Rockwell Automation 1771-PM, D17716.5.18 User Manual

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AllenBradley

Clutch/Brake Module

User

(Cat. No. 1771-PM)

Manual

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

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

Objectives

Of This Manual

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

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

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

Chapter System Components 21 Figure 2.1

Objectives

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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

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Placement

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

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

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

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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

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est Inputs

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

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

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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

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able 7.C

737. . . . . . . . . . . .

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

I/O FROM /T

O LISTS

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

Introduction

Chapter

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

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

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

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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.

120V AC Output Module

120V AC Input Modules

1771OA

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

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)

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

I/O Scanner Module (PLC -2)

Connector on PLC - 5 Processor

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

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

2 and/or 3

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

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

Switch Settings

Chassis A and B

Switches

5678

Position:

OFF

Make backplane switch settings in chassis A and B identical.

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 F F

SW-1

5678

Rack Addresses

PLC-2/30 PLC-5/25

1 2 3 4 5 6 7

SW-2

1234

Always ON (star Module Group 0)

ting

O F F

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

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

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

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

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

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

riac switching time

otal response time

(ms)

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 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

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

12252

314

Chapter

PLC Ladder Programming

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

(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

Air pressure feedback

Ungrounded or grounded AC power

Onthehop 06

Halfstroke or Strokeandahalf

Dump valve circuit

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

067

057

067

057

067

057

067

Ungrounded AC power

On-the-hop not used

Strokeandahalf used

Optional dump valve triacs used

057

067

057

067

057

067

057

067

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

O0067

(

O0067

)

(

)

O0067

(

O0067

(

O0067

(

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

)

O:067

(

O0057

)

O0067

(

O0067

(

O0067

(

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

O:67

O:57

03 O:67 L

O:57 U

O:67

O:57

05 O:67 L

O:57

O:67

O:57

O:67

O:57 L

)

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

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

Chapter 4

PC Ladder Programming

PLC Command Rungs

Your ladder diagram program can send four commands to the clutch/brake controller by setting command bits 10-13 in the output image word for module group (MG) 7, Slot 1 for I/O chassis A and B:

Command Bit

enable

Press Stopontop Reset latched messages Lamp test

10 11 12 13

These commands can be issued manually by an operator pushing a switch, or automatically by a switch closure in your machinery. They function as follows:

Output Status Condition

Press Enable

Bit 10

Stopontop

(Continuous mode, only)

Bit 1

must be ON

OFF

offtoon transition

must be OFF

o enable motion in any mode

Immediately turns OFF triac outputs

urns OFF solenoid outputs the next time the

runon cam switches open

o start or maintain continuous stroking

Controlled by PM Module

Reset Latched Message

Bit 12

Lamp T

est

Bit 13

Holding this bit ON may inhibit the capture of subsequent L or t messages.

offtoon transition

OFF

Clears any latched or tripped message code

shown in MG 5, Slot 1, as long as the condition that caused the message no longer exists.

urns ON all these outputs Brake Fault , Run Window and other diagnostic message lamps

urns OFF these outputs

Bit addresses for these command bits are shown in Figure 4.2. Example PLC command rungs are shown in Figure 4.6 through Figure 4.8.

To enable these commands, write ladder program rungs that are conditioned with examine-on/examine-off instructions to monitor corresponding switch inputs wired to I/O chassis C. You can use any available discrete module terminals (excluding those in chassis A or B) for these inputs (Figure 6.15). For additional information refer to chapter 6, Inputs to Chassis C .

, Microinch Message,

48

Chapter 4

PC Ladder Programming

132

PRESS ENABLE Switch

STOP-ON-TOP Switch

RESET Switch

Figure 4.6 Example

Optional conditions

Enable Press Operation

Command Stop-on-top

Reset latched messages

PLC Command Rungs for Bits 10 thru 13 (PLC2 Family)

057

067

057

067

057

067

132

NOTE:

LAMP TEST Switch

Test optional indicators

PLC command bits 10 through 13 use conditioned logic. Do not latch or unlatch instructions. Corresponding switch input wiring is shown in Figure 6.15.

057

067

49

Chapter 4

PC Ladder Programming

PRESS ENABLE Switch

Figure 4.7 Example PLC Command Rungs for Bits 10 thru 13 (PLC3 and PLC5/250)

Optional conditions

I0032

Enable Press Operation

STOP-ON-TOP Switch

Command Stop-on-top

RESET Switch

Reset latched messages

LAMP TEST Switch

O0057

O0067

410

NOTE:

Test optional indicators

PLC command bits 10 through 13 use conditioned logic. Do not latch or unlatch instructions. Corresponding switch input wiring is shown in Figure 6.15.

Use this address format for PLC-5/250 processors

O:057

)

O:067

(

PRESS ENABLE Switch

Optional conditions

Chapter 4

PC Ladder Programming

Figure 4.8 Example PLC Command Rungs for Bits 10 thru 13 (PLC5)

I032

Enable Press Operation

STOP-ON-TOP Switch

Command Stop-on-top

RESET Switch

Reset latched messages

LAMP TEST Switch

O:57

O:67

O:57

O:67

O:57

O:67

O:57

NOTE:

Test optional indicators

PLC command bits 10 through 13 use conditioned logic. Do not latch or unlatch instructions. Corresponding switch input wiring is shown in Figure 6.15.

O:67

411

Chapter 4

PC Ladder Programming

Summary of PLC Configuration and Command Rungs

Output image table word, Module Group 7, Chassis

A & B

Bit Bit

No: Function: Set Reset Rung:

03 V

Stations 3 and 4

Motion Detector Feedback

alve Stem Feedback

We summarize the bits in module group 7 used for determining configuration requirements and enabling operator commands (Figure 4.9).

Figure 4.9 Functions

17161514131211100706050403020100

of PLC Configuration and Command Bits

PLC Configuration Bits

PLC Command Bits

Status

Used

Not Used

Unconditioned

ype of

06 OnTheHop Used

11 StopOnT

NOTES: Do not use bits 00 and 15  17 for any purpose. See Figure 4.2 See Figure 4.3

Air Pressure Feedback

AC Power Configuration

Strokeandahalf or Halfstroke

Press Enable (PLC Command)

op (PLC Command)

Latched Messages (PLC Command)

Lamp T

est (PLC Command)

Dump V

alve T

riacs Used

for bit addresses

through 4.8 for programming

Ungrounded Grounded Unconditioned

Used

Not Used

Enabled Disabled Conditioned

Not Used

Used Unconditioned

Not used

Unconditioned

12254

412

Chapter 4

PC Ladder Programming

Module Group 5, Slot 0 Reserved for MicroInch

Module Groups 6 and 7 Reserved for Data Storage

Important: Use module group 5, slot 0 only if your mechanical power press is equipped for micro-inch.

When you insert an input module (1771-IA) into this slot of chassis A and B, the processor recognizes micro-inch inputs at terminals 0, 1, 2. For the wiring of these terminals refer to chapter 6, Figure 6.4 or Figure 6.8.

Module group 6 is non-functional and reserved for future use.

Your program must use the output image table word associated with module group 7 as a storage word for configuring your clutch/brake modules (Figure 4.9). The processor transmits configuration data to the clutch/brake modules in each I/O scan.

CAUTION: Do not assign any I/O module to module group 7 of the rack address assigned to chassis A and B. Unexpected press operation will occur with possible damage to equipment and/or injury to personnel. However, you may install a slot power supply in module group 7, if needed.

Monitoring Clutch/Brake Controller Inputs and Outputs

Important: Be sure to assign full rack addresses for chassis A and B, regardless of whether you are using the optional dump valve and/or micro-inch circuit. This guards against assigning an I/O module to module group 7.

Refer to Rack Address of Chassis A and B, in chapter 3, for instructions on assigning rack addresses.

Your PLC ladder program cannot control outputs of your clutch/brake controller. However, your PLC ladder program can monitor any clutch/brake controller input or output because the I/O image table of chassis A and B is in the PLC data table.

Input image table bit addresses for chassis A and B are listed in tables A thru F in appendix 1. You may monitor these addresses. However, do not examine them as conditions for configuration rungs shown in Figures 4.3 through Figure 4.5. If you do, PM modules may stop the press. Then you must cycle power to restart.

413

Chapter 4

PC Ladder Programming

For an example of monitoring a clutch/brake controller function, assume that you wish to turn on a indicator while your clutch/brake controller is in continuous mode. You would wire your CONTINUOUS indicator to a terminal of an output module in any I/O chassis. You would also program a rung with one examine-on instruction and one output-energize instruction:

the examine-on instruction monitors input image bit 03 for module

group 0 chassis A or B.

the output energize instruction controls the CONTINUOUS indicator.

Important: Do not store data in unused data table addresses for chassis A and B. These are reserved for future enhancements for the clutch/brake controller.

Report Generation

Your PLC ladder program can monitor clutch/brake controller functions for report generation. This allows you to display, through an RS-232-C peripheral device, any of the following:

operator instructions fault correction procedures status reports diagnostic message codes

The clutch/brake module generates diagnostic message codes presented in table 7.C. Use them to generate messages that you have stored in PLC memory. These messages can be troubleshooting instructions to your press operators. For detailed descriptions of report generation, see the following publications:

For PLC-2 family processors:

PLC-2 Family Report Generation Module (cat. no. 1770-RG) User’s

Manual (publication 170-815)

For PLC-3 processors:

I/O Scanner-Message Handling Module (cat. no. 1775-S4B) User’s

Manual (publication 1775-6.5.3)

Peripheral Communications Module (cat. no. 1775-GA) User’s Manual

(publication 1775-6.5.4)

414

For PLC-5 family processors:

BASIC Module (cat. no. 1771-DB) User’s Manual (publication

1771-6.5.34)

Chapter 4

PC Ladder Programming

Summary of Clutch/Brake Controller Functions

Function or Command

You should now be familiar with required and optional PLC ladder programming needed to configure and monitor your clutch/brake controller. Complete your ladder diagram programming addresses after you have wired your press system as described in chapter 6. Clutch/brake controller functions (Table 4.B) are summarized on the next page.

Table 4.B Summary

 Off

 Inch

 Microinch

 Singlestroke

of Clutch/Brake Controller Functions

Operating Mode

[ 1 ]

Description

Clutch/brake controller locks out press motion

The operator can jog the press through a complete cycle by pressing and releasing the pair of INCH buttons. If INCH buttons are held, the press will stop at the top of its stroke.

This mode of operation lets you run your press at low speeds (1 to 5spm) for setting up dies and making trial runs. Y supply a separate drive and clutch/brake assembly to drive the shaft with full tonnage capacity at low press speeds, bypassing the flywheel.

The press completes one cycle and then stops on top, provided the operator holds both RUN buttons until completion of the down stroke.

ou must

 Continuous

[ 1 ]

Stopontop (cycle stop)

Onthehop Singlestroke

Halfstroke or

Strokeandahalf

[ 1 ] Cam limit switches must indicate that the press is in the neartop position before motion can start in single or continuous mode.

Continuous

Operators must assert the ARM CONTINUOUS switch and all station RUN buttons within five seconds, and then hold the RUN buttons for half a stroke (or 1 1/2 strokes) if so configured to start the press in continuous mode. Thereafter until stopped by a stopontop command, or when a fault is detected.

This command, from a switch wired to the clutch/brake

controller or from the PLC, stops the press at a predetermined

point.

Releasing and pressing both RUN buttons during a specific portion of the upstroke causes the press to continue running onto the next stroke without stopping. This is a configurable option.

The operator must press both RUN buttons for 1/2 or 1 1/2 press cycles before the press can run on its own. This is a configurable option. Run buttons must be held until Runon (takeover) Cams are made.

, the press runs

415

Chapter 4

PC Ladder Programming

Function

or Command

Interrupted stroke

Antitiedown All

Antirepeat Singlestroke

Operating Mode

Continuous

Singlestroke

Inch

Description

If an operator releases a RUN button during a down stroke, the press stops immediately operator releases both RUN buttons and presses them again, the press continues the downstroke. If more than five seconds elapses, the operator must inch the press to top, select continuous mode, and follow the first Continuous procedure above..

Same as Continuous mode except there is no time limit on reapplying the RUN button.

