Brake Monitor - Pressroom Electronics

Brake Monitor - Pressroom Electronics
BM-1600
Time-Based
BrakeMonitor
Installation& Operation Manual
Rev. 2.4
Mac
hiner
y Guar
ds and Contr
ols
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hinery
Guards
Controls
! for
info
Punch Press Controls (Resolver or Rotary Cam Based)
Punch Press Automation Controllers
Time-Based Brake Monitors
Mute-out Packages
Components & Accessories
Brake Performance Tester
Press Brake Guards and Controls
PressCam 8-“Control Reliable” Punch Press Automation
Controller: Programmable Limit Switch, 16 Station Die Protection System,
Time-Based Brake Monitor, Five Counters, Servo-Feed Interface, Tonnage
Monitoring, 150 Job Memory, 8” Operator Screen
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www.pressroomelectronics.com
BM-1600
Time-Based Brake Monitor
Installation and Operation Manual
Pressroom Electronics, Inc.
3715 Swenson Avenue
St. Charles, IL 60174
P/N: 28-003r2-4
Customer Service: 630-443-9320 (CST)
(Please have Model #, Serial #, and Software Rev # Available)
Sales and Marketing: 800-937-4334 (EST)
www.pressroomelectronics.com
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sales@pressroomelectronics.com
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service@pressroomelectronics.com
Pr
oper Use and Limita
tions
Proper
Limitations
Limita
tion of Lia
bility
Limitation
Liability
The BM-1600 Brake Monitor is critical for monitoring
brake performance. Repairs should only be made by
factory authorized personnel. The manufacturer cannot
be held responsible for your repair attempts or the unit’s
subsequent safe operation.
In the event of any claim for breach of any obligations of
manufacturer under any order , whether expressed or
implied, and particularly in the event of any claim of a
breach of the warranty or warranties contained in the
paragraph “Warranty” or of any other warranties,
expressed or implied, which might despite the paragraph
entitled “Disclaimer”, be determined to be incorporated
in any order, the company shall under no circumstances
be liable for any consequential or special damages, either
in law or in equity, or for losses or expenses or claims
for the same arising from the use of, or inability to use,
the products of the manufacturer for any purpose
whatsoever.
As the BM-1600 Brake Monitor is a single function
device, that of determining press stopping times while
simultaneously determining that it is capable of just that,
any internal malfunction will cause the unit to shut down.
We will not supply individual component p arts of any
circuit board but will supply the individual circuit board
complete.
The information disclosed herein includes proprietary
rights of the manufacturer . Neither this document nor
the information disclosed herein shall be reproduced or
transferred to other documents or used or disclosed to
others for manufacturing purposes, or for any other
purposes, except as specifically authorized in writing by
the manufacturer. If this manual is supplied in connection
with the sale or delivery of manufacturer’s equipment, it
is to be used solely for maintenance, repair or installation
of such equipment.
War
arrranty
Manufacturer warrants that this product will be free from
defects in material and workmanship for a period of
twelve months from the date of shipment thereof. Within
the warranty period, manufacturer will repair or replace
such products which are returned with shipping charges
prepaid and which will be disclosed as defective upon
examination by the manufacturer. This warranty will not
apply to any product which will have been subject to
misuse, negligence, accident, restriction and use not in
accordance with manufacturer ’s instructions or which
will have been altered or repaired by person’s other than
the authorized agent or employees of the manufacturer.
Disc
laimer
Disclaimer
The provisions of the paragraph “Warranty” are the sole
obligations of the manufacturer and exclude all other
warranties of merchant ability, expressed or implied.
Further, there are no warranties which extend beyond
the above warranty.
We have designed our equipment to the very highest
performance and safety standards known to the current
technological state of the art. However, the installation,
usage, suitability, and fitness of our equipment for any
purpose, known or unknown, is interdependent upon the
performance of other equipment not manufactured,
installed, or secured or maintained by manufacturer.
We cannot and do not accept responsibility for any overall
system performance when factors, such as these, are
beyond our control.
WARNING: The entire machine safety system
must be tested at the start of every shift. Machine
testing should include: (1) proper machine
operation and stopping capability; and (2)
verification of proper installation and settings of
all point of operation guards and devices before
the operation is released for production.
