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6556?.5.1

1. 20 219 210 1771 1771 0016 45 Ra ele 8 8 100 77 10 2 o 10118 n 1218 121 12112 MEE gt 14 1612 1612 16 2 2 S TI 1812 S 20 20 262 210 22 22 SO 26 26 2610 oes 28 221281241 2819 QHA sr el S 32 32 32 2 8 36 JO m 86 36 gt Moe SA 40 ES 140 I0 S 00
2. 06 48 1771 0016 120VAC ISOLATED INPUT E RACK A00 105L1 10512 MODULE GROUP 3 RIGHT RUN STATION 1 702PB T 105L1 07 02 2 120 INPUTO 41 9930 RIGHT RUN STATION 1 N O 702PB ok 05 Q 07 03 4 12 1 INPUT1 gL 90301 RUN STATION 1 BUTTON N C 703 LEFT RUN STATION 1 703PB ED 105L2 j STATION 1 ACTIVE PIN 07 04 12 2 INPUT2 5 Al 003 02 OS b RIGHT RUN STATION 2 N O 705PB 07 05 4 8 12 3 INPUTS 7 2 003 03 l STATION 1 ACTIVE f 07 06 d NOTUSED 5 RIGHT RUN STATION 2 705PB Al 003 04 LEFT RUN STATION 2 BUTTON N C 707PB iba 07 07 12 12 4 INPUT 4 14 STATION 2 ACTIVE PIN LEFT RUN STATION 2 707PB 07 08 412 5 INPUTS 13 2 003 05 SS OX gt i RIGHT RUN STATION 3 N O 709PB 07 09 id 12 6 12929996 LEFT RUN STATION 3 BUTTON N C 710PB D C STATION 2 ACTIVE f 07 10 18 12 7 17 40030 53 RIGHT RUN STATION 3 709 07 11 2 NOTUSED 19 d lt lt Q 003 10 STATION 3 PIN 012 22 12 10 INPUT 10 21 LEFT RUN STATION 3 710PB RIGHT RUN STATION 4 N O 713PB OS
3. Figure 3 20 Delete Valve stem Feedback for Clutch Auxiliary and or Micro inch Valves Module Group 4 RACK A00 RACK MODULE GROUP 4 MODULE GROUP 4 INPUTO 1 MICRO INCH 1 FEEDBACK Reserved Do Not Use Reserved Do Not Use MICRO INCH 1 FEEDBACK 11 INPUT 0 INPUT 1 3 MICRO INCH 2 FEEDBACK Reserved Do Not Use Reserved Do Not Use MICRO INCH 2 FEEDBACK 3 INPUT 1 INPUT 2 5 VALVE STEMCLUTCH1 Reserved Do Not Use Reserved Do Not Use VALVE STEM CLUTCH1 15 INPUT 2 INPUT 7 VALVE STEM CLUTCH Reserved Do Not Use Reserved Do Not Use VALVE STEM CLUTCH 2 7 INPUT NOT USED 9 9 NOT USED INPUT 4 11 VALVE STEM AUX 1 Reserved Do Not Use Reserved Do Not Use VALVE STEMAUX1 11 INPUT 4 INPUT 5 INPUT 5 13 VALVE STEM AUX 2 Reserved Do Not Use Reserved Do Not Use VALVE STEMAUX2 13 Figure 3 21 Delete Unused Selector Switch Positions Module Group 4 RACK 00 RACK 800 MODULE GROUP 4 MODULE GROUP 4 MODE SEL SW 809SS DIE CONTINUOUS SINGLE INCH OFF OFF INCH SINGLE CONTINUOUS MODE SELECTOR SWTCH 809SS INPUT 6 5 004 06 sf A ME SR FROM 08 17 004 06 5 INPUT 6 1 f d pa d p 7 2 004 07 sh 11 x s 8 004 07 7
4. 09 01 RACK A00 08 24 08 08 V MODULE GROUP 5 52 10811 115 AO 005 105L2 09 02 2 L1 0 OUTPUT 0 1 005 000 gt 06 32 CLUTCH 1 VALVE 005 01 09 03 4 Li 1 ourPur 43 005 0 gt TO 06 33 CLUTCH 2 VALVE 09 04 6 11 2 ouTPUT2 5 RESERVED DO NOT USE 09 05 11 3 OUTPUT3 7 RESERVED NOT USE 09 06 10 NOTUSED 9 09 07 4 12 1 40 11 50086 gt 06 29 AUXILIARY VALVE 1 09 08 L1 5 output 5 fyah 9 005 05 5 06 31 AUXILIARY VALVE 2 09 09 6 11 6 OUTPUT6 15 RESERVED DO NOT USE 09 10 8 1 7 OUTPUT7 i7 RESERVED DO NOT USE 09 11 20 NOT USED 19 AO 09 12 422 L1 10 OUTPUT 10 21 2005 10 08 26 MICRO INCH 1 aal AO 7 09 13 24 Li M OUTPUT 11723 910051 5 1008 27 MICRO INCH 2 09 14 26 11 12 OUTPUT 12 25 RESERVED DO NOT USE 09 15 28 11 13 OUTPUT 13 27 RESERVED DO NOT USE 30 NOT USED 29 09 16 gt 01 15 06 10 __ TE CONTROLLER OK 917CR 09 17 4132 Li 14 OUTPUT 14 31 2 CROW BAR RELAY 918CR 09 18 11 15 OUTPUT 15 33 0 005 5 e SEAL RELAY 919CR 09 19 Hae 1 16 OUTPUT 16 5 0008 16 5 09 20 38 11 17 OUTPUT 17 37 09 21 40 NOT USED 39 09 22 108L1 09 23 v 09 25 09 24
5. RACK A00 Pr MODULE GROUP 5 AO 2 11 0 OUTPUT 0 1 ae TO 06 32 CLUTCH 1 VALVE 005 01 q4 11 1 OUTPUT 1 3 TO 06 33 CLUTCH 2 VALVE CLUTCH 1 904SOL 6 11 2 OUTPUT 2 5 40 005 02 oN o CLUTCH 2 905510 8 11 3 output 7 0 005 03 oN o lad NOT USED 9 AO 4 id 1 4 OUTPUT 4 11 9 00 06 29 AUXILIARY VALVE 1 AO 14 L1 5 OUTPUT 5 13 005 05 06 31 AUXILIARY VALVE 2 AUXILIARY VALVE 1 909SOL OPTIONAL 18 L1 6 OUTPUT 6 15 9 005 06 o AUXILIARY VALVE 2 910SOL OPTIONAL 18 11 7 OUTPUT 7 17 9 005 07 a 20 USED 19 Ex 005 1 22 L1 10 OUTPUT 10 21 gt 008 26 MICRO INCH 1 lt 005 11 24 11 11 OUTPUT 11 23 gt 1008 27 MICRO INCH 2 MICRO INCH 1 914SOL OPTIONAL 26 11 12 OUTPUT 12 253 99 M Si MICRO INCH 2 915SOL OPTIONAL 28 L1 13 OUTPUT 13 27 40 005 13 30 NOT USED 29 be Lo CONTROLLER OK 917CR 32 11 14 OUTPUT 14 1 9 005 14 oo 01715 CROW BAR RELAY 918CR 06 10 L pi Mw a4 Lt 15 OUTPUT 15 33 59 09915 SEAL RELAY 919CR Hae 11 16 OUTPUT 16 35 PO 005 16 88 11 17 OUTPUT 17 37 40 NOT USED 39 Publication 6556 6 5 1 October 1996 ALL 120 VAC WIRES ARE 16 AWG RED UNLESS MARKED OTHERWISE
6. Always OFF Always OFF Bottom View of PLC 5 46 Processor in Chassis A Install and Wire the Clutch Brake Control System Leave the serial port configuration for channel 0 at default for RS 232C with SW2 Figure 6 2 unless your application requires RS 422A or RS 423 Figure 6 2 Serial port Setting with SW2 DOOQOOOOOOO 00000905 OOO HBBBEHHBEH Switch Side View Always OFF aile all Te 1 2 3 4 5 7 8 9 10 Cb ll 1 2 3 4 5 7 8 9 10 1 2 3 4 5 6 7 8 9 10 Same setting for both Default RS 232C Same setting for both RS 422A Same setting for both RS 423 Bottom View of PLC 5 26 Processor in Chassis B Front of Frontof 5 Processor Processor q mm OOO 4 Always OFF 1 2 3 4 5 6 7 8 9 10 Pr 1 2 3 4 5 6 7 8 9 10 mulu Iul aL 1 2 3 4 5 6 7 8 9 10 Publication 6556 6 5 1 October 1996 Install and Wire the Clutch Brake Control System Jumper a
7. NSD VRE P062 Converter Resolver NSD 3P RPT Eis E Cable 1771 IBD Input Module in Module Group 0 4 Repeat step 3 if using dual resolvers 5 Forone or both I O chassis with a resolver input remove RCLSs from circuit wiring by jumpering RCLS inputs to respective power rails For instructions to do this refer to wiring customization instructions Module Group 2 sheet 2 in chapter 3 of this manual 6 Study the RCLS operation shown in Figure 7 1 and Table 7 B You will need to simulate RCLS operation with ladder logic We show you how in the next section Ladder Logic to Simulate If using resolver inputs you must program all three of the following Rotary Cam Limit command bits to simulate rotary cam limit switches shown in Figure 7 1 Switches Bit ON OFF States BCAM B151 00 ON in downstroke OFF in all other zones TCAM B151 01 ON in upstroke and ACAM open zone OFF in all other zones ACAM B151 02 ON in all zones except ACAM open zone OFF in ACAM open zone for at least 75 ms Publication 6556 6 5 1 October 1996 7 6 Set Up or Simulate Rotary Cam Limit Switches Publication 6556 6 5 1 October 1996 We present ladder logic to simulate rotary cam limit switches Figure 7 5 Use software bits TCAM B151 00 BCAM B151 01 and ACAM B151 02 to simulate hardware cams when using resolver or encoder inputs We assume t
8. Rung 9 18 Off Mode Last Confirmed Brake Time B160 CLR 1201 CLEAR 16 Dest N91 1 0 45 n Last Brake Angle CLR Dest N91 3 0 Rung 9 19 Last Brake Time Brake Time Monitor Fault GEQ N91 2 GRTR THAN OR EQUAL Source A 91 1 0 0 Source B 91 20 500 End Publication 6556 6 5 1 October 1996 4 28 Programming Write Ladder Logic Variable speed Top Stop Publication 6556 6 5 1 October 1996 The purpose of the variable speed top stop program is to make the press stop at the top when commanded regardless of press speed Requirements of this program are the following You must use a resolver as a position monitoring device Your program must simulate the action of rotary cam limit switches Your program should adjust the TCAM setting only during downstroke Shifting the TCAM in any other zone of the press cycle may trigger a software cam transition fault In the following example program Figure 4 28 N123 36 holds the press speed which is buffered once per stroke at 90 The LES and GTR instructions in the TCAM rung are used for backing the TCAM OFF position from 340 to 300 for increasing press speeds of 10 to 26 SPM Figure 4 28 Example Program for a Variable speed Top Stop SBR
9. stroking regardless of releasing Run buttons Have you pressed a Stop on top button Y The stroke continues until the Has the PLC received a 68 press reaches the top Stop on top command No Is the press in the No Has a stop condition near top position been detected Yes Yes i WARNING If the press coasts Both processors de energize _ past the near top position while Both processors de energize their outputs to stop the press braking the brake is faulty and outputs to stop the press in the near top position hazardous Repair it immediately NOTE The press strokes continuously until you press a Stop on top button the PLC processor receives a stop on top command or a stop condition is detected Publication 6556 6 5 1 October 1996 Timing Diagrams for Control System Feedback Appendix B Feedback Timing Diagrams We define the controller s feedback response time for these signals triac and valve stem feedback where valve stem feedback pertains to main auxiliary and or micro inch valves with external fault detection motion detector feedback When PLC 5 x6 processors command triacs ON or OFF they check that feedback signals triac valve stem and motion detector have turned ON or OFF in the order shown and within the times shown Has a turn on time measured and a turn off time measured from off to on tran
10. Jumper and Switch Settings for Chassis and B Keying the Backplane 1771 1016 Input Modules Install PLC Processors 1 0 Modules and Power Supplies Connect PLC Processors and Programming Terminal Convert Controller OK Relay Contacts from N O to Wire Your Control System iv Table of Contents Set Up or Simulate Rotary Cam Limit Switches Chapter Setting Up Position Monitoring Devices Setup If Using Rotary Cam Limit Switches omit if using only resolvers Setup If Using Resolvers omit if using only RCLSs Ladder Logic to Simulate Rotary Cam Limit Switches How Bits Indicate Shaft Position How Transition Faults Stop the Press Troubleshoot the Setup of Your Position Monitoring Devices Lp Test Your Clutch Brake Control System Chapter Static Wiring Tests Controller Test CRM Relay Test et Seal Relay Test Crowbar Relay Test If using crowbar relays Test Ru
11. Rung 9 8 First Scan Last Bit Brake Time Seal CLR B CLEAR 15 Dest 91 1 0 Last Brake Angle FLL NS FILL FILE Source 0 Dest N91 3 Length 5 Rung 9 9 C B Dual Valves Looking For Engaged Zero Speed B160 B90 mE TEE x L 170 32 Rung 9 10 Looking For C B Dual Valves Zero Speed Engaged B90 B160 B90 RAE equ T T z GP 32 170 34 Clutch Feedback 1 6 0 Rung 9 11 Get the Speed and Angle B90 1 001 34 Publication 6556 6 5 1 October 1996 4 24 Write Ladder Logic Rung 9 12 Starting Brake Angle B90 B90 MOV 1 OSR 34 33 Source TX Dest N91 Final Brake Angle MOV MOVE Source Tes 1 0 Dest N91 5 0 Brake Time STI Count CLR b 4 Dest N91 6 0 o Angle Change STI Count 4 C Dest N91 7 Rung 9 13 Brake Time STI Count B90 ADD I 34 Source 91 Source Dest N91 6 No Angle Change STI Count ADD 1 Source A N91 7 Source B 1 Dest N91 7 Publication 6556 6 5 1 October 1996 Write Ladder Logic 4 25 Rung 9 14 Resolver A
12. 09 01 RACK A00 MODULE GROUP 2 TAKEOVER LIMIT 60215 10801 2 12 0 INPUT of 1 Al 002 00 ANTIREPEAT CAM LIMIT SW 60315 4 12 1 INPUT 173 A 002 01 4 BRAKE MONITOR CAM LIMIT SW 60415 6 12 2 INPUT 2 5 _ 002 02 a o 4 ssl qus Inpur 7 80 00504 AUXILIARY VALVE 1 FEEDBACK 3 19 NOT USED 9 lf 12 4 INPUT 4 51 0 005 05 AUXILIARY VALVE 2 FEEDBACK lt og 3p 2 125 INPUT s 13 80 05 00 CLUTCH 1 FEEDBACK jme Ja 12 6 INPUT 6 1g BO 005 01 CLUTCH 2 FEEDBACK pus E SEAL RELAY A 918CR 2 18 12 7 INPUTZ 47 Al 002 07 gt bo 20 NOT USED 9 CLUTCH BRAKE POWER RESET NO 117 oa 12 10 INPUT 10 21 002 10 t 5 4 gt 06 36 s 115 CLUTCH BRAKE POWER FEEDBACK 12 12 INPUT 12 25 119A CROWBAR RELAY A FEEDBACK CRMA 113CR 28 12 13 INPUT 13 27 _ 00273 of Lo 4 30 NOT USED 29 laj a INPUT 14 5 112A CRM POWER FEEDBACK rer CLUTCH BRAKE AIR PRESSURE 34 12 15 INPUT 15 33 Al 002 15 7 06 42 MAIN MOTOR FORWARD dae 12 16 INPUT 16 35 Al 002 16 o Lo MOTION DETECTOR faa 12 17 INPUT 17 37 Al 002 17 H Fo 4 40 NOT USED a9 108L1 Publication 6556 6 5 1 October 1996 07 01 Wiring Drawings for a Gr
13. S0c ii Software Revision 11 soc ii Using This P 1 Information in the Appendices P 2 Concerning Rockwell Programming Software P 2 Overview of the Clutch Brake Control System 1 1 Manual Objectives P 1 Qualifications for Applying this P 1 Summary of Installation Tasks P 1 We ve Simplified Your Wiring Documentation 2 Terms and Abbreviations P 3 Chapter Objectives 1 1 The Application Package 1 1 Software and Documentation 41 1 Typical Hardware for the cat no 6556 Application Package 1 2 Related Safety Information 1 2 Control by Redundant Processors 1 3 How the Software Controls Your Press 1 4 Organization of Program Files 1 4 Scanning Program Files 1 4 Protected Memory in PLC 5 x6 Processors 1 6 Passwords and Levels of Memory Protection 1 6 Functional Block Diagram 1 7 Modes of Control System operation 1 7 Clutch B
14. TA c do BI An NOT USED 19 ot ot Hoch Gt if 19 NOT USED 1 1 1 1 NPUT 10 Al 004 10 sik 4 it 1 Bsr 8 004 0 5 1 004 11 A 1 4 41 pt BEAT 5 1 1 V 3 1 1 12 25 Reserved Do Not Use 4754 tig 1 1 5 3 Reserved Do Not Use 25 INPUT 12 1 1 13 27 Reserved Do 519 E be HH ie rat gt D re Reserved Do Not Use 27 INPUT 13 1 1 1 NOT USED 29 Br d RENE lk dp od 29 NOT USED 1 1 it 1 1 INPUT 14 3 Al 004 14 s A 1 004 14 a NPUT 14 L TO 08 33 LL 108L1 Publication 6556 6 5 1 October 1996 3 18 Customize the Wiring I O Module Group 5 sheet 9 of 9 Grounded AC Power For this modification Use Valves With Internal Fault Detection Delete Auxiliary Valve Outputs Delete Micro inch Valve Outputs Delete Crowbar Relay Outputs Clutch 1 and 2 Outputs Controller OK Seal Relay Make these changes No change to output wiring in I O group 5 Important Write ladder logic to reset bit B151 20 Auxiliary Valve Stems Enabled Write ladder logic to reset bit B151 21 C B Valve Stems E
15. 105L2 07 01 DWG NO 40001797 0 SHEET 6 9 06 25 06 26 06 27 06 28 06 29 06 30 06 31 06 32 06 33 06 34 06 35 06 36 06 37 06 38 06 39 06 40 06 41 06 42 06 43 06 44 06 45 06 46 06 47 06 48 DATE 05 26 95 Publication 6556 6 5 1 October 1996 H 6 Wiring Drawings for a Grounded System 06 48 06 24 1771 0016 120VAC ISOLATED INPUT v RACK A00 10512 MODULE GROUP 3 RIGHT RUN STATION 1 702PB 10811 07 02 2 L20 INPUT o q 003 00 RIGHT RUN STATION 1 N O 702 E 07 03 121 inpur 1pg _Al 008 01__ LEFT RUN STATION 1 BUTTON N C 703PB LEFT RUN STATION 1 703PB L STATION 1 ACTIVE PIN 07 04 fg 12 2 npuT 2 5 A0802 A b gal RIGHT RUN STATION 2 N O 705PB S ET 07 05 a 123 input 3 7 4009 03 l STATION 1 ACTIVE c 07 06 id NOTUSED 5 RIGHT RUN STATION 2 705PB LEFT RUN STATION 2 BUTTON 707 07 07 99 124 114100304 a ses 4 E STATION 2 ACTIVE PIN LEF
16. Allen Bradley Clutch Brake Control System PLC 5 Series Cat No 6556 Pxxxx ClutchBrake Design Manual Important User Information Because of the variety of uses for the products described in this publication those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements including any applicable laws regulations codes and standards The illustrations charts sample programs and layout examples shown in this guide are intended solely for purposes of example Since there are many variables and requirements associated with any particular installation Allen Bradley does not assume responsibility or liability to include intellectual property liability for actual use based upon the examples shown in this publication Allen Bradley publication SGI 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control available from your local Allen Bradley office describes some important differences between solid state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication Reproduction of the contents of this copyrighted publication in whole or in part without written permission of Allen Bradley Company Inc is prohibite
17. Hm 1771 1771 1771 1016 Publication 6556 6 5 1 October 1996 6 6 Install and Wire the Clutch Brake Control System We suggest that you use slots 0 and 1 for low level dc input modules such as a resolver input module This helps segregate dc and ac signals Figure 6 5 Module Locations in Chassis B 0 1 2 3 4 5 7 H H PLC 5 26 2 g T 514 m 1771 212 g2 gj 0016 P4S
18. Low Limit 5 01 Test N155 0 High Limit 190 LIM L LIMIT TEST CIR 4 Low Limit 10 Test N155 0 High Limit 185 ACam LIM H B151 LIMIT TEST CIR Low Limit 275 02 Test N155 0 High Limit 240 LIM L LIMIT TEST CIR 4 Low Limit 280 Test N155 0 High Limit 235 Publication 6556 6 5 1 October 1996 7 8 Set Up or Simulate Rotary Cam Limit Switches How Bits Indicate Shaft Position Publication 6556 6 5 1 October 1996 The software sets bits to indicate which of six zones the shaft is rotating through during a press stroke Important The software reads these zones according to the on off positions of ACAM BCAM and TCAM switches that you set Figure 7 1 mechanically for hardware switches or that the software reads from resolver inputs if using resolvers to simulate your RCLSs The zones and corresponding indicator bits in bit file B160 are shown in the following table and in Figure 7 7 While the shaft is in this zone The software sets this bit Top B160 60 Downstroke 61 Near Bottom 59 First Upstroke 62 ACAM Open 64 Second Upstroke 63 Figure 7 7 Zones of Rotation That Indicate Shaft Position During a Press Stroke and Corresponding Indicator Bits Example indicator bit 315 09 909 Upstroke Near bottom Zone 1809 Read these bits in your ladder logic to indicate shaft position How Transition Faults Stop the Press BCAM
19. Publication 6556 6 5 1 October 1996 Wiring Drawings for a Grounded System H 11 1771 OD16 120VAC ISOLATED OUTPUT RACK 00 09 23 09 25 MODULE GROUP 5 Y BO 005 00 CLUTCH 1 925501 105L2 2 L1 0 OUTPUT 0 4 O NO 09 26 y LUTCH 1 VALVE BO ODE _ cLUTC CLUTCH 2 926S0L 4 11 1 OUTPUT 1 3 4 09 27 gt 06 09 CLUTCH 2 VALVE 6 11 2 ouTPUT 2 5 RESERVED DO NOT USE 09 28 3 11 3 OUTPUT 3 7 RESERVED DO NOT USE 09 29 0 NOT USED 9 09 30 Seca AUXILIARY VALVE 1 931801 OPTIONAL 12 1 4 OUTPUT 4 11 09 31 x 21 1006 05 AUXILIARY VALVE 1 AUXILIARY VALVE 2 932501 OPTIONAL 14 L1 5 OUTPUT 5 13 ONG e 09 32 gt 06 07 AUXILIARY VALVE 2 16 11 6 OUTPUT 6 15 RESERVED DO NOT USE 09 33 18 11 7 OUTPUT 7 17 RESERVED DO NOT USE 09 34 20 NOT USED 19 09 35 BOUE MICRO INCH 1 936801 OPTIONAL 22 11 10 OUTPUT 10 21 lt 09 36 bon gt 08 02 MICRO INCH 1 MICRO INCH 2 937801 OPTIONAL 24 11 11 OUTPUT 11 23 09 37 gt To 08 03 MICRO INCH 2 26 11 12 OUTPUT 12 25 RESERVED DO USE 09 38 28 Li 13 OUTPUT 13 27 RESERVED
20. DO NOT USE 09 39 USED 29 09 40 CONTROLLER OK 941CR i 01 15 sj ia 809094 0941 CROW BAR RELAY 942CR P 01 21 5 34 11 15 OUTPUT 15 33 890055 C cp SEAL RELAY 943CR 1 15 06 34 36 11 16 16 35 80 005 16 o Jo 0715 06 34 5 58 45 38 1 17 OUTPUT 17 37 09 44 40 NOT USED 39 09 45 09 46 09 47 09 48 GROUNDED SYSTEM WIRING RACK A00 GROUP 5 RACK B00 GROUP 5 CUST DWN TLD DATE 05 26 95 DWG NO DWG REV 40001797 0 9 9 Publication 6556 6 5 1 October 1996 12 Wiring Drawings for Grounded System Notes Publication 6556 6 5 1 October 1996 6 Rockwell Automation Allen Bradley a Rockwell Automation Business has been helping its customers improve productivity and quality for more than 90 years We design manufacture and support a broad Allen Bradley range of automation products worldwide They include logic processors power and motion control devices operator interfaces sensors and a variety of software Rockwell is one of the world s leading technology companies Worldwide representation PE dae Lp A __ M Argentina e Australia e Austria e Bahrain Belgium Brazil e Bulgaria e Canada Chile e China PRC Colombia Costa Rica Croatia e Cyprus Czech Republic
21. Figure 3 22 Customize the Wiring 3 19 Delete Auxiliary Valve Outputs Module Group 5 12 Figure 3 23 Lt 4 Li 5 RACK 800 MODULE GROUP 5 OUTPUT 4 OUTPUT 5 1 13 AUX VALVE 1 Reserved Do Not Use AUX VALVE 2 Reserved Do Not Use Delete Micro inch Valve Outputs Module Group 5 Figure 3 24 Lt 10 RACK 800 MODULE GROUP 5 OUTPUT 10 OUTPUT 11 el 23 MICRO INCH 1 Reserved Do Not Use MICRO INCH 2 Reserved Do Not Use Delete Crowbar Relay Outputs Module Group 5 U 15 RACK B00 MODULE GROUP 5 OUTPUT 15 33 CROW BAR RELAY 942CR Reserved Do Not Use Publication 6556 6 5 1 October 1996 3 20 Customize the Wiring Notes Publication 6556 6 5 1 October 1996 Chapter Objectives Overview of Memory Organization Chapter 4 Write Ladder Logic To help you write ladder logic to customize the operation of your clutch brake control system we present the following information overview of memory organization for processors A and e data files reserved for control system data how command bits act on control logic in protected memory e select from these command bits steps to write ladder logic programming command bits using fault and prompt bits exchanging data between processors with the scanner adapter channel programming shorter prese
22. Publication 6556 6 5 1 October 1996 Wiring Drawings for a Grounded System H 7 771 1016 120VAC ISOLATED INPUT 2724 IM RACK B00 MODULE GROUP 3 10512 LEFT RUN STATION amp 1N 0 703PB BIOOSO0 F WweuTo L20 z 4 07 26 RIGHT RUN STATION 1 BUTTON N C 702PB__BI 003 01 5 44 07 27 STATION 1 ACTIVE PIN p 003 02 5 wwpure 12 2 6 07 28 LEFT RUN STATION 2 N O 707PB D 8100303 7 12 3 8 07 29 9 NOTUSED 10 07 30 RIGHT RUN STATION 2 BUTTON 705PB 8 003 04 1741 INPUT4 12 4 125 oral STATION 2 ACTIVE PIN 003005 iwpUTS 12 5 4 07 32 LEFT RUN STATION 3 N O 710PB 8003 06 fF 6 12 6 18 07 33 RIGHT RUN STATION 3 BUTTON N C 709PB 00307 7 12 7 18 07 34 19 NOTUSED 20 Ds TATION 3 ACTIVE PIN STATION 3 Al 003 10 gt NPpUT10 12 10 021 07 36 LEFT RUN STATION 4 714 UN STATIO BEOOSM 53 INpUT 4 L2 tfza 4 07 37 RIGHT RUN STATION 4 BUTTON 713 _ 00312 56 iNpUT 12 12 1226 07 38 STATION 4 ACTIVE PIN Al 003 13 55 INPUT 13 12 13 280
23. Subroutines to control auxiliary press functions Same as PF3 Scanning Program Files Both PLC 5 x6 processors scan assigned program files shown in Figure 1 3 Figure 1 3 Program Scan for the Processor in Chassis A Your Auxiliary Control Program Subroutine PFs that you program to control optional auxiliary functions Your Clutch Brake Interface Program PF15 The processor in chassis B scans the same Factory configured program files We suggest that you mini Clutch Brake Code mize PF3 in processor B for a faster scan PF16 time and a faster system response Overview of the Clutch Brake Control System 1 5 The Clutch Brake Application Package includes the clutch brake code in PF2 and PF16 You program the remaining machine applications Figure 1 4 Figure 1 4 Example Software Architecture of a Press Control System with Auxiliary Press Functions Slide Adjust Control subroutine PF28 in Processor A Die Clamp Control subroutine PF27 in Processor A Bolster Die Cart Control subroutine PF30 in Processor A Subroutine to Call Auxiliary Control Programs in Processors and Clutch Brake Interface PF15 in Processors A and B Automation Valve Control subroutine PF31 in Processor A Counter Balance Air Control subroutine PF25 in Processor A Clutch Brake Code PF2 PF16 in Processors A and B Input
24. With the simulated condition of step 3 attempt to start the press Observe that the press does not start and that fault codes 47 and 127 are indicated Return the chain break input to its normal condition and attempt to start the press Observe that it starts and that fault codes 47 and 127 are absent Operating Modes of the Clutch Brake Controller Appendix A Description of Operating Modes You can select any one of the following operating modes with the mode selector switch Off Remote Inch e Micro inch e Single stroke e Continuous stroking Off When an operator selects OFF the control system is designed to turn off all outputs to press valves Remote Mode When an operator switches the mode selector switch to Remote mode the control system can operate in the following modes when enabled by the corresponding mode select command bit in your ladder logic PF15 remote inch mode B151 10 remote single stroke mode B151 13 remote continuous mode B151 14 remote micro inch mode B151 24 remote automatic single stroke B151 26 For examples of enabling remote modes refer to ladder logic in chapter 4 Figures 4 8 4 11 4 17 4 18 4 19 4 20 Next we describe the remaining operating modes with flow charts Publication 6556 6 5 1 October 1996 A 2 Description of Operating Modes Publication 6556 6 5 1 October 1996 Inch and Micro inch Modes Before entering s
25. 6 2 2 6 2 2 6 118 2 68 Dial tee TO ria HS 8 212 sni Rete 21014 21021 are Ea s 24 26 A 26 252 28 CT v 28 262 28 S SES a opie gr ES enis BS se B6 40 40 2 2c f IF TBI 1771 1771 1 1016 1016 1016 Publication 6556 6 5 1 October 1996 Install and Wire the Clutch Brake Control System 6 7 Connect PLC Processors Connect PLC processors in chassis A and B with Belden 9463 cables and Programming and the programming terminal with a 1784 CP6 cable Figure 6 6 Terminal as follows Figure 6 6 Typical Connections Between Processors PLC 5 46 F Configured for PLC 5 26 in Chassis B Configured for Adapter Mode DH Station 1 Rack Addr 02 in Chassis A Scanner Mode DH Station 0 For DH link connectors marked Clear 6 shield M Blue For remote I O connectors marked B 150 ohm Blue terminatio shield resistor SZ Clear Channel 1A DH to Programming Terminal 1784 CP6 Cable 8 ap Channel 1A for DH Link Station 0 Ha Channel 1B for Remote I O
26. Customize the Wiring to Suit Your Application In this chapter we present default configurations of the control system and show you how to modify them to meet your application requirements We list default wiring configurations and modifications you can make explain how to install wiring drawing diskettes on your hard drive explain how to perform the wiring modifications give example figures showing completed modifications Here are the modifications that you can make to customize the wiring of the control system to suite your application rotary cam limit switches hardwired switches valve stem feedback Use This Default Configuration Or Modify Your Wiring Drawings to replace RCLSs with resolvers hardwired relays you must set B151 15 delete the crowbar relay circuit hardwired switch replace with an analog pressure sensor hardwired switch replace with a drive feedback hardwired switch replace with resolver input delete up to three active pin is wired delete active pin wiring hardwired switch replace arm continuous with stroke and a half valves with external fault detection use valves with internal fault detection 7 position switch delete unused selector positions use auxiliary valves for soft C B or dump delete them use micro inch buttons and valves delete them We organized the modifications by I O module group number according to the wiring drawing on which the configuration is presented Modifications ar
27. Subroutines application programming as needed independent of processor A You call these subroutines from Publication 6556 6 5 1 October 1996 4 2 Write Ladder Logic Reserved Program and Data Files How Command Bits Act On Control Logic in Protected Memory Publication 6556 6 5 1 October 1996 Allen Bradley has adopted certain conventions for assigning press control functions to specific subroutine files For standardization we suggest that you assign subroutine files and corresponding data files for press control functions in addition to the clutch brake as listed in Appendix E We recommend that in program file PF3 you call a subroutine for each press control function with Jump to Subroutine Subroutine and Return instructions We designed the software with this in mind Important For standardization when programming your press control requirements we recommend that you follow the assigned files as listed in Appendix E Command bits B151 00 29 let you customize the operation of your clutch brake control system to include control of press operations beyond that of the clutch brake mechanism alone Their use is optional The clutch brake control system will control the clutch brake mechanism without them If you selected no command bits for your press application in chapter 2 skip to Exchanging Data Between Processors for required programming later in this chapter In both processors your interface pro
28. 1 004 13 p 08 15 28 L2 13 INPUT 13 27 To 08 16 30 NOT USED 29 Al 004 14 A 08 17 75 32 12 14 INPUT 14 31 511 TO 08 33 08 18 sd 12 15 iNPUT 15 agh 00415 SPARE L 004 16 CONTROL CHECK POWER 08 19 77 136 12 16 INPUT 16 35 CHAIN BREAK INDICATOR 08 20 38 12 17 INPUT 17 37 lt gt N O H C 08 21 40 NOT USED 39 08 22 1051 10512 115 08 24 08 25 08 25 Publication 6556 6 5 1 October 1996 Wiring Drawings for an Ungrounded System G 9 1771 116 120VAC ISOLATED INPUT 27748 05 24 0 RACK B00 105L1 10512 115C 08 25 MODULE GROUP 4 119B MICRO INCH 1 FEEDBACK 005 10 i INPUT O uo 21 oos TED MICRO INCH 2 FEEDBACK 005 11 5 INPUT alt as VALVE STEM CLUTCH 1 80415 IM 08 04 gt 0402 ifs INPUT2 122 6 Te VALVE STEM CLUTCH 2 805LS 08 05 gt AE004 08 7 INPUT3 12 3 8 08 29 9 NOTUSED 10 08 30 VALVE STEM AUXILIARY 1 807LS 08 07 gt 1 004 04 11 INPUT 4 12 4 125 08 31 VALVE STEM AUXILIARY 2 80815 08 08 gt Aloe 13 INPUT5 12 5 4427 08 32 OFF INCH SINGLE CONTINU REMOTE MICRO DIE MODE
29. 105L1 105L2 Wiring Drawings for an Ungrounded System G 11 1771 OD16 120VAC ISOLATED OUTPUT RACK B00 08 48 08 48 MODULE GROUP 5 10527 Y 1198 CLUTCH 1 VALVE TO 06 08 1 OUTPUT O L1 0 2 09 26 BO 005 01 CLUTCH 2 VALVE TO 06 09 lt 3 OUTPUT 1 14 09 27 005 02 11 26 09 28 BO 005 03 7 OUTPUT3 L1 3 8 09 29 9 NOT USED 19 09 30 BO 4 AUXILIARY VALVE 1 TO 06 05 11 OUTPUT 4 12 09 31 BO AUXILIARY VALVE 2 TO 06 07 lt 00905 15 OUTPUTS 11 9 14 09 32 BO 005 06 ourpurg 11 616 005 07 17 OUTPUT7 11 718 09 34 19 NOT USED 20 09 35 BO 005 10 MICRO INCH 1 TO 08 02 lt a 21 OUTPUT10 11 10 22 09 36 BO 005 11_ MICRO INCH 2 EO 123 OUTPUT 11 L1 1124 09 37 8000512 155 OUTPUT12 11 126 09 38 BO 005 13 57 ourPUT 13 11 13 28 09 39 29 NOT USED 30 09 40 CONTROLLER OK 941CR 01 19 BO 005 14 1751 14 11 1432 4 09 41 CROW RELAY 942CR BO 005 15 gt A gt lt 33 OUTPUT15 11 19345 09 42 SEAL RELAY 943CR BO 005 16 5 OUTPUT16 11 1636 17 09 43 SPARE 37 OUTPUT17 11 1738 09 44 39 NOT USED 40 09 45 105L1 09 46 105L2 05 09 47
30. 37 CONTINUOUS SETUP BUTTON N O CONTINUOUS SETUP BUTTON 0 37 INPUT 17 Reserved Do Not Use RIGHT INCH P B 718PB Reserved Do Not Use NOT USED 39 gt 39 NOT USED LEFT INCH 719PB 5 1 e Qo 10511 10512 Publication 6556 6 5 1 October 1996 3 8 Customize the Wiring 1 0 Module Group 4 sheet 8 of 9 Ungrounded AC Power For this modification Use Micro inch Valves With Internal Fault Detection Delete Micro inch Valves Use C B Valves With Internal Fault Detection Use Auxiliary Valves With Internal Fault Detection Delete Auxiliary Valves Delete Unused Selector Switch Positions Chain Break Delete micro inch valve stem limit switches and wiring from input terminals 1 and 3 We deleted the wiring Figure 3 8 and added the label Reserved Do Not Use If deleting the micro inch valves remove output wiring in module group 5 Delete clutch valve stem limit switches and wiring from input terminals 5 and 7 We deleted the wiring Figure 3 8 and added the label Reserved Do Not Use Important Write ladder logic to reset bit B151 21 C B Valve Stems Enabled Delete auxiliary valve stem limit switches and wiring from input terminals 11 and 13 We deleted the wiring Figure 3 8 and added the label Reserved Do Not Use Important Write ladder logic to reset bit B151 20 Auxi
31. 40 to 85 C 40 to 185 F e Relative Humidity 5 to 95 without condensation Designed to comply with e ANSI B11 1 OSHA 1910 217 CSA CAN CSA Z142 M90 B151 00 B151 01 B151 02 B151 03 B151 04 B151 05 B151 06 B151 07 B151 08 B151 09 B151 10 B151 11 B151 12 B151 13 B151 14 B151 15 B151 16 B151 17 B151 18 B151 19 B151 20 B151 21 B151 22 B151 23 B151 24 B151 25 B151 26 B151 27 B151 28 B151 29 Chapter Objectives 1 Verify Your Factory configured Options Chapter 2 Define Your Control System Characteristics This chapter helps you complete the design of your Clutch Brake Control System by specifying design characteristics on a worksheet as follows verify your factory configured options assign valves to specific outputs select the type of valve fault detection select input switches select the type of position sensor select command bits for your clutch brake interface logic select other options select watchdog timer presets optional record on off positions of rotary cam limit switches Use the worksheet at the end of the chapter to record your selections The numbered section headings match those on the worksheet To verify your choice of factory configured options inspect the label on the software diskette in your Application Package to be sure it matches the catalog number that you ordered 6556 PLILILILI K Full Kit Mx Note 1 P Yes 0 No What ha
32. 8041 __ 08 04 2004 02 5 INPUT2 12 2 6 08 28 VALVE STEM CLUTCH 2 80515 4100403 INPUTS 123 a a 9 NOTUSED 10 08 30 VALVE STEM AUXILIARY 1 8071 08 07 gt 004044 ii INPUT4 L2 4 12 08 31 VALVE STEM AUXILIARY 2 808LS __ 08 08 gt 00405 id INPUTS 12 5 14 08 32 OFF INCH SINGLE CONTINU REMOTEMICRO DIE MODE SELECTOR SWITCH 809SS MODE STROKE MODE INCH CHANGER FROM 08 17 5 BE004 06 1 INPUT6 12 6 16 08 33 4 E ed 00407 ig INPUT L2 7 18 08 34 19 NOTUSED 20 08 35 BIOO410 f3 INPUT10 12 10 22 2 08 36 910041 21 INPUT 11 12 11241 08 37 4 BTE 80412 55 INPUT12 L2 i2 26 08 38 l B erro BL004 3 57 INPUT13 12 13 08 39 29 NOTUSED 30 08 40 B l 81 00404 541 INPUT14 L2 14 32 5 08 41 SPARE 0415 ga INPUT15 L2 i5 a4 08 42 NON NON AT NN NTROL CHECK POWER 910046 INPUT16 12 1636 08 43 SS BREAK INDIC 4 BI 004 17 57 INPUT17 12 17 38 08 44 N O H C 39 NorUsED 40 08 45 08 46 08 47 10811 10512 08 48 09 01 09 01 GROUNDED SYSTEM I O WIRING DWN DATE 05 26 95 ALLEN B RACK A00 GROUP 4 A ROCKWELL INT DNAL COMPANY RACK GROUP 4 40001797 0 CUST SHEET 8 OF 9 GAG Publication 6556 6 5 1 October 1996 H 10 Wiring Drawings for a Grounded System 1771 OD16 120VAC ISOLATED OUTPUT
33. CRM and CRM Power Feedback Delete the three pairs of limit switches RLCSs at input terminals 1 3 and 5 Wire input terminals 1 3 and 5 to power rails wire high for rack A00 to 10511 for rack to 10512 Write ladder logic to simulate the action of the rotary cam limit switches Delete wiring crowbar relay feedback to input terminal 25 for chassis A and B We deleted the wiring Figure 3 2 and added the label Reserved Do Not Use Delete Crowbar Relays A and B from the Power Distribution Drawing sheet 1 of 9 See Module Group 5 Delete Crowbar Relays and wiring from output terminal 33 for chassis A and B We deleted the wiring Figure 3 12 and added the label Reserved Do Not Use Delete the clutch brake air pressure switch at input terminal 33 for chassis A Wire input terminal 33 of chassis A and B to power rail 105L1 wire high Write ladder logic to monitor clutch brake air pressure Delete the main motor forward switches at input terminal 35 for chassis A and B Wire input terminal 35 to the power rail wire high for rack A00 to 10511 for rack to 10512 Write ladder logic to monitor the device that detects forward motion Delete the motion detector switches at input terminal 37 for chassis A and B Wire input terminal 37 to the power rail wire high for rack A00 to 10511 for rack BOO to 10512 Write ladder logic to simulate the action of the motion detector swi