The press will not start if you tie down one or more RUN buttons. After all RUN buttons are released, the operator must press both RUN buttons at a station simultaneously operators at active stations must press all RUN buttons within five seconds of each other to start the press.

The same applies to the pair of INCH buttons.

The press is limited to a single stroke, even if the operator continues to press both RUN buttons. The operator must release both RUN buttons and press them again to start press motion.

The same applies to a pair of INCH buttons as described for Singlestroke.

. If within five seconds of stopping, an

, and/or

Motion detector

TopstopCheck All

Singlestroke

Continuous

The clutch/brake controller detects press motion using your motion detector which provides a 120AC input signal. This is a configurable option.

The clutch/brake controller signals a worn or faulty brake by monitoring the T T

opstopcheck cam closed after a normal cycle stop has been initiated and before the press comes to a top stop, it prevents the press from restarting and energizes the brakefault output.

opstopcheck cam inputs. Should it see the

416

Chapter

Voting Processor Firmware

Chapter Objectives

Operation of Voting Processors

This chapter will help you become familiar with:

operation of your voting processor firmware operational sequences for controlling your press

A clutch/brake controller has two clutch/brake modules, one in chassis A and the other in chassis B. Each clutch/brake module contains firmware that makes it function as a voting processor. Both voting processors contain identical firmware programs that independently monitor your clutch/brake controller I/O while controlling the press.

While running their firmware programs, both voting processors constantly “vote” on the status of your press. Both voting processors must always have a consensus. If they find that they don’t agree on their perceived conditions of your press, they either stop the press or prevent it from starting.

Also, both voting processors constantly check their communication channels. Press motion is stopped or inhibited if either voting processor detects a loss of communications with the PLC or the other voting processor. A failure in one voting processor is immediately seen as a communication loss by the other voting processor.

Emergency Shut Down

Finally, voting processors control the operational sequences that your operators must perform in inch, single, and continuous modes.

Each voting processor (PM module) controls one seal relay and one crowbar relay. All E-STOP switches are connected in series with seal relay contacts. If any of these contacts opens or if the PM module detects a trip condition, solenoid power is disconnected. If a PM module detects that solenoid power should be off when on, it turns on the crowbar relay to blow the solenoid power line fuses. At clutch/brake start, both PM modules test their crowbar relays without blowing the line fuses. Wiring diagrams in chapter 6 show these connections.

51

Chapter 5

Voting Processor Firmware

Fault Monitoring

PM modules continuously monitor your clutch/brake system for a trip or stop condition. Either condition halts and/or prevents press operation.

For

this condition

Trip

Stop T

PM modules remove solenoid power by

Removing power from field wiring arms

urning of

controlling the solenoids

f outputs from the output module

Trip condition - A PM module turns off swing arm output power by de-energizing its seal relay output when it detects these trip conditions:

lost communications with the other PM module for 100ms a change in wiring of operator stations 1 thru 4 a short or open solenoid triac short or open solenoid feedback [1] connections are wired but not configured feedback connections are configured but not wired feedback signals are not working correctly

[1]

feedback from valve stem switches, air pressure sensors, and motion detector contacts

Whenever a PM module detects a trip condition, it:

trips power to the wiring arms of the I/O chassis sets rack fault bits stops communication with the PLC

If programmed to monitor rack fault bits, the PLC sees the clutch/brake I/O chassis as faulted until both PM modules verify that power to wiring arms has been removed. Then they resume communications automatically.

Stop condition - A PM module stops the press or prevents it from starting by turning off output triacs to solenoid valves when it detects stop conditions such as:

lost communications with the other PM module for 50ms lost communications with the PLC for one second cam limit switch signals out of sequence barrier guard opened during continuous mode

This is described further in Chapter 7, Diagnostic Message Codes.

52

Chapter 5

Voting Processor Firmware

Operation of Cam Limit Switches

The PM Module uses cam limit switches to determine press slide position. (Figure 5.1 and Table 5.A). You set two independent cam limit switch assemblies to the same settings so that:

run-on contacts are closed in the near bottom and upstroke zones top-stop-check contacts are closed in the downstroke and near-bottom

zones

anti-repeat contacts open during mid-upstroke for at least 70ms. Set the

open span to the approximate number of rotational degrees (10

0 -

450)

according to the speed of the press (1spm - 100spm).

UpStroke

Press Speed

Span vs. Press Speed for AntiRepeat Contacts

SPM

100

OpenSpanDuringUp-Stroke

12971

The anti-repeat cam is not required while operating in inch or micro-inch mode. However, before entering any operating mode, the PM module checks that at least one cam limit switch is closed at any point in the cycle.

53

Chapter 5

Voting Processor Firmware

Figure 5.1

Limit Switch Settings

Cam

Run - On

Upstroke

Anti - Repeat

Near Top

Position

70 ms

Near Bottom

Zone

Top-stopcheck

Downstroke

Table 5.A Operation

NOTE: Install two mechanically independent cam limit switch assemblies each with three cams and three limit switches. Set the assemblies to similar settings according to the requirements of your press.

You can set cam limit switches to other configurations provided they meet the make/break conditions listed below:

Cam Linit Switch Settings

Top-Stop

Zone

-Check MAKE

Downstroke

MAKE

Near Bottom

BREAK

Upstroke

BREAK

Near Top

Refer to Diagnostic Messages, table 7.C. Hex codes 80 thru AA, for descriptions of faults caused by cam limit switches.

Run-On

BREAK

MAKE

BREAK

AntiRepeat

MAKE

BREAK

MAKE

Topstopcheck

before run-on contacts make, or the controller faults.

Run-on contacts must make (not necessarily at the same time) before

opstopcheck contacts must break (not necessarily at the same time)

before antirepeat contacts break or the controller faults. Anti-repeat contacts must break for at least 70ms during

upstroke, then make before run-on contacts break, or the controller faults.

Anti-repeat contacts must make (not necessarily at the same time) before run-on contacts break, or the controller faults.

Run-on contracts must break (not necessarily at the same time)

before T

contacts must make (not necessarily at the same time)

opstopcheck contacts break, or the controller faults.

opstopcheck contacts make or the controller faults.

Comments

of Cam Limit Switches

12970

54

This Cam

Anti Repeat

Runon

TopStop Check

In this Mode

Onthehop single stroke

Inch and Microinch (forward) and Single stroke

Continuous

Single stroke and Continuous

any

Inch and Microinch (reverse)

ith these

Conditions

Run buttons released past bottom

Cam opens at neartop position T

Cam opens at neartop position after stopontop command

Cam closes at nearbottom position

Cam closes during stopontop

Cam opens in neartop position

Provides the PM Module a Signal:

o allow a second stroke when run buttons

are pressed a second time

o turn OFF triac output for

stopontop (cycle stop)

o let operator release any depressed run buttons without interrupting a single stroke or continuous stroking

o energize a Brake Fault output to warn that the brake is faulty (Hazardous Condition)

o turn OFF solenoid outputs to stop the cycle

Chapter 5

Voting Processor Firmware

Clutch/Brake Operating Modes

Select inch or microinch

Has an operator released

both INCH buttons?

Has an operator pressed

both INCH buttons

Inch and Microinch Modes

Use inch or micro-inch mode before entering single or continuous mode to position the shaft near the top, or for machine tool set-up. You may jog the shaft either forward or in reverse. The shaft stops when it moves into the near top position or when you release an INCH button.

Figure 5.2 Operational

mode

Yes

simultaneously?

Yes

Sequence for Inch or MicroInch Mode

WARNING: To guard against the

possibility of personal injury, install a keylock mode select switch so that only supervisory personnel can select inch mode.

Both voting processors

energize their solenoid triacs

to actuate the clutch

Has the shaft moved into its

neartop position?

deenergize their solenoid

triacs to stop the shaft in its

NOTE: Use inch or microinch mode to position the shaft near the top. Operators may jog the shaft in either direction. The shaft stops when it moves near top position or when an operator released an INCH button.

Yes

Both voting processors

neartop position

Has an operator released

either INCH button?

Yes

WARNING: If the shaft

coasted past its neartop

position while braking, the

brake is faulty and

hazardous. Repair it

immediately.

12261

55

Chapter 5

Voting Processor Firmware

Single Stroke Mode

Use single-stroke mode to actuate the press through a single cycle.

During the downstroke (Figure 5.3)

releasing a RUN button stops the press if the shaft did not enter the near bottom zone, you may resume the

downstroke

if the shaft entered the near bottom zone, you must inch the press back

to the near top position before restarting

During the upstroke (Figure 5.4)

the shaft continues automatically through the upstroke

If you enabled on-the-hop , you can start another cycle without stopping the press if you

release all RUN buttons after the near bottom position press all RUN buttons after the anti-repeat contacts open during the

upstroke

56

Chapter 5

Voting Processor Firmware

Start onthehop

downstroke.

From figure 5.4

Figure 5.3 Operational

Select single mode

Main Motor Forward

Yes

Is the shaft near the top?

Yes

Have all operators released all

RUN buttons?

Yes

Has each operator pressed his

RUN buttons simultaneously,

and within 5 seconds for all

stations?

Yes

Both voting processors

energize their solenoid triacs to

actuate the clutch for the

downstroke

Sequence for Downstroke in Single Mode

Select inch mode and position the shaft near the top.

Has an operator released a

RUN button?

Is the shaft past the near

bottom zone?

Yes

Start upstroke.

Go to figure 5.4

NOTE: Releasing a RUN button during the downstroke stops the press. If the shaft does not reach the nearbottom zone, operators may resume the downstroke. If the shaft reaches the nearbottom zone, an operator must inch the press back to the neartop position.

Both voting processors

deenergize their solenoid

triacs to stop the shaft. A stop

condition message is

Did the shaft coast into the

near bottom zone while

Have all operators released all

Has each operator pressed his

Yes

RUN buttons simultaneously,

and within 5 seconds for all

Yes

displayed.

breaking?

RUN buttons?

Yes

stations?

Yes

CAUTION: Releasing a RUN button late in the downstroke

can damage the press

12262

57

Chapter 5

Voting Processor Firmware

Both voting processors

deenergize their solenoid triacs

to stop the shaft. A stop condition

mesage is displayed.

Yes

Has the shaft moved into its

neartop position?

Figure 5.4 Operational

Start upstroke.

From figure 5.3

Upstroke continues regardless of

releasing RUN buttons

Have both voting processors

detected that antirepeat cams

have opened?

Yes

Has onthehop been enabled?

Sequence for Upstroke in Single Mode

Yes

Have all operators released all RUN buttons?

Yes

Has each operator pressed his RUN buttons simultaneously, and within 5 seconds for all stations?

Yes

Has the shaft moved into its neartop position?

Yes

Has the shaft moved into its

neartop position?

NOTE: The shaft continues automatically through its upstroke, then stops. If onthehop has been enabled, operators can start another downstroke without stopping at the top. Do this by releasing all RUN buttons after the downstroke. Then, press all RUN buttons after the antirepeat contacts open on the upstroke.

Yes

Both voting processors

deenergize their solenoid triacs

to stop the shaft in its neartop

position

WARNING: If the shaft coasted

past its neartop position while

braking, the brake is faulty and

hazardous. Repair it immediately.

Has an operator released a RUN button?

Yes

Start onthehop downstroke.

Go to figure 5.3

12263

58

Chapter 5

Voting Processor Firmware

Continuous Mode

Select continuous mode when you want to run your press continuously. Do this as follows:

inch the press to the near top position close the barrier guard(s) select continuous mode, and press the ARM CONTINUOUS button (Figure 5.5)

During the first downstroke (Figure 5.6).

releasing a RUN button or opening a barrier guard stops the press if the shaft did not enter the near bottom zone, you may resume the

downstroke within five seconds after a stop

if the shaft entered the near bottom zone and is stopped, you must inch

the press to the near top position and press the ARM CONTINUOUS button in order to restart press operation.