Table of Contents
Overview ...................................................................................................................................... 1
Specifications .............................................................................................................................. 3
Installation ................................................................................................................................... 5
Adjusting the Set-Points
Drive Failure .......................................................................................................................................................... 7
90° Down from Top Stop Test ................................................................................................................................ 7
270° Down from Top Stop Test .............................................................................................................................. 7
Stop Time Warning and Failure ............................................................................................................................. 7
Storing New Set-Point Values ................................................................................................................................ 7
Reset .................................................................................................................................................................... 7
Adjusting the Set-Points
Starting the Press .................................................................................................................................................. 9
Stopping the Press ................................................................................................................................................ 9
Motion Detection ................................................................................................................................................... 9
Safety Distance Calculation ...................................................................................................... 11
Appendix A: Standards and Requirements
ANSI Standard B11.1-2001 ............................................................................................................................. AA-1
ANSI Standard Requirements ......................................................................................................................... AA-1
OSHA Standard Requirements ........................................................................................................................ AA-2
Appendix B: Definitions and Display Codes
Indicator Definitions ......................................................................................................................................... AB-1
Display Codes ................................................................................................................................................. AB-1
Appendix C: Dimensions and Diagrams
Cabinet Mounting ............................................................................................................................................ AC-1
Encoder Mounting ........................................................................................................................................... AC-1
Panel Cut-Out Dimensions .............................................................................................................................. AC-2
Wiring ............................................................................................................................................................. AC-3
-I-
Overview
BM-1600 Brake Monitor
The encoder is used to detect speed and motion of the
press by sending pulses to the Brake Monitor controller
where the number of pulses per millisecond relates
linearly to the speed of the press.
The BM-1600 Brake Monitor is designed to measure
speed from 0 to 999 RPM and stop time from 0 to 999
milliseconds each time the brake on the mechanical
power press is applied. Set-points for Drive Failure,
Brake Failure and Brake W arning are all stored along
with the last occurring error in nonvolatile memory . A
microcontroller, three watchdog timers, and two captive
contact output relays assure control reliability.
The Brake Monitor meet s requirements of the ANSI
Standard B11.1-2001 for time brake monitors as well as
OSHA 1910.217b(14).
Care must be taken when installing the Brake Monitor
to provide easy access to the Brake Monitor controller
and assure that the cable connecting it to the encoder
will not be crushed or damaged in any way.
All control and timing is done using the microcontroller.
The watchdog timers assure that if the microcontroller
fails, the relay contacts will always open. Dual captive
contact relays assure that if a contact welds or one relay
gets stuck closed, the other relay will automatically shut
down and open up the remaining relay contact. The
press Emergency Stop Circuit should be connected in
series with the Brake Monitor relay contacts to allow the
Brake Monitor to shut down the press if the brake fails
to stop the press in the required time limit. Nonvolatile
memory records any errors that occurred until they are
reset using the keyswitch.
Refer to ANSI Standard B11.1-2001 for information on
setpoints and safety distances (see Appendix A:
Standards and Requirements, page AA-1).
1
Specifications
BM-1600 Brake Monitor
Controller
Power:
Standard:
Optional:
Optional:
Relay Configuration:
Dual self-checking force-guided captive contact safety relays
Relay Contact Rating:
8 amps @ 250VAC resistive for safety relays
4 amps @ 250VAC resistive for alarm relay
System Accuracy:
+/- 1 millisecond
Set Points:
Drive failure:
Brake warning:
Brake failure:
1 to 25 tenths of a second
1 to 999 milliseconds
1 to 999 milliseconds
Display:
Speed:
0 to 290 +/- 1 RPM
291 to 999 +/- 4 RPM
0 to 999 +/- 1 msecs.
Stop time:
120 +/- 10% VAC, 50-60hz, 8 Watts
240 +/- 10% VAC, 50-60hz, 8 Watts
24 +/- 10% VDC, 8 Watts
Indicators:
Brake Fault – Red LED
Brake Warning – Yellow LED
Drive Failure – Red LED
Brake ON – Yellow LED
Ready – Green LED
Not Ready – Red LED
Stop Time Display – Red LED
RPM – Red LED
Brake Warning Setpoint – Red LED
Brake Limit Setpoint – Red LED
Inputs:
Encoder:
Clutch:
Output Circuit:
Two captive contact self-checking N.O. relays in series.