34. Figure 3 20 and added the label Reserved Do Not Use If deleting the micro inch valves delete output wiring in module group 5 Delete clutch valve stem limit switches and wiring from input terminals 5 and 7 We removed the wiring Figure 3 20 and added the label Reserved Do Not Use Important Write ladder logic to reset bit B151 21 C B Valve Stems Enabled Delete auxiliary valve stem limit switches and wiring from input terminals 11 and 13 We removed the wiring Figure 3 20 and added the label Reserved Do Not Use Important Write ladder logic to reset bit B151 20 Auxiliary Valve Stems Enabled If deleting the auxiliary valves remove output wiring in module group 5 You must retain at least the OFF position as shown on sheet 8 of 9 Label unused selector switch inputs on wiring drawings Reserved Do Not Use Delete wiring from unused switch positions to corresponding input terminals Use successive switch positions leave no blank positions For example 1 off 2 inch 3 single 4 continuous 5 die change 6 and 7 not used Required for chain driven position monitoring device as shown on on sheet 8 of 9 Publication 6556 6 5 1 October 1996 And see Figure 3 20 Figure 3 23 Figure 3 20 and Figure 4 15 Figure 3 20 and Figure 4 15 Figure 3 22 Figure 3 21 NIA Customize the Wiring 3 17
35. Protected memory in PF2 sets these bits to default status These bits are turned ON every scan with these exceptions Where noted by 1 below these bits are turned OFF every scan ON OFF States B151 00 Refer to chapter 7 Figure 7 1 01 02 B151 03 ON must be ON to enable run buttons OFF may turn OFF after the press starts B151 04 ON must be ON before pressing run buttons OFF turns OFF press outputs in single and continuous mode B151 05 ON last logical condition to start downstroke OFF prevents movement in downstroke zone B151 06 ON must be ON during upstroke when on take over cam OFF stops upstroke B151 07 ON must be ON to start continuous stroking OFF turns clutch output OFF at next stroke top B151 08 ON must be ON to inch the press OFF stops inch motion B151 09 Used with remote inch mode bit 10 and remote micro inch mode bit 24 1 simulates pressing manual inch buttons OFF simulates releasing inch buttons B151 10 1 ON lets your logic switch the mode to inch OFF inhibits use of bit 09 Simulate Inch and logic must select another remote mode B151 11 ON must turn ON for single continuous stroking OFF disables press outputs at loss of pressure must be OFF to start single or continuous B151 12 ON must be ON for single continuous stroking OFF disables press outputs at loss of motion must be OFF to start single or continuous
36. RACK 00 3 MODULE GROUP 3 105L1 105L2 LEFT RUN STATION 1 N O 703PB BI 003 00 INPUT 0 12 0 21 4 07 26 a RIGHT RUN STATION 1 BUTTON 702PB 003 01 07 27 STATION 1 ACTIVE PIN AL003 02 eur 2 1825 ae b LEFT RUN STATION 2 N O 707PB 8003 03 pura 2 3 51 07529 9 NOT USED 0 07 30 RIGHT RUN STATION 2 BUTTON N C 705PB 8 003 04 741 INPUT4 12 4 12 07 81 d STATION 2 ACTIVE PIN 1 003 05 19 INPUTS 12 5 07 32 LEFT RUN STATION 3 N O 710PB 8003 06 is pure 12 6 8 RIGHT RUN STATION 3 BUTTON 709PB 8 003 07 17 7 12 7 18 07 34 1g NorUsED 20 s g STATION 3 ACTIVE PIN 003 10 21 INPUT 10 12 10 55 07 36 LEFT RUN STATION 4 N O 714PB 1 h BEO08 M 5 INPUT 11 12 11 94 07 37 RIGHT RUN STATION 4 BUTTON 713PB 003 12 12 12 12 55 07 38 STATION 4 ACTIVE PIN 003 13 53 INPUT13 12 13 58 07 39 29 NOTUSED 30 07 40 STOP ON TOP N C 717PB 003 14 31 INPUT 14 12 14 a2 07 41 k LEFTINCHBUTTONNO 7ISPB giopsrts 132 12465814 us RIGHT INCH BUTTON N C 718 __ 003 16 INPUT 16 12 16 36 07 43 CONTINUOUS SETUP BUTTON N O 720 __ 7 27 INPUT17 12 17 1 07 44 39 NOTUSED 40 07 45 n 07 46 4 07 47 10511 10512 08 25 08 01 0748 10512 UNGROUNDED SYSTEM WIRING DWN TLD DATE 01 22 93 RACK A00 GROUP 3 DWG NO
37. To avoid confusion from two sets of drawings remove and or discard the unused set printed and electronic versions Check which of the following options are applicable Refer to Wiring Refer to Logic Enable its ladder logic by setting bit B151 15 Figure 4 12 Omit the wiring for the crowbar relay circuit sheets 1 2 9 N A Remove from wiring drawings Omit switch wiring sheet 2 Figure 4 9 Rewire the input Modify the drawings Simulate the switch with ladder logic Figure 4 13 N A sheet 7 Using the crowbar relay circuit Not using the crowbar relay circuit Replacing the clutch brake air pressure switch with an analog sensor Replacing the main motor forward switch with a drive feedback Replacing the motion detector switch with a resolver signal Using fewer than four run stations Omit the wiring of unused stations Remove from wiring drawings You did NOT purchase the active pin option Omit the wiring for active pin sheet 7 N A Remove from wiring drawings You purchased the stroke and a half option Omit the wiring for the arm continuous button sheet 7 N A Remove from wiring drawings Using valves with internal fault detection Omit valve stem switch wiring sheet 8 Figure 4 15 Remove from wiring drawings Enable ladder logic by setting bits B151 20 and or 21 Using fewer than seven operating modes Rewire the mode selector switch sheet 8 N A Remove unused wiring fr
38. We describe how to use these files in chapter 4 We designed the software using selected program files Important For standardization we suggest that you program your ladder logic for the control of the clutch brake and other press functions in the program and subroutine files listed below If your application requires additional press control functions not listed assign them to subroutine files labeled Spare Processor A Processor B PF2 Processor Control Program 1 PF15 Your Clutch Brake Interface PF16 Clutch Brake Control 1 PF3 Your Main Control Program and Subroutine Director to the following Optional PFs PF4 Initialization PF2 Processor Control Program 1 PF15 Similar to Processor A PF16 Identical to Processor A 1 Available if needed PF5 Analog PF6 Lube Hydraulic We suggest that you minimize PF7 Mode Change programming in processor B PF8 Slide Angle for faster processor and system PF9 Spare response time PF10 Part Transfer Monitor PF11 Die Identification PF12 Recipe Management PF13 Fault Response PF14 Spare PF17 Operator Interface PF18 Supervisor Interface PF19 Feeder Blank Roll Interface PF20 Automation Interface 1 locked read only file Mapping of Data and Program Files E 3 Processor A Processor PF21 Spare PF22 Auto die Change Sequencer PF23 Main Motor Control PF24 Inch Motor Control PF25 Counter Balance Air Control PF26 Cushion Air Control PF27 Die Clamp
39. We include duplicate wiring drawings in appendices G and H Software diskettes in your C B Application Package consist of Diskette Contents C B Control Logic for Processors A and B about 2K words each for PF2 and PF16 Program Files PF2 and PF16 Factory configured proprietary ladder logic for controlling the clutch brake mechanism Processors in chassis A and B monitor press inputs and feedback from the opposite chassis and control outputs to press solenoid valves Program File PF15 Empty file that you program to integrate C B control with that for the rest of the stamping press Program File 3 Empty file that you program to call subroutines for the control of or to directly control auxiliary machine functions Wiring Drawings in AutoCAD and DXF formats System wiring Software version of all wiring drawings Use it as the base to document all application wiring Both AutoCAD release 11 0 DWG and Interchange format DXF files are included Publication 6556 6 5 1 October 1996 1 14 Overview of the Clutch Brake Control System Control System Specifications Publication 6556 6 5 1 October 1996 Type of processor e PLC 5 x6 master processor e PLC 5 x6 redundant processor Type of ac power grounded ungrounded Mode selections off inch single stroke e continuous e remote e micro inch die change Type of valves external fault detection e internal fault detection
40. an Delimiters Publication 6556 6 5 1 October 1996 Understanding the types of data that your processor handles and how your processor stores them may help you conserve memory achieve a faster processor data scan Types of Data The types of data that your processor handles depend on the processor but essentially falls into three categories bit word and element Data are stored in files which are blocks of data of similar type Some types of data can be stored in more than one type of file Each type of file has an ID letter to identify it in an address Type of Data Description of File File ID smallest unit of data 0 1 on off set reset bit I O image 16 bits can represent a numeric value such as with binary coded decimal BCD For example 0000 0000 0000 0110 6 timer 1 counter control 1 element a multiple number of words For example timer element 3 words preset accumulated control status bits 1 Each timer counter or control element uses three words Addressing Your Data Logical address formats Figure 4 vary depending on the type of data Addresses contain these characters e file type ID e file number delimiter to separate address numbers number location of the structure word bit and or I O hardware Figure F 4 Typical Address Formats Address for Word type Data Address for Bit type Data Address for 1 0 Image D File Type I
41. continuous mode located more than 24 apart Left hand Lets you inch the press up or down Inch Assures 2 hand operation of the press when positioned more than 24 from other button Right hand e Lets you inch the press up or down Inch Assures 2 hand operation of the press when positioned more than 24 from other button E Stop Wire in series Distribute as needed to stop press quickly You are responsible for meeting applicable codes Mode Select Micro inch Single Continuous Remote Die ll Arm Continuous Main Motor Forward If not it opens to prevent running the press in Interlock single or continuous mode Air Pressure e Assures 2 hand operation of the press in single or Position RUN stations per ANSI B11 1 appendix dual contact normally closed N C and normally open N O Momentary pushbuttons dual contact N C and N O Momentary pushbuttons contact Momentary pushbutton single N C contact Rotary 7 position key lockable N O single contact Motion Detects press motion in single or continuous mode Detector Must cycle ON OFF with press motion Interlock f using resolvers program this function Control e Lets you manually reset power to valve outputs at Momentary pushbutton Reset power up or after an E stop single N O contact Clutch Brake Lets you manually reset clutch power and Power Reset crowbars if used on power up
42. presets We show you how in chapter 4 On the worksheet check the timers you want to change and record their shorter presets Define Your Control System Characteristics 2 7 Configuration Worksheet 1 Verify Your Factory configured Options Do this by inspecting the label on the software diskette in your Application Package and matching it to your order number such as cat 6556 PA H P3K Factory configured Options by Cat No 1 Method to Start Arm continuous or Continuous Mode Stroke and a half 2 On the hop With this feature Omit this feature 3 Active Pin With active pin or in Run Stations Omit active pin 4 Hardware Kit Full kit Minimum bundle 1 1 For hardware lists of various kits see the C B Packing Data publication 6556 5 1 2 Assign Outputs Match 1771 OD16 outputs to your clutch brake valves For output wiring refer to wiring drawing sheet 9 Output 1771 0D16 Address Your Designation Clutch 1 005 02 and BO 005 02 Clutch 2 Brake 0 005 03 and BO 005 03 Auxiliary 1 Auxiliary 2 Micro inch 1 Micro inch 2 005 13 and BO 005 13 Auxiliary valves in unison with or in opposition to clutch valves If not used set corresponding command bit Publication 6556 6 5 1 October 1996 2 8 Define Your Control System Characteristics Publication 6556 6 5 1 October 1996 3 Record the Type s of Valve Fault Detection Important If using a mix o
43. wiring and welded closed and will not turn ON operation of input module in slot 2 E Stop relay C B power will not turn ON Check E Stop relay circuit and failed to close operation of input module in slot 2 CRMA relay Check E Stop relay circuit and welded closed operation of input module in slot 2 Mode select failed Check mode selector switch wiring and operation of input module in slot 4 C B power is de energized and will not turn ON C B power will not turn ON 009 Processor Mode Mismatch Each processor sees Press will not stroke Check mode selector switch wiring a different mode and operation of input module in slot 4 010 Processor A Station 1 Not Active nor Bypassed 011 Processor A Station 2 Not Active nor Bypassed 012 Processor A Station 3 Not Active nor Bypassed 013 Processor A Station 4 Not Active nor Bypassed 014 Processor A Station 1 Tiedown 015 Processor A Station 2 Tiedown Run button failure or Prevents single or continuous improper wiring stroking Run button failure or Prevents single or continuous Check run buttons and wiring improper wiring stroking Run button failure or Prevents single or continuous Check run buttons and wiring improper wiring stroking Run button failure or Prevents single or continuous Check run buttons and wiring improper wiring stroking Run button held too long before Press will not start a stroke Release then press run buttons pres
44. with a resolver module in slot zero at address 1 000 Store Resolver Input Angle Source 1 000 349 Dest N155 0 349 Motion Detect Time Delay e TON 4 IMER ON DELAY EN Timer ELS 720 Time Base 0 01 00 Preset 10 Accum 06 Time to Check Current vs old Press In Slide Angle Angle Motion T157 0 B151 I NOT EQUAL 4 DN Source 155 0 12 349 Motion Source 155 1 Detect to 349 Other t Processor Motion 0 027 Time to Detect to 3 F Check Other 00 Slide Angl Processor 11570 0 027 1 1 DN 00 Time to Check Motion Detect Slide Angle Time Delay FESQ T157 0 1 I z RES DN Save Current To Old Angle MOV MOVE Pak Source N155 0 349 Dest N155 1 349 Publication 6556 6 5 1 October 1996 4 12 Write Ladder Logic Publication 6556 6 5 1 October 1996 Figure 4 11 Example Commands to Select Single Mode B151 13 and Continuous Mode B151 14 from a Remote Selector Use these mode select command bits to change operating mode from a remote location such as a master controller Important The main selector switch must be in remote mode Line Supervisor Single Stroke Mode 1 040 E es Remote B151 Single Mode 03 Line Su
45. 09 48 UNGROUNDED SYSTEM I O WIRING DWN TLD DATE 01 25 93 RACK A00 GROUP 5 DWG NO DWG REV RACK B00 GROUP 5 40001797 0 CUST SHEET9 OF 9 AD Publication 6556 6 5 1 October 1996 G 12 Wiring Drawings for an Ungrounded System Notes Publication 6556 6 5 1 October 1996 Wiring Drawings Appendix Wiring Drawings for Grounded System The wiring option of your Clutch Brake Application Package included either one of two choices grounded system I O wiring this appendix or e ungrounded system I O wiring appendix G We present the following wiring drawings for I O racks 00 and BOO for grounded system I O wiring See Appendix G for the Ungrounded System Sheet Title 1 of 9 Power Distribution 2 3 4 5 omitted because they are of 9 not wiring drawings 6 of 9 System I O Rack Group 2 7 of 9 System I O Rack Group 3 8 of 9 System I O Rack Group 4 9 of 9 System I O Rack Group 5 Publication 6556 6 5 1 October 1996 2 Wiring Drawings for Grounded System Notes Publication 6556 6 5 1 October 1996 Wiring Drawings for a Grounded System 440 VAC FROM CUSTOMER 1 12 AWG BLK 103L1 10CCB 105L1 GROUND LT 7 TR CLUTCH BRAKE TRANSFORMER 1KVA H3 H1 H2 H4 lt 10 10512 FROM CUSTOMER L2 14 AWG GREEN 108L1 EMERGENCY STOP 112 108L1 14 AWG BLK B
46. 11 004 04 4 08 31 lt VALVE STEM AUXILIARY 2 80815 1 004 08 08 14 12 5 INPUT 5 13 004 05 09 01 08 09 gt d 12 6 15 500406 E Al 004 07 08 10 18 12 7 INPUT7 17 aK 08 11 20 NorUsED 19 1 004 10 A 08 12 22 12 10 INPUT 10 21 Al 004 11 08 13 24 12 11 INPUT 11 23 P l Al 004 12 08 14 Hos 12 12 INPUT 12 95 ST 6 Al 004 13 08 15 2528 12 13 INPUT 13 27 Se J 08 16 30 NOTUSED 29 004 14 08 17 12 14 INPUT 14 31 SO 08 33 08 18 Haa L245 INPUT 15 a3 004 15 SPARE 004 16 CONTROL CHECK POWER 08 19 426 12 16 INPUT 16 35 M5A 59 ES a CHAIN BREAK INDICATOR 08 20 38 12 17 INPUT 17 37 AU 009 17 ee i N O H C 08 21 140 NOTUSED 39 08 22 08 23 08 24 119 08 25 Publication 6556 6 5 1 October 1996 Wiring Drawings for a Grounded System H 9 1771 1016 120VAC ISOLATED INPUT 08724 RACK B00 10512 08 25 MODULE GROUP 4 eee MICRO INCH 1 FEEDBACK 005 10 F puto L20 2 L weiss MICRO INCH 2 FEEDBACK AO 005 11 12 Ta pene VALVE STEM CLUTCH 1
47. 360 500 900 500 1000 Some processor families faster at executing selected groups of instructions than other processor families Table Table F B Comparing Processors for Typical If True Execution Times Type of Instruction relay such as examine energize latch and unlatch timer and counter arithmetic such as add subtract multiply divide trig functions such as sin cos tan 375 500 10 n 0 025 move and compare shift register such as shift left right load and unload depends on number of bits or words operated on n number of bits subroutine jump return instructions p of parameters 300 360 500 900 500 1 000 immediate 1 0 to queue up for processing process control such as PID gain computation block transfer transfer time for 10 word transfer first in queue 1 full remote logical rack 57 6K baud PLC 5 11 20 30 40 80 PLC 5 10 12 15 25 0 4 1 5 30 44 18 82 cannot do it 26 63 90 4w w of words 56 21 160 200 600 600 Publication 6556 6 5 1 October 1996 Programming Considerations for PLC 5 Processors Data Format The processor operates faster when you use integer data as compared with floating point data Table F C Table F C Comparing Data Types for Typical If True Execution Times for Selected Instructions for PLC 5 11 20 30 40 80 Processors Type of Instruction Integ
48. 5 and from power rail 105L1 for chassis A and B Delete run stations Delete the right run station pushbutton switch wired to input terminal 7 15 or 23 Figure 3 6 2 3 and or 4 for chassis A and to input terminal 11 17 or 25 for chassis B respectively Wire input terminal 7 15 or 23 for chassis A and input terminal 11 17 or 25 You must have at least for chassis B respectively to the power rail 105L1 wire high one active run station Delete the left run station pushbutton switch wired to input terminal 11 17 or 25 for chassis A and to input terminal 7 15 or 23 respectively for chassis B Wire input terminal 11 17 or 25 for chassis A and input terminal 7 15 or 23 for chassis B respectively to the power rail 105L2 wire high Delete active pin wiring from input terminal 13 21 or 27 and from power rail 105L1 for chassis A and B Delete active pin If you ordered the factory configured option of NO active pin Figure 3 6 factory configured 1 Delete active pin wiring from input terminals 5 13 21 and 27 and from option power rail 105L1 for chassis A and B We deleted the wiring Figure 3 6 and added the label Reserved Do Not Use Delete Arm Continuous 1 Remove the arm continuous switch and wiring at input terminal 37 in chassis A and B Figure 3 7 factory configured We deleted the wiring Figure 3 7 and added the label R
49. Control PF28 Slide Adjust Control PF29 Cushion Stroke Adjust Control Bolster Die Cart Control PF31 Automation Device Control PF32 PTO Control Transfer Electronic Feeder Control PF34 Crossbar Control PF35 Safety Gate Control PF36 Slide Lock Control PF37 Turnover Control PF38 Prebender Rotator Control 9 Nest Station Control PF40 Exit Conveyor Control PF41 Scrap Chute Control PF42 Temperature Control PF43 Spare PF44 Stack Roll Feeder Control PF45 Spare PF46 Production Data PF47 Lamp Check PF48 Spare PF49 Automation Compensation We give programming examples for PF15 in chapter 4 Publication 6556 6 5 1 October 1996 E 4 Mapping of Data and Program Files Notes Publication 6556 6 5 1 October 1996 Purpose of this Appendix Program Scan How the Processor Scans a Program Signals from input devices such as proximity switches photo electric sensors contact switches bar code readers pushbutton switches Input Module gt Appendix F Programming Considerations for PLC 5 Processors The purpose of this appendix is to help you make correct decisions when writing ladder logic for controlling machine functions We divided this guide into these sections e Program Scan How the Processor Scans a Program e What Affect Does Your Ladder Logic Have on Program Scan How to Program a Faster Response e What are Subroutines and Why Use Them Working with Data Tr
50. Control System How the Software Controls Your Press Factory configured Master Control Program PF2 Update Publication 6556 6 5 1 October 1996 Program File PF2 Locked PF3 PF15 PF16 Locked PFxx The clutch brake control system can control the entire press because you can add your own ladder logic for other press functions Factory protected logic for control of the clutch brake mechanism is stored in locked program files PF2 and PF16 You store your own clutch brake interface logic in an unlocked program file PF15 Either processor can use program file PF3 to call subroutines PFxx or to directly control auxiliary press functions that you program Organization of Program Files We organized selected program files in both PLC 5 x6 processors as follows to control the clutch brake and other press functions Description Processor in Chassis A Description Processor in Chassis B Factory configured Master Control Program Identical to the processor in chassis A Used to program or call subroutines to control Optional but available for application auxiliary press functions such as automation programming independent of the valve die protection etc processor in chassis A Used to program the clutch brake interface Similar to the processor in chassis A with machine sequencing to customize the clutch brake code in PF16 Factory configured clutch brake code Identical to the processor in chassis A
51. Run Run Station Station 1 Station 2 Station 3 Station 4 Y Stroke Position Input Device to Monitor Stroke Position PLC 5 46 Processor PLC 5 26 Processor in Chassis A in Chassis B Signals to from Stroke Main Solenoid Valves Position Ede Input Clutch Brake Chi Sup Assembly e Main Solenoid Valves Air to clutch Device P to Monitor Control System operation Stroke Position C Crankshaft at Top Position Flywheel driven Crankshaft Cod NEN Crankshaft at Bottom Position 122454 You select the mode of control system operation with a selector switch In accordance with ANSI B11 1 Section 4 12 4 1 the means of selecting the operational mode must be capable of being fixed by a supervisor Typically this is interpreted as to mean a keyswitch This Mode Lets you Off Disable operation of the clutch brake control system when not in operation Inch Move the press up or down to the desired position with Inch pushbuttons or by ladder logic to set up dies and tooling not intended for production Micro inch Same as Inch but at a slower speed Requires a separate drive assembly and operates from a separate set of outputs Single Cycle the press through a single uninterrupted strok
52. SELECTOR SWITCH 809SS MODE STROKE MODE INCH CHANGEg __ FROM 08 17 BI 004 06 15 INPUT6 12 6 16 08 33 i i BEO04 07 i7 12 7 186 08 34 19 NOTUSED 20 08 35 B 714 BE004 70 INPUT10 12 10 22 08 36 B BI 004 11 23 INPUT 11 L2 11 24 lt 08 37 B M T o 00412 INPUT12 12 42 26 x 08 38 004 13 27 INPUT 13 12 13 28 08 39 29 NOTUSED 30 08 40 4 gt cb BL004 14 41 INPUT 14 12 14 821 08 41 SPARE 004 15 44 INPUT15 12 15 34 08 42 NON NON ON nN NNN CONTROL CHECK POWER 004 16 115 gt 35 INPUT 16 12 1636 08 43 CHAIN BREAK INDICATOR BE00417 37 INPUT17 12 17 387 08 44 N O H C 39 NOTUSED 40 08 45 105L2 08 46 47 10511 08 10511 10512 115C 119 08 48 09 01 09 25 09 01 09 25 UNGROUNDED SYSTEM I O WIRING_DWN__KAC DATE 03 31 93 RACK 00 GROUP 4 DWG NO DWG REV IONAL EOMEANY RACK B00 GROUP 4 40001797 0 SHEET 8 OF 9 CRD Publication 6556 6 5 1 October 1996 G 10 09 01 09 02 09 03 09 04 09 05 09 06 09 07 09 08 09 09 09 10 09 11 09 12 09 13 09 14 09 15 09 16 09 17 09 18 09 19 09 20 09 21 09 22 09 23 09 24 Wiring Drawings for Ungrounded System 1771 0016 120VAC ISOLATED OUTPUT
53. TCAM ACAM Off Off On Near Top Zone Downstroke Zone Upstroke Zone Set Up or Simulate Rotary Cam Limit Switches 7 9 The software is designed to fault when it sees conditions other than the correct progression of these three rotational zones during a press stroke Top zone Downstroke Upstroke Important The software reads these zones according to the on off positions of ACAM BCAM and TCAM switches that you set Figure 7 1 mechanically for hardware switches or that the software reads from resolver inputs if using resolvers to simulate your RCLSs During each stroke the rotary cam limit switches must cycle as follows linear representation of Figure 7 1 On On d d BCAM and TCAM can transition within the same scan or overlap their On states When the software detects any one of the following fault conditions it is designed to turn outputs off and set the corresponding fault bit in B168 When the software detects this condition It turns outputs Off and sets and this fault bit for this fault bit for Processor A Processor B B168 xxx All three limit switches go Off 106 BCAM turns Off before TCAM turns On at bottom 108 BCAM On when ACAM is Off 106 113 ACAM does not cycle 114 during upstroke Important The ladder logic for turning outputs off and setting fault bits is factory configured for you No programming is required Important For suggestions o
54. This Manual Information in the Appendices We ve Simplified Your Wiring Documentation Concerning Rockwell Programming Software Publication 6556 6 5 1 October 1996 The last part of the manual contains appendices Appendix A contains these descriptions of control system operating modes e inch and micro inch e single stroke continuous Other appendices include e timing diagram of control system feedback in Appendix e fault codes to help you debug the control system in Appendix C operator prompts to help you run the press in Appendix C class privileges and read write access by class in Appendix D e reserved data files and program files in Appendix E programming considerations for PLC processors in Appendix F wiring drawings for ungrounded ac power distribution in Appendix G wiring drawings for grounded ac power distribution in Appendix H Wiring drawings are included on diskette so that you can modify them with your own Computer Aided Drafting CAD system They are stored in these file formats e AutoCAD Release 11 0 DWG e INTERCHANGE Software DXF Choose the one that matches your CAD system There are two sets of wiring drawings one for ungrounded the other for grounded ac power distribution Select the set you will use and dispose of the other to avoid confusion We include fold out wiring drawings in a separate package that accompanies this manual and a duplicate set in Append
55. a fault the control program takes a snapshot of the bit logic controlling the press the instant the outputs are turned off You can use this information to troubleshoot the cause of the shutdown Do this by comparing the status of the snapshot bits with what the status should have been according to your ladder logic Start at the last rung controlling main valve outputs and work backwards until you find all discrepancies The snapshot status of bit logic is stored in file N167 21 as follows The processor substitutes actual status for illustrated bit status 0000 Real time Storage 15 Snapshot Status 0 N168 0000 0000 0000 0000 0 0000 0000 0000 0000 1 0000 0000 0000 0000 2 0000 0000 0000 0000 9 N160 0000 0000 0000 0000 0 0000 0000 0000 0000 1 0000 0000 0000 0000 2 0000 0000 0000 0000 19 0000 0000 0000 0000 20 0000 0000 0000 0000 21 Publication 6556 6 5 1 October 1996 C 10 Troubleshooting with Fault Codes Operator Prompts and Snapshot Status Bits Notes Publication 6556 6 5 1 October 1996 Appendix D Classes of Memory Protection Class Privileges We have assigned privileges to four classes of memory protection Class 1 has access to all processor functions The password for class 1 is kept confidential at the factory We show you how to assign your own passwords to classes 2 4 in chapter 5 Privilege Class 1 Class 2 Class 3 Class 4 Modify privileges X Create delete data table
56. available from American National Standards Institute 1430 Broadway NY NY 10018 3363 NFPA No 79 Electrical Standard for Metalworking Machine Tools CAN CSA Z142 M90 Code for Punch Press and Brake Press Operation Health Safety and Guarding Requirements Canadian Standards Assoc 178 Rexdale Blvd Rexdale Toronto Ontario Canada MOW 183 Also refer to Important User Information inside the front cover Without this knowledge your control system could be unsafe resulting in possible personal injury and or damage to equipment Overview of the Clutch Brake Control System 1 3 Control by The clutch brake control system uses two independent PLC 5 x6 Redundant Processors processors Figure 1 1 such as but not limited to e PLC 5 46 processor operating in scanner mode in chassis A PLC 5 26 processor operating in adapter mode in chassis Both processors monitor all clutch brake I O and exchange information regarding machine status They are linked by hardwired I O and a communication channel so that if one processor detects a condition different from that detected by the other its control logic is designed to declare a fault and turn off all outputs to press valves The other processor is designed to follow suit Chassis A or B may contain additional optional I O modules for other press functions Otherwise I O modules in both chassis are identical Figure 1 1 Typical Architecture for Redundant Control Lin
57. designed to stroke the press once from top to bottom to top with the concurrent use of all active run buttons Once the press reaches the takeover cam TCAM operators can release Run buttons without stopping the press it continues to the near top position During downstroke releasing a Run button stops the press Figure A 2 To restart the press press the Run buttons Once the press reaches the takeover cam the press continues automatically through the upstroke Figure A 3 If you purchased software with on the hop you can start another cycle without stopping the press if you release all Run buttons Then press and hold Run buttons during the upstroke Publication 6556 6 5 1 October 1996 A 4 Description of Operating Modes Figure A 2 Typical Operational Sequence for Downstroke in Single Mode Select single mode Y No Is the motor running forward Yes Y Y No Have you released all Run buttons since the previous stroke lt Yes Have you pressed all Run buttons concurrently see table below R1 Yes No Have you released _________ Both processors energize their a Run button outputs to actuate the clutch for Yes downstroke _ Both processors de energize their outputs to stop the press Is the press into the No upstroke zone Yes Have you
58. e Denmark e Ecuador Egypt e El Salvador e Finland France Germany e Greece e Guatemala e Honduras Hong Kong Hungary e Iceland India e Indonesia Ireland e Israel e Italy e Jamaica e Japan Jordan Korea Kuwait e Lebanon e Malaysia Mexico Netherlands New Zealand e Norway e Pakistan Peru e Philippines Poland Portugal Puerto Rico Qatar e Romania e Russia CIS e Saudi Arabia Singapore e Slovakia e Slovenia South Africa Republic e Spain e Sweden e Switzerland e Taiwan Thailand Turkey United Arab Emirates e United Kingdom United States Uruguay Venezuela Yugoslavia Allen Bradley Headquarters 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Publication 6556 6 5 1 October 1996 Supersedes Publication 6556 6 5 1 October 1995 PN 955128 04 Copyright 1996 Allen Bradley Company Inc Printed in USA
59. example the following example shortens the timeout value for Clutch A Failed to Turn OFF from 1 second to 1 2 second Figure 4 25 Example Logic to Shorten a Timer Preset Greater Than or Equal B152 Source A T162 43 ACC m Source 50 43 e Write Ladder Logic 4 21 This is the list of internal timers The time base is 0 01 second for all timers Timer Crowbar Relay Weld Crowbar Relay Failed to Turn On Seal relay Failed to Turn On Seal Relay Weld E Stop Relay Failed to Turn On E Stop Weld No Valid Mode Selected Clutch Brake Mode Mismatch Station 1 Anti tiedown Station 2 Anti tiedown Station 3 Anti tiedown Station 4 Anti tiedown Multiple Active Station Anti tiedown Inch Button Anti tiedown Clutch Brake Air Pressure Clutch Brake Air Pressure Exhausted BCAM Soft Cam Compare TCAM Soft Cam Compare ACAM Soft Cam Compare Motion Detector Watchdog Uncommanded Motion Detected Micro inch Feedback Valve A Off Micro inch Feedback Valve B Off Micro inch Feedback Valve A On Micro inch Feedback Valve B On Arm Continuous Button Arm for Continuous on Demand Clutch 1 Failed to Turn On Clutch 1 Failed to Turn Off Clutch 2 Failed to Turn On Clutch 2 Failed to Turn Off Clutch Valve stem 1 Failed to Turn On Clutch Valve stem 1 Failed to Turn Off Clutch Valve stem 2 Failed to Turn On Clutch Valve stem 2 Failed to Turn Off Aux
60. for at least 1 2 stroke Or 5 Continuous for Stroke and a half start continuous stroking by holding run buttons into Mode the second stroke If released before the second closure the press comes to a stop at the top if after the second closure the press keeps running 0 On the Hop stroke the press in single mode without stopping by releasing and again pressing run buttons when in the upstroke zone Por 0 include or exclude active pin wiring to detect the absence of a run station K M M1 M3 Hardware Kit select PLC 5 x6 processors power supplies and I O for clutch brake control Programming Ladder logic Commands To customize the control system to your application we help you program any combination of the following command bits that interface to the protected clutch brake control program See chapter 4 To program this objective Use these command bits Simulate rotary cam limit switches brake monitor BCAM when using resolvers instead of RCLSs take over TCAM anti repeat ACAM Interface press and machine functions permit cycle start during automatic continuous mode permit run permit downstroke or delayed start permit upstroke top stop permit inch simulate inch buttons simulate run buttons arm for continuous on demand inch output enabled initiate automatic single stroke Select operating mode remotely remote inch mode with your ladder logic remote single stroke mode remote continuous mode remote micro