During the first upstroke (without stroke-and-a-half) (Figure 5.7)

releasing a RUN button does not stop the press opening a barrier guard stops the press if the shaft did not stop in the near top position, inch it there and repeat

the procedure from the beginning

If you configured for half-stroke or stroke-and-a-half requirement

continue holding the RUN buttons until the shaft runs through the first

(or second) downstroke and first (or second) near bottom position

releasing a RUN button stops the press, and first downstroke conditions

apply

Once in continuous operation (NO TAG), the press stops whenever

you press stop-on-top the PLC transfers a stop-on-top command a barrier guard opens either voting processor detects a trip or stop condition

59

Chapter 5

Voting Processor Firmware

Figure 5.5 Operational

Select continuous mode

Is the barrier guard closed?

Is the shaft in the neartop

Main Motor Forward

Have all operators released all

STOPONTOP buttons?

Have all operators released all

Sequence for Starting Continuous Mode

Yes

position?

Yes

RUN buttons?

Select inch mode and position the

shaft to the neartop position

Arming Sequence

Yes

Has an operator pressed the ARM

CONTINUOUS button?

Yes

Have 5 seconds elapsed since

pushing ARM CONTINUOUS?

Has each operator pressed his

RUN buttons simultaneously, and

within 5 seconds for all stations?

Yes

Go to First Downstroke

Figure 5.6

NOTE: The arming sequence guards against accidently starting operation in continuous mode.

Yes

12264

510

Chapter 5

Voting Processor Firmware

First Downstroke.

From figure 5.5

Both voting processors

energized their solenoid triacs

for the first downstroke

Has the shaft reached the

nearbottom position?

Yes

Go to First Upstroke.

Figure 5.7

Figure 5.6 Operational

Sequence for First Downstroke in Continuous Mode

Go to Figure 5.5

Select Continuous Mode

Select inch mode and position the

shaft near the top.

Has an operator released a

RUN button, or has a barrier

guard opened?

Yes

Both voting processors

deenergize their solenoid triacs

to stop the shaft. A stop

condition mesage is displayed.

Stop Condition

From figure 5.7

Did the shaft coast into the

nearbottom zone while

braking?

Have 5 seconds elapsed since

the solenoid triacs were

deenergized?

Have all operators released all

NOTE: Releasing a RUN button during the first downstroke stops the press. If the shaft has not entered the near bottom zone, operators can resume the downstroke within 5 seconds of releasing a RUN button. After 5 seconds, operators must restart continuous mode by means of the arming sequence.

RUN buttons?

Yes

Has each operator pressed his

RUN buttons simultaneously,

and within 5 seconds for all

stations?

Yes

CAUTION: Releasing a RUN button late in the downstroke can damage the press.

12265

511

Chapter 5

Voting Processor Firmware

First Upstroke.

From figure 5.6

Has 1/2 or 1 1/2 stroke been

configured?

Yes

Both voting processors continue

actuating the clutch for the first

upstroke

Has an operator released a RUN

button, or has the barrier guard

opened?

Is the shaft in the neartop

position?

Both voting processors continue

actuating the clutch for the

second downstroke

Yes

Figure 5.7 Operational

Yes

Sequence for First Upstroke and Second Downstroke in Continuous Mode

Go to Figure 5.5

Select Continuous Mode

Both voting processors

de-energized their solenoid

triacs to stop the press.

Did the shaft stop in the

nearbottom position?

Select inch mode and position the shaft near the top.

Has an operator released a RUN

button, or has a barrier guard

opened?

Continuous

Stroking

Figure 5.8

NOTE: Halfstroke or Strokeandahalf requires all operators to hold all RUN buttons until the first or second downstroke is completed. Releasing a RUN button during the (first) upstroke requires restarting continuous mode at the arming sequence. Releasing a RUN button in the first or second downstroke requires restarting as if an operator had stopped the press in the first downstroke.

512

Go to

Yes

Go to

Stop Condition

Figure 5.6

12266

Continuous Stroking

From figure

5.7

Both voting processors allow

continuous stroking regardless of

releasing RUN buttons.

Chapter 5

Voting Processor Firmware

Has an operator pressed a

STOPONTOP button?

Has the PLC transferred a

stopontop command?

Has a barrier guard opened?

Yes

Both voting processors trip triac

power to stop the shaft. A trip

condition message is displayed.

NOTE: The press strokes continuously until an operator presses a STOPONTOP button, the PLC transfers a stopontop command, or barrier guard opens.

Yes

The stroke continues until the

shaft reaches the neartop

position

Is the shaft in the neartop

position?

Both voting processors

deenergize their solenoid triacs

to stop the shaft in its neartop

position.

Yes

WARNING: If the shaft coasts

past its neartop position while braking, the brake is faulty and

hazardous. Repair it immediately.

12267

513

Chapter

Connections to Field Wiring Arms

Chapter Objectives

Installation Considerations

Electrical Connections and Safety Requirements

This chapter will help you:

Connect the field wiring arms of chassis A and B install either ungrounded or grounded 120V AC power distribution

Before continuing, be sure that you configured your clutch/brake controller chassis and modules as shown in chapter 3. For installation details, refer to the installation publication for your processor. These publications are listed in our Publications Index (publication SD499).

In order to design, build, install, and operate a safe press system, you should also refer to other publications. In addition to local codes and laws, adhere to 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

Some electrical connections are mandatory, others are optional. If you omit mandatory connections or electrical components, you violate safety requirements discussed and referred to in this manual.

For

AC Power That Is

Ungrounded 6.1

Ungrounded

Grounded 6.5

Grounded 6.7

Use This Mandatory Figure

6.3

For these Connections

AC Power and Crowbar T Press Interlock Switch

Main and Auxiliary V Crowbar and Seal Relays MOV Surge Suppression

AC Power and Crowbar T Press Interlock Switch

Main and Auxiliary V Crowbar and Seal Relays MOV Surge Suppression

alve Solenoids

est Inputs

61

Chapter 6

Field Wiring Arm Connections

Use

This

Mandatory

Figure

For These Connections

6.9

6.10

6.11

Cam Limit Switch Assemblies

Main Motor Forward Barrier Guard Stopontop Arm Continuous Mode Select Switch

Operator Stations 1 & 2 Dummy Plugs Inch Pushbutton Switches

WARNING: To guard against injury to personnel and damage to your press, connect your clutch/brake controller exactly as shown in these figures.

The connections for optional features are shown in the following figures:

Use

this Figure

6.2 or 6.6

For These Optional Connections

Switches on Main V

alve Stems Air Pressure Sensors Motion Detector

62

6.4 or 6.8

6.12

6.13

6.14

Dump and/or Microinch V

Operator Stations 3 & 4 Dummy plugs Diagnostic Message Display

Brake Fault Indicator Run Window Indicator Microinch Indicator

alves

Important: Use 14 AWG stranded copper wire with 3/64-inch insulation for all solenoid and relay coil connections to the 1771-OD modules. We also recommend the same wire size for all field wiring arm connections.

Chapter 6

Field Wiring Arm Connections

Control Power

Connect your clutch/brake controller to either an ungrounded AC power configuration (Figure 6.1) or a grounded AC power configuration (Figure 6.5). Either figure shows two separately fused 120V AC power circuits. Power lines 3L1 and 3L2 provide power to the field wiring arms at module group 3, slot 0 and module group 4, slot 0 in chassis A and B. Power lines 2L1 and 2L2 provide power to all other field wiring arms, the PLC power supply, and chassis A and B power supplies.

Either AC power configuration lets your PLC, clutch/brake controller, and inputs remain on after solenoid power has been disconnected as shown in Figure 6.1 or Figure 6.5. Disconnecting solenoid power stops press operation. Solenoid power is disconnected if an E-Stop switch opens, a seal relay trips, or a crowbar relay turns on. When solenoid power is disconnected, both voting processors continue to run and generate diagnostic message codes. Status indicators of input modules continue to show which switches are on or off. Therefore, either AC power configuration lets you more easily troubleshoot most problems that cause your press to shut down.

Important: Be sure that your clutch/brake controller is properly grounded to provide greater safety and reduced electrical noise interference. For details, refer to PLC Grounding (publication 1770-4.1).

EStop Switches, Seal Relays, and Crowbar Relays

The E-Stop circuit allows an operator or a voting processor to quickly stop the press. Connect all E-Stop switches and contacts in series with seal A and B contacts, as shown in Figure 6.1 or Figure 6.5.

WARNING: To guard against possible injury to personnel and damage to your press, connect seal relays, crowbar relays, and operator station E-Stop switches exactly as shown in Figure 6.1 and Figure 6.3 or Figure 6.5 and Figure 6.7.

You may connect any number of additional E-Stop switches and contacts in series with the mandatory operator station E-Stop switches. These can include, but are not limited to, remote E-Stop switches, air pressure switch contacts, and relay contacts for monitoring the power supply.

63

Chapter 6

Field Wiring Arm Connections

Install at least one E-Stop switch at each operator station. Then, any operator who sees a problem can press an E-Stop switch to stop the press. Also when either voting processor detects a fault, it de-energizes its seal relay to stop the press.

Opening any E-Stop switch or de-energizing either seal relay removes AC power (3L1) from main valve solenoids A and B, auxiliary valve solenoids A and B, dump valve solenoids A and B, crowbar relays A and B, and seal relays A and B, as shown in Figure 6.1, Figure 6.3 and Figure 6.4 or Figure 6.5, Figure 6.7 and Figure 6.8. When either voting processor detects that 3L1 is off, it immediately commands its seal relay to remain de-energized. If either voting processor detects that 3L1 is still on after commanding its seal relay to de-energize, it energizes its crowbar relay. This shorts 3L1 to 3L2, which blows the 3L1 and 3L2 line fuse or fuses.

Crowbar Test Inputs

Crowbar tests inputs, shown in Figure 6.1 or Figure 6.5, allow the voting processors to test their crowbar relays without blowing the 3L1 and 3L2 line fuse or fuses. This test occurs while you push the START button shown in Figure 6.1 or Figure 6.5.

To allow for the crowbar test, you should press the START button (break-before-make pushbutton switch) for more than one-half second. As you begin pressing the START button, its two sets of N.C. (normally closed) contacts open first, isolating crowbar A and B relay contacts from 3L2. As you press the START button all the way in, its N.O. (normally open) contacts close, applying 3L1 power to module group 3, slot 0. Before you release the START button, each voting processor briefly energizes its crowbar relay and checks, through its crowbar test input, that the relay turns on then off. Each voting processor energizes its seal relay only after its crowbar relay is tested as working correctly. At any time after you release the START button, either crowbar relay can blow the 3L1 and 3L2 line fuse or fuses shown in Figure 6.1 and Figure 6.5.

64

Chapter 6

Field Wiring Arm Connections

Optional Hardwire Inputs

Triac Command

Triac Feedback

alve Stem Feedback

Air

Pressure Feedback

0  100ms

[5]

[6]

[1]

Connect optional hardwire inputs as needed to chassis A and B so voting processors can monitor any of the following inputs:

Input Terminal MG Slot Figure

Main Valve Stem Motion Detector Air Pressure Auxiliary V

Microinch V

alve Stem

alve Stem Microinch Air Pressure Dump V

alve Stem

0 1 2 7

1 2 4

2 2 2 2

5 5 4

0 0 0 0

0 0 1

6.2 or 6.6

6.4 or 6.8

6.4, 6.8

When connected these inputs function as follows:

OFF

0200ms

[4]

0500ms

OFF

[4]

OFF

0100ms

[2]

0100ms

[4]

ON OFF

0510ms

[3]

Motion Detector must turn ON before upstroke (before Topstopcheck cams turn OFF

[1]

Time

[2] [3] [4]

[5] [6]

window for faultless operation measured from Triac Command of

Time

window for faultless operation measured from T

Time

window for faultless operation measured from Valve Stem feedback of

Time

window for faultless operation measured from ontoof

Ontoof

Applies

[7]

Applies

[8]

f transitions need not occur sequentially

to Main, Auxiliary, Dump, and Microinch valves to Main, MicroInch, Auxiliary

Motion Detector transition of

to firmware revision A/D and later

For additional valve stem requirements, see section title Internal/External Fault Detection

[7] [8]

04 seconds

[4]

riac Feedback of

f transition of the T

, and Dump (if configured) solenoids

ftoon is position dependent, ontoof

OFF

ftoon transition ftoon transition

ftoon transition

riac Command.

f is time dependent

65

Chapter 6

Field Wiring Arm Connections

When PM modules command triacs ON or OFF, they check that feedback signals (triac, valve stem, air pressure, and motion detector) have turned ON or OFF in the order shown and within the times shown.