Isolated (DRY) Normally open contacts --||--||-Alarm relay will close when a warning or failure setpoint is exceeded.
Operating Temperature:
0° to 50° C
Enclosure:
Lockable NEMA 12 steel
Enclosure Dimensions:
8” (203mm) Height x 7” (178mm) Width x 4” (127mm) Depth
see below
120 +/- 10% VAC
Encoder (Part #E-160 — CW or CCW Rotation Capable)
Cable:
20’ (6m) is supplied standard; 100’ (2540mm) maximum length.
Gauge: 20 AWG – 3 connectors plus drain
Rating: 300 VAC @ 60 C
Shaft Loading:
Radial: 35 lbs.
Axial: 40 lbs
Operating Temp.:
0° to 50° C
Dimensions:
5.5" (140mm) Height x 3.75" (95mm) Width x 3-9/16" (90mm) Depth
Warranty:
1 year
2
Installation
BM-1600 Brake Monitor
Connect the encoder cable wires to their proper
terminals on both ends:
WARNING: The entire machine safety system
must be tested at the start of every shift. Machine
testing should include: (1) proper machine
operation and stopping capability; and (2)
verification of proper installation and settings of
all point of operation guards and devices before
the operation is released for production.
Wire
Color
RED
BLACK
CLEAR
BARE
1) The bottom of the Brake Monitor has two 1/2"
conduit size holes punched in it. The right
punch-out will provide for AC power, brake
solenoid signal, and emergency stop circuit
lines. The left punch-out is used for the encoder
cable only. Do not run the encoder cable in
the same punch-out hole as the high voltage
lines.
Main
Enclosure
3
4
5
6
Encoder
Box
VCC (+5V)
GROUND
DATA
SHIELD
6) Tap off the wire going to your clutch (in parallel)
and run this wire to Terminal 9 of the main
enclosure. If your clutch uses a voltage other
than 120VAC, you must have your Brake Monitor
modified to handle this voltage. You should have
120VAC on Terminal 9 when the press is moving
and OV when it is stopped. (See Appendix C:
Dimensions and Diagrams, page AC-2).
2) Mount the Brake Monitor controller box in a
visible location.
3) Mount the motion detector to the main drive
shaft by chain, or direct coupling for a 1:1 turning
ratio. If the unit is to be chain driven, care must
be taken not to exceed the load limits of the
motion detector (see Specifications, page 3).
7) Connect the Emergency Stop Circuit to the
Output Relay Contact Terminals 7 & 8 so that
the Brake Monitor can control the Stop
Circuit.
8) Connect power to the circuit through Terminals
10 G,11 N, and 12 L.
4) Dress the encoder cable around the press, but
keep the cable away from noise generating
devices and high current carrying power
lines to prevent the Brake Monitor from
picking up noise.
9) Read ANSI Standard B11.1-2001 for guidelines
on how to determine brake limit setpoint s and
safety distances (see Appendix A: Standards
and Requirements, page AA-1).
Supplied standard is 20’ of shielded cable,
however, the maximum length that can be used
is 100’ and you may shorten the cable to any
length under 100’.
3
Adjusting the Set-Points
BM-1600 Brake Monitor
Dri
ve F
ailur
e
Driv
Failur
ailure
270° Do
wn fr
om Top Stop Test
Down
from
Description: When 120VAC is applied to the clutch input
(indicating that the brake has been released) the Brake
Monitor will de-energize its safety relays and issue a C8
error code if it does not see motion of the press within
the Drive Failure Set-Point delay period. This detects a
chain break, faulty wiring, or bad encoder.
Description. The brake monitor will allow the press to
travel 630° which is 1-3/4 times around. The press will
start to stop at the 270º mark. This is used to check for
proper counter balance.
To Run Test. Simply go into the 90° test and hit the “+”
key to change the display from C6 to C1 1, then follow
steps B and C of the 90° test.