61. for the station 2 active pin for chassis A and B to power rail 108L1 wire high Delete active pin If you ordered the factory configured option of NO active pin Figure 3 18 factory configured 1 Delete active pin wiring from input terminals 5 13 21 27 and from option power rail 108L1 for chassis A and B We deleted the wiring Figure 3 18 and added the label Reserved Do Not Use Delete Arm Continuous 1 Delete the arm continuous switch and wiring at input terminal 37 in chassis A and Figure 3 19 factory configured We deleted the wiring Figure 3 19 and added the label Reserved Do Not Use Stop on top 1 No modifications allowed You must wire these inputs as shown on sheet 7 of 9 forthe N A Left Right Inch control system to work correctly Publication 6556 6 5 1 October 1996 Customize the Wiring 3 15 Figure 3 17 Delete Run Station 1 Module Group 3 06 24 RACK A00 RACK BOO MODULE GROUP 3 108L1 MODULE GROUP 3 INPUT o _ 003 00 RIGHT RUN STATION 1 NO 702PB 1 l LEFT RUN STATION ji NO 70588 BEOOS O0 CT wpyt O INPUT 1 31 003 01 LEFT RUN STATION 1 BUTTON N C 703PB RIGHT RUN STATION 1 BUTTON N C 70208 003 01 1 INPUT 2 S STATION 1 ACTIVE Reserved Do Not Use 1 1 Reserved Do Not Use STATION PIN 5 IN
62. or after an E stop Chain Break Indicator Monitors the chain drive When it detects breakage it opens to stop a downstroke or to prevent starting the press Momentary pushbutton triple contact 1 and 2 N O limit switch held closed Publication 6556 6 5 1 October 1996 Define Your Control System Characteristics 7 Select Optional Command Bits for C B Interface Logic Select command bits for your clutch brake interface PF15 We grouped bits by similar kind For logic examples see chapter 4 Important Some bits are listed more than once based on usage Simulate the brake monitor BCAM with a resolver B151 00 Simulate the take over TCAM B151 01 Simulate the anti repeat ACAM B151 02 Enable run buttons B151 03 Monitor safety interlocks B151 04 Enable press motion in downstroke after pressing buttons B151 05 Stop press operation in upstroke B151 06 Turn OFF clutch output at next top zone B151 07 Start the press automatically in remote automatic modes B151 25 Start the arming timer for continuous on demand B151 27 Start inch with inch buttons and this bit set remotely B151 28 Lets you start auto single stroke without cycling the press B151 29 Allow inching Permit Inch B151 08 Simulate hardwired inch buttons during setup Simulate Inch Buttons B151 09 Allow simulated inch buttons during setup Remote Inch Mode B151 10 Allow simulated micro inch buttons during setup Remote Micro inch Mode
63. released then pressed No all Run buttons concurrently Yes x For This Mode Remote Inch Remote Micro inch Replace Run Buttons With Simulate Inch Buttons Command Bit Remote Automatic Single Simulate Run Buttons Continuous on Demand Command Bit B151 09 B151 25 Publication 6556 6 5 1 October 1996 Both processors de energize their outputs to stop the press Description of Operating Modes Figure A 3 Typical Operational Sequence for Upstroke in Single Mode A 5 R2 gt Have you released all Run buttons Y before the ACAM closes again No Upstroke continues regardless Yes of releasing Run buttons Yes Has either detected Have you pressed all Run buttons No pro before the ACAM closes again a cam transition fault No Yes 5 Yes Has the slide moved into 15 on the hop a feature gt its near top position No N Aof Have you released a Run button No No Yes Yes No Has the press moved into the Go to 1 near top position Figure A 2 Yes Both processors de energize their outputs to stop the press in the near top position WARNING If the press coasted past the near top position while braking the brake is faulty and hazardous Repair it immediately NOTE The press continues automatically thro
64. setting this bit 27 Continuous 1 for 5 min to start continuous on demand For a completely automatic press on Demand OFF toggles after timed out Ingores mechanical run buttons Inch Output B151 28 ON last logical condition to start inch Use with inch buttons pressed Enabled OFF prevents starting inch or stops it once ON and held until this bit is set Initiate B151 29 ON lets you start the press in auto single mode Used in remote operation Automatic 1 without first cycling the press with bits 25 26 and 27 Single Stroke OFF operator must start auto single mode by cycling the press with Run buttons Refer to Figure 4 19 1 Important These bits are held OFF in ladder logic unless your custom ladder logic turns them ON Important We designed the clutch brake code in PF16 with the requirement that you must program most of the command bits with nearly identical logic and hardware conditions for processors A and B The following table designates which command bits do NOT have that requirement Logic and Hardware Conditions Can be Different for Processors A and B For These Bits Permit cycle start B151 03 Permit upstroke B151 06 Permit run B151 04 Permit cycle start 8151 08 Permit downstroke 151 05 Press in motion B151 12 Publication 6556 6 5 1 October 1996 Steps to Write Ladder Logic If Processor A Is This Type PLC 5 26 PLC 5 46 PLC 5 86 Write Ladde
65. settings 035 038 Spare C B Air Pressure Software detected no air pressure Clutch valves are Check I O wiring Not Detected after energizing main valves de energized Check air pressure switch 040 Spare 041 Brake Monitor Cam Processor A sees the BCAM while Press will stop or not run in Check soft cam logic or hard cams Mismatch Between processor B does not single or continuous mode for proper operation or settings Processors 042 Takeover Mismatch Processor A sees the Press will stop or not run in Check soft cam logic or hard cams Between Processors TCAM while processor B does not single or continuous mode for proper operation or settings 043 Anti repeat Cam Mismatch Processor A sees the while Press will stop or not run in Check soft cam logic or hard cams Between Processors processor B does not single or continuous mode for proper operation or settings 044 Cam Mismatch Fault Any of 041 043 detected Press will stop or not run in Check soft cam logic or hard cams single or continuous mode for proper operation or settings 6 Spare oe 046 Brake Monitor Fault On a stop on top command the press slid onto the BCAM zone before stopping Press cannot operate in single Check the brake and or continuous mode until it brake monitor cam settings stops in the near top zone 047 Chain Break Fault Software detected fault Press cannot operate
66. switch to OFF Publication 6556 6 5 1 October 1996 7 12 Set Up or Simulate Rotary Cam Limit Switches Notes Publication 6556 6 5 1 October 1996 Chapter Objectives Static Wiring Tests Chapter 8 Test Your Clutch Brake Control System Once you have completed the installation and programming of your clutch brake controller test it to verify proper operation We give you the procedures in this chapter for the following Static Wiring Tests Dynamic tests of operating modes e Switch Tests ATTENTION Before starting this chapter be sure that installation of all clutch brake control hardware is complete a clutch brake wiring is complete control system is in compliance with all applicable standards Otherwise personal injury and or property damage could result This section describes the following static wiring tests e Controller OK CRM e Seal Relay Crowbar Relay e Run Buttons e Inch Buttons e Stop on top Button e Arm Continuous Button Mode selector Switch Valves and Valve Feedback Controller OK Test This is an internal test The C B software is designed to detect and indicate a fault in the controller OK relay circuit should one occur See fault codes 003 and 083 in appendix C Publication 6556 6 5 1 October 1996 8 2 Test Your Clutch Brake Publication 6556 6 5 1 October 1996 CRM Relay Test 1 Power up the system 2 Visually and with a voltmet
67. techniques program a jump forward or back to avoid scanning portions of your ladder logic not required under certain programmed conditions program a jump to a subroutine and a return when you require intermittent use of a block of ladder logic The processor scans it only when needed Use Single Transfer When Possible When transferring data between the processor and I O modules the use of single transfer programming is faster than block transfer for up to 1 word transfers per rung even if you add extra rungs for transferring more words Other Considerations Other considerations for a faster program scan are select a faster processor e dedicate an additional processor to critical functions put critical 1 0 in the local I O chassis rather than in a remote 1 0 chassis minimize the use of remote I O chassis minimize the queuing of block transfer instructions put most frequently accessed data in lower file addresses under word 254 minimize the number of and size of gaps between program file numbers use integer data rather than floating point data use direct addressing select faster instructions arithmetic instructions are faster than compute What Are Subroutines A subroutine is a block of ladder logic stored in a separate program file Generally it performs a specific function independently The use of subroutines helps you e simplify your ladder logic e subdivide it into independent
68. wiring 155 159 Spare To clear this latched fault bit you must enable the fault reset bit or turn the mode select switch to OFF Prom pts for Whenever a PLC 5 x6 processor detects conditions worthy of a Operating the Press prompt it sets corresponding bits in Bit File 169 in the data table We list conditions for which the software is designed to detect and signal a prompt We recommend that you program a method to display bit numbers of detected prompt conditions Then you can respond quickly by looking them up in the following table Publication 6556 6 5 1 October 1996 Troubleshooting with Fault Codes Operator Prompts and Snapshot Status Bits C 7 Prompts Associated with Processor A B169 Suggested Message Cause of the Prompt Condition Effect of Prompt Condition How to Correct the Condition 000 Spare 001 E Stop actuated E stop button was pressed or CRM and seal relays opened Release E stop btn Press control E stop circuit failed power and C B power reset btns 002 004 Spare 005 006 007 008 009 010 Software inch mode enabled You pressed an inch button when Hardware inch buttons void Release hardware inch buttons software inch mode bit was set when this bit is set Software inch mode is not Inch mode selected but software inch Valve outputs turn OFF Set the software inch mode bit enabled mode bit is not set Downstroke stopped by software Permit downstroke bit was reset
69. 07 39 29 NOTUSED 30 00730 TOP ON TOP N C 717PB STOP ON TOP N C 00314 14 12 14 07 51 LEFT INCH BUTTON 719 00315 1 4 INPUT15 12 15 34 07 42 RIGHT INCH BUTTON 71828 0316 12 1656 07 43 CONTINUOUS SETUP BUTTON 720PBBI 003 17 37 INPUT 17 12 17 87 07 44 39 NOTUSED 40 47 49 07 46 07 47 10512 08 01 9e GROUNDED SYSTEM I O WIRING DWN TLD DATE 05 26 95 ALLIER JE Y RACK A00 GROUP 3 DWG NO DWG REV ROCKWELL INTERNATIONAL COMPANY RACK GROUP 3 40001797 0 OF 9 CAB CUST SHEET 7 Publication 6556 6 5 1 October 1996 H 8 Wiring Drawings for a Grounded System 29 1771 1016 120 ISOLATED INPUT M 08 01 10512 RACK A00 115 ica MODULE GROUP 4 08 02 U gt 120 INPUT of 7 BO 905 10 MICRO INCH 1 FEEDBACK 08 03 INPUT 1 1 0 005 1 MICRO INCH 2 FEEDBACK T A VALVE STEM CLUTCH 1 8041 08 04 122 5 004 02 a 0 gt wc 08 28 gt VALVE STEM CLUTCH 2 80515 08 05 gt e 12 8 inputs 7 4004 03 a 2 08 29 lt 08 06 19 Notused 9 VALVE STEM AUXILIARY 1 80715 08 07 2412 12 4 INPUT4
70. 12 BN NM M e 004 14 L 08 33 10512 10511 Publication 6556 6 5 1 October 1996 INPUT 6 INPUT 7 NOT USED INPUT 10 INPUT 11 INPUT 12 INPUT 13 NOT USED INPUT 14 3 10 Customize the Wiring Module Group 5 sheet 9 of 9 Ungrounded AC Power For this modification Make these changes Use Valves With No change to output wiring in I O group 5 Internal Fault Detection 4 Important Write ladder logic to reset bit B151 20 Auxiliary Valve Stems Enabled Write ladder logic to reset bit B151 21 C B Valve Stems Enabled Delete Auxiliary Delete Auxiliary Valve 1 and wiring from output terminal 15 for chassis A and B Valve Outputs Delete Auxiliary Valve 2 and wiring from output terminal 17 for chassis A and We deleted the wiring Figure 3 10 and added the label Reserved Do Not Use Important Write ladder logic to reset bit B151 19 Auxiliary Valve 1 Enabled Write ladder logic to reset bit B151 22 Auxiliary Valve 2 Enabled Delete Micro inch Delete Micro inch Valve 1 and wiring from output terminal 25 for chassis A and B Valve Outputs Delete Micro inch Valve 2 and wiring from output terminal 27 for chassis A and We deleted the wiring Figure 3 11 and added the label Reserved Do Not Use Delete Crowbar Delete Crowbar Relays and wiring from output terminal 33 for chassis A and B Relay Outputs We del
71. 150 SUBROUTINE Input Parameter 0 Resolver Store Press Position Speed Inputs GEQ B170 GREATER THAN OR EQUAL ONS MOVE Source A N80 0 10 Source N123 36 128 Source B 200 Dest N80 1 128 t Resolver Position TCam ES H LIM 151 ESS THAN LIMIT TEST CIR cese Les Source A N80 1 Low Limit 170 0 128 Source B 100 Test N80 0 110 F High Limit 340 Resolver Position LIM T LIM IMIT TEST CIR LIMIT TEST CIR pee Low Limit 101 Low Limit 170 Test 80 1 Test N80 0 128 110 High Limit 140 High Limit 337 Write Ladder Logic 4 29 Resolver Position LIM LIM LIMIT TEST CIR 4 LIMIT TEST CIR Low Limit 141 Low Limit 170 Test 80 1 Test N80 0 128 110 High Limit 180 High Limit 330 Resolver Position LIM LIM LIMIT TEST CIR 4 LIMIT TEST CIR Low Limit 181 Low Limit 170 Test N80 1 Test N80 0 128 110 High Limit 220 High Limit 320 Resolver Position LIM LIM LIMIT TEST CIR LIMIT TEST CIR Low Limit 221 Low Limit 170 Test 80 1 Test N80 0 128 110 High Limit 260 High Limit 310 Resolver Position GTR LIM GREATER THAN LIMIT TEST CIR Source A N80 1 Low Limit 170 128 Source B 261 Test N80 0 110 High Limit 300 Resolver Pos
72. 19 01 20 01 21 01 22 002 10 dicis T0 06 12 01 24 Luse 06 0 1006 01 lt 198 Figure 3 4 Delete Clutch Brake Air Pressure Main Motor Forward and Motion Detector Switches Module Group 2 RACK 800 MODULE GROUP 2 CLUTCH BRAKE AIR PRESSURE CLUTCH BRAKE AIR PRESSURE 4 3L 002 15 4 06 18 gt 002 5 5 INPUT 15 Eus 06 42 MAIN MOTOR FORWARD MAIN MOTOR FORWARD Bl 002 16 FLL 002 16 4 4 3 35 16 MOTION DETECTOR MOTION DETECTOR z7 002 17 4 4 8 002 17 i 39 39 NOT USED 10511 10512 06 25 07 01 Publication 6556 6 5 1 October 1996 3 6 Customize the Wiring Module Group 3 sheet 7 of 9 Ungrounded AC Power For this modification Then see Delete run station 1 Delete the right run station pushbutton switch wired to input terminal 1 chassis Figure 3 5 and to input terminal 3 for chassis B You must have at least 2 wire input terminal 1 for chassis A and input terminal 3 for chassis B to the one active run station power rail 105L1 wire high Delete the left run station pushbutton switch wired to input terminal 3 for chassis A and to input terminal 1 for chassis B Wire input terminal 3 for chassis A and input terminal 1 for chassis B to the power rail 105L2 wire high Delete active pin wiring from input terminal
73. 4 07 13 24 12 11 INPUT 11 23 LEFT RUN STATION 4 BUTTON 714PB T 07 14 26 12 12 INPUT 12 28 1 003 12 2 STATION 3 RIGHT RUN STATION 4 713PB 07 15 2 28 12 13 INPUT 13 57 003 13 STATION 4 ACTIVE PIN T 4 OS 4 Ee tg 0716 a NorUSED 29 j LEFT RUN STATION 4 714PB 07 17 12 14 INPUT 14 5 003 14 A RIGHT INCH BUTTON 718PB SERE 07 18 6 34 12 15 INPUT 15 33 999 19 ote 4 y STATION 4 ACTIVE LEFT INCH BUTTON N C 719PB 07 19 4 36 12 16 INPUT 16 35 003 16 STOP ON TOP N C 717PB Q LJ CONTINUOUS SETUP BUTTON 720P m 07 20 2 38 12 17 INPUT 17 a7 903 16 RIGHT INCH 718PB 07 21 40 NOTUSED 39 4 4 07 22 9 LEFT INCH 719 07 23 99 t o 105L1 105L2 m 07 24 NOTE ato l ALL 120 VAC WIRES ARE 16 AWG RED CONTINUOUS SET UP P B N O 720PB 07 25 UNLESS MARKED OTHERWISE 10511 0512 Publication 6556 6 5 1 October 1996 Wiring Drawings for an Ungrounded System G 7 07 24 1771 1016 120VAC ISOLATED INPUT i H 00 38
74. 6 6 5 1 October 1996 Security When programmed with either version of Rockwell programming software PLC 5 x6 processors provide enhanced security Designated program files such as those storing factory configured clutch brake control logic are locked at the factory You can read them but you cannot edit locked program files of a PLC 5 x6 processor restore PLC 5 x6 programs to other PLC 5 processors Other program files in the PLC 5 x6 processors are available for your application programming Programs written for PLC 5 x6 processors are transferrable between PLC 5 x6 processors only with the Rockwell software used to write the original program Passwords and Levels of Memory Protection Either version of Rockwell software and PLC 5 x6 processors provide four levels of memory protection The password to the highest level including access to program files PF2 and PF16 is kept confidential at the factory We pre assigned access privileges to other levels They include a read only privilege at the lowest level You create your own passwords for the three lower levels We show you how to assign privileges and passwords in chapter 5 Overview of the Clutch Brake Control System 1 7 Functional Block Diagram Modes of The functional block diagram in Figure 1 5 shows the relationships between various mechanical components of a stamping press and the control system Figure 1 5 Functional Block Diagram Master Run Run
75. 73 detected C B power is removed Check valve and valve wiring 075079 Spar i To clear this latched fault bit you must enable the fault reset bit or turn the mode select switch to OFF Publication 6556 6 5 1 October 1996 C 4 Troubleshooting with Fault Codes Operator Prompts and Snapshot Status Bits Faults Associated with Processor B B168 Suggested Message Cause of Fault Effect of Fault How to Correct the Fault 080 Processor B Remote 1 0 link channel 1B failed C B power is de energized Check remote I O cable to chnl 1A Communication Timeout Check port configuration 081 Crowbar Relay B Crowbar relay B C B power is de energized Check crowbar relay wiring and Weld Fault welded closed and will not turn ON operation of input module in slot 2 082 Crowbar Relay B Crowbar relay B C B power will not turn ON Check crowbar relay wiring and Failed to Turn ON failed to close operation of input module in slot 2 083 Controller OK relay Not wired according to C B power will not turn ON Change wiring per SW revision 1 3 test failed latest drawings 084 Seal Relay B Seal relay B C B power will not turn ON Check seal relay wiring and Timeout Fault failed to close operation of input module in slot 2 085 Seal Relay Seal relay C B power is de energized Check seal relay wiring and Weld Fault welded closed and will not turn ON operation of input module in slot 2 086 E Stop Relay E Stop relay C
76. B power will not turn ON Check E Stop relay circuit and Failed to Turn ON failed to close operation of input module in slot 2 087 E Stop Relay CRMB relay C B power is de energized Check E Stop relay circuit and Weld Fault welded closed and will not turn ON operation of input module in slot 2 088 No Valid Mode Mode select failed C B power will not turn ON Check mode selector switch wiring and operation of input module in slot 4 089 Processor Mode Mismatch Each processor sees a different Press will not stroke Check mode selector switch wiring mode and operation of input module in slot 4 090 Processor B Station 1 Run button failure or Prevents single or continuous Check run buttons and wiring Not Active nor Bypassed improper wiring stroking 091 Processor B Station 2 Run button failure or Prevents single or continuous Check run buttons and wiring Not Active nor Bypassed improper wiring stroking 092 Processor B Station 3 Run button failure or Prevents single or continuous Check run buttons and wiring Not Active nor Bypassed improper wiring stroking 093 Processor B Station 4 Run button failure or Prevents single or continuous Check run buttons and wiring Not Active nor Bypassed improper wiring stroking 094 Processor B Station 1 Run button held too long before Press will not start a stroke Release then press run buttons Tiedown pressing other Run button single or continuous mode simultaneously Che
77. B151 13 1 ON lets your logic switch the mode to single OFF prevents same When OFF your logic must select another remote mode B151 14 1 ON lets logic switch the mode to continuous OFF prevents same When OFF your logic must select another remote mode B151 15 ON crowbar relay circuit is enabled 1 OFF crowbar relay circuit is passive Example Application Monitor the shaft position during press strokes If not set prior to pressing Run buttons operator must release and re press them Use to ensure that safety interlocks are in safe state before enabling Run buttons Use with run buttons for delayed start Run buttons can be pressed and held until this bit is set Halts upstroke if a mechanical device is in a danger zone Halts continuous stroking Permissive switches must be OK to start or continue inch motion Simulates the pressisng of manual inch buttons Allows automatic inch motion with Simulated Inch Buttons bit 09 For analog input Must turn ON to detect that press is powered Must turn ON within preset 8 sec of C B power to detect that the press is moving Set main selector switch to remote and use automation simulated run buttons Automated presses are cycled from a master controller or from a line supervisor Supplements E Stop Shorts L1 to L2 if seal relay does not open 1 Important These bits are held OFF in ladder logic unless your custom ladde
78. B151 24 Simulate a pressure switch with an analog input Clutch Pressure 151 11 Simulate a motion switch with a resolver input Press in Motion 1 151 12 Simulate a motion switch with a drive input Main Motor Forward B151 18 Select the operating mode remotely with your ladder logic Remote Inch Mode B151 10 Main selector switch must be switched to remote mode Remote Single stroke Mode Remote Continuous Mode 151 14 Remote Micro inch 151 24 Remote Automatic Single stroke B151 26 Use a pushbutton to reset the processor after a C B fault B151 23 Enable the crowbar relay circuit to dead short the ac line Enable Crowbar Relay B151 15 Determine the sequencing of auxiliary valve operation B151 16 Also used with bits 19 and 22 for soft C B valves Aux Valve 2 Cycles with Clutch Outputs B151 17 Program soft clutch and and brake valve operation Aux Valve 1 Enabled B151 19 Also used to delete the use of auxiliary valves 1 and 2 Aux Valve 2 Enabled 151 22 Delete valve stem feedback when using valves with Aux Valve Stems Enabled B151 20 detection Valve Stems Enabled B151 21 1 for resolver inputs only Publication 6556 6 5 1 October 1996 Define Your Control System Characteristics 2 11 8 Select Options That Affect System Wiring Check the ac distribution system wiring you will use ungrounded appendix or grounded appendix H Important
79. Check chain break switch and wiring 048 No Motion Detected Upon command to move The press will not start in Check motion detector switch wiring no motion was detected single or continuous mode and motion detector logic 049 Spare 050 Uncommanded Motion was detected when no C B outputs are de energized Check motion detector switch wiring Motion Detected motion was commanded and motion detector logic 051 At Rest On switching to inch the software The press will not inch Check prompts for reasons why press Inch Button Tiedown detected a held inch button will not inch Check inch button wiring To clear this latched fault bit you must enable the fault reset bit or turn the mode select switch to OFF Publication 6556 6 5 1 October 1996 Troubleshooting with Fault Codes Operator Prompts and Snapshot Status Bits 3 168 Suggested Message Cause of Fault Effect of Fault How to Correct the Fault 052 At Rest On switching to run the software The press will not run in single Check prompts for reasons why press Run Button Tiedown detected a held run button or continuous mode will not run Check run button wiring 053 At Rest Arm Continuous button was not The press will not start in Press the Arm Continuous button Run Button Tiedown pressed before Run buttons continuous mode before pressing the Run buttons 054 Micro inch Valve 1 Valve failed to de energize C B power is removed Check valve and valve wi
80. Clutch Valve stem 2FailedtoTumOn 1 Clutch Valve stem 2 Failed to Turn Off Auxiliary Valve 1 Failed to Turn On 1 Auxiliary Valve 2 Failed to Turn 1 Auxiliary Valve 2 Failed to Tum Of 1 Auxiliary Valve stem 1 Failed to Turn On Auxiliary Valve stem 1 Failed to Turn Off 1 Auxiliary Valve stem 2 Failed to Turn On Auxiliary Valve stem 2 Failed to Turn Off 1 Automatic Single stroke Time Out 3 0 Publication 6556 6 5 1 October 1996 Define Your Control System Characteristics 2 13 10 Select Options That Require Programming We give you examples to help you program the following options If Then Refer to Logic Using delayed start logic Program your own Figure 4 4 Using a soft clutch and brake eee Figure 4 14 Starting remote automatic single stroke cycles Starting remote automatic continuous on demand Exchanging data between processors Using fault and prompt bits Using shorter presets for internal timers Using press ready to start indicators Using a brake monitor Using variable speed top stop Publication 6556 6 5 1 October 1996 2 14 Define Your Control System Characteristics Notes Publication 6556 6 5 1 October 1996 Chapter Objectives How to Customize the Default Wiring For This Category crowbar air pressure main motor forward motion detector run stations active pin arm continuous press mode selector auxiliary valves micro inch valves Chapter 3
81. Configurable option designed to detect press motion from a hardware or software input or Continuous Brake Monitor Configurable option designed to prevent restarting the press when the system detects a faulty brake signal from the brake monitor cam BCAM or from a time based input On the hop Stop on top cycle stop Interrupted stroke Anti repeat Motion detector Publication 6556 6 5 1 October 1996 Overview of the Clutch Brake Control System 1 9 Required In put Switches The clutch brake control system requires input switches Table 1 B lists representative types Select the right input switches for your application Table 1 B Required Input Switches Device Symbol Purpose Type Allen Bradley Type Qty Palm P ae Lets press operators start the press Momentary pushbuttons 2 Articulated Palm up Buttons for Assures 2 hand operation dual contact Buttons 800P F2CA to Run Stations OO Note Position RUN buttons at least 24 apart normally closed N C 4 Left Right and RUN stations in accordance with and normally open ANSI 11 1 appendix A Left hand Lets you inch the press up or down Momentary pushbuttons Articulated Palm 1 Inch Note Position INCH buttons at least 24 apart dual contact N C and Buttons 800P F2CA Right hand Lets you inch the press up or down Momentary pushbuttons Articulated Palm 1 Inch Note Position INC
82. D File Type ID File Type ID File Number File Number 2 digit Rack Nu Word or Element Number Word Number Group Bit Number Terminal 4 4 N7 15 5 0 00213 Delimiter Delimiters Delimiters Programming Considerations for PLC 5 Processors F 11 Creating Data Storage Files You create data storage files in two ways by directly creating data storage files each time you assign an address to an instruction Good programming techniques suggest that you keep data storage areas as small as possible to minimize scan time and avoid wasting memory storage Directly Creating Data Storage Files You create data storage files with your programming terminal by entering the file address of the highest numbered element that you want in the file For example If you create a file by entering the address N7 9 the processor allocates to that address all words or elements from that address down to zero 10 words or down to the next lower assigned address If the next lower assigned address was N7 3 your file at address N7 9 would include six words down to N7 3 Figure F 5 Figure F 5 How the Processor Allocates Data Storage When You Create a File or Assign an Address File N7 File N7 If there is no other address for File N7 If you previously created File N7 3 assigning an address of N7 9 creates a assigning an address of N7 9 creates a 10 word file 6 word file down to word 3 Data Storage Created by Assigning A
83. DWG REV RACK B00 GROUP 3 40001797 0 7 AILILIEN IBIRJAIDIL A ROCKWELL INTERNATIONAL Publication 6556 6 5 1 October 1996 G 8 Wiring Drawings for an Ungrounded System 4 07748 06 24 774 1016 120VAC ISOLATED INPUT 5 gt 08 01 115C RACK A00 gt 10512 MODULE GROUP 4 us 4 2 T INPUT 4L 8O 005 10 MICRO INCH 1 FEEDBACK lt 09 36 Hal 12 INPUT 1 _ 9 006 11 MICRO INCH 2 FEEDBACK 09 87 bans VALVE STEM CLUTCH 1 804LS 08 04 76 12 2 INPUT 2 5 gt 08 28 lt _ 1 ditus VALVE STEM CLUTCH 2 805LS 08 05 48 L2 3 INPUT3 7 08 29 lt 08 06 10 NOT USED 9 VALVE STEM AUXILIARY 1 8071 08 07 b 12 L2 4 INPUT4 11 0405 e 08 31 lt 8 25 PS _ VALVE STEM DUMP 2 AUXILIARY 808LS 08 08 14 12 5 INPUT5 13 NG tid 12 6 1 6 155 1004 06 Lid 1 004 07 P 08 10 2118 L2 7 INPUT7 17 c J 08 11 20 NOT USED 19 Isl Al 004 10 f QA 08 12 1 22 L2 10 INPUT 10 21 619 k 08 13 4 12 INPUT 11 pg A 004 11 51 Al 004 12 4 QA 08 14 26 L2 12 INPUT 12 25 5179
84. H buttons at least 24 apart dual contact N C and N O Buttons 800P F2CA Stop on Top Stops press at top during continuous stroking Momentary pushbutton Yellow Mushroom 1 ale single N C contact head 800T D9B E Stop pom Stops the press immediately Momentary pushbutton Jumbo Mushroom 1 Note Wire switches in series as needed single N C contact head 800T FXP16RA5 more Mode e Lets you select the operating mode Rotary 7 position N A 1 Select e O O0 Off key lockable Inch Micro inch onde Continuous Remote Die Change Arm Lets you begin a multi second time window to Momentary pushbutton Black Momentary 1 Continuous start continuous mode single N O contact Pushbutton 800T A2A Main Motor Monitors whether motor forward starter is N O auxiliary contact for Motor Starter 2 Forward engaged If not it opens to prevent running the forward motor starter Auxiliary Contact 595 A Interlock press in single or continuous mode Air Pressure Pressure Switch 836 C8JX321 Motion Detects if motion is stopped in single or N A Detector continuous mode Interlock Note If using resolvers you program this function Control Reset Clutch Brake e Lets you manually reset clutch power and Momentary pushbutton Power Reset Chain Break crowbars if used on power up or after E stop Monitors the chain drive Note When it detects br
85. Inch Buttons B151 09 and Select Remote Inch Mode B151 10 Use these two command bits in an automatic operation In this example they are used to inch the press to bottom Important The main selector switch must be in remote mode Master Controller ADC Inch Remote Command Inch Mode 1 030 8151 pese Co 01 10 Master Controller Slide In ADC Inch ADC Inch Bottom to Bottom Command Zone Complete 1 030 160 B156 Ut cerca 2 73 01 59 03 ADC Inch to Bottom Complete 8156 Poss 03 Master Controller ADC Inch Simulate ADC Inch to Bottom Permit Inch Command Complete Inch Buttons 1 030 8156 B151 B156 dcc MEE lI E 01 03 08 09 Figure 4 9 Example of the Command for Clutch Pressure ON B151 11 Use the signal from a pressure transmitter and 1771 IFE module to detect that clutch brake air pressure reached setpoint Air Pressure Clutch Reached Setpoint Pressure ON GEQ 151 GREATER THAN OR EQUAL Source N40 0 14 Source B 70 Clutch Air Pressure Pressure Noise ON Reduction B151 LEQ FLESS THAN OR EQUAL LI Source A N40 0 Source B 65 Publication 6556 6 5 1 October 1996 Write Ladder Logic 4 11 Figure 4 10 Example of the Command for Press in Motion B151 12 Use the press in motion command to detect shaft motion
86. LLER bod 119A 198 pion 119 OK Q pt 06 14 TO 08 19 942CR A RELAY 121 TO 06 38 AI 002 10 TO 06 12 NOTE ALL 120 VAC WIRES ARE 14 AWG RED UNLESS MARKED OTHERWISE DWN TLD DATE 01 22 93 UNGROUNDED SYSTEM DWG NO POWER DISTRIBUTION 40001797 0 Publication 6556 6 5 1 October 1996 Wiring Drawings for an Ungrounded System 1771 1D16 120VAC ISOLATED INPUT 06 01 01 09 01 24 01 24 RACK 00 01 09 m 1198156 MODULEGHOURS TAKEOVER CAM LIMIT SW 602LS 06 02 2 120 INPUT of 1 002 00 ANTIREPEAT CAM LIMIT SW 60315 06 03 4 12 INPUT 1 3 1002 01 BRAKE MONITOR CAM LIMIT SW 60415 06 04 6 12 2 INPUT 2 5 90 92 b AUXILIARY VALVE 1 FEEDBACK n 6 8 12 3 INPUT 3 _80 005 04 09 31 06 06 0 NOT USED 9 AUXILIARY VALVE 2 FEEDBACK 06 07 4 12 INPUT 4 1 8900505 09 32 CLUTCH VALVE 1 FEEDBACK Saco 14 12 5 INPUT 5 13 O 005 00 09 26 CLUTCH VALVE 2 FEEDBACK d s INPUT 6 ig BO 005 01 tse SEAL RELAY 919CR dit 8 127 INPUT7 17 002 07 of bo 06 11 20 NOT USED 19 CLUTCH BRAKE POWER RESET NO 117PB 06 12 22 12 10 INPUT 10 214100210 4 577 E 06 36 CLUTCH BRAKE POWER FEEDBACK 06 58 Joa 12 11 INPUT 11 23 115 01 15 06 14 H os 12 12 INPUT 12 25 119A CROWBAR RELAY A FEEDBACK dd CRMA 113CR 28 1213 IN
87. Micro inch Valve 2 Valve failed to energize Press will not cycle in Check valve and valve wiring Failed to Turn ON when output was turned ON micro inch mode To clear this latched fault bit you must enable the fault reset bit or turn the mode select switch to OFF Publication 6556 6 5 1 October 1996 C 6 Troubleshooting with Fault Codes Operator Prompts and Snapshot Status Bits 168 Suggested Message Cause of Fault Effect of Fault How to Correct the Fault 138 Aux Valve 1 Valve failed to energize Press will not cycle Check valve and valve wiring Failed to Turn ON when output was turned ON 139 Aux Valve 1 Valve failed to de energize C B power is removed Check valve and valve wiring Failed to Turn OFF when output was turned OFF 140 Aux Valve 2 Valve failed to energize Press will not cycle Check valve and valve wiring Failed to Turn ON when output was turned ON 141 Aux Valve 2 Valve failed to de energize C B power is removed Check valve and valve wiring Failed to Turn OFF when output was turned OFF 142 Aux Valve Stem 1 Valve failed to energize Press will not cycle Check valve and valve wiring Failed to Turn ON when output was turned ON 143 Aux Valve Stem 1 Valve failed to de energize C B power is removed Check valve and valve wiring Failed to Turn OFF when output was turned OFF 144 Aux Valve Stem 2 Valve failed to energize Press will not cycle Check valve and valve wiring Failed to Turn ON w
