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Design

Manual

Clutch/Brake

Control System

PLC5 Series

(Cat. No. 6556Pxxxx)

AllenBradley

ClutchBrake

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Содержание PLC-5 series

Страница 1: ...Design Manual Clutch Brake Control System PLC 5 Series Cat No 6556 Pxxxx Allen Bradley ClutchBrake...

Страница 2: ...elines for the Application Installation and Maintenance of Solid State Control available from your local Allen Bradley office describes some important differences between solid state equipment and ele...

Страница 3: ...Contacts 7 Simplified the RCLS zones for easier setup and faster response Setting Up Position Monitoring also described in chapter 2 Retained revision 1 2 logic for indication of shaft position but e...

Страница 4: ...24 Figure 4 17 Automatic single stroke mode to start a cycle in this mode remotely 25 and 26 Figure 4 18 19 Armed for remote automatic continuous mode to start on demand 25 and 27 Figure 4 18 20 Press...

Страница 5: ...or the cat no 6556 PxxxK Application Package 1 2 Related Safety Information 1 2 Control by Redundant Processors 1 3 How the Software Controls Your Press 1 4 Organization of Program Files 1 4 Scanning...

Страница 6: ...ional 2 6 1 Verify Your Factory configured Options 2 7 2 Assign Outputs 2 7 3 Record the Type s of Valve Fault Detection 2 8 4 Select the Type and Location of Position Monitors 2 8 5 Record On Off Pos...

Страница 7: ...peed Top Stop 4 28 Assigning Passwords to Your Program and Data Files 5 1 Chapter Objectives 5 1 What Can Privilege Classes Protect 5 1 How We Assigned Privileges to Privilege Classes 5 2 Privilege Cl...

Страница 8: ...sts 8 1 Controller OK Test 8 1 CRM Relay Test 8 2 Seal Relay Test 8 2 Crowbar Relay Test If using crowbar relays 8 3 Test Run Buttons all four stations 8 3 Test Inch Buttons 8 4 Test Stop on top and A...

Страница 9: ...1 Useable Data E 2 Reserved Program Files E 2 Programming Considerations for PLC 5 Processors F 1 Purpose of this Appendix F 1 Program Scan How the Processor Scans a Program F 1 How the Processor Scan...

Страница 10: ...torage Files F 11 Directly Creating Data Storage Files F 11 Data Storage Created by Assigning Addresses F 11 Wiring Drawings for an Ungrounded System G 1 Wiring Drawings G 1 Wiring Drawings for a Grou...

Страница 11: ...the information in this manual We summarize the tasks that your integration team will perform as follows These Tasks Are Covered in Browse through the overview in chapter 1 Browse through the entire...

Страница 12: ...unded ac power distribution in Appendix H Wiring drawings are included on diskette so that you can modify them with your own Computer Aided Drafting CAD system They are stored in these file formats Au...

Страница 13: ...e lets the operator stop the press quickly by releasing a RUN button during a downstroke in single stroke or continuous mode bottom the part of the press cycle when the die is closed near top the part...

Страница 14: ...Using This Manual P 4 Publication 6556 6 5 1 October 1996 Notes...

Страница 15: ...Timers System Response Time Control System Specifications ATTENTION This control system is designed for use only with mechanical stamping presses having a part revolution friction brake Applying this...

Страница 16: ...esses OSHA 1910 217 and other applicable standards pertaining to safety recommendations related to machine construction general electrical machine guarding point of operation guards light curtains gat...

Страница 17: ...has these program files PF2 Factory configured master control program locked PF3 Your file for calling auxiliary press control functions PF15 Your file for customizing clutch brake control in PF16 PF1...

Страница 18: ...or call subroutines to control auxiliary press functions such as automation valve die protection etc Optional but available for application programming independent of the processor in chassis A PF15...

Страница 19: ...ors A and B To facilitate standardized programming we suggest that you use the following program file numbers for auxiliary press functions PF4 Initialization PF5 Analog PF6 Lube Hydraulic PF7 Mode Ch...

Страница 20: ...able for your application programming Programs written for PLC 5 x6 processors are transferrable between PLC 5 x6 processors only with the Rockwell software used to write the original program Password...

Страница 21: ...accordance with ANSI B11 1 Section 4 12 4 1 the means of selecting the operational mode must be capable of being fixed by a supervisor Typically this is interpreted as to mean a keyswitch This Mode Le...