At what value should it be set? This set-point should be
set as low as possible, but higher than the time it takes
for the press to start moving. Initially the delay is set to 5
which equals .5 seconds. If this value is too high, the
press could completely cycle without ever detecting the
Drive Failure.
Stop Time War
ning and F
ailur
e
arning
Failur
ailure
Description. When 120VAC is removed from the clutch
input (brake applied), the brake monitor will determine
how long it takes for the press to come to a complete
stop.
To change set-point:
a) Turn the keyswitch to “Select Brake W arning
Time.”
a) If the actual stop time exceeds the warning setpoint, then the amber warning light will come
on to indicate that you are getting close to the
failure set-point.
b) Push both the REV and FWD keys until the
“Brake Warn Time” LED indicator turns off.
b) If the actual stop time exceeds the failure setpoint, then the red failure light will come on and
the safety relays will de-energize and shut down
the press from further cycles until you clear the
error.
c) The display now shows drive failure delay time
in tenths of seconds (i.e., 10 = 1.0 seconds).
d) Select a new value using the REV and FWD
push buttons. When the keyswitch is turned, the
new value is stored.
What value should it be set? Read ANSI Standard B11.12001 before going any further (see Appendix A:
Standards and Requirements, page AA-1). The failure
set-point is used in the safety distance formula; the larger
the value, the further you will have to place your guards
from the pinch point, but you won’t have to replace the
brake as often.
90° Do
wn fr
om Top Stop Test
Down
from
Description. This test is to determine the worst case
stopping time for your press and is used in determining
the press stop time used in the safety distance formula.
The test allows the press to rotate 90° then automatically
stops it. Refer to ANSI Standard B11.1-2001 (see
Appendix A: Standards and Requirements, page AA1).
To change set-point:
a) Turn the keyswitch to the “select brake warning
time” position.
To run test.
b) Select a new warning set-point using the REV
and FWD push buttons.
a) Place the press at top stop, turn keyswitch to
“Select Brake Limit Time” and press the REV
and FWD keys until the digital display shows
C6.
c) Turn the keyswitch to the “select brake limit time”
position.
d) Select a new failure set-point.
b) Move the keyswitch back into the RUN position
and cycle the press.
e) Turn the keyswitch back to “run.”
c) The Brake Monitor will open its relay contacts
when the press travels 90° from top stop then,
automatically, computes the stop time.
Storing Ne
w Set-P
oint Values
New
Set-Point
When the keyswitch is moved back into the “run”
position, the new settings are permanently stored in
nonvolatile memory and does not require a battery.
Reset
Use the “reset” position to clear faults when they occur.
Reset will not reset set-points.
4
Operation
BM-1600 Brake Monitor
Motion Detection
Star
ting the Pr
ess
Starting
Press
If the press moves and the Brake Monitor did not get
the 120VAC Clutch Input signal, the Brake Monitor will
shut down and turn on both the amber warning and red
failure lights. An error code C7 will be issued to
permanent memory and may indicate incorrect wiring.
a) The Brake Monitor receives a 120V AC signal
from the Clutch Input (Terminal 9) to signal that
the brake has been released.
b) If no motion is detected by the Brake Monitor
within the Drive Failure set-point time the Brake
Monitor shuts down and issues a C8 error code.
The error code will be recorded into permanent
memory.
c) If motion was detected, the display will show
RPM/SPM until the brake is reapplied.
Stopping the Pr
ess
Press
a) The Brake Monitor no longer detect s 120VAC
present on the Clutch Input (Terminal 9). This
indicates that the brake is now reapplied.
b) The internal Brake Monitor timer starts to count
in 1 millisecond increments.
c) The display shows the accumulating stop time
rising.
d) If the current stop time exceeds the warning setpoint, then the amber warning light will turn on,
but no error will have occurred.
e) If the current stop time exceeds the failure setpoint, then the amber warning light will turn off
and the red failure light will turn on. The final
stop time will be recorded into permanent
memory along with the failure code.
f)
If the final stop time is less than the failure setpoint by more than 80%, then the amber warning
light will come on and an error code of C10 will
be issued, but not recorded. This indicates that
the actual press stopping time is too low
compared to the set-point. This may indicate a
faulty encoder or that someone has tampered
with the set-point by raising it up to prevent shut
downs.
g) The final stop time will be displayed until the
next cycle starts.