88. NPUT 7 VALVE STEM CLUTCH2 Reserved Do Not Use Reserved Do Not Use VALVE STEM CLUTCH 2 7 INPUT 3 NOT USED 9 9 NOT USED INPUT 4 1 VALVE STEM AUX 1 Reserved Do Not Use Reserved Do Not Use VALVE STEM AUX1 111 INPUT 4 INPUT 5113 VALVE STEM AUX 2 Reserved Do Not Use Reserved Do Not Use VALVESTEMAUX2 19 INPUTS Figure 3 9 Delete Unused Selector Switch Positions Module Group 4 RACK 00 MODULE GROUP 4 INPUT 6 004 06 sts x 4 R 2 e FROM 08 17 B004 06 ee 7 NPUT 7 71 2004 0 I tix 8 004 07 5 It toot NOT USED 19 1 toot I Sl 19 101 rot MEME le 1 1 1 1 1 1 BIE EE WB sm g e 1 1 1 1 1 1 1 me MEE RE EE MR CURE ES E 1 Pri paoi 1 INPUT 12 25 Reserved Do Not Use ses H i m e Reserved Do Not Use 25 1 1 1 1 uel EIE 13 27 Reserved Do Not Use 87779 Reserved Do Not Use 27 m NOT USED 29 1 29 NU E NU NPUT 14 00414 NE NE
89. OT use Read only File Reserved for Image Table 1 002 1 004 Input words monitored by PF16 1 020 1 025 Scanner cross checking between processors 1 026 Scanner word reserved for future use 0 005 Output bits controlled by PF16 0 020 0 025 Scanner cross checking between processors 0 026 Scanner word reserved for future use Bit Files B20 B29 Bits used in PF2 B160 169 Bits used in PF16 Block Transfer Files BT163 Block transfer words for PF16 Control Register R165 Control words used in PF16 Integer Files N160 N169 Integer words used in PF16 Timer Files T21 Timers used in PF2 T162 Timers used in PF16 Publication 6556 6 5 1 October 1996 E 2 Mapping of Data and Program Files Reserved Program Files Publication 6556 6 5 1 October 1996 Useable Data When writing ladder logic for your control system you may write to the following data files for their intended purpose Use These Files For B150 0 Programmable output bits in PF15 B151 0 1 Programmable command bits in PF15 B152 Other bits for you to use in PF15 B168 0 9 Read only fault bits in PF16 for troubleshooting B169 0 9 Read only prompt bits in PF16 I 027 0 027 Programmable data exchange between processors N22 N29 Integer words for other press functions N30 N39 Integer words for you to use in PF3 N40 N149 Integer words for other press functions N153 N159 Integer words for you to use in PF15 N170 N499 Integer words for other press functions
90. PUT 13 27 002 18 Fo 06 16 30 NOT USED 29 RM POWER FEEDBACK 06 17 32 12 14 INPUT 14 3 112A ERO 01 13 CLUTCH BRAKE AIR PRESSURE 5248 34 12 15 INPUT 15 33 1902 15 E gt 06 42 i MAIN MOTOR FORWARD 06 19 36 12 16 INPUT 16 35 _ 002 16 Fo MOTION DETECTOR 06 20 38 12 17 INPUT 17 a7 5 002 17 o 06 21 40 NOT USED 39 06 22 10511 06 23 410802 198 1150 06 25 Publication 6556 6 5 1 October 1996 Wiring Drawings for an Ungrounded System RACK B00 GROUP 2 SHEET 6 OF 9 TET 1771 1016 120VAC ISOLATED INPUT ORT bs v RACK 800 06 25 1052 TAKEOVER CAM LIMIT SW 6261 8 MODULE GROUP 1051 1198 On 00200 1 INPUT 0 L2 0 2 06 26 ANTIREPEAT CAM LIMIT SW 62715 Ox 9 81 09201 3 INPUT 1 L2 1 L465 Sa 06 27 BRAKE MONITOR CAM LIMIT SW 62815 81002102 5 INPUT 2 12 2 ler 06 28 A
91. PUT 2 Figure 3 18 Delete Run Stations and Active Pin Module Group 3 0 10811 RACK BOO MODULE 3 MODULE GROUP 3 MUT 003 RIGHT RUN STATION 0 7 PB RUN STATON N0 7 PB BI 003 NPUT NUT 003 RUN STATON BUTTON NC 7 PB RIGHT RUN STATION BUTTON NC 7 PB BI 003 INPUT INPUT STATION Reserved Do Not Use Reserved Do Not Use STATION INPUT Figure 3 19 Delete Arm Continuous Switch Module Group 3 m RACK BOO MODULE GROUP 3 INPUT 17 37 CONTINUOUS SETUP BUTTON 0 Reserved Do Not Use NOT USED RIGHT INCH 718PB 5 eto LEFT INCH 719PB 4 9 amp 3 Q 10811 08 01 MODULE GROUP 3 CONTINUOUS SETUP BUTTON N O 37 INPUT 17 Reserved Do Not Use 39 NOT USED Publication 6556 6 5 1 October 1996 3 16 Customize the Wiring 1 0 Module Group 4 sheet 8 of 9 For this modification Use Micro inch Valves With Internal Fault Detection Delete Micro inch Valves Use C B Valves With Internal Fault Detection Use Auxiliary Valves With Internal Fault Detection Delete Auxiliary Valves Delete Unused Selector Switch Positions Chain Break Grounded AC Power Delete micro inch valve stem limit switches and wiring from input terminals 1 and 3 We removed the wiring
92. Response F 5 Program a Faster Response with Special Instructions F 5 Scan Logic Only When F 6 Other Considerations F 6 Using Subroutines F 6 How Subroutines Are Scanned F 7 Using Immediate I O Instructions F 9 Passing Data Into and Out of a Subroutine F 9 Working With Data F 10 Data 5 23 cos qur E F 10 Addressing Your F 1 vi Table of Contents Creating Data Storage Files Directly Creating Data Storage Files Data Storage Created by Assigning Addresses Wiring Drawings for an Ungrounded System Wiring Drawings Wiring Drawings for a Grounded System Wiring Drawings Manual Objectives Qualifications for Applying this Product Summary of Installation Tasks Using This Manual Preface This manual shows you how to apply the Clutch Brake Application Package cat no 6556 Pxxxx to your mechanical stamping press The manual helps you design install and test the clutch brake control system and interface it with optional auxiliary press functions Only qualified installers should apply the Clutch Brake Application Package to a mechanical stamping press We assume th
93. Slot 5 1771 OD16 between 22 and 24 34 and 36 Ses fsm between between 10 and 12 10 and 12 14and16 14 and 16 1771 ID16 between 10 and 12 14 and 16 Install PLC Processors I O Modules Power Supplies PLC 5 46 Install and Wire the Clutch Brake Control System 6 5 1771 1016 Input Modules These modules have an input filter with a configurable time constant It is factory set to the faster response time Leave jumpers JPR1 and JPR2 in their factory set position If you need additional information refer to the Product Data publication 1771 2 189 Install processors and modules in designated slots of chassis A Figure 6 4 and chassis B Figure 6 5 as follows Chassis A Chassis B PLC 5 46 PLC 5 26 Reserved for your use Reserved for your use Isolated Input Module 1771 1016 Isolated Input Module 1771 1016 Isolated Output Module 1771 0016 Isolated Output Module 1771 0016 Reserved for your use Reserved for your use Slot Power Supply 1771 P4S Slot Power Supply 1771 P4S Figure 6 4 Module Locations in Chassis A gt CM 689 gt ED gt gt Conse gt e 9
94. Status Bits C 1 Troubleshooting with Fault Codes C 1 Prompts for Operating the Press C 6 Troubleshooting with Snapshot Status Bits C 9 NDIBS T sated wees LE C 10 Classes of Memory D 1 Class Privileges D i Read Write Access by Class D i Programi Files prion qup ewes a dr RS coe See D 1 Data Files D 2 Mapping of Data and Program Files E 1 Reserved Data E 1 Reserved FIGS a d ph cecus Kees DE RE ERE E 1 Useable 2 Reserved Program Files 2 Programming Considerations for PLC 5 Processors F 1 Purpose of this Appendix F 1 Program Scan How the Processor Scans a Program F 1 How the Processor Scans the Program 2 The Processor F 2 Affect Your Ladder Logic Has on the Program Scan F 2 sri HOR ER RE SE F 2 Processor Family F 3 Bala Format x REOR Se ees 2 F 4 Addressing F 4 How to Program a Faster
95. Switches X zu Run Stations m Valves Citron ode subroutine optional auxiliary x press function To facilitate standardized programming we suggest that you use the following program file numbers for auxiliary press functions Main Motor Control subroutine PF23 in Processor A Safety Gate Control subroutine PF35 in Processor A PF4 Initialization Spare PF36 Slide Lock Control PF5 Analog Auto Die Change Control PF37 Turnover Control PF6 Lube Hydraulic Main Motor Control PF38 Prebender Rotator Control PF7 Mode Change Inch Motor Control PF39 Nest Station Control PF8 Slide Angle Counter Balance Air Control PF40 Exit Conveyor Control PF9 Spare Cushion Air Control PF41 Scrap Chute Control PF10 Part Transfer Monitor Die Clamp Control PF42 Temperature Control PF11 Die Identification Slide Adjust Control PF43 Spare PF12 Recipe Management Cushion Stroke Adjust Control PF44 Stack Roll Feeder Control PF13 Fault Response Bolster Die Cart Control PF45 Spare PF14 Spare Automation Valve Control PF46 Production Data PF17 Operator Interface PTO Control PF47 Lamp Check PF18 Supervisor Interface Transfer Electronic Feeder Control PF48 Spare PF19 Feeder Blank Roll Interface Crossbar Control PF49 Automation Compensation PF20 Automation Interface Safety Gate Control Publication 6556 6 5 1 October 1996 1 6 Overview of the Clutch Brake Control System Protected Memory in PLC 5 x6 Processors Publication 655
96. T RUN STATION 2 707PB 07 08 14 12 5 iNPUT 5 13 003 05 mats 1 Te RIGHT RUN STATION 3 N O 709PB 07 09 241 12 6 1 0 15 003 06 alot 003 07 LEFT RUN STATION 3 BUTTON N C 710PB STATION 2 ACTIVE e f 07 10 25419 12 7 INPUT7 17 RIGHT RUN STATION 3 709 07 1 2 NOTUSED 1 Spee 4 E ato 9 sa Al 003 10 STATION 3 ACTIVE PIN 0712 12 10 INPUT 10 21 LEFT RUN STATION 3 710PB i RIGHT RUN STATION 4 N O 713PB 5 h 07 13 71 24 12 11 INPUT 11 23 LEFT RUN STATION 4 BUTTON N C 714PB 07 14 7 41 12 12 INPUT 12 26 0091 4 y STATION 3 ACTIVE l d RIGHT RUN STATION 4 713PB 07 15 g 12 13 INPUT 13 27 003 13 STATION 4 ACTIVE PIN Eu j 07 16 30 NOTUSED 29 TOPON SUE LEFT RUN STATION 4 714PB 07 17 2 14 12 14 INPUT 14 1 003 4 a 3 RIGHT INCH BUTTON 718PB ER 07 18 12 15 INPUT 15 33 003 15 8 STATION 4 ACTIVE 2 ES 003 16 LEFT INCH BUTTON N C 719PB 07 19 se 12 16 INPUT te as 0816 STOP ON TOP N C 717PB ra Q LI m L CONTINUOUS SETUP BUTTON 720 07 20 38 12 17 INPUT 17 37 Al 008 16 RIGHT INCH 718PB 07 21 40 NOTUSED 39 e l o n 07 22 LEFT INCH P B 719PB 07 23 d S T e 5 6 10512 els 07 24 CONTINUOUS SET UP 720PB 5 10811 08 01
97. TES E 108 02 Run Continuous Ready Indicator B160 0 007 ue X 159 03 The brake monitor program is designed to monitor and compute stopping time This example program is contained in a selectable timed interrupt STI subroutine with a 2 ms interrupt The program detects stopping time by counting the number of interrupts from when the brake is applied until press motion stops The accuracy is one interrupt period 2 ms in this example Selecting the Interrupt Period The example program scan jumps to the STI subroutine every interrupt period executes the subroutine returns to the main program and continues executing the main program until interrupted again Interrupt Period Executes Executes STI Subroutine Main Program Starts Returns to Starts STI Main Program STI Write Ladder Logic 4 23 The time required to execute the example STI program Figure 4 27 is about 1 2 ms so we suggest an STI interrupt interval of about 2 ms The shorter you make the STI interrupt interval to increase the accuracy of the brake monitor the less time remains to execute the main program so its overall execution time increases The program uses the following words Address Description N91 1 last brake time N91 3 last brake angle N91 4 starting brake angle 1 7 571 count for no angle change Figure 4 27 Example Brake Monitor Program
98. UXILIARY VALVE 1 FEEDBACK E d 09 07 BO DUS 17 INPUT 3 123 8 06 29 9 NOTUSED 10 06 30 AUXILIARY VALVE 2 FEEDBACK 09 08 gt SHUUSIUS 11 INPUT 4 L2 4 285 06 31 CLUTCH VALVE 1 FEEDBACK 09 02 AO 009 00 44 INPUTS 1255 14 06 32 CLUTCH VALVE 2 FEEDBACK 005 01 09 03 005 0 15 INPUT 6 L2 6 6 06 33 SEAL RELAY B 94308 of Bl 002 07 17 INPUT 7 12 7 18 06 34 19 USED 20 06 35 LUTCH BRAKE POWER RESET rA 10512 CLUTCH 5 1 002 10 gt INPUT10 12 10 22 POWER FEEDBACK EE oris gt CLUTCHI 115C 5 1214 See ROWBAR RELAY B FEEDBACK 01 21 gt CRO 121 25 INPUT12 12 12 26 06 38 CRMB 114CR se 002 13 27 INPUT13 12 13 28 4 06 39 29 NOT USED 30 06 40 CRM POWER FEEDBACK 01 13 men 31 INPUT14 L2 14 a2 4 06 41 CLUTCH BRAKE AIR PRESSURE 06 18 ALOO2HS 33 INPUT15 12 15 34 06 42 MAIN MOTOR FORWARD o ko 8 00216 35 INPUT16 12 1636 H 06 43 MOTION DETECTOR o bo 37 INPUT17 12 17 38 06 44 39 NOT USED 40 06 45 06 46 7 10512 10511 084 07 01 07 01 08 01 06 48 EN UNGROUNDED SYSTEM I O WIRINHDWN TLD pATE 01 22 93 J2 ALLEN BRADLE RACK A00 GROUP 2 DWG NO DWG REV A ROCKWELL INTERNATIONAL COMPANY 40001797 0 Publication 6556 6 5 1 October 1996 G 6 Wiring Drawings for an Ungrounded System
99. Valve outputs two clutch valves two auxiliary valves two micro inch valves Position monitoring inputs two rotary cam limit switch assemblies two resolver assemblies one of each of the above Machine inputs top stop motion detector clutch brake air pressure motor forward CRM CRM power Number of run stations e four or fewer Response time of C B control from switched input to turned OFF output 21ms typical excluding other functions Command bits for clutch brake logic e simulate simulate BCAM simulate TCAM e permit cycle start permit run permit downstroke delayed start e permit upstroke top stop e permit inch simulate inch buttons remote inch mode clutch pressure on press in motion remote single stroke mode remote continuous mode enable crowbar relay auxiliary valve 1 cycles with clutch auxiliary valve 2 cycles with clutch motor running forward auxiliary valve 1 enabled auxiliary valve stems enabled e C B valve stems enabled auxiliary valve 2 enabled fault reset remote micro inch mode simulate run buttons remote automatic single stroke mode arm for continuous on demand inch output enabled initiate automatic single stroke Environmental conditions Operating Temperature 0 to 60 C 32 to 140 F Storage Temperature
100. W 5 C counter RW RW RW RW 6 R control RW RW RW RW 7 N integer RW RW RW RW 8 F floating point RW RW RW RW 9 19 reserved for customer RW RW RW RW 20 B binary or bit RW R R R 21 T timer RW R R R 22 28 reserved for customer RW RW RW RW 29 N integer RW R R R 30 149 reserved for customer RW RW RW RW 150 B binary or bit RW RW RW RW 151 B binary or bit RW RW RW RW 152 B binary or bit RW RW RW RW 153 159 reserved for customer RW RW RW RW 160 B binary or bit RW R R R 161 only in processor RW R R R 162 T timer RW R R R 163 BT block transfer RW R R R 164 N integer RW R R R 165 R control RW R R R 166 N integer RW R R R 167 N integer RW R R R 168 B binary or bit RW R R R 169 B binary or bit RW R R R Publication 6556 6 5 1 October 1996 5 4 Assigning Passwords to Your Program and Data Files Publication 6556 6 5 1 October 1996 Program File Privileges We assigned R read only or RW read write privileges to classes 1 4 for controlling access to program files To view the Program File Privileges screen that allocates these privileges follow this procedure for 6200 series software the procedure for AI5 software would be similar 1 Start at the Main Menu 2 Press F1 Processor Functions The system displays the Processor Functions screen 3 Press F2 Modify Privileges You get the Program File Privileges screen We assigned the following privileges for classes 1 4 at the factory File Name Type Class1 Class2 Clas
101. Y CUSTOMER TO 06 01 CONTROL RESET 113CR 114CR CRMA CRMB gt gt 12 AWG BLK 01 25 01 26 01 27 01 28 01 29 01 30 01 31 01 32 06 17 TO 06 41 01 33 01 34 105L2 c 14 AWG WHT 01 35 01 36 CRMA 113CR 01 13 01 15 06 15 N p aa 917 941CR CONTROLLER CONTROLLER 113CR OK CRMA N N 144CR GRMB 115 919CR SEAL RELAY 115C 01 37 01 13 01 19 06 39 01 38 115 _ 115 RERO US off ao lo 2 _ gt TO 08 43 gt TO 08 19 M 117PB CLUTCH BRAKE POWER RESET TO 06 13 TO 06 37 01 39 01 40 01 41 918CR CROWBAR RELAY ote 119A TO 06 14 942CR CROWBAR RE i 121 TO 06 38 Al 002 10 TO 06 12 TO 08 01 ALT A ROCKWELL GROUNDED SYSTEM POWER DISTRIBUTION 01 42 01 43 01 44 01 45 01 46 01 47 01 48 DWN TLD DATE 05 26 95 DWG NO 40001797 0 Publication 6556 6 5 1 October 1996 06 01 06 02 06 03 06 04 06 05 06 06 06 07 06 08 06 09 06 10 06 11 06 12 06 13 06 14 06 15 06 16 06 17 06 18 06 19 06 20 06 21 06 22 06 23 06 24 01 09 M 105L2 10512 06 25 Wiring Drawings for a Grounded System 1771 1016 120VAC ISOLATED INPUT
102. ain program We do NOT provide examples for this subroutines to We do NOT provide examples for this Identify and map the program and data files that we provide see appendix E that your application requires For clutch brake logic review programming examples and command bit descriptions to be sure that you understand associated logic Write your own ladder logic If adding other press control functions use the pre assigned subroutines Attention Be sure to program the scanning of your subroutines in the correct sequence Otherwise possible unexpected motion could cause damage injury or death Thoroughly check your ladder logic data and I O addresses Check your ladder logic against the worksheet in chapter 2 to verify that you programmed all required functions When your programming is free of errors make a back up copy of your software diskette Publication 6556 6 5 1 October 1996 4 6 Write Ladder Logic Programming Command Bits Publication 6556 6 5 1 October 1996 We present programming examples for command bits B151 03 B151 29 logic If using our examples do so only after modifying them to suit your application Direct use or misapplication of these examples could result in unexpected machine motion with possible personal injury and or damage to equipment ATTENTION You are responsible for your own application Command Bit or Function Logic Permit Cycle Start Figure 4 1 Permi
103. ardware When NOT using hardware wiring Enabled and standard wiring Program a rung for the bit B151 20 OFF tells software to ignore corresponding Delete hardware and wiring Stems Enabled hardware inputs because they are absent 3 Correct your wiring drawings Figures 3 10 3 11 3 21 3 22 Valve Stems 151 21 Write ladder logic similar to Enabled Figure 4 15 Auxiliary Valve 2 B151 22 Enabled Fault Reset Auxiliary Valve B151 23 1 B151 24 1 OFF inhibits Simulate Inch Button bit 09 motion with Simulated Inch Button Logic must select another remote mode bit 09 Remote Micro inch Mode Simulate Run ON initiates automatic start of single stroke Operator must cycle one stroke in Buttons for Auto B151 25 cycle from near top position automatic single stroke mode Single Mode OFF Must cycle ON OFF every cycle Then set this bit to start next cycle Continuous 1 ON initiates automatic start of continuous mode Your logic must set this bit within 5 on Demand OFF prevents same minutes of setting bit 27 Remote B151 26 ON lets the logic switch the mode to auto single Allows automatic single stroke Automatic 1 OFF prevents same When OFF your logic with Simulated Run Button bit 25 Single Stroke must select another remote mode Armed for B151 27 ON remote continuous mode arms C B logic Set bit 25 after
104. ass2 Class3 Class 4 Channel 0 System P 2 P Class 4 RW RW RW RW Channel 1A Class 4 RW RW RW RW Channel 1B Scanner Class 4 RW RW RW RW Channel 2A unused Class 4 RW RW RW RW Channel 2B unused Class 4 RW RW RW RW Channel 3A N A Offline Class 4 Publication 6556 6 5 1 October 1996 5 6 Assigning Passwords to Your Program and Data Files Assigning Passwords to Classes Gaining Access to Protected Memory Files Publication 6556 6 5 1 October 1996 You can assign a password to each of classes 2 3 and 4 We suggest that you distribute passwords within your organization based on the access that each password allows responsibilities of password users within your organization Important Only class 1 privileges include modifying privileges of other classes The password for class 1 is maintained confidential at the factory Neither a customer nor any authorized Allen Bradley sales service representative can obtain this password This lets us maintain protection of the factory configured clutch brake code We assigned the password RETURN to classes 2 4 at the factory You can change this password with the following procedure for 6200 series software the procedure for software would be similar 1 Start at the Program Directory for Processor screen 2 Press F7 General Utility The system displays a new set of function keys 3 Press F5 Privileges The system displays the Privi
105. at the installation team includes a professional stamping press builder or re builder knowledgeable in press and press control standards a programmer experienced with programmable controllers especially with the Allen Bradley PLC 5 family of processors an electrical technician skilled in installing electronic equipment Before starting the installation we suggest that you familiarize yourself with the information in this manual We summarize the tasks that your integration team will perform as follows These Tasks Browse through the overview in chapter 1 Browse through the entire manual and appendices Select control options for the stamping press Define control system characteristics Customize the wiring drawings to match control options Program the interface to clutch brake control logic Write ladder logic for auxiliary press functions Assign passwords to guard against unauthorized access Install processors and I O modules I O chassis Connect cables Wire the control system according to selected options Set up rotary cam limit switches or resolvers If using resolvers simulate cam limit switches Test system wiring Test press operation Are Covered in All chapters All appendices Chapter 2 and Appendices A B Chapter 3 Chapter 4 and Appendix E Chapter 5 and Appendix D Chapter 6 and wiring drawings Chapter 7 Chapter 8 Appendices A C Publication 6556 6 5 1 October 1996 P 2 Using
106. ator interface you use The following logic Figure 4 24 generates a BCD fault number whenever control logic sets a fault or prompt bit Publication 6556 6 5 1 October 1996 4 20 Write Ladder Logic Programming Shorter Presets for Your Internal Timers Publication 6556 6 5 1 October 1996 Figure 4 24 Example Logic to Generate a BCD Fault Number y FILE BIT COMPARE EN Source B168 0 DN Reference B156 0 FD Result N10 0 IN Cmp Control R6 0 ER Length 160 Position 0 Result Control R6 1 Length 1 Position 0 Fault Convert Fault Found to BCD for display R6 0 t TO BCD 08 Source N10 0 Dest 9 0 Fault Light QUOS We 01 Important In the FBC instruction above B156 0 is a 10 word file cleared to zero R6 0 09 IN is set for single fault detection For additional information on the FBC instruction refer to the instruction set documentation for your programming software If you need to shorten presets of internal timers do this in program file 15 For each timer that you want to change add a rung as follows Figure 4 25 input instruction GEQ greater than or equal to Source A is the address of the timer whose preset you want to change Source B is the new preset base 01 sec output instruction Bit address associated with the timer For
107. bit with your programming terminal and refer to Appendix C for e fault codes in bit file B168 for troubleshooting prompts in bit file B169 for operating the press Important The software must see real or simulated position monitor signals as described in chapter 7 Otherwise one or more transition faults are designed to shut down the system You can vary the ON OFF times but not the sequence nor overlap of signals This is particularly important during start up Fault bits B168 026 033 and B168 106 113 indicate which position monitor signals are missing or out of sequence Test dynamic press operation with the following procedures Inch Mode 1 Switch both processors to run mode 2 Power up the system by pressing the Control Rest and Clutch Brake Power Reset buttons 3 Visually and with a voltmeter verify that seal relays and CRM relays are energized Place the mode selector switch in inch mode Concurrently press and hold both Inch buttons Observe that the press cycles and stops on top Release the Inch buttons and press again for 1 2 seconds Nl 2 Un Observe that the press cycles until you release an Inch button at which time the press stops Test Your Clutch Brake 8 9 Single stroke Mode e Select inch and inch the press to the top Place the mode selector switch in single stroke mode 1 2 3 4 5 Press and hold Run buttons for more than 1 2 stroke Observe that the press
108. ch button simultaneously Check button wiring 025 Automatic single stroke Automatic single stroke not initiated Press will stop or not run Check logic of your automatic cycle start fault single stroke cycle start 026 Illegal RCLS Combination Software hardware cams produced Press will stop or not run in Check soft cam logic or hard cams invalid combination single or continuous mode for proper operation or settings 027 Forward Transition Software hardware cams did not go Press will stop or not run in Check soft cam logic or hard cams from Top from top to downstroke single or continuous mode for proper operation or settings 028 Forward Transition Software hardware cams did not Press will stop or not run in Check soft cam logic or hard cams from Downstroke enter upstroke single or continuous mode for proper operation or settings 029 Forward Transition Software hardware cams did not Press will stop or not run in Check soft cam logic or hard cams from Upstroke enter near top zone single or continuous mode for proper operation or settings 080 082 Spare HM EDEN 033 Forward Shaft Position Any of 027 029 detected Press will stop or not run in Check soft cam logic or hard cams Transition Faults single or continuous mode for proper operation or settings 034 ACAM Upstroke ACAM did not cycle in upstroke Press will stop or not run in Check soft cam logic or hard cams single or continuous mode for proper operation or
109. ck button wiring 095 Processor B Station 2 Run button held too long before Press will not start a stroke Release then press run buttons Tiedown pressing other Run button single or continuous mode simultaneously Check button wiring 096 Processor B Station 3 Run button held too long before Press will not start a stroke Release then press run buttons Tiedown pressing other Run button single or continuous mode simultaneously Check button wiring 097 Processor B Station 4 Run button held too long before Press will not start a stroke Release then press run buttons Tiedown pressing other Run button single or continuous mode simultaneously Check button wiring 098 Processor Run Stations Among run stations others must be Press will not start a stroke in Press all run stations within timed Tiedown pressed after the first is pressed single or continuous mode interval Check button wiring 099 103 Spare 104 Inch Button Inch button held too long before Release then press inch buttons Tiedown pressing other Inch button simultaneously Check button wiring 105 Automatic single stroke Automatic single stroke not initiated Press will stop or not run Check logic of your automatic cycle start fault single stroke cycle start 106 Illegal RCLS Combination Software hardware cams produced Press will stop or not run in Check soft cam logic or hard cams invalid combination single or continuous mode for p
110. command bit to start either of two remote automatic operations with B151 26 to select remote automatic single stroke Figure 4 19 with B151 27 to arm for remote continuous on demand Figure 4 20 Remote Cycle Start Simulate Command Run Buttons B156 8151 C 59 25 Simulate Slide in Run Buttons Bottom Zone B151 B160 I ec 25 59 Important Before starting remote automatic single stroke with this bit an operator must first cycle the press through one complete stroke in automatic single stroke mode and stop on top with mechanical run buttons Write Ladder Logic 4 17 Figure 4 19 Example Command to Select Automatic Single stroke Mode from a Remote Selector B151 26 Use this command bit to switch press mode to auto single stroke from a remote selector Start the press with bit B151 25 Figure 4 18 ANSI B11 1 requires that your logic include a setup reset action or operator decision prior to the manual actuation of the operator control s Start Set Remote Auto Auto Single Auto Single Pushbutton Single 1 040 1 040 Bil 1 i de 03 09 26 151 26 Important To select press operating modes remotely from a remote selector such as a hardware or software line supervisor an operator must select remote mode with the main selector switch Then your software can select from the following mode select bits one at a time remote i
111. ction parameter such as source destination length etc Here are some suggestions for programming a faster response program a faster response with special instructions e scan logic only when needed with program control instructions e use single transfer for up to 16 bits one word at a time per rung other considerations Program a Faster Response with Special Instructions Rather then trying to minimize program scan time consider responding faster with special programming techniques such as program critical inputs and outputs with Immediate Input IIN and Immediate Output IOT instructions where the processor interrupts the program scan to immediately monitor the subject input or control the subject output each time it scans these instructions in your ladder logic program critical logic with a Selectable Timed Interrupt STI file where the processor interrupts and suspends the normal program scan at periodic intervals to scan this subroutine You preset the interval With either technique the processor suspends the program scan while executing each of these instructions The resulting program scan is longer but the processor responds more quickly where when needed Publication 6556 6 5 1 October 1996 F 6 Programming Considerations for PLC 5 Processors Using Subroutines Publication 6556 6 5 1 October 1996 Scan Logic Only When Needed Use program control instructions to reduce program scan time with these
112. cycles and stops on top Release the Run buttons and press again This time release Run buttons in the downstroke Observe that the press stops immediately Bring the press to top by pressing Run buttons and release in upstroke Repeat steps 3 and 4 This time hold Run buttons for the entire cycle Observe that the press runs through one stroke and stops at the top Continuous Mode with Arm Continuous Place the mode selector switch in continuous mode Press the Arm Continuous button Immediately press Run buttons and release after downstroke 1 2 3 4 5 6 7 Observe that the press continues to cycle Press the Stop on top button Observe that the press completes the cycle and stops on top Attempt to start the press at step 3 but wait until after 5 seconds or until after the Arm continuous timer has timed out before pressing Run buttons Observe that the press does not start Repeat steps 3 through 7 Publication 6556 6 5 1 October 1996 8 10 Test Your Clutch Brake Switch Tests Publication 6556 6 5 1 October 1996 Continuous Mode with Stroke and a half nan A N Place the mode selector switch in continuous mode Press and hold Run buttons for 1 1 2 strokes before releasing them Observe that the press continues to cycle Press the Stop on top button Observe that the press completes the cycle and stops on top Attempt to start the press but hold Run but
113. d Throughout this manual we use notes to make you aware of safety considerations ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attention statements help you to e identify a hazard avoid the hazard recognize the consequences Important Identifies information that is critical for successful application and understanding of the product PLC is a registered trademark of Allen Bradley Company Inc Software Revision 1 3 Series B Summary of Changes Summary of Changes Wiring Changes Important Revision 1 3 software cannot be operated on a machine wired for Revision 1 2 or earlier software without changing the wiring for power distribution sheet 1 of 9 and module group 4 sheet 8 of 9 Summary of Changes We revised this manual to reflect wiring changes and the upgrade to software revision 1 3 as follows Chapter We Made These Changes in Section Title 1 Referred to Rockwell 6200 and 15 software The Application Package 4 Added Command Bits Inch Output Enabled B151 28 e Initiate Auto Single Stroke B151 29 Included 6200 and 5 software procedures Steps to Write Ladder logic Corrected a bit error in Figure 4 17 Programming Command Bits Added ANSI requirement to Figure 4 19 Clarified the description Exchanging Processor Data 5 Referred to 6200 and 15 software procedures throughout 6 Added p
114. d B151 x 0 21 Aux Valve 2 Enabled B151 Figure 4 16 Example of the Command to Clear a Fault Generated by C B Software B151 23 0 22 You can clear a processor fault by switching the press mode selector to OFF As an alternative you can use a remote pushbutton to clear a processor fault by programming bit B151 23 as follows Remote Fault Pushbutton Reset 8156 8151 x E 13 23 Publication 6556 6 5 1 October 1996 4 16 Write Ladder Logic Publication 6556 6 5 1 October 1996 Figure 4 17 Example Commands to Select Remote Micro inch Mode B151 24 and Simulate Inch Buttons B151 09 Use these two command bits in an automatic operation In this example they are used to inch the press to bottom Important The main selector switch must be in remote mode Master Controller Remote Micro inch Micro inch Command Mode 1 030 B151 I AE Co 01 24 Master Controller Slide In Micro inch Micro inch Bottom to Bottom Command Zone Complete 1 030 160 B156 C 01 59 03 Micro inch to Bottom Complete B156 03 Master Controller Micro inch Simulate Micro inch to Bottom Permit Inch Command Complete Inch Buttons 1 030 8156 8151 8156 tao tho MSS lI x 01 03 08 09 Figure 4 18 Example Command to Start Remote Automatic Press Motion with Simulated Run Buttons B151 25 Use this
115. d to limit press operation to a single cycle if the actuating means is held actuated Anti repeat requires the release of all means of actuation before a repeat stroke can occur brake monitor a part of the control system designed to prevent the next stroke if stopping time or distance exceeds a preset takeover a part of the control system designed to allow upstroke without the operator holding the run buttons Valves clutch valve the main valve that controls the flow of air to the clutch brake mechanism auxiliary valve valve used in addition to the clutch valve such as for dump soft clutch brake etc dump valve the valve that vents a large volume of air to from the clutch brake mechanism solenoid valve an on off electrically driven valve valve stem feedback fault detection for valves a signal from a switch on the valve stem that tells when the valve is open or closed external designed so a signal from an external valve stem switch detects when the valve is malfunctioning internal the valve is designed to turn itself off in the event of valve failure Publication 6556 6 5 1 October 1996 P 4 Using This Manual Publication 6556 6 5 1 October 1996 Notes Chapter Objectives The Application Package Chapter 1 Overview of the Clutch Brake Control System This chapter acquaints you with the Allen Bradley clutch brake control system for part revolution mechanical stamping presses with a fricti
