6556-UM001A–EN–P, Clutch/Brake Control with MicroLogix

Allen-Bradley

Clutch/Brake

Control with

MicroLogix

Processors

(Cat. No. 6556-MLCBK and 6556-MLCBKDC)

User

Manual

–1

Important User

Information

Publication 6556-UM001B–EN–P August, 2000

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 prohibited.

Throughout this manual we use notes to make you aware of safety considerations:

!

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage or economic loss.

Attention statements help you to:

• identify a hazard

• avoid the hazard

• recognize the consequences

Important: Identifies information that is critical for successful application and understanding of the product.

PanelBuilder, PanelView and MicroLogix are trademarks of Rockwell Automation.

Preface

Using This Manual

Manual Objectives

This manual describes how to apply the 6556-MLCBK or

6556-MLCBKDC Clutch/Brake (C/B) Control Kit to your mechanical stamping press. The manual helps you install, test, and operate the clutch/brake control.

Qualifications for

Applying this Product

Only qualified installers should apply this control to a mechanical stamping press. We assume that the installation team includes:

• a professional stamping press builder or re-builder knowledgeable in press and press control standards

• an electrical technician skilled in installing electronic control equipment

Terms and Abbreviations

You should become familiar with these abbreviated terms. For complete definitions of clutch/brake terms, refer to ANSI B11.1-1988 section 3.

Term Definition anti-repeat (ACAM) RCLS bottom position brake monitor (BCAM) RCLS buttons clutch/brake valve a device designed to limit press operation to a single cycle if the actuating means is held actuated.

the part of the press cycle where the dies are closed a device designed to prevent the next stroke if stopping time or distance exceeds a preset palm-type pushbutton switches used by an operator for starting and stopping the press the main valve that controls the flow of air to the clutch/brake mechanism continuous mode downstroke zone fault detection for valves the mode where the control maintains continuous stroking after an operator starts the press the part of the press cycle when the press travels from near-top zone (through bottom) to the upstroke zone

internal: valve is designed to turn itself off when it faults.

grounded ac power inch mode ac power distribution where the “L2” side of the ac line is grounded a mode that lets an operator move the press incrementally by pressing and releasing run-station buttons micro–inch mode near top zone a mode that lets an operator move the press incrementally by pressing and releasing run-station buttons using a slower motor the part of the press cycle when the press is at the top of its stroke

RCLS - rotary cam limit switch a switch that rides a rotating cam to provide information on the position of the press drive shaft run station single-stroke mode solenoid valve a press operator’s point of operation that typically contains a pair off pushbuttons to start or stop the press a mode that allows the operator to run one complete press stroke, usually started at the top an on/off electrically-driven valve takeover (TCAM) RCLS top stop upstroke zone a device designed to allow upstroke without the operator holding the run/inch buttons a command designed to stop the press at the top of its stroke the part of the press cycle when the press travels from the end of downstroke to the near-top position

Publication 6556–UM001A–EN–P – August 2000

P–2

Notes:

Using This Manual

Publication 6556-UM001A–EN–P – August 2000

Table of Contents

Overview

Quick Start

Installing and Wiring

Customer Interface Inputs and Motion Detect Inputs

Chapter 1

Chapter Objective . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents of Your Clutch/Brake Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Control by Redundant Controllers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Protected Memory in MicroLogix 1500 Processors . . . . . . . . . . . . . . . .

Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Functional Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch/Brake Control Functions

Panel Switches

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotary Cam limit Switches

Input Switches

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Response Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Related Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-1

1-2

1-2

1-3

1-3

1-4

1-4

1-5

1-5

1-5

1-6

1-6

1-7

1-8

Chapter 2

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Chapter 3

Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Check the Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mount the Network Interface Modules and Base Units . . . . . . . . . . . . .

Wire the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wire the Network Interface Module . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Attach the I/O Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Set Up Rotary Cam Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Install Input Switches

Connect Cables

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cross–Check Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connections to I/O Modules

Wire Your Control

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1

3-1

3-1

3-1

3-1

3-2

3-3

3-4

3-5

3-7

3-10

3-14

Chapter 4

Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Customer Interface Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Motion Detect Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1

4-1

4-2


toc–ii Table of Contents

Circuit Testing

Testing the Operation

Description of

Operating Modes

Fault Codes and

Operator Prompts

Wiring Drawings

Index

Chapter 5


Testing Circuits and Failure-mode Operation . . . . . . . . . . . . . . . . . . . .

5-1

5-1

Chapter 6


Troubleshooting the Setup of Your RCLS Assemblies

Test the Operating Modes

. . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Test the Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1

6-1

6-2

6-4

Appendix A

Clutch/Brake Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

Appendix B

Fault Codes for Troubleshooting

Prompts for Operating the Press

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B-1

B-4

Appendix C

How We Present Wiring Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1

Index

A-Z . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I-1


Chapter Objective

Chapter

1

Overview

The purpose of this chapter is to acquaint you with your Allen-Bradley

Clutch/Brake Control (cat. no. 6556-MLCBK). Topics include:

•

Contents of the kit

•

Control by redundant processors

•

Protected memory in MicroLogix-1500 processors

•

Modes of operation

•

Functional block diagram

•

Clutch/Brake control functions

•

Panel Switches

•

Rotary cam limit switches for position monitoring

•

Input switches

•

Outputs

•

Response time

•

Related safety documentation

•

Control system specifications

ATTENTION: The clutch/brake control system is designed for use only with mechanical stamping presses having a part-revolution friction clutch and/or brake.

Applying this control to any other type of press could result in personal injury and/or damage to equipment.

Publication 6556-UM001A–EN–P August 2000

1–2 Overview

Contents of the Kit

Control by

Redundant Controllers

Clutch/brake control kit (cat. no. 6556-MLCB or -MLCBDC) includes:

Hardware Included for -MLCBK for -MLCBKDC Hardware That You Pro- vide

Micrologix 1500 Processor 1764–LSP (2) 1764–LSP (2)

DC Base W/ DC 16IN/12OUT 1764–28BXB (2) 1764–28BXB (2)

• nput itc es un

Stations (Application

Memory Module w/ Real Time

Clock

1764–MMIRTC (2) 1764–MMIRTC (2)

•

Rotary Cam Limit

16 pt Input Module

8 pt Input Module

1769–IA16 (ac) (2)

1769–IA8I (ac) (4)

1769–IQ16 (dc) (6)

•

Solenoid Valves (4)

8 pt AC/DC Isolated Relay

Module

1769–OW8I (ac/dc)

(4)

1769–OW8I (ac/dc)

(4)

Detection

Compact I/O Terminator Cap

RT

1769–ECR (2) 1769–ECR (2)

• perator nter ace 1

– PanelView 550

(6556-PV550) or

(6656–PV600)

Important: The purchase of this kit includes the license to use this control on one stamping press.

This clutch/brake control uses two independent MicroLogix–1500 controllers A and B.

Both controllers monitor all clutch/brake I/O and exchange information about machine status. They are linked by hardwired I/O so that if one controller 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 controller is designed to follow suit.


Overview 1–3

Press Control Panel

PanelView

Cable 1747–C20

Network Interface Modules

MicroLogix 1500 Controllers

Network Interface module

MicroLogix 1500 A Controller

Clutch/Brake I/O to/from the press

Protect Memory in

MicroLogix 1500

Processors

Modes of Operation

Network Interface module

MicroLogix 1500 B Controller

Clutch/Brake I/O to/from the press

31071–M

The logic of this control is pre-programmed and burned into processor memory at the factory. It cannot be changed except by return to

Allen-Bradley. This Protect Memory is pre–installed into the

MicroLogix 1500 Processor.

The operator can select the mode of operation with the selector switch located on a control panel. In accordance with ANSI B11.1 Section

4.12.4.1, the selection of operating mode must be capable of supervision (lockable).

This Mode: Lets the Operator:

Off Disable operation of the clutch/brake control when the press is not in operation.

Inch Jog the press through successive parts of the cycle by pressing and releasing the pair of inch buttons. If the buttons are held, the press will stop at the top of its stroke.

Single-stroke Run the press through one complete cycle by holding both run buttons until completion of the down stroke.

Continuous Run the press continuously until stopped by a stop-on-top command, or until a fault is detected. To start the press, you press the ARM CONTINUOUS switch and then press the pair of run buttons within five seconds.

Micro Inch Jog the press through successive parts of the cycle by pressing and releasing the pair of inch buttons using a slower motor. If the buttons are held, the press will stop at the top of its stroke.


1–4 Overview

Functional Block Diagram

The functional block diagram in shows the relationships between mechanical components of a stamping press and the C/B control.

Run Station

1 pair of buttons for run and

1 pair of buttons for inch

MicroLogix 1500 Controller A MicroLogix 1500 Controller B

Signals to/from

Main Solenoid Valves

Stroke

Position

Input

Clutch/Brake

Assembly

Flywheel

RCLS to Monitor

Stroke Position

Air to clutch

Main Solenoid Valves

Press

Air Supply

Stroke

Position

Input

RCLS to Monitor

Stroke Position

Crankshaft Crankshaft at Top Position

Crankshaft at Bottom Position

Clutch/Brake

Control Functions

Clutch/brake control functions are summarized in the following table.

Control Function: Operating Mode:

Stop-on-top

(cycle stop)

Interrupted stroke

Continuous

Anti-tie-down

Single-stroke or Continuous

All

Anti-repeat

Motion detector

Brake Monitor

Single-stroke

Inch or Micro

Inch

Single-stroke or Continuous

All

Description:

Lets the operator stop the press at top of stroke

Lets the operator stop the press by releasing a run/inch button during downstroke.