Страница 22: ...remotely inch micro inch single stroke automatic single stroke continuous Lets you program automatic press motion with simulate inch buttons simulate run buttons arm for continuous on demand On the ho...

Страница 23: ...room head 800T FXP16RA5 1 or more Mode Select Lets you select the operating mode Off Inch Micro inch Single Continuous Remote Die Change Rotary 7 position key lockable N A 1 Arm Continuous Lets you be...

Страница 24: ...auxiliary valves You can program these outputs in unison with or in opposition to C B valve outputs micro inch separate micro inch drive Used in micro inch mode only The worst case time required for t...

Страница 25: ...are not synchronized so minimize the scan time of one processor ATTENTION You are responsible for system response time The combination of fast press stroking and additional program logic could extend...

Страница 26: ...include or exclude active pin wiring to detect the absence of a run station K M M1 M3 Hardware Kit select PLC 5 x6 processors power supplies and I O for clutch brake control Programming Ladder logic...

Страница 27: ...ed ac power To facilitate wiring your control system we include drawings for Wiring to I O modules for grounded and ungrounded ac power Power distribution and relay backup circuits Fold out drawings a...

Страница 28: ...e start B151 03 permit run B151 04 permit downstroke delayed start B151 05 permit upstroke B151 06 top stop B151 07 permit inch B151 08 simulate inch buttons B151 09 remote inch mode B151 10 clutch pr...

Страница 29: ...ify your choice of factory configured options inspect the label on the software diskette in your Application Package to be sure it matches the catalog number that you ordered What hardware Kit K Full...

Страница 30: ...lves We cover this under Command Bits in chapter 4 Record your assignment of control system outputs on the worksheet There are two types of valve fault detection internal the valve checks itself for f...

Страница 31: ...position where the press comes to a stop Designed to prevent the press from starting if it stops too late 1 N O contact 2 switches per system Take over TCAM In Single Mode Lets the press complete a s...

Страница 32: ...troke ACAM should remain On for the entire stroke except for an On Off On cycle while TCAM is On during upstroke The dual sets of contacts need not cycle at the same moment An offset of up to 1 second...

Страница 33: ...otor Forward B151 18 Select operating mode remotely with your ladder logic Main selector switch must be switched to remote mode Reset processor with keyswitch after C B fault Remote Inch Mode B151 10...

Страница 34: ...trol system for application options program ladder logic in PF15 We tell you how to implement these options in chapters 3 and 4 Refer to the list of options and corresponding wiring drawings and or co...

Страница 35: ...Active Pin With active pin or P in Run Stations Omit active pin 0 4 Hardware Kit Full kit K Minimum bundle 1 M M1 M5 1 For hardware lists of various kits see the C B Packing Data publication 6556 5 1...

Страница 36: ...4 Select the Type and Location of Position Monitors Record the type of position monitor and to which I O chassis it will be wired If using resolvers record the rack group slot number rack address of...

Страница 37: ...re responsible for meeting applicable codes Momentary pushbutton single N C contact Mode Select Lets you select the operating mode Off Inch Micro inch Single Continuous Remote Die Change Rotary 7 posi...

Страница 38: ...setup Simulate Inch Buttons B151 09 Allow simulated inch buttons during setup Remote Inch Mode B151 10 Allow simulated micro inch buttons during setup Remote Micro inch Mode B151 24 Simulate a pressur...

Страница 39: ...eedback Modify the drawings Simulate the switch with ladder logic sheet 2 Figure 4 13 Replacing the motion detector switch with a resolver signal sheet 2 Figure 4 10 Using fewer than four run stations...

Страница 40: ...ft Cam Compare 1 Motion Detector Watchdog 3 Motion Detector Permissive 3 Micro inch Feedback Valve 1 Off 1 Micro inch Feedback Valve 2 Off 1 Micro inch Feedback Valve 1 On 1 Micro inch Feedback Valve...

Страница 41: ...n PF15 Figure 4 4 Using a soft clutch and brake logic in PF15 Figure 4 14 Starting remote automatic single stroke cycles Figure 4 18 19 Starting remote automatic continuous on demand Figure 4 18 20 Ex...

Страница 42: ...2 14 Define Your Control System Characteristics Publication 6556 6 5 1 October 1996 Notes...

Страница 43: ...elete the crowbar relay circuit air pressure hardwired switch replace with an analog pressure sensor main motor forward hardwired switch replace with a drive feedback motion detector hardwired switch...

Страница 44: ...ng Drawings diskette 2 Change to a drive 3 At the a prompt type Install C You get the Select the Appropriate Drawings window 4 To select ungrounded and or grounded ac wiring drawings cursor to your ch...