5
Safety Distance Calculation
BM-1600 Brake Monitor
Saf
ety Distance Calcula
tion
Safety
Calculation
Formula: Safety Distance displayed equals 64 inches/
sec * (35msec guard response time + tot al BM-1600
detected time msec) + DPF of 2"
Description: Safety Distance is the separation (in inches)
between the hazardous point of operation and the
guarding device (i.e., light curtain).Your guarding device
manual will contain a formula to calculate this distance.
You need to know the total response time of your system
(the time from a body part blocking the guard to the total
cessation of motion).
IMPORTANT NOTE: This Safety Dist ance
Calculation does not take into account the FAIL
set-point. As the break wears, the stop time will
increase until it reaches the FAIL setpoint (limit).
This will increase the Safety Distance if the FAIL
setpoint is larger then the actual stop time.
The BM-1600 can calculate Safety Distance based on
the ANSI Standard B11.1-2001 formula.
With Light Guard: Wire 120VAC LINE through the N.O.
Auxiliary Output of your light guard toTerminal 13 of the
BM-1600. Wire NEUTRAL to Terminal #14 of the BM1600. You should have 120VAC across Terminal #13 #14 when the guard is GREEN (not blocked) and 0V
when the guard is RED (blocked).
Without Light Guard: Wire 120VAC LINE to Terminal
#13 of the BM-1600 and Neutral to Terminal #14.
NOTE: If you do not want the stop time to reflect
the Press control response time, do not put any
voltage across Terminals #13 and #14
To Run Test: Put BM-1600 into 90° or 270° stop test
mode. Start the press (then block guard if you have one).
The stop time is computed from the guard blockage (or
end of test) to the cessation of motion.
The BM-1600 will add 35mSec (guard response time)
to the total response time, if you block the guard during
the test. If you do not have a guard, Start the press and
let the BM-1600 end the test.The BM-1600 will not add
any additional time.
Safety Distance can be read (in inches) by pushing and
holding the + or - key on the front panel (the Stop Time
LED will dim to let you know your viewing distance).
NOTE: If the Stop time exceeds the FAIL setpoint,
you will not be able to view distance. You will have
to temporarily raise the FAIL setpoint for this test.
NOTE: If you fail to block the guard before the
test is over, you will be viewing the stop time that
includes the time it took for the Press control to
respond to the BM-1600 but not the guard
response time.
IMPORTANT NOTE: The default Depth
Penetration Factor (Dpf) is set to 2". Your light
Guard manual will instruct you on what your Dpf
is. If it is larger , you must add the additional
amount. (I.E. Dpf is 5, then you must add an
additional 3" to the safety distance displayed)
6
Appendix “A”
Standards and Requirements
ANSI Standar
d B11.1-2001
Standard
The total stopping time of the press should include the
total response time of the control system and the time it
takes the press to cease slide motion. The following
formula should be used when calculating the safety
distance (Ds):
Ds = K (Ts + Tc + Tbm)
ANSI B11.14-1996 Coil Slitting Machines - Safety
Requirements for Construction, Care and Use
ANSI B11.15-2001 Safety Requirements for Pipe,
Tube and Shape Bending Machines
ANSI B11.17-1996 Horizontal Hydraulic Extrusion
Presses - Safety Requirements for Construction, Care
and Use
ANSI B11.18-1997 Coil Processing Systems - Safety
Requirements for Construction, Care and Use
ANSI B11.20-1991 (R1996) Manufacturing Systems /
Cells - Safety Requirements for Construction, Care
and Use
ANSI B11.21-1997 Machine Tools Using Lasers Safety Requirements for Construction, Care and Use
ANSI B11.22-2002 Safety Requirements for
Numerically Controlled Turing Machines
ANSI B11.23-2002 Safety Requirements for
Machining Centers
ANSI B11.24-2002 Safety Requirements for Transfer
Machines
Where:
K = 63 inches/second (hand speed constant).
Ts = the stop time of the press measured from the final
de-energized control element, usually the air valve.