116. dditional program logic could extend the stopping time resulting in possible death personal injury and or damage to the press and or tangential machinery ATTENTION You are responsible for system response Where fast press stroking and considerable program logic are required for your application consider an independent PLC 5 processor for other press functions The clutch brake control program contains timers with factory set presets You may change timer presets to time out faster but never slower than the factory set presets See chapter 4 Examples of internal timers include Type of Timer Preset sec Anti tiedown 3 Motion Detector 3 Arm Continuous 5 Clutch or Auxiliary Valve Feedback Publication 6556 6 5 1 October 1996 1 12 Overview of the Clutch Brake Control System Options to Suit Your Application Publication 6556 6 5 1 October 1996 To customize the control system to suit your application we help you e select your factory configured options program your clutch brake interface with ladder logic commands wire your control system Selecting Factory Configured Options When you purchased your Application Package you designated factory configured options by a coded catalog number 6556 Pxxxx from combinations of these features Order Code Option Lets You A Method to for Armed Continuous start continuous stroking by pressing the Arm Start Continuous button and all active run buttons
117. ddresses When you assign an address to an instruction the processor allocates memory storage in a data file The processor creates the data file automatically The size of the file is equal to the number of elements words or bits from the assigned address down to zero or down to the next lower assigned address Publication 6556 6 5 1 October 1996 F 12 Programming Considerations for PLC 5 Processors Publication 6556 6 5 1 October 1996 For example if your first assigned timer in your program has the address T4 99 the processor allocates storage for timers T4 99 down to T4 0 whether you use them or not Since each timer address uses three words timers are 3 word elements your timer address of T4 99 has created a 300 word data storage file As another example if you assign the address N7 9 to store a word or element the processor opens a file from that address down to zero or down to the next lower assigned address If the next lower address was N7 3 address N7 9 would include all words down to N7 3 Figure E 5 For further information refer to either of these programming manuals PLC 5 Programming Software Instruction Set Reference publication 1785 6 1 e PLC 5 Programmable Controllers User Manual publication 1785 6 2 12 Use this template for your appendices If it were not for the different running head this would read like any other chapter Wiring Drawings Appendix G Wiring Drawings for an Ungrou
118. e from top to bottom to top with RUN buttons with or without on the hop Continuous Run the press with uninterrupted stroking for production operation Remote Select Inch Micro inch Single Auto Single or Continuous mode remotely Simulate inch and run buttons and arm for continuous on demand Die Change Run die change only Publication 6556 6 5 1 October 1996 1 8 Overview of the Clutch Brake Control System Clutch Brake Clutch brake control functions are summarized in Table 1 A Control Functions Table 1 A Summary of Clutch Brake Control Functions Control Function Operating Mode Description Selector Switch ot Prevents energization of clutch brake outputs LN Lets the operator jog the press through through successive parts of the 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 Micro inch This mode of operation lets you run your press a low speeds 1 spm typical for setting up dies You must supply a separate drive and clutch brake assembly to drive the shaft at low press speeds bypassing the flywheel Single stroke Lets the operator jog the press through one complete cycle stopping on top by holding both RUN buttons until completion of the down stroke Continuous Lets the operator run the press continuously until stopped by a stop on top command or until a fault is detected The method to start the press is a fact
119. e Supervisor For programming networking troubleshooting and information management Press Control Panel Operator Interface 8 Clutch Brake I O amp 0000000000 other to from the press for auxiliary functions DH Network PLC 5 46 Processor A scanner has these program files PF2 Factory configured master control program locked PF3 Your file for calling auxiliary press control functions PF15 Your file for customizing clutch brake control in PF16 PF16 Factory configured clutch brake program locked Clutch Brake to from the press PLC 5 26 Processor B adapter rack 02 of processor A has the same program files but the use of is optional Remote 1 to drives pneumatic valves optional processor for additional automation and man machine interface Dual processors control outputs to clutch brake valves To illustrate the redundant control concept we show how processor outputs are linked to processor inputs Figure 1 2 where are processor outputs and are processor inputs Figure 1 2 Redundant Control of Processor Outputs for Ungrounded AC Power Processor A Valve Solenoid Processor B N ye j 12 Publication 6556 6 5 1 October 1996 1 4 Overview of the Clutch Brake
120. e also grouped according to ungrounded ac system power grounded ac system power Publication 6556 6 5 1 October 1996 3 2 Customize the Wiring Install Your Wiring Drawing Diskettes Publication 6556 6 5 1 October 1996 We provide you with wiring drawings on diskette so you can install them on your computer and modify them electronically according to the options that you choose for your application e DWG AutoCAD release 11 0 DXF File Interchange Follow this procedure to install your wiring drawings and to select the format that suits your computer 1 Insert the Clutch Brake Wiring Drawings diskette 2 Change to a drive 3 At the a prompt type Install You get the Select the Appropriate Drawings window 4 To select ungrounded and or grounded ac wiring drawings cursor to your choice of ungrounded grounded both Then press ENTER You get the Select Appropriate File Types window 5 To select the type of file cursor to your choice of DXF File Interchange DWG AutoCAD release 11 0 a both Then press ENTER This installs the file s in the following subdirectories 6556 UNGROUND V6556 GROUNDED 6 Referto your CAD system instructions for the procedure to access these files Customize the Wiring 3 3 Generalized Instructions To customize the wiring drawings to suit your application to Customize Your Wiring 1 Select the modifications that apply to
121. e deleted the wiring Figure 3 14 and added the label Reserved Do Not Use Delete Crowbar Relays A and B from the Power Distribution Drawing sheet 1 of 9 Figure 3 15 See Module Group 5 Delete Crowbar Relays and wiring from output terminal 33 for chassis A and B Figure 3 24 We deleted the wiring Figure 3 24 and added the label Reserved Do Not Use Delete the clutch brake air pressure switch at input terminal 33 for chassis A Figure 3 16 Wire input terminal 33 of chassis A and B to power rail 108L1 wire high Write ladder logic to monitor clutch brake air pressure Figure 4 9 Delete the main motor forward switches at input terminal 35 for chassis A and B Figure 3 16 Wire input terminal 35 to power rail 108L1 wire high Write ladder logic to monitor the device that detects forward motion Figure 4 13 Delete the motion detector switches at input terminal 37 for chassis A and B Figure 3 16 Wire input terminal 37 to power rail 108L1 wire high Write ladder logic to simulate the action of the motion detector switch Figure 4 10 No modifications allowed You must wire these inputs as shown on sheet 1 of 9 N A for the control system to work correctly 108L1 Customize the Wiring 3 13 Figure 3 13 Replace RCLSs wit
122. e start bit has not been toggled has not been toggled automatic single stroke mode Software stop on top is enabled The stop on top bit is set The press will complete the None cycle and stop at top Stop on top button is pressed Stop on top button is pressed The press will complete the None cycle and stop at top 021 Continuous mode not armed You did not press the arm continuous You cannot start the press Press the arm continuous button button continuous mode 022 Release inch buttons You did not release inch buttons after You cannot start the press Release the inch buttons reaching the top until you release the buttons 023 024 Downstroke Disabled Permit downstroke bit should be You cannot start the press Set the permit downstroke bit set when starting the press single or continuous mode 222 22 025 Proc not requesting inch mode Processor not requesting inch mode Check remote wiring 026 027 028 029 Proc not engaging inch mode Processor B not engaging inch mode You cannot inch Check remote wiring Proc not engaging single mode Processor not engaging single mode You cannot start single stroke Check remote I O wiring Proc not requesting arm contin Processor B not requesting arm contin You cannot start continuous Check remote I O wiring Proc not engaging contin mode Processor not engaging contin mode You cannot start co
123. e to the pressure line This is because we changed the logic of the clutch brake pressure switch from cycles with the clutch brake valve to must be ON to run the press Additional New Features Control Bits Press Start Continuous Mode from Any Point in the Press Cycle Operation Examples Variable speed Top Stop n a Ladder Logic to Guard Against Reverse motion Faults Resolver Inputs n a Troubleshooting Troubleshoot the Setup of Your Position Monitoring Devices n a Figure numbers refer to this revision of the manual revision 1 3 dated October 1996 You must change the type of chain break switch from normally closed held open to normally open held closed This is because we changed the chain break logic from input goes ON for a chain break to input goes OFF See wiring drawing sheet 8 module group 4 See Example Figure 4 4 Figure 4 15 Figure 4 16 Figure 4 17 Figure 4 18 19 Figure 4 18 20 in chapter 8 and appendix A Figure 4 27 Figure 4 28 Figure 7 6 in chapter 7 Important Revision 1 1 software cannot be operated on a machine wired for Revision 1 0 software without this change This change remains throughout subsequent software revisions Publication 6556 6 5 1 October 1996 Table of Contents Summary of Changes soc i Software Revision 1 3 Series Soc i Software Revision 1 2
124. eakage it opens to stop a downstroke or to prevent starting the press triple contact 1 N O and 2 N C N O limit switch held closed 1 800T A2A 1 800T A2B 1 Limit Switch 802M AY5 1 with Operating Lever 802MC W1A Publication 6556 6 5 1 October 1996 1 10 Overview of the Clutch Brake Control System Choice of Position Monitoring Devices Control System Outputs System Response Time Publication 6556 6 5 1 October 1996 Purchased separately you have a choice of dual position monitors rotary cam limit switches resolvers combination of both If using rotary cam limit switches we recommend e a pair of Allen Bradley Cat No 803 B94 or 803 P94 If using a resolver we recommend one of these solutions e AMCI Series 1700 Resolver and Absolute Resolver Input Module that plugs into the 1771 I O chassis NSD VRE P062 Resolver and VE 2A Single Turn Converter decoder that connects to a high speed input module such as a 1771 IBD The clutch brake control system is designed with three pairs of outputs available for your application Use these Valve Outputs for these Functions Notes clutch clutch brake valves For clutch or clutch brake valves auxiliary auxiliary valves You can program these outputs in unison with or in opposition to C B valve outputs micro inch separate micro inch drive Used in micro inch mode only The worst case time required for the clutch brake control t
125. ent states of the output image bits program scan makes these states immediately available for the next remote 1 0 scan Passing Data Into and Out of a Subroutine The jump to subroutine instruction JSR and return instruction RET let you pass data to and receive data from a subroutine You can pass integer or floating point numbers program constants or designate addresses to from which integer or floating point numbers variables can be passed Examples of passing data include pass variables to the subroutine for mathematical computations and return the result for use in the main program pass presets to a generic subroutine for multiple recipe operations This instruction lets you by specifying in the instruction e integer or floating point constants addresses in the main program Jump to subroutine pass Input Parameters to the subroutine JSR from which parameter are passed receive Return Parameters e addresses in the main program from the subroutine to which parameters are returned Subroutine SBR store Input Parameters storage addresses in the subroutine Return RET return parameters addresses in the subroutine to the main program from which parameters are returned Publication 6556 6 5 1 October 1996 F 10 Programming Considerations for PLC 5 Processors Working With Data Address for Structure type Data File Type ID File Number Word Structure Number Member Number T4 7 ACC
126. ependent position sensors to monitor the slide position You select the type of position sensor from e dual rotary cam limit switches RCLS dual resolvers with RCLSs simulated in ladder logic e combination of both Rotary Cam Limit Switches These switches monitor the position of the slide by riding rotating cams The switches open or close according to the cam geometry that you can adjust to represent the six rotational zones in the press cycle You must use two independent switch assemblies one wired to chassis A the other to chassis B with these limit switches brake monitor BCAM takeover TCAM e anti repeat Purpose Type In Single Mode Monitors press motion to limit operation to 1 N O contact a single stroke if operators hold RUN buttons too long 2 switches per system In Single or Continuous Mode Monitors the slide 1 N O contact position where the press comes to a stop Designed to 2 switches per system prevent the press from starting if it stops too late In Single Mode Lets the press complete a stroke when 1 N O contact operators release run buttons after downstroke 2 switches per system In Continuous Mode Lets the press continue stroking Stops the press at the end of a stroke when commanded If using rotary cam limit switches record the fact on the worksheet We assist you in setting up your rotary cam limit switches in chapter 7 Resolver Resolvers monitor the position
127. eps e resolver connected to an AMCI interface module Figure 7 3 NSD resolver decoder and 1771 IBD input module Figure 7 4 Follow these steps as applicable 1 Install resolvers one on each end of the crankshaft that drives the slide so they can detect crankshaft breakage The same applies to a resolver RCLS combination Refer to installation instructions provided by the resolver manufacturer 2 Install a resolver input module into module group 0 and or 1 of an I O chassis Use module group 0 for a 1 slot input module or module groups 0 and 1 for a 2 slot input module If using a pair of resolvers repeat for the other I O chassis Refer to installation instructions provided by the manufacturer of the resolver input module 3 Wire the resolver converter module if applicable and input module for the respective I O chassis Refer to wiring instructions provided by the manufacturer Set Up or Simulate Rotary Cam Limit Switches 7 5 Figure 7 3 Resolver and Interface Module Chassis 5 4 m Hen H ETE AMCI Brushless Resolver AMCI Interface Module in Module Group 0 Figure 7 4 NSD Resolver and Converter with 1771 IBD Input Module Chassis m 8 B HG NSD VE 2A
128. er For this modification Make these changes And see Delete run station 1 1 Delete the right run station pushbutton switch wired to input terminal 1 for chassis A Figure 3 17 and to input terminal 3 for chassis B You must have at least 2 Wire input terminal 1 for chassis A and input terminal 3 for chassis B to the one active run station power rail 108L1 wire high 3 Delete the left run station pushbutton switch wired to input terminal 3 for chassis A and to input terminal 1 for chassis B 4 Wire input terminal 3 for chassis A and input terminal 1 for chassis B to the power rail 108L2 wire high 5 Wire input terminal 5 for the station 1 active pin for chassis A and B to power rail 108L1 wire high Delete run stations 1 Delete the right run station pushbutton switch wired to input terminal 7 15 23 for Figure 3 18 2 3 and or 4 chassis A and to input terminal 11 17 25 for chassis B 2 Wire input terminal 7 15 23 for chassis A and input terminal 11 17 25 for You is chassis to the power 10811 wire high one ee 3 Delete the left run station pushbutton switch wired to input terminal 11 17 25 for chassis A and to input terminal 7 15 23 for chassis 4 Wire input terminal 11 17 25 for chassis A and input terminal 7 15 23 for chassis B to the power rail 108L2 wire high 5 Wire input terminal 13 21 27
129. er verify that CRMA and CRMB relays are not energized no ac on wire 112A outputs to all press valves do not have power 3 Reset the E Stop circuit by pressing the Control Reset button 4 Visually and with a voltmeter verify that CRM relays are energized 120v ac across 112A and 105L2 outputs to all press valves do not have power 5 Reset control power by pressing the Clutch Brake Power Reset button 6 With a voltmeter verify that all press valve outputs have power 120v ac across 115C and 119B 7 Press the E Stop button 8 Visually and with a voltmeter verify that seal relays and CRM relays are de energized no ac across 115C and 119B Seal Relay Test 1 Power up the system 2 Reset the E Stop circuit by pressing the Control Reset button 3 With a voltmeter verify that seal relays are not energized outputs to all press valves do not have power 4 Reset control power by pressing the Clutch Brake Power Reset button 5 Visually and with a voltmeter verify that seal relays are energized outputs to all press valves have power 120v ac across 115C and 119B For This Condition Run stations wired with dummy plugs Run stations wired with run buttons Test Your Clutch Brake 8 3 Crowbar Relay Test If using crowbar relays 1 Power up the system 2 Reset the E Stop circuit by pressing the Control Reset button 3 Reset control power by pressing the C B Power R
130. er 0 Floating point arithmetic such as add subtract multiply divide 4 36 trig functions such as sin cos tan 375 500 compare 4 5 8 process control such as PID gain computation 880 1150 Addressing The processor operates faster with direct addressing Other types of addressing take longer Table and Table Table F D Typical Additional Instruction Execution Times for Indirect Addressing for PLC 5 10 12 15 25 Processors For This Type of Data When the Instruction Address When the File Address in the Expression contains an Indirect Address or Destination Contains an Indirect Address for a Bit or Element Add 1 for the File or Element Number Add bit integer 45 us floating point 48 us timer counter or control 48 us conversion integer to float 1 Add only the larger time if the address contains two indirect addresses Publication 6556 6 5 1 October 1996 How to Program a Faster Response Programming Considerations for PLC 5 Processors 5 Table F E Typical Additional Instruction Execution Times for Various Types of Addressing for PLC 5 11 20 30 40 60 80 Processors For This of Address With This Type of Data Add for Each Operand indexed integer 1 us floating point 2 us timer counter control 2 5 us immediate integer 0 2 us floating point 1us indirect LE cd 7 0 1 words us conversion such as float to integer 6 us 1 An operand is an instru
131. er near top zone single or continuous mode cams for proper operation or settings 113 Forward Shaft Position Any of 107 109 detected Press will stop or not run in Check software cam logic or hardware Transition Faults single or continuous mode cams for proper operation or settings 114 Upstroke ACAM did not cycle in upstroke Press will stop or not run in Check software cam logic or hardware single or continuous mode cams for proper operation or settings 121 Brake Monitor Cam Mis Processor A sees the BCAM while Press will stop or not run in Check software cam logic or hardware match Between Processors processor B does not single or continuous mode cams for proper operation or settings 122 Takeover Cam Mismatch Processor A sees the Press will stop or not run in Check software cam logic or hardware Between Processors TCAM while processor B does not single or continuous mode cams for proper operation or settings 123 Anti repeat Cam Mismatch Processor A sees the ACAM while Press will stop or not run in Check software cam logic or hardware Between Processors processor B does not single or continuous mode cams for proper operation or settings 124 Cam Mismatch Fault Any of 121 123 detected Press will stop or not run in Check software cam logic or hardware single or continuous mode cams for proper operation or settings To clear this latched fault bit you must turn the mode select
132. eserved Do Not Use Stop on top 1 No modifications allowed You must wire these inputs as shown on sheet 7 of 9 forthe Left Right Inch control system to work correctly Publication 6556 6 5 1 October 1996 Customize the Wiring 3 7 Figure 3 5 Delete Run Station 1 Module Group 3 RACK A00 RACK BOO MODULE GROUP 3 MODULE GROUP 3 Weuro T 003 00 RIGHT RUN STATION 1 0 702PB 105L1 LEFT RUN STATION 1 1 0 703PB BL 003 001 wero PUT 1 A 003 0 LEFT RUN STATION 1 BUTTON N C 703PB RIGHT RUN STATION BUTION NC T02PB 003 01 10512 INPUT 2 5 STATION 1 ACTIVE PIN Reserved Do Not Use Reserved Do Not Use STATION 1 ACTIVE PIN 5 INPUT 2 Figure 3 6 Delete Run Stations and Active Pin Module Group 3 RACK 00 10511 00 MODULE GROUP 3 105L2 MODULE GROUP 3 INPUT 003 RIGHT RUN STATION 0 7 4 LEFT RUN STATION N O 7 Bl 003 INPUT 003 LEFT RUN STATION BUTTON NC 7 PB RIGHT RUN STATION BUTTON NC 7 003 INPUT STATION Reserved Do Not Use 1 1 Reserved Do Not Use STATION PIN INPUT Figure 3 7 Delete Arm Continuous Switch Module Group 3 RACK 00 RACK BOO MODULE GROUP 3 MODULE GROUP 3 INPUT 17
133. eset button 4 Verify that crowbar relays are not energized by observing that their output LEDs are OFF at Module Group 5 output 15 in chassis A and B 5 Verify that you have enabled the use of the crowbar circuit by your ladder rung in PF15 that sets B151 15 unconditionally ON 6 Press the E Stop button to shut down power 7 Reset the E Stop circuit by pressing the Control Reset button 8 Verify that crowbar relays energize and then go OFF Do this by observing their output LEDs at Module Group 5 output 15 in chassis A and B when you restore control power in step 9 9 Restore control power by pressing the C B power reset button and verify crowbar relay operation step 8 Test Run Buttons all four stations Test Run button wiring by observing input LEDs in Module Group 3 Check the OK box after verifying that the LED indication is correct In Module Group 3 OK In Module Group 3 OK These Input LEDs are OFF These Input LEDs are ON 2 Chassis A and Chassis A and B If using active pin Inputs 2 5 10 13 Inputs 0 1 3 4 6 7 11 12 Chassis A and B Chassis A and B Inputs 0 3 6 11 Inputs 1 4 7 12 If using active pin Inputs 2 5 10 13 Chassis B Input 1 E Chassis A Input 0 Chassis B Input 4 Chassis A Input 3 Chassis B Input 7 iz Chassis A Input 6 Chassis B Input 12 Chassis A Input 11 Chassis A Input 1 n Chassis B Input 0 Chassis A Input 4 Chassis Input 3 Chassis A Input 7 Cha
134. ess as shown in the following example timing diagram Engage clutch Disengage clutch and to start the press engage brake clutch engaged to stop the press 1 clutch time delay brake engaged i gt je soft brake time delay Cycled Valves Clutch Brake Aux 1 Aux 2 lt slip action pressure relief slip action pressure relief 6 pressure 6 full pressure Time To program a soft clutch and brake use control bits B151 16 17 19 and 22 Important The sequence and logic of these bits are application dependent For example Bit B151 Bit Function Note 16 Auxiliary 1 Cycles With Clutch remains ON to energize with clutch valve 17 Auxiliary 2 Cycles With Clutch remains OFF to energize with brake valve 19 Auxiliary 1 Enabled valve relieves pressure when OFF 22 Auxiliary 2 Enabled valve relieves pressure when ON Sequence of Events clutch valve energized soft clutch timer timed out clutch valve de energized and brake engaged soft brake timer timed out Publication 6556 6 5 1 October 1996 4 14 Write Ladder Logic Publication 6556 6 5 1 October 1996 Figure 4 14 Example Commands to Control Soft Clutch and Brake Operation B151 16 B151 17 B151 19 and B151 22 Aux Valve 2 Follows Clutch Outputs B151 4 0 17 Clutch Brake Clutch Brake Soft Dual Val
135. eted the wiring Figure 3 12 and added the label Reserved Do Not Use Clutch 1 and 2 Outputs No modifications allowed You must wire these inputs as shown on sheet 9 of 9 Controller OK for the control system to work correctly Seal Relay Publication 6556 6 5 1 October 1996 Then see Figure 4 15 Figure 3 10 Figure 4 15 Figure 3 11 Figure 3 12 Customize the Wiring 3 11 Figure 3 10 Delete Auxiliary Valve Outputs Module Group 5 RACK A00 RACK BOO MODULE GROUP 5 MODULE GROUP 5 OUTPUT 6 5 AUX 1 VALVE Reserved Do Not Use Reserved Do Not Use AUX 1 VALVE 15 OUTPUT 6 OUTPUT 7 7 AUX2VALVE Reserved Do Not Use Reserved Do Not Use AUX 2 VALVE 7 OUTPUT 7 Figure 3 11 Delete Micro inch Valve Outputs Module Group 5 RACK A00 RACK BOO MODULE GROUP 5 MODULE GROUP 5 OUTPUT 12 25 MICRO INCH 1 Reserved Do Not Use Reserved Do Not Use MICRO INCH 1 25 OUTPUT 12 OUTPUT 13 27 MICRO INCH 2 Reserved Do Not Use Reserved Do Not Use MICRO INCH 2 27 OUTPUT 15 Figure 3 12 Delete Crowbar Relay Outputs Module Group 5 RACK 00 RACK 800 MODULE GROUP 5 MODULE GROUP 5 OUTPUT 15 33 BAR RELAY 918CR Reserved Do Not Use Reserved Do Not Use CROW BAR RELAY 942CR 33 OUTPUT 15 Publication 6556 6 5 1 October 1996 3 12 Customize the Wiring Customize a Grounded AC System To c
136. f valves having external and internal fault detection you must use valve stem feedback on all valves with external fault detection simulate valve stem feedback on valves with internal fault detection Press Valves External Internal Reference Clutch 1 amp 2 Auxiliary 1 amp 2 Sheets 8 and 9 Micro inch 1 amp 2 Valve stem feedback yes no 4 Select the Type and Location of Position Monitors Record the type of position monitor and to which I O chassis it will be wired If using resolvers record the rack group slot number rack address of the resolver input module Position Monitor Chassis B Rotary Cam Limit Switches Resolver and Input Module s AMCI Series 1700 Resolver and Input Module NSD VE 2A VRE P062 1771 IBD 5 Record On Off Positions of Rotary Cam Limit Switches Write down the press manufacturer s recommended on off positions for rotary cam limit switches RCLSs or for resolver simulation You may adjust them later Name of RCLS Rotation OFF Rotation Brake Monitor BCAM Takeover TCAM Anti repeat ACAM Define Your Control System Characteristics 2 9 6 Select Input Switches Record the quantity and locations of your input switches Type Qty Location Device Symbol Purpose Palm ak ak Used by press operators to start the press in single Momentary pushbuttons Buttons for or continuous mode Run Stations 1 pr station Left Right
137. files Create delete program files gt gt lt gt x gt lt gt lt x gt lt gt lt Write edit ladder files IX X xX xX Download ladder files IX X xX Read ladder files X Upload ladder files X Change processor mode X Fore TO Force I O in Sequential Function Charts Clear memory x Edit on line Read Write Access We have assigned the following R Read W write access by class by Class to clutch brake control program and data files files not listed are not protected Program Files File Name Type Class 1 Class 2 Class 3 Class 4 ie isd me fee mr 8 ae mr RW eee Res mr mr 8 Publication 6556 6 5 1 October 1996 D 2 Classes of Memory Protection Publication 6556 6 5 1 October 1996 Data Files status RW _ 150 fot RW RW RW _ rw _ jeu RR Reserved Data Files Appendix E Mapping of Data and Program Files We designed the software using selected data files Some of these files are locked We present this information with two purposes overall mapping of data reserved for the control system e useable data for your application Reserved Files When mapping your data table for controlling press operations do NOT use the following data files Type of File and Address Do N
138. for proper operation or settings 028 Forward Transition Software hardware cams did not Press will stop or not run Check software cam logic or hardware from Downstroke enter upstroke single or continuous mode cams for proper operation or settings 029 Forward Transition Software hardware cams did not Press will stop or not run Check software cam logic or hardware from Upstroke enter near top zone single or continuous mode cams for proper operation or settings 033 Forward Shaft Position Any of 027 029 detected Press will stop or not run Check software cam logic or hardware Transition Faults single or continuous mode cams for proper operation or settings 034 ACAM Upstroke ACAM did not cycle in upstroke Press will stop or not run Check software cam logic or hardware single or continuous mode cams for proper operation or settings 041 Brake Monitor Cam Mis Processor A sees the BCAM while Press will stop or not run Check software cam logic or hardware match Between Processors processor B does not single or continuous mode cams for proper operation or settings 042 Takeover Cam Mismatch Processor A sees the Press will stop or not run Check software cam logic or hardware Between Processors TCAM while processor B does not single or continuous mode cams for proper operation or settings 043 Anti repeat Cam Mismatch Processor A sees the while Press wil
139. functions for custom re engineering organize it for easier troubleshooting save scan time Programming Considerations for PLC 5 Processors F 7 How Subroutines Are Scanned Subroutines are accessed from your main program file or from other subroutines nested by means of these instructions Figure E 2 Jump To Subroutine JSR located anywhere in your ladder logic e Subroutine SBR the first instruction in the subroutine file and the target of the JSR instruction directs the processor scan to the subject subroutine Return RET returns the processor scan to the rung immediately following the originating JSR instruction Figure F 2 Program Scan for an Example Jump to Subroutine and Return Main Program or Subroutine Target Subroutine cm to SBRn Scan Publication 6556 6 5 1 October 1996 F 8 Programming Considerations for PLC 5 Processors You may add subroutines to the clutch brake ladder program For example the program scan for the following program files is shown in Figure Main Program PF2 Call Subroutines PF3 Clutch Brake Interface PF15 Clutch Brake Code PF16 e Auxiliary Press Function PFxx e Automation Function PFyy Figure Scan of the Allen Bradley Clutch Brake Ladder Program I 2 Call Subroutines PF3 RH gt SBR3 Auxiliary Press Func
140. gram PF15 contains your ladder logic that interfaces with the clutch brake control logic in protected memory PF16 You control operations in the clutch brake control logic PF16 by manipulating inputs to that logic by outputs from your clutch brake interface logic PF15 For example output command bits x y and z from your interface ladder logic in PF15 are inputs X Y and Z to the clutch brake control logic in PF16 Clutch brake Interface Clutch brake Control Typically the processors in chassis A and B must see identical conditions or declare a fault Important We programmed input rungs for command bits at the end of protected memory in PF16 The command bits used for these inputs are described in the next table Most are held ON unless your custom ladder logic in PF15 turns them OFF Exceptions are noted in the next table they are held OFF unless turned ON Select from These Command Bits Bit ACAM BCAM and TCAM Permit Cycle Start Permit Run Permit Downstroke Permit Upstroke Top Stop Permit Inch Simulate Inch Buttons Remote Inch Mode Clutch Pressure ON Press in Motion Remote Single Mode Remote Continuous Mode Enable Crowbar Relay Write Ladder Logic You may program one or more of the following command bits in Program File 15 to customize the operation of your press Your control system will control the clutch brake mechanism even if you program none of them Important
141. gt 218 9 gi Belden 9463 Ie Station 1 0 Rack 2 2 4 Publication 6556 6 5 1 October 1996 6 8 Install and Wire the Clutch Brake Control System Convert Controller OK Relay Contacts from N O to N C Wire Your Control System Publication 6556 6 5 1 October 1996 The default mode of 700P relay contacts as shipped in this package is normally open N O You must convert the contacts to the normally closed N C mode To do this remove each of the relay cartridges and flip the screw terminals to the N C position as follows 1 Remove the coverplate by unscrewing the two captive screws 2 Remove the red crossbar by unscrewing its captive screw 3 Remove each relay cartridge from the housing by inserting a screwdriver blade under a screw terminal pressure plate and prying out the cartridge 4 On the relay cartridge locate the screw terminals and corresponding contact mode symbols l for and for N C 5 convert the contacts from to N C mode A Unscrew the screw terminals 2 turns B Flip each of the screw terminals from the l N O position to the I I N C position 6 Insert the relay cartridges into the case so the screw terminals now in the N C position face front and are accessible 7 Reassemble the red crossbar and coverplate and securely tighten the captive screws For additional information refer to the Instruction Sheet that accompanied the 700P re
