Applied Safety Solutions
Machine Safety Services
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Stop Time Measurements and Safety Distance Calculations
• Assure compliancy of light curtain and area guarding device
installations.
• Help determine ergonomic and operational advantages of
safeguarding options.
Safety Circuit Design
• Including limited and sequential shutdown and applications.
Probability of Failure on Demand Calculations
• Help assure a system architecture can obtain a desired Safety
Integrity Level (SIL) based on IEC 61508.
The implementation of a comprehensive machine safety program
will involve many disciplines. Only Rockwell Automation has the
entire spectrum covered. From the design and integration of safety
critical circuits using the most advanced controls to the
implementation of hard guarding. Rockwell Automation has the
experience necessary to fulfill all your needs.
Typical machine system integration services can include:
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Risk assessments, risk reduction planning
and project services allow companies to
plan and implement safety programs for
machine safeguarding applications to help
reduce costs, improve compliance and
enhance plant floor safety.
Description
Rockwell Automation’s Machine Safety Services include consulting,
system integration and long-term support services for machines that
must meet standards set forth by OSHA and ANSI in the United
States. These services complement Rockwell Automation’s expertise
in metalforming and automation projects, including over 15 years of
experience in automating mechanical and hydraulic stamping
presses.
Rockwell Automation’s Machine Safety Services include:
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Standards Training
• Customer training on current standards and industry accepted
interpretations.
• Standards updates as necessary.
Risk Assessment and Risk Reduction Planning
• Coach/train client through procedures of risk assessment.
• Provide assistance with interpretation of standards and
documentation of assessments.
• Facilitate an iterative process of mitigating each identified
hazard by redesign or additional measures.
Technical Specification Development
• Assist in the development of a machine safety standard that
addresses safety solutions for an entire company, facility or
machine.
Conformity Audits
• Machine audits to verify and document compliance. A
complete step-by-step assessment determines which standards
are applicable and whether or not they have been satisfied.
13-2
System Integration Services
• Project management
• System architecture design
• Panel design
• Material procurement
• RA products
• Third party products (including hard guarding solutions)
• Assembly
• Software development
• Hardware/software integration testing
• Factory acceptance
• Start-up assistance
Rockwell Automation’s support and follow through are available at
every stage to handle any situations that may arise. Our long term
support services include:
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On-Site Training
• Maintenance and operator training four our installed machine
safety solutions
Preventive Maintenance Programs
• Verify that installed safety systems are operating within
defined parameters.
Field Service
• Field work to be done on a contractual or as needed basis.
Applied Safety Solutions
Advanced Burner Management Systems
Our BurnerMaster™ family of burner management systems are
designed for single burner (BurnerMaster SB™) or multi-burner
applications for boilers, process heaters, furnaces, kilns and any
other fuel-burning processes.
In addition to our family of burner management systems, Rockwell
Automation offers related systems for control of combustion related
processing including:
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Combustion temperature/pressure control
Fuel handling systems
Ash handling and emission control systems
Soot blowing
Water treatment (related to powerhouse)
Description
Rockwell Automation advanced burner management systems are
pre-engineered to provide ignitor (pilot) and main flame detection,
as well as control and monitoring of burner start-up and shutdown
sequences including master fuel trip and purge.
The systems can help you:
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Protect against damage to your combustion process equipment
and surrounding areas due to explosion or other undesirable
event
Qualify for lower insurance premiums resulting from compliance
with applicable industry standards such as NFPA, IRI and FM
Reduce installation times because our systems are fully
assembled, completely programmed and thoroughly tested—
designed for immediate field installation
Simplify unit operation through alarm management and operator
displays.
Reduce start-up time with advanced diagnostics and operator
help messages.
Reduce critical troubleshooting time through the use of pinpoint
diagnostic messaging
Enhance communication and reporting capabilities to other
systems in your facility
Keep your combustion process safe and minimize fuel usage on
the same platform!
13-3
Applied Safety Solutions
Press Control Systems
Description
Rockwell Automation offers various systems, bundled packages, and
kits for meeting the safety-related control standards for the clutch/
brake of mechanical stamping presses. These solutions are designed
to meet the safety requirements of ANSI B11.1, OSHA 1910.217,
CAN/CSA Z142-M90, IEC-61508, EN-954 and EN-692.
