for stations 1 and 3 Important Configure or do not configure stations 3 and 4 through backplane switch settings as described in chapter 3 and PLC configuration bits as described in chapter 4 If you configure plug in station 3 and or station 4 but do not use either or both you must bypass the unused station s with a dummy plug s If you have not configured for stations 3 and 4 you need not place a 1771 IA module in module group 1 slot 0 chassis A and B Connect the NC and NO contacts of each RUN button to opposite chassis exactly as shown in Figurd 6 11 and Figure 6 12 for all stations This allows both voting processors to monitor and cross check all RUN buttons for correct operation Chapter 6 Field Wiring Arm Connections Figure 6 11 Connections for Operator Stations 1 and 2 Dummy Plugs and Inch Pushbutton Switches
70. e that makes it function as a voting processor Both voting processors contain identical firmware programs that independently monitor your clutch brake controller I O while controlling the press While running their firmware programs both voting processors constantly vote on the status of your press Both voting processors must always have a consensus If they find that they don t agree on their perceived conditions of your press they either stop the press or prevent it from starting Also both voting processors constantly check their communication channels Press motion is stopped or inhibited if either voting processor detects a loss of communications with the PLC or the other voting processor A failure in one voting processor is immediately seen as a communication loss by the other voting processor Finally voting processors control the operational sequences that your operators must perform in inch single and continuous modes Each voting processor PM module controls one seal relay and one crowbar relay All E STOP switches are connected in series with seal relay contacts If any of these contacts opens or if the PM module detects a trip condition solenoid power is disconnected If a PM module detects that solenoid power should be off when on it turns on the crowbar relay to blow the solenoid power line fuses At clutch brake start both PM modules test their crowbar relays without blowing the line fuses Wiring diagrams in c
71. e Controller Processor with Remote 1 0 The firmware in voting l C B processors A and B Press J monitors and controls the press Your ladder diagram program configures and 1771 PM f enables voting processors Voting and B while it monitors Processor and controls I O through remote I O adapters 1771 ASB L Remote 1 0 Chassis Adapter A Control Rungs optional Configuration Rungs Other inputs Configuration that are Switch independent Ladder Inputs of the Program Clutch brake troll I O Control Rungs S 4 2 12253 Chapter 4 PC Ladder Programming Configuration Rungs You have flexibility in selecting clutch brake controller functions by setting resetting configuration bits Use any of the following functions according to your application requirements Functions Bit Stations 3 and 4 01 Motion detector feedback 02 Valve stem feedback 03 Air pressure feedback 04 Ungrounded or grounded AC power 05 On the hop 06 Half stroke or Stroke and a half 07 Dump valve circuit 14 You enable various functions by programming configuration rungs to set turn on or reset turn off configuration bits 01 thru 07 and 14 in the output image table word for module group 7 chassis A and chassis B Bit addresses are shown in Figure 4 2
72. e Sw A 7 SIS JS S e S n S S m 10 g gc J 22 22 12 u fi L e Switches on Dump Valve Stems A L i 211 Chassis B oom Chassis B Dump Valve Solenoids Micro inch 2 0 S IS Valve Stem B 1S A B 4 JO J5 5 SS IQ p Sw B A TO SI ressure Sw 7 SIS SIS y 1 SIS al B 8 19 TO e 10 O S C B B 2 1 22 if 212 3 CIN ER e NOTES Use this wiring with figur 65 to ungrounded AC power 1 LRA and LRB load resistors for triac feedback are 2K ohm 15 watt resistors 2 Each solenoid or relay coil should draw at least 60mA 3 Connect one MOV to the 3L1 side of each solenoid load and to 3L2 for electrical noise suppression Micro inch Valve JL2 Solenoids 17889 6 19 Chapter 6 Field Wiring Arm Connections Cam Limit Switches 6 20 Install two separate cam limit switch assemblies each with three cams and three cam limit switches Connect cam limit switches exactly as shown in Figure 6 9 This allows each voting processor to monitor its own limit switches for top stop check TCAM run on RCAM anti repeat ACAM Each cam limit switch assembly must be independently driven by the press shaft through a separate coupling device Couple each cam limit switch assembly to the shaft through a separate direct coupling a separate gear assembly or a separate chain assembly WARNING To guard against
73. e controller will not operate if you manually configure chassis A and B to a half rack Warning To guard against injury to personnel open and lock the main power disconnect before adjusting replacing or repairing any mechanical or electrical component in your press system This consists of the press clutchbrake controller and all associated wiring and control panels 12290 7 3 Chapter 7 Troubleshooting General Troubleshooting Procedure Troubleshooting Hints 7 4 Although the procedure for troubleshooting your clutch brake controller varies with each problem use the following steps as a general procedure E Examine Figure 7 2 and NO TAG 2 Answer questions in Figure 7 2 and NO TAG until you see a reference to another figure or table Tabld 7 C llists diagnostic codes 3 Place a bookmark at Figure 72r NO TAG and go to the figure or table that it referred to in step 2 That figure or table might contain other references Therefore you may need several bookmarks while working among various figures and tables throughout this manual Table 7 D is your primary reference 4 Isolate the problem using the guidelines in Figur 7 2 or NO TAG Table 7 C other references 5 Correct the problem WARNING To guard against injury to personnel or damage to your press open and lock the main power disconnect to turn off all AC and DC power before manually turning the press shaft adjusting or repairing any
74. eir input terminals to the input terminals for the main valve stem switches If your valves have internal fault detection no valve stem switches do not configure for valve stem fault detection and delete valve stem input connections from Figurd 6 4 or Figure 6 8 hnd Figurd6 2 Each main valve solenoid should draw at least 60mA If not connect an appropriate load resistor in parallel with it For neatness and safety we recommend that you connect feedback and load resistors only at convenient terminal strips not at the field wiring arms 6 8 Optional Auxiliary Valve Solenoids Optional Dump Valve Solenoids Chapter 6 Field Wiring Arm Connections Use auxiliary valve solenoids when you want to boost the volume of air to the clutch brake assembly Do this by placing auxiliary valves in parallel with main valves in your high pressure air line If you use auxiliary valves connect auxiliary valve solenoids A and B shown in Figurel6 3 for ungrounded solenoids or Figure 6 7 for grounded solenoids If you don t use one or both auxiliary valve solenoids you must connect a 2k ohm 15W resistor in place of each Figurel6 3 or Figurd 6 7 also shows connections for feedback from auxiliary valve solenoid triacs that allows both voting processors to monitor the on or off state of each triac and check for shorted or open triacs and shorted or open auxiliary valve solenoids load resistors LRA and LRB for triac feedback from auxi
75. es E STOP 6 5 STOP ON TOP 6 10 65 6 26 Optional Binary Display Optional Indicators Chapter 6 Field Wiring Arm Connections Important When mounting RUN and INCH buttons ensure that all RUN buttons and both INCH buttons are either guarded or flush head pushbutton switches such as Allen Bradley Bulletin 800P Palm Operated Pushbuttons You can operate guarded buttons only by reaching through their guard rings the distance between each left RUN or INCH button and its corresponding right RUN or INCH button is great enough to allow operation of both buttons only by both hands all RUN and INCH buttons are located at greater than minimum safe distance from the point of operation of your press as specified in OSHA Regulations Title 29 Labor Chapter XVII Section 1910 217 and ANSIB11 1 section 5 3 Formulas for calculating the minimum safe distance are included Use the optional diagnostic binary display shown in Figure 6 13 to troubleshoot your press Chapter 7 lists the diagnostic messages We recommend Allen Bradley Small Pilot Lights Transformer Type cat no 800T PS16R with 1771 OA Output Modules You may order color caps separately red is standard Red cat no 800T N122R Green Cat no 800T N122G Amber cat no 800T N122A Blue cat no 800T N122B White cat no 800T N122W Clear cat no 800T N122C You may also want to order Small Pilot Light Guards cat no 800T N226 to protect the
76. es which ones you will use Then configure your clutch brake controller Motion Detectors and accordingly Air Pressure Switches Optional Valve stem Feedback If main and auxiliary valve solenoids do not have valve stem switches then consider omitting valve stem feedback If either one has valve stem switches consider using valved stem feedback Then if some valves do not have valve stem feedback you must simulate valve stem feedback for the valve s without valve stem switches Follow these instructions if using valve stem feedback If Using Then Valve stem feedback 1 Enable valve stem feedback with backplane switches ronis PC configuration rungs Figure 4 4 2 All valves must use or simulate it 3 Wire valve stem switch circuits to 2L1 Figurd 6 2 o 6 6 Valve stem feedback but Main or Aux valve is NOT equipped with external fault detection has internal detection Modify above as follows 1 Omit wiring the valve stem switch circuit to 2L1 for that valve Figurd amp 2 o 6 6 2 Simulate feedback for that valve by jumpering terminals 0 and 7 in chassis A the same in chassis B No valve stem feedback 1 Do not enable it 2 Do not wire valve stem switches 3 Do not jumper terminals for simulation 6 7 Chapter 6 Field Wiring Arm Connections Optional Motion Detectors and Air Pressure Switches For either one of these optional features you may use a single switch or redundant switches Figure le