142. h Ladder Logic Module Group 2 RACK A00 M a RACK BOO MODULE GROUP 2 2 108L TAKEOVER CAM LIMIT SW 62615 MODULE CROUP 2 M RUPEE 002 00 TAKEOVER CAM LIMIT SW 60215 BI 002 00 aay n ANTIREPEAT CAM LIMIT SW 627LS irit Al 002 01 ANTIREPEAT CAM LIMIT SW 60315 B 002 01 S TARDA BRAKE MONITOR CAM LIMIT SW 60415 BRAKE MONITOR CAM LIMIT SW 628LS 2 5 002 02 4 8 002 02 I Figure 3 14 Delete Crowbar Relay Feedback Module Group 2 RACK A00 RACK B00 MODULE GROUP 2 MODULE GROUP 2 INPUT 12 25 CROWBAR RELAY A FEEDBACK Reserved Do Not Use Reserved Do Not Use CROWBAR RELAY B FEEDBACK 25 INPUT 12 Figure 3 15 Delete Crowbar Relay Power Distribution 117PB 01 16 CLUTCH BRAKE POWER RESET 01 17 01 18 01 19 01 20 01 21 01 22 55 002 10 jit 10 06 12 01 24 Leo S FIO 08 61 TO 06 01 lt 119 Figure 3 16 Delete Clutch Brake Air Pressure Main Motor Forward and Motion Detector Switches Module Group 2 RACK A00 RACK 800 MODULE GROUP 2 MODULE GROUP 2 CLUTCH BRAKE AIR PRESSURE i INPUT 15 55 002 15 CLUTCH BRAKE AIR PRESSURE 06 18 002 15 52 pur 15 06 42 WAN MOTOR FORWARD WAIN MOTOR FORWARD INPUT 16 ss 00216 Bi 002 16__I r 16 MOTION DETECTOR MOTION DETECTOR INPUT 17 57 5 002 17 00217 i NOT USED 39 39 NOT USED Publication 6556 6 5 1 October 1996 3 14 Customize the Wiring 1 0 Module Group 3 sheet 7 of 9 Grounded AC Pow
143. hat the resolver module is in slot 0 at address 1 000 Figure 7 5 Ladder Logic to Simulate RCLSs When Using Resolver Inputs Store Resolver Inputs MOVE Source 1 000 0 Dest N155 0 0 Takeover Cam LIM B151 LIMIT TEST CIR Low Limit 170 00 Test N155 0 High Limit 350 Brake Monitor Cam LIM B151 LIMIT TEST CIR 4 Low Limit 10 01 Test N155 0 High Limit 190 Anti repeat Cam LIM B151 LIMIT TEST CIR 4 Low Limit 280 02 Test N155 0 High Limit 240 If NOT using anti backlash couplings and you experience reverse motion faults Faults 033 and 113 due to gear chatter you may need to modify your ladder logic to shift cam turn ON and turn OFF positions back about 5 instantly at each transition to compensate for gear chatter Figure 7 6 Set Up or Simulate Rotary Cam Limit Switches Figure 7 6 Ladder Logic to Guard Against Reverse motion Faults When Using Resolvers Store Resolver Inputs F MOV ie x t MOVE Source 1 000 0 Dest N155 0 0 TCam LIM H 151 LIMIT TEST CIR Low Limit 165 00 Test N155 0 High Limit 350 LIM L LIMIT TEST CIR Low Limit 170 Test N155 0 High Limit 345 BCam LIM H 151 LIMIT TEST CIR H
144. he near bottom zone and open at a point that allows the press to stop at the top anti repeat contacts open during mid upstroke for at least 75ms Position monitor inputs should operate as follows Table 7 A Table 7 A Operation of Cam Limit Switches This Cam jin this Mode With these Conditions Provides a Signal That Anti Repeat On the hop Cams open momentarily after run Prevents a second stroke unless run buttons ACAM in Single stroke buttons are released past bottom are pressed a second time Take over Inch or Cams open in near top zone Turns OFF triac outputs for stopping the press TCAM Single stroke at top of stroke stop on top Continuous Cams open in near top zone after stop on top command Single stroke or Cams close near bottom just when Lets the press complete a single stroke or run Continuous or before BCAM opens continuously after run buttons are released Indicates that braking distance is excessive Brake monitor Single Stroke or When press stops in downstroke BCAM Continuous beyond BCAM closure Turns OFF solenoid outputs to prevent restart Publication 6556 6 5 1 October 1996 7 2 Set Up or Simulate Rotary Cam Limit Switches Set Up or Simulate Rotary Cam Limit Switches as Follows A During downstroke BCAM must be On During upstroke TCAM must be On and BCAM must be Off from On to Off to On while TCAM is On During upstroke must cycle Important Figure 7 1 show
145. hen ACAM is Off c ACAM does not cycle while TCAM is On during upstroke ACAM should remain On for the entire stroke except for an On Off On cycle while TCAM is On during upstroke The dual sets of contacts need not cycle at the same moment Important See your press manufacturer s recommendations An offset of up to 1 second is acceptable You can reduce this preset for On Off settings of ACAM BCAM and TCAM switches Write down initial on off positions of cam limit switches on the worksheet We tell you how to set up your rotary cam limit switches in chapter 7 6 Select Input Switches The control system monitors input switches as listed on the worksheet As you review this list record the quantity and location of each switch that you will use We left space if you need additional switches 7 Select Command Bits Command bits Table 2 A that you program in file PF15 let you interface for C B Interface Logic your application to the clutch brake code in PF16 These bits let you e simulate RCLS for resolver inputs program operator interface functions e interface machine functions during automatic continuous mode use auxiliary valves for operations such as soft clutch and brake simulate inch and or micro inch buttons during setup monitor clutch pressure and press motion select the operating mode from a remote selector control and monitor other functions Publication 6556 6 5 1 October 1996 Define Your Contr
146. hen output was turned ON 145 Aux Valve Stem 2 Valve failed to de energize C B power is removed Check valve and valve wiring Failed to Turn OFF when output was turned OFF 146 Clutch Valve 1 Valve failed to energize Press will not cycle Check valve and valve wiring Failed to Turn ON when output was turned ON 147 Clutch Valve 1 Valve failed to de energize C B power is removed Check valve and valve wiring Failed to Turn OFF when output was turned OFF 148 Clutch Valve 2 Valve failed to energize Press will not cycle Check valve and valve wiring Failed to Turn ON when output was turned ON 149 Clutch Valve 2 Valve failed to de energize C B power is removed Check valve and valve wiring Failed to Turn OFF when output was turned OFF 150 Clutch Valve Stem 1 Valve failed to energize Press will not cycle Check valve and valve wiring Failed to Turn ON when output was turned ON 151 Clutch Valve Stem 1 Valve failed to de energize C B power is removed Check valve and valve wiring Failed to Turn OFF when output was turned OFF 152 Clutch Valve Stem 2 Valve failed to de energize Press will not cycle Check valve and valve wiring Failed to Turn OFF when output was turned ON 153 Clutch Valve Stem 2 Valve failed to de energize C B power is removed Check valve and valve wiring Failed to Turn OFF when output was turned OFF 154 Clutch Valve Fault Any of 134 153 detected C B power is removed Check valve and valve
147. ices G and H We included both versions of Rockwell software on diskette Series 6200 Series Throughout the manual we tell you the version of software that applies to the software procedures Using This Manual P 3 You should become familiar with these abbreviated terms For complete definitions of clutch brake terms refer to ANSI B11 1 1988 section 3 Category Term Definition Hardware active pin run station wiring that provides a signal to indicate that pairs of run buttons are active not replaced by dummy plugs optional feature Terms and Abbreviations brake time monitor a solid state device that monitors press stopping time at any point in the stroke buttons palm type pushbutton switches used by an operator for starting and stopping the press dummy plug jumpers used in place of a run station when removing a run station from the press control circuit resolver a solid state device that detects and transmits the angular position of the press drive shaft run station a press operator s point of operation that typically contains a pair off pushbuttons to start the press continuous Operating Mode lets the control system maintain continuous stroking after an operator starts the press lets an operator move the press intermittently by pressing and releasing a pair of inch buttons micro inch the same as Inch but at a slower speed Requires a separate drive assembly and a sepa
148. iled to Turn ON 003 Controller OK relay test failed 004 Seal Relay A Timeout Fault 005 Seal Relay Weld Fault 006 E Stop Relay Failed to Turn ON 007 E Stop Relay Weld Fault 008 No Valid Mode Appendix Troubleshooting with Fault Codes Operator Prompts and Snapshot Status Bits Whenever a PLC 5 x6 processor detects a fault it sets a corresponding bit Bit File 168 in the data table We list the conditions that for which the software is designed to detect and signal a fault We recommend that you program a method to display bit numbers of detected faults Then you can respond quickly by looking them up in the following table Faults Associated with Processor A Cause of Fault Effect of Fault How to Correct the Fault Remote link channel 1B failed C B power is de energized Check remote 1 0 cable to chnl 1B Check port configuration Crowbar relay A C B power is de energized Check crowbar relay wiring and welded closed and will not turn ON operation of input module in slot 2 Crowbar relay A C B power will not turn ON Check crowbar relay wiring and failed to close operation of input module in slot 2 Not wired according to C B power will not turn ON Change wiring per SW revision 1 3 latest drawings Seal relay A C B power will not turn ON Check seal relay wiring and failed to close operation of input module in slot 2 Seal relay A C B power is de energized Check seal relay
149. iliary Valve 1 Failed to Turn On Auxiliary Valve 1 Failed to Turn Off Auxiliary Valve 2 Failed to Turn On Auxiliary Valve 2 Failed to Turn Off Auxiliary 1 Valve stem Failed to Turn On Auxiliary 1 Valve stem Failed to Turn Off Auxiliary 2 Valve stem Failed to Turn On Auxiliary 2 Valve stem Failed to Turn Off Automatic Single stroke Time out Address 162 10 162 31 B152 45 B152 46 B152 47 B152 48 100 1162 49 8152 49 10 16250 815260 100 16251 _ 8152 51 DEED 100 T162 55 B152 55 100 16256 _ B152 56 100 16257 _ B152 57 300 T162 58 15258 Publication 6556 6 5 1 October 1996 4 22 Write Ladder Logic Programming Press ready to start Indicators Programming a Brake Monitor patent pending Publication 6556 6 5 1 October 1996 When starting multiple presses in a transfer line you can program ladder logic in program file PF15 that indicates when the clutch brake control modes are ready to start Figure 4 26 Examine the following ready bits that tell when permissives are satisfied to start running the press Bit Address B160 86 B160 108 B160 159 Bit Name inch mode ready single stroke ready run continuous ready Figure 4 26 Example Logic to Indicate the Press is Ready to Start Inch Mode Ready Indicator B160 0 007 cere ig ee t 3 86 01 Single Stroke Ready Indicator B160 0 007 ae E
150. inch mode remote automatic single stroke mode Monitor clutch pressure and press motion clutch pressure ON press in motion motor running forward Wiring Drawings Information on Diskette Overview of the Clutch Brake Control System 1 13 To program this objective Use these command bits B151 Apply crowbar enable crowbar relay 15 Sequence the operation of auxiliary valves aux valve 1 cycles with clutch valve aux valve 2 cycles with clutch valve Turn clutch and brake valves on off aux valve 1 cycles with clutch valve with soft operation aux valve 2 cycles with clutch valve auxiliary valve 1 enabled auxiliary valve 2 enabled Omit valve stem feedback when using auxiliary valve stems enabled valves with internal fault detection C B valve stems enabled Reset processor following C B fault fault reset Wiring Your Control System Your application determines the wiring options to your control system We show you how to customize your wiring in chapter 3 e four or fewer run stations micro inch and or micro inch feedback valve stem feedback or valves with internal fault detection hardware or software motion detection crowbar shutdown grounded or ungrounded ac power To facilitate wiring your control system we include drawings for e Wiring to I O modules for grounded and ungrounded ac power Power distribution and relay backup circuits Fold out drawings accompany your manual as a separate package
151. ingle or continuous mode use inch or micro inch mode to jog the press to the near top position to set up the machine Use micro inch mode only if your press is equipped with a separate micro inch drive With either mode the press stops when it moves into the near top position or when you release an Inch button Figure A 1 Figure A 1 Typical Operational Sequence for Inch or Micro Inch Mode Select inch or micro inch mode Y WARNING To guard against the possibility of personal injury install a keylock mode select switch so that mode selection can be supervised NO Have you released both Inch buttons Yes Have you pressed both Inch No buttons simultaneously Yes Both processors energize their outputs to actuate the clutch Has the press moved into the No _ Have you released near top position either Inch button No Yes Both processors de energize their outputs to stop the press WARNING If the press goes past the near top position while braking the brake is faulty and hazardous Repair it immediately NOTE Use inch or micro inch mode to position the press near the top You may jog the press up or down The press stops when it moves into the near top position or when you release an Inch button Description of Operating Modes A 3 Single Stroke Mode Single stroke mode is
152. ition BCam LIM 8151 IMIT TEST CIR a e Low Limit 10 01 Test N80 0 110 High Limit 190 Resolver Position ACam LIM B151 IMIT TEST CIR Low Limit 290 02 Test N80 0 110 High Limit 250 End Publication 6556 6 5 1 October 1996 4 30 Write Ladder Logic Notes Publication 6556 6 5 1 October 1996 Chapter 5 Chapter Objectives What Can Privilege Classes Protect Assigning Passwords to Your Program and Data Files Program and data files of PLC 5 x6 processors can be protected from unauthorized access by assigning privileges and a password to each of four privilege classes We have assigned these at the factory This chapter explains how we assigned privileges to privilege classes we restricted access to certain program and data files youassign your own passwords to privilege classes 2 4 you gain access to protected memory files Privilege classes can control read write access to e data files program files communication channels They can also protect the control system from unauthorized changes such as e modifying privileges e uploading downloading processor memory forcing bits on off e changing processor mode Publication 6556 6 5 1 October 1996 5 2 Assigning Passwords to Your Program and Data Files How We Assigned Privileges to Privilege Classes Publication 6556 6 5 1 October 1996 The software is factory configured for access privileges for securi
153. l stop or not run Check software cam logic or hardware Between Processors processor B does not single or continuous mode cams for proper operation or settings Check software cam logic or hardware 044 Cam Mismatch Fault Any of 041 043 detected Press will stop or not run in single or continuous mode cams for proper operation or settings To clear this latched fault bit you must turn the mode select switch to OFF Publication 6556 6 5 1 October 1996 Set Up or Simulate Rotary Cam Limit Switches 7 11 Faults Associated with Processor B B168 Suggested Message Cause of Fault Effect of Fault How to Correct the Fault 106 Illegal RCLS Combination Software hardware cams produced Press will stop or not run in Check software cam logic or hardware invalid combination single or continuous mode cams for proper operation or settings 107 Forward Transition Software hardware cams did not Press will stop or not run in Check software cam logic or hardware from Top go from top to downstroke single or continuous mode cams for proper operation or settings 108 Forward Transition Software hardware cams did not Press will stop or not run in Check software cam logic or hardware from Downstroke enter upstroke single or continuous mode cams for proper operation or settings 109 Forward Transition Software hardware cams did not Press will stop or not run in Check software cam logic or hardware from Upstroke ent
154. lay Wire your control system according to wiring drawings at the end of this manual We provide you with two sets of wiring drawings ungrounded ac power grounded ac power Choose the set that matches the ac power distribution of your press For See Power Distribution sheet 1 of 9 Module Group 2 sheet 6 of 9 Module Group 3 sheet 7 of 9 Module Group 4 sheet 8 of 9 Module Group 5 sheet 9 of 9 Wire the power supplies according to instructions that accompanied them Chapter 7 Set Up or Simulate Rotary Cam Limit Switches Chapter Objectives In this chapter we help you set up your position monitoring RCLS devices read status bits in ladder logic to indicate shaft position use transition fault bits to stop the press e simulate RCLSs with ladder logic e troubleshoot the setup of your RCLSs Setting Up Position The control system can monitor the rotational position of the press Monitoring Devices stroke with either of these position monitoring devices e dual assemblies containing rotary cam limit switches e dual resolvers that require ladder logic to simulate cam limit switches Important With either method you must use dual independent positional inputs with the same settings so that brake monitor contacts must close at a point that indicates unsafe brake wear and open in the near bottom zone after the take over contacts close take over contacts must close after the press has closed in t
155. lege Class Information screen 4 Press F1 Modify Password to assign a password to each class The system displays the Modify Privilege Class Password window 5 For each class you want to use type class for example Class 2 old password if one exists new password 8 characters max A z 0 9 and _ verify new password Repeat steps 2 and 3 as needed for the other classes Class 3 4 When finished assigning passwords press ESC The system displays the General Utility screen When you first attempt to edit program or data files you will be denied access You must establish yourself as a class 2 or class 3 user to edit program and data files respectively for those classes To do so follow this procedure for 6200 series software the procedure for 15 software would be similar 1 From any screen below the Menu the highest level screen press these keys at the same time Alt P You get the Select New Privilege Class window 2 Type your privilege class name class 2 or class 3 and press Enter The cursor moves to the password entry field 3 Type your password for that privilege class and press Enter Now you can access all functions available for that class Chapter Objectives Set Jumpers and Switches Chapter 6 Install and Wire the Clutch Brake Control System In this chapter we assume that the press is ready for installation of its control system We help you install it
156. liary Valve Stems Enabled If deleting the auxiliary valves remove output wiring in module group 5 You must retain at least the OFF position as shown on sheet 8 of 9 Label unused selector switch inputs on wiring drawings Reserved Do Not Use Delete wiring from unused switch positions to corresponding input terminals Use successive switch positions leave no blank positions For example 1 off 2 inch 3 single 4 continuous 5 die change 6 and 7 not used Required for chain driven position monitoring device as shown on sheet 8 of 9 Publication 6556 6 5 1 October 1996 Then see Figure 3 8 Figure 3 11 Figure 3 8 and Figure 4 15 Figure 3 8 and Figure 4 15 Figure 3 10 Figure 3 9 N A Customize the Wiring RACK B00 MODULE GROUP 4 Figure 3 8 Delete Valve stem Feedback for Clutch Auxiliary and or Micro inch Valves Module Group 4 RACK A00 RACK 00 MODULE GROUP 4 MODULE GROUP 4 INPUT O 1 _ MICRO INCH 1 FEEDBACK Reserved Do Not Use Reserved Do Not Use MICRO INCH 1 FEEDBACK 1 INPUT INPUT 1 3 2 FEEDBACK Reserved Do Not Use Reserved Do Not Use MICRO INCH 2 FEEDBACK 3 INPUT 1 INPUT 2 5 VALVE STEMCLUTCH1 Reserved Do Not Use Reserved Do Not Use VALVE STEMCLUTCH1 5 INPUT 2 I
157. n Buttons all four stations Test Inch Buttons Test Stop on top and Arm Continuous Buttons Test Mode Selector Switch Valves and Valve Feedback Dynamic Tests of Operating Modes Inch Single stroke Mode Continuous Mode with Arm Continuous Continuous Mode with Stroke and a half Switch Tests Air Pressure Switch Main Motor Forward Switch Motion Detector Switch Chain Break Switch Description of Operating Modes Operating Modes of the Clutch Brake Controller ees Remote Mode Inch and Micro inch Modes Single Stroke Mode Continuous Table of Contents Feedback Timing Diagrams B 1 Timing Diagrams for Control System Feedback B 1 NOES ew on ate dena ae B 2 Troubleshooting with Fault Codes Operator Prompts and Snapshot
158. n troubleshooting your position monitoring devices continue to the next section For the complete listing of fault codes refer to appendix C Fault Codes and Operator Prompts Publication 6556 6 5 1 October 1996 7 10 Set Up or Simulate Rotary Cam Limit Switches Troubleshoot the Setup of The processor monitors signals from your position monitoring Your Position Monitoring devices to ensure that the motion Devices e isin the forward direction progresses through the correct sequence of real or simulated cams downstroke upstroke near top When the processor detects a malfunction in the operation of position monitoring devices it faults and sets one or more of the following fault bits to help you troubleshoot the fault We recommend that you program a method to display bit numbers of detected faults Then you can respond quickly by looking them up in the following tables taken from appendix C Faults Detected by Processor A B168 Suggested Message Cause of Fault Effect of Fault How to Correct the Fault 026 Illegal RCLS Combination Software hardware cams produced Press will stop or not run Check software cam logic or hardware invalid combination single or continuous mode cams for proper operation or settings 027 Forward Transition Software hardware cams did not go Press will stop or not run in Check software cam logic or hardware from Top from top to downstroke single or continuous mode cams
159. nabled Delete Auxiliary Valve 1 and wiring from output terminal 15 for chassis A and B Delete Auxiliary Valve 2 and wiring from output terminal 17 for chassis A and B We deleted the wiring Figure 3 22 and added the label Reserved Do Not Use Important Write ladder logic to reset bit B151 19 Auxiliary Valve 1 Enabled Write ladder logic to reset bit B151 22 Auxiliary Valve 2 Enabled Delete Micro inch Valve 1 and wiring from output terminal 25 for chassis A and B Delete Micro inch Valve 2 and wiring from output terminal 27 for chassis A and B We deleted the wiring Figure 3 23 and added the label Reserved Do Not Use Delete Crowbar Relays and wiring from output terminal 33 for chassis A and B We deleted the wiring Figure 3 24 and added the label Reserved Do Not Use No modifications allowed You must wire these inputs as shown on sheet 9 of 9 for the control system to work correctly Publication 6556 6 5 1 October 1996 And see Figure 4 15 Figure 3 22 Figure 4 15 Figure 3 23 Figure 3 24 N A RACK 00 MODULE GROUP 5 OUTPUT 4 AUX VALVE1 Reserved Do Not Use OUTPUT 5 13 AUX VALVE 2 Reserved Do Not Use RACK 00 MODULE GROUP 5 OUTPUT 10 2 MICRO INCH1 Reserved Do Not Use OUTPUT 11 23 MICRO INCH 2 Reserved Do Not Use RACK 00 MODULE GROUP 5 OUTPUT 15 33 CROW BAR RELAY 918CR Reserved Do Not Use
160. nch bit 10 remote single stroke bit 13 remote continuous bit 14 remote micro inch bit 24 remote automatic single stroke bit 26 Figure 4 20 Example Command to Arm for Automatic Continuous on Demand B151 27 Use these commands bits to switch the press mode to remote continuous mode from a remote selector and start the armed for continuous timer Use bit B151 25 Figure 4 18 to start press motion after arming Line Supervisor Remote Continuous Mode Continuous Mode I 040 B151 04 14 Armed for Arm Continuous Continuous on Demand PB on Demand 1 040 8151 07 23 When B151 27 is turned ON it starts a 5 minute one shot timed interval in which your logic must simulate pressing run buttons by setting B151 25 Use B151 27 under these conditions completely automated press with run buttons ignored remote continuous mode bit 14 ON and manual selector switch in remote mode Publication 6556 6 5 1 October 1996 4 18 Write Ladder Logic Exchanging Data Between Processors Publication 6556 6 5 1 October 1996 Figure 4 21 Example Command to Start Inch Mode After Pressing Inch Buttons B151 28 Use this bit as the last logical condition to start inch motion in combination with pressing Inch buttons manually Simulate Inch Inch Output Buttons Enabled B156 151 gt 9 28 Figure 4 22 Example Command to Allow Immedia
161. nd Switch Settings for Chassis A and Locate the jumper and switch assembly on the left hand inside backplane Figure 6 3 Set them identically in chassis A and B Figure 6 3 Jumper and Switch Settings for I O Chassis A and B Important Settings for chassis A and B must be identical Leave jumper at the Y default position for the plug in power supply module Important When using a power supply module you cannot aug ment power to the chassis with an external power supply A A Set switches by pressing rocker arms Press in OFF side for off and ON side for on d E mmo ZO EH y OFF Chassis outputs are turned off when fault is detected 5 EH AMD Always OFF C 9 mm 7 OFF stg addressing Tom oo ON c ON 4 cg EEPROM does not transfer processor faults E OFF ur OFF RAM protected against writes and edits Keying the Backplane Install keying bands supplied with your I O chassis in numerical locations so backplane slots will accept only the designated processor or I O module Leftmost Slots0 1_ Processor between Depends 40 and 42 module 54and56 See specs Publication 6556 6 5 1 October 1996
162. nded System The wiring option of your Clutch Brake Application Package included either one of two choices e ungrounded system I O wiring this appendix or e grounded system I O wiring appendix We present the following wiring drawings for I O racks 00 and BOO for ungrounded system I O wiring See Appendix H for the Grounded System Sheet Title 1 of 9 Power Distribution 2 3 4 5 omitted because they are of 9 not wiring drawings 6 of 9 System I O Rack Group 2 7 of 9 System I O Rack Group 3 8 of 9 System I O Rack Group 4 9 of 9 System I O Rack Group 5 Publication 6556 6 5 1 October 1996 G 2 Wiring Drawings for an Ungrounded System Notes Publication 6556 6 5 1 October 1996 Wiring Drawings for an Ungrounded System G 3 440 VAC FROM CUSTOMER FROM CUSTOMER L1 12 12 AWG BLK 7 CLUTCH BRAKE TRANSFORMER 1KVA lt 12 AWG BLK H3 H2 H4 GROUND GROUND 10512 10512 To 06 01 7006 01 lt 10812 55 14 AWG RED 108L1 EMERGENCY CONTROL 14 AWG RED RESET TO 06 17 E 12 a TO 06 41 113CR 114CR CRMA 113CR CRMA CRMB lt o 917CR CONTROLLER 919CR 943CR E SEAL SEAL 01 18 RELAY A RELAY B 01 19 o4 06 39 we TO 06 13 CLUTCH BRAKE ne POWER RESET o 918CR CROWBAR 114CR CONTRO
163. ng a Run button during first upstroke stops the press when it reaches the top Once in continuous stroking operation the press stops at the next near top position whenever it receives stop on top command Figure 7 However the press stops immediately whenever either processor detects a trip or stop condition arequired condition or command bit is removed an operator presses the E stop button Description of Operating Modes A 7 Figure A 4 Typical Operational Sequence to Prepare to Start Continuous Mode R3 Select continuous mode Is the motor running forward Yes 1 Have you released all Stop on top buttons Yes No Is the press configured for Arm Continuous Publication 6556 6 5 1 October 1996 Description of Operating Modes Figure A 5 Typical Operational Sequence for Arm Continuous in Continuous Mode R4 Have you released all Run buttons Yes Y No Have you pressed the _ Arm Continuous button ye ie Have you pressed Has the Arm Continuous Yes all Run buttons _ timer timed out Yes Both processors P energized their outputs Y No Has the press reached Have you released a Run button the upstroke zone No or has a stop condition occurred Yes Yes Som R6 Both process
164. ngle Change B90 SUB lI SUBTRACT 34 Source A 0 Source B N91 5 0 Dest N91 8 0 Resolver Angle Change LIM NEG LIMIT TEST Low Lim 10 Source N91 8 0 Test N91 8 Dest N91 8 0 0 High Lim 10 Rung 9 15 Resolver No Angle Change Angle Change STI Count B90 GRT CLR GREATER THAN CLEAR 34 Source A N91 8 Dest N91 7 0 0 Source B 0 Final Brake Angle MOV MOVE Source I 1 1 0 Dest N91 5 0 Publication 6556 6 5 1 October 1996 4 26 Write Ladder Logic Brake Time STI Count SUB SUBTRACT Source A N91 6 0 Source B N91 7 0 Dest N91 6 0 Last Brake Time MUL MULTIPLY 4 Source A N91 6 0 Source B S230 0 Dest N91 1 0 Last Brake Angle SUB SUBTRACT Source A N91 5 0 Source B N91 4 0 Dest N91 3 0 Looking For Zero Speed Rung 9 16 No Angle Change STI Count B90 EQU T EQUAL 34 Source A N91 7 0 Source B 100 Rung 9 17 Last Brake Angle ES LESS THAN Source A N91 3 0 Source B 0 Publication 6556 6 5 1 October 1996 B90 U 32 Last Brake Angle SUB SUBTRACT 4 Source A 360 Source B N91 4 0 Dest N91 3 0 ADD 4 ADD 4 Source A N91 3 0 Source B N91 5 0 Dest N91 3 0 Write Ladder Logic 4 27
165. not cycle Check valve and valve wiring Failed to Turn ON when output was turned ON 065 Aux Valve Stem 2 Valve failed to de energize C B power is removed Check valve and valve wiring Failed to Turn OFF when output was turned OFF 066 Clutch Valve 1 Valve failed to energize Press will not cycle Check valve and valve wiring Failed to Turn ON when output was turned ON 067 Clutch Valve 1 Valve failed to de energize C B power is removed Check valve and valve wiring Failed to Turn OFF when output was turned OFF 068 Clutch Valve 2 Valve failed to energize Press will not cycle Check valve and valve wiring Failed to Turn ON when output was turned ON 069 Clutch Valve 2 Valve failed to de energize C B power is removed Check valve and valve wiring Failed to Turn OFF when output was turned OFF 070 Clutch Valve Stem 1 Valve failed to energize Press will not cycle Check valve and valve wiring Failed to Turn ON when output was turned ON 071 Clutch Valve Stem 1 Valve failed to de energize C B power is removed Check valve and valve wiring Failed to Turn OFF when output was turned OFF 072 Clutch Valve Stem 2 Valve failed to energize Press will not cycle Check valve and valve wiring Failed to Turn ON when output was turned ON 073 Clutch Valve Stem 2 Valve failed to de energize C B power is removed Check valve and valve wiring Failed to Turn OFF when output was turned OFF 074 Clutch Valve Fault Any of 054 0
166. ns 2 6 9 Reduce Watchdog Timer Presets Optional 2 6 1 Verify Your Factory configured Options 2 7 2 Assign Outputs 2 7 3 Record the Type s of Valve Fault Detection 2 8 4 Select the Type and Location of Position Monitors 2 8 5 Record On Off Positions of Rotary Cam Limit Switches 2 8 6 Select Input Switches 2 9 7 Select Optional Command Bits for C B Interface Logic 2 10 8 Select Options That Affect System Wiring 2 11 9 Reduce Watchdog Timer Presets as an Option 2 12 10 Select Options That Require Programming 2 13 Customize the Wiring to Suit Your Application 3 1 Chapter 3 1 How to Customize the Default Wiring 3 1 Install Your Wiring Drawing Diskettes 3 2 Generalized Instructions to Customize Your Wiring 38 3 Customizing Ungrounded AC System 3 3 Customize a Grounded AC System 3 12 NoleS os I 3 20 Table of Contents Write Ladder Logic Chapter ObjecIiVes caves dude Ex exces Overview of Memory Organization Reserved Program and Data H
167. ntinuous Check remote I O wiring 080 078 Spare 079 Processor A or B detected a fault Processor or B detected fault See fault table in Appendix C See fault table Publication 6556 6 5 1 October 1996 C 8 Troubleshooting with Fault Codes Operator Prompts and Snapshot Status Bits Prompts Associated with Processor B B169 Message Cause of the Prompt Condition Effect of Prompt Condition How to Correct the Condition 080 Spare 081 E Stop actuated E stop button was pressed or CRM and seal relays opened Release E stop btn Press control E stop circuit failed reset and C B power reset btns 082 084 Sparo ee 085 Software inch mode enabled You pressed an inch button when the Hardware inch buttons void Release hardware inch buttons software inch mode bit was set when this bit is set 086 Software inch mode is not Inch mode selected but software inch Valve outputs turn OFF Set the software inch mode bit enabled mode bit is not set 087 Downstroke stopped by software Permit downstroke bit was reset while Valve outputs turn OFF Set the permit downstroke bit and the press was in downstroke inch the press to near top position 088 stopped by software Permit upstroke bit was reset while the Valve outputs turn OFF Set the permit upstroke bit and press was in upstroke inch the press to near top position 089 Permit start is not enabled The permit start bit is no
168. o inch Important If using dump valves to assist in controlling the brake you can program whether dump valves turn ON OFF in unison with or opposite to clutch valves We cover this under Command Bits in chapter 4 Record your assignment of control system outputs on the worksheet 3 Select the Type of There are two types of valve fault detection Valve Fault Detection e internal the valve checks itself for failure external the control system checks a valve actuated switch on the spool or stem to verify that the valve cycles every stroke The type of fault detection determines whether you use valve stem feedback If Your Valves Have Then the Valve And your control system This Fault Detection internal closes automatically when it detects a fault omits valve stem feedback will NOT open unless both solenoids work in unison has NO valve stem switches external has valve stem switches must have valve stem feedback provides an external signal of its valve position when valve is open switch is ON Important If one or more valves have valve stem feedback all valves must have it or simulate it We show you how in chapter 3 Record the type of valve fault detection and valve stem feedback Publication 6556 6 5 1 October 1996 4 Select the Type of Position Sensor Anti repeat ACAM Brake Monitor BCAM Take over TCAM Define Your Control System Characteristics 2 3 The control system uses dual ind
