Rockwell Automation 1771-PM, D17716.5.18 User Manual

AllenBradley

Clutch/Brake
Module

User

(Cat. No. 1771-PM)

Manual

Table of Contents

Introduction 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Objectives
How To Use This Manual 11
Terminology 12
Firmware Revision Record 12

Objectives

Of This Manual

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

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

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

11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Press System Description 21. . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
System Components 21
Figure 2.1

Related

Objectives

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

Functional Block Diagram 22. . . . . . . . . . . . . . . . . . . . . . . . . . .

Safety Documentation

21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23. . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch/Brake Controller Hardware 31. . . . . . . . . . . . . . . . . . .

Chapter
General Hardware Considerations 31
Description of your Clutch/Brake Controller 31
Twinaxial Cable Connections 34
Multiple Clutch/Brake Controllers 36
Panel Switches and Operator Stations 36
Interlock Switches 37
Configuring Your Clutch/Brake Controller 37
Rack Address of Chassis A and B 39
Setting
Response Time 311
Module
Keying 314

Objectives

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

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

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

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

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

the Communication Rate

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

Placement

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

31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

311. . . . . . . . . . . . . . . . . . . . . . . . .

312. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PLC

Ladder Programming

Chapter
Programming Fundamentals 41
Configuration Rungs 43
Matching Configuration Bits and Backplane Switches 47
PLC Command Rungs 48
Summary of PLC Configuration and Command Rungs 412
Module Group 5, Slot 0 Reserved for MicroInch 413
Module Groups 6 and 7 Reserved for Data Storage 413
Monitoring Clutch/Brake Controller Inputs and Outputs 413
Report Generation 414
Summary of Clutch/Brake Controller Functions 415

Objectives

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

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

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41. . . . . . . . . . . . . . . . . . . . . . . . .

41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Table of Contentsii

Voting Processor Firmware 51. . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Operation
Emergency Shut Down 51
Fault
Operation
Clutch/Brake Operating Modes 55

Objectives

of V

oting Processors 51. . . . . . . . . . . . . . . . . . . . . . . . . .

Monitoring

of Cam Limit Switches

51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53. . . . . . . . . . . . . . . . . . . . . . . . .

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

Connections to Field Wiring Arms 61. . . . . . . . . . . . . . . . . . .

Chapter
Installation Considerations 61
Electrical Connections and Safety Requirements 61
Control Power 63
EStop Switches, Seal Relays, and Crowbar Relays 63
Crowbar T
Optional Hardwire Inputs 65
Internal/External
Optional

Main Valve Solenoids A and B 68
Optional Auxiliary Valve Solenoids 69
Optional Dump Valve Solenoids 69
Optional Microinch Valve Solenoids 610
Electrical Noise Suppression 611
Cam
Required Hardwire Inputs 622
Inch Buttons and PlugIn Operator Stations 624
Optional Binary Display 627
Optional Indicators 627
Lamp Test 631
Inputs to Chassis C 631

Objectives

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

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

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

. . . . . . . . . . .

est Inputs

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

Fault Detection

Valve

Stem Switches,
Motion Detectors, and
Air Pressure Switches 67

Limit Switches

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

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

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

61. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

64. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

66. . . . . . . . . . . . . . . . . . . . . . . . .

620. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Troubleshooting 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Chapter
Troubleshooting Considerations and Requirements 71
Troubleshooting
General Troubleshooting Procedure 74
Troubleshooting
Troubleshooting Example 76
Display of Diagnostic Message Codes 78
Types of Diagnostic Message Codes 79
Messagecode Priority 712
Processing Diagnostic Message Codes 713

Objectives

with LED'

Hints

71. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

s 71. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

Table of Contents iii

Diagnostic Message Codes (Table 7.C) 713. . . . . . . . . . . . . . . . . . . .

Complete Listing of diagnostic message codes 723
Summary 737
Diagnostic diagnostic message codes in T

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

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

able 7.C

737. . . . . . . . . . . .

Bit Monitoring Addresses A1. . . . . . . . . . . . . . . . . . . . . . . . .