77. eshooting BRAKE OR MOTION DETECTOR MESSAGES HEX PROBLEM CORRECTIVE ACTION CODE 084 L RUN ON CAM SWITCH CLOSED SHOWING REVERSE Check for proper cam operation Check for proper MOTION operation of pc logic Check clutch operation 085 ALT CHASSIS Both the run on and brake monitor cams were off signaling the press was in the near top position and then the run on cam switch signal came on again Note Can only occur if the main motor forward input is on CAM LIMIT SWITCH TRANSITION TO DOWNSTROKE MESSAGES 086 RUN ON CAM SWITCH CLOSED See Standard Corrective Action 087 ALT CHASSIS The press is in transition to down stroke brake monitor cam on and run on cam off and the run on cam came back on BCAM SWITCH BOUNCED WHEN TURNING ON CONTACTS 1 Replace BCAM contacts 088 WORN OR DIRTY 2 Press Reset latched msg PB 0D code appears 3 Cycle swingarm power and restart press 08A BRAKE MONITOR OPENED WHEN RUN ON CAM SWITCH IS See Standard Corrective Action CLOSED 08B LOCAL BRAKE MONITOR OPEN REMOTE RUN ON CAM SWITCH CLOSED 08C REMOTE BRAKE MONITOR OPEN LOCAL RUN ON CAM SWITCH CLOSED 08D REMOTE BRAKE MONITOR OPEN REMOTE RUN ON CAM SWITCH CLOSED The PM needs to see the downstroke near bottom and upstroke cam conditions in order for correct opertion This message indicates that the PM saw a downstroke and then a upstroke without passing through the near bottom zone 08E
78. for descriptions of faults caused by cam limit switches Table 5 A Operation of Cam Limit Switches On the hop single stroke Inch and Micro inch forward and Single stroke Continuous Single stroke and Continuous Inch and Micro inch reverse With these Conditions Run buttons released past bottom Cam opens at near top position Cam opens at near top position after stop on top command Cam closes at near bottom position Cam closes during Stop on top Cam opens in near top position 12970 Provides the PM Module a Signal To allow a second stroke when run buttons are pressed a second time To turn OFF triac output for stop on top cycle stop To let operator release any depressed run buttons without interrupting a single stroke or continuous stroking To energize a Brake Fault output to warn that the brake is faulty Hazardous Condition To turn OFF solenoid outputs to stop the cycle Chapter 5 Voting Processor Firmware Inch and Micro inch Modes Use inch or micro inch mode before entering single or continuous mode to position the shaft near the top or for machine tool set up You may jog the shaft either forward or in reverse The shaft stops when it moves into the near top position or when you release an INCH button Clutch Brake Operating Modes Figure 5 2 Operational Sequence for Inch or Micro Inch Mode
79. for reasons why you must restrict the use of this address Triacs of your clutch brake controller turn on in sequential order Triacs connected to the high AC power line L1 turn on before those in the triac solenoid string connected to the low AC power line L2 If the addresses are reversed the triacs will turn on out of sequence and the clutch brake controller will not operate Set switch 1 on switch assembly SW 2 to the ON position This sets the module s communication rate at 57 6K baud Be sure that you set the communication rate of both 1771 PM modules and the processor s scanner to 57 6K baud as well The worst case time required for the clutch brake controller to respond to a change of input depends on Module response and triac switching times Characteristic 1771 module response time 1771 PM module response time Triac switching time Total response time 3 11 Chapter 3 Clutch Brake Controller Hardware Module Placement 3 12 The number of degrees that the shaft continues to rotate beyond the moment in time when the input changes depends on the speed of rotation The greater the number of strokes per minute SPM the further the shaft rotates before a command from the clutch brake controller is applied The response time of 44ms is represented in degrees of shaft rotation that increases as the rate of press operation increases Figure 3 5 Figure 3 5 Response Time of Clutch Brake Controller
80. gram Operator Operator Operator Operator Station Station Station Station No 1 No 2 No 3 No 4 E q Allen Bradley Clutch Brake Controller NE Monitors operator inputs Monitors shaft position using cam limit switch feedback Controls the press using solenoid triac outputs A A Cam Switch Triac Y Y _ __ 55 Outputs Air Supply Feedback Inputs to Main Solenoids 4 Main Solenoid Valves A Clutch Brake Assembly Flywheel TH Air to Clutch Cam Press Cam Switch Switch Assembly Y 2 Assembly y Crankshaft Shaft at Top Position pot Shaft at Bottom Position gt gt gt 12245 2 2 Related Safety Documentation Chapter 2 Press System Description This manual concentrates on safety considerations relative to the clutch brake controller Study this entire manual and all technical documentation provided by the press manufacturer before you install your press system In addition to local codes and laws follow the safety requirements detailed in the following publications OSHA Regulations Title 29 Labor Chapter XVII Section 1910 217 Mechanical Power Presses ANSI B11 1 America
81. hapter 6 show these connections 5 1 Chapter 5 Voting Processor Firmware Fault Monitoring PM modules continuously monitor your clutch brake system for a trip or stop condition Either condition halts and or prevents press operation For this condition modules remove solenoid power by Trip Removing power from field wiring arms Stop Turning off outputs from the output module controlling the solenoids Trip condition A PM module turns off swing arm output power by de energizing its seal relay output when it detects these trip conditions lost communications with the other PM module for 100ms achange in wiring of operator stations 1 thru 4 short or open solenoid triac short or open solenoid feedback 1 connections are wired but not configured feedback connections are configured but not wired feedback signals are not working correctly 1 feedback from valve stem switches air pressure sensors and motion detector contacts Whenever a PM module detects a trip condition it trips power to the wiring arms of the I O chassis sets rack fault bits stops communication with the PLC If programmed to monitor rack fault bits the PLC sees the clutch brake I O chassis as faulted until both PM modules verify that power to wiring arms has been removed Then they resume communications automatically Stop condition A PM module stops the press or prevents it from starting by turning off output triac
82. he Codes corresponding message code You can display diagnostic message codes with an optional display device connected to output modules in these locations in chassis A and B module group 5 slot 1 8 bit binary code module group 3 slot 1 bit 2 9 bit for micro inch When using micro inch mode diagnostic diagnostic message codes are 9 digit binary 3 digit hex rather than 8 digit binary 2 digit hex for other diagnostic message codes The most significant bit bit 9 indicates a micro inch code When set 2 digit hex codes XX become 3 digit hex codes 1 XX for micro inch You can display diagnostic message codes in 9 digit binary or use an optional binary to hex converter and display diagnostic message codes in easy to read hexadecimal notation No programming is required Just install output modules in those locations and connect display devices Figured 6 13 hnd Figures 6 14 You can also view diagnostic message codes with an Allen Bradley programming or display terminal using the data monitor feature If using this processor Use this device PLC 2 family Industrial Terminal 1770 T3 Hand held Terminal 1770 T11 PLC 3 family Industrial Terminal 1770 T4 Data access panel on the front of the processor or 1784 T45 T47 or T50 Programming Terminal PLC 5 family 1784 T45 T47 or T50 Programming Terminal PLC 5 250 1784 T45 T47 or T50 Programming Terminal 7 8 Types of Diagnostic Message Codes Chapter 7 T
83. ids Each solenoid or relay coil should draw at least 60mA Connect one MOV between 3L1 312 for electrical noise suppression 5 Connect one MOV to the 3L1 side of each solenoid load and to 3L2 for electrical noise suppression 17890 6 18 Chapter 6 Field Wiring Arm Connections Figure 6 8 Connections for Optional Dump and or Micro inch Valve Solenoids with MOV Surge Suppression Grounded AC Power For either option For optional Dump Valve For optional Micro inch Valve 1771 OD 312 1771 IA 1771 1A Module Group 4 Module Group 4 Module Group 5 Slot 0 Slot 1 Slot 0 Chassis A 1 Chassis A LRA LRB LRB LRA Micro inch Position 3L1 i AG on Selector Switch AST Microinch 211 T 9 Q gt e 00 Valve Stem A e 3 iS T 2 2 I I M 2 9 2 6 34 5 3 3 5 IS S Pressur
84. injury to personnel and damage to your press install two separate cam limit switch assemblies that are independently driven by the press shaft through separate coupling devices Two separate cam limit switch assemblies allow your clutch brake controller to stop press motion in case there is a failure within either cam limit switch assembly or a breakage in either coupling device Set each pair of cam limit switches to similar settings as shown in Figure 5 1 If the settings are not similar the voting processors can disagree on their perceived shaft zones and cause nuisance shutdowns We recommend the Allen Bradley Rotating Cam Limit Switch cat no 803 P3 This rugged duty cam limit switch assembly is well suited for press applications For ordering information see the Allen Bradley Industrial Control Catalog or contact your local Allen Bradley sales engineer or distributor Because the Cat No 803 P3 is an industrial grade heavy duty limit switch we recommend that it switch a power circuit drawing at least 0 25 Amp Install a 470 or 500 ohm 50 watt load resistor in parallel with the AC input to generate this current You need to mount the resistors on the subpanel to keep dissipated heat from resistors away from modules and because the resistor s axial leads are not compatible with the wiring arm Chapter 6 Field Wiring Arm Connections Figure 6 9 Connections for Cam Limit Switch Assemblies
85. ion reversed 1010 0111 A7 Run on cam switch bounced or motion reversed 7 32 Chapter 7 Troubleshooting diagnostic message codes are displayed by indicators connected to module group 5 slot 1 figure 6 18 or by displaying the corresponding data table word using the industrial terminal Use this table in conjunction with figurd 7 1 and figure references shown in parentheses Type of Message Code N Non latched P at Power up L Latched Alt Alternate chassis T Trip Condition Ethr Either chassis Top Top chassis Bot Bottom chassis Diagnostic Message figure References LT jwmswswimwee md 1011 1110 Air pressure signal on when triacs are on LT pr O T me perme 1100 0010 1100 0101 1100 0111 perme 1100 1010 LL 7 33 ET Clad Troubleshooting diagnostic message codes are displayed by indicators connected to module group 5 slot 1 figure 6 18 or by displaying the corresponding data table word using the industrial terminal Use this table in conjunction with figur 7 1 and figure references shown in parentheses Type of Message Code N Non latched P at Power up L Latched Alt Alternate chassis T Trip Condition Ethr Either chassis Top Top chassis Bot Bottom chassis Diagnostic Message figure References LT 1101 0011 Triac 1 off when commanded