The 6556 Clutch/Brake kits are bundled packages consisting of
redundant PLC components with application software, wiring
diagrams, relays and documentation. Some packages have TUV
certification. Each solution is designed with independent redundant
programmable controllers with additional electromechanical
components and the application software to provide the necessary
monitoring, self testing, security, and verification that make up a
control-reliable design.
The PLC-5/x6 based kits come with the clutch/brake software
secured in program file #16, and the user can add other logic to
other files. The PLC-5-based kits are designed for large presses with
extensive automation.
The fixed SLC and MicroLogix kits are pre-programmed with the
ladder program locked in flash memory. Certain features in the fixed
kits are configurable. The MicroLogix and SLC 5/02 kits provide
only the basic clutch/brake functions. The SLC 5/03-based Omega
kit, for example, has a variety of standard features to control
ancillary functions such as lube and programmable limit switch that
can be configured through optional pre-programmed PanelView
screens. The fixed kits are easy to use, require no programming, and
are designed for small to medium-size presses retrofitted by the user.
The StamProTM system is a complete, ready-to-install, Logix-based
press control system that comes with controllers and hardware for
controlling a stamping press. Ancillary control functions, which can
be purchased from Rockwell Automation or supplied by the user, are
integrated into the system hardware and software designs. The
StamPro system is designed for end users, OEMs and integrators.
The system can be purchased either with pre-programmed optional
functions or can be programmed by the user.
Some press functions which can be integrated with our solutions
include:
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Clutch/Brake. The Allen-Bradley controller designed system
that controls the dual-valve clutch/brake mechanism as found on
all mechanical stamping presses. This system includes dual
redundant controllers with application software for monitoring
and self-testing to achieve safety regulation compliance.
Programmable Limit Switch (PLS). Ladder Logic for
switching outputs according to crankshaft position. The PLS is
often used to integrate and synchronize other press auxiliary
functions such as feeders, grippers, blow-off and ejector valves.
This feature requires a resolver position input for accuracy. The
PLS is usually pre-programmed and configured by the user for
each job or die.
Die Monitoring. Logic that monitors a variety of in-die sensors
to determine misalignment, double blanks, misfeeds, part
positioning, plus other critical conditions. The die monitor
function requires a resolver input and is generally preprogrammed and configured for each job or tool.
Modes of Operation
The following table lists the modes of operation for each Rockwell
Automation press control solution.
Press
Modes of
Operation
Off
Inch
Micro inch
Single
Continuous
Remote &
Auto Single
MicroSLC 5/02
Logix (6556- Fixed (6556SCBK2)
(6556-SCBK3)
X
X
X
X
X
X
X
X
X
X
X
X
X
StamPro
System➊
X
X
X
X
X
X
➊ Contact your local sales office for pricing and order information.
Press Features/Functions
The table below summarizes the various press control functions
available for each press control solution.
(S = Standard, O = Optional, P = User Programmable, Blank table cell = Function not available).
Press Control Features
Clutch/Brake Control
Operator Interface
E-Stop & MCR Relays
Run Sta. Monitored
Main Motor Control
RCLS Position Capable
Resolver Capable
Brake Time Monitor
Var. Speed Top Stop
Production Counters
Maintenance Timers
Prog. Limit Switch
Die Protection Mon.
Recipe Storage
Var. Speed Comp.
Lubrication Control
Tonnage Monitoring
Auto Counterbalance
Shut Height Adjust
Var. Speed Drive Interf.
Servo Feed Interface
Robot Interface
Coil Feed Interface
Die Cushion Control
Die Clamp Control
Bolster/Die Cart Cntl.
Automation Control
Aux. Automation Intrf.
Prod. Monitoring/OEE
Hydrlc. Overload Cntl.