I/O FROM /T

O LISTS

B1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Introduction

Chapter

1

Chapter Objectives

Objectives Of This Manual

How To Use This Manual

This chapter will help you become familiar with the:

objectives of this manual
procedure for using this manual

We have written this manual to help an electrical engineering technician,
or any person with a similar background:

design a clutch/brake controller for a mechanical power press using the

1771-PM clutch/brake module.
install the clutch/brake controller
troubleshoot the clutch/brake controller

The overall safety of your mechanical power press rests upon your
knowledge of this manual and other referenced documents. Moreover, the
ease with which you can understand each chapter rests upon your
knowledge of previous chapters.

To simplify your installation and maintenance tasks, we recommend that
you become familiar with this entire manual before installing your
clutch/brake controller. The following suggestions should help you use
this manual:

Before reading this manual, scan through it. This will help you

understand its organization.
Before installing your clutch/brake controller, read this manual

thoroughly. You should also read other publications that we refer.
While installing or troubleshooting your clutch/brake controller, use

this manual as a reference.

11

Chapter 1

Introduction

Terminology

Firmware Revision Record

We define new terms where they first appear in this manual. You should
be familiar with the following terms because we use them throughout this
manual.

a press is a mechanical (part revolution) power press that is actuated by

a clutch and stopped by a brake
a clutch/brake controller is an Allen-Bradley controller, which

includes chassis A and B, two Clutch/Brake Modules (cat. no.

1771-PM), and associated I/O modules.
a press system includes your mechanical power press, clutch/brake

controller, and all associated wiring and components.
a PLC is any Allen-Bradley programmable controller that has 1771

remote I/O operation.
TCAM is the acronym for Top-Stop-Check Cam switch
ACAM is the acronym for Anti-repeat Cam switch
RCAM is the acronym for Run-on Cam switch

The firmware has been revised as follows:

Firmware

Revision Change in operation

A/B Micro-inch added
A/C None

(corrected intermittent stoppage in continuous mode)
A/D Motion detector time-out increased to 4 sec
A/E None

(corrected intermittent communications problem)

12

Chapter

Press System Description

2

Chapter Objectives

System Components

This chapter will help you become familiar with:

major components of a typical press system
safety requirements for a press system

A press system, as referred to in this manual, includes:

a mechanical power press
an Allen-Bradley clutch/brake controller
all associated control panels and operator stations
all associated output and feedback devices
all wires and cables that interconnect system components

A functional block diagram of a typical press system is shown in
Figure 2.1. This figure shows general relationships between major
components. Specific functional relationships vary according to the
requirements of your particular press system. For details, refer to;

chapters 3 thru 7 of this manual
technical documentation provided by your press manufacturer
ANSI B11.1, American National Standard for Machine Tools,

Mechanical Power Presses, Construction, Care, and Use

Important: Use an Allen-Bradley clutch/brake controller only with a
mechanical power press that has a part-revolution clutch. A
part-revolution clutch can be disengaged at any position of the shaft. This
allows your clutch/brake controller to stop the press at any position. In
contrast, a full-revolution clutch can be disengaged and stop the press
only at the top position of the stroke.

21

Chapter 2

Press System Description

Figure 2.1
Functional Block Diagram

Triac
Outputs
to Main

Solenoids

Clutch/Brake Assembly

Flywheel

Cam

Switch

Assembly

Operator

Station

No. 1

Operator

Station

No. 2

Allen - Bradley Clutch/Brake Controller

- Monitors operator inputs

- Monitors shaft position using cam limit switch feedback

- Controls the press using solenoid triac outputs

Main Solenoid Valves

Air to Clutch

Operator

Station

No. 3

Air Supply

Press

Operator

Station

No. 4

Cam Switch

Feedback

Inputs

Cam

Switch

Assembly

22

Crankshaft

Shaft at Top Position

Shaft at Bottom Position

12245

Chapter 2

Press System Description

Related Safety Documentation

This manual concentrates on safety considerations relative to the
clutch/brake controller. Study this entire manual and all technical
documentation provided by the press manufacturer before you install your
press system. In addition to local codes and laws, follow the safety
requirements detailed in the following publications:

OSHA Regulations, Title 29-Labor, Chapter XVII, Section 1910.217,

Mechanical Power Presses

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

Mechanical Power Presses, Construction, Care, and Use

NFPA No. 79, Electrical Standard for Metalworking Machine Tools

23

Chapter

3

Clutch/Brake Controller Hardware

Chapter Objectives

General Hardware Considerations

This chapter will help you become familiar with the:

hardware components of your Allen-Bradley clutch/brake controller
functional relationships between your PLC and clutch/brake controller
interconnections between your PLC and clutch/brake controller
switch settings that configure your clutch/brake controller and establish

its rack addresses

For details on how to install the I/O chassis and modules, refer to the
installation publications that apply to your particular PLC. These
publications, listed in our Publications Index (publication SD-499),
discuss general layout rules, mounting dimensions, enclosure
considerations, module keying, and field wiring arm connection
technique.