Prevents the press from starting a new stroke if the control detects that an operator has tied down the run/inch buttons. After run/inch buttons are released, the operator must press both buttons at the same time.

Limits press operation to a single stroke, even if the operator continues to press both run/inch buttons. The operator must release and press them again to start the next stroke.

Detects press motion from a hardware or software input.

Prevents restarting the press when the control detects an over-travel condition.


Overview 1–5

Panel Switches

Typically, your control panel would have these switches: 5-position key- lockable mode selector, E-stop, cycle stop, control reset, and

C/B power reset. You purchase them separately. For more information, see the table below.

Rotary Cam

Limit Switches

You will need two pairs of rotary cam limit switches. We recommend

Allen-Bradley Cat. No. 803-P775 that you purchase separately.

Input Switches

Device

Palm

Buttons for

Run Station

Stop on Top

E-Stop

Mode

Select

Arm

Continuous

Main Motor

Forward

Interlock

Air Pressure

Motion

Detector

Interlock

Control

Reset

Clutch/Brake

Power Reset

Symbol

Left Right

The clutch/brake control requires input switches listed below:

You purchase them separately.

Purpose

•

Lets press operators start the press

•

Assures 2-hand operation

Note: Position run/inch buttons at least 24” apart., and the run station in accordance with

ANSI B11.1 appendix A.

•

Stops press at top during continuous stroking

•

No effect in single mode

•

Stops the press immediately

Note: Wire switches in series as needed.

Type

Momentary pushbuttons dual contact normally closed (N.C.) and normally open (N.O.)

Momentary pushbutton single N.C. contact

Momentary pushbutton single N.C. contact

•

Lets you select the operating mode:

Off

Inch

Single

Continuous

•

Micro Inch

•

Lets you begin a timed interval within which to start continuous mode.

•

Monitors whether motor-forward starter is engaged. If not, it opens to prevent running the press in single or continuous mode.

•

Monitors Clutch/Brake air pressure.

Note: Switch must be ON to engage the clutch.

•

Detects if motion is stopped in single or continuous mode.

Rotary, 5-position key lockable

Momentary pushbutton single N.O. contact

N.O. auxiliary contact for forward motor starter

N.O. single throw from pressure switch

N.O. single contact

•

Lets you manually reset power to valve solenoids at power up or after an E-stop.

•

Lets you manually reset clutch power on power up or after E-stop.

Momentary pushbutton single N.O. contact

Momentary pushbutton triple contact 1 N.O. and 2 N.C.

Allen-Bradley Type Qty

(2) Articulated Palm

Buttons 800P-F2CA or

800Z–HLZY

1 pair

Yellow Mushroomhead 800T-D9B

1

Jumbo Mushroomhead 800T-FXP16RA5

N/A

1 or more

1

Black Momentary

Pushbutton 800T-A2A

Motor Starter

Auxiliary Contact 595-A

1

2

Pressure Switch

836-C8JX321

N/A

800T-A2A

800T-A2B

1

2

1

1


1–6

Outputs

Overview

Response Time

The clutch/brake control has two pairs of outputs from each I/O chassis (chassis A and B) for your clutch/brake valves.

Important: The control is designed to operate with valves that have

internal fault detection. There are no inputs for valve-stem feedback. Examples of dual solenoid safety valves with internal fault detection are the Herion XSz Series or Ross SERPAR Crossflow

Double Valve with L–G Monitor.

The worst case time required for the clutch/brake control to respond to a change of input depends on the sum of these response times:

Device:

Input Module 1769-IQ16 response time

Processor scan of C/B code (2k words)

Output Module 1769-OW8I switching time

Total worst-case response time

Delay (ms):

8

3

10

21

The number of degrees that the shaft continues to rotate beyond the moment at which the input changes depends on the speed of rotation.

The greater the speed (strokes per minute), the further the shaft rotates before a command from the control is applied. We graphed the degrees of shaft rotation vs press speed for a response time of 21 ms.

Figure 1.1

Shaft Rotation for a 21 ms Response Time of the Clutch/Brake

Control System

SPM

20

10

0

50

40

30

100

90

80

70

60

0 3 6 9 12

Degrees of Shaft Rotation

15

Important: When estimating the braking distance in degrees of rotation, you must add the rotation occurring during system response time to the specified downstroke braking distance. (For example, at

100 SPM, the shaft rotates 12 o during a 21 ms system response time plus the braking distance.)


Related Safety Information

Overview 1–7

You are responsible for the safety of the installed press control, and for meeting all applicable laws, codes, and safety requirements. This control deals only with electrical control portions of the clutch/brake mechanism.

ATTENTION: The installer of this control must follow

ANSI B11.1 regarding mechanical power presses, OSHA

1910.217, and other applicable standards pertaining to safety recommendations related to:

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 (Available at www.osha_slc.gov/OshStd–data/1910_0217.html)

•

ANSI B11.1, American National Standard for Machine Tools,

Mechanical Power Presses, Construction, Care, and Use

(available from American National Standards Institute 1430

Broadway NY, NY 10018-3363 or http://web.ansi.org)

•

NFPA No. 79, Electrical Standard for Metalworking Machine Tools

•

IEC 61508, Part 1–7 Functional Safety of a PES Safety Related System

•

EN 692 Mechanical Press Safety

•

CAN/CSA-Z142-M90 Code for Punch Press and Brake Press Operation:

Health, Safety, and Guarding Requirements (Canadian Standards Assoc.

178 Rexdale Blvd. Rexdale (Toronto) Ontario Canada M9W 1R3)

Other applicable standards include EN 954 and EN 60204

Also refer to Important User Information inside the front cover.


1–8 Overview

Specifications

Type of processor

• pair of MicroLogix 1500 processors

Type of power:

• grounded ac (6556-MLCBK)

• dc (6556-MLCBKDC)

Mode selections

• off

• inch

• single stroke

• continuous

• micro inch

Valve outputs

• two clutch/brake valves

Type of valves

• internal fault detection

Position monitoring inputs

• two rotary cam limit switch assemblies

Response time

•

21 ms worst case from switched input to turned-OFF output

Machine inputs

• cycle stop

• E-stop

Machine inputs (continued)

• run station (1)

• mode select (rotary switch)

• clutch/brake air pressure

• motor forward interlock

• motion detector interlock

• arm for continuous on demand

• control reset

•

C/B power reset

Environmental conditions

•

Operating Temperature

0 to 60 o

C (32 to 140 o

•

Storage Temperature

–40 to 85 o

F)

C (–40 to 185

•

Relative Humidity o F)

5 to 95% (without condensation)

Designed to comply with

•

ANSI – B11.1

•

OSHA – 1910.217

•

CSA – CAN/CSA-Z142-M90

•

NFPA No. 79


Procedure

2.

3.

4.

Chapter

2

Quick Start

Use this chapter as an abbreviated procedure for setting up the control, or as an overview if you need more information.

1.

Verify That You have All of the Hardware Shipped in the Kit this manual chapter 1

Hardware Included for -MLCBK for -MLCBKDC Hardware That You Pro- vide

Micrologix 1500 Processor 1764–LSP (2) 1764–LSP (2)

DC Base W/ DC 16IN/12OUT 1764–28BXB (2) 1764–28BXB (2)

• nput itc es un

Stations (Application

Memory Module w/ Real Time

Clock

16 pt Input Module

8 pt Input Module

1764–MMIRTC (2) 1764–MMIRTC (2)

•

Rotary Cam Limit

1769–IA16 (ac) (2)

1769–IA8I (ac) (4)

1769–IQ16 (dc) (6)

•

Solenoid Valves (4)

8 pt AC/DC Isolated Relay

Module

1769–OW8I (ac/dc)

(4)

1769–OW8I (ac/dc)

(4)

Detection

Compact I/O Terminator Cap

RT

1769–ECR (2) 1769–ECR (2)

• perator nter ace 1

– PanelView 550

(6556-PV550)

Mount the Network Interface Module and MicroLogix 1500 Base Unit

(with processor and memory module pre–installed)

Wire the Power Supply on the MicroLogix 1500 Base Unit

Wire the Network Interface Module

DeviceNet (DNT) or Advanced Interface Convertor (AIC) publications

1764–5.1

and

1761–5.11

publication

1764-5.1

Publication

1761–5.11


2–2 Quick Start

5.

Install the Compact I/O Modules

this manual chapter 3

6.

.

3

4

1

2

5 n/a

Slot # Controller A (same for Controller B) n/a

MicroLogix 1500 Base Unit (1764–28BXB) with Processor

(1747-LSP) and Memory Module w/ Real Time Clock

(1764–MMIRTC) pre–installed

Input Module 1769-IA16 (ac) or 1769-IQ16 (dc)

Input Module 1769-IA8I (ac) or 1769-IQ16 (dc)

Input Module 1769-IA8I (ac) or 1769-IQ16 (dc)

AC/DC Isolated 8pt Relay Module 1769-OW8I

AC/DC Isolated 8pt Relay Module 1769-OW8I

Compact I/O Terminator Cap RT 1769–ECR

Publication

1764–5.1

1769–5.1

1769–5.1

1769–5.1

1769–5.13

1769–5.13

1769–5.9

this manual chapter 1

Description: run station, inch/run

E-stop mode selection cycle stop arm continuous

E-stop reset

C/B power reset main motor forward motion detector air pressure

Install Input Switches (You wire them in step 9.)