Light Curtain Interface
Disconnect/Starters
Colour HMI
Open Net. Interface
Capable ➋
TUV Certification
User Prog. Capable
Enclosure assembled
Complete System
Micro
Logix
Compact
Press
Master
S
O
S
1
O
S
O
O
SLC
Omega
StamPro
S
O
S
1
S
S
S
1
S
S
O
S
S
S
S
S
S
20
S
S
O
O
O
O
S
S
S
O
O
S
S
O
O
O
O
O
O
S
O
O
S
S
S
O
O
O
S
S
S
1
S
S
S
S
O
S
S
S
O
SLC
5/02
S
S
S
4+
S
O/P
S
S
O
S
S
O
O
30+
S
O/P
O/P
O/P
O/P
O/P
O/P
O/P
O/P
O/P
O/P
O/P
O/P
S
O/P
O/P
S
S
S
S
O
S
O
O
O
S
O
O
➋ Ethernet, DeviceNet, Controlnet, RS232
13-4
Compact
Press
Master➊
X
X
X
X
X
SLC
Omega
MLCBK)
S
S
O
O
Applied Safety Solutions
Press Control Systems
StamPro—A Logix Based Press Control Engineered Solution
Reduce operating costs and downtime with
reliable, flexible programmable press
controls.
Standard features include:
■ Stop time monitoring for hands in die
■ Safety Interlocks and Light Curtain interface
■ Main Motor/Pump Control, including a reversing motor starter
■ Lubrication control, including a motor starter
■ Manual Slide Adjust/ Ram Profile Control
■ A 10 inch color operator interface terminal with Alarm Status/
History and Fault/Prompt
■ Clutch/Brake Safety Control
■ Interface for four run stations with anti-tiedown protection
■ Fully assembled and mounted in a NEMA 12 rated industrial
enclosure with one set of operator run palm-buttons
The Rockwell Automation StamPro™ System is an advanced
programmable controller-based system used for the control and
monitoring of mechanical and hydraulic stamping presses. The
StamPro control system is for customers who want to reduce cost
and risk by purchasing a complete pre-engineered system, ready for
installation.
System Description
The StamPro System is a flexible, pre-engineered press control
system based on standard Rockwell Automation components
available locally and supported worldwide. StamPro Systems provide
press control, operator interface, and magnetics in an integrated
package with a complete set of documentation. The use of fieldproven hardware and software helps users minimize cost, risk, and
comply with the necessary ANSI, OSHA and CSA standards.
System Architecture
The StamPro System uses the Allen-Bradley Logix family of
processors. The safety kernel, executed in dual Logix processors, is
based on standard Bulletin 6556 clutch/brake or ram control
software, designed by Rockwell Automation to comply with ANSI
B11.1/B11.2, OSHA 1910.217, CSAZ142-2002, and EN 954. This
safety kernel is coupled with optional application software that
provides all other press automation control, monitoring,
information and network requirements. The Logix programming
environment allows the user to add their own additional custom
software into the same processors where the safety kernel resides, to
minimize control hardware costs. The standard operator interface is
a pre-programmed colour PanelView 1000 (key pad or touch
screen). The system is available in a freestanding console or an
upright enclosure with a press mounted operator station.
Optional features include:
■ Automatic Slide Adjust Control
■ Die Protection Monitoring
■ Programmable Limit Switch
■ Tonnage Monitoring
■ Die Clamp Control
■ Die Cushion Control
■ Bolster Control
■ Light Curtain with muting
■ Hydraulic Overload Control
■ Recipe Management
■ Automatic Die Change
■ Automatic Counterbalance Air Pressure Control
Results
A StamPro System will help provide:
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Features
The StamPro System is modular, which allows each system to be
configured to the requirements of each specific application, and
easily accommodates control expansion for future needs.
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StamPro Architecture
Main Control Enclosure
ControlNet (included)
(Optional I/O)
Die
Protection
Field I/O
(1)
(2)
(3)
(4)
Main Operator Station
10 inch PanelView
Terminal (included)
Field Devices
(Optional)
Die Clamps
Tonnage
Monitor
PLS Outputs
(Optional)
(0)
Reduced downtime through comprehensive operator diagnostic
messages, on-line control system troubleshooting and replaceable
modular components available worldwide.
Increased flexibility through open integration of press control
functions and industry-standard connectivity to other equipment
including coil feeds, computers, drives, robots and servo transfer
feeds.
Improved quality through recipe-based control of process
parameters such as shut height, counterbalance air pressure,
motor speed, die protection and programmable limit switch.
Reduced costs through the use of standard Rockwell Automation
industrial control hardware, field-proven application software,
and a comprehensive documentation package.