Important: If you are using a large mechanical power press that
generates high levels of shock and vibration, we recommend that you
shock-mount each I/O chassis of your clutch/brake controller.

Important: Electrostatic discharge can damage integrated circuits or semi
conductors in the PM Module if you touch backplane connector pins or
internal components.

Description of your Clutch/Brake Controller

CAUTION: Rid yourself of charge before handling the module
by touching a grounded object.

Your clutch/brake controller consists of chassis A and B connected to
your PLC in a serial chain with remote I/O chassis, as shown in
Figure 3.1. Table 3.A. lists required and optional clutch/brake controller
hardware.

Chassis A and B are similar to remote I/O chassis. The major difference
is that the left-most slot of chassis A and B contains a clutch/brake
module. In contrast, the left-most slot of an I/O chassis contains an I/O
adapter module.

31

Chapter 3

Clutch/Brake Controller Hardware

Figure 3.1
Overview

Remote I/O

Communications

A-B Programmable Controller

with Remote I/O

of a Clutch/Brake Controller

Remote

I/O

Clutch/Brake

Remote

I/O

Voting Processor A

Clutch/Brake Module

Chassis A

Voting Processor B

Clutch/Brake Module

Chassis B

Remote I/O
Adapter Module

Remote

I/O

Chassis C

Remote I/O
Adapter Module

Remote I/O Chassis

other I/O chassis
independent of the
Clutch/Brake Controller

12246

32

Table 3.A
Required and Optional Hardware

Chapter 3

Clutch/Brake Controller Hardware

Quantity Item

Important: (Y

2

2

2

10

2

2

1

2

2

2

ou must use 8point modules with 2slot addressing)

Clutch/Brake Module

Wiring Arm

I/O Chassis

120V AC Input Modules

120V AC Isolated Output Modules
(Series C)

120V AC Output Modules

120AC Output Module

120V AC Input Modules

120V AC Isolated Output Modules
(Series C)

I/O chassis

Cat. No.

Required Hardware

1771PM

1771WB

1771A2B

1771IA

1771OD

Optional Hardware

1771OA

1771OA

1771IA

1771OD

1771A4B

Function

Monitors and controls the press

Connections to 1771PM

Contains the modules

Monitors press inputs

Controls press outputs

Display of diagnostic messages

Controls optional indicators

Dump valve circuit

Dump valve and/or microinch circuit

Substitute chassis when using the
optional dump valve circuit.

1

2

2

120V AC Output Module

120V AC Input Modules

120V AC Input Modules

1771OA

1771IA

1771IA

Microinch indicator

Microinch circuit

Additional operator stations

Clutch/brake modules operate in parallel to monitor and control your
press. Clutch/brake modules are also called “voting processors” because
they must always have a consensus. Unless both voting processors
constantly agree that they sense identical conditions in your clutch/brake
press system, either or both voting processors stop press motion or
prevent it from starting.

Your clutch/brake controller monitors and controls your press. Although
your PLC does not control your press, it does configure and enable the
clutch/brake controller. Your PLC ladder program can monitor inputs to,
and the status of, your clutch/brake controller. This allows your PLC to
control other indicators, machines, or processes related to your press
system.

33

Chapter 3

Clutch/Brake Controller Hardware

In addition to chassis A and B, you must connect your PLC to at least one
local or remote I/O chassis, chassis C. You need two, three, or four inputs
at a local or remote I/O chassis.

Important: You must use 2-slot addressing and 8-point (single-density)
I/O modules.

Twinaxial Cable Connections

Typical twinaxial cable connections of your clutch/brake controller are
shown in Figure 3.2. Connect your clutch/brake controller to your PLC as
part of its remote I/O distribution network. Use Twinaxial Cable (cat.no.
1770-CD) and Terminators (cat. no. 1770-XT).