If and when a PM module detects that a triac or feedback signal has not turned ON or OFF within the times shown, it trips seal relay output to remove power from the wiring arms of 1771-OD output modules.

Be sure that you configure your clutch/brake controller accordingly by setting your backplane switches (chapter 3) and programming your configuration bits (chapter 4).

Connect either one or both motion detector switches and either one or both pressure switches if so configured.

Internal/External Fault Detection

If your main valves have external fault detection switches and you configured for valve stem feedback, all other clutch/brake solenoid valves must have external valve stem feedback. If auxiliary valve solenoids have internal fault detection (do not have valve stem switches), jumper terminal 7 to terminal 0, Module group 2, slot 0 (Figure 6.2 or 6.6) in chassis A and B.

There are two general types of solenoid valves: those with external fault detection, and those with internal fault detection.

Solenoid valves with external fault detection have switches on the valve stems which you use to feed back the status of valve stems to your clutch/brake controller. The firmware in your clutch/brake module performs the fault detection.

A valve with external fault detection, Figures 6.2 or 6.6, provides an external signal of its valve position. When the valve is energized, the external signal is “on”. Interfacing this type of valve to the clutch/brake system requires:

66

enabling valve stem feedback with backplane switches (Figure 3.3) enabling valve stem feedback in PC configuration rungs (Figure 4.3)

If you configure for valve stem feedback, all valves must have valve stem feedback or simulate it (have their respective terminals jumpered to the input terminals of the main valve stem switches for simulated inputs).

Chapter 6

Field Wiring Arm Connections

Solenoid valves with internal fault detection close automatically when the valves detect a mechanical fault. They have no valve stem switches. When using this type of solenoid valve, do not configure your clutch/brake controller for valve-stem fault detection.

A valve with internal fault detection mechanically assures that both solenoids energize in unison before the valve passes air. Should a fault occur and only one side energizes, the valve will not pass air. Some valves of this type have a poppet valve which blows and vents to the atmosphere. The poppet valve must be manually reset.

Optional Valve Stem Switches, Motion Detectors, and Air Pressure Switches

Using

alvestem feedback

alvestem feedback, but Main or Aux valve is NOT equipped with external fault detection (has internal detection)

All switches shown in Figure 6.2 or Figure 6.6 are optional. Decide which ones you will use. Then, configure your clutch/brake controller accordingly.

Optional Valve-stem Feedback

If main and auxiliary valve solenoids do not have valve-stem switches, then consider omitting valve-stem feedback. If either one has valve-stem switches, consider using valved-stem feedback. Then if some valves do not have valve-stem feedback, you must simulate valve-stem feedback for the valve(s) without valve-stem switches.

Follow these instructions if using valve-stem feedback:

Then

1) Enable valvestem feedback with  backplane switches (Figure 3.3)  PC configuration rungs (Figure 4.4)

All valves must use (or simulate) it.

Wire valvestem switch circuits to 2L1 (Figure 6.2 or 6.6)

Modify above as follows:

Omit wiring the valvestem switch circuit to 2L1 for that valve (Figure 6.2 or 6.6).

Simulate feedback for that valve by jumpering terminals 0 and 7 in chassis A, the same in chassis B.

No valvestem feedback 1)Do not enable it

Do not wire valvestem switches

Do not jumper terminals for simulation

67

Chapter 6

Field Wiring Arm Connections

For

this wiring And this feature

Singleswitch Motion detector

Optional Motion Detectors and Air Pressure Switches

For either one of these optional features, you may use a single switch or redundant switches (Figure 6.2 or 6.6):

Follow these instructions

Connect the jumper between terminal 1 (chassis A) and terminal 1 (chassis B)

Air pressure

Connect the jumper between terminal 2 (chassis A) and terminal 2 (chassis B)

Redundantswitch

Main Valve Solenoids A and B

either of above

Motion detector

Air pressure

either of above

Omit dottedline wiring for redundantswitch circuits

Remove the jumper between terminal 1 (chassis A) and terminal 1 (chassis B) Remove the jumper between terminal 1 (chassis A) and terminal 1 (chassis B) Add dottedline wiring for redundantswitch circuits (for motion detector and/or air pressure)

Connect main valve solenoids A and B as shown in Figure 6.3 or Figure 6.7 with these connections:

feedback from main valve solenoid triacs that allows both voting

processors to monitor the on or off state of each triac, and check for shorted or open triacs, and open or shorted main valve solenoids.

load resistors, LRA and LRB, for triac feedback from main valve

solenoids A and B

crowbar relay coils and seal relay coils

If your main valves use valve stem switches for external fault detection, you must configure for valve stem fault detection by setting backplane switches (chapter 3) and programming configuration bits (chapter 4). Then, your optional auxiliary and/or dump valves must also use valve stem switches. If not, you must simulate their inputs by jumpering their input terminals to the input terminals for the main valve stem switches.

68

If your valves have internal fault detection (no valve stem switches), do not configure for valve stem fault detection, and delete valve stem input connections from Figure 6.4 or Figure 6.8 and Figure 6.2.

Each main valve solenoid should draw at least 60mA. If not, connect an appropriate load resistor in parallel with it. For neatness and safety, we recommend that you connect feedback and load resistors only at convenient terminal strips, not at the field wiring arms.

Chapter 6

Field Wiring Arm Connections

Optional Auxiliary Valve Solenoids

Use auxiliary valve solenoids when you want to boost the volume of air to the clutch/brake assembly. Do this by placing auxiliary valves in parallel with main valves in your high pressure air line.

If you use auxiliary valves, connect auxiliary valve solenoids A and B shown in Figure 6.3 for ungrounded solenoids, or Figure 6.7 for grounded solenoids. If you don’t use one or both auxiliary valve solenoids, you must connect a 2k ohm, 15W resistor in place of each. Figure 6.3 or Figure 6.7 also shows connections for:

feedback from auxiliary valve solenoid triacs that allows both voting

processors to monitor the on or off state of each triac, and check for shorted or open triacs and shorted or open auxiliary valve solenoids.

load resistors, LRA and LRB, for triac feedback from auxiliary valve

solenoids.

Each auxiliary valve solenoid should draw at least 60mA. If not, connect an appropriate load resistor in parallel with it. For neatness and safety, we recommend that you connect the feedback resistor and the load resistor only at convenient terminal strips, not at the field wiring arms.

Optional Dump Valve Solenoids

If you use auxiliary valves with internal fault detection (no valve stem switches) but you have configured for external fault detection, simulate the inputs of the auxiliary valve stem switches. Do this by jumpering the input terminals of field wiring arms for auxiliary valve stem switches to the input terminals for the main valve stem switches. Jumper terminal 7 to terminal 0, module group 2, slot 0, for chassis A and B (Figure 6.2).

Use optional dump valves and solenoids when you want to accelerate the evacuation of air from the clutch/brake assembly.

If you use dump valves, install two output modules (cat. no. 1771-OD, series C or later). Place them in module group 4, slot 0, chassis A and B to control the dump valve solenoids. Also install two input modules (cat. no. 1771-IA). Place them in module group 4, slot 1, chassis A and B to monitor feedback inputs from the dump valve solenoids. Set configuration bit 14 unconditionally as shown in Figure 4.3, Figure 4.4 or Figure 4.5.

Connect dump valve solenoids and valve stem switches (if you use them) as shown in Figure 6.4 for ungrounded solenoids, or Figure 6.8 for grounded solenoids.

69

Chapter 6

Field Wiring Arm Connections

Each dump valve solenoid should draw at least 60mA. If not, connect an appropriate load resistor in parallel with it. For neatness and safety, we recommend that you connect the load resistor only at convenient terminal strips, not at the field wiring arms.

If you use dump valves with internal fault detection (no valve stem switches) but you have configured for external fault detection, simulate the inputs of the dump valve stem switches. Do this by jumpering the input terminals of field wiring arms for dump valve stem switches to the input terminals for the main valve stem switches. Jumper terminal 4, module group 4, slot 1 (Figure 6.4 or Figure 6.8) to terminal 0, module Group 2, slot 0 (Figure 6.2 or Figure 6.6) for chassis A and B.

Optional Microinch Valve Solenoids

Micro-inch mode lets you run your press at low speed (1 to 5 strokes per minute) for setting up dies and making trial runs. Micro-inch mode requires that you provide a separate drive and clutch/brake assembly to drive the shaft with the flywheel bypassed. Micro-inch mode functions only when the main clutch/brake assembly is inoperative, and vice versa. The advantage of the micro-inch mode operation is full press tonnage capacity at low press speeds. Other characteristics include:

Micro-inch motion is initiated using INCH buttons. Micro-inch solenoid valves function only when the mode select switch

is in the MICRO-INCH position.

Diagnostic codes for micro-inch mode are listed in the look-up table.

They are 9-bit binary (3-digit hex) as compared with 8-bit binary (2-digit hex) for all other diagnostic codes.

Voting processors inhibit main valve, auxiliary valve, and dump valve

solenoids whenever you use micro-inch. Voting processors monitor these outputs in micro-inch mode to verify they are not on or shorted.

Connect valve solenoids A and B for micro-inch mode as shown in Figure 6.4 for ungrounded solenoids and Figure 6.8 for grounded solenoids. If you do not use micro-inch, no connections are needed. Figure 6.4 and Figure 6.8 also show connections for:

610

feedback from micro-inch valve solenoid triacs that allows both voting

processors to monitor the on or off state for each triac, check for shorted or open triacs, and shorted or open solenoids of the micro-inch valves.

load resistors, LRA and LRB, for triac feedback from micro-inch valve

solenoids.

switch inputs for the mode select switch, valve stem switches, and

pressure switch for micro-inch circuits.

Chapter 6

Field Wiring Arm Connections

Each solenoid valve should draw at least 60mA. If not, connect an appropriate load resistor in parallel with it. For neatness and safety, we recommend that you connect feedback and load resistors only at convenient terminal strips, not at the field wiring arms.

Select the same type of solenoid valve for micro-inch as you select for main and auxiliary solenoid valves (internal or external fault detection).

Electrical Noise Suppression

Use series C or later 1771-OD output modules because they have improved electrical noise immunity.

To provide additional immunity against surge transient noise, we recommend that you connect metal oxide varistors (MOVs) to the triac outputs of your 1771-OD modules for main and auxiliary valve solenoids, and dump valve solenoids, if used. Typical connections are shown for auxiliary valve solenoids for ungrounded AC power (Figure 6.4)) and grounded AC power (Figure 6.8). Connect the MOVs as close to the field wiring arm terminals as possible. In the grounded AC power configuration, make connections to 3L2 (not located on the field wiring arm) as short as possible.

611

Chapter 6

Field Wiring Arm Connections

120V AC

F u s e

Ground Fault Lamps and Text Switches

1LT 2LT

E-stop

Customer Contacts

E-stop

Station 2

E-stop

Station 1

Figure 6.1 Ungrounded

Isolation/ Step Down Transformer

F u s e

AC Power Connections, Crowbar T

Incoming

Disconnect

Equipment Grounding Conductors

u s

1L1

1L2 1L3

To Motor Starters

Back Panel Ground Bus

To Earth Ground

F u

est Inputs, and Press Interlock Switch

1771-IA Module Group 2 Slot 0

3L1

Chassis A

2L2

E-stop

Station 3

Seal A

E-stop

Station 4

Seal B

Start

Crowbar A

Crowbar B

3L1 3L2

120V AC Power for:

Module group

Slot

0 0

Figure

6.3

6.4

Processor

Power Supply

Press Interlock

Crowbar A Test Input

Crowbar B Test Input

Modulegroup

0 0 1 1 2 2 3 4 5 5

2L2

2L1

120V AC Power for:

Slot

0 1 0 1 0 1 1 1 0 1

3L1

Figure

6.10

6.11

6.12

6.9

6.2

6.3

6.14

6.4

6.13

Chassis B

2L2

12268

612

Figure 6.2 Connections for Optional Switches on Main V Detectors (Ungrounded AC Power)

1771IA Module Group 2 Slot 0

Chapter 6

Field Wiring Arm Connections

alve Stems, Air Pressure Sensors, and Motion

Remove this jumper when using Motion Detector Switch B.