(5)
(6)
(Optional)
Slide Adjust
Operator Station I/O
(optional)
Press Position
with CAMS
Processor “A” (included)
(0)
(1)
(2)
(3)
Slide Safety Control Is Standard
DeviceNet (included)
Magnetics I/O
Printer
Lap top
(0)
(1)
(2)
(3)
Magnetics Enclosure
Plant Wide Network
with Equipment (optional)
(4)
Workstation
(4)
Ethernet (optional)
Hub
Network Data
Server
(Optional)
Main Motor
PowerFlex
AC Drive
(Optional) Bolster Drives
13-5
Applied Safety Solutions
Press Control Systems
FeederPro—A Logix Based Press Coil Feed Engineered Solution
Helping stampers improve uncoiling,
straightening and feeding to make better
parts.
Reliability Is Designed into the Solution
The Rockwell Automation FeederPro system provides a reliable
solution for press feeders based upon standard, off-the-shelf AllenBradley components. The system provides a press feed controller
that uses familiar configuration and troubleshooting tools on the
Logix™ family of controllers. Built-in set-up routines and
diagnostics make the FeederPro easy for your press room operators
and maintenance personnel to run and troubleshoot the system by
themselves, maximizing their productivity and reducing the
downtime of the feeder system. The FeederPro application software
provides the commands to the drives. This enables the system to
closely follow the motions of the press for tight control of the
manufacturing process.
As manufacturers demand higher quality components from their
suppliers, handling of raw material feed stock becomes critical. In
the stamping process, that means feeding the coil into the press has
to be accomplished with greater emphasis on:
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Speed
Flexibility of coil sizes
Faster change over
Minimal impact to the material
Rockwell Automation has developed a pre-engineered automated
press feed control system to help increase productivity and reduce
the high costs of scrap in the stamping room.
Results—A Smooth Operator
The FeederPro system uses the Rockwell Automation
SmoothProfile™ press feed profile to smoothly accelerate and
decelerate the feed rolls. This approach dramatically reduces roll
slippage and virtually eliminates material marking. The FeederPro
system is available as a pre-engineered bundle of engineering and
components or as a completely assembled and tested control system.
Rockwell Automation’s FeederPro is available in a range of
configurations, from a pre-engineered bundle of hardware for small
press feeds to turnkey systems for the largest flat metal line
processing systems.
The open network architecture of the FeederPro System allows for
simple connectivity to a StamPro press control, for even better
control of your stamping process.
Straightener
Unwind
Work Roller
Feed Rolls
Diameter
Sensing
Empty Loop
Photo Switch
Stamping Press
Empty Loop
Photo Switch
B
AC
B
AC
R
SM
ControlLogix
PowerFlex
1394
Digital
Servo
Controller
Shunt
Resister
Flex I/O
Flex I/O
Miscellaneous
Machine I/O
13-6
PanelView
Applied Safety Solutions
Press Control Systems
STFPro—A Logix Based Servo Transfer Feed Engineered Solution
Make parts faster by replacing
mechanically-driven transfer system with
press control, feed control and servo
transfer control on a common platform.
Servo Transfer Feed Functionality
The STFPro application software provides the commands to the
drives that enable the system to closely follow the motions of the
press machine, for tight control of the manufacturing process.
Proven Solutions Get Results
Global manufacturers are striving to create more flexible and
productive manufacturing facilities. In many stamping rooms, this is
being accomplished through the use of servo-driven, rather than
mechanically driven, inside the press part transfer systems. Servo
Transfer Feed (STF) systems-deliver increased flexibility and
improved productivity by allowing users to configure the paths of
their transfer systems. Rockwell Automation offers a variety of
STFPro systems for customers.
Rockwell Automation has applied extensive expertise in Servo
Transfer Feed systems to develop the hardware/software products
users need to efficiently and reliably operate their complex machines.
Routines for building a SmoothProfile™ motion cam are standard
with Rockwell Automation’s STFPro software. The result is highly
repeatable parts transfer with minimum machine wear. The
demonstrated success of this software shortens system development
time and reduces the risks associated with developing an application
from scratch.
The Logix Solution
Manufacturers who use the Logix family of controllers want to run
their presses with one neatly integrated system for both their press
controls and their STF functions. This split dramatically simplifies
the overall system architecture, operation, and maintenance.