Connect chassis A next to chassis B in the serial chain as shown in
Figure 3.2. You may connect one or more remote I/O chassis in the same
serial chain. Also, you may connect remote I/O chassis to other
distribution channels at the I/O scanner module of your PLC.

Connect four Terminator Resistors (cat. No. 1770-XT) as shown in
Figure 3.2. Connect one at:

the scanner module
the last chassis, whether it is a clutch/brake chassis or a remote I/O

chassis

each end of the cable that connects chassis A and B at terminals 7, 8

and 9 of the 1771-PM module field wiring arms

For more information on how to connect remote I/O channels, refer to the
installation publications that apply to your particular PLC. Also refer to
Product Data of the Remote I/O Adapter Module. These publications are
listed in our Publications Index (publication SD499)

34

Terminator
(cat. no.
1770 -XT)

Figure 3.2
Typical

Processor/Scanner

Shield

Clear

T

winaxial Cable Connections

Blue

Chapter 3

Clutch/Brake Controller Hardware

Use Twinaxial Cable
(cat. no. 1770 -CD)
for all cable connections.

Chassis A

Terminator
(cat. no.
1770-XT)

Terminal Strip on 1772 - SD,
SD2 Remote I/O Scanner/
Distribution Module (PLC - 2)

or

Terminal Block on
1775 - S4A, - S4B, -S5,

I/O Scanner Module (PLC -2)

or

Connector on PLC - 5
Processor

or

Connector on 5/50 - RS2
Remote I/O Scanner (PLC -5/250)

Chassis C

Blue

Shield

Clear

Remote
I/O Chassis
1771 -ASB
Adapter
Module

Blue

Shield

Clear

Blue

Shield

Clear

1771 - PM
Module

Shield

Clear

Shield

Clear

Blue

Blue

Blue

Shield

Clear

Terminator
(cat. no.
1770 -XT)

1771 - WB
Wiring Arm

Chassis B

Blue

Shield

Clear

Terminator
(cat. no.
1770 -XT)

1771 - WB
Wiring Arm

1771 - PM
Module

12248

35

Chapter 3

Clutch/Brake Controller Hardware

Multiple Clutch/Brake Controllers

Panel Switches and Operator Stations

Although this manual describes a single clutch/brake controller, you may
connect your PLC to multiple controllers, each controlling a separate
press. Each clutch/brake controller uses two remote I/O racks for chassis
A and B. For example, since a PLC-3 controller can support as many as
32 I/O racks, you may connect it to as many as 15 clutch/brake controllers
with two additional I/O racks for modules in chassis C.

You can operate your press using up to four operator stations and an
optional control panel. Installations vary according to the type of
mechanical press and its application requirements. The number of
stations, control switches contained in each, and the control panel could
be as follows:

Assembly Control

Control Panel and/or Station 1

Mode select
Arm continuous
Stopontop
L/R Inch
Press enable
Reset latched messages
Lamp test
L/R Run
EStop

Switches

Notes

1
1

1 and/or 3

2
3
3
3
2
2

Stations 2 thru 4

1 Connect these switches to input modules in chassis A and B (Figure 6.10).
2 Connect these switches to input modules in chassis A and B (Figures 6.11 thru

6.12).
3 These switches are inputs for command rungs (Figures 4.6 thru 4.8). Connect
these

switches to input modules in remote I/O chassis C (Figure 6.15).

L/R Run
Stop On T
EStop

op

2

2 and/or 3

2

36

Chapter 3

Clutch/Brake Controller Hardware

Interlock Switches

Configuring Your Clutch/Brake Controller

Various interlock switches are required for safety as specified in ANSI
B11.1. The locations, types, and quantities vary with the type of
mechanical press and its application requirements. Use these interlock
switches to prevent the press from starting or to stop the press when
operation could cause injury to personnel or damage to the press.

Interlock

Barrier guard

Press interlock

Motion detector

Main motor forward

Cam limit switch assembly

topstopcheck (TCAM)

runon (RCAM)
antirepeat (ACAM)

Switch

Quantity Reference

1 or more

1

1

1

2

Figures 6.10 and 6.15

Figures 6.1 and 6.5

Figure 6.2 and 6.6

Figure 6.10

Figure 6.9

You have flexibility in selecting clutch/brake controller functions. You
may select any of the following functions according to your application
requirements by setting switches on the I/O chassis.