169. o move The press will not start in Check motion detector switch no motion was detected single or continuous mode wiring and motion detector logic 129 Spare Uncommanded Motion was detected when no C B outputs are de energized Check motion detector switch Motion Detected motion was commanded wiring and logic At Rest On switching to inch the software The press will not inch Check prompts for reasons why press Inch Button Tiedown detected a held inch button will not inch Check inch button wiring At Rest On switching to run the software The press will not run in single Check prompts for reasons why press Run Button Tiedown detected a held run button or continuous mode will not run Check run button wiring At Rest Arm Continuous button was not The press will not start in Press the Arm Continuous button Run Button Tiedown pressed before Run buttons continuous mode before pressing the Run buttons Micro inch Valve 1 Valve failed to de energize C B power is removed Check valve and valve wiring when output was turned OFF Failed to Turn OFF Valve failed to de energize C B power is removed Check valve and valve wiring when output was turned OFF Micro inch Valve 2 Failed to Turn OFF Valve failed to energize Press will not cycle in Check valve and valve wiring when output was turned ON micro inch mode 135 136 Micro inch Valve 1 Failed to Tum ON 137
170. o respond to a change of input depends on the sum of these response times excluding scan time for auxiliary press functions that you can compute from corresponding ladder logic Response Time Delay ms 1771 1016 input module PLC 5 x6 scan time for typical control logic 1771 OD16 triac switching time Total response time The number of degrees that the shaft continues to rotate beyond the moment when the input changes depends on the speed of rotation The greater the speed strokes per minute the further the shaft rotates before a command from the control system is applied The response time of 21 ms is represented in degrees of shaft rotation that increases as press speed increases Figure 1 6 Internal Timers Overview of the Clutch Brake Control System 1 11 Figure 1 6 Shaft Rotation for a 21 ms Response Time of the Clutch Brake Control System SPM 100 90 80 70 60 50 40 30 20 10 0 0 3 6 9 12 15 Degrees of Shaft Rotation Important When estimating the braking distance in degrees of rotation you must add the response time of the control system Figure 1 6 to the specified downstroke or upstroke braking distance of your press If you program additional ladder logic for other press functions in processor A or B you will increase the scan time of that processor Program scans in both processors are not synchronized so minimize the scan time of one processor time The combination of fast press stroking and a
171. ocessor Memory Logical Write Download All Processor Memory Physical Write Upload Blocks of Processor Memory Logical Read Upload All Processor Memory Physical Read Change Processor Mode Force I O Force I O in Sequential Function Charts Clear Memory Restore Memory from Archive Edit On line gt lt gt lt gt lt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt OK gt lt gt lt gt lt gt lt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt gt lt X X gt lt lt gt lt gt lt gt lt Assigning Passwords to Your Program and Data Files 5 3 Data Table Privileges We assigned R read only or RW read write privileges to classes 1 4 for controlling access to data files To view the Data Table Privileges screen that allocates these privileges follow this procedure for 6200 series software the procedure for software would be similar 1 Start at the Main Menu 2 Press F7 General Utility The system displays the General Utility screen 3 Press F1 Memory Map The system displays the Memory Map screen 4 Press F2 Modify Privileges You get the Data Table Privileges screen We assigned the following privileges for classes 1 4 at the factory File Type Class1 Class2 Class3 Class 4 0 O output RW RW RW RW 1 input RW RW RW RW 2 5 status RW RW RW RW 3 B binary or bit RW RW RW RW 4 T timer RW RW RW R
172. of the press slide electronically so are free from contact failure We recommend either group of resolver devices AMCI Series 1700 resolver and interface module for I O chassis e NSD VRE P062 resolver VE 2A decoder and 1771 IBD input module When using resolvers you must simulate the action of cam limit switches with ladder logic We assist you in doing this in chapter 7 We reserved slots 0 and 1 of I O chassis A and B for resolver input modules This slot location helps you isolate ac and dc input signals If using resolvers record the brand and model on the worksheet Publication 6556 6 5 1 October 1996 2 4 Define Your Control System Characteristics 5 Record On Off Positions During installation of your rotary cam limit switches you must set of Rotary Cam Limit the on and off positions of these switches Figure 2 1 Use the Switches initial on off positions specified by the press manufacturer Figure 2 1 Guidelines for Setting the On Off Positions of the Rotary Cam Limit Switches Set Up or Simulate Rotary Cam Limit Switches as Follows A During downstroke BCAM must be On During upstroke TCAM must be On and BCAM must be Off During upstroke ACAM must cycle from On to Off to On while TCAM is On 0 Near top BCAM and TCAM must be Off while ACAM remains On Other Conditions The software is designed to fault if when it detects a ACAM BCAM and TCAM are OFF all at the same time b BCAM is On w
173. ol System Characteristics 2 5 Table 2 A Command Bits for Your Clutch Brake Interface To program Program these bits in PF15 this feature Name Address Simulate rotary cam limit switches Brake Monitor B151 00 for resolver input Takeover B151 01 Anti repeat B151 02 Operator interface and press automation Permit Run B151 04 robotic functions in automatic continuous mode Permit Cycle Start B151 03 Permit Downstroke B151 05 Permit Upstroke B151 06 Top Stop B151 07 Simulate Run Buttons B151 25 Arm for Continuous on Demand B151 27 Inch Output Enabled B151 28 Initiate Automatic Single Stroke B151 29 Simulate inch or micro inch buttons Permit Inch B151 08 during start up or for automatic die change Simulate Inch Buttons B151 09 Remote Inch Mode B151 10 Remote Micro inch Mode B151 24 Monitor clutch pressure and press motion Clutch Pressure OK B151 11 Press in Motion B151 12 Main Motor Forward B151 18 Select operating mode remotely with your ladder Remote Inch Mode B151 10 logic Main selector switch must be switched to Remote Single stroke Mode B151 13 remote mode Remote Continuous Mode B151 14 Remote Micro inch Mode B151 24 Remote Automatic Single stroke Mode 151 26 Reset processor with keyswitch after C B fault Fault Reset B151 23 Enable the crowbar relay circuit Enable Crowbar Relay B151 15 As a last resort for an E Stop condition the processor sets a bit that closes a relay to dead short the ac line This is designed to trip the circ
174. om Chassis A Mod Grp Number 5 0 005 00 1 5 005 01 3 5 0 005 04 11 5 005 05 5 0 005 10 5 0 005 11 To Chassis OK Mod Grp Term p Co 4 80715 ea 4 80815 Ee ej To Chassis B p Tex Test Your Clutch Brake 8 7 From Chassis B To Solenoids amp Chassis A OK Mod Grp Wire Number Term Mod Grp Term s 80050 1 925501 5 BO 005 01 3 B 926SOL a 931501 BO 005 04 0 005 05 E 932501 005 10 uc A 936SOL EET is From Chassis A To Solenoids amp Chassis B OK 4 Al 004 02 ia Z REP mau m S RSS C pees 80415 4 1 004 04 80715 4 004 05 80815 Publication 6556 6 5 1 October 1996 8 8 Test Your Clutch Brake Dynamic Tests of Operating Modes Publication 6556 6 5 1 October 1996 This section tests ladder logic in PF15 for press operation in these modes inch single stroke continuous started by arm continuous or stroke and a half Important We assume that you have downloaded your ladder programs with 6200 Software Revision 4 4 or later into processors A and B Important If the press control system faults or does not operate as expected in this procedure read the resulting fault or prompt
175. om wiring drawings Not using auxiliary valves Enable ladder logic by setting bits B151 19 and or 22 sheet 9 N A Omit output wiring and remove from wiring drawings Not using micro inch valves Omit output wiring of micro inch valves sheet 9 N A Remove from wiring drawings Publication 6556 6 5 1 October 1996 2 12 Define Your Control System Characteristics 9 Reduce Watchdog Timer Presets as an Option Check the timers you want to change and record shorter presets in seconds Preset New Preset Data Highway Heartbeat Triac Feedback Watchdog Crowbar Relay Weld Crowbar Relay Failed to Turn On Seal Relay Watchdog E Stop Relay Failed to Turn On E Stop Weld No Valid Mode Selected Clutch Brake Mode Mismatch Station 1 Anti tiedown Station 2 Anti tiedown Station 3 Anti tiedown Station 4 Anti tiedown Inch Button Anti tiedown Clutch Brake Air Pressure Clutch Brake Air Pressure Exhausted BCAM Soft Cam Compare TCAM Soft Cam Compare ACAM Soft Cam Compare Motion Detector Watchdog Motion Detector Permissive Micro inch Feedback Valve 1 Off Micro inch Feedback Valve 2 Off Micro inch Feedback Valve 1 On Micro inch Feedback Valve 2 On Arm Continuous Button Arm for Continuous on Demand Clutch 1 Failed to Turn On Clutch 1 Failed to Turn Off Clutch 2 Failed to Turn On Clutch 2 Failed to Turn Off Clutch Valve stem 1 Failed to Turn On Clutch Valve stem 1 Failed to Turn Off
176. on clutch brake mechanism Topics include The Application Package Related Safety Documentation Control by Redundant Processors How the Software Controls Your Press Protected Memory in PLC 5 x6 Processors Functional Block Diagram Modes of Control System Operation Options to Suit Your Application Wiring Drawings Information on Diskette Choice of Position Monitoring Devices Input Switches Control System Outputs Internal Timers System Response Time Control System Specifications ATTENTION This control system is designed for use only with A mechanical stamping presses having a part revolution friction brake Applying this control system to any other type of press could result in personal injury and or damage to equipment The 6556 series Application Packages consists of the following Software and Documentation e diskette of ladder logic that controls the clutch brake mechanism e diskette of wiring drawings in AutoCAD Release 11 0 and DXF formats user manual including fold out wiring drawings pocket sized operator s guide In addition you must use Rockwell 6200 Series Software revision 5 11 or later or AI5 Software revision 7 20 or later You can program the clutch brake control system with an IBMXT AT compatible computer Publication 6556 6 5 1 October 1996 1 2 Overview of the Clutch Brake Control System Related Safety Information Publication 6556 6 5 1 October 1996 Typical Hard
177. ors de energize their Figure A 7 outputs to stop the press NOTE Releasing a Run button during first downstroke stops the press If the slide has not entered the upstroke zone you can resume downstroke within 5 seconds of pressing the Arm Continuous button The Arm Continuous preset could be less than 5 seconds After 5 seconds the press is stopped you must restart continuous mode with the arming sequence Publication 6556 6 5 1 October 1996 Description of Operating Modes A 9 Figure A 6 Typical Operational Sequence for Stroke and a half in Continuous Mode R5 Have you released No all Run buttons Yes Have you pressed all Run buttons Yes Both processors energized their outputs Has the press completed Have you released a Run button 1 1 2 strokes No orhas a stop condition occurred Yes Go to R6 Both processors Figure A 7 stop the press NOTE Stroke and a half requires you to hold all Run buttons until downstroke is completed a second time Releasing a Run button beforehand stops the press To restart release and press all Run buttons Publication 6556 6 5 1 October 1996 10 Description of Operating Modes Figure A 7 Typical Operational Sequence To Stop Continuous Stroking R6 24 Both processors allow continuous
178. ory configured option close the ARM CONTINUOUS switch and press both RUN buttons in all active stations within five seconds hold both RUN buttons for half a stroke until take over run on cams close or for 1 1 2 strokes if so configured Lets you program the selection of these modes remotely inch micro inch single stroke automatic single stroke continuous Lets you program automatic press motion with simulate inch buttons simulate run buttons arm for continuous on demand Single stroke Lets the operator recycle the press without stopping by releasing and pressing both RUN buttons during a specific portion of the upstroke factory configured option Continuous Lets the operator stop the press at top of stroke after the take over cam signal turns off Single stroke Lets the operator stop the press quickly by releasing a RUN button during a downstroke or Continuous Anti tie down Prevents the press from starting if the system detects that an operator has tied down one or more RUN buttons After all RUN buttons are released the operator must press both RUN buttons at a station at the same time The same applies to the pair of INCH buttons Single stroke Limits press operation to a single stroke even if the operator continues to press both RUN buttons The operator must release and press them again to start the next stroke Limits press operation to a single stroke when using a pair of INCH buttons Single stroke
179. oubleshooting the Clutch Brake Controller For additional information on these topics refer to the 1785 PLC 5 Programmable Controllers User Manual publication 1785 6 5 12 What is the Program Scan The program scan is the mechanism by which the processor operates It is sequential occurring as fast as 100 times per second Here is what the processor does during the program scan Figure F 1 Figure F 1 The program scan lets the processor monitor inputs and control outputs based on decisions programmed by your ladder logic 7 Output Module Signals to output devices such as Input Image motors solenoids Output Image gt p indicators heaters Data Table relays amp contactors Ladder Logic Program Sets outputs based on Scan input conditions Publication 6556 6 5 1 October 1996 F 2 Programming Considerations for PLC 5 Processors Affect Your Ladder Logic Has on the Program Scan Publication 6556 6 5 1 October 1996 How the Processor Scans the Program The Processor 1 Monitors Inputs Monitors the status of input devices by means of input modules The off on or analog signal of each input appears as a corresponding 0 1 or BCD bit pattern in the input image table Controls Outputs Controls the status of output devices by means of output modules Sets outputs to an off on or analog value according to the 0 1 or BCD bit pattern stored in the output image table for the corre
180. ounded System 1771 1D16 120VAC ISOLATED INPUT 06 24 10512 TAKEOVER CAM LIMIT SW 6261 MODULE GROUP 2 E 200200 1 INPUTO 12 0 ak ANTIREPEAT CAM LIMIT SW 62715 800201 3 INPUT 1 L2 1 4 BRAKE MONITOR CAM LIMIT SW 628LS 002 02 5 INPUT2 12 2 6 ee AUXILIARY VALVE 1 FEEDBACK 005 04 gt INPUTS 123 felt 9 NOT USED 0 68 06 AUXILIARY VALVE 2 FEEDBACK 005 05 1 INPUT Lea diio CLUTCH 1 FEEDBACK 005 00 id INPUTS 12 5 14 ae CLUTCH 2 FEEDBACK 005 01 S pd 2 6 1 SEAL RELAY B 942CR E BI 002 07 51 INPUT 12 7 58 19 NOT USED 20 CLUTCH BRAKE POWER 002 10 a 0115 _CLUTCH BRAKE POWER FEEDBACK 115 NETT air mS CROWBAR RELAY B FEEDBACK 121 ER T TELE CRMB 114CR od Lo mE 27 INPUT13 12 13 28 29 NOT USED 30 RM POWER FEEDBACK 01 13 CRM RO x 1158 31 INPUT 14 L2 14 32 CLUTCH BRAKE AIR PRESSURE 4 06 18 AL002 19 INPUT 15 12 15 34k MAIN MOTOR FORWARD 51 00216 35 INPUT 16 12 1636 MOTION DETECTOR o4 Fo BIOS 37 INPUT 17 12 17 38 39 NOT USED 40 ONAL COMPANY ADLEY GROUNDED SYSTEM WIRING RACK A00 GROUP 2 RACK B00 GROUP 2
181. ow Command Bits Act On Control Logic in Protected Memory Select from These Command Bits Steps to Write Ladder Logic Programming Command Bits Soft Clutch and Brake Exchanging Data Between Processors Using Fault and Prompt Bits Programming Shorter Presets for Your Internal Timers Programming Press ready to start Indicators Programming a Brake Monitor patent pending Selecting the Interrupt Period Programming Variable speed Top Stop Assigning Passwords to Your Program and Data Files Chapter What Can Privilege Classes Protect How We Assigned Privileges to Privilege Classes Privilege Classes Data Table Privileges Program File Communication Channel Privileges Assigning Passwords to Classes Gaining Access to Protected Memory Files Install and Wire the Clutch Brake Control System Chapter Objectives Set Jumpers and Switches 5 6 Processors
182. pervisor Continuous Mode 1 040 B151 Remote 13 Continuous Mode Ej 04 Figure 4 12 Example Commands to Enable Crowbar Relay B151 15 and to Let Auxiliary Valves Cycle With Clutch Valves B151 16 and B151 17 Program these command bits unconditionally to suit your application Use the Always False Instruction AFI to maintain B151 16 and or B151 17 in the OFF state 14 8151 Auxiliary Cycles With Clutch AFI same for 151 17 Figure 4 13 Example off the Command for Main Motor Forward B151 18 Use this command bit to detect motor rotation In this example rotational status signals from an A B drive are inputs to an input module at I 051 16 Drive Drive Main Running Running Motor in Reverse Forward 21054 T5051 B151 keep 1 1 SERS SSeS MIS p 5 05 06 18 Write Ladder Logic 4 13 Soft Clutch and Brake A soft clutch brake provides smoother starting and stopping of press motion The clutch and brake are activated with a 2 step valve sequence using auxiliary pressure relief valves in series with the main clutch brake valves You preset auxiliary valve time delays to provide a brief interval of pressure relieved slip action turn auxiliary valves ON or OFF for full pressure at time out You select time delay presets in the range of 0 1 1 0 seconds according to the speed of the pr
183. pressed Part All Active In Run Buttons Permit Place Pressed Downstroke 1 030 8160 8151 qe UU EIUS ee F 10 49 05 Figure 4 5 Example of the Permit Upstroke Command B151 06 Use the upstroke command in any mode to prevent or stop an upstroke Some condition Permit Upstroke 1 040 B151 c ee oe 79 02 06 Figure 4 6 Example of the Top Stop Command B151 07 Use the top stop command in continuous mode to halt the press at the next top of stroke It is typically asserted from a remote master controller Master Controller Auto Die Change Request Top Stop 1 040 8151 xc _____ ME 03 07 ciim Write Ladder Logic 4 9 Figure 4 7 Example of the Permit Inch Command B151 08 Use the permit inch command to allow inching used to inch the press to bottom during manual die change in this example Stop Press Press at Bottom Bottom B156 B156 ONS 00 03 Stop Inch Stop Inch Press at Buttons Until Inch Bottom Pressed PB Released B156 B160 B156 TR TE 03 08 02 Stop Inch Until Inch PB Released B156 02 Die Stop Inch Change Until Inch Permit Mode PB Released Inch 1 004 B156 8151 Tx 14 02 08 Inch Inch Mode Mode I 004 B151 n 17 02 Publication 6556 6 5 1 October 1996 4 10 Write Ladder Logic Figure 4 8 Example Commands to Simulate
184. r Logic 4 5 Follow these guidelines when writing ladder logic for your C B interface in PF15 We present programming examples afterwards 1 10 Install your programming software on your hard drive Use instructions in the manual that accompanied your software Execute the following procedure to install program files onto your hard drive from the diskette in your Application Package a _ Insert the diskette into drive A b Change to a drive install program files at the prompt type Install If using 6200 Software installs to C IPDS ARCH PLCS5 If using software installs to C PLCS PROGS Rename our program files only if using AI5 software as follows If using 6200 series software skip this step You can download a PLC 5 86 program to a PLC 5 26 or 5 46 processor Make This the By Renaming Processor Make This the By Renaming Default File Is This Type Default File Pxxx_A26 x5 5 PLC 5 26 Pxxx_B26 x5 5 Pxxx_A46 x5 PLC 5 46 B46x5 5 PLC 5 86 Important With software you can download a program file of designated type only to that type of processor Select the program for your designated processor and rename it so you can download and view the program with comments and symbols List all operations that you must program and assign them to your interface program file PF15 m
185. r both Do NOT delete the motion detector switch I O module group 2 Figure 3 4 or 3 16 and do NOT write ladder logic for motion detection with a resolver input Figure 4 10 Important To set up your real or simulated ACAM BCAM and TCAM on off positions according to Figure 7 1 and Table 7 B go to the next page Publication 6556 6 5 1 October 1996 7 4 Set Up or Simulate Rotary Cam Limit Switches Setup If Using Rotary Cam Limit Switches omit if using only resolvers Setup If Using Resolvers omit if using only RCLSs Publication 6556 6 5 1 October 1996 If using rotary cam limit switches follow these steps 1 Set up the cam angles for each RCLS switch assembly as described above Use on off settings recommended by the press manufacturer Important Mount these assemblies on opposite ends of the crankshaft that drives the slide so a mismatch will occur if the crankshaft breaks 2 Wire one assembly to the 1771 ID16 input module in module group 2 chassis A Repeat for chassis B Refer to Wiring Drawings sheet 6 3 The ladder logic for RCLS is included in the clutch brake code stored in protected memory Some applications combine one RCLS assembly with one resolver If this applies to your application go to the next section to set up the resolver If not using resolvers ignore the remainder of this chapter because resolvers do not apply to your application If using rotary cam limit switches follow these st
186. r logic turns them ON Example Ladder Logic Refer to chapter 7 Figure 7 5 LS home B151 03 Interlocks B151 04 Fl H 1 Timer DN B151 05 E LS danger B151 06 2 Remote cycle stop B151 07 Permissives B151 08 E LA E C Inch Logic B151 09 EI Enable B151 10 GEQ B151 11 a Ea ee 6 Centrifugal Sw B151 12 EM gt Master Control Remote Selector B151 13 Master Control Remote Selector B151 14 151 15 Publication 6556 6 5 1 October 1996 4 4 Write Ladder Logic Bit Address ON OFF States Example Application Example Ladder Logic Auxiliary Valve 1 B151 16 ON auxiliary valve energizes with clutch valves Controls the order in which press B151 16 Cycles with OFF energizes with brake valves valves sequence 7 Clutch Valve Auxiliary Valve 2 B151 17 ON auxiliary valve energizes with clutch valves B151 17 Cycles with OFF energizes with brake valves Clutch Valve B151 18 ON simulates main motor in forward direction Uses rotational signals from a DC Drive Status OFF simulates main motor stopped or reversed drive to detect motor rotation Main Motor Forward Auxiliary Valve 1 151 19 ON default for using corresponding h
187. r resolver rotational signals in Table 7 B Use this table to record the settings for position monitoring on your press Table 7 B Example Settings for Your Rotary Position Monitor Turns ON Turns OFF Typical Your 1 at a position at a position ON OFF OFF near top beyond which the e when overlapped by TCAM in ON position 10 190 software detects a faulty brake near bottom e that lets the press will stop correctly ontop 170 350 e when or before BCAM turns before BCAM turns ON Publication 6556 6 5 1 October 1996 This Turns ON RCLS ata position Set Up or Simulate Rotary Cam Limit Switches 7 3 Turns OFF Typical Your 1 ON OFF at a position ON OFF Remains ON for the entire stroke except of an Off span during upstroke Figure 7 2 290 250 1 Important To determine exact settings refer to recommendations provided by the press manufacturer Press Speed SPM Set the ACAM off span to the number of degrees 00 90 according to the speed of the press 0 200 strokes per minute from Figure 7 2 contacts should remain open for at least two program scans Figure 7 2 Anti Repeat Contacts Up stroke ON span vs Press Speed 200 180 160 140 120 100 80 60 40 20 0 300 60 900 OFF Span of Anti repeat Contacts During Up Stroke Important When using RCLSs you must also use the hardware motion detector for the subject chassis A or B o
188. rake Control Functions 1 8 Required Input Switches 1 9 Choice of Position Monitoring Devices 1 10 Control System Outputs 1 10 System Response Time 1 10 Internal NIMES 1 11 Options to Suit Your 1 12 Selecting Factory Configured Options 1 12 Programming Ladder logic Commands 1 12 Wiring Your Control System 1 13 Wiring Drawings 1 13 Table of Contents Information on Diskette 1 13 Control System Specifications 1 14 Define Your Control System Characteristics 2 1 Chapter 2 1 1 Verify Your Factory configured Options 2 1 2 Assign Valves to Specific Outputs 2 2 3 Select the Type of Valve Fault Detection 2 2 4 Select the Type of Position Sensor 2 3 Rotary Cam Limit Switches 2 3 2 3 5 Record On Off Positions of Rotary Cam Limit Switches 2 4 6 Select Input Switches 2 4 7 Select Command Bits for C B Interface Logic 2 4 8 Select Other Optio
189. rate set of outputs disables operation of the clutch brake control system when not in operation single stroke lets the operator run one complete press stroke usually started at the top Press Cycle anti tie down prevents the press from starting if the system detects that an operator has tied down a RUN or INCH button After all buttons are released the operator must press both RUN or INCH buttons at the same time downstroke the part of the press cycle when the press travels from the near top to the near bottom position interrupted stroke lets the operator stop the press quickly by releasing a RUN button during a downstroke in single stroke or continuous mode the part of the press cycle when the die is closed near top the part of the press cycle when the press is at the top of its stroke on the hop option that lets an operator continue stroking in single stroke mode by pressing run buttons on each upstroke stop on top command designed to stop the press at the top of its stroke stroke and a half upstroke a method to initiate continuous stroking where an operator holds down the run buttons for 1 1 2 press cycles the part of the press cycle when the press travels from the near bottom to the near top position Rotary Cam Limit Switch a switch that rides a rotating cam to provide information on the position of the press drive shaft anti repeat a part of the control system designe
190. rdware Kit Use an Active Pin connection to detect a disabled run station Use On the Hop in single stroke mode to continue single stroking What method to start A Press Armed Continuous pushbutton Continuous Mode S Press run buttons for Stroke and a Half Note 1 Minimum kit designators define processor type For example M PLC 5 26 and 5 46 processors plus minimum hardware M1 pair of PLC 5 26 processors plus minimum hardware M3 pair of PLC 5 46 processors plus minimum hardware M4 pair or PLC 5 86 processors plus minimum hardware M5 PLC 5 26 and 5 86 processors plus minimum hardware See the C B Packing Data publication 6556 5 1 Publication 6556 6 5 1 October 1996 2 2 Define Your Control System Characteristics 2 Assign Valves to Each processor has three pairs of outputs for press valves Specific Outputs 6 outputs per processor 12 outputs per system The pairs are Clutch 1 and Clutch 2 Clutch and Brake e Auxiliary 1 and Auxiliary 2 e Micro inch 1 and Micro inch 2 Assign your press valves to specific outputs as follows If your press has Then use these outputs Clutch 1 and Clutch 2 for both Clutch 1 for clutch Clutch 2 for brake Auxiliary 1 and Auxiliary 2 for other one set of valves for clutch and brake auxiliary valves for other functions such as soft C B and or dump valves Micro inch 1 and micro inch 2 for micro inch one additional set of valves for micr
191. ring Failed to Turn OFF when output was turned OFF 055 Micro inch Valve 2 Valve failed to de energize C B power is removed Check valve and valve wiring Failed to Turn OFF when output was turned OFF 056 Micro inch Valve 1 Valve failed to energize Press will not cycle in Check valve and valve wiring Failed to Turn ON when output was turned ON micro inch mode 057 Micro inch Valve 2 Valve failed to energize Press will not cycle in Check valve and valve wiring Failed to Turn ON when output was turned ON micro inch mode 058 Aux Valve 1 Valve failed to energize Press will not cycle Check valve and valve wiring Failed to Turn ON when output was turned ON 059 Aux Valve 1 Valve failed to de energize C B power is removed Check valve and valve wiring Failed to Turn OFF when output was turned OFF 060 Aux Valve 2 Valve failed to energize Press will not cycle Check valve and valve wiring Failed to Turn ON when output was turned ON 061 Aux Valve 2 Valve failed to de energize C B power is removed Check valve and valve wiring Failed to Turn OFF when output was turned OFF 062 Aux Valve Stem 1 Valve failed to energize Press will not cycle Check valve and valve wiring Failed to Turn ON when output was turned ON 063 Aux Valve Stem 1 Valve failed to de energize C B power is removed Check valve and valve wiring Failed to Turn OFF when output was turned OFF 064 Aux Valve Stem 2 Valve failed to energize Press will
192. rocedure to convert from NC to NO Controller OK Relay Contacts 7 Simplified the RCLS zones Setting Up Position Monitoring for easier setup and faster response also described in chapter 2 Retained revision 1 2 logic for indication of shaft How Bits Indicate position but explained its operation as different Shaft Position from the simplified RCLS zones Added this section How Transition Faults Stop the Press Revised the fault codes for simplified RCLS Troubleshoot Position Monitor 8 Changed Controller OK test per appendix G Static Wiring Test Revised tests for Air Pressure Main Motor Switch Tests Motion and Chair Break A Revised the diagrams to include Operational Diagrams starting the press from any position B Deleted the feedback diagram for air pressure Timing Diagrams Troubleshooting Fault Codes G Rewired the Controller OK relay Pwr Distribution sheet 1 of 9 Added Input 16 Control Check Power Module Group 4 sheet 8 of 9 H Rewired the Controller OK relay Pwr Distribution sheet 1 of 9 Added Input 16 Control Check Power Module Group 4 sheet 8 of 9 Publication 6556 6 5 1 October 1996 soc ii Summary of Changes Software Revision 1 2 Hardware Changes Software Revision 1 1 Important Revision 1 2 software cannot be operated on a machine wired for Revision 1 1 or earlier software without this change You must move the pressure switch from the port line of the clutch brake valv
193. roper operation or settings 107 Forward Transition Software hardware cams did not go Press will stop or not run in Check soft cam logic or hard cams from Top from top to downstroke single or continuous mode for proper operation or settings To clear this latched fault bit you must enable the fault reset bit or turn the mode select switch to OFF Press will not inch Publication 6556 6 5 1 October 1996 Troubleshooting with Fault Codes Operator Prompts and Snapshot Status Bits 5 168 Suggested Message Cause of Fault Effect of Fault How to Correct the Fault 108 Forward Transition Software hardware cams did not Press will stop or not run in Check soft cam logic or hard cams from Downstroke enter upstroke single or continuous mode for proper operation or settings 109 Forward Transition Software hardware cams did not Press will stop or not run in Check soft cam logic or hard cams from Upstroke enter near top zone single or continuous mode for proper operation or settings 110 112 Spare 113 Forward Shaft Position Any of 107 109 detected Press will stop or not run in Check soft cam logic or hard cams Transition Faults single or continuous mode for proper operation or settings 114 115 118 Spare 119 C B Air Pressure Software detected no air pressure Clutch valves Check 1 wiring Not Detected after energizing main valves de energized Check air pressure s
194. s relationships required by control system software To determine exact settings for actual or simulated limit switches refer to recommendations provided by the press manufacturer Important Any variation from this scheme will cause one or more transition faults where the software is designed to shut down the system You can vary the ON OFF times but not the sequence nor overlap of signals This is particularly important during start up If necessary refer to Troubleshooting the Setup of Your Position Monitoring Devices at the end of this chapter Figure 7 1 Guidelines for Setting Up the On Off Positions of the Rotary Cam Limit Switches Up Near top BCAM and TCAM must be Off 9790 Stroke 900 while remains Other Conditions The software is designed to fault if when it detects a ACAM BCAM and TCAM are OFF all at the same time b BCAM is On when ACAM is Off Zone c ACAM does not cycle while TCAM is On during upstroke a ottom ACAM should remain On for the entire stroke except for an On Off On cycle while TCAM is On during upstroke Important See press manufacturer s recommendations for Near top Zone The dual sets of contacts need not cycle at the same moment Bottom An offset of up to 1 second is acceptable You can reduce this preset On Off settings of ACAM BCAM and TCAM switches This RCLS BCAM TCAM As an example we show typical ON OFF settings for rotary cam limit switches o
195. s3 Class 4 0 system RW RW RW RW 1 undefined RW RW RW RW 2 MAIN ladder RW R R R 3 USER MAIN ladder RW RW RW RW 4 undefined RW RW RW RW 5 undefined RW RW RW RW 6 undefined RW RW RW RW 7 undefined RW RW RW RW 8 undefined RW RW RW RW 9 undefined RW RW RW RW 11 undefined RW RW RW RW 12 undefined RW RW RW RW 13 undefined RW RW RW RW 14 undefined RW RW RW RW 15 CB INTERFACE ladder RW RW R R 16 CONTROL ladder RW R R R Assigning Passwords to Your Program and Data Files 5 5 Communication Channel Privileges We assigned class 4 as the default privilege class for channel communication and R read only or RW read write privileges to classes 1 4 for controlling channel access Important Default class privileges cannot be assigned to scanner or adapter channels just to channel 0 or any channel configured for a DHt network for communication with a programming terminal To view the Channel Privileges screen that allocates these privileges follow this procedure for 6200 series software the procedure for 15 software would be similar 1 Start at the Main Menu 2 Press F7 General Utility The system displays the General Utility screen 3 Press F4 Channel Overview The system displays the Channel Overview screen 4 Press F2 Channel Privileges You get the Channel Privileges screen We assigned privileges for classes 1 4 at the factory RWzread write R read only for CB code Default Priv Class Class1 Cl