Type: rotary, key-lockable

7.

Set Up or Simulate Rotary Cam Limit Switches as Follows:

A During downstroke, BCAM must be On.

B During upstroke, TCAM must be On and

BCAM must be Off.

Install Rotary Cam Limit Switches

C During upstroke, ACAM must cycle from On to Off to On while TCAM is On.

D Near top, BCAM and TCAM must be Off while ACAM remains On 270 o

Up stroke

Zone

C

0 o

Near-top

Zone

D

A

TCAM

ACAM

BCAM this manual chapter 3

Down stroke

Zone

90 o

Other Conditions:

The software is designed to fault if/when it detects: a. ACAM, BCAM, and TCAM are OFF all at the same time.

b. BCAM is On when ACAM is Off.

c. ACAM does not cycle while TCAM is On during upstroke.

ACAM should remain On for the entire stroke except for an On/Off/On cycle while TCAM is On during upstroke.

Dual sets of contacts need not cycle at same moment.

An offset of up to 1 second is acceptable.

B

Bottom

180 o

Important: See press manufacturer’s recommendations for on/off settings of ACAM, BCAM, and TCAM switches.


Quick Start 2–3

8.

Connect the Cables this manual chapter 3

See the Installation Instructions that accompanied the Network Interface module for the terminations.

Network Interface

Module

DeviceNet

Use this cable: to connect: notes:

AIC+ Advanced

Interface Converter

DeviceNet or AIC+

Advanced Interface

Converter

1485C–PI–Cxxx

Raw Drop Cable or equivalent that you make

1761–CBL–AM00 between DeviceNet Interface modules in controller A and controller B between AIC+ Advanced Interface

Converters in controller A and controller B

DeviceNet Interface Module to the

MicroLogix 1500 see DeviceNet

Interface module installation instructions in

Publication

1761–6.5

see Advanced

Interface Converter installation instructions in

Publication

1761–6.5

came with the

DeviceNet

Interface module, two required chapter 3 appendix C

9.

.

Wire the I/O Modules, RCLS, and Input Switches

For wiring instructions, refer to chapter 3, Connections to I/O Modules, and to appendix C.

10.

Test the Wiring and Clutch/Brake Operation

For instructions on testing the wiring, refer to chapter 4.

For instructions on testing C/B operation, refer to chapter 5 chapters 4 and 5


2–4

Notes:

Quick Start


Chapter

3

Installing and Wiring


Check Hardware

Mount the Network

Interface Modules and

Base Units

Wire the Power Supply

Wire the Network Interface

Module

In this chapter, we help you install the C/B control with these steps:

• check hardware

• mount the network interface and base unit

• wire the power supply

• wire the network interface module

• attach I/O modules

• set up rotary cam limit switches

• install input switches

• connect cables

• connections to I/O modules

• wire your control

To check the contents of the kit, refer to Contents of Kit in chapter 1.

If items are missing, contact your local salesperson or distributor.

To mount the network interface modules and base units:

For

DeviceNet Interface Module

(1761–NET–DNI) or Advanced Interface

Converter, (1761–NET–AIC) Mounting

Instructions

MicroLogix 1500 Base Unit (Cat. No

1764–28BXB) mounting instructions

Refer To Publication

1764-5.11 Installation Instructions for

DeviceNet Interface Module

(1761–NET–DNI) and Advanced Interface

Converter (1761–NET–AIC)

1764–5.1 MicroLogix 1500 Programmable

Controller Base Units Installation

Instructions

Look for these publications in the boxes that contain the network interface module and base units.

To wire the power supply contained in the base unit (Cat. No.

1764-28BXB), refer to publication 1764-5.1, MicroLogix 1500

Programmable Controller Base Units Installation Instructions. Look for this publication in the box that contains the base units.

To wire the network interface module (DeviceNet Cat. No.

1761-NET–DNI or Advanced Interface Converter Cat. No

1761–NET–AIC), refer to publication 1761–5.11. Look for this publication in the box that contains network interface module. Keep the instruction sheet handy because you will use it to fabricate and connect cables.


3–2 Installing and Wiring

Attach the I/O Modules

Attach the I/O modules in designated sequence for MicroLogix 1500

A and MicroLogix 1500 B as follows:

1 2 3 4 5

1761–DNI MicroLogix 1500

31060–M

Location

#

n/a n/a

1

2

3

4

5 n/a

DC Controller A (same for controller B)

AC Controller A (same for controller B)

DeviceNet Interface Module (Cat. No. 1761–NET–DNI) or Advance Interface

Converter (Cat. No. 1761–NET–AIC) (customer selection)

MicroLogix 1500 Base Unit (Cat. No. 1761–28BXB) containing Processor

(Cat. No. 1747-LSP) with Memory Module w/ Real Time Clock (Cat. No.

1764–MMIRTC)

Compact 1769-IQ16 24V dc

Sink/Source Input Module



Compact 1769-IA16 120V ac Input

Module

Compact 1769-IA8I 120V ac Input

Module



Compact 1769-IA8I 120V ac Input

Module

Compact 1769-OW8I AC/DC Relay Output Module


Compact I/O Terminator Cap RT 1769–ECR

I/O modules can be attached to the base unit or an adjacent I/O module before or after mounting. For attaching or mounting I/O modules, refer to the following publications installation instructions for that specific module.

For Attaching or Mounting Compact I/O Modules

I/O Module

Compact 1769-IQ16 24V dc Sink/Source Input Module

Compact 1769-IA16 120V ac Input Module


Compact RT 1769–ECR I/O Terminator Cap

Compact 1769–IA8I 120V ac Input Module

Refer to Publication

1769–5.3

1769–5.1

1769–5.13

1769–5.9

1769–5.12


Installing and Wiring 3–3

Set Up Rotary Cam

Limit Switches

To set up rotary cam limit switches, set up the cam angles for each switch assembly as described below and according to the press manufacturer’s installation instructions.

Important: Mount these assemblies on opposite ends of the crankshaft so a mismatch (fault) will occur if the crankshaft breaks.

• brake-monitor (BCAM) contacts close at a point that lets the system detect an increase in braking distance

• take-over (TCAM) contacts close at bottom to let the press complete a stroke, and open during upstroke to let the press stop at the top

• anti-repeat (ACAM) contacts limit press operation to a single stroke in single-stroke mode

This Cam: In this Mode: With these Conditions:

Anti-Repeat

(ACAM)

Take-over

(TCAM)

Inch, Micro

Inch or

Single stroke

Inch, Micro

Inch or

Single stroke

Continuous

Cams open and close in upstroke Prevents a second stroke in these modes

Cams open in near-top zone

Provides a Signal That:

Turns OFF triac outputs for stopping the press at top of stroke (stop-on-top)

Brake-monitor

(BCAM)

Single stroke or Continuous

Single Stroke or Continuous

Cams open in near-top zone after stop-on-top command

Cams close near bottom just when (or before) BCAM opens

When press stops in downstroke beyond BCAM closure

Lets the press complete a single stroke or run continuously after run buttons are released

Indicates that braking distance is excessive.

Turns OFF solenoid outputs to prevent restart.

Set Up or Simulate Rotary Cam Limit Switches as Follows:

A During downstroke, BCAM must be On.

B During upstroke, TCAM must be On and

BCAM must be Off.

C During upstroke, ACAM must cycle from On to Off to On while TCAM is On.

D Near top, BCAM and TCAM must be Off while ACAM remains On.

270 o

Up stroke

Zone

C

0 o

Near-top

Zone

D

A

TCAM

ACAM

BCAM

Down stroke

Zone

90 o

Other Conditions:

The software is designed to fault if/when it detects: a. ACAM, BCAM, and TCAM are OFF all at the same time.

b. BCAM is On when ACAM is Off.

c. ACAM does not cycle while TCAM is On during upstroke.

ACAM should remain On for the entire stroke except for an On/Off/On cycle while TCAM is On during upstroke.

The dual sets of contacts need not cycle at the same moment.

An offset of up to 1 second is acceptable.

B

Bottom

180 o

Important: See press manufacturer’s recommendations for:

* Near-top Zone

* Bottom

* On/Off settings of ACAM, BCAM, and TCAM switches



As an example, we show typical ON/OFF settings for rotary cam limit switches in the following table where you can write down your initial settings.

This

RCLS:

Turns ON at a position:

Turns OFF at a position:

Typical

ON OFF:

BCAM

• near top, beyond which the software detects a faulty brake

• when overlapped by TCAM in ON position 10 o 190 o

TCAM

• near bottom

• when or before BCAM turns OFF

•

• that lets the press stop correctly on top before BCAM turns ON

170 o 350 o

ACAM

•

Remains ON for entire stroke except for an Off span during upstroke (see graph) 290 o 250 o

1 Important: To determine exact settings, refer to recommendations provided by the press manufacturer.

Your 1

ON OFF:

Set the ACAM off span to the number of degrees (0 0 - 90 0 ) according to the speed of the press (0-200 strokes per minute).

Press

Speed

(SPM)

200

180

160

140

120

100

80

60

40

20

0

30

0

60

0 90

OFF Span of Anti-repeat Contacts During Up Stroke

0

Install Input Switches

Verify that your press has the following switches. They are required inputs to your clutch/brake control. Refer to chapter 1 for switch specifications.