86. ion will occur with possible damage to equipment and or injury to personnel However you may install a slot power supply in module group 7 if needed A CAUTION Do not assign any I O module to module group 7 Important Be sure to assign full rack addresses for chassis A and B regardless of whether you are using the optional dump valve and or micro inch circuit This guards against assigning an I O module to module group 7 Refer to Rack Address of Chassis A and B in chapter 3 for instructions on assigning rack addresses Your PLC ladder program cannot control outputs of your clutch brake controller However your PLC ladder program can monitor any clutch brake controller input or output because the I O image table of chassis A and B is in the PLC data table Input image table bit addresses for chassis A and B are listed in tables A thru F in appendix 1 You may monitor these addresses However do not examine them as conditions for configuration rungs shown in Figures 4 3 through Figure 4 5 If you do PM modules may stop the press Then you must cycle power to restart 4 13 Chapter 4 PC Ladder Programming Report Generation For an example of monitoring a clutch brake controller function assume that you wish to turn on a indicator while your clutch brake controller is in continuous mode You would wire your CONTINUOUS indicator to a terminal of an output module in any I O chassis You would also program a rung with one
87. is A amp B dule group 6 slots 0 amp 1 inputs chassis A amp B remove them if you do mo not configure for stations 3 amp 4 module group 7 slots 0 amp 1 module group 1 slot 0 y i CAAA 1771 PM module Chassis 1771 M MB Required 1771 OD modules for outputs Optional modules for dump to solenoid valves Chassis A amp B valve in chassis A amp B module group 3 slot 0 7 1771 OD module group 4 slot 0 Optional micro inch indicator chassis B 1771 1 module group 4 slot 1 Chassis A 1771 M MB 1771 OA module group 3 slot 1 Important Use 1771 A2 A2B chassis when not using optional dump valves display of diagnostic message codes nor micro inch inputs 12247 3 13 Chapter 3 Clutch Brake Controller Hardware Keying Install the keying bands on the I O chassis backplane connector as shown in Figure 3 7 After you install keying bands in chassis A and B you can insert only a clutch brake module in the left most slot of chassis and B Figure 3 7 Keying Chassis A and B Insert keying bands so that you can install only a 1771 PM module in this slot 12252 Chapter Objectives Programming Fundamentals PLC Ladder Programming This chapter will help you become familiar with programming fundamentals as they relate to your clutch brake controller the need for press configuration rungs relationships between your press configur
88. k Air pressure feedback Ungrounded or grounded AC power On the hop Half stroke or Stroke and a half Dump valve circuit Micro inch 3 7 Chapter 3 Clutch Brake Controller Hardware Figure 3 3 Backplane Switch Settings Chassis lt A and B Backplane Switches Assembly QS NM e gt a o mmo zo ON OFF or 0 Function Use Stations 3 and 4 Stations 3 and 4 not used Use Motion Detector Feedbck Motion Detector Feedback not used Use Valve Stem Feedback 9 Valve Stem Feedback not used Use Air Pressure Feedback Air Pressure Feedback not used o Ungrounded AC Power Grounded AC Power eomm E On The Hop not used Always OFF ad Use Half Stoke Use Stroke And A Half IMPORTANT Make backplane switch settings in chassis A and B identical 12249 3 8 Rack Address of Chassis A and B Chapter 3 Clutch Brake Controller Hardware Important There is no backplane switch setting to configure the optional dump valve circuit You configure the optional dump valve circuit by inserting dump valve modules cat no 1771 OD and 1771 IA into module group 4 slots 0 and 1 respectively of chassis A and B You must also set bit 14 unconditionally in your configuration rungs Important To configure your clutch brake controller for Micro inch see chapter 4
89. le group 3 slot 1 bit 2 chassis A and B for MSB Micro inch valve stem input is present though not configured Micro inch clutch pressure input is present though not configured E a T it a esate T irate pes gt a eS NEENEN rr Triac 8 is off when commanded on T Eth Triac is off when commanded on Chapter 7 Troubleshooting diagnostic message codes are displayed by indicators connected to module group 5 slot 1 figure 6 18 or by displaying the corresponding data table word using the industrial terminal Use this table in conjunction with figur 7 1 and figure references shown in parentheses Type of Message N Non latched L Latched T Trip Condition 1 1101 1000 11101 1001 1 1101 1110 1 1101 1111 1 1110 0100 1 1110 0101 1 1110 1010 1 1110 1000 1E8 1 1111 1111 Code P at Power up Alt Alternate chassis Ethr Either chassis Top Top chassis Bot Bottom chassis Diagnostic Message figure References Triac 8 remains on after triacs turn off Triac 9 remains on after triacs turn off T Micro inch valve stem input is on when triacs are off Micro inch valve stem input is on when triacs are off Micro inch valve stem input is off when triacs are on Lamp test in progress Refer to ACTIVE indicator table 7 A or FAULT indicators tabld 7 B Summary Now that you have read this chapter you should have a general idea of ho
90. liary valve solenoids Each auxiliary valve solenoid should draw at least 60mA If not connect an appropriate load resistor in parallel with it For neatness and safety we recommend that you connect the feedback resistor and the load resistor only at convenient terminal strips not at the field wiring arms If you use auxiliary valves with internal fault detection no valve stem switches but you have configured for external fault detection simulate the inputs of the auxiliary valve stem switches Do this by jumpering the input terminals of field wiring arms for auxiliary valve stem switches to the input terminals for the main valve stem switches Jumper terminal 7 to terminal 0 module group 2 slot 0 for chassis A and B Figure 6 2 Use optional dump valves and solenoids when you want to accelerate the evacuation of air from the clutch brake assembly If you use dump valves install two output modules cat no 1771 OD series C or later Place them in module group 4 slot 0 chassis A and B to control the dump valve solenoids Also install two input modules cat no 1771 IA Place them in module group 4 slot 1 chassis A and B to monitor feedback inputs from the dump valve solenoids Set configuration bit 14 unconditionally as shown in Figure 4 3 Figure 4 4 br Figurd 4 5 Connect dump valve solenoids and valve stem switches if you use them as shown in Figurd 6 4 for ungrounded solenoids or Figure 6 8 for grounded solenoids
91. lot 0 1771 OD Figurd 6 4 oj 6 8 Addresses PLC 2 30 Chassis Chassis A B A B Triac 7 for Dump Solenoid B 1 4 01 164 01 10ab4 01 10ac4 01 Term Function PLC 3 Slot 1 1771 IA Figure 6 4 or 6 8 Addresses Term PLC 2 30 PLC 3 Chassis Chassis B A EM Feedback input from Triac 6 Chassis A 1a4 10 1b5 10 10ab4 10 10ac4 10 E Feedback input from Triac 6 Chassis B 1a4 11 1b4 11 10ab4 11 10ac4 11 Feedback input from Triac 7 Chassis A 1a4 12 1b4 12 10ab4 12 10ac4 12 Feedback input from Triac 7 Chassis B 1a4 13 1b4 13 10ab4 13 10ac4 13 4 Input from Dump Valve Stem NO Switch A 1a4 14 10ab4 14 10ac4 14 Switch B 1b4 14 Optional A 6 Appendix A Bit Monitoring Address Module Group 5 Slot 0 1771 IA Figurd 6 4 6 8 Function PLC 2 30 PLC 3 Chassis Chassis B A Input from Micro inch valve stem 1a5 01 1b5 01 10ab5 01 10ac5 01 Feedback input from Triac 8 Chassis A 185 04 1b5 04 10ab5 04 10ac5 04 Slot 1 1771 Figure 6 13 Addresses PLC 2 30 PLC 3 Chassis Chassis B A 2 Bit 12 1 5 12 15 12 10ab5 12 10ac5 12 185 13 1b5 13 10ab5 13 10ac5 13 A 7 Appendix I O FROM TO LISTS In the following tables of from to lists we use the notation CGST to designate field wiring arm terminals where C chassis A or B S slot number G module group T terminal number For example a connection to chassis A module group 3 slot 1 terminal 12 woul
92. m Chapter Objectives System Components Press System Description This chapter will help you become familiar with major components of a typical press system safety requirements for a press system A press system as referred to in this manual includes a mechanical power press an Allen Bradley clutch brake controller all associated control panels and operator stations all associated output and feedback devices all wires and cables that interconnect system components A functional block diagram of a typical press system is shown in Figure 2 1 This figure shows general relationships between major components Specific functional relationships vary according to the requirements of your particular press system For details refer to chapters thru 7 of this manual technical documentation provided by your press manufacturer ANSI B11 1 American National Standard for Machine Tools Mechanical Power Presses Construction Care and Use Important Use an Allen Bradley clutch brake controller only with a mechanical power press that has a part revolution clutch A part revolution clutch can be disengaged at any position of the shaft This allows your clutch brake controller to stop the press at any position In contrast a full revolution clutch can be disengaged and stop the press only at the top position of the stroke 2 1 Chapter 2 Press System Description Figure 2 1 Functional Block Dia
93. ment the use of these switches refer to Figurd 4 6 Figure 4 7 Figurel4 8 12287 6 32 Chapter Objectives Troubleshooting Considerations and Requirements Troubleshooting with LED s Troubleshooting After you have read all previous chapters this chapter can help you safely isolate and correct problems in your press system interpret diagnostic messages generated by your clutch brake controller use the module indicators in chassis A and B while troubleshooting your press system This chapter explains troubleshooting techniques and refers to previous chapters We recommend that you read the entire manual and all technical documentation provided by the press manufacturer before troubleshooting any problem with your press system We also recommend that you adhere to the safety requirements detailed in local code and laws and in the following publications OSHA Regulations Title 29 Labor Chapter XVII Section 1910 217 Mechanical Power Presses ANSI B11 1 American National Standard for Machine Tools Mechanical Power Presses Construction Care and Use NFPA No 79 Electrical Standard for Metal working Machine Tools Familiarity with this documentation makes your troubleshooting not only safer but easier as well Use these figures and tables when troubleshooting with LED indicators Reference Description Figurd 7 1 Location of LED indicators Figur7 A Howto read the Module s ACTIVE indic