Tc = the response time of the control.
Tbm = the additional time allowed by the brake monitor
before it detects stop time deterioration.
NOTE - Ts + Tc are usually measured by a stop time
measuring device.
When the press stopping-performance monitor timer
or STOP position sensor is changed, the safety distance
should be recalculated.
ANSI B11.TR1-1993 Ergonomic Guidelines for the
Design, Installation and Use of Machine Tools
American National Standards Institute
Standard Requirements
ANSI B11.TR2-1997 Mist Control Considerations for
the Design, Installation and Use of Machine Tools
Using Metalworking Fluids
ANSI B11.1-2001 Safety Requirements for Mechanical
Power Presses
ANSI B11.2-1995 (R2000) Hydraulic Power Presses Safety Requirements for Construction, Care and Use
ANSI B11.3-2002 Safety Requirements for Power Press
Brakes
ANSI B11.4-2003 Safety Requirements for Shears
ANSI B11.5-1988 (R2002) Iron W orkers - Safety
requirements for Construction, Care and Use
ANSI B11.6-2001 Safety Requirement s for Manual
Turning Machines
ANSI B11.7-1995 (R2000) Cold Headers and Cold
Formers - Safety Requirements for Construction, Care
and Use
ANSI B11.8-2001 Safety Requirement s for Manual
Millindg, Drilling and Boring Machines
ANSI B11.9-1975 (R1997) Grinding Machines - Safety
Requirements for Construction, Care and Use
ANSI B11.10-2003 Metal Sawing Machines - Safety
Requirements for Construction, Care and Use
ANSI B11.11-2001 Safety Requirement s for Gear &
Spline Cutting Machines
ANSI B11.12-1996 Roll Forming and Roll Bending
Machines - Safety Requirements for Construction, Care
and Use
ANSI B11.13-1992 (R1998) Automatic Screw/Bar and
Chucking Machines - Safety Requirement s for
Construction, Care and Use
ANSI B11.TR3-2000 Risk Assessment and Risk
Reduction - A guide to estimate, evaluate and reduce
risks associated with machine tools
AA - 1
Appendix “A”
Standards and Requirements
Occupational Safety and Health
Administration (OSHA)
29 CFR Part 1910 Subpart O
Machinery and Machine Guarding
1910.211 - Definitions.
1910.212 - General requirements for all machines.
1910.213 - Woodworking machinery requirements.
1910.214 - Cooperage machinery. [Reserved]
1910.215 - Abrasive wheel machinery.
1910.216 - Mills and calenders in the rubber and
plastics industries.
1910.217 - Mechanical power presses.
1910.217 - (Appendix A) Mandatory requirements for
certification/validation of safety systems
for presence sensing device initiation of
mechanical power presses
1910.217 - (Appendix B) Nonmandatory guidelines
for certification/validation of safety
systems for presence sensing device
initiation of mechanical power presses
1910.217 - (Appendix C) Mandatory requirements for
OSHA recognition of third-party validation
organizations for the PSDI standard
1910.217 - (Appendix D) Nonmandatory
supplementary information
1910.218 - Forging machines.
1910.219 - Mechanical power-transmission
apparatus.
AA - 2
Appendix “B”
Definitions and Display Codes
Indica
tor Def
initions
Indicator
Definitions
Display Codes
Brake Warning. Press stopping time exceeded the
warning set-point but not the limit set-point. The relay
contacts remain closed and the unit does not need to be
reset.
C1
Stop Circuit Relay(s) On, Should Be Off
Cause(s): a) Relay contact may be welded.
b) Relay drive circuit may be faulty
.
Brake Failure. Press stopping time exceeded the limit
set-point. The relay contacts open and the unit must be
reset.
Cure(s):
Drive Failure. No motion was detected within the setpoint time (initially .5 sec) by the Brake Monitor when
the brake was released. A C8 error code is also
displayed.
Push nylon tie-wraps out of the way
and remove both relays (do not cut
the tie-wraps).
a) Check relay contacts for scoring
or pitting. If so, check the circuit
that the Brake Monitor is in
series with for current draw. Do
not exceed half the relay rating.