Type: Description: run station, inch/run

E-stop mode selection cycle stop arm continuous

E-stop reset

C/B power reset main motor forward motion detector air pressure position monitor rotary, key-lockable rotary cam limit switches


Connect Cables

Installing and Wiring

Connect cables as shown:. You must make the cable

(1485CPI–PI–Cxxx) that connects between the two network interface modules. Refer to the Network Wiring Detail in each drawing. Use the 1761–CBL –AMOO cable to connect each interface module to the MicroLogix 1500.

3–5

Cable Connections for DeviceNet Interface Module

1761–DNI MicroLogix 1500 A

BLK

BLU

SHLD

WHT

RED

DNIA

V–

CAN_L

SHIELD

CAN_H

V+

BLK

BLU

SHLD

WHT

RED

DNIB

V–

CAN_L

SHIELD

CAN_H

V+

1485CPI

Cxxx cable

NOTES:

1. Use 1485C–P1–Cxxx (A–B) raw drop cable or equiv. for

DeviceNet network connection.

2. DeviceNet 24VDC power supplied externally to clutch

brake panel.

Network Wiring Detail

1761–DNI

1761–CBL–AM00 cable

MicroLogix 1500 B


31060–M

Connect Cable between DeviceNet Interface modules of

MicroLogix 1500 A and MicroLogix 1500

B

Use this cable:

1485C–PI–Cxxx Raw Drop

Cable or equivalent between DeviceNet Interface Module and the MicroLogix 1500 Base Unit

1761–CBL–AM00 notes: see DeviceNet

Interface module installation instructions in

Publication

1761–6.5

came with the

DeviceNet

Interface module, two required



Cable Connections for Advanced Interface Converter

1761–AIC MicroLogix 1500 A

TERM

A

B

COM

SHIELD

CHS GND

AICA

4

3

6

5

2

1

1485CPI

Cxxx cable

AICB

TERM

A

B

COM

SHIELD

CHS GND

3

2

1

6

5

4

NOTES:

1. Use 1485C–P1–Cxxx (A–B) raw drop cable or equiv. for

AIC network connection.

2. AIC 24VDC power supplied externally to clutch

brake panel.

Network Wiring Detail

1761–AIC


MicroLogix 1500 B


31061–M

Connect: Cable between Advanced Interface Converters

(1761–NET–AIC) of MicroLogix 1500 A and MicroLogix 1500 B

Use this cable: that you make. Refer to

Network Wiring Detail in drawing between Advanced Interface Converter

(1761–AIC+) Interface Module and the

MicroLogix 1500 Base Unit

1761–CBL–AM00 notes: see Advanced

Interface Converter installation instructions in

Publication

1761–6.5

came with the

Advanced Interface

Converter, two required


Cross–Check Wiring


Important: Wiring between inputs of controller A of the

1761–28BXB Base Unit and outputs of controller B in the

1761-28BXB Base Unit provides cross-checking between controllers. With cross-check wiring, inputs to the base unit of controller A are wired to outputs in the base unit of controller B, and inputs to the base unit of controller B are wired to outputs in the base unit of controller A.

MicroLogix 1500 Input and Output Block Layouts

Input Block Layout

NOT

USED

NOT

USED

DC

COM 0

I/1

I/0 I/2

I/3

DC

COM 1

I/4 I/6

I/5 I/7

DC

COM 2

I/8

I/9

I/10

I/11

I/12

I/13

I/14

I/15

28BXB

MicroLogix 1500 Base Unit

Cat. No. 1761–28BXB

NOT

USED

NOT

USED

DC

COM 0

I/0

I/1

I/2

I/3

DC

COM 1

I/4

I/5

I/6

I/7

DC

COM 2

I/8

I/9 I/11 I/13

I/10 I/12 I/14

I/15

28BXB

COM

24 VDC

+24V

VAC

VDC 0

VAC

VDC 1

O/0 O/1

VDC 2

O/3 O/5

O/2 O/4 O/6

O/7

VAC

VDC3

VDC

COM 2

O/9

O/8

O/10

VAC

VDC4

28BXB

O/11

24 VDC

+24V

COM

VAC

VDC 0

VAC

VDC 1

O/0 O/1

VDC 2

O/2

O/3 O/5 O/7

O/4 O/6

VAC

VDC3

VDC

COM 2

O/8

O/9 O/10

VAC

VDC4

28BXB

O/11

Output Block Layout

31059–M



Cross Check Wiring Between Processors



Cross Check Wiring Connection Tables

Wiring Inputs Of Base Unit A To Outputs Of Base Unit B

Base Unit A

Input Module

Terminal

I/4

I/5

I/6

I/7

I/8

I/9

I/10

I/11

I/12

I/13

I/14

I/15

Base Unit B

Output Module

Terminal

O/0

O/1

O/2

O/3

O/4

O/5

O/6

O/7

O/8

O/9

O/10

O/11

Controller B Air Pressure

Controller B OK to Energize Seal

Controller B Clutch Output On

Controller B HeartBeat

Controller B Anti–Repeat CAM

Controller B Brake Monitor CAM

Controller B Takeover CAM

Spare

Controller B Mode (BCD Bit 1)



Main Motor Forward

Wiring Outputs Of Base Unit A To Inputs Of Base Unit B

Base Unit A

Output Module

Terminal

O/0

O/1

O/2

O/3

O/4

O/5

O/6

O/7

O/8

O/9

O/10

O/11

Base Unit B

Input Module

Terminal

I/4

I/5

I/6

I/7

I/8

I/9

I/10

I/11

I/12

I/13

I/14

I/15

Controller A Air Pressure

Controller A OK to Energize Seal

Controller A Clutch Output On

Controller A HeartBeat

Controller A Anti–Repeat CAM

Controller A Brake Monitor CAM

Controller A Takeover CAM

Spare

Controller A Mode (BCD Bit 1)



Main Motor Forward

3–9



Connections to I/O

Modules

Terminal

Strip

Module

Door

IN 1

IN 2

IN 3

IN 4

IN 5

IN 6

IN 7

DC

COM 1

IN 9

IN 8

IN 11

IN 10

IN 13

IN 12

IN 15

DC

COM 2

IN 14

Each I/O module has a removable terminal block for wiring to I/O devices. The label inside the module door identifies the terminals.

We present wiring call–outs for each I/O module. Refer to the B–size wiring drawings included in this kit. Modules attached to controllers

A and B are wired the same except where noted.