Operator station 3 and 4
Motion detector feedback
Valve stem feedback
Air pressure feedback
Ungrounded or grounded AC power
On-the-hop
Half stroke, or Stroke-and-a-half
Dump valve circuit
Micro-inch

37

Chapter 3

Clutch/Brake Controller Hardware

Always OFF

1234

O
N

O
F
F

Switch
No:

IMPORTANT:

Figure 3.3
Backplane

Backplane

Assembly

2

3

4

5

6

7

8

Switch Settings

Chassis
A and B

Switches

5678

Position:

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

Make backplane switch settings in chassis A and B identical.

ON

OFF

OFF

Function:

Use Stations 3 and 4

Stations 3 and 4 not used

Use Motion Detector Feedbck

Motion Detector Feedback not used

Use Valve Stem Feedback

Valve Stem Feedback not used

Use Air Pressure Feedback

Air Pressure Feedback not used

Ungrounded AC Power

Grounded AC Power

Use On-The-Hop

On-The-Hop not used

Use HalfStoke

Use StrokeAndAHalf

12249

38

Chapter 3

Clutch/Brake Controller Hardware

Important: There is no backplane switch setting to configure the optional
dump valve circuit. You configure the optional dump valve circuit by
inserting dump valve modules (cat. no. 1771-OD and 1771-IA) into
module group 4, slots 0 and 1, respectively of chassis A and B. You must
also set bit 14 unconditionally in your configuration rungs.

Important: To configure your clutch/brake controller for Micro-inch, see
chapter 4 “Module Group 5, Slot 0 Reserved for Micro-inch”.

Important: Your PLC ladder program must include unconditioned
configuration rungs that set or reset configuration bits to match the
settings of backplane switches. Refer to chapter 4.

Rack Address of Chassis A and B

Establish the address of chassis A and B in each clutch/brake module so
the PLC can communicate with it. Use valid rack addresses as
determined by your PLC.

Switch assembly SW-1 determines the rack address. It is located under a
sliding cover plate on the left side of the clutch/brake module near the top.
Loosen the two screws holding the cover plate and slide it open. Locate
switch assembly SW-1 at the top of the printed circuit board as shown in
Figure 3.4.

Using switch assembly SW-1, designate chassis A and B as follows:

Chassis A - any rack address having position 6 OFF
Chassis B - next consecutive upper or lower rack address

Important: If your ladder program monitors rack adapter fault bits for
each chassis containing a clutch/brake module, the fault bits will indicate
a faulted rack whenever the module trips power to I/O swingarms. This is
because clutch/brake modules stop all communciation with the PLC until
they verify that swingarm power has been disconnected.

Important: Always configure I/O racks assigned to clutch/brake
controllers as full

racks, so the PLC can write configuration bits to each

PM chassis in Module Group 7.

39

Chapter 3

Clutch/Brake Controller Hardware

Figure 3.4

Address Switch Setting on 1771PM Module

Rack

1234

O

N

O
F
F

SW-1

5678

Rack Addresses

PLC-2/30
PLC-5/25

1
2
3
4
5
6
7

SW-2

1234

O

Always ON (star
Module Group 0)

ting

N

O
F
F

ON

OFF

OFF

Always OFF

Always ON(57.6K baud)

Switch Assembly SW-1 Position

PLC-3

PLC-5/250

00
01
02
03
04
05
06
07
10
11
12
13
14
15
16
17
20
21
22
23
24
25
26
27
30
31
32
33
34
35
36
37

NOTE: Chassis A and B must have consecutive rack address

on
on
on
on
on
on
on
on
on
on
on
on
on
on
on
on
on
on
on
on
on
on
on
on
on
on
on
on
on
on
on
on

1

on
on
on
on
on
on
on
on
on
on
on
on
on
on
on
on
off
off
off
off
off
off
off
off
off
off
off
off
off
off
off
off

2

on
on
on
on
on
on
on
on
off
off
off
off
off
off
off
off
on
on
on
on
on
on
on
on
off
off
off
off
off
off
off
off

3

4

on
on
on
on
off
off
off
off
on
on
on
on
off
off
off
off
on
on
on
on
off
off
off
off
on
on
on
on
off
off
off
off

5

on
on
off
off
on
on
off
off
on
on
off
off
on
on
off
off
on
on
off
off
on
on
off
off
on
on
off
off
on
on
off
off

es.

on
off
on
off
on
off
on
off
on
off
on
off
on
off
on
off
on
off
on
off
on
off
on
off
on
off
on
off
on
off
on
off

Chassis

6

B
A
B
A
B
A
B
A
B
A
B
A
B
A
B
A
B
A
B
A
B
A
B
A
B
A
B
A
B
A
B
A

12250

310

Chapter 3

Clutch/Brake Controller Hardware

For example, if you choose rack address 2 for chassis A, you must choose
rack address 1 or 3 for chassis B.