Remove this jumper when using Air Pressure Switch B.

Chassis A

Chassis B

Motion Detector(s)

Switches on Auxiliary Valve Stems

2L1

Make this connection when using Motion Detector Switch B.

Switches on Main Valve

Stems

2L1

Air Pressure Switch(es)

Make this connection when using Air Pressure Switch B.

one or both valves have internal fault detection (no valve stem switches), but you configured for valvestem feedback, then jumper terminals 0 and 7 in chassis A, and do the same in chassis B.

2L1

12284

613

Chapter 6

Field Wiring Arm Connections

Figure 6.3 Connections

for Main and Auxiliary Valve Solenoids, MOV Surge Suppression, Crowbar and

Seal Relays (Ungrounded AC Power)

1771IA 1771OD Module Group 2

Slot 1

Chassis A

2L2

LRA

3L2

LRB

LRBLRA

Module Group 3 Slot 0

Chassis A

Crowbar Relay

Seal Relay

Main Valve Solenoids

3L1

Auxiliary Valve Solenoids

3L2

Chassis B

2L2

NOTES: Use this wiring with figure 6.1 for ungrounded AC power.

LRA and LRB load resistors for triac feedback are 2K ohm, 15 watt resistors

Each solenoid or relay coil should draw at least 60mA.

Connect one MOV between 3L1 and 3L2 for electrical noise suppression.

Connect one MOV to the 3L1 side of each solenoid load and to 3L2 for electrica

If solenoid are not used, replace with 2K ohm, 15 watt resistors.

Crowbar Relay

3L1

l noise suppression.

Seal Relay

3L2

17882

614

Chapter 6

Field Wiring Arm Connections

Figure 6.4 Connections for Optional Dump and/or Microinch V Suppression (Ungrounded AC Power)

For either option For optional Dump Valve For optional Micro-inch Valve

3L2

Module Group 4 Slot 0

1771IA1771OD Module Group 4 Slot 1

alve Solenoids with MOV Surge

1771IA Module Group 5 Slot 0

Dump Valve Solenoids

Chassis A

LRBLRA LRALRB

3L1

Micro-inch Valve

Solenoids

2L1

2L2 2L2

Chassis B

Micro-inch Position on Selector Switch (figure 6.10)

Micro-inch

2L1

ValveStemA

Pressure Sw. A

Switches on Dump Valve Stems

3L2

2L2

Micro-inch ValveStemB

Pressure Sw. B

2L2

NOTES: Use this wiring with figure 6.1 for ungrounded AC power.

LRA and LRB load resistors for triac feedback are 2K ohm, 15 watt resistors

Each solenoid or relay coil should draw at least 60mA.

Connect one MOV to the 3L1 side of each solenoid load and to 3L2 for electrical noise suppressii ss

17881

615

Chapter 6

Field Wiring Arm Connections

Figure 6.5 Grounded AC Power Connections, Crowbar T

est Inputs, and Press Interlock Switch

F u s e

E-stop

Station 2

E-stop

Station 3

Seal A

Crowbar A

Crowbar B

120V AC

Customer Contacts

E-stop

Station 1

E-stop

Station 4

Seal B

Start

Isolation/ Step Down Transformer

Incoming

Disconnect

F u s e

1L1 To Motor Starters

Equipment Grounding Conductors

F u s e

Processor

Power Supply

Crowbar A Test Input

Crowbar B Test Input

F u

1L2 1L3

Back Panel Ground Bus

To Earth Ground

2L2

2L1

1771-IA

Module Group 2 Slot 0

F u s e

3L1

2L2

Chassis A

3L1

2L2

616

3L1 3L2

odule group

3 4

120V AC Power for :

Slot

0 0

Figure

6.7

6.8

2L1

Press Interlock

120V AC Power for:

Module group

0 0 1 1 2 2 3 4 5 5

Slot

Chassis B

Figur e

0 1 0 1 0 1 1 1 0 1

6.10

6.11

6.12

6.9

6.5

6.7

6.14

6.8

6.13

2L2

12273

Remove this jumper when using Motion Detector Switch B.

Chapter 6

Field Wiring Arm Connections

Figure 6.6 Connections for Optional Switches on Main V Air Pressure Sensors, and Motion Detectors (Grounded AC Power)

1771IA Module Group 2 Slot 0

Chassis A

Switches on Auxiliary Valve Stems

2L1

alve Stems,

Make this connection when using Motion Detector Switch B.

Motion Detector(s)

2L1

Remove this jumper when using Air Pressure Switch B.

Chassis B

Switches on Main Valve

Stems

2L1

Air Pressure Switch(es)

Make this connection when using Air Pressure Switch B.

one or both valves have internal fault detection (no valve stem switches), but you configured for valvestem feedback, then jumper terminals 0 and 7 in chassis A, and do the same in chassis B.

2L1

12284

617

Chapter 6

Field Wiring Arm Connections

Figure 6.7 Connections

for Main and Auxiliary Valve Solenoids, Crowbar and Seal Relays, and MOV

Surge Suppression (Grounded AC Power)

1771IA

Module Group 2 Slot 1

Chassis A

Chassis B

2L2

LRA

LRB

3L2

LRBLRA

1771OD

Module Group 3 Slot 0

Chassis A

Chassis B

11 12

Crowbar Relay

Seal Relay

3L1

Crowbar Relay

Seal Relay

3L2

Main

Valve Solenoids

618

NOTES: Use this wiring with figure 6.5 for grounded AC power. 1

LRA and LRB load resistors for triac feedback are 2K ohm, 15 watt resistors

If auxiliary solenoids are not used, replace with 2K ohm, 15 watt resistors.

Each solenoid or relay coil should draw at least 60mA.

Connect one MOV between 3L1 and 3L2 for electrical noise suppression.

Connect one MOV to the 3L1 side of each solenoid load and to 3L2 for electrical noise suppression.

3L1

3L2

Auxiliary Valve Solenoids

17890

3L1

Chapter 6

Field Wiring Arm Connections

Figure 6.8 Connections for Optional Dump and/or Microinch V Suppression (Grounded AC Power)

For either option For optional Dump Valve For optional Micro-inch Valve

1771OD Module Group 4 Slot 0

Chassis A

3L2

LRBLRA

1771IA Module Group 4 Slot 1

LRALRB

Micro-inch Position on Selector Switch

2L2 2L2

alve Solenoids with MOV Surge

1771IA Module Group 5 Slot 0

Chassis A

Micro-inch

Valve Stem A

Pressure Sw. A

2L1

Dump Valve Solenoids

3L2

Chassis B

Micro-inch Valve Solenoids

Switches on Dump Valve Stems

2L2

2L1

Chassis B

Micro-inch Valve Stem B

Pressure Sw. B

2L2

17889

NOTES: Use this wiring with figure 6.5 for ungrounded AC power.

LRA and LRB load resistors for triac feedback are 2K ohm, 15 watt resistors

Each solenoid or relay coil should draw at least 60mA.

Connect one MOV to the 3L1 side of each solenoid load and to 3L2 for electrical noise suppression.

619

Chapter 6

Field Wiring Arm Connections

Cam Limit Switches

Install two separate cam limit switch assemblies each with three cams and three cam limit switches. Connect cam limit switches exactly as shown in Figure 6.9. This allows each voting processor to monitor its own limit switches for:

top-stop-check (TCAM) run-on (RCAM) anti-repeat (ACAM)

Each cam limit switch assembly must be independently driven by the press shaft through a separate coupling device. Couple each cam limit switch assembly to the shaft through a separate direct coupling, a separate gear assembly, or a separate chain assembly.

WARNING: To guard against injury to personnel and damage to your press, install two separate cam limit switch assemblies that are independently driven by the press shaft through separate coupling devices.

Two separate cam limit switch assemblies allow your clutch/brake controller to stop press motion in case there is a failure within either cam limit switch assembly or a breakage in either coupling device.

Set each pair of cam limit switches to similar settings as shown in Figure 5.1. If the settings are not similar, the voting processors can disagree on their perceived shaft zones and cause nuisance shutdowns.

We recommend the Allen-Bradley Rotating Cam Limit Switch (cat. no. 803-P3). This rugged duty cam limit switch assembly is well suited for press applications. For ordering information, see the Allen-Bradley Industrial Control Catalog or contact your local Allen-Bradley sales engineer or distributor.

Because the Cat. No. 803-P3 is an industrial grade heavy-duty limit switch, we recommend that it switch a power circuit drawing at least 0.25 Amp. Install a 470 or 500 ohm 50-watt load resistor in parallel with the AC input to generate this current.

You need to mount the resistors on the subpanel to keep dissipated heat (from resistors) away from modules, and because the resistor’s axial leads are not compatible with the wiring arm.

620

Chapter 6

Field Wiring Arm Connections

Cam Limit Switch Assembly A

Cam Limit Switch Assembly B

Figure 6.9 Connections

Topstopcheck (TCAM)

Run-On (RCAM)

Anti-Repeat (ACAM)

2L1

Topstopcheck (TCAM)

Run-On (RCAM)

Anti-Repeat (ACAM)

for Cam Limit Switch Assemblies

Chassis A

Chassis B

1771-IA

Module Group 1

Slot 1

[1]

2L2

[1]

2L2

2L1

[1]

470 ohm 50 watt 1%, or 500 ohm 5% on seperate terminal strip.

12278

621

Chapter 6

Field Wiring Arm Connections

Required Hardwire Inputs

This

Input

Mode Select (terminals 03)

Main Motor Forward (terminal 4) Inch or

Connect hardwire inputs in parallel to chassis A and B so each voting processor can monitor the following inputs in parallel:

Input Terminal MG Slot Figure

Mode

Select Switch Main Motor Forward Barrier Guard Stopontop Arm Continuous

Press Interlock

03

0 4 5 6 7

0 0 0 0 0

6.10

6.1, 6.5

When connected, these inputs function as follows:

With

PM in

this Mode

Determines the mode

Microinch

ith this

Status

ON or OFF

The PM module:

detects the selected mode

uses these signals to determine proper CAM action

Barrier Guard (terminal 5)

Arm Continuous (terminal 7)

Press Interlock (terminal 6) chassis A & B MG 2, Slot 0

Single stroke and Continuous

Continuous OFF

Continuous, only

any ON

if turned OFF after motion has started

momentary (less than 3 sec)

if turned OFF

WARNING: To guard against injury to personnel, wire you barrier guard switch exactly as shown in Figure 6.10. Conform to all requirements for safeguarding the point of operation of your press as detailed in OSHA Regulations, Title 29-Labor, Chapter XVII, Section 1910.217.

detects one of the permissives to start or maintain a stroke

immediately turns OFF solenoid outputs

prevents press from starting, or stops it immediately

Each ON/OFF transition starts a 5sec period in which you must press all Pressing Arm Continuous again within 5 seconds starts another 5sec period.

detects one of the permissives to start or maintain a stroke after transition

immediately stops the press, or prevents it from starting

active RUN buttons to start continuous stroking.

622

Chapter 6

Field Wiring Arm Connections

If you have more than one operator station, connect the STOP-ON-TOP buttons in series.

Figure 6.10 Connections

for Main Motor Forward, Barrier Guard, Stop on Top, Arm Continuous, and

Mode Select Switches

Main Motor Forward

Barrier Guard

Station 1 Station 2

Stop-on-top

Station 3 Station 4

Arm Continuous

2L1

[1]

Station

MICRO-INCH (figures 6.4 and 6.8)

1771IA Module Group 0

Slot 0

Chassis A

[1]

2L2

Off

Mode Select

Inch

Single Stroke

2L1

[1]

This normally open limit switch must be closed for continous operation.

Continuous

Chassis B

2L2

12279

623

Chapter 6

Field Wiring Arm Connections

Inch Buttons and PlugIn Operator Stations

Connect the (NC) and (NO) contacts of each INCH button to opposite chassis exactly as shown in Figure 6.11. This allows both voting processors to monitor and cross check both INCH buttons for correct operation. You may locate the INCH buttons at an operator control panel. However, they are not part of any plug-in operator station. Wire them directly as shown in Figure 6.11.