I/O Modules for DC Clutch/Brake Control

1769-IQ16 (DC) in Slot 1

Connections

Mode select: Inch

Mode select: Continuous

Anti Repeat Cam

Take Over Cam

Main Motor FWD

C/B Air Pressure

Controller A Seal Relay

Controller A OK Relay

COMMONS

CONNECTED INTERNALLY

IN 1

IN 3

IN 5

IN 7

IN 9

IN 11

IN 13

IN 15

DC

COM 2

IN 0

Mode select: Off

Mode select: Single Stroke

IN 2

IN 4

IN 6

Mode select: Micro Inch

Brake Monitor Cam

DC

COM 1

IN 8

Motion Detect

IN 10

Top Stop

Control Reset

IN 12

Controller B OK Relay

IN 14

Terminal

Strip

Module

Door

IN 1

IN 2

IN 3

IN 4

IN 5

IN 6

IN 7

IN 9

DC

COM 1

IN 8

IN 11

IN 10

IN 13

IN 12

IN 15

DC

COM 2

IN 14

1769-IQ16 (DC) in Slot 2

Controller B Clutch 2 Feedback IN 1

Controller B Micro Inch 2 Feedback

IN 3

Clutch/Brake Power Feedback IN 5

Fault Reset

IN 7

IN 9

IN 10

IN 11

IN 13

Connections

IN 0

IN 2

Controller B Clutch 1 Output Feedback

Controller B Micro Inch 1 Output Feedback

Perimeter Guard A

IN 4

IN 6

DC

COM 1

Arm Continuous

IN 8

IN 10

COMMONS


IN 15

AC

COM

IN 12

IN 14


Terminal

Strip

Module

Door

IN 1

IN 2

IN 3

IN 4

IN 5

IN 6

IN 7

DC

COM 1

IN 9

IN 8

IN 11

IN 10

IN 13

IN 12

IN 15

DC

COM 2

IN 14


1769-IQ16 (DC) in Slot 3

Connections

IN 0

Left Run Station

IN 1

Left Inch Button

IN 3

User Permit Run

IN 5

User Permit Downstroke

IN 7

Controller OK Relay Contact

IN 9

IN 2

IN 4

IN 6

DC

COM 1

IN 8

IN 11

IN 13

IN 10

IN 12

COMMONS


IN 15

DC

COM 2

IN 14

Right Run Station

Right Inch Button

User Dieset Mode

User Permit Start

Terminal

Strip

1769-OW8I (AC or DC) in Slot 4

Module

OUT 0

OUT 1

OUT 2

OUT 3

OUT 4

OUT 5

OUT 6

OUT 7

Door

VAC–VDC

0

Label

VAC–VDC

1

VAC–VDC

2

VAC–VDC

3

VAC–VDC

4

VAC–VDC

5

VAC–VDC

6

VAC–VDC

7

Connections

Perimeter Guard A Input

Seal Relay

Controller OK Relay

Continuous Armed

Air Pressure Present

Brake Monitor Fault

Cam Fault

Clutch Control Fault

VAC–VDC

0

OUT 0

VAC–VDC

1

OUT 1

VAC–VDC

2

OUT 2

OUT 3

OUT 4

VAC–VDC

3

VAC–VDC

4

VAC–VDC

5

OUT 5

VAC–VDC

6

OUT 6

VAC–VDC

7

OUT 7

VDC COM

VDC COM

COMMONS


3–11



Terminal

Strip


Module

OUT 0

OUT 1

OUT 2

OUT 3

OUT 4

OUT 5

OUT 6

OUT 7

Door

VAC–VDC

0

Label

VAC–VDC

1

VAC–VDC

2

VAC–VDC

3

VAC–VDC

4

VAC–VDC

5

VAC–VDC

6

VAC–VDC

7

Connections

Clutch/Brake 1 Output Feedback

Clutch/Brake 1 Valve



Microinch 1 Output Feedback

Microinch 1 Valve


Microinch 2 Valve

VAC–VDC

0

OUT 0

VAC–VDC

1

OUT 1

OUT 2

OUT 3

OUT 4

VAC–VDC

2

VAC–VDC

3

VAC–VDC

4

VAC–VDC

5

OUT 5

VAC–VDC

6

OUT 6

VAC–VDC

7

OUT 7

VDC COM

VDC COM

COMMONS


Terminal

Strip

Module

Door

IN 0

IN 3

IN 2

IN 5

IN 4

IN 7

IN 6

IN 9

IN 8

IN 11

IN 10

IN 13

IN 12

IN 14

AC

COM

IN 15

AC

COM

I/O Modules for AC Clutch/Brake Control

1769-IA16 (AC) in Slot 1

Connections

IN 0

Mode select: Inch

IN 1

IN 2

Mode select: Continuous

IN 3

MicroInch 1 Output Feedback

IN 5

Emergency Stop Master Relay

IN 7

Controller OK Relay

IN 9

IN 4

IN 6

IN 8

IN 10

Clutch 1 Output Feedback

IN 11

Anti Repeat CAM (ACAM)

IN 13

Top Stop CAM (TCAM)

IN 15

AC COM

COMMONS


IN 12

IN 14

AC COM

Mode select: Off

Mode select: Single Stroke

Mode select: Micro Inch

MicroInch 2 Output Feedback

Controller OK Relay Feedback

Seal Relay


Break Monitor CAM (BCAM)



1769-IA8I (AC) in Slot 2

Terminal

Strip

Module

AC

COM

0

Door

IN 1

1

IN 2

2

IN 3

3

IN 4

4

IN 5

5

IN 6

6

IN 7

7

NC

NC

AC

COM 5

AC

COM 6

AC

COM 7

AC

COM

Connections

IN 0

AC

COM 0

AC

COM 1

AC

COM 2

AC

COM 3

AC

IN 1

IN 2

IN 3

IN 4

IN 5

IN 6

IN 7

NC



Micro Inch 1 Output Feedback

Micro Inch 2 Output Feedback

Perimeter Guard

C/B Power Feedback

Arm Continuous

Fault Reset

3–13

1769-IA8I (AC) in Slot 3

Terminal

Strip

Module

AC

COM

0

Door

IN 1

1

IN 2

2

IN 3

3

IN 4

4

IN 5

5

IN 6

6

IN 7

7

NC

NC

AC

COM 5

AC

COM 6

AC

COM 7

AC

COM

Connections

IN 0

AC

COM 0

AC

COM 1

AC

COM 2

AC

COM 3

AC

IN 1

IN 2

IN 3

IN 4

IN 5

IN 6

IN 7

NC

Right Run Station

Left Run Station

Right Inch Button

Left Inch Button

Die Set Mode

Permit Run

User Permit Start

User Permit Downstroke



Terminal

Strip


Module

OUT 0

OUT 1

OUT 2

OUT 3

OUT 4

OUT 5

OUT 6

OUT 7

Door

VAC–VDC

0

Label

VAC–VDC

1

VAC–VDC

2

VAC–VDC

3

VAC–VDC

4

VAC–VDC

5

VAC–VDC

6

VAC–VDC

7

Connections

Perimeter Guard Input

Spare

Spare

Spare

Seal Relay

Controller OK Relay

Continuous Armed


VAC–VDC

0

OUT 0

VAC–VDC

1

OUT 1

OUT 2

OUT 3

OUT 4

VAC–VDC

2

VAC–VDC

3

VAC–VDC

4

VAC–VDC

5

OUT 5

VAC–VDC

6

OUT 6

VAC–VDC

7

OUT 7

VDC COM

VDC COM

COMMONS


Terminal

Strip


Module

OUT 0

OUT 1

OUT 2

OUT 3

OUT 4

OUT 5

OUT 6

OUT 7

Door

VAC–VDC

0

Label

VAC–VDC

1

VAC–VDC

2

VAC–VDC

3

VAC–VDC

4

VAC–VDC

5

VAC–VDC

6

VAC–VDC

7

Connections






Microinch 1 Valve


Microinch 2 Valve

VAC–VDC

0

OUT 0

VAC–VDC

1

OUT 1

OUT 2

OUT 3

OUT 4

VAC–VDC

2

VAC–VDC

3

VAC–VDC

4

VAC–VDC

5

OUT 5

OUT 6

VAC–VDC

6

VAC–VDC

7

OUT 7

VDC COM

VDC COM

COMMONS


Wire Your Control

We provide the same set of wiring drawings and user manual for both the ac and dc versions of this control. For the dc version (Cat.

No. 6556-MLCKBDC), wire your I/O modules and dc power distribution according to those drawings.

Important: For the ac version (Cat. No. 6556-MLCBK), refer to appendix C for modifications you must make to the dc wiring drawings before wiring your I/O modules and power distribution.



Inputs and outputs by I/O module and location are as follows:

For

Power Distribution

Inputs to 1764–28BXB base unit of Controller cross–checked inputs (same as cross–checked outputs, next)

Outputs to 1764–28BXB base unit

Cross–checked Outputs

•

OK To Energize Seal

•

BCD Mode

•

ACAM,BCAM,TCAM

•

Clutch Output ON

•

Heartbeat

Inputs to 1769–IQ16 (dc) or 1769–IA16 (ac)

•

Mode Select

•

ACAM, BCAM, TCAM

•

Motion Detect

•

Main Motor Forward

• Cycle Stop

•

Clutch/Brake Air Pressure

•

Emergency Stop Relay

•

Seal Relay

•

Controller OK Relays

Inputs to 1769–IQ16 (dc) or 1769–IA8 (ac)

•

Clutch/Brake 1 Feedback

•


•

Microinch 1 Feedback

•

Microinch 2 Feedback

•

Perimeter Guard

•

Clutch/Brake Power Feedback

•

Arm Continuous

•

Fault Reset

Inputs to 1769–IQ16 (dc) or 1769–IA8I (ac)

•

Left & Right Run Station

•

Left & Right Run Inch Buttons

•

User Permits

1769–OW8I (dc or ac) Outputs

•

Perimeter Guard

•

Seal Relay

•

Controller OK Relay

•

Continuous Arm Light

•

Air Pressure Light

• Brake Monitor Fault Light

•

Cam Fault Light

•

Clutch Control Fault Light


•

Clutch/Brake 1 Outputs

•

Clutch/Brake 2 Outputs

•

Microinch 1 Outputs

• Microinch 2 Outputs

In I/O Module Location

Base unit

Base unit

Base Unit

Slot 1

Slot 2

Slot 3

Slot 4

Slot 5

See Drawing Sheet

1 of 10

2 of 10

3 of 10

4 of 10

5 of 10

6 of 10

7 of 10

8 of 10

Wire power supplies according to instructions that accompanied them.


3–16

Notes:



Customer Interface Inputs and Motion Detect Inputs

Chapter

4


Customer Interface Inputs

Use this chapter to understand the customer interface inputs and motion detect inputs.

Permit Run – I:03/05

The permit run input is used as a permissive to allow the press to run in inch, single stroke. or continuous mode. If the permit run input is

“off”, the press will not be able to start motion. If the press is in motion it will stop immediately.

Important: If you are not using the permit run input, you must wire it high to allow the press to cycle.

Permit Start – I:03/06

The permit start input is used as an initial condition to start the press cycle in single–stroke and continuous mode. The input must be “on” to start the press cycle. Once the press cycle starts, the permit start input is not required to be “on.”

Important: If you are not using the permit start input, you must wire it high to allow the press to cycle.

Permit Downstroke – I:03/07

The permit downstroke input is required in inch, single stroke, and continuous as the last permissive in the logic to start the motion on the press. This permissive is in place after the inch or run buttons have been pressed. This allows the press to stop and restart as long as the operator keeps the inch or run buttons pressed.

Important: If you are not using the permit downstroke input, you must wire it high to allow the press to cycle.

Dieset Mode – I:03/04

When turned “on”, the dieset mode input stops the press at the bottom. It stops at the top when in inch mode.


4–2 Customer Interface Inputs

Motion Detect Inputs

Motion Detect – I:0/0

This motion detect input is a pulsed input. You should use this input if your motion detect device produces a square pulse output when it is in motion and no output when the press is stopped.

Motion Detect – I:01/08

This motion detect input is a continuous input. You should use this input if your motion detect device produces a high signal when the press is in motion and a low signal when the press is stopped.



Chapter

5

Circuit Testing

Once you have completed the installation of your clutch/brake control and wired your I/O devices, use this chapter to check circuit wiring.

ATTENTION: Before starting this chapter, be sure that:

• all clutch/brake control hardware is installed

• clutch/brake wiring is complete

• the control is in compliance with all applicable standards

Otherwise, personal injury or property damage could result.