Страница 45: ...the modification We present instructions according to I O module group because the wiring for each I O module group is presented on a separate drawing in your set of wiring drawings Important If using...

Страница 46: ...re 3 3 Figure 3 12 Delete Clutch Brake Air Pressure Switch 1 Delete the clutch brake air pressure switch at input terminal 33 for chassis A 2 Wire input terminal 33 of chassis A and B to power rail 10...

Страница 47: ...Figure 3 2 Delete Crowbar Relay Feedback Module Group 2 Reserved Do Not Use Reserved Do Not Use CROWBAR RELAY A FEEDBACK CROWBAR RELAY B FEEDBACK Figure 3 3 Delete Crowbar Relay Power Distribution Mod...

Страница 48: ...respectively 2 Wire input terminal 7 15 or 23 for chassis A and input terminal 11 17 or 25 for chassis B respectively to the power rail 105L1 wire high 3 Delete the left run station pushbutton switch...

Страница 49: ...Delete Run Station 1 Module Group 3 Reserved Do Not Use Reserved Do Not Use Figure 3 6 Delete Run Stations and Active Pin Module Group 3 Reserved Do Not Use Reserved Do Not Use Figure 3 7 Delete Arm C...

Страница 50: ...nabled Figure 3 8 and Figure 4 15 Use Auxiliary Valves With Internal Fault Detection or Delete Auxiliary Valves 1 Delete auxiliary valve stem limit switches and wiring from input terminals 11 and 13 W...

Страница 51: ...se Reserved Do Not Use VALVE STEM CLUTCH 1 Reserved Do Not Use VALVE STEM CLUTCH 2 VALVE STEM AUX 1 VALVE STEM AUX 2 Reserved Do Not Use Reserved Do Not Use Reserved Do Not Use MICRO INCH 1 FEEDBACK R...

Страница 52: ...e label Reserved Do Not Use 3 Important Write ladder logic to reset bit B151 19 Auxiliary Valve 1 Enabled Write ladder logic to reset bit B151 22 Auxiliary Valve 2 Enabled Figure 3 10 Figure 4 15 Dele...

Страница 53: ...ot Use AUX 2 VALVE Reserved Do Not Use AUX 1 VALVE Reserved Do Not Use AUX 2 VALVE Reserved Do Not Use Figure 3 11 Delete Micro inch Valve Outputs Module Group 5 Reserved Do Not Use Reserved Do Not Us...

Страница 54: ...d B We deleted the wiring Figure 3 14 and added the label Reserved Do Not Use 2 Delete Crowbar Relays A and B from the Power Distribution Drawing sheet 1 of 9 3 See Module Group 5 Delete Crowbar Relay...

Страница 55: ...ith Ladder Logic Module Group 2 Figure 3 14 Delete Crowbar Relay Feedback Module Group 2 Reserved Do Not Use Reserved Do Not Use Figure 3 15 Delete Crowbar Relay Power Distribution Figure 3 16 Delete...

Страница 56: ...erminal 11 17 25 for chassis B 2 Wire input terminal 7 15 23 for chassis A and input terminal 11 17 25 for chassis B to the power rail 108L1 wire high 3 Delete the left run station pushbutton switch w...

Страница 57: ...Delete Run Station 1 Module Group 3 Reserved Do Not Use Reserved Do Not Use Figure 3 18 Delete Run Stations and Active Pin Module Group 3 Reserved Do Not Use Reserved Do Not Use Figure 3 19 Delete Arm...

Страница 58: ...led Figure 3 20 and Figure 4 15 Use Auxiliary Valves With Internal Fault Detection or Delete Auxiliary Valves 1 Delete auxiliary valve stem limit switches and wiring from input terminals 11 and 13 We...

Страница 59: ...Reserved Do Not Use VALVE STEM CLUTCH 1 Reserved Do Not Use VALVE STEM CLUTCH 2 VALVE STEM AUX 1 VALVE STEM AUX 2 Reserved Do Not Use Reserved Do Not Use Reserved Do Not Use MICRO INCH 1 FEEDBACK Res...

Страница 60: ...label Reserved Do Not Use 3 Important Write ladder logic to reset bit B151 19 Auxiliary Valve 1 Enabled Write ladder logic to reset bit B151 22 Auxiliary Valve 2 Enabled Figure 3 22 Figure 4 15 Delet...