94. mode only forward motion is allowed This message occurs when the PM sees a transition to upstroke run on cam on brake monitor cam off and then sees the brake monitor cam come back on before the run on cam opens CAM LIMIT SWITCH UPSTROKE MESSAGES 09E 09F 0A0 0A1 0A2 0A3 BRAKE MONITOR CLOSED WHEN RUN ON CAM SWITCH See Standard Corrective Action OPENED LOCAL BRAKE MONITOR CLOSED WHEN REMOTE RUN ON CAM SWITCH OPENED REMOTE BRAKE MONITOR CLOSED WHEN LOCAL RUN ON CAM SWITCH OPENED REMOTE BRAKE MONITOR SIGNAL IS ON WHEN REMOTE PM S RUN ON CAM SIGNAL IS OFF The PM saw that the press was in a upstroke run on cam on and brake monitor cam going off and then saw an incorrect zone transition to downstroke run on cam off and brake monitor cam on without going through the near top zone BRAKE MONITOR CAM SWITCH CLOSED SHOWING See Standard Corrective Action Also check for proper REVERSE MOTION clutch operation ALT CHASSIS During single stroke or continuous mode only forward motion is allowed The PM saw that the press was in an upstroke and then saw an incorrect zone transition back to the near bottom zone BRAKE MONITOR CAM SWITCH CLOSED See Standard Corrective Action Also check for a ALT CHASSIS possible brake problem The PM logic was momentarily in a zone transition state between the upstroke and near top zones Before being able to fully transition to
95. module See the solenoid Check solenoid Figure 7 1 wiring Yes Replace the fuse Y Does the status indicator for the No Replace the input switch or input to the 1771 IA module check its wiring respond See Figure 7 1 Yes Replace the 1771 IA module Warning To guard against injury to personnel open and lock the main power disconnect before adjusting replacing or repairing any mechanical or electrical component in your press system This consists of the press clutchbrake controller and all associated wiring and control panels 12291 7 5 Chapter 7 Troubleshooting Troubleshooting Example 7 6 5 Trace wire leads and or inspect the faulted device If you wired the PM system in a manner other than outlined in this manual faults are more difficult to track Proceed as follows Determine if the fault and corresponding diagnostic code was caused by alterations in system wiring i e if the fault is a run station fault are the run stations wired directly to the PM system or through auxiliary chassis controlled by the programmable controller If the latter is the case you should look at the programmable controller s ladder program Determine if you have an I O problem The PM module can only diagnose its own I O level That is it alerts you to the exact input or output within the system that it sees as incorrect
96. moving parts in your press repairing or replacing any wiring in your press system including any field wiring arm or cable connections replacing any electronic or electrical components such as clutch brake controller and I O modules power supplies or chassis replacing blown fuses in your press system Diagnostic codes are specific and point to the exact input or output device that controls PM operation When your system is wired as outlined in this manual you can identify the cause of a fault as follows 1 Review the section Diagnostic diagnostic message codes below 2 Note the diagnostic code for both PM modules Chapter 7 Troubleshooting 3 Determine the input or device causing the fault from the section sub section heading in Table 7 D where the fault code was tabulated and from other figures or tables referred to 4 Interpret the messages Was this output supposed to be on Was that device supposed to be off Figure 7 3 Troubleshooting Flowchart for Diagnostic diagnostic message codes Press will not run Is a di Y N s a diagnostic message 0 Go to figura 7 2 displayed Y See Tabld 7 C Y Does the problem relate to an No Does the problem relate to a No Take action according to Table input switch or connection solenoid or its triac gt Yes Is a blown fuse indicator on for No Replace the 1771 OD module or any 1771 OD
97. n National Standard for Machine Tools Mechanical Power Presses Construction Care and Use NFPA No 79 Electrical Standard for Metalworking Machine Tools 2 3 Chapter Objectives General Hardware Considerations Description of your Clutch Brake Controller Clutch Brake Controller Hardware This chapter will help you become familiar with the hardware components of your Allen Bradley clutch brake controller functional relationships between your PLC and clutch brake controller interconnections between your PLC and clutch brake controller switch settings that configure your clutch brake controller and establish its rack addresses For details on how to install the I O chassis and modules refer to the installation publications that apply to your particular PLC These publications listed in our Publications Index publication SD 499 discuss general layout rules mounting dimensions enclosure considerations module keying and field wiring arm connection technique Important If you are using a large mechanical power press that generates high levels of shock and vibration we recommend that you shock mount each I O chassis of your clutch brake controller Important Electrostatic discharge can damage integrated circuits or semi conductors in the PM Module if you touch backplane connector pins or internal components A Rid yourself of charge before handling the module by touching a grounded object Y
98. n wiring figurd 6 10 Check for faulty switch broken wire etc figurd 6 10 Chapter 7 Troubleshooting MISCELLANEOUS MESSAGES cont d HEX PROBLEM CORRECTIVE ACTION CODE 0A N L PC ENABLE DROPOUT OR ABSENT LATCHED MESSAGE The PC enable bit from the processor must be maintained to the When the PM is actually in the off mode the PC enable bit PM while in any mode other than off The PM must also see the may be turned off PC enable bit maintained while switching to off mode NON LATCHED MESSAGE This condition should be used as a status prompt that The PM must first see the PC enable bit go on before it sees any indicates the user program has not given final permission request to change modes If this does not happen this message to enter the selected mode Check programming in will occur fuis 0B STOP ON TOP SIGNAL FROM PC PREVENTING ENTRY TO Check ladder logic figure 4 6 4 7 4 8 CONTINUOUS MODE PM module is still receiving STOP ON TOP command from the PC processor This command must be absent before PM can enter continuous mode 0C AWAITING RELEASE OF INCH BUTTONS FOR ENTERING Refer to figurd 5 2 Check wiring in figurd 6 11 INCH MODE Inch button inputs must indicate that both inch buttons have been released then pushed again before its PM Module will allow inching motion This is the ante tie down feature of the PM Module refer to figureg 5 2 and 6 11 oD 0E PC RUN MODE DROPOUT OR ABSENT Corre
99. nch mode are 9 bit binary 3 digit hex with 1 as the first digit Figure 6 14 Diagnostic message codes for all other 4613 13 modes 8 bit binary 2 digit hex Figure Chapter 6 Field Wiring Arm Connections Figure 6 13 Connections for Optional Diagnostic Message Display 1771 Module Group 5 We recommend Allen Bradley Small Pilot Lights Slot 1 Transformer type cat no 800T PS16R Chassis A AQ 211 e 1 S JS JS D SI S 7S S Bit Bit Bit Bit Bit Bit Bit 16 15 14 131211 10 E 7 Chassis B AG 211 1S 26 4S SI QM S Bit Bit Bit Bit Bit Bit Bit Bit 17 16 15 14 13 12 11 10 y M En N ne UN S E Oe Core Ce e e e e e 2L2 12285 6 29 Chapter 6 Field Wiring Arm Connections Figure 6 14 Connections for Brake Fault Run Window and Micro Inch Indicators 1771 Module Group 3 Slot 1 Chassis A Stop On Top Fault I v I Paid Run Window 0 W recommend Allen Bradley Small Pilot Lights f Transformer type cat no 800T PS16R jepeperern nmy mne B
100. nctions Chapter 4 PC Ladder Programming You should now be familiar with required and optional PLC ladder programming needed to configure and monitor your clutch brake controller Complete your ladder diagram programming addresses after you have wired your press system as described in chapte Clutch brake controller functions Table 4 B are summarized on the next page Table 4 B Summary of Clutch Brake Controller Functions Function or Command Operating Mode Micro inch Single stroke 1 Continuous 1 Stop on top Continuous cycle stop On the hop Single stroke Half stroke or Continuous Stroke and a half Clutch brake controller locks out press motion The operator can jog the press through a complete cycle by pressing and releasing the pair of INCH buttons If INCH buttons are held the press will stop at the top of its stroke This mode of operation lets you run your press at low speeds 1 to 5spm for setting up dies and making trial runs You must supply a separate drive and clutch brake assembly to drive the shaft with full tonnage capacity at low press speeds by passing the flywheel The press completes one cycle and then stops on top provided the operator holds both RUN buttons until completion of the down stroke Operators must assert the ARM CONTINUOUS switch and all station RUN buttons within five seconds and then hold the RUN buttons for half a stroke or 1 1 2 strokes if so
101. nnections Figure 6 12 Connections for Operator Stations 3 and 4 and Dummy Plugs S 771A pog odule Group 1 jo DN i chao eee Lett Active Q1 AG BIETEN UA MS FR Ch AA S EE ght Run ChA2 5X EE Ch BO B c QUAS 01 7 Right active gt ChB2 SEET 1 1 Ch 5 pog Right 2L1 SIC I 21 SIS Stop On Top S p dp e 7 See figure 6 10 8001 22 EN E stop oSsSefeeebe i Chassis A Dummy Plug Plug in for Station Operator Stations 7 qut fern tar mm Ch B0 Ss hB la 11 oTo si Joo OnB8 2 E Lett Adwe _ _ ChAS Ch B4 SI e ABS TS rot i AIS Right Run ChB3 ES oTo Fo PW wu ME gS 22 Roht adve ChB5 E Right 211 211 Stop OnTop nd P DR assis See ref E stop See aes Dummy Plug Plug in n bog Plug either the operator station m s NE MN NN or dummy plug into the control panel Jen IMPORTANT For These Connections Ses Fi
102. o o E stop Customer Contacts 9 E stop E stop Q Station 2 Station 1 E stop E stop Ola Q Station 3 Station 4 Seal A Seal B 2 B Start Crowbar e Q Y Y 3L1 120V AC Power for 3L2 Module group Slot Figure 3 0 4 0 6 4 6 12 F F u u u S S S e e e 17714A Module Group 2 Slot 0 1L1 1L2 1L3 A To Motor Starters 0 Panel 1 round Bus 3H E m 4 Earth Equipment roun Grounding 7 22 Conductors B F IF U S S Chassis A 2L2 Processor AIS Power Supply WS 116 21 e gt J r 5 Press Interlock IS IUS Crowbar A Test Input a L e Crowbar B Test Input Y 120V AC Power for Chassis B Y 2L1 Module group Slot Figure 2L2 0 0 6 10 0 1 0 1 1 69 2 0 2 1 3 1 4 1 5 0 5 1 6 13 12268 Chapter 6 Field Wiring Arm Connections Figure 6 2 Connections for Optional Switches on Main Valve Stems Air Pressure Sensors and Motion Detectors Ungrounded AC Power 1771 1A Module Group 2 Slot 0 Chassis A Remove this jumper when using Motion Detector Switch Bis