If you see a spark on the relay
contact when the relays
energize or de-energize, then
you are drawing too much
current though the relay
contacts. Try placing a MOV
across the terminals of any relay
coils that are energized by this
circuit.
Brake On. Directly linked to the 120VAC Clutch Input.
This LED is of f when the 120V AC signal is present
indicating the brake is released.
Ready. Directly linked to the captive contact output relays
to indicate that the circuit is closed.
Not Ready. Directly linked to the captive contact output
relays to indicate that the circuit is open which indicates
that either the keyswitch is in the reset position or a failure
occurred.
b) Also, check for bad solder joints
or shorts on the bottom of the
board holding the relays.
Stop Time (msec). Indicates that the digital display is
showing the press stopping time in milliseconds.
RPM. Indicates that the digital display is showing the
press speed in revolutions or strokes per minute.
C2
Brake Warn Time. Indicates that the digital display is
showing the select warning time set-point. This means
you can change the warning set-point time.
Stop Circuit Relay(s) Off, Should Be On
Cause(s):
a) Relay drive circuit may be faulty.
b) VAC line voltage may be low.
Brake Limit Time. Indicates that the digital display is
showing the select limit time set-point. This means you
can change the failure set-point time.
Cure:
C3
Check solder joints, relays, and line
voltage.
Failure in EEPROM (nonvolatile memory)
Cause(s): a)
b)
Cure:
C4
AB - 1
VAC line voltage may be low.
Bad EEPROM.
Check line voltage. May require
new EEPROM.
EEPROM Needs to be Initialized
Cause:
After a C3 error code, the computer
tries to initialize the EEPROM over
and over until it takes.
Cure:
Computer will automatically try to
reprogram chip.
Appendix “B”
Definitions and Display Codes
C5
C6
Internal RAM Fault in Microprocessor
Cause:
Ram integrity test failed.
Cure:
Shut off power for 1 minute and try
again. May require a new
microprocessor chip.
on the front panel, it should be of f
only when you initiate the press. If
it is off at any other time, then the
Clutch Input is not hooked up to the
clutch.
If the press did not have a chance
to move before the error occurred,
then you must change the Drive
Failure set-point (see Adjusting the
Set-Points, page 4). Check the
encoder cable wiring on both ends.
90° Mode Selected
The Brake Monitor will allow the press to travel
only 90° from its starting point and compute a
stop time.
Cause:
Cure:
C7
The keyswitch was moved into the
select brake limit position and both
REV and FWD keys were pushed
simultaneously.
C9
This will remove any error code(s) from memory
and erase the last stop time.
Cycle the press.
Cause:
Keyswitch was moved from the
“run” position into the “reset”
position.
Cure:
Place keyswitch back into “run”
position.
Motion Detected While Press Stopped
Cause:
Brake Monitor did not get Clutch
Input signal and press moved.
Cure(s):
a) Check
clutch solenoid
connections
C11
c) Tighten chain or belt.
d) Place MOV devices on power
terminals of nearby motors,
solenoids, etc.
Drive Failure (no signal from encoder)
The computer received a 120VAC signal from
the Clutch Input telling it to expect the press to
start moving; after an initial waiting period (from
.1 to 2 seconds) the computer shut downs because it did not receive any signal back from
the encoder to indicate that the press did move.
Cause(s):
a) Encoder cable hooked up
wrong.
b) Faulty encoder.
c) Drive Failure set-point too low.
d) Encoder not linked to main drive
shaft.
e) Main drive shaft not turning.
f) Faulty clutch signal.
Cure:
270° Mode Selected
The Brake Monitor will allow the press to travel
630° which is 1-3/4 times around. The press
will start to stop at the 270° mark. This is used
to check for proper counter balance.
b) Check encoder mounting and
coupling.
C8
Keyswitch in Reset
Check the “brake on” yellow LED
AB - 2
Cause:
Hitting the “+” key while in C6 mode.
Cure:
Cycle the press.