Set the rack address in each clutch/brake module. Place a label on each
clutch/brake module to identify in which chassis, A or B, it belongs.

Important: Chassis A and B rack addresses must be unique. No I/O
chassis can have the same rack address as either chassis A or B. This
restriction prohibits using the rack address of either chassis A or B for any
complementary I/O chassis (a chassis with the same module addresses but
having input modules where chassis A and B have output modules, and
output modules where chassis A and B have input modules). This
restriction also prohibits using the rack address of either chassis A or B
for any partial remote I/O chassis (a chassis that starts with module group
2, 4, or 6). (Refer to chapter 4, Module Group 7, PLC Command Rungs,
for reasons why you must restrict the use of this address.)

Setting the Communication Rate

Response Time

Triacs of your clutch/brake controller turn on in sequential order. Triacs
connected to the high AC power line (L1) turn on before those in the
triac-solenoid string connected to the low AC power line (L2). If the
addresses are reversed, the triacs will turn on out of sequence, and the
clutch/brake controller will not operate.

Set switch 1 on switch assembly SW-2 to the ON position. This sets the
module’s communication rate at 57.6K baud. Be sure that you set the
communication rate of both 1771-PM modules and the processor’s
scanner to 57.6K baud, as well.

The worst case time required for the clutch/brake controller to respond to
a change of input depends on Module-response and triac-switching times:

Delay

Characteristic

1771IA

module

response time

1771PM module
response time

T

riac switching time

T

otal response time

(ms)

26

10

8

44

311

Chapter 3

Clutch/Brake Controller Hardware

The number of degrees that the shaft continues to rotate, beyond the
moment in time when the input changes, depends on the speed of rotation.
The greater the number of strokes per minute (SPM), the further the shaft
rotates before a command from the clutch/brake controller is applied. The
response time of 44ms is represented in degrees of shaft rotation that
increases as the rate of press operation increases (Figure 3.5).

Figure 3.5
Response

Time of Clutch Brake Controller

SPM

100

90
80
70
60
50
40
30
20
10

0

0 5 10 15 20 25

DegreesofShaftRotation

12251

Important: When estimating the braking distance in degrees of rotation,
add the response time of the controller (Figure 3.5) to the specified
downstroke or upstroke braking distance of your press.

Module Placement

312

Locations of all clutch/brake controller modules are shown in Figure 3.6.
Note that some of these modules are optional.

CAUTION: Do not place any I/O module in module groups
6 or 7 of chassis A or B. These module group locations are
non-functional and reserved for future use. If you use a slot
power supply, install it in module group 7.

Important: Use series C or later 1771-OD modules because they have
improved electrical noise immunity. Refer to Electrical Noise
Suppression, in chapter 6, for a method of suppressing surge transient
noise.

1771 -PM
module

Figure 3.6

Locations

Module

Required 1771 -IA modules for
press inputs chassis A & B
module group 0, slots 0 & 1
module group 1, slot 1
module group 2, slots 0 & 1

01234567

Chapter 3

Clutch/Brake Controller Hardware

Optional 1771 -OA modules for display of
message codes, brake fault, run window and micro inch.
module group 3, slot 1 chassis A
module group 5, slot 1, chassis A & B
Optional 1771 -IA modules for micro-inch inputs, chassis A & B
mdoule group 5, slot 0

Chassis A
1771 -A4, -A4B

Optional 1771 -IA modules for station 3 & 4
inputs chassis A & B (remove them if you do
not configure for stations 3 & 4
module group 1, slot 0

01234567

1771 -PM
module

Chassis A
1771 -A4, -A4B

Required 1771 -OD modules for outputs
to solenoid valves, Chassis A & B
module group 3, slot 0
Optional micro -inch indicator, chassis B
1771 -OA, module group 3, slot 1

Important: Use 1771A2, A2B chassis when not using optional dump valves,

display of diagnostic message codes, nor microinch inputs.