Страница 61: ...erved Do Not Use AUX VALVE 1 Reserved Do Not Use AUX VALVE 2 Reserved Do Not Use Figure 3 23 Delete Micro inch Valve Outputs Module Group 5 MICRO INCH 1 MICRO INCH 2 MICRO INCH 1 MICRO INCH 2 Reserved...

Страница 62: ...3 20 Customize the Wiring Publication 6556 6 5 1 October 1996 Notes...

Страница 63: ...and PF16 are factory programmed and pass word protected for read only You will program your clutch brake interface in program file PF15 and your machine related functions such as for robotics lubrica...

Страница 64: ...em If you selected no command bits for your press application in chapter 2 skip to Exchanging Data Between Processors for required programming later in this chapter In both processors your interface p...

Страница 65: ...ps inch motion Permissive switches must be OK to start or continue inch motion Permissives B151 08 Simulate Inch Buttons B151 09 1 Used with remote inch mode bit 10 and remote micro inch mode bit 24 O...

Страница 66: ...es automatic start of single stroke cycle from near top position OFF Must cycle ON OFF every cycle Operator must cycle one stroke in automatic single stroke mode Then set this bit to start next cycle...

Страница 67: ...C 5 86 Pxxx_A x5 n a PLC 5 86 Pxxx_B x5 n a Important With AI5 software you can download a program file of designated type only to that type of processor Select the program for your designated process...

Страница 68: ...ay 15 Fi 4 12 Auxiliary Valve Cycles with Clutch Valve 16 17 Figure 4 12 Main Motor Forward 18 Figure 4 13 Control Soft Clutch and Brake Operation 15 16 19 22 Figure 4 14 Indicate Absence of Physical...

Страница 69: ...only from the near top position Robot arm Part Slide in Permit at home in Place Top Zone Cycle Start I 030 I 030 B160 B151 00 10 60 03 Figure 4 2 Example of the Permit Run Command B151 04 Use this com...

Страница 70: ...wnstroke I 030 B160 B151 10 49 05 Figure 4 5 Example of the Permit Upstroke Command B151 06 Use the upstroke command in any mode to prevent or stop an upstroke Some condition Permit Upstroke I 040 B15...

Страница 71: ...ress to bottom during manual die change in this example Stop Press at Press at Bottom Bottom B156 B156 ONS 00 03 Stop Inch Stop Inch Press at Buttons Until Inch Bottom Pressed PB Released B156 B160 B1...

Страница 72: ...nch Bottom to Bottom Command Zone Complete I 030 B160 B156 01 59 03 ADC Inch to Bottom Complete B156 03 Master Controller ADC Inch Simulate ADC Inch to Bottom Permit Inch Command Complete Inch Buttons...

Страница 73: ...349 Motion Detect Time Delay TON TIMER ON DELAY EN Timer T157 0 Time Base 0 01 DN Preset 10 Accum 06 Time to Check Current vs old Press In Slide Angle Angle Motion T157 0 NEQ B151 NOT EQUAL DN Source...

Страница 74: ...14 Figure 4 12 Example Commands to Enable Crowbar Relay B151 15 and to Let Auxiliary Valves Cycle With Clutch Valves B151 16 and B151 17 Program these command bits unconditionally to suit your applica...

Страница 75: ...engage brake to stop the press Aux 2 soft clutch time delay soft brake time delay clutch engaged brake engaged slip action pressure relief full pressure slip action pressure relief full pressure Time...

Страница 76: ...Valve 1 Dual Valve 2 Clutch 926SOL 927SOL Timer O 005 O 005 TON TIMER ON DELAY EN 00 01 Timer T4 0 Time Base 0 01 DN Preset 25 Accum 0 Clutch Brake Clutch Brake Soft Dual Valve 1 Dual Valve 2 Brake 92...

Страница 77: ...0 Aux Valve Stems Enabled Auxiliary valves have no valve stem switches B151 21 C B Valve Stems Enabled C B valves have no valve stem switches B151 22 Aux Valve 2 Enabled Auxiliary valve 2 is not used...

Страница 78: ...Controller Micro inch Simulate Micro inch to Bottom Permit Inch Command Complete Inch Buttons I 030 B156 B151 B156 01 03 08 09 Figure 4 18 Example Command to Start Remote Automatic Press Motion with...

Страница 79: ...re can select from the following mode select bits one at a time remote inch bit 10 remote single stroke bit 13 remote continuous bit 14 remote micro inch bit 24 remote automatic single stroke bit 26 F...