103. ode to the processor so your ladder logic can process it and to pre determined slots in its I O chassis so output modules can display it When you correct the condition and press the MESSAGE RESET button the PM module sends the next highest priority message code if an error condition still exists A message code of higher priority overrides a message code of lower priority For error conditions of equal priority the PM module sends the message code corresponding to the first detected condition Processing Diagnostic Message Codes Diagnostic Message Codes Table 7 C Chapter 7 Troubleshooting If you want to maintain a record of diagnostic message codes or process them for reasons other than display you can write ladder logic to examine the 9 bit binary message code that PM modules return to the processor Do this by examining bits in the input image table corresponding to module group 5 slot 1 8 binary code module group 3 slot 1 bit 2 9 bit for micro inch For example examine a bit as follows I5 where is the I O rack number 16 If recording a history of diagnostic message codes such as stored in a FIFO stack we suggest that you record only diagnostic message codes that exist for longer than one second and disregard all diagnostic message codes resulting from transient conditions of shorter duration This guards against storing no fault status diagnostic message codes such as generated during start
104. oil should draw at least 60mA 3 Connect one MOV to the 3L1 side of each solenoid load and to 312 for electrical noise suppressii ss 17881 6 15 Chapter 6 Field Wiring Arm Connections Figure 6 5 Grounded AC Power Connections Crowbar Test Inputs and Press Interlock Switch Incoming L1 12 13 ee odule Group 2 Ht utt H4 Disconnect Slot 0 H3 Hi E P Step Down Transformer 51 51 S AQ vvv e e e SIS 120V Le RS aC X1 X2 218 gt 8I iLi 12 13 SS u To Motor Starters SI e rum ae E S Customer round Bus C E stop Contacts 212 Ce To Earth r gt OLO Equipment Ground Station 2 Station 1 Grounding Chassis A F Conductors E stop E stop e A S Station 3 Station 4 212 AIC Seal Seal B Processor S I Power Supply 1S Start 2 S I 21 gt _ 5 Crowbar JM b T Crowbar A Test Input 9 Crowbar B BIS 7 Crowbar B Test Input gt 212 Ome e d Press Interlock Y 120V AC Power for y Chassis B 3H 120V AC Power for 32 21
105. op L R Inch Press enable Reset latched messages Lamp test L R Run E Stop and or 3 gt Stations 2 thru 4 2 2 and or 3 2 1 Connect these switches to input modules in chassis A and B Figure 6 10 2 Connect these switches to input modules in chassis A and B Figures 6 11 hru 3 These switches are inputs for command rungs Figures 4 6 t hru4 8 Connect these switches to input modules in remote I O chassis C Figurg 6 15 Chapter 3 Clutch Brake Controller Hardware Interlock Switches Various interlock switches are required for safety as specified in ANSI 11 1 The locations types and quantities vary with the type of mechanical press and its application requirements Use these interlock switches to prevent the press from starting or to stop the press when operation could cause injury to personnel or damage to the press Barrier guard 1 or more Figures 16 10 hnd 6 15 Press interlock 1 s Motion detector 1 Figurd 6 2 pnd 6 6 Main motor forward 1 Figurd 6 10 Cam limit switch assembly 2 Figurel6 9 top stop check TCAM run on RCAM anti repeat ACAM Configuring Your Clutch Brake You have flexibility in selecting clutch brake controller functions You Controller may select any of the following functions according to your application requirements by setting switches on the I O chassis Operator station 3 and 4 Motion detector feedback Valve stem feedbac
106. op Used Not Used Unconditioned 07 Stroke and a half or Half stroke Not Used Used Unconditioned 10 Press Enable PLC Command Enabled Disabled Conditioned 11 Stop On Top PLC Command Enabled Disabled Conditioned 12 Latched Messages PLC Command Enabled Disabled Conditioned 13 Lamp Test PLC Command Enabled Disabled Conditioned Dump Valve Triacs Not used Unconditioned NOTES Do not use bits 00 and 15 17 for any purpose See Figurg 4 2 bit addresses See Figure 4 31 rough 4 8 lor programming 12254 4 12 Module Group 5 Slot 0 Reserved for Micro Inch Module Groups 6 and 7 Reserved for Data Storage Monitoring Clutch Brake Controller Inputs and Outputs Chapter 4 PC Ladder Programming Important Use module group 5 slot 0 only if your mechanical power press is equipped for micro inch When you insert an input module 1771 IA into this slot of chassis A and B the processor recognizes micro inch inputs at terminals 0 1 2 For the wiring of these terminals refer to 6 Figure 6 4 br Figure 6 8 Module group 6 is non functional and reserved for future use Your program must use the output image table word associated with module group 7 as a storage word for configuring your clutch brake modules Figure 4 9 The processor transmits configuration data to the clutch brake modules in each I O scan of the rack address assigned to chassis A and B Unexpected press operat
107. our clutch brake controller consists of chassis A and B connected to your PLC in a serial chain with remote I O chassis as shown in Figure 3 1 Table 3 A lists required and optional clutch brake controller hardware Chassis A and B are similar to remote I O chassis The major difference is that the left most slot of chassis A and B contains a clutch brake module In contrast the left most slot of an I O chassis contains an I O adapter module 3 1 Chapter 3 Clutch Brake Controller Hardware 3 2 Figure 3 1 Overview of a Clutch Brake Controller Remote 1 0 Voting Processor A Clutch Brake Module Remote yo Clutch Brake Communications A B Programmable Controller with Remote 1 0 Chassis A Voting Processor B Clutch Brake Module sss Remote yo Chassis B Adapter Module Remote I O Remote 1 0 ol E 8 Chassis C LE Remote I O Adapter Module Remote I O Chassis
108. p Position Figures 5 1 6 11 1000 0000 t Brake monitor and run on cam switches both closed 1000 0001 ef Brake monitor for this chassis and run on cam switch for the other chassis both closed 1000 0010 EMEN Brake monitor for this chassis and run on cam switch for the other chassis both closed 1000 0011 1000 0100 6 11 1000 0110 t Run on cam switch closed 1000 0111 Alt Run on cam switch closed 7 30 Chapter 7 Troubleshooting diagnostic message codes are displayed by indicators connected to module group 5 slot 1 figure 6 18 or by displaying the corresponding data table word using the industrial terminal Use this table in conjunction with figurd 7 1 and figure references shown in parentheses Type of Message Code N Non latched P at Power up L Latched Alt Alternate chassis T Trip Condition Ethr Either chassis Top Top chassis Bot Bottom chassis Diagnostic Message figure References eroan anono O O O Downstroke Figured 16 1 ENENLILLLIILLLLLLILILIIL I _ 1000 1100 Brake monitor for this chassis open when run on cam switch for the other chassis is closed 1000 1101 Brake monitor open when run on cam switch is closed 1000 1110 Brake monitor can switch open showing reverse motion 1000 1111 Brake monitor can switch open showing reverse motion Transition to Near Bottom Zone Figured 5 1 6 11 E prno Near Bottom Zone Figured 516 11 1001 01
109. perator pressed the ARM CONTINUOUS button Arming Sequence Yes Y Have 5 seconds elapsed since Yes pushing ARM CONTINUOUS 7 L Has each operator pressed his RUN buttons simultaneously and No within 5 seconds for all stations Yes Go to First Downstroke Figurd 5 6 NOTE The arming sequence guards against accidently starting operation in continuous mode 12264 5 10 First Downstroke From figurd 5 5 Chapter 5 Voting Processor Firmware Figure 5 6 Operational Sequence for First Downstroke in Continuous Mode Go to Figurd 5 5 Select Continuous Mode Both voting processors A A energized their solenoid triacs for the first downstroke Has the shaft reached the No near bottom position lt Select inch mode and position the Y shaft near the top es n Has an operator released a Go to First Upstroke RUN button or has a barrier Figurd 57 No guard opened Yes Both voting processors de energize their solenoid triacs m gt to stop the shaft A stop condition mesage is displayed Stop Condition From figurd 5 7 Did the shaft coast into the near bottom zone while Yes CAUTION Releasing a RUN button braking late in the downstroke can damage the press Have 5 seconds elapsed since the solenoid tria
110. r all field wiring arm connections 6 2 Control Power E Stop Switches Seal Relays and Crowbar Relays Chapter 6 Field Wiring Arm Connections Connect your clutch brake controller to either an ungrounded AC power configuration Figurd 6 1 or a grounded AC power configuration Figure 6 5 Either figure shows two separately fused 120V AC power circuits Power lines 3L1 and 3L2 provide power to the field wiring arms at module group 3 slot 0 and module group 4 slot 0 in chassis A and B Power lines 2L1 and 2L2 provide power to all other field wiring arms the PLC power supply and chassis A and B power supplies Either AC power configuration lets your PLC clutch brake controller and inputs remain on after solenoid power has been disconnected as shown in Figurd 6 1 or Figure 6 5 Disconnecting solenoid power stops press operation Solenoid power is disconnected if an E Stop switch opens a seal relay trips or a crowbar relay turns on When solenoid power is disconnected both voting processors continue to run and generate diagnostic message codes Status indicators of input modules continue to show which switches are on or off Therefore either AC power configuration lets you more easily troubleshoot most problems that cause your press to shut down Important Be sure that your clutch brake controller is properly grounded to provide greater safety and reduced electrical noise interference For details refer to PLC Grounding p
111. red Downstroke Fault f RUN button in station 1 released too late in the downstroke 5 3 5 6 6 13 DENEN RUN button in station 1 released too late in the downstroke 5 3 5 66 13 Ll RUN button in station 1 released too late in the downstroke 5 35 66 13 7 28 Chapter 7 Troubleshooting diagnostic message codes are displayed by indicators connected to module group 5 slot 1 figure 6 18 or by displaying the corresponding data table word using the industrial terminal Use this table in conjunction with figurd 7 1 and figure references shown in parentheses Type of Message N Non latched L Latched T Trip Condition Binary 0110 0011 0110 0100 0110 0101 0110 0110 0110 0111 0110 1000 0110 1001 0110 1010 0110 1011 0110 1100 0110 1101 0110 1110 0110 1111 0111 0000 0111 0001 Hex Code P at Power up Alt Alternate chassis Ethr Either chassis Top Top chassis Bot Bottom chassis Type Code Diagnostic Message figure References t RUN button in station 1 released too late in the downstroke 5 3 5 6 6 13 PN Anti repeat cam switch open while awaiting start or restart of downstroke 6 11 Anti repeat cam switch open while awaiting start or restart of downstrokd 6 11 t Anti repeat cam switch open during downstrokg 6 11 Anti repeat cam switch open during downstroke 6 11 Upstroke Fault Run on cam switch opened too soon or anti repe