The use of standardized, well-documented software also helps make
STFPro systems more easily supported in the field, resulting in
improved up time and reduced training costs. The well-designed
hardware solution ensures that all the electrical design details are
documented. Rockwell Automation’s proven STFPro system is
available as a hardware/software bundle or included in a complete
turnkey system for both OEMs and end users.
The ControlLogix system has a commercial off the shelf
architecture, freeing stampers from “black box” controllers that are
difficult to maintain and troubleshoot. The STFPro system
implements the motion control application using easy to understand
software. This open approach enables a wide range of personnel to
understand and troubleshoot the system.
The open network architecture of the STFPro System allows for
simple connectivity to a StamPro press control, for even better
control of your stamping process.
Transfer Axis
B530E
Encoders
DNE
Clamp Axis
B530E
DNE
B530E
DNE
Lift Axis
B530E
DNE
B530E
DNE
B530E
DNE
Encoder
Encoder
1394 Digital
Servo
Controller
1394 Digital
Servo
Controller
Sercos
Ethernet
6180 Computer
Typical Architecture
13-7
Applied Safety Solutions
Press Control Systems
Compact PressMaster—A MicroLogix Based Complete Mechanical Press Control Solution
Reduce operating costs and downtime with
reliable and flexible MicroLogix press
controls.
The Rockwell Automation Compact PressMaster System is a cost
competitive, programmable controller-based system used for the
control and monitoring of mechanical stamping presses. Reduce cost
and risk by purchasing a complete system, pre-wired and tested,
ready for installation. The system is designed to modernize your
press controls, increase control system reliability, and reduce
downtime by providing comprehensive operator diagnostics.
Compact PressMaster provides press users, rebuilders, and OEMs a
low cost PLC based control system to remain competitive and
reduce risk.
System Description
The Compact PressMaster System an expandible press control
system based on standard Rockwell Automation components
available locally and supported worldwide. Compact PressMaster
Systems provide press control, operator interface with
comprehensive diagnostics, expandability, and motor controls in a
single integrated package. The system is provided, ready to install,
with a complete set of documentation.
The Compact PressMaster System is based on a Bulletin 6556
clutch/brake control with dual processors and software designed by
Rockwell Automation to help customers comply with ANSI B11.1,
OSHA 1910.217, CSAZ142-2002, and EN 954. Allen-Bradley motor
controls and an Allen-Bradley PanelView 3" monochrome operator
interface with key pad is included, to complete the system and
provide maximum reliability.
Standard Features
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■
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■
■
■
■
■
■
■
■
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Safety Interlocks and Light Curtain Interface
Clutch/Brake Safety Control with Inch, Single Stroke,
Continuous, Modes of Operation, including a mode select key
switch
Main Motor Control, including a 25 Hp reversing motor starter
and forward/stop/reverse push-button
Lubrication Control, including a 1 Hp motor starter and lube
verification
60 Amp/460V Lockable Power Disconnect
Press Mountable, NEMA 12 Rated Industrial Enclosure
Operator Fault and Prompt Messages, Alarm Status Operator
Screen on a 3 inch PanelView Display
One Industrial Brushless Absolute
Brake Time Monitoring and 90 Degree Stop Test
Interface for One Run Station with Anti-Tiedown Protection
Press Stroking Anti-Repeat and Top Stop Overrun Protection
Clutch/Brake and Counterbalance Air Pressure Monitoring
User Immediate and Top Stop Control Interlocks
4 Programmable Limit Switch Outputs
Production counters and maintenance timers
Optional Features
■ Manual or automatic slide adjust
■ 8 Channels of Die Protection
■ 8 Programmable Limit Switch Outputs
■ Hydraulic Overload Control
■ Light Curtains with muting
■ OEM packages
■ Automatic counterbalance control
■ Variable speed compensation
■ 6 inch colour operator display terminal
Results
A Compact PressMaster System helps provide:
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Reduced downtime through advanced diagnostic messages,
helpful operator prompts, and on-line control system
troubleshooting.
Improved system reliability through the use of standard Rockwell
Automation industrial control hardware and software.
Increased operational flexibility and expandability, while reducing
costs and risk.
Compliance with ANSI, OSHA, and CSA regulations.
A press control that can grow with your stamping operations.