Plug-in operator stations 1 thru 4 and dummy plugs that you may use to bypass these stations are shown in Figure 6.11 and Figure 6.12. You may alter this configuration according to the number of bypassable stations that you need for your press system.

If all run stations are bypassed, you may still operate in inch or micro-inch mode using INCH buttons.

For example, if you have only one operator station, you may wire station 1 as shown in Figure 6.11, using direct wiring instead of operator station plug connections. However, you must also bypass station 2, using direct wiring instead of dummy plug connections. In other words, to bypass station 2, you may simply connect terminals 3 and 4 of each field wiring arm to 2L1.

For another example, if you have three operator stations, and only station 2 will be in constant use, build and wire plug-in stations 1 and 3 as shown in Figure 6.11 and Figure 6.12. Directly wire station 2 according to Figure 6.11. Directly wire station 4 bypass according to Figure 6.12. You must also build and wire the dummy plugs for stations 1 and 3.

Important: Configure or do not configure stations 3 and 4 through backplane switch settings as described in chapter 3 and PLC configuration bits as described in chapter 4. If you configure plug-in station 3 and/or station 4, but do not use either or both, you must bypass the unused station(s) with a dummy plug(s). If you have not configured for stations 3 and 4, you need not place a 1771-IA module in module group 1, slot 0, chassis A and B.

Connect the (NC) and (NO) contacts of each RUN button to opposite chassis exactly as shown in Figure 6.11 and Figure 6.12 for all stations. This allows both voting processors to monitor and cross check all RUN buttons for correct operation.

624

Chapter 6

Field Wiring Arm Connections

Figure 6.11 Connections

Dummy Pl ug for Station Bypass

for Operator Stations 1 and 2, Dummy Plugs, and Inch Pushbutton Switches

1771IA

Left Run

Left Active

Left 2L1

Right Run

Right Active

Right 2L1

Stop-On-Top

E-st op

Plug-in Operator Stati on 1

Left Run

Left Active

Left 2L1

Right Run

Right Active

Right 2L1

Stop-On-Top

E-st op

Ch A-

Ch B-

Ch A-

Ch B

-0

Ch A-

Ch B-

Seefigure6.10

See figure 6.1 or 6.5

Ch A

Ch B-

Ch A-

Ch B-

Ch A-

Ch B-

Seefigure6.10

See figure 6.1 or 6.5

2L1

Module Group 0

Ch A

Chassis A

Ch B-

Chassis B

Left Inch

Slot 1

Right Inch

2L2

Dummy Pl ug for Station Bypass

IMPORTANT:

Plug-in Operator Stati on 2

For These Connections

E - STOP STOP-ON-TOP

Plug either the operator station or dummy plug into the control panel.

See Figures

6.1 or 6.5

6.10

2L1

17879

625

Chapter 6

Field Wiring Arm Connections

Figure 6.12 Connections for Operator Stations 3 and 4, and Dummy Plugs

Dummy Plug for Station Bypass

Left Run

Left Active

Left 2L1

Right Run

Right Active

Right 2L1

Stop-On-Top

E-stop

Plug-in Operator Station 3

Left Run

Left Active

Left 2L1

Right Run

Right Active

Right 2L1

Stop-On-Top

E-stop

Ch A-0

Ch B-1 Ch A-2

Ch B-0 Ch A-1 Ch B-2

2L1

See figure 6.10

See figure 6.1 or 6.5

Ch A-3 Ch B-4 Ch A-5

Ch B-3 Ch A-4 Ch B-5

2L1

See figure 6.10

See figure 6.1 or 6.5

1771-IA Module Group 1 Slot 0

Ch A-0 Ch A-1 Ch A-2 Ch A-3 Ch A-4 Ch A-5

Chassis A

Ch B-0 Ch B-1 Ch B-2 Ch B-3 Ch B-4 Ch B-5

Chassis B

2L2

626

Dummy Plug for Station Bypass

IMPORTANT:

Plug-i n Operator Stati on 4

For These Connections

E - STOP STOP-ON-TOP

Plug either the operator station

or dummy plug into the control panel.

See Figures

6.1 or 6.5

6.10

17880

Chapter 6

Field Wiring Arm Connections

Important: When mounting RUN and INCH buttons, ensure that:

all RUN buttons and both INCH buttons are either guarded or

flush-head pushbutton switches, such as Allen-Bradley Bulletin 800P Palm Operated Pushbuttons. You can operate guarded buttons only by reaching through their guard rings.

the distance between each left RUN or INCH button and its

corresponding right RUN or INCH button is great enough to allow operation of both buttons only by both hands.

all RUN and INCH buttons are located at greater than minimum safe

distance from the point of operation of your press as specified in OSHA Regulations, Title 29-Labor, Chapter XVII, Section 1910.217, and ANSIB11.1, section 5.3 Formulas for calculating the minimum safe distance are included.

Optional Binary Display

Optional Indicators

Use the optional diagnostic binary display shown in Figure 6.13 to troubleshoot your press. Chapter 7 lists the diagnostic messages.

We recommend Allen-Bradley Small Pilot Lights, Transformer Type (cat. no. 800T-PS16R) with 1771-OA Output Modules. You may order color caps separately (red is standard):

Red

= cat. no. 800T Green = Cat. no. 800T Amber = cat. no. 800T Blue = cat. no. 800T White = cat. no. 800T Clear = cat. no. 800T

N122R

N122G

N122A

N122B

N122W

N122C

You may also want to order Small Pilot Light Guards (cat. no. 800T-N226), to protect the caps against accidental breakage.

STOP-ON-TOP FAULT - tells an operator that the brake is faulty. If the shaft overshoots the near top position in inch, single, or continuous mode, both voting processors prohibit clutch actuation, and turn on this indicator. (See Table 5.a and Figure 6.14)

RUN WINDOW - turns on when starting the press in these modes:

single-stroke: When both RUN buttons have been pressed at one

station, other active stations have 5 seconds to press their RUN buttons as shown by this indicator.

627

Chapter 6

Field Wiring Arm Connections

continuous: Each ON/OFF transition of the ARM CONTINUOUS

button starts a 5-second period in which you must press all active RUN buttons to start continuous stroking as shown by this indicator. Pressing the ARM CONTINUOUS button again within 5 seconds (after the transition) starts another

Important: Press the momentary ARM CONTINUOUS button less than 3 seconds. Pressing it for a longer time may inhibit its function and require you to release and press it again.

MICRO-INCH - turns on when voting processors detect an error in micro-inch mode and display a diagnostic message code which is displayed by means of the diagnostic message display. Use look-up table

7.C to determine the fault or error.

You can use the micro-inch output in two ways:

to turn on the MICRO-INCH indicator to set the most significant bit in a 9-bit binary output.

Diagnostic codes for micro-inch mode are 9-bit binary (3-digit hex) with 1 as the first digit (Figure 6.14). Diagnostic message codes for all other modes are 8-bit binary (2-digit hex). (Figure 6.13)

628

Chapter 6

Field Wiring Arm Connections

Chassis A

Chassis B

Figure 6.13 Connections

1771-OA Module Group 5 Slot 1

for Optional Diagnostic Message Display

We recommend Allen-Bradley Small Pilot Lights, Transformer type (cat. no. 800T-PS16R).

2L1

Bit17Bit16Bit15Bit14Bit13Bit12Bit11Bit

2L2

2L1

Bit17Bit16Bit15Bit14Bit13Bit12Bit11Bit

2L2

12285

629

Chapter 6

Field Wiring Arm Connections

Figure 6.14 Connections for Brake Fault, Run W

1771OA

odule Group 3

Slot 1

Chassis A

StopOnTop Fault

2L1

Run Window

Micro-Inch

indow

, and MicroInch Indicators

W recommend AllenBradley Small Pilot Lights, Transformer type (cat. no. 800T PS16R).

2L2

Chassis B

2L1

Micro-Inch

2L2

12286

630

Chapter 6

Field Wiring Arm Connections

Lamp Test

Inputs to Chassis C

When you configure the lamp test feature, you can check that all indicators are working by pressing the LAMP TEST switch connected to chassis C. The clutch/brake controller energizes the outputs to the following indicators while the lamp test input is on:

Module Group 5, Slot 1, Chassis A and B for the diagnostic display Module Group 3, Slot 1, Chassis A and B for BRAKE FAULT, RUN

WINDOW, and MICRO-INCH indicators.

Since hex (hexadecimal) numbers are easier than binary for people to read, you may want to display hex message codes. You may provide a device to convert the eight-digit binary outputs of chassis A and B, module group 2, slot 1 to two-digit hex displays. Select output modules that provide proper voltage to the device. For assistance, contact your local Allen-Bradley sales engineer or distributor.

In chapter 7, we describe other methods of displaying hex message codes.

Chassis C provides for these functions:

reset latched messages lamp test customer interlock (redundant to Figure 6.1 or 6.5) barrier guard (redundant to Figure 6.10) stop-on-top (redundant to Figures 6.11 and 6.12)

This chassis is optional because you can:

omit redundant functions use alternatives for the non-redundant functions

As alternatives, you can program the PLC to transfer the message reset bit (bit 14) and/or the lamp test bit (bit 16) to the clutch/brake modules to provide those functions. If already using A-B’s PanelView



, use that

operator interface to implement these functions.

If you use chassis C, follow these steps:

1. Wire PLC command switches as shown in Figure 6.15

2. Include command rungs, Figure 4.6, 4.7, or 4.8.

3. Set the backplane switches of chassis C to a valid rack address for

your PLC and clutch/brake system.

631

Chapter 6

Field Wiring Arm Connections

Chassis C can be any remote or local I/O chassis connected to your PC. Refer to sections titled “Panel Switches and Operator Stations”in chapter 3, and “Configuration Rungs” in chapter 4, for additional information.

Figure 6.15 Connections

2L1

Customer Interlock

for Optional PLC Command Switches

Chassis C

(Remote I/O Chassis)

1771-IA AC Input Module

Rack 3, Module

Group 2

Bits 10 thru 17

Barrier Guard

Bit 13 Bit 14

Reset Latched Messages

Bit 15

Bit 16

Stop-On-Top

Lamp Tes

To write the ladder program to implement the use of these switches, refer to

Figure 4.6, Figure 4.7 or Figure 4.8.

2L2

632

12287

Troubleshooting

Chapter

Chapter Objectives

Troubleshooting Considerations and Requirements

After you have read all previous chapters, this chapter can help you:

safely isolate and correct problems in your press system interpret diagnostic messages generated by your clutch/brake controller use the module indicators in chassis A and B while troubleshooting your

press system

This chapter explains troubleshooting techniques and refers to previous chapters. We recommend that you read the entire manual and all technical documentation provided by the press manufacturer before troubleshooting any problem with your press system.

We also recommend that you adhere to the safety requirements detailed in local code and laws and 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 Metal working Machine Tools

Troubleshooting with LED's

Familiarity with this documentation makes your troubleshooting not only safer, but easier as well.

Use these figures and tables when troubleshooting with LED indicators

Reference Description

7.1

Figure

Figure 7.A

Figure 7.B

Figure 7.2

Location of LED indicators

How to read the PM Module'

How to read the PM Module' CBM F

AUL

T indiators

How to troubleshoot with LED indicators

s ACTIVE indicator

s I/O RACK F

AUL

T and

71

Chapter 7

Troubleshooting

Figure 7.1

Indicators for Chassis A or B

Module

Input Module Indicators

Input status indicators are clear. On = input One indicator per terminal.