These slots must remain empty in chassis A & B
module group 6, slots 0 & 1
module group 7, slots 0 & 1

Optional modules for dump
valve in chassis A & B
1771 -OD, module group 4, slot 0
1771 -IA, module group 4, slot 1

12247

313

Chapter 3

Clutch/Brake Controller Hardware

Keying

Install the keying bands on the I/O chassis backplane connector as shown
in Figure 3.7. After you install keying bands in chassis A and B, you can
insert only a clutch/brake module in the left-most slot of chassis A and B.

Figure 3.7
Keying

Chassis A and B

2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56

2
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32
34
36
38
40
42
44
46
48
50
52
54
56

Insert keying bands so that you
can install only a 1771-PM
module in this slot.

12252

314

Chapter

PLC Ladder Programming

4

Chapter Objectives

Programming Fundamentals

This chapter will help you become familiar with:

programming fundamentals as they relate to your clutch/brake

controller

the need for press configuration rungs
relationships between your press configuration rungs and backplane

switch settings

relationships between configuration rungs and voting processor

firmware

the option of monitoring the press through your PLC ladder program
the option of using PLC report generation to display messages that you

have stored.

Your PLC ladder program is composed of instructions that you enter into
PLC memory. These instructions are organized into rungs. They
typically monitor inputs and control outputs.

Your PLC ladder program does not control your clutch/brake controller,
but it does configure and enable it. Although your ladder program cannot
control any clutch/brake controller outputs, it controls output image table
bits to configure and enable the voting processors. Your ladder program
may examine input image table bits to monitor clutch/brake controller
functions as we will explain later.

This chapter concentrates on PLC ladder programming that relates to your
clutch/brake controller. For more details on ladder programming, refer to
the programming manual that applies to your PLC processor. These
publications are listed in our Systems Division Publication Index
(publication SD499).

PLC ladder programming is described in this chapter as it relates to
clutch/brake controller hardware and voting processor firmware
(Figure 4.1).

41

Chapter 4

PC Ladder Programming

Figure 4.1
Overview

A-B Programmable Controller
with Remote I/O

Your ladder diagram
program configures and
enables voting processors
A and B, while it monitors
and controls I/O through
remote I/O adapters.

I/O Control Rungs

of Clutch/Brake Controller

Thefirmwareinvoting
processors A and B
monitors and controls the press.

1771 - PM

Voting

Processor

1771 - PM

Voting

Processor

1771 - ASB
Remote I/O

Adapter

Chassis

A

Chassis

B

Chassis

C

(optional)

C/B
Press

PLC
Ladder
Program

Configuration Rungs

I/O Control Rungs

Configuration

Switch

Inputs

Other inputs
that are
independent
of the
Clutch/brake
controller

12253

42

Chapter 4

PC Ladder Programming

Configuration Rungs

You have flexibility in selecting clutch/brake controller functions by
setting/resetting configuration bits. Use any of the following functions
according to your application requirements:

Functions Bit

3 and 4

Stations

Motion detector feedback

alve stem feedback

V

Air pressure feedback

Ungrounded or grounded AC power

Onthehop 06

Halfstroke or Strokeandahalf

Dump valve circuit

01

02

03

04

05

07

14

You enable various functions by programming configuration rungs to set
(turn on) or reset (turn off) configuration bits 01 thru 07 and 14 in the
output image table word for module group 7, chassis A and chassis B.
Bit addresses are shown in Figure 4.2. Example configuration rungs are
shown in Figure 4.3 through Figure 4.5. Program your configuration
rungs according to the requirements of your press system.

Be sure to set or reset each configuration bit 01 thru 07 and 14 with
unconditioned rungs. They contain only output instructions, such as latch,
unlatch, or output energize. Bits set by these rungs do not change during
press operation. The latching or unlatching of these bits must correspond
with backplane switch settings covered in chapter 3.