Testing Circuits and

Failure-mode Operation

This section describes the following tests:

•

Controller OK (failure mode)

•

CRM Relay

•

Seal Relay (circuit)

•

Seal Relay (failure mode)

•

Run Station Buttons

•

Inch Buttons

•

Cycle Stop Button

•

Arm Continuous Button

•

Mode Selector Switch

•

Rotary Cam Limit Switches


5–2 Circuit Testing


Controller OK Test (failure mode)

This test verifies the correct failure-mode operation of the Controller

OK relay for controller A. You will repeat this procedure for controller B.

1. With power off, place a jumper across the wired contacts of

Controller OK relay (CRAO0402).

2. Power up.

3. Press the C/B Control Reset button to energize the CRM relay.

4. Press (and momentarily hold) the C/B Power Reset button.

5. Verify that:

– the Controller OK relay is NOT energized (red plunger is not recessed)

– “Controller OK Check Failed” prompt is displayed on PanelView screen (or equivalent prompt code 003 is displayed on the DTAM display)

6. Shut off system power.

7. Remove the jumper.

8. Repeat steps 1-7 for Controller B (Controller OK relay

CRBO0402).

Safety Relay Test (circuit)

This test verifies that pressing the E-stop button will de-energize the seal and safety relays.

1. Power up.

2. Visually and with a voltmeter, verify that:

– safety relay is not energized

– outputs to all press valves are Off.

3. Reset the E-Stop circuit by pressing the Control Reset button.


– safety relay is energized

– outputs to all press valves are Off

5. Reset control power by pressing the C/B Power Reset button.

6. With a voltmeter, verify that power rails to C/B outputs are energized.

7. Press the E-Stop button.

8. Visually and with a voltmeter, verify that seal relays and safety relay are de-energized.

Circuit Testing 5–3

Seal Relay Test (circuit)

This test verifies that when the seal relay is off, press valves are off; and when the seal relay is on, outputs to press valves are energized.

1. Power up (if not already powered up).


3. With a voltmeter, verify that:

– seal relay is not energized

– outputs to all press valves do are Off



– seal relay is energized

– power rails to C/B outputs are energized

6. Shut off system power.

Seal Relay Test (failure mode)

This test verifies the correct failure-mode behavior of the seal relays for chassis A and B.

1. With power off, place a jumper across the wired contacts of seal relay (CRAO0401).

2. Power up.


4. Verify that:

– the seal relay is NOT energized

– Controller OK relay is energized

– “Seal Relay Weld Fault” prompt is displayed on PanelView (or Fault

Code 005 is displayed on the DTAM display).

5. Shut off system power and remove the jumper.

6. Restore system power.


8. Verify that:

– safety relay is energized

– there is NO fault message

9. Press (and momentarily hold) the C/B Power Reset button.

10.Verify that the seal relay is energized

11. Shut off system power.

12.Repeat steps 1–11 for chassis B (Seal Relay CRBO0401)


5–4 Circuit Testing

Test Run Station Buttons

Test the wiring of Run Station buttons by observing LEDs in slot 3.

Check each OK? box after verifying that the LED indication is correct.

For This Condition Slot 3, Controller A

Input LED Is

OFF ON

Right Run Station button is pressed

Left Run Station button is pressed Input 1

Both Run Station buttons not pressed

Input 0

Input 0 Input 1

OK?

Slot 3 Controller B

Input LED Is

OFF ON

Input 1

Input 0

Input 0

Input 1

OK?

Test Inch Buttons

Test the wiring of Inch buttons by observing LEDs in slot 3. Check each

OK? box after verifying that the LED indication is correct.

For This Condition

Right Inch button is pressed

Left Inch button is pressed

Both Inch buttons not pressed

Slot 3, Controller A

Input LED Is

OFF ON

Input 2

Input 3

Input 2 Input 3

OK?

Slot 3 Controller B

Input LED Is

OFF ON

Input 3

Input 2

Input 2 Input 3

OK?

Cycle Stop and Arm Continuous Buttons

Test the wiring of these buttons by observing input LEDs.


2

2

1

1

Slot For This Condition Verify both A and B

Chassis Slot 2 Input LED

Is

OFF ON

Cycle Stop not pressed

Cycle Stop pressed Input 10

Arm Continuous not pressed Input 6

Arm Continuous pressed

Input 10

Input 6

OK?


Circuit Testing 5–5

Test Mode Selector Switch

Test the wiring of this switch by observing input LEDs in slot 1.


For This Mode-select Position Slot 1 Input LEDs Are OFF Slot 1 Input LED Is ON OK?

Off

Inch

Single

Continuous

Micro Inch

(input 0)

(input 1)

(input 2)

(input 3)

(Input 4)

A & B: Inputs 0, 1, 2, 3, 4,

Test Rotary Cam Limit Switches

Test the wiring of the RCLSs by observing input LEDs in slot 1. Check each OK? box after verifying that the LED indication is correct.

For This Condition

ACAM, BCAM, TCAM at rest

ACAM, BCAM, TCAM actuated

Slot 1 Input LED Is

OFF ON

A & B, Inputs 5, 6, 7

A & B, Inputs 5, 6, 7

OK?


5–6

Notes:

Circuit Testing


Chapter

6

Testing the Operation


Once you have checked the wiring of your clutch/brake control, use this chapter to test its operation. Tests include:

• troubleshoot the setup of your RCLS assemblies

• tests the operating modes

• test the switches

Troubleshooting the Setup of Your RCLS Assemblies

BCAM

TCAM

Off

Off

We recommend that you test the rotary cam limit switches (RCLS) in

Inch mode. The processor monitors RCLS signals to ensure that the motion progresses through the correct sequence of:

• downstroke

• upstroke

• top zone

During each stroke, rotary cam limit switches must cycle through these zones.

near bottom

Top Zone Downstroke Upstroke

On

*

On

ACAM On

Off

* BCAM and TCAM can transition within the same scan or overlap their On states.

Important: The software reads the zones according to the on/off status of ACAM, BCAM, and TCAM switches that you set mechanically.

When the software detects any one of the following fault conditions, it is designed to turn outputs off and set the corresponding fault message #.


6–2 Testing the Operation

Use the following look-up table to take corrective action.

Processor Faults

Msg # PanelView Message Cause of Fault Effect of Fault How to Correct the Fault

027* Illegal RCLS Combination Software/hardware cams produced invalid combination.

028* Forward Transition from Top

029* Forward Transition from Downstroke

Software/hardware cams did not go from near top to downstroke.

Software/hardware cams did not enter upstroke.

030* Forward Transition from Upstroke

034* Forward Shaft Position

Transition Faults

035* ACAM Upstroke

Software/hardware cams did not enter near top zone.

Any of 027-030 detected.

ACAM did not cycle in upstroke.

ar are ca s or proper operation or settings.

042* BCAM Mismatch Between

Processors

043* TCAM Mismatch Between

Processors

044* ACAM Mismatch Between

Processors

045* Cam Mismatch Faults

One processor sees the BCAM while the other does not.

One processor sees the TCAM while the other does not.

One processor sees the ACAM while the other does not.


047* Brake Monitor Fault On a top-stop command, the press slid onto BCAM before stopping.

Press cannot operate in single or continuous mode.

* To clear this latched fault bit, you must enable the fault reset bit or turn the mode-select switch to OFF.

Check the brake and brake monitor cam settings.

Test the Operating Modes

Here are procedures to test dynamic operation of the press in these modes:

• inch

• single-stroke

• continuous with the arm-continuous method to start this mode

• micro inch

Important: If the press control faults or does not operate as expected, read the fault or prompt message (or bit number) and see Appendix B for:

• faults in bit file B168 for troubleshooting

• prompts in bit file B169 for operating the press

Inch Mode

1. Place the mode selector switch in Inch mode.

2. Power up by pressing the Control Reset and C/B Power Reset buttons.

3. Verify that seal relays and CRM relays are energized.

4. Concurrently, press and hold both Inch buttons.

5. Observe that the press cycles and stops on top.


Testing the Operation 6–3

6. Release the Inch buttons and press again for 1-2 seconds.

7. Observe that the press cycles until you release a button, then stops.

Single-stroke Mode

1. Place the mode selector switch in Single-stroke mode.

2. Press and hold Run buttons for more than 1/2 stroke.


4. Release Run buttons and press again. Then release in downstroke.

5. Observe that the press stops immediately.

6. Bring the press to top by pressing Run buttons and release in upstroke.

7. Repeat steps 2 and 3. This time hold Run buttons for the entire cycle.

8. Observe that the press runs through one stroke and stops at the top.

Continuous Mode with Arm Continuous

1. Place the mode selector switch in Continuous mode.

2. Press the Arm Continuous button.

3. Immediately press Run buttons and release after downstroke.

4. Observe that the press continues to cycle.

5. Press the Cycle Stop button.

6. Observe that the press completes the cycle and stops on top.

7. Return to step 2 and press the Arm Continuous button.

This time, wait for 5 seconds (or until the Arm-continuous timer has timed out) before pressing Run buttons.