PM Module Indicators

ACTIVE

(green)

CBM

FAULT

(red)

I/O RACK

FAULT

(red)

Refer to tables 7.A and 7.B

1771-PM Module 1771-IA Modules

Output Module Indicators

Output status indicators are red. On = output

Blown fuse indicators are clear. On = blown fuse

1771-OD Module

Table 7.A ACTIVE Indicator

If the ACTIVE indicator is blinking, identify the problem by the number of blinks. There are 2 sets of blinks:

first set of blinks short pause second set of blinks long pause

repeat continuously

12292

Number of Blinks

1st Set

1 3

1 4

2 1

2 3

3 2

3 4

4 1

4 3

72

2nd Set

Problem Correction

Faulty RAM

Faulty PROM

Illegal rack address

The 1771PM modules contain dif

ferent firmware

Missing a 1771PM module at power up

Illegal interrupt

Replace 1771PM module

Set the 1771PM module switches as detailed in chapter 3

Install 1771PM modules with identical revision codes

Install and fully seat both 1771PM modules

Cycle power Replace 1771PM module

Firmware fault Replace 1771PM module

Lost communications between 1771PM modules, or watchdog timed out

Check connections between 1771PM modules or Replace 1771PM module

Table 7.B I/O RACK F

AUL

T and CBM F

AUL

T Indicators

Chapter 7

Troubleshooting

I/O RACK

FAULT

CBM

FAULT

On Off

or OFF

Press will not run.

Is a diagnostic message displayed

Are all status indicators for

inputs to the 1771IA module

off? (See Figure 7.1)

Is the mode select switch off?

Problem Correction

Intermittent electrical noise, faulty 1771PM module, or shorted I/O chassis backplane

Intermittent electrical noise or faulty 1771PM

module

Figure 7.2

roubleshooting Flowchart for Module Indicators

Yes

No No

Go to table 7.C.

All power is off.

(See figure 6.1 or 6.5)

Select proper

mode.

Cycle power Replace 1771PM module Replace each I/O module one at a time Replace I/O chassis

Cycle power Replace 1771PM module

Does the

press run?

Yes

Resume

normal

operation.

Check the 1771PM module indicators. (See figure 7.1)

Are both ACTIVE indicators on?

Is either ACTIVE indicator blinking?

Is either I/O RACK FAULT indicator on?

Is either CBM FAULT indicator on?

Replace the 1771PM module whose ACTIVE indicator is off, or check the chassis power supply.

[ 1 ] The controller will not operate if you manually configure chassis A and B to a half rack

Warning: To guard against injury to personnel, open and lock the main power disconnect before adjusting, replacing, or repairing any mechanical or electrical component in your press system. This consists of the press, clutchbrake, controller, and all associated wiring and control panels.

Yes

Are rack addresses, rack size [1], and/or baud rate set correctly?

Yes

Press should run. Refer to press builder's documentation.

Go to table 7.A

Go to table 7.B

12290

73

Chapter 7

Troubleshooting

General Troubleshooting Procedure

Although the procedure for troubleshooting your clutch/brake controller varies with each problem, use the following steps as a general procedure:

1. Examine Figure 7.2 and NO TAG.

2. Answer questions in Figure 7.2 and NO TAG until you see a

reference to another figure or table. Table 7.C lists diagnostic codes.

3. Place a bookmark at Figure 7.2 or NO TAG and go to the figure or

table that it referred to in step 2. That figure or table might contain other references. Therefore you may need several bookmarks while working among various figures and tables throughout this manual. Table 7.D is your primary reference.

4. Isolate the problem using the guidelines in Figure 7.2, or NO TAG,

Table 7.C, and other references.

5. Correct the problem.

Troubleshooting Hints

WARNING: To guard against injury to personnel or damage to your press, open and lock the main power disconnect to turn off all AC and DC power before:

manually turning the press shaft adjusting or repairing any moving parts in your press repairing or replacing any wiring in your press system,

including any field wiring arm or cable connections

replacing any electronic or electrical components, such as

clutch/brake controller and I/O modules, power supplies, or chassis

replacing blown fuses in your press system

Diagnostic codes are specific and point to the exact input or output device that controls PM operation. When your system is wired as outlined in this manual, you can identify the cause of a fault as follows:

1. Review the section “Diagnostic diagnostic message codes”, below.

74

2. Note the diagnostic code for both

PM modules

Press will not run.

Chapter 7

Troubleshooting

3. Determine the input or device causing the fault from the

section/sub-section heading in Table 7.D where the fault code was tabulated and from other figures or tables referred to.

4. Interpret the messages. Was this output supposed to be on? Was that

device supposed to be off?

Figure 7.3 Troubleshooting

Flowchart for Diagnostic diagnostic message codes

Is a diagnostic message

displayed?

Yes

See Table 7.C

Does the problem relate to an

input switch or connection?

Does the status indicator for the

input to the 1771IA module

respond correctly? (See Figure

7.1)

Yes

Go to figure 7.2

Does the problem relate to a

solenoid or its triac?

Yes

Is a blown fuse indicator on for

any 1771OD module? (See

Figure 7.1)

Yes

Replace the fuse.

Replace the input switch or

check its wiring.

Take action according to Table

7.C

Replace the 1771OD module or

the solenoid. Check solenoid

wiring.

Replace the 1771IA module.

12291

75

Chapter 7

Troubleshooting

5. Trace wire leads and/or inspect the faulted device.

If you wired the PM system in a manner other than outlined in this manual, faults are more difficult to track. Proceed as follows:

1. Determine if the fault and corresponding diagnostic code was caused

by alterations in system wiring, i.e., if the fault is a run station fault, are the run stations wired directly to the PM system or through auxiliary chassis controlled by the programmable controller? If the latter is the case, you should look at the programmable controller’s ladder program.

2. Determine if you have an I/O problem. The PM module can only

diagnose its own I/O level. That is, it alerts you to the exact input or output within the system that it “sees” as incorrect. You must interpret from there.

Troubleshooting Example

Assume that your press is running normally, then stops suddenly. For this example, we will follow the general troubleshooting procedure.

1. Examine Figure 7.2 and Figure 7.3.

2. The first question asked in both figures is whether a diagnostic

message is displayed. For this example, we assume that chassis A and B are displaying these diagnostic messages:

chassis A 0010 1001 (hex 29) chassis B is displaying 0010 1000 (hex 28)

Because your answer is yes, see Table 7.D to define the problem.

3. In Table 7.D you find that:

Binary 0010 1001 (hex 29) is a T-type (trip condition) message that

tells us: Station 1 active connection is open (for alternate chassis). Check wiring. (figure 6.11).

Since chassis A is displaying this message, the alternate chassis is

chassis B.

Binary 0010 1000 (hex 28) is the same message. It is for the

chassis displaying the message, chassis B in this case.

76

Chapter 7

Troubleshooting

In Table 7.C, the numbers in parentheses are figure references. In this example, both messages refer to Figure 6.11. Therefore, place a bookmark at Table 7.D and go to that figure.

4. Figure 6.11 shows station 2 active connections for both chassis:

Left Active connects to terminal 5 of field wiring arm for module

group 0, slot 1 in chassis A.

Right Active connects to terminal 5 of field wiring arm for module

group 0 slot 1 in chassis B.

Since you learned in step 3 that the problem relates to chassis B, you can concentrate on the Right Active connection.

5. To further isolate the problem, place a bookmark at Figure 6.11 and

return to Figure 7.3. The next question in this figure asks: Does the problem relate to an input switch or connection? In this example, your answer is yes, which leads you to another question. Does the status indicator for the input to the 1771-IA module respond correctly? (See Figure 7.1).

6. Figure 7.1 shows you where to find the input status indicators. For

this example, assume that the input status indicator in chassis B for module group 0 slot 1, terminal 5 is off.

As shown in Figure 6.11, the Right Active connection is jumpered as long as Plug-In Operator Station 2 is plugged in. Therefore, the indicator for Right Active should be on.

7. Return to NO TAG. Since this indicator is off, your answer is no to

the question: Does the input status indicator respond correctly? NO TAG tells you to replace the input switch or check its wiring.

8. Correct the problem after first opening and locking the main power

disconnect. Inspect and test the Right Active connection (Figure

6.11). For this example, you find a broken wire in Plug-In Operator Station 2. Repair the broken wire then, close the main disconnect and return the press to normal operation.

77

Chapter 7

Troubleshooting

Display of Diagnostic Message Codes

When the PM module detects a condition, it immediately generates the corresponding message code. You can display diagnostic message codes with an optional display device connected to output modules in these locations in chassis A and B:

module group 5, slot 1 (8-bit binary code) module group 3, slot 1, bit 2 (9th bit for micro-inch)

When using micro-inch mode, diagnostic diagnostic message codes are 9-digit binary (3-digit hex) rather than 8-digit binary (2-digit hex) for other diagnostic message codes. The most significant bit (bit 9) indicates a micro-inch code. When set, 2-digit hex codes XX become 3-digit hex codes 1XX for micro-inch.

You can display diagnostic message codes in 9-digit binary, or use an optional binary-to-hex converter and display diagnostic message codes in easy-to-read hexadecimal notation. No programming is required. Just install output modules in those locations and connect display devices (Figures 6.13 and Figures 6.14).

You can also view diagnostic message codes with an Allen-Bradley programming or display terminal using the data monitor feature:

using this

processor

PLC2 family

PLC3 family

PLC5 family

PLC5/250

Use this device

Industrial T Handheld T

Industrial T Data access panel on the front of the processor or 1784T45, T47, or T50 Programming T

1784T45 ,T47, or T50 Programming T

1784T45, T47, or T50 Programming T

erminal (1770T3)

erminal (1770T1

erminal (1770T4)

erminal

78

Chapter 7

Troubleshooting

Types of Diagnostic Message Codes

PM modules detect operational and equipment faults, and indicate corresponding diagnostic message codes for more than 250 detected conditions. Diagnostic diagnostic message codes refer to specific inputs or outputs, such as a contact on a switch or cam. Upon detecting a condition, each PM module generates its own diagnostic code. Quick succession of events may cause each PM module to detect a different condition, one condition resulting from the other.

PM modules generate three types of diagnostic message codes according to the severity of the condition:

Code Type Priority Method

N nonlatched least

L latched moderate

L latched

followed by "0D"

moderate

of reset

Clears itself when conditions no longer exist

Correct the condition Press the RESET LA

Correct the condition Restore power Inch the press to neartop position Push the RESET LA Press the ST

TCHED MSG pushbutton

T button

T tripped highest

Correct the condition Press the RESET LA Press the ST

T button

TCHED MSG pushbutton

Nonlatched Messages (lowest priority)

Non-latched messages occur when the PM module detects an error condition while the press is idle (clutch/brake solenoids are OFF) and the control seal relays are either open or closed. The PM module:

prevents press operation as long as the error is present

After you correct the error conditions, the PM module automatically clears the message and readies itself for operation. These messages are typically related to a wiring error or equipment malfunction.

Example: A broken or loose wire on the active line of Run Station 1 (Figure 6.13) could cause the PM module to generate the following message code:

Error 10 (Hex) Check RUN button signals. Activate or bypass the station.

79

Chapter 7

Troubleshooting

Latched Messages (medium priority)

Latched messages occur when the PM module detects error conditions while the press is running (clutch/brake solenoids are ON). The module:

stops press motion immediately latches ON a diagnostic message turns OFF solenoid valve triacs

(seal relays remain closed)

The latched-message condition remains until you correct the problem and press the RESET LATCHED MSG pushbutton wired to chassis C. Typical error conditions are equipment failures or improper mechanical adjustments.

Example: If the barrier guard switch should open while the press is running in continuous mode, the PM module would immediately turn OFF the solenoid valve triacs and generate the following message code:

Error 09 (Hex) Barrier guard dropout or absent

Latched Messages Followed by 0D" (corrective intervention)

Whenever a diagnostic message code is followed by the ”0D” message code, the maintenance technician must reset the PM system by removing control power, and then re-applying power. This forces the technician to correct the problem before press operation can continue.

Standard Corrective Action

Because the ”0D” message code accompanies a variety of other diagnostic message codes, we recommend a standard corrective action. Use it when correcting faults for “OD” diagnostic message codes presented in Table

7.C. Check for proper cam setting and operation.

(Refer to Figure 5.1 in this manual.) Check for bad or frozen cam contacts If more than one cam assembly is used for multi-speed press operation,

check switching of these cams. Check for proper wiring of cam switches. Check for proper wiring of I/O module swing arms.

710

Chapter 7

Troubleshooting

Restarting the Press

You re-start the press with this procedure:

1. When the “OD” message is displayed, press ESTOP to drop the seal

relays.