112. ress operation to continue 079 L MOTION DETECTOR SIGNAL DISAPPEARS AT NEAR Check for proper cam configuration and operation fig BOTTOM Check for proper motion detector feedback 07A MOTION DETECTOR SIGNAL DISPAPPEARS AT NEAR TOP The motion detector signal must come on by the time the brake monitor cam opens in the near bottom zone and must remain on to continue stroking This message will also occur when the press is in an upstroke and the motion detector signal disappears 07B T MOTION DETECTOR SIGNAL COMES ON WHILE PRESS IS Check for a faulty motion detector or a shorted wire STOPPED condition Check for proper clutch operation 07C MOTION DETECTOR SIGNAL REMAINS ON AFTER PRESS Check for a faulty motion detector or a shorted wire STOPS condition Check for proper clutch operation The motion detector signal needs to drop out within 4 seconds after clutch solenoid outputs are de energized 080 BRAKE MONITOR AND RUN ON CAM SWITCHES ARE BOTH Check for proper cam configuration and operation See fig CLOSED Check for a faulty cam limit switch 081 BRAKE MONITOR FOR THIS CHASSIS AND RUN ON CAM FOR THE OTHER CHASSIS BOTH CLOSED 082 BRAKE MONITOR FOR THE OTHER CHASSIS AND RUN ON CAM FOR THIS CHASSIS BOTH CLOSED 083 ALT BRAKE MONITOR AND RUN ON CAM SWITCHES ARE BOTH CLOSED There should not be any overlap of the brake monitor and run on cam switches at the near top position Chapter 7 Troubl
113. rocessor ea o cat no or Clear 1770 XT e Connector on 5 50 RS2 CN Remote I O Scanner PLC 5 250 CI c3 1771 WB Wiring Arm 1771 PM JU Module Chassis C Chassis B Blue Blue Blue 8 Shield Shield Shield Clear Clear c Clear JIS i 5 5 Q 5 S Blue i erminator S Remote shield cat no TS 1 0 Chassis Clear S 1770 XT am 1771 ASB I JS Adapter Q TO Module JS 1771 WB S IS Wiring Arm 1771 PM Module 128 3 5 Chapter 3 Clutch Brake Controller Hardware Multiple Clutch Brake Controllers Panel Switches and Operator Stations 3 6 Although this manual describes a single clutch brake controller you may connect your PLC to multiple controllers each controlling a separate press Each clutch brake controller uses two remote I O racks for chassis A and B For example since a PLC 3 controller can support as many as 32 I O racks you may connect it to as many as 15 clutch brake controllers with two additional I O racks for modules in chassis C You can operate your press using up to four operator stations and an optional control panel Installations vary according to the type of mechanical press and its application requirements The number of stations control switches contained in each and the control panel could be as follows Assembly Control Switches Notes Control Panel and or Station 1 Mode select Arm continuous Stop on t
114. roubleshooting PM modules detect operational and equipment faults and indicate corresponding diagnostic message codes for more than 250 detected conditions Diagnostic diagnostic message codes refer to specific inputs or outputs such as a contact on a switch or cam Upon detecting a condition each PM module generates its own diagnostic code Quick succession of events may cause each PM module to detect a different condition one condition resulting from the other PM modules generate three types of diagnostic message codes according to the severity of the condition Code Priority Method of reset N non latched least Clears itself when conditions no longer exist L latched moderate Correct the condition Press the RESET LATCHED MSG pushbutton L latched moderate Correct the condition followed by 0D Restore power Inch the press to near top position Push the RESET LATCHED MSG pushbutton Press the START button T tripped highest Correct the condition Press the RESET LATCHED MSG pushbutton Press the START button Non latched Messages lowest priority Non latched messages occur when the PM module detects an error condition while the press is idle clutch brake solenoids are OFF and the control seal relays are either open or closed The PM module prevents press operation as long as the error is present After you correct the error conditions the PM module automatically clears the message and readies itself for operation
115. rs We design manufacture and support a broad range Allen Bradley of automation products worldwide They include logic processors power and motion control devices operator interfaces sensors and a variety of software Rockwell is one of the worlds leading technology companies Worldwide representation Argentina e Australia e Austria e Bahrain e Belgium Brazil e Bulgaria e Canada Chile e China Colombia e Costa Rica Croatia e Cyprus e Czech Republic e Denmark Ecuador e Egypt El Salvador Finland France Germany Greece e Guatemala e Honduras e Hong Kong Hungary Iceland e India Indonesia e Ireland e Israel Italy e Jamaica Japan e Jordan Korea Kuwait e Lebanon e Malaysia e Mexico e Netherlands New Zealand e Norway Pakistan e Peru e Philippines e Poland e Portugal Puerto Rico Qatar e Romania Russia CIS e Saudi Arabia e Singapore Slovakia Slovenia e South Africa Republic e Spain e Sweden Switzerland Taiwan e Thailand Turkey e United Arab Emirates e United Kingdom United States Uruguay 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 1771 6 5 18 February 1992 PN 955111 35 Supersedes 1771 6 5 18 August 1986 Copyright 1992 Allen Bradley Company Inc Printed in USA
116. s A Chassis A IS I e 3L1 IS e 2 Q e 7 4 2 Q E 3 8 e IS 5 i 5 IS LRALRB LRAILRB 95 nd Don e S HA 242 Auxiliary a HS Valve Seal Relay Solenoids 312 312 B Main Valve B 2 Solenoids 2 5 z 4 Chassis B Chassis B 9 1 219 e e 16 3 i SL EY 516 3 5O TIS I L I 8 80 Crowbar Relay SK r7 B B 212 HS i e 2 fait O i Seal Relay NOTES Use this wiring with figurd 6 1 for ungrounded AC power e 1 1 LRA and LRB load resistors for triac feedback are 2K ohm 15 watt resistors 3 Each solenoid or relay coil should draw at least 60mA 3L1 3L2 3 Connect one MOV between 3L1 and 312 for electrical noise suppression s Connect one MOV to the 3L1 side of each solenoid load and to 3L2 for electrical noise suppression 5 If solenoid are not used replace with 2K ohm 15 watt resistors 6 14 17882 Chapter 6 Field Wiring Arm Connections Figure 6 4 Connections for Optional Dump and or Micro inch Valve Solenoids with MOV Surge Suppression Ungrounded AC Power
117. s are released the operator must press both RUN buttons at a station simultaneously and or operators at active stations must press all RUN buttons within five seconds of each other to start the press The same applies to the pair of INCH buttons Anti repeat Single stroke The press is limited to a single stroke even if the operator continues to press both RUN buttons The operator must release both RUN buttons and press them again to start press motion The same applies to a pair of INCH buttons as described for Single stroke Motion detector Single stroke The clutch brake controller detects press motion using your Continuous motion detector which provides a 120AC input signal This is a configurable option Top stop Check The clutch brake controller signals a worn or faulty brake by monitoring the Top stop check cam inputs Should it see the Top stop check cam closed after a normal cycle stop has been initiated and before the press comes to a top stop it prevents the press from restarting and energizes the brake fault output 4 16 Chapter Objectives Operation of Voting Processors Emergency Shut Down Voting Processor Firmware This chapter will help you become familiar with operation of your voting processor firmware operational sequences for controlling your press A clutch brake controller has two clutch brake modules one in chassis A and the other in chassis B Each clutch brake module contains firmwar
118. s needed to chassis A and B so voting processors can monitor any of the following inputs Input Terminal MG Slot Figure Main Valve Stem 0 2 62 Motion Detector 1 2 0 Air Pressure 2 2 0 Auxiliary Valve Stem 7 2 0 Micro inch Valve Stem 1 5 0 6 4 of 6 8 Micro inch Air Pressure 2 5 0 6 8 Dump Valve Stem 4 4 1 6 4 6 8 When connected these inputs function as follows OFF Triac Command ON 0 100ms aes i 0 100ms Triac Feedback i on 0 1 vl Valve Stem Feedback 5l ON OFF Q 510ms 8 Air Pressure Feedback 6 ON Wd OFF Motion Detector must turn ON before upstroke 7 8 before Top stop check cams turn OFF i T a OFF 1 Time window for faultless operation measured from Triac Command off to on transition 2 Time window for faultless operation measured from Triac Feedback off to on transition 3 Time window for faultless operation measured from Valve Stem feedback off to on transition 4 Time window for faultless operation measured from on to off transition of the Triac Command On to off transitions need not occur sequentially 5 Applies to Main Auxiliary Dump and Micro inch valves 6 Applies to Main Micro Inch Auxiliary and Dump if configured solenoids 7 Motion Detector transition off to on is position dependent on to off is time dependent 8 Applies to firmware revision A D and later For
119. s to solenoid valves when it detects stop conditions such as lost communications with the other PM module for 50ms lost communications with the PLC for one second cam limit switch signals out of sequence barrier guard opened during continuous mode This is described further in Chapter 7 Diagnostic Message Codes 5 2 Chapter 5 Voting Processor Firmware Operation of Cam Limit Switches PM Module uses cam limit switches to determine press slide position Figure 5 1 hna Table You set two independent cam limit switch assemblies to the same settings so that run on contacts are closed in the near bottom and upstroke zones top stop check contacts are closed in the downstroke and near bottom zones anti repeat contacts open during mid upstroke for at least 70ms Set the open span to the approximate number of rotational degrees 100 450 according to the speed of the press 1spm 100spm Up Stroke Span vs Press Speed for Anti Repeat Contacts SPM 100 90 80 70 Press 60 Speed 5o 40 30 20 10 150 30 45 Open Span During Up Stroke 12971 The anti repeat cam is not required while operating in inch or micro inch mode However before entering any operating mode the PM module checks that at least one cam limit switch is closed at any point in the cycle 5 3 Chapter 5 Voting Processor Firmware 5 4 Run On Near Top Position Near Bottom Zone Figure 5 1 Cam Limi