Ordering Information
Contact your local Rockwell Automation Sales office or distributor.
Catalogue Number
Base System
Dual Absolute Encoder Option
Die Protection Monitoring Option
4 Additional PLS Outputs Option
One Operator Run Stand
6 Inch Color Operator Display Option
Dual Absolute Encoder Option with Light
Curtain Muting
13-8
6556-GCPM
6556-GMRP2
6556-GCDP1
6556-GCPLS1
6556-GTSTAND
6556-GCPV600
6556-GCMUTE
Applied Safety Solutions
Press Control Systems
Fixed MicroLogix 1500 Clutch/Brake Control
System Requirements
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Rotary Cam Limit Switch
Motion detection device
Self-checking valve
Ordering Information
The purchase of one kit includes the license to use this control on
one stamping press.
Network options must be ordered separately. Options include the
DeviceNet network (catalogue number 1761-NET-DNI) and the
RS–232–C/DH–485 Advanced Interface Converter (catalogue
number 1761-NET-AIC).
The MMI option, which must be ordered separately from the basic
Clutch/Brake package, includes pre loaded software and cables
(catalogue numbers 6556-GMPV300).
Description
The 6556 clutch/brake control package also comes in two versions:
A MicroLogix 1500 processor-based Clutch/Brake Package is a
bundle of hardware, software, and documentation that controls the
basic clutch/brake mechanisms on mechanical stamping presses.
This package requires no user programming. It can be interfaced
with other controllers such as the ControlLogix system.
Package with 120V AC I/O (catalogue number 6556-MLCBK)
■
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The package uses redundant MicroLogix 1500 processors with
application software for self testing and verification to help meet the
safety requirements of ANSI B11.1, OSHA 1910.217 and CAN/
CSA Z142-M90 press safety regulations for mechanical stamping
presses. The DC version has TUV certification for IEC–61508,
EN–954, EN–692 and DIN 19250. Each MicroLogix 1500
processor has the basic clutch/brake functionality as well as the basic
diagnostics to interface to several display options making it an easyto-use cost-effective solution for small presses. Since you don’t need
programmable controller experience; you can just wire and mount
the equipment.
For other press functions such as programmable limit switch,
automation control, brake time monitoring, die protection monitoring,
resolver based consider using the Compact PressMaster system. If you
require resolvers and break time monitor only, add the 6556GMRP1 option. If you require more automation flexibility or need a
custom system, consider using the StamPro system.
Control Features
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■
■
■
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One set of Run buttons monitored
One set of Inch buttons monitored
AC and DC versions
Hard wired cross-checking
Open communication for diagnostics
Modes of operation:
• – Off
– Inch
– Micro Inch
– Single
– Continuous (Armed)
Brake monitoring
Top stop overrun and anti-repeat protection
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MicroLogix 1500, 1764–LSP (2)
Output Module, 1769–OW8I (4)
Memory Module, 1764–MMIRTC (2)
Terminator cap, 1769–ECR (2)
DC base unit, 1764–28BXB (2)
Relay, 700CF310D (4)
AC Input Module, 1769–IA16 (2)
Safety Relay, 700ZBR520AZ1 (1)
AC Input Module, 1769–IA8I (4)
Package with 24V DC I/O (catalogue number 6556-MLCBKDC)
■
■
■
■
■
■
■
■
MicroLogix 1500, 1764–LSP (2)
Output Module, 1769–OW8I (4)
Memory Module, 1764–MMIRTC (2)
Terminator cap, 1769–ECR (2)
DC base unit, 1764–28BXB (2)
Relay, 700CF310ZJ (4)
DC Input Module, 1769–IQ16 (6)
Safety Relay, 700ZBR520AZ1 (1)
New—Enhanced Options for MicroLogix Clutch/
Brake Controllers
Reference #
6556-GM4RUN
6556-GMPV300
Option Description
Interface for 4 run stations + software
Display-3” LCD PanelView300
Micro+cable+software
6556-GMRP1
1 Encoder and an existing user supplied CAM box
with Brake Time Logic + software
6556-GMRP2
2 Encoders and no CAMS needed with Brake Time
Logic + software
6556-GMMDS
Motion Detect Device and cable
6556-GTSTAND One operator run station on T-Stand with run, top
stop, and e-stop push-buttons
6556-GCAM1
6 CAM box with Integral Motion Detect Device
6556-GCAM2
6 CAM box without Integral Motion Detect Device
6556-GCAM6
3 CAM box with Integral Motion Detect Device and
ability to mount 6556-GMRP1 inside
13-9
Applied Safety Solutions
Press Control Systems
Omega—An SLC500 Based Press Control Solution
Description
Features
The Omega™ Configurable Press Control Kit is designed to control
basic functions on mechanical stamping presses and to meet the
safety requirements of ANSI B11.1, OSHA 1910.217 and CAN/
CSA Z142–M90 press safety regulations for mechanical stamping
presses. The system comes as a bundled package consisting of
hardware, all application software, and documentation.