8. Observe that the press does not start.

9. Repeat steps 2 through 6 for a final verification.

Micro Inch Mode

1. Place the mode selector switch in Micro Inch mode.

2. Power up by pressing the Control Reset and C/B Power Reset buttons.

3. Verify that seal relays and CRM relays are energized.

4. Concurrently, press and hold both Inch buttons.



6–4 Testing the Operation

Test the Switches

6. Release the Inch buttons and press again for 1-2 seconds.

7. Observe that the press cycles until you release a button, then stops.

Test the following switches with an operating clutch/brake control:

•

C/B air pressure

• motion detector

• main motor forward

C/B Air Pressure Switch

1. Remove the C/B air pressure switch input from chassis A at slot 1 – terminal 11.

2. Place the mode selector switch in single-stroke mode.

3. Attempt to start the press and observe that it does not start.

4. Reconnect the air pressure switch input to chassis A (step 1).

5. Remove the switch input from chassis B (slot 1 – terminal 11) to repeat the test.


7. Reconnect the air pressure switch input to chassis B (step 5).

Motion Detector Switch

1. Remove the motion detector switch input from chassis A at slot 1 – terminal 8.


3. Start the press and observe that it stops before reaching bottom.

If the press reaches bottom, the circuit is not functioning correctly.

4. Reconnect the motion detector switch input to chassis A (step 1).


6. Start the press and observe that it stops before reaching bottom.

7. Reconnect the switch input to chassis B (step 5).


Testing the Operation

Main Motor Forward Switch

1. Remove the main motor forward switch input from chassis A at slot 1 – terminal 9.



4. Reconnect the main motor forward switch input.


6. Repeat steps 3 and 4.

6–5


6–6

Notes:

Testing the Operation


Appendix

A

Clutch/Brake

Operating Modes

Description of Operating Modes

You can select any one of the following operating modes with the mode selector switch:

•

Off

•

Inch

•

Single stroke

•

Continuous stroking

•

Micro Inch

Off

When an operator selects OFF, the control system is designed to:

• turn off all outputs to press valves.

• reset faults

Inch Mode

Before entering single or continuous mode, use inch mode to jog the press to the near-top position to set up the machine. The press stops when it moves into the near-top position or when you release a Inch button (Figure A.1).

No

Figure A.1

Typical Operational Sequence for Inch Mode

Select inch mode

ATTENTION: To guard against the possibility of personal injury, install a keylock mode select switch so that mode selection can be supervised.

Have you released both Inch buttons?

Yes

Have you pressed both Inch buttons concurrently?

Yes

Both processors energize their outputs to actuate the clutch

No

Has the press moved into the near-top position?

No

No Yes

Have you released either Inch button?

Yes

Both processors de-energize their outputs to stop the press.

Yes ATTENTION: If the press coasted past the near-top position while braking, the brake is faulty and

hazardous. Repair it immediately.

12261


A–2 Description of Operating Modes

Single Stroke Mode

Single stroke mode is designed to stroke the press once, from top to bottom to top, with the concurrent use of the Run buttons. Once the press reaches the takeover cam (TCAM), the operator can release the

Run buttons without stopping the press. It continues to the near-top position.

In downstroke, releasing a Run button stops the press (Figure A.2).

Then, if the press did not enter the upstroke zone (TCAM On), you may resume downstroke by again pressing Run buttons.

Once the press reaches the takeover cam (TCAM), the press continues automatically through the upstroke (Figure A.3).

Figure A.2

Typical Operational Sequence for Downstroke in Single Mode

Select single mode

No

Is the motor running forward?

Yes

Have you released both Run buttons since the previous stroke?

Yes

Have you pressed both

Run buttons concurrently?

Yes

Both processors energize their outputs to actuate the clutch for downstroke

No

No

No

No

Have you released a

Run button?

Yes


Is the press into the upstroke zone?

Yes

Go to R1

(Figure A.3)

Have you released, then pressed both Run buttons concurrently?

Yes

No

Figure A.3

Typical Operational Sequence for Upstroke in Single Mode

R1

Upstroke continues regardless

of releasing Run buttons


Yes Has either processor detected a critical fault?

No


Yes

Both processors de-energize their outputs to stop the press in the near-top position

ATTENTION: If the press coasted past the near-top position while braking, the brake is faulty and



NOTE: Releasing a Run button during first downstroke stops the press. If the slide has not entered the upstroke zone, you can resume downstroke within 5 seconds of pressing the Arm Continuous button. After

5 seconds (and the press is stopped), you must restart continuous mode with the arming sequence.

Description of Operating Modes A–3

Continuous Mode with Arm Continuous

To run your press continuously, ready the press as follows:

• select continuous mode

• press the arm continuous button

• press both Run buttons within 5 seconds

During the first downstroke (Figure A.4), releasing a Run button stops the press. Then, if the press did not enter the upstroke zone

(TCAM still off), you may resume downstroke within 5 seconds if you release and press both Run buttons again. If 5 seconds passes and the press stops, you must press the Arm Continuous button and

Run buttons again to restart.

During the first upstroke (Figure A.4) when TCAMs come on, you may release Run buttons and the press will continue stroking. If you start the press in upstroke, you must press the Arm Continuous button and then hold Run buttons for a complete cycle until next upstroke.

Once in continuous stroking operation (Figure A.5), the press stops at the next near-top position whenever it receives a stop-on-top command.

However, the press stops immediately whenever either processor detects a trip or stop condition or a required condition is removed.

Figure A.4

Typical Operational Sequence to Start Continuous Mode

R2

Select continuous mode

Yes

Is the motor running forward?

Yes

Have you released the Cycle

Stop button?

Yes

Have you released both Run buttons?

Yes

Have you pressed the

Arm Continuous button?

Yes

Have you pressed both Run buttons?

Yes

Both processors energized their outputs

Has the press reached the upstroke zone?

Yes

Go to R3

(Figure A.5)

No

No

No

No

No

No

No

Has the Arm Continuous timer timed out?

Yes

No

Have you released a Run button, or has a stop condition occurred?

Yes



A–4 Description of Operating Modes

Figure A.5

Typical Operational Sequence for Continuous Stroking

R3

Both processors allow continuous stroking regardless of releasing Run buttons.

No

Have you pressed

a Cycle Stop button?

No

Has the MicroLogix processor received the Top-stop command ?

No

Has a stop condition been detected?

Yes

Both processors de-energize outputs to stop the press.

Yes

Yes

The stroke continues until the press reaches the top.

Is the press in the near-top position?

Yes

Both processors de-energize their outputs to stop the press in the near-top position.

No

NOTE: The press strokes continuously until you press a Cycle Stop button, the

MicroLogix 1500 processor receives a stop-on-top command, or a stop condition is detected.




Description of Operating Modes A–5

Micro Inch Mode

Before entering single or continuous mode, use micro inch mode to jog the press to the near-top position to set up the machine. The press stops when it moves into the near-top position or when you release a

Inch button (Figure A.6).

No

Figure A.1

Typical Operational Sequence for Inch Mode

Select micro inch mode

ATTENTION: To guard against the possibility of personal injury, install a keylock mode select switch so that mode selection can be supervised.

Have you released both Inch buttons?

Yes

Have you pressed both Inch buttons concurrently?

Yes

Both processors energize their outputs to actuate the clutch

No


No

No Yes

Have you released either Inch button?

Yes


Yes

12261




A–6

Notes:

Description of Operating Modes


Appendix

B

Processor Faults and Operator

Prompts

Fault Codes for

Troubleshooting

Whenever a MicroLogix processor detects a fault, it sets a corresponding Fault # or PanelView message. We list the conditions for which the software is designed to detect and signal faults. Fault

#s (read from the data table) are independent of interface module used.

For message #s, use the following table to look up the Fault # and respond to the fault.

Processor Faults

Fault # Fault Description Cause of Fault Effect of Fault How to Correct the Fault

001 PLC HeartBeat Failed Processor failure.

C/B power is de–energized.

Troubleshoot processor to determine cause of failure.

002-003 Spare

004*

005*

006*

007*

008*

009

Processor OK Relay check Controller OK relay failed to close.

Seal Relay failed to turn on Seal relay A failed to close.

Seal Relay failed to turn off Seal relay A welded closed.

E-Stop Relay failed to Turn ON.

E-Stop relay failed to close.

E-Stop Relay failed to turn OFF.

No Valid Clutch/Brake

Mode

0010* C/B Mode Mismatch between processors

011-014 Spare

CRMA relay welded closed.

Mode-select failed.

Each processor sees a different mode.

015 Run Station Tiedown Time between pressing

Run/inch buttons was too long.

016-024 Spare

025 Inch Button Tiedown Time between pressing

Run/inch buttons was too long.

026 Spare

027* Illegal Cam Combination

028*

029*

Slide Transitioned from

Top Zone to Upstroke

Slide Transitioned from

Downstroke to Top Zone

030* Slide Transitioned from

Upstroke to Downstroke

031-033 Spare

Software/hardware cams produced invalid combination.

Software/hardware cams did not go from top to downstroke.

Software/hardware cams did not enter upstroke.

Software/hardware cams did not enter near top zone.

C/B power will not turn ON.


C/B power is de-energized and will not turn ON.


C/B power is de-energized and will not turn ON.


Press will not stroke.

Press will not start a stroke in single or continuous mode.

Press will not inch.

Press will stop or not run in single or continuous mode.




Check Controller OK relay and wiring.

Check operation of input module in slot 2.

Check seal relay and wiring.

Check operation of input module in slot 1

Check seal relay and wiring.


Check E-Stop CRM relay circuit.


Check E-Stop CRM relay circuit.


Check mode selector switch and wiring.


Check mode selector switch and wiring.


Release, then press run buttons simultaneously. Check button wiring.