Message code “50” is displayed (swingarm power dropout)

2. Press the START button.

3. Press the RESET LATCHED MSG button.

4. Select INCH mode if not already selected.

5. Inch the press to the near-top position.

Types of OD" Diagnostic Message Codes

The “OD” diagnostic message code accompanies the following type of diagnostic messages.

Type of Message Hex Code

Downstroke 066  067

Upstroke 068  069

Brake or Motion Detector 072  079, 07A

Cam Limit Switch

Near Top Position

Transition to Downstroke

Downstroke

Transition to Near Bottom Zone

Near Bottom Zone

Transition to Upstroke

080  085

086  089

08A  08F

090  093

094  099

09A  09D

Upstroke

Transition to Near Top Position

Hardware or Cable 0F1  0F3

09E  09F, 0A0  0A3

0A4  0A7

711

Chapter 7

Troubleshooting

Tripcondition Message (highest priority)

Trip-condition messages occur anytime the PM module detects a fault condition that casts doubt on the system’s ability to:

measure the press’s shaft angle control power to the solenoid valve triacs

When it detects this type of fault, the PM module immediately:

stops press motion opens the seal relays

If it detects that the seal relays did not open, it

blows the main power fuses with crowbar relays

The trip-condition fault remains until you correct the problem and press the RESET LATCHED MSG pushbutton wired to chassis C. Typical fault conditions are due to system configuration, feedback signals, run stations, or triacs. After corrrecting the fault condition, get back into operation with the same steps as 0D Latched Message, above.

Messagecode Priority

Example: If the motion detection input (Figure 6.2) should turn ON while the press is operating, and you did not configure for motion detection, the PM module would generate the following message:

Error BB (Hex)

Motion detector signal present though motion detector feedback is not configured.

Diagnostic diagnostic message codes are not queued. When the PM module detects multiple latched or tripped message conditions, it sends the highest priority message code to the processor so your ladder logic can process it, and to pre-determined slots in its I/O chassis so output modules can display it. When you correct the condition and press the MESSAGE RESET button, the PM module sends the next highest priority message code if an error condition still exists. A message code of higher priority overrides a message code of lower priority. For error conditions of equal priority, the PM module sends the message code corresponding to the first detected condition.

712

Chapter 7

Troubleshooting

Processing Diagnostic Message Codes

If you want to maintain a record of diagnostic message codes or process them for reasons other than display, you can write ladder logic to examine the 9-bit binary message code that PM modules return to the processor. Do this by examining bits in the input image table corresponding to:

module group 5, slot 1 (8-binary code) module group 3, slot 1, bit 2 (9

bit for micro-inch)

For example, examine a bit as follows:

I:r5 ||

where r is the I/O rack number

If recording a history of diagnostic message codes such as stored in a FIFO stack, we suggest that you record only diagnostic message codes that exist for longer than one second and disregard all diagnostic message codes resulting from transient conditions of shorter duration. This guards against storing no-fault status diagnostic message codes such as generated during start-up.

Diagnostic Message Codes (Table 7.C)

Table 7.C explains message codes generated by PM modules.

For each message code, the table states:

type of diagnostic message the problem causing the diagnostice message to be displayed recommended corrective action

In Table 7.C we use mnemonics for cam switches for the sake of brevity as follows:

ACAM: anti-repeat cam switch RCAM: run-on cam switch TCAM: sto-top-check cam switch

713

Chapter 7

Troubleshooting

Table 7.C Diagnostic

MISCELLANEOUS MESSAGES

HEX CODE

01 N IMPROPER MODE SELECTION

02 N ALL STATIONS BYPASSED

03 N SHAFT NOT AT TOP. CAN NOT ENTER SINGLE OR

TYPE PROBLEM CORRECTIVE ACTION

The PM module expects to see one of the allowable press modes (off, inch, microinch, single, continuous, within 0.1 sec's after swingarm power is sealed in, and will only allow one mode at any given time.

In the single stroke or continuous mode, the PM will not allow the press to cycle if all operator run stations are bypassed. At least one station must be present. Inch and microinch modes will operate with all run stations bypassed.

CONTINUOUS MODE

The PM is selected to go into the single or continuous mode, but the cam switches, which indicate shaft position, are telling the PM that the press is not at the top.

Message Codes Associated with the "0D" Message Code

Check selector switch wiring in figure 6.10 and operation. Check wiring to swingarm. Check I/O module for correct operation.

Check station wiring in figures 6.11 and 6.12. Check swingarm wiring and I/O module for proper operation.

Check for proper cam settings in figure 5.1. Check for proper cam wiring in figure 6.9. Inch press to the top position.

04 N AWAITING RELEASE OF ALL RUN BUTTONS FOR ENTERING

SINGLE OR CONTINUOUS MODES

05 N/L MAIN MOTOR FORWARD CONTACT DROPOUT OR ABSENT

The main motor forward input needs to be on in order to enter single or continuous modes. Once in single or continuous mode, the press will stop if that input goes off.

06 N ACAM OPEN, PREVENTING ENTRY INTO SINGLE OR

CONTINUOUS MODE.

07 N AWAITING RELEASE OF ALL STOPONTOP BUTTONS FOR

ENTERING CONTINUOUS MODE.

You must release STOPONTOP buttons of all active stations before the PM can switch to another mode of press operation.

08 N AWAITING RELEASE OF ARM CONTINUOUS BUTTON FOR

ENTERING CONTINUOUS MODE.

You must release the ARM CONTINUOUS button and press the RUN buttons of all active stations before the PM can switch to continuous mode.

09 L BARRIER GUARD DROPOUT OR ABSENT.

Press stops operation.

Release all run buttons. Check for proper operation of all buttons. Check button wiring in figures 6.11 and 6.12.

Check feedback contact and wiring in figure 6.10. Check swingarm wiring and I/O module for proper operation.

Check wiring of ACAM in figure 6.9 and check ACAM position in figure 5.1.

Check RUN button wiring figures 6.11 and 6.12.

Check ARM CONTINUOUS button wiring figure 6.10.

Check for faulty switch, broken wire, etc. figure 6.10.

714

MISCELLANEOUS MESSAGES (cont'd)

Chapter 7

Troubleshooting

HEX CODE

0A N/L PC ENABLE DROPOUT OR ABSENT

0B N STOPONTOP SIGNAL FROM PC PREVENTING ENTRY TO

0C N AWAITING RELEASE OF INCH BUTTONS FOR ENTERING

TYPE PROBLEM CORRECTIVE ACTION

*LATCHED MESSAGE The PC enable bit from the processor must be maintained to the PM while in any mode other than off. The PM must also see the PC enable bit maintained while switching to off mode.

*NON LATCHED MESSAGE The PM must first see the PC enable bit go on before it sees any request to change modes. If this does not happen, this message will occur.

CONTINUOUS MODE.

PM module is still receiving STOPONTOP command from the PC processor. This command must be absent before PM can enter continuous mode.

INCH MODE.

Inchbutton inputs must indicate that both been released, then pushed again before its PM Module will allow inching motion. This is the antetiedown feature of the PM Module. refer to figures 5.2 and 6.11.

inch buttons have

When the PM is actually in the off mode, the PC enable bit may be turned off.

This condition should be used as a status prompt that indicates the user program has not given final permission to enter the selected mode. Check programming in figure4.6.

Check ladder logic (figure 4.6, 4.7, 4.8).

Refer to figure 5.2. Check wiring in figure 6.11.

0D N

0E N PC RUN MODE DROPOUT OR ABSENT

PC processor is not in RUN mode, probably due toa processor fault.

0F N PRESS INTERLOCK DROPOUT OR ABSENT Check wiring of press interlock switch in figure 6.1 or 6.5.

10 N CHECK RUN BUTTON SIGNALS. MAKE STATION ACTIVE OR

BYPASSED.

15 N MAKE LEFT AND RIGHT ACTIVE CONNECTIONS IDENTICAL. Check station #1 (figure 6.11).

Correct processor fault. Switch to RUN mode.

The cactivestation input is absent, but the PM module is detecting a changeofstate of operator RUN buttons. Check station #1 (figure 6.11).

715

Chapter 7

Troubleshooting

STATION MESSAGES

HEX CODE

6A N AWAITING RELEASE OF ALL ACTIVE RUN BUTTONS"

TYPE PROBLEM CORRECTIVE ACTION

OCCURS UNDER THE FOLLOWING CONDITIONS:

1. If after pressing 1 active run button and then not pressing all active run buttons within 5 seconds. After an additional 5

seconds the message will occur.

2. During single stroke mode and at the end of a normal stroke, the PM is looking for all active run buttons to be released within

1 second of deenergizing clutch valve outputs.

3. After the arm continuous button is released, if all

active station run buttons are not released within 0.1 second.

IN GENERAL, THESE MESSAGES OCCUR TO PREVENT THE FOLLOWING:

1 ANTITIE DOWN  The PM requires that both buttons be

released if both were pressed and then one has been released. There is no time delay for this condition to cause a trip message. The PM also requires that once one button is pressed, the other button needs to be pressed within 0.5 seconds to continue to operate without a problem.

2. Indication of change in the station active/bypass state or nc/no contact wiring.

Check for proper wiring of station run buttons. Check for proper operation of run button contacts.

6B N AWAITING RELEASE OF BOTH INCH BUTTOns. You must press, release, and press again both INCH

buttons before PM can allow further press motion.

6C N AWAITING RELEASE OF ARM CONTINUOUS BUTTON. After releasing the ARM CONTINUOUS button, you have 5

seconds to press all RUN buttons before the PM can enter continuous mode.

6D N CONTINUOUS CYCLE NOT ARMED. You cannot enter continuous mode until you press the

ARM CONTINUOUS button. You must release it before pressing all RUN buttons within 5 seconds.

6E N AWAITING PC TO INHIBIT STOPONTOP SIGNAL. The PM module is still receiving the STOPONTOP

command. It must cease before the PM can enter continuous mode. Check your ladder logic (figure 4.6, 4.7, or 4.8).

6F N AWAITING RELEASE OF ALL STOPONTOP BUTTONS. You must release the STOPONTOP buttons of all active

stations before the PM can start any press motion resulting from pressing RUN buttons.

716

Rockwell Automation 1771-PM, D17716.5.18 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Table of Contents

Chapter Objectives

Objectives Of This Manual

How To Use This Manual

Terminology

Firmware Revision Record

Chapter Objectives

System Components

Related Safety Documentation

Chapter Objectives

General Hardware Considerations

Description of your Clutch/Brake Controller

Twinaxial Cable Connections

Multiple Clutch/Brake Controllers

Panel Switches and Operator Stations

Interlock Switches

Configuring Your Clutch/Brake Controller

Rack Address of Chassis A and B

Setting the Communication Rate

Response Time

Module Placement

Keying

Chapter Objectives

Programming Fundamentals

Configuration Rungs

Matching Configuration Bits and Backplane Switches

PLC Command Rungs

Summary of PLC Configuration and Command Rungs

Module Groups 6 and 7 Reserved for Data Storage

Monitoring Clutch/Brake Controller Inputs and Outputs

Report Generation

Summary of Clutch/Brake Controller Functions

Chapter Objectives

Operation of Voting Processors

Emergency Shut Down

Fault Monitoring

Operation of Cam Limit Switches

Clutch/Brake Operating Modes

Chapter Objectives

Installation Considerations

Electrical Connections and Safety Requirements

Control Power

Crowbar Test Inputs

Optional Hardwire Inputs

Internal/External Fault Detection

Optional Valve Stem Switches, Motion Detectors, and Air Pressure Switches

Main Valve Solenoids A and B

Optional Auxiliary Valve Solenoids

Optional Dump Valve Solenoids

Electrical Noise Suppression

Cam Limit Switches

Required Hardwire Inputs

Optional Binary Display

Optional Indicators

Lamp Test

Inputs to Chassis C

Chapter Objectives

Troubleshooting Considerations and Requirements

Troubleshooting with LED's

General Troubleshooting Procedure

Troubleshooting Hints

Troubleshooting Example

Display of Diagnostic Message Codes

Types of Diagnostic Message Codes

Processing Diagnostic Message Codes

Diagnostic Message Codes (Table 7.C)