Clutch/Brake Control is the standard logic used in all Rockwell
Automation Omega series press control systems. Clutch/Brake
Control features are:
Configurable features include tonnage monitoring, shut height
adjustment, PLS, lubrication, die monitor, automatic counterbalance,
and servo feeds. All configurable features require that you add
resolver modules to the control system. For instance, you can add a
tonnage monitoring module or a resolver from one of our
Encompass partners. For more information, refer to the Encompass
Program Product Directory, publication 6873.
Functional Design
The Omega Press Control System provides basic clutch/brake
control as well as press control. No user programming is required.
One set of Run buttons monitored
One set of Inch buttons monitored
■ Modes of Operation
• Off
• Inch
• Single
• Continuous
■ One Resolver (required, not supplied)
■ One Resolver or Rotary Cam (required, not supplied) for second
position device
■ Clutch/brake time monitor
Other standard control features include:
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Mechanical Design
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The control system includes redundant SLC 5/03 processors with
application software for self testing and verification to conform with
ANSI and OSHA regulations.
Both SLC 5/03 processors are located in separate chassis. They
monitor all clutch/brake I/O and exchange information about
machine status. They are linked 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 do the same.
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Production monitor and counters
Die monitoring (16 channels)
Programmable Limit Switch (8 channels)
Recipe Storage (20 die recipes)
Maintenance Timers
Multi-function lube control
Main Motor Control
Ordering Information
The purchase of one kit includes the license to use this control on
one stamping press.
See below for 6556 catalog numbers to order.
The MMI must be ordered separately [PanelView 600 (catalogue number 6556–SPV600) configuration screens are burned in flash.] Resolvers
and resolver modules must be ordered separately.
Hardware Included
For 6556–SCBK3
(AC version)
For 6556–SCBK3DC
(DC version)
Hardware That You Provide
SLC 5/03 Processor (2)
Link Coupler (DH–485) (2)
Power Supply (2)
7-slot I/O chassis (1)
10-slot I/O chassis (1)
Input Module (4)
Input Module (1)
Output Module (2)
Relay Output Module (2)
Relays (4)
1747–L532
1747–AIC
1746–P2
1746–A7
1746–A10
1746–IA16 (AC)
1746–ITV16
1746–OA16
1746–OX8
700–P400A1
1747–L532
1747–AIC
1746–P2
1746–A7
1746–A10
1746–IB16 (DC)
1746–ITV16
1746–OB16
1746–OX8
700DC–F310Z24
Input Switches and Run Stations (application dependent)
Rotary Cam Limit Switch (1, if used)
Resolver (minimum of 1)
Resolver Input Module (minimum of 1)
Solenoid Valves (4) with internal fault detection
Operator Interface (1) colour PanelView 600
(6556–SPV600)
Tonnage Module (optional, 2 maximum)
Analog I/O Module (1, optional)
Sensors for die monitoring
Reference Number
6556-GSRP1
6556-GSRP2
6556-GSMDS
1746-NIO4V
6556-GTSTAND
6556-GCAM3
6556-GCAM5
13-10
Option Description
1 Resolver and an existing user supplied CAM box with Brake Time Logic + software
2 Resolvers and no CAMS needed with Brake Time Logic + software
Motion Detect Switch, device and cable
Auto Counterbalance Control, Shut Height Position Monitor, Variable Speed Main Drive Control
One operator run station on T-Stand with run, top stop, and e-stop push-buttons
3 CAM box with Integral Motion Detect Device
3 CAM box without Integral Motion Detect Device