Release, then press inch buttons simultaneously. Check button wiring.

Check software cam logic or hardware cams for proper operation or settings.





034*

035*

Forward Shaft Position

Transition Faults

ACAM Did Not Off During

Upstroke


ACAM did not cycle during upstroke.






B–2 Processor Faults and Operator Prompts

Fault # Fault Description Cause of Fault Effect of Fault How to Correct the Fault

036-039 Spare

040* C/B Air Pressure Software detected no air pressure after energizing main valves.

Clutch valves are de-energized.

Check I/O wiring.

Check air pressure switch.

041

042*

043*

044*

045*

Spare

Brake Monitor Cam

Mismatch between

Processors

Takeover Cam Mismatch between Processors

Anti-repeat Cam Mismatch between Processors

Soft Cam Fault Present

One processor sees the BCAM while the other does not.

One processor sees the TCAM while the other does not.

One processor sees the ACAM while the other does not.










046 Spare

047* Brake Monitor On a stop-on-top command, the press slid onto the BCAM before stopping.

Press cannot operate in single or continuous mode until it stops in the near top zone.

Check the brake and brake monitor cam settings.

048 Spare

049* C/B Valve On and No

Motion Detected

050 Spare

051*

052

Motion Detected with C/B

Valves Off

At Rest

Inch Button Tiedown

Upon command to move, no motion was detected.

Motion was detected when no motion was commanded.

On switching to inch, the software detected a held inch button.

The press will not start in single or continuous mode.

Check motion detector switch and wiring.

Check motion detector logic.

C/B outputs are de-energized.

Check motion detector switch and wiring.

The press will not inch.

Check motion detector logic.

Check prompts for reasons why press will not inch. Check inch button wiring.

053

054

Spare

At Rest

Run Button Tiedown

055*

056*

057*

058*

Micro Inch Valve 1

Failed to Turn ON

Micro Inch Valve 1

Failed to Turn OFF

Micro Inch Valve 2

Failed to Turn ON

Micro Inch Valve 2

Failed to Turn OFF

059-066 Spare

067*

068*

069*

070*

Clutch/Brake Dual Valve 1

Failed to Turn ON


Failed to Turn OFF


Failed to Turn ON


Failed to Turn OFF

071-074 Spare

075 Clutch Valve Fault

On switching to run, the software detected a held run button.

Valve failed to energize when output was turned ON.

Valve failed to de-energize when output was turned OFF.








The press will not run in single or continuous mode.

Press will not cycle.

C/B power is removed.








076-080 Spare


Check prompts for reasons why press will not run. Check run button wiring.

Check valve and valve wiring.










Processor Faults and Operator Prompts B–3

Prompts for

Operating the Press

Whenever the processor detects conditions worthy of a prompt, it sets corresponding Prompt #s or equivalent PanelView prompts.

We list conditions for which the software is designed to detect and signal a prompt. Prompts #s (read from the data table) are independent of interface module used.

Operator Prompts

Prompt

#

PanelView Prompt Cause of the Prompt

Condition

Effect of Prompt Condition How to Correct the Condition

001

002

003

004

005

Spare

E-Stop actuated

Select mode

Release buttons

Push buttons

E-stop button was pressed, or

E-stop circuit failed.

The press has stopped. You have not yet selected the operating mode.

Static-state tiedown fault:, with either fault message 051 (inch) or

052 (run).

Logic is ready to start, but you haven’t pressed run/inch buttons.

006-007 Spares

008

009

User Halted Downstroke

Prompt

Spare

User Inch/Downstroke is not set

010

011

User Start Permissive Missing User Permit Start/Inch/Run bit is not set

User Run Permissive Missing User Permit Run (Immediate

Stop) bit is not set.

012–013 Spares

014 Main motor is not running forward.

Main motor not running forward in single or continuous mode.

015

026

027

028

C/B power is not reset.

029

030

Other Processor Not Arming

Continuous

Other Processor Continuous

Not Engaged

031-079 Spares

080

Other Processor Inch Mode

Not Requested

Other Processor Inch Mode

Not Engaged

Other Processor Single Not

Engaged

Clutch/Brake Fault Present

Seal relay is not closed.

016–020 Spares

021 Stop-on-top button pressed.

The stop-on-top button is pressed.

022 Continuous mode not armed.

You did not press the arm continuous button.

023–025 Spares

Other Processor not requesting Inch Mode

Other Processor not engaging

Inch Mode


Single Mode

Other Processor not requesting Arm Continuous


Continuous Mode

CRM and seal relays opened.

Release E-stop btn. Press control reset and C/B power reset btns.

You cannot reset C/B power.

Select either Inch, Single, or

Continuous mode.

You cannot start the press.

Press is ready to start.

Press will not start in single or continuous mode

Valve outputs turn OFF.

Valve outputs remain OFF.

The press will complete the cycle and stop at top.

You cannot start the press in continuous mode.

You cannot Inch

You cannot Inch

Release run/inch buttons. Look for other fault or prompt messages.

You cannot start single stroke Check remote I/O wiring

You cannot start continuous stroke

You cannot start continuous stroke

Press run/inch buttons.

Determined by user

Determined by user

Determined by user

Start the main motor (forward).

Clear faults. Reset control power.

None

Press the arm continuous button.

Check remote I/O wiring





B–4

Notes:

Processor Faults and Operator Prompts


How We Present

Wiring Drawings

Appendix

C

Wiring Drawings

We show the following dc wiring drawings for your clutch/brake control.

Inputs and outputs by I/O module and slot location are as follows:

For

Power Distribution

Inputs to 1764–28BXB base unit of

Controller cross–checked inputs (same as cross–checked outputs, next)

Outputs to 1764–28BXB base unit

Cross–checked Outputs

•

OK To Energize Seal

•

BCD Mode

•

ACAM,BCAM,TCAM

•

Clutch Output ON

• Heartbeat

Inputs to 1769–IQ16 (dc) or 1769–IA16

(ac)

•

Mode Select

•

Emergency Stop Master Relay

•

Controller OK relays

•

Seal Relay

•


•


•

Controller B MicroInch 1 and 2 Output

Feedbacks

•

ACAM,BCAM,TCAM

Inputs to 1769–IQ16 (dc) or 1769–IA16

(ac)

•

Clutch/Brake Power Feedback

•

Clutch/Brake Air Pressure

•

Perimeter Guard A

•

Motion Detect

•

Main Motor Forward

•

Cycle Stop

•

Arm Continuous setup

•

Fault Reset

•

User Permits

•

Left and Right Run Stations

•

Left and Right Inch Pushbuttons

In I/O Module

Location

Base unit

Base unit

Base Unit

Slot 1

Slot 2

See

Drawing

Sheet

1 of 8

2 of 8

3 of 8

4 of 8

5 of 8


C–2 Wiring Drawings

For In I/O Module

Location

See

Drawing

Sheet

6 of 8 1769–OW8I (dc or ac) Outputs

• Perimeter Guard A Input

•

Controller Seal Relay

•

Controller OK Relay

•

Continuous Armed

•



•

Controller A Clutch/Brake 1 and 2

Output Feedbacks

•

Controller B Clutch/Brake 1 and 2

Output Feedbacks

•

Controller A MicroInch 1 and 2 Output

Feedbacks

•

Controller B MicroInch 1 and 2 Output

Feedbacks

Slot 3

Slot 4 7 of 8

Wire power supplies according to instructions that accompanied them.


Wiring Drawings C–3










































C–24

Notes:

Wiring Drawings


Index

A, B

abbreviations, P-1 advanced interface converter

(1761–NET–AIC),1-2, 3-1 audience, P-1 base unit (1764–28BXB), 3-1, 3-2 block diagram, 1-4

C

cables installation, 3-5 network interface module, 3-5 clutch, part-revolution, friction, 1-1 connections, to I/O modules, 3-10 – 3-13 control functions, C/B, 1-3 cross–check wiring, 3-7

D, E, F, G, H

dc version of controller, C-1 faults, processor, B-1 hardware, 1-1, 1-3, 3-2, 3-3

I, J, K

input switches list of, 1-5 installation, 3-4 installation cables, 3-5 hardware, 3-1 network interface module, 3-5 rotary cam limit switches, 3-3

I/O modules, in kit, 1-2 kit, contents of, 1-2

L, M, N

LEDs, in switch tests, 4-4 license, software, 1-1 network interface module, 3-1, 3-5

O

operating modes of C/B description of, 1-3, A-1 testing of, 5-2 operator prompts, B-3 output s, 1-6 overview of C/B control, 1-1

P, Q

panel switches, 1-5 power supply, 3-1 processor (1747-LSP) faults, B-1 protected memory, 1-2 redundant use, 1-2 quickstart, 2-1

R

response time, of C/B control, 1-6 rotary cam limit switches installation, 3-3 on/off settings, 3-4 troubleshooting, 5-1

S

safety information, 1-7 specifications, 1-8 switches, 1-5


I–2 Index

T, U, V

terms, P-1, 1-3 testing circuits and fault modes, 4-1 operating modes of C/B, 5-2 switches, 5-3 switches with LEDs, 4-4 troubleshooting operator prompts, B-3 processor faults, B-1 rotary cam limit switches, 5-1

W, X, Y, Z

wiring, 3-7, 3-8, 3-9, C-1 dc version, C-1



Publication 6556-UM001A–EN–P August 2000 PN 957293-25

Copyright 2000 Rockwell International Corporation. Printed in USA

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