Figure 4.2

addresses of Output Image T

Bit

PLC-2/20 PLC-3
PLC-2/30 PLC-5/250

0y7/xx Oyy7/xx O:y7/xx

where yy = rack address per Figure 3.4
xx = bit number 00 - 17

Important: Do not use bits 00 and 15-17 for any purpose.

able W

ord for Module Group 7 of Chassis A & B

PLC-5

43

Chapter 4

PC Ladder Programming

Figure 4.3
Example

Stations 3 and 4 not used

Motion detector feedback used

Valve stem switch feedback used

Air pressure switch feedback not used

PLC Configuration Rungs for Bits 01 thru 07 and 14 (PLC2 Family)

057

U

01

067

U

01

057

L

02

067

L

02

057

L

03

067

L

03

057

U

04

067

U

04

Ungrounded AC power

On-the-hop not used

Strokeandahalf used

Optional dump valve triacs used

057

L

05

067

L

05

057

U

06

067

U

06

057

U

07

067

U

07

057

L

14

067

L

14

44

Chapter 4

PC Ladder Programming

Figure 4.4
Example PLC Configuration Rungs for Bits 01 thru 07 and 14
(PLC3 and PLC5/250)

Stations 3 and 4 not used

Motion detector feedback used

Valve stem switch feedback used

Air pressure switch feedback not used

Ungrounded AC power

O0057

U

01

O0057

L

02

O0057

L

03

O0057

U

04

O0057

L

05

O0067

(

U

01

O0067

)

(

L

02

)

)

)

O0067

(

L

O0067

(

U

O0067

(

L

03

04

05

On-the-hop not used

Half-stroke or Stroke-and-a-half used

Optional dump valve triacs used

NOTE: Unconditionally latch or unlatch bits 0 through 7 and 14 for chassis A and B as shown to use these functions.

Use this address format for PLC-5/250 processors

O:057

U

01

)

O:067

(

U

01

O0057

U

06

O0057

U

07

O0057

L

14

)

)

)

O0067

(

U

O0067

(

U

O0067

(

L

06

07

14

45

Chapter 4

PC Ladder Programming

Figure 4.5
Example PLC Configuration Rungs for Bits 01thru 07 and 14
(PLC5 family)

Stations 3 and 4 not used

Motion detector feedback used

Valve stem switch feedback used

Air pressure switch feedback not used

Ungrounded AC power

On-the-hop not used

Stroke-and-a-half or Half-stroke used

Optional dump valve triacs used

NOTE: Unconditionally latch or unlatch bits 0 through 7 and 14 for chassis A and B as shown to use these functions.

(

O:57

(

(

(

(

(

(

(

O:67

O:57

U

01

O:67

U

01

L

02

O:67

L

02

O:57

L

03
O:67
L

03

O:57
U

04

O:67

U

04

O:57

L

05
O:67
L

05

O:57

U

06

O:67

U

06

O:57

U

07

O:67

U

07

O:57
L

14

L

14

)

)

)

46

Chapter 4

PC Ladder Programming

Matching Configuration Bits and Backplane Switches

As listed in Table 4.A, backplane switch positions 2 thru 8 correspond
with configuration bits 01 thru 07. The voting processors in your
clutch/brake modules allow press operation only if the set (on) and reset
(off) states of configuration bits in your program correctly match the ON
and OFF settings of corresponding backplane switches. The voting
processors check for correct configuration when you apply power to your
clutch/brake controller or change its mode of operation using the mode
select switch.

Table 4.A
Corresponding

Backplane

Switch

Settings

(figure 3.3)

Pos. Setting Bit: Status: Function:

2 ON 01 Set

Backplane Switch Settings and Configuration Bits

Configuration

Bits

OFF reset

Backplane switch settings and configuration bits
must be identical

Use Stations 3 and 4

Stations 3 and 4 not used

3 ON 02 set

OFF reset

4 ON 03 set

OFF reset V

5 ON 04 set

OFF reset

6 ON 05 set

OFF reset

7 ON 06 set

OFF reset

8 ON 07 set

OFF reset

Module Group 4
Slot 1, Chassis A&B
1771IA

Module Group 4
Slot 1, Chassis A&B
is EMPTY

14

Set

reset

Use Motion Detector Feedback

Motion Detector Feedback not used

Use V

alve Stem Feedback

alve Stem Feedback not used

Use Air Pressure Feedback

Air Pressure Feedback not used

Ungrounded AC Power

Grounded AC Power

Use OnTheHop

OnTheHop not used

Use Halfstroke

Use StrokeAndAHalf

Use Dump V

alve Outputs

Dump V

alve Outputs not used

47