196. se the following bits 151 03 permit cycle start e 151 04 permit run 151 05 permit downstroke or delayed start Figure 4 1 Example of the Permit Cycle Start Command B151 03 Use this command in single or continuous mode to ensure that the piece is in place before pressing Run buttons to start the press Include B160 60 if you want to start only from the near top position Robot arm Part Slide in Permit at home in Place Top Zone Cycle Start 1 030 1 030 160 151 pense sess pee sp cree cmc ree ed 00 10 60 03 Figure 4 2 Example of the Permit Run Command B151 04 Use this command in single or continuous mode to ensure that safety interlocks are in a safe state Counter Barrier Dies Lube Balance Guard Permit clamped OK Air OK Closed Run B68 B78 B88 B98 B151 Jti ce 00 10 10 10 04 Figure 4 3 Example of the Permit Downstroke Command 151 05 Use the downstroke command in any mode to start the downstroke after all other conditions are met for starting press motion Robot Arm in Safe Zone Permit 15 Downstroke 1 040 8151 2263 01 05 Publication 6556 6 5 1 October 1996 4 8 Write Ladder Logic Publication 6556 6 5 1 October 1996 Figure 4 4 Example of the Delayed Start Command With B151 05 You can program a delayed start initiated by the AND of part in place and all Run buttons
197. sing other Run button single or continuous mode simultaneously Check button wiring Run button held too long before Press will not start a stroke Release then press run buttons pressing other Run button single or continuous mode simultaneously Check button wiring Check run buttons and wiring To clear this latched fault bit you must enable the fault reset bit or turn the mode select switch to OFF Publication 6556 6 5 1 October 1996 C 2 Troubleshooting with Fault Codes Operator Prompts and Snapshot Status Bits B168 Suggested Message Cause of Fault Effect of Fault How to Correct the Fault 016 Processor A Station 3 Run button held too long before Press will not start a stroke Release then press run buttons Tiedown pressing other Run button single or continuous mode simultaneously Check button wiring 017 Processor A Station 4 Run button held too long before Press will not start a stroke Release then press run buttons Tiedown pressing other Run button single or continuous mode simultaneously Check button wiring 018 Processor Run Stations Among run stations others must be Press will not start a stroke Press all run stations within timed Tiedown pressed after the first is pressed single or continuous mode interval Check button wiring 019 023 Spare 024 Inch Button Inch button held too long before Press will not inch Release then press inch buttons Tiedown pressing other In
198. sition of from on to off transition of Triac 1 triac command 4 triac command Valve stem 2 triac feedback Motion Detector Turns ON before upstroke This feedback signal Before BCAMs turn OFF Triac t ON 0 1 sec 0 1 sec Triac Feedback __ ON 4 0 1 sec 0 1 sec Valve Stem Feedback ON 4 OFF Motion Detector must turn ON before upstroke before Brake montor cams BCAMs turn OFF TENE Off to on transition On to off transition 4 i OFF position dependent Time dependent If and when a PLC 5 x6 processor 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 arm of 1771 OD16 output module If your main valves have external fault detection with valve stem switches and you configured for valve stem feedback you have two options for the other solenoid valve inputs e they also must have external valve stem switches and feedback or e if they have internal fault detection you must simulate external valve stem feedback for them See wiring drawings 8 and 9 Publication 6556 6 5 1 October 1996 B 2 Feedback Timing Diagrams Notes Publication 6556 6 5 1 October 1996 Troubleshooting with Fault Codes B168 Suggested Message 000 Processor A Communication Timeout 001 Crowbar Relay A Weld Fault 002 Crowbar Relay A Fa
199. sponding output device Executes Ladder Logic Manipulates data makes decisions and or controls outputs based on the status of inputs according to your ladder logic instructions Time is the issue A shorter program scan gives a faster system response Each of the following contributes to the time required for a program scan Instructions Processor Family Data format Addressing Instructions Each instruction contributes a small portion of time to the program scan The processor operates on some instructions very quickly but takes longer operating on others Whether the instruction is true or false also affects instruction execution time Table F A Programming Considerations for PLC 5 Processors Table F A Typical Execution Times for Selected Instructions for PLC 5 11 20 30 Processors Type of Instruction If False approx us relay such as examine energize latch and unlatch timer and counter arithmetic such as add subtract multiply divide trig functions such as sin cos tan move and compare shift register such as shift left right load and unload bit dependent where n number of bits operated on immediate 1 0 time to queue up for processing process control such as PID gain computation block transfer transfer time for 10 word transfer first in queue 1 full remote logical rack 57 6K baud Processor Family If True approx us 375 500 10 0 025 300
200. ssis Input 6 Chassis A Input 12 Chassis B Input 11 Publication 6556 6 5 1 October 1996 8 Test Your Clutch Brake Test Inch Buttons Test Inch button wiring by observing input LEDS in Module Group 3 Check the OK box after verifying that the LED indication is correct For This Condition In Module Group 3 OK In Module Group 3 This Input LED is OFF This Input LED is ON Right hand Inch button pressed Chassis B Input 16 mU Chassis A Input 15 Left hand Inch button pressed Chassis A Input 16 iE Chassis B Input 15 Left and Right Inch buttons not pressed Chassis A and B Input 15 Ei Chassis A and B Input 16 Test Stop on top and Arm Continuous Buttons Test the wiring of these buttons by observing input LEDS in Module Group 3 for chassis A and B Check the OK box after verifying that the LED indication is correct For This Condition In Module Group 3 In Module Group 3 This Input LED is OFF This Input LED is ON Stop on top pressed Arm Continuous not pressed Input 12 Arm Continuous pressed Input 12 Test Mode Selector Switch Test the wiring of this switch by observing input LEDS in Module Group 3 for chassis A and B Check the OK box after verifying that the LED indication is correct For This Mode select Position In Module Group 3 In Module Group 3 OK These Input LEDs are OFF This Input LED is ON Off of 6 7 10 11 12 13 14 Input 6 Inch except for the input that Single is
201. t Run 04 Figure 4 2 Permit Downstroke 05 Figure 4 3 or Delayed Start Figure 4 4 Permit Upstroke 06 Figure 4 5 Top Stop 07 Figure 4 6 Permit Inch 08 Figure 4 7 Simulate Inch Button 09 Remote Inch Mode 10 Fig re 4 8 Clutch Pressure ON Figure 4 9 Press in Motion Figure 4 10 Mode Change from Remote Selector 13 14 Figure 4 11 Enable Crowbar Relay Auxiliary Valve Cycles with Clutch Valve Figure 4 12 Main Motor Forward 18 Figure 4 13 Control Soft Clutch and Brake Operation 15 16 19 22 Figure 4 14 Indicate Absence of Physical Inputs Figure 4 15 Fault Reset 23 Figure 4 16 Remote Micro inch Mode 24 Figure 4 17 Simulate Run Buttons 25 Figure 4 18 Remote Automatic Single stroke Mode Figure 4 19 Arm for Continuous on Demand 27 Figure 4 20 Inch Output Enabled 28 Figure 4 21 Initiate Automatic Single Stroke 29 Figure 4 22 Program these bits by turning them ON Program all other bits by turning them OFF We present these additional programming examples under separate headings later in this chapter How to Exchange Scanner Data Between Processors Figure 4 23 Using Fault and Prompt Bits Generate BCD Number Figure 4 24 Programming Shorter Presets for Internal Timers Figure 4 25 Figure 4 26 Figure 4 27 Figure 4 28 Programming Press Ready to start Indicators Programming a Brake Monitor Programming a Variable Speed Top Stop Write Ladder Logic 4 7 To start press motion we recommend that you u
202. t codes 13 and 93 are indicated Reconnect the main motor forward switch input Remove the switch input from chassis B to repeat the test wire 002 16 module group 2 terminal 35 Repeat steps 3 and 4 Motion Detector Switch 1 Remove the motion detector switch input from chassis A wire AI 002 17 module group 2 terminal 37 Place the mode selector switch in single stroke mode Start the press Observe that it stops before reaching bottom and fault codes 48 and 128 are indicated If the press reaches bottom shorten timer preset T162 28 by programming B152 28 to a value that stops the press in downstroke If necessary refer to chapter 4 Reconnect the motion detector switch input to chassis A step 1 Publication 6556 6 5 1 October 1996 8 12 Test Your Clutch Brake Publication 6556 6 5 1 October 1996 5 6 7 Remove the switch input from chassis B to repeat the test wire AI 002 17 module group 2 terminal 37 Start the press and observe that it stops before reaching bottom Reconnect the switch input to chassis B step 5 Chain Break Switch Place the mode selector switch in continuous mode Start and run the press Simulate tripping the chain break limit switch as if the chain had broken Observe that the press stops immediately Do this by shorting the chain break input high Short input terminal 37 of module group 4 to high in chassis A or B
203. t in processor 0 027 03 in processor A I 027 03 in processor B an input in processor A an output in processor B 1 027 03 in processor O 027 03 in processor Using Fault and Prompt Bits Write Ladder Logic 4 19 For example if processor A monitors position with resolver inputs and processor B controls all pilot lights for press operational status processor A could transmit the status of top dead center to processor B as follows Figure 4 23 Figure 4 23 Example Logic to Exchange Data Over a Scanner Adapter Channel Processor A LES t GRT 0 027 LESS THAN THAN Source A 40 0 Source 40 0 01 Source B 5 Source B 399 Processor B Press at Top Press at Top Top Dead from Processor A to Processor A Cntr Light 1 027 0 027 0 010 74 1 gt 01 01 00 We designed internal diagnostics such that when control logic detects fault conditions or other conditions worthy of attention it sets a corresponding bit in either of two bit files e fault bits in B168 0 B 168 159 prompt bits in B169 0 B169 80 We provide you with a look up table that states the type of fault and suggests what to do to correct it Refer to Appendix E and the Operators Guide for identical look up tables We suggest that you design a method to monitor these bits and display the triggered condition depending on the type of oper
204. t set Press will not start in Set the permit start bit single or continuous mode 090 Permit run is not enabled The permit run bit is not set Valve outputs turn OFF Set the permit run bit and the press to near top position 091 092 Spare Main motor is not running forward EN motor not running forward in Valve outputs turn NEN Start the main motor forward single or continuous mode C B power is not reset Seal relay is not closed Seal relay is not closed is not closed Valve outputs remain OFF Clear faults Reset control power Press is not in near top position Press is not in near top position You cannot stroke in single or Inch the press to near top position continuous mode All run buttons are not released The press has stopped and all run You cannot start the press Release all run buttons buttons are not released Release inch buttons The press has stopped and inch Release inch buttons buttons are not released Cycle start bit The cycle start bit Press will not cycle in Toggle the cycle start bit has not been toggled has not been toggled automatic single stroke mode Software stop on top is enabled The software stop on top bit is set The press will complete the cycle and stop at top The stop on top button is pressed The press will complete the cycle and stop at top 101 Continuous mode not armed You did not press the arm continuous You cannot start the press Press the arm contin
205. tch No modifications allowed You must wire these inputs as shown on sheet 2 of 9 for the control system to work correctly Publication 6556 6 5 1 October 1996 And see Figure 3 1 Figure 7 5 Figure 3 2 Figure 3 3 Figure 3 12 Figure 3 4 Figure 4 9 Figure 3 4 Figure 4 13 Figure 3 4 Figure 4 10 N A Customize the Wiring 3 5 Figure 3 1 Replace RCLSs with Ladder Logic Module Group 2 RACK A00 01 09 06 24 RACK 800 MODULE GROUP 2_ 10511 10512 MODULE GROUP 2 TAKEOVER CAM LIMIT SW 602LS TAKEOVER CAM LIMIT SW 62615 INPUT 1 00200 B 002 00 F pur 0 ANTIREPEAT MIT SW ANTIREPEAT CAM LIMIT SW 627LS neut 1 pr A 002 01 NTIREPEAT CAM LIMIT SW 60315 002 01 7 eur be BRAKE MONITOR CAM LIMIT SW 628LS NUT 215 A002 02 BRAKE MONITOR CAM LIMIT SW 604LS 8 002 02 Si Wu Figure 3 2 Delete Crowbar Relay Feedback Module Group 2 RACK A00 RACK 800 RACK A00 MODULE GROUP 2 MODULE GROUP 2 INPUT 15 INPUT 16 INPUT 17 NOT USED INPUT 12 25 CROWBAR RELAY FEEDBACK Reserved Do Not Use Reserved Do Not Use CROWBAR RELAY MODULE GROUP 2 B FEEDBACK 25 INPUT 12 Figure 3 3 Delete Crowbar Relay Power Distribution Module Group 2 117PB 01 16 CLUTCH BRAKE POWER RESET 01 17 gt 01 18 01
206. te Press Start in Auto Single Mode B151 29 Use this bit in automatic single stroke mode to start press motion without first cycling the press manually with Run buttons Start Initiate Auto Auto Single Single 1 040 B151 kem n CIT m ag TREE 10 2 9 PLC 5 processors have unique feature that transfers data between processors in a scanner mode adapter mode configuration The clutch brake software uses channel 1B and rack address 02 on the remote I O network to transfer required information between processors The C B software configures the processor in chassis A for scanner mode and the processor in chassis B for adapter mode Important For the adapter mode processor chassis B we have changed the adapter mode configuration of channel 1B from rack 03 default to rack 02 For more information refer to the documentation that accompanied your programming software on this network use rack addresses other than rack 02 and take care not to excessively load the network and extend system response time Either could cause unpredictable machine response with possible personal injury and or equipment damage ATTENTION If your application requires additional I O racks If you want to transfer discrete data bits between processors in chassis A and B we reserved one I O image table word O 27 for you to use The processors exchange information as follows output in processor A an inpu
207. tion PFxx to SBRxx I rH ER Ld E aR APPS NR DN PEERS TU n Uc mer LAC 7 Publication 6556 6 5 1 October 1996 gt Programming Considerations for PLC 5 Processors F 9 With subroutine programming you can update critical I O within the subroutine with immediate I O instructions pass data into and out of a subroutine Using Immediate 1 0 Instructions Immediate I O instructions are output instructions that when enabled interrupt the program scan to update a specified word of I O image table You would program them immediately ahead of rungs that examine I O that are critical to the subroutine Otherwise all image tables are updated only after the processor has completed scanning the main program and all enabled subroutines This instruction when enabled updates For the local chassis the processor For a remote chassis the processor Immediate Input a word of input image bits sets input image bits to the current updates the input image with the latest states of inputs before continuing the input states from the remote I O buffer program scan from the most recent remote I O scan Immediate Output IOT an group of outputs sets outputs to the current states of updates the remote I O buffer with the output image bits before continuing the curr
208. tons for less than 1 1 2 strokes Observe that the press starts and then stops when you release Run buttons If You Release Run Buttons the Press in first or second downstroke stops immediately in first upstroke stops at the top Bring the press to top by pressing Run buttons and release in upstroke Repeat steps 3 through 6 This section tests the following switches in the clutch brake control system air pressure main motor forward motion detector chain break Air Pressure Switch 1 Remove the air pressure switch input from chassis A wire AI 002 15 module group 2 terminal 33 Place the mode selector switch in single stroke mode Attempt to start the press Observe that it will not start and that fault codes 39 and 119 are indicated Test Your Clutch Brake 8 11 Reconnect the air pressure switch input to chassis A step 1 Remove the switch input from chassis B to repeat the test wire 002 15 module group 2 terminal 33 Attempt to start the press Observe it will not start and that fault codes 39 and 119 are indicated Reconnect the air pressure switch input to chassis B step 5 Main Motor Forward Switch 1 Remove the main motor forward switch input from chassis A wire 002 16 module group 2 terminal 35 Place the mode selector switch in single stroke mode Attempt to start the press Observe that it will not start and that promp
209. ts for your internal timers programming press ready to start indicators programming a brake monitor programming a variable speed top stop Important We suggest that you study the entire chapter before you begin writing your logic Your clutch brake control system has dual PLC 5 x6 processors one in I O chassis A the other in chassis B Memory organization is similar in both processors Program files PF2 and PF16 are factory programmed and pass word protected for read only You will program your clutch brake interface in program file PF15 and your machine related functions such as for robotics lubrication and die change in pre assigned subroutine files We organized processor memory as follows Program File Description Processor in Chassis A Description Processor in Chassis B PF2 Factory configured Master Control Program Identical to processor in chassis A Locked PF3 Used to call subroutines to control auxiliary Optional but available for application press functions such as automation valve programming independent of die protection robotics etc processor in chassis A PF15 Where you program the clutch brake Similar to processor in chassis A interface with machine sequencing to customize the clutch brake code in PF16 PF16 Factory configured clutch brake code Identical to processor in chassis A read only Other Pre assigned subroutines that you write for Available for application programming
210. turned ON Continuous Micro inch Die Change Publication 6556 6 5 1 October 1996 Test Your Clutch Brake 8 5 Valves and Valve Feedback Test output wiring and input feedback to from press valves by ringing out your I O connections using the following table Check the OK box after verifying each connection Important Disconnect one side of each solenoid valve to guard against current flow through solenoids Reconnect them when done For Ungrounded AC Wiring From Chassis A Mod Grp BO 005 00 BO 005 01 BO 005 02 BO 005 03 To Chassis B amp Solenoids OK 904SOL 905SOL 909SOL 910501 al 914501 915501 pee s w T w EEE w s w v w pea m p s w m w To Chassis A amp Solenoids OK EBENE 2 ESSE 904S0L N A 905SOL 5 0 005 05 13 2 11 BO 005 06 BO 005 07 15 N A 909SOL 17 N A B 910SOL 5 Bo 005 10 21 4 1 5 005 11 23 3 BO 005 12 BO 005 13 915501 Publication 6556 6 5 1 October 1996 8 6 Test Your Clutch Brake Publication 6556 6 5 1 October 1996 From Chassis A Mod Grp Number 4 Al 004 02 5 4 Al 004 03 5 4 Al 004 04 5 4 Al 004 05 5 For Grounded AC Wiring Fr
211. ty We assigned privileges to privilege classes read or read write access to program and data files Class 1 has all privileges The password to class 1 is held confidential at the factory We assigned privileges to classes 2 4 at the factory and withheld the privilege to modify privileges from these classes Important As a result of withholding the capability to modify privileges in classes 2 4 you cannot modify privileges on the following screens Privilege screen Data File Privilege screen Program File Privilege screen Since you cannot modify privileges our purpose in describing access to these screens is informational to show you how we assigned privileges We did this to protect the proprietary clutch brake control program and data files Important With this privilege structure you may create program and data files for your own ladder logic You will have RW access to them Privilege Classes We assigned combinations of privileges to each of four different classes from all privileges class 1 to fewest privileges class 4 To view the Privilege screen that allocates privileges type Alt P from any screen You get the Privilege Class Information screen We assigned the following privileges to classes 1 4 at the factory X privilege allowed Privileges Privilege Class Names Classi Class2 Class3 Class4 Modify Privileges Create Delete Data Files Create Delete Program Files Download Blocks of Pr
212. ugh upstroke then stops If your software includes on the hop you can start another cycle without stopping at the top Do this by releasing then pressing and holding all Run buttons during upstroke Publication 6556 6 5 1 October 1996 6 Description of Operating Modes Publication 6556 6 5 1 October 1996 Continuous Mode When you want to run your press continuously ready the press as follows for starting from any position in the press cycle select continuous mode press the arm continuous button Figure A 4 if you have this feature press all active Run buttons within 5 seconds within the preset time In first downstroke releasing a Run button stops the press Figure A 5 If the slide has not entered the upstroke zone you can resume downstroke within 5 seconds of pressing the Arm Continuous button The Arm Continuous preset could be less than 5 seconds After 5 seconds the press is stopped you must restart continuous mode with the arming sequence If the slide entered the upstroke zone the first time and your press does NOT have stroke and a half Figure A 6 when both TCAMs come on you may release a Run button and the press will continue stroking If the press is configured for stroke and a half continue holding the Run buttons until the press runs through downstroke a second time releasing a Run button early in downstroke stops the press and first downstroke conditions apply e releasi
213. uit breaker supplying the control system Soft clutch and brake operation Aux Valve 1 Cycles with Clutch Outputs 151 16 Aux Valve 2 Cycles with Clutch Outputs 151 17 Aux Valve 1 Enabled B151 19 Aux Valve 2 Enabled B151 22 Required programming if you Aux Valve 1 Enabled B151 19 omit auxiliary valves and or Aux Valve 2 Enabled B151 22 use valves without valve stem switches Aux Valve Stems Enabled B151 20 C B Valve Stems Enabled B151 21 Record the command bits required for your application on the worksheet We present examples of how to use these bits in chapter 4 Publication 6556 6 5 1 October 1996 2 6 Define Your Control System Characteristics 8 Select Other Options 9 Reduce Watchdog Timer Presets Optional Publication 6556 6 5 1 October 1996 We provide you with wiring drawings on paper and diskette for ac power grounded e ungrounded Important Select the type of ac wiring system used for your press Discard the other set of drawings on paper and diskette to avoid confusion Other options relate to the way you wire your control system for application options program ladder logic in PF15 We tell you how to implement these options in chapters 3 and 4 Refer to the list of options and corresponding wiring drawings and or command bits in the worksheet Browse through the wiring drawings and select wiring related options on the worksheet You may program shorter watchdog timer presets but never longer
214. uous button button continuous mode Release inch buttons You did not release inch buttons after You cannot start the press Release the inch buttons reaching the top until you release the buttons Bl Downstroke disabled Set the permit downstroke bit set when starting the press single or continuous mode 104 Spare 105 Proc A not requesting inch mode Check remote I O wiring 106 Proc A not engaging inch mode Check remote I O wiring 107 Proc A not engaging single mode Processor A not engaging single mode You cannot start single stroke Check remote I O wiring 108 Proc A not requesting arm contin Check remote I O wiring 109 Proc A not engaging contin mode Check remote I O wiring 110 58 Spar 159 Processor A B detected a fault fault table 095 099 None Stop on top button pressed None Publication 6556 6 5 1 October 1996 Troubleshooting with Fault Codes Operator Prompts and Snapshot Status Bits C 9 Troubleshooting with Snapshot Status Bits The primary means of troubleshooting the clutch brake control system is by means of reading fault codes and operator prompts as presented earlier in this appendix or in the Operator s Guide publication 6556 6 9 1 for PLC processors We present the following troubleshooting strategy as an alternative Whenever the processors turn off outputs to the main clutch brake valves such as due to detecting
215. ustomize the wiring of I O module groups 2 5 to suit your application refer General Instructions to Customize Your Wiring page 3 and follow the instructions below Instructions and examples are on facing pages Important If using ungrounded ac power go back to the previous section operation with possible injury to personnel and or machinery damage do not modify the wiring of system power distribution sheet 1 of 9 except as follows ATTENTION To guard against unexpected machine 1 Deletion of crowbar relays 2 Enter your own wiring in the EMERGENCY STOP BY CUSTOMER zone 01 12 for such switches as E Stop pushbuttons die block air pressure for C B and counterbalance 1 0 Module Group 2 sheet 6 of 9 Grounded AC Power For this modification Replace RCLSs with resolvers Delete Crowbar Relays Delete Clutch Brake Air Pressure Switch Delete Main Motor Forward Switch Replace Motion Detector Switch with Ladder Logic Seal Relay C B Power Reset and Feedback CRM and Feedback Publication 6556 6 5 1 October 1996 Make these changes And see Delete the three pairs of limit switches RLCSs at input terminals 1 3 and 5 Figure 3 13 Wire input terminals 1 3 and 5 to power 108L1 wire high Write ladder logic to simulate the action of the rotary cam limit switches Figure 7 5 Delete wiring crowbar relay feedback to input terminal 25 for chassis A and B Figure 3 14 W
216. ve 1 Dual Valve 2 Clutch 926SOL 92780L Timer 0 005 0 005 1 I IMER ON DELAY EN 4 00 01 Timer T4 0 Time Base 0 01 DN Preset 25 Accum 0 Clutch Brake Clutch Brake Soft Dual Valve 1 Dual Valve 2 Brake 926SOL 92756 1 Timer 0 005 0 005 1 1 IMER ON DELAY 4 00 01 Timer T4 1 Time Base 0 01 DN 4 Preset 25 Accum 0 Soft Clutch Aux Valve 1 Timer Done enabled T4 0 8151 DN 19 Aux Valve 1 Soft Brake Aux Valve 2 Enabled Timer Done Enabled B151 151 pes 1 1 19 DN 22 Figure 4 15 Example Commands to Indicate the Absence of Physical Inputs B151 20 B151 21 and Physical Outputs B151 19 B151 22 Write Ladder Logic 4 15 When customizing your design to omit certain valve hardware wiring program the following command bits unconditionally to tell the software to ignore corresponding physical inputs that are absent Program this bit B151 19 B151 20 B151 21 B151 22 Aux Valve 1 Enabled Aux Valve Stems Enabled C B Valve Stems Enabled Aux Valve 2 Enabled When Auxiliary valve 1 is not used Auxiliary valves have no valve stem switches C B valves have no valve stem switches Auxiliary valve 2 is not used Aux Valve 1 Enabled B151 0 19 Auxiliary Valve Stems Enabled 8151 U 20 Clutch Brake Valve Stems Enable
217. ware for the cat no 6556 PxxxK Application Package PLC 5 46 processor scanner mode chassis A PLC 5 26 processor adapter mode chassis two 1771 A2B 8 slot I O chassis e six 1771 ID16 16 point isolated input modules two 1771 OD16 16 point isolated output modules two 1771 P4S slot power supplies six 700 P400 master control and seal relays Important You must provide various input switches to the clutch brake control system We cover this in chapter 2 You are responsible for the safety of the entire installed control system and for meeting all applicable laws codes and safety requirements The application package deals only with the electrical control portion of the clutch brake device ATTENTION As the installer of this control system you must be knowledgeable of ANSI B11 1 regarding mechanical power presses OSHA 1910 217 and other applicable standards pertaining to safety recommendations related to machine construction general electrical machine guarding point of operation guards light curtains gates 2 hand switches In addition to local codes and laws you are responsible for the safety recommendations detailed in all applicable codes and standards including 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
218. while Valve outputs turn OFF Set the permit downstroke bit and the press was in downstroke inch the press to near top position Upstroke stopped by software Permit upstroke bit was reset while the Valve outputs turn OFF Set the permit upstroke bit and press was in upstroke inch the press to near top position Permit start is not enabled The permit start bit is not set Press will not start in Set the permit start bit single or continuous mode Permit run is not enabled The permit run bit is not set Valve outputs turn OFF Set the permit run bit and or will not energized inch the press to near top position 011 012 Spare 013 014 015 016 017 018 019 020 Main motor is not running forward Main motor not running forward in Valve outputs turn OFF Start the main motor forward single or continuous mode C B power is not reset Seal relay is not closed Valve outputs remain OFF Clear faults Press control power and C B power reset buttons Press is not in near top position Press is not in near top position You cannot stroke in single or Inch the press to near top position continuous mode All run buttons are not released The press has stopped and all run You cannot start the press Release all run buttons buttons are not released Release inch buttons The press has stopped and inch Release inch buttons buttons are not released Cycle start bit The cycle start bit Press will not cycle in Toggle the cycl
219. witch ACAM Upstroke ACAM did not cycle in upstroke Press will stop or not run in Check soft cam logic or hard cams single or continuous mode for proper operation or settings 120 Spare 121 Brake Monitor Cam Processor B sees the BCAM while Press will stop or not run in Check soft cam logic or hard cams Mismatch Between processor A does not single or continuous mode for proper operation or settings Processors 122 Takeover Cam Mismatch Processor B sees the TCAM while Press will stop or not run in Check soft cam logic or hard cams Between Processors processor A does not single or continuous mode for proper operation or settings 123 Anti repeat Cam Mismatch Processor B sees the ACAM while Press will stop or not run in Check soft cam logic or hard cams Between Processors processor A does not single or continuous mode for proper operation or settings 124 Cam Mismatch Fault Any of 121 123 detected Press will stop or not run in Check soft cam logic or hard cams single or continuous mode for proper operation or settings 16 Spar fa SCENE 126 Brake Monitor Fault On stop on top command the Press cannot operate in single Check the brake and press slid into BCAM zone before or continuous mode until it brake monitor cam settings stopping stops in the near top zone 127 Chain Break Fault Software detected a fault Press cannot operate Check chain break switch wiring 128 No Motion Detected Upon command t
220. with these steps set jumpers and switches install PLC processors I O modules and power supplies connect PLC processors and programming terminal wire ac power distribution to the controller convert controller OK relay contacts from N O to N C wire your control system Important Installing and or checking other press functions such as lubrication systems slide adjustments dies cushions counter balances and clamps are beyond the scope of this chapter We encourage you to contact your press manufacturer for that information We help you set jumpers and switches on these components PLC 5 x6 processors e 1771 T O chassis A and B 1771 ID16 input modules Output module 1771 OD16 has no jumpers or switches Publication 6556 6 5 1 October 1996 Rear View of PLC 5 Processor Switch Assembly SW1 Publication 6556 6 5 1 October 1996 Install and Wire the Clutch Brake Control System PLC 5 x6 Processors You may set the DH station number channel 1A for PLC 5 46 and PLC 5 26 processors respectively to 0 and 1 so they can communicate Figure 6 1 You may modify these switch settings if you application requires it Figure 6 1 Setting the DH Station Numbers with SW1 PLC 5 46 in Chassis A DH Station Number 0 PLC 5 26 in Chassis B DH Station Number 1 Switch Side View Switch Side View
221. your application from tables on left hand pages in this section 2 Follow the instructions for the modification Some modifications require that you write ladder logic to replace the function of the deleted wiring or that you wire an input terminal to a power rail 3 Observe the corresponding example wiring diagram on the right hand page that results from making the modification We present instructions according to I O module group because the wiring for each I O module group is presented on a separate drawing in your set of wiring drawings Customizing an Important If using grounded ac power skip to the next section Ungrounded AC System operation with possible injury to personnel and or machinery damage do not modify the wiring of system power distribution sheet 1 of 9 except as follows ATTENTION To guard against unexpected machine 1 Deletion of crowbar relays 2 Enter your own wiring in the EMERGENCY STOP BY CUSTOMER zone 01 12 for such switches as E Stop pushbuttons die block C B air pressure counterbalance air pressure Publication 6556 6 5 1 October 1996 3 4 Customize the Wiring I O Module Group 2 sheet 6 of 9 Ungrounded AC Power For this modification Replace RCLSs with resolvers Delete Crowbar Relays Delete Clutch Brake Air Pressure Switch Delete Main Motor Forward Switch Replace Motion Detector Switch with Ladder Logic Seal Relay C B Power Reset and Feedback

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