Appendix “C”
Dimensions and Diagrams
Ca
binet Mounting
Cabinet
Dimensions
A
7.00" (178mm) Width
B
4.00" (102mm) Distance between holes
on each side
C
8.00" (203mm) Height
D
4.00" (102mm) Depth
8.65" (220mm) Distance between holes
top to bottom
Encoder Mounting
AC - 1
Appendix “C”
Dimensions and Diagrams
Panel Cut-Out Dimensions (#11-073)
AC - 2
Appendix “C”
Dimensions and Diagrams
Wiring
Terminal
Label
Definition
1,2
ALARM
N.O. dry contact closes when error occurs, during a stop time
warning, or stop time failure. N.O.
3
+5V
Supply voltage to encoder.
4
GND
Supply ground to encoder.
5
DTA
Data line from encoder to brake monitor.
6
SHIELD
Electrical shield for encoder cable.
7,8
SAFETY
Two captive contact safety relays in series forming a N.O. dry
output contact for use in series with your stop circuit.
9
CLUTCH
120VAC input signal coming from your clutch to signal when it is
disengaged (tells the brake monitor that the press should start
moving.
10
EARTH
11
N
Neutral side of 120VAC / 240VAC.
12
L
Line side of 120VAC / 240VAC.
Earth ground (to case).
NOTE: If you have the 24VDC option (no transformer), then
Terminals 11 and 12 are used as your +/- terminals. These
terminals are non-polarized so you can hook up power in either
direction (+ - or - +).
13,14
LIGHT GUARD Used to check system response time. See “Safety Distance
Calculation” section for wiring.
INCH MODE
(optional)
110VAC across Terminals 13 and 14 will increase stop time
setpoints by 25% to prevent accidental tripping out the brake
monitor during setup.
AC - 3
Notes
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WARRANTY
Manufacturer warrants that this product will be free from defects in
material and workmanship for a period of one year from the date of
shipment thereof. Within the warranty period, manufacturer will repair
or replace such products which are returned to it with shipping charges
prepaid and which will be disclosed as defective upon examination by
the manufacturer. This warranty will not apply to any product which will
have been subject to misuse, negligence, accident, restriction, and use
not in accordance with manufacturer ’s instructions or which will have
been altered or repaired by persons other than the authorized agent or
employees of the manufacturer.
DISCLAIMER
The provisions of the paragraph “Warranty” are the sole obligations of
the manufacturer and exclude all other warranties of merchant ability,
expressed or implied.
Further, there are no warranties which extend beyond the above warranty
.
LIMITATION OF LIABILITY
In the event of any claim or breach of any obligations of manufacturer
under any order, whether expressed or implied, and p articularly in the
event of any claim or a breach of the warranty or warranties contained
in the paragraph “Warranty” or of any other warranties, expressed or
implied which might, despite the p aragraph entitled “Disclaimer,” be
determined to be incorporated in any order , the company shall under
no circumstances be liable for any consequential or special damages,
either in law or in equity , or for losses or expenses or claims for the
same arising from the use of, or inability to use, the products of the
manufacturer for any purpose whatsoever.
WARNING: The entire machine safety system must be tested
at the start of every shift. Machine testing should include:
(1) proper machine operation and stopping capability; and
(2) verification of proper installation and settings of all point
of operation guards and devices before the operation is
released for production.
Sales and Marketing Offices
Customer Service (630) 443-9320
United States
We have designed our equipment to the very
highest performance and safety standards known
to the current technological state of the art, as
evidenced by our U.S.A. and foreign patents issued
and pending. However , the inst allation, usage,
suitability, and fitness of our equipment for any
purpose, known or unknown, is interdependent
upon the performance of other equipment not
manufactured, installed, secured or maintained by
Pressroom Electronics, Inc.
Pressroom Electronics, Inc.
P.O. Box 99875
Pittsburgh, PA 15233
Toll Free: 800-937-4334
Direct: 412-262-1115
Fax: 412-262-1197
Canada
Pressroom Electronics, Inc.
8-1734 Orangebrook Court
Pickering, Ontario L1W 3G8
Toll Free: 888-285-8885
Direct: 905-831-1111
Fax: 905-831-4064
We cannot and do not accept responsibility for any
overall system performance when factors, such as
these, are beyond our control.
www.pressroomelectronics.com
sales@pressroomelectronics.com
service@pressroomelectronics.com
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