120. seconds for all stations Yes Has the shaft moved into its near top position Has an operator released a RUN button Yes Both voting processors de energize their solenoid triacs to stop the shaft in its near top position WARNING If the shaft coasted past its near top position while braking the brake is faulty and hazardous Repair it immediately Yes Start on the hop dos Go to figurd 5 3 NOTE The shaft continues automatically through its upstroke then stops If on the hop has been enabled operators can start another downstroke without stopping at the top Do this by releasing all RUN buttons after the downstroke Then press all RUN buttons after the anti repeat contacts open on the upstroke 12263 Chapter 5 Voting Processor Firmware Continuous Mode Select continuous mode when you want to run your press continuously Do this as follows inch the press to the near top position close the barrier guard s select continuous mode and press ARM CONTINUOUS button Figure 5 5 During the first downstroke Figure 5 6 releasing a RUN button or opening a barrier guard stops the press if the shaft did not enter the near bottom zone you may resume the downstroke within five seconds after a stop if the shaft entered the near bottom zone and is stopped you must inch the press to the near top position
121. so requires that once one button is pressed the other button needs to be pressed within 0 5 seconds to continue to operate without a problem Indication of change in the station active bypass state or no contact wiring AWAITING RELEASE OF BOTH INCH BUTTOns AWAITING RELEASE OF ARM CONTINUOUS BUTTON CONTINUOUS CYCLE NOT ARMED AWAITING PC TO INHIBIT STOP ON TOP SIGNAL AWAITING RELEASE OF ALL STOP ON TOP BUTTONS CORRECTIVE ACTION Check for proper wiring of station run buttons Check for proper operation of run button contacts You must press release and press again both INCH buttons before PM can allow further press motion After releasing the ARM CONTINUOUS button you have 5 seconds to press all RUN buttons before the PM can enter continuous mode You cannot enter continuous mode until you press the ARM CONTINUOUS button You must release it before pressing all RUN buttons within 5 seconds The PM module is still receiving the STOP ON TOP command It must cease before the PM can ente continuous mode Check your ladder logic gura 7 oaa You must release the STOP ON TOP buttons of all active stations before the PM can start any press motion resulting from pressing RUN buttons Chapter 7 Troubleshooting HEX TYPE PROBLEM CORRECTIVE ACTION CODE DOWNSTROKE MESSAGES ANTI REPEAT CAM SWITCH OPEN DURING DOWNSTROKE See Standard Corrective Action During downstroke and before the near bottom zone the
122. ss has traveled too far Code 73 means that the press was in the single stroke or continuous mode and now must be inched back to the near top position 074 MOTION DETECTOR SIGNAL IS LATE OR MISSING Check for the proper dip switch settings Check for proper 075 MOTION DETECTOR SIGNAL DISAPPEAR ON UP STROKE cam configuration and operation Check for proper motion detector feedback The motion detector input signal must come on by the time the brake monitor cam goes off This message will also occur when the press is in a up stroke and the motion detector signal disappears 076 MOTION DETECTOR SIGNAL DISAPPEARANCE DURING Check for proper cam configuration and operation see fig ON HOP DOWNSTROKE 5 1 Check for proper motion detector feedback A successful on hop operation was achieved and during the down stroke the motion detector signal was missing for a time period greater than 0 11 seconds 7 17 ET Clad Troubleshooting 7 18 BRAKE OR MOTION DETECTOR MESSAGES HEX PROBLEM CORRECTIVE ACTION CODE 077 MOTION DETECTOR SIGNAL DISAPPEARANCE ON 2ND Check for proper cam configuration and operation ig 5 1 DOWNSTROKE Check for proper motion detector feedback signal 078 MOTION DETECTOR SIGNAL DISAPPEARANCE DURING Requires stopping and existing continuous mode Inch to CONTINUOUS CYCLE near top zone to start next single continuous stroke Proper motion detection must be seen for p
123. ssis Chassis A A Station 3 left RUN NC contacts 1a1 00 10ab1 00 right RUN NC contacts 101 00 10 1 00 Station 3 right RUN NO contacts 1a1 01 10ab1 01 left RUN NO contacts 1b1 01 10ac1 01 2 Station 3 left Active 1a1 02 10ab1 02 right Active 1b1 02 10ac1 02 3 Station 4 left RUN NC contacts 1a1 03 10ab1 03 right RUN NC contacts 1b1 03 10ab1 03 4 Station 4 right RUN NO contacts 1 1 04 10ab1 04 left RUN NO contacts 1b1 04 10ac1 04 5 Station 4 left Active 1a1 05 right Active 1b1 05 10ab1 05 10ac1 05 6 Not Used Slot 1 1771 1A Figur 6 9 Addresses Function PLC 2 30 PLC 3 Chassis Chassis B A wu c Not Used 5 Top stop check Cam A NC limit switch 1a1 15 10ab1 15 Cam B NC limit switch 1b1 15 10ac1 15 6 Run on Cam A NC limit switch 1a1 16 10ab1 16 Cam B NC limit switch 1b1 16 10ac1 16 7 Anti Repeat Cam A NC limit switch 1a1 17 10ab1 17 Cam B NC limit switch 1b1 17 10ac1 17 A 3 Appendix A Bit Monitoring Address Module Group 2 Slot 0 1771 1A Figures 6 1 and 6 2 o 6 5 6 Addresses Function PLC 2 30 Chassis Input from Main Valve Stem NO Switch A 1a2 00 Switch B Input from Motion Detector NO Contacts A 1a2 01 Contacts B 2 Input from Air Pressure NO Switch A 1a2 02 Switch B Power Monitor Mod Grp 3 Slot 0 Chassis A 1a2 03 Chassis B Crowbar Test Input Crowbar A Crowbar B mm 1b2 00 1
124. stic Message figure References Code Press Operation Inhibited for oN Improper mode selection 6 12 All stations bypassed 6 13 thru 6 16 oN Shaft not near top Can not enter single or continuous mode 6 16 11 16 11 ELS Awaiting release of all RUN buttons for entering single or continuous 6 13 6 13 hru 6 16 Main motor forward dropout or absent 6 12 Anti repeat cam switch open preventing entry to single or continuous model Awaiting release of all STOP ON TOP buttons for entering continuous mode Awaiting release of ARM CONTINUOUS button for entering continuous mode stp Barrier guard dropout or absent 5 5 5 5 6 12 N PC enable dropout or absent CREA Stop on top signal from PC preventing entry to continuous mode 4 5 4 7 e Awaiting release of INCH buttons for entering inch mode Awaiting solenoid power to reset stop condition Press E STOP then START buttons CENE PC run mode dropout or absent Press interlock dropout or absent Station 1 Figure 6 13 KEES Check RUN button signals Make station active or bypassed N RUN button not released Check NO contacts 12Alt RUN button not released Check NO contacts 7 24 Chapter 7 Troubleshooting Diagnostic message codes are displayed by indicators connected to module group 5 slot 1 figure 6 18 or by displaying the corresponding data table word using the ind
125. t Switch Settings NOTE Top stop Install two mechanically independent cam limit switch assemblies each with three cams and three limit switches Set the assemblies to similar settings according to the requirements of your press You can set cam limit switches to other configurations provided they meet the make break conditions listed below nstroke Cam Linit Switch Settings Top Stop Anti Comments Zone Check Run ON Repeat Down MAKE BREAK Top stop check contacts must make not necessarily at the same time stroke before run on contacts make or the controller faults Near MAKE MAKE MAKE Run on contacts must make not necessarily at the same time Bottom before Top stop check contacts break or the controller faults Up BREAK MAKE MAKE Top stop check contacts must break not necessarily at the same time stroke before anti repeat contacts break or the controller faults BREAK MAKE BREAK Anti epeat contacts must break for at least 70ms during upstroke then make before run on contacts break or the controller faults BREAK MAKE Antitepeat contacts must make not necessarily at the same time before run on contacts break or the controller faults Near BREAK BREAK MAKE Run on contracts must break not necessarily at the same time Top before Top stop check contacts make or the controller faults Refer to Diagnostic Messages tabld 7 C Hex codes 80 thru AA
126. the near top zone the brake montior cam signal came on signaling instead a zone transition to downstroke 7 21 Chapter 7 Troubleshooting CAM LIMIT SWITCH TRANSITION TO NEAR TOP ZONE MESSAGES cont d HEX PROBLEM CORRECTIVE ACTION CODE 0A6 RUN ON CAM SWITCH BOUNCED OR MOTION REVERSED See Standard Corrective Action Also check for proper ALT CHASSIS clutch operation 0A7 During single stroke or continuous mode only forward motion is allowed The PM saw that it was in transition to the near top zone and then saw the run on cam input come back on possible showing reverse motion DIAGNOSTIC MESSAGES F1 L LOST COMMUNICATION BETWEEN 1771 PM MODULES Check rack communication cable Cycle rack power F2 LOST COMMUNICATION TO PROGRAMMABLE Check rack communication cable Check for proper rack CONTROLLER and scanner configuration Check for potential electrical noise problem Cycle rack power AA ALL CAM SWITCHES TURN OFF 1 Disconnected ground to 1771 IA module Disconnected power to CAM switches disconnected swingarm to 1771 IA bad 1771 IA module 2 Press Reset latched msg PB A8 EN CAM SWITCHES CANNOT DETECT SHAFT POSITION Same as AA except not a latched message code A9 IE ALL CAM SWITCHES ARE OFF NEVER DETECTED ON Same as A8 7 22 Complete Listing of diagnostic message codes Chapter 7 Troubleshooting The complete diagnostic message table is divided into sections and s
127. the problem relates to chassis B you can concentrate on the Right Active connection 5 To further isolate the problem place a bookmark at Figure 6 11 and return to Figure 7 3 The next question in this figure asks Does the problem relate to an input switch or connection In this example your answer is yes which leads you to another question Does the status indicator for the input to the 1771 IA module respond correctly See Figure 7 1 Figure 7 1 you where to find the input status indicators For this example assume that the input status indicator in chassis B for module group 0 slot 1 terminal 5 is off As shown in Figure 6 11 the Right Active connection is jumpered as long as Plug In Operator Station 2 is plugged in Therefore the indicator for Right Active should be on Return to NO TAG Since this indicator is off your answer is no to the question Does the input status indicator respond correctly NO TAG tells you to replace the input switch or check its wiring Correct the problem after first opening and locking the main power disconnect Inspect and test the Right Active connection Figure 6 11 For this example you find a broken wire in Plug In Operator Station 2 Repair the broken wire then close the main disconnect and return the press to normal operation 7 7 ET Clad Troubleshooting Display of Diagnostic Message When the PM module detects a condition it immediately generates t
128. tically through the upstroke If you enabled on the hop you can start another cycle without stopping the press if you release all RUN buttons after the near bottom position press all RUN buttons after the anti repeat contacts open during the upstroke Figure 5 3 Chapter 5 Voting Processor Firmware Operational Sequence for Downstroke in Single Mode Select single mode lt Y Y No Main Motor Forward I Yes No Y Is the shaft near the top Yes Y Have all operators released all RUN buttons Start on the hop downstroke From figure Yes Has each operator pressed his RUN buttons simultaneously and within 5 seconds for all stations No gt Select inch mode and position the shaft near the top A Yes Both voting processors energize their solenoid triacs to actuate the clutch for the downstroke Is the shaft past the near bottom zone No Yes Start upstroke Go to figurd 5 4 No Has an operator released a RUN button Y Yes Both voting processors de energize their solenoid triacs to stop the shaft A stop condition message is displayed Did the shaft coast into the near bottom zone while breaking y No No Have all operators released all RUN buttons Yes
129. ublication 1770 4 1 The E Stop circuit allows an operator or a voting processor to quickly stop the press Connect all E Stop switches and contacts in series with seal A and B contacts as shown in Figurd 6 1 or Figured 6 5 WARNING To guard against possible injury to personnel and damage to your press connect seal relays crowbar relays and operator station E Stop switches exactly as shown in Figure 6 1 and Figure 6 3 or Figure 6 5 and Figure 6 7 You may connect any number of additional E Stop switches and contacts in series with the mandatory operator station E Stop switches These can include but are not limited to remote E Stop switches air pressure switch contacts and relay contacts for monitoring the power supply 6 3 Chapter 6 Field Wiring Arm Connections Crowbar Test Inputs 6 4 Install at least one E Stop switch at each operator station Then any operator who sees a problem can press an E Stop switch to stop the press Also when either voting processor detects a fault it de energizes its seal relay to stop the press Opening any E Stop switch or de energizing either seal relay removes AC power 3L1 from main valve solenoids A and B auxiliary valve solenoids and B dump valve solenoids A and B crowbar relays A and B and seal relays A and B as shown in Figure 6 1 igure 6 3 hna Figure 6 4 br Figure 6 5 Figurd 6 7 pnd Figure 6 8 When either voting processor detects that 3L1 is off it immedi
130. ubsections common to a device operating condition or hardware condition to assist your troubleshooting When a diagnostic condition is detected and a message code is displayed look for the problem in the section subsection in which the message code is tabulated Table 7 D also refers you to figures and or tables to assist you in determining the cause of the fault condition We present a complete list of diagnostic message codes to assist in troubleshooting They are grouped as follows Press operation Stations 1 2 3 and 4 Inch button Valve stem inputs not configured Downstroke fault Upstroke fault Fault in setup for continuous mode Faulty brake or motion detector Faulty cam limit switch General faults Configuration error Motion detector and pressure switch faults Triac faults Fault in valve stem feedback Hardware or cable faults Micro inch diagnostic codes 7 23 ET Clad Troubleshooting Table 7 D Diagnostic Messages Diagnostic message codes are displayed by indicators connected to module group 5 slot 1 figure 6 18 or by displaying the corresponding data table word using the industrial terminal Use this table in conjunction with figurd 7 1 figure references shown in parentheses of Message Code N Non latched atPower up L Latched Alt Alternate chassis T Trip Ethr Either chassis Condition Top Top chassis Bot Bottom chassis Diagno
131. unications with PC Reset latched mesage check cables or cycle power Lost communications with PC Reset latched mesage check cables or cycle power 3 3 Lost communications between 1771 PM modules 2 Hardware fault in 1771 PM module Replace it PN Turn off backplane switch 1 3 4 Hardware fault in 1771 PM module Hardware fault in 1771 PM module 1771 PM modules must be same revision PN y Hardware fault in 1771 PM module Replace it 7 35 ET Clad Troubleshooting diagnostic message codes are displayed by indicators connected to module group 5 slot 1 figure 6 18 or by displaying the corresponding data table word using the industrial terminal Use this table in conjunction with figurd 7 1 and figure references shown in parentheses of Message Non latched Latched T Trip Condition 1111 1100 1111 1101 1111 1110 1111 1111 1 0101 1010 1 0101 1011 1 1011 1100 1 1011 1101 1 1011 1110 1 1011 1111 1 1100 0000 11100 0001 11100 0110 11100 0111 1 1100 1100 1 1100 1101 1 1101 0010 1 1101 0011 7 36 Code P at Power up Alt Alternate chassis Ethr Either chassis Top Top chassis Bot Bottom chassis Diagnostic Message figure References Backplane error Replace chassis 2 EE Hardware fault in 1771 PM module Hardware fault in 1771 PM module a Power up other 1771 PM module Micro inch Diagnostic Codes Examine modu
132. until an operator presses a STOP ON TOP button the PLC transfers a stop on top command or barrier guard opens WARNING If the shaft coasts past its near top position while braking the brake is faulty and hazardous Repair it immediately 12267 5 13 Chapter Objectives Installation Considerations Electrical Connections and Safety Requirements Connections to Field Wiring Arms This chapter will help you Connect the field wiring arms of chassis and B install either ungrounded or grounded 120V AC power distribution Before continuing be sure that you configured your clutch brake controller chassis and modules as shown in chapter 3 For installation details refer to the installation publication for your processor These publications are listed in our Publications Index publication SD499 In order to design build install and operate a safe press system you should also refer to other publications In addition to local codes and laws adhere to safety requirements detailed in the following publications OSHA Regulations Title 29 Labor Chapter XVII Section 1910 217 Mechanical Power Presses ANSI B11 1 American National Standard for Machine Tools Mechanical Power Presses Construction Care and Use NFPA No 79 Electrical Standard for Metalworking Machine Tools Some electrical connections are mandatory others are optional If you omit mandatory connections or electrical components
133. up Tabld 7 C explains message codes generated by PM modules For each message code the table states type of diagnostic message the problem causing the diagnostice message to be displayed recommended corrective action In Table e use mnemonics for cam switches for the sake of brevity as follows ACAM anti repeat cam switch RCAM run on cam switch TCAM sto top check cam switch 7 13 ET Clad Troubleshooting 7 14 Table 7 C Diagnostic Message Codes Associated with the 0D Message Code MISCELLANEOUS MESSAGES 02 03 04 05 06 07 08 09 TYPE PROBLEM IMPROPER MODE SELECTION The PM module expects to see one of the allowable press modes off inch micro inch single continuous within 0 1 sec s after swingarm power is sealed in and will only allow one mode at any given time ALL STATIONS BYPASSED In the single stroke or continuous mode the PM will not allow the press to cycle if all operator run stations are bypassed At least one station must be present Inch and micro inch modes will operate with all run stations bypassed SHAFT NOT AT TOP CAN NOT ENTER SINGLE OR CONTINUOUS MODE The PM is selected to go into the single or continuous mode but the cam switches which indicate shaft position are telling the PM that the press is not at the top AWAITING RELEASE OF ALL RUN BUTTONS FOR ENTERING SINGLE OR CONTINUOUS MODES MAIN MOTOR FORWARD CONTACT DROPOUT OR ABSEN
134. ustrial terminal Use this table in conjunction with figurd 7 1 and figure references shown in parentheses of Message Code N Non latched at Power up L Latched Alt Alternate chassis T Trip Ethr Either chassis Condition Top Top chassis Bot Bottom chassis Diagnostic Message figure References Code S D nen a nem M MN Make left and right active connections identical I C IU MM Active input changed from closed to open Check wiring NC RUN button bypass is open Check wiring fe T mme e cmm De qme 7 Statio m ornans essei 21 RUN button not released Check NO contacts rites Oca 000000000 LMENLILLL mm r re em 00000000000 eem NC RUN button is open Check button or wiring ERE NO RUN button is shorted Check button or wiring 7 25 ET Clad Troubleshooting Diagnostic message codes are displayed by indicators connected to module group 5 slot 1 figure 6 18 or by displaying the corresponding data table word using the industrial terminal Use this table in conjunction with figure 7 1 figure references shown in parentheses Type of Message Code N Non latched at Power up L Latched Alt Alternate chassis T Trip Ethr Either chassis Condition Top Top chassis Bot Bottom chassis Code m T tities dors _ NC RUN
135. w to safely troubleshoot your press system This chapter showed you how to interpret the diagnostic diagnostic message codes and status indicators of your clutch brake controller It also referred you to the associated connection diagrams for locating the fault Diagnostic diagnostic message codes in Table 7 C 7 37 ET Clad Troubleshooting Diagnostic message codes are displayed by indicators connected to module group 5 slot 1 figure 6 18 or by displaying the corresponding data table word using the industrial terminal Use this table in conjunction with figurd 7 1 and figure references shown in parentheses Type of Message Code N Non latched P at Power up L Latched Alt Alternate chassis T Trip Condition Ethr Either chassis Top Top chassis Bot Bottom chassis Diagnostic Message figure References Other Cam Limit Switch Faults Figure 5 1 6 11 DW T eons eet ston uem _ 1010 1001 P All cam switches are open 1 ranen 1010 1011 AB N amp L waren Caserta 1010 1101 AD N Awaiting turn off of crowbar relay test I M NN WW p qememewme 000 Configuration Error 1011 0000 Alt Configuration error in alternate module Configure it correctly or match inputs to your configuration 1011 0001 PN y Turn off backplane switch 1 1011 0010 ENT Stations 3 and 4 configuration bitr and backplane switch mismatched 1011 0011 PN y Motion detector configuration bit and backplan switch mismatched

1771-6.5.18, Clutch/Brake Module, User Manual

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