Страница 80: ...tware configures the processor in chassis A for scanner mode and the processor in chassis B for adapter mode Important For the adapter mode processor chassis B we have changed the adapter mode configu...

Страница 81: ...or A Cntr Light I 027 O 027 O 010 01 01 00 We designed internal diagnostics such that when control logic detects fault conditions or other conditions worthy of attention it sets a corresponding bit in...

Страница 82: ...e FBC instruction refer to the instruction set documentation for your programming software If you need to shorten presets of internal timers do this in program file 15 For each timer that you want to...

Страница 83: ...Detected 300 T162 29 B152 29 Micro inch Feedback Valve A Off 100 T162 30 B152 30 Micro inch Feedback Valve B Off 100 T162 31 B152 31 Micro inch Feedback Valve A On 100 T162 32 B152 32 Micro inch Feed...

Страница 84: ...Ready Indicator B160 O 007 159 03 The brake monitor program is designed to monitor and compute stopping time This example program is contained in a selectable timed interrupt STI subroutine with a 2...

Страница 85: ...s Address Description N91 1 last brake time N91 3 last brake angle N91 4 starting brake angle N91 5 final brake angle N91 6 STI count for brake time N91 7 STI count for no angle change N91 8 resolver...

Страница 86: ...1 0 Dest N91 4 0 Final Brake Angle MOV MOVE Source I 1 1 0 Dest N91 5 0 Brake Time STI Count CLR CLEAR Dest N91 6 0 No Angle Change STI Count CLR CLEAR Dest N91 7 0 Rung 9 13 Brake Time STI Count B90...

Страница 87: ...Source B N91 5 0 Dest N91 8 0 Resolver Angle Change LIM NEG LIMIT TEST NEGATE Low Lim 10 Source N91 8 0 Test N91 8 Dest N91 8 0 0 High Lim 10 Rung 9 15 Resolver No Angle Change Angle Change STI Count...

Страница 88: ...N91 7 0 Dest N91 6 0 Last Brake Time MUL MULTIPLY Source A N91 6 0 Source B S 30 0 Dest N91 1 0 Last Brake Angle SUB SUBTRACT Source A N91 5 0 Source B N91 4 0 Dest N91 3 0 Looking For Zero Speed B90...

Страница 89: ...tober 1996 Rung 9 18 Off Mode Last Confirmed Brake Time B160 CLR CLEAR 16 Dest N91 1 0 Last Brake Angle CLR CLEAR Dest N91 3 0 Rung 9 19 Last Brake Time Brake Time Monitor Fault GEQ N91 2 GRTR THAN OR...

Страница 90: ...holds the press speed which is buffered once per stroke at 90o The LES and GTR instructions in the TCAM rung are used for backing the TCAM OFF position from 340 to 300o for increasing press speeds of...

Страница 91: ...0 0 128 110 High Limit 220 High Limit 320 Resolver Position LIM LIM LIMIT TEST CIR LIMIT TEST CIR Low Limit 221 Low Limit 170 Test N80 1 Test N80 0 128 110 High Limit 260 High Limit 310 Resolver Posit...

Страница 92: ...4 30 Write Ladder Logic Publication 6556 6 5 1 October 1996 Notes...

Страница 93: ...assigned privileges to privilege classes we restricted access to certain program and data files you assign your own passwords to privilege classes 2 4 you gain access to protected memory files Privile...

Страница 94: ...m and data files Important With this privilege structure you may create program and data files for your own ladder logic You will have RW access to them Privilege Classes We assigned combinations of p...

Страница 95: ...t the factory File Type Class 1 Class 2 Class 3 Class 4 0 O output RW RW RW RW 1 I input RW RW RW RW 2 S status RW RW RW RW 3 B binary or bit RW RW RW RW 4 T timer RW RW RW RW 5 C counter RW RW RW RW...

Страница 96: ...s The system displays the Processor Functions screen 3 Press F2 Modify Privileges You get the Program File Privileges screen We assigned the following privileges for classes 1 4 at the factory File Na...

Страница 97: ...ates these privileges follow this procedure for 6200 series software the procedure for AI5 software would be similar 1 Start at the Main Menu 2 Press F7 General Utility The system displays the General...

Страница 98: ...ge Class Information screen 4 Press F1 Modify Password to assign a password to each class The system displays the Modify Privilege Class Password window 5 For each class you want to use type class nam...

Страница 99: ...n to the controller convert controller OK relay contacts from N O to N C wire your control system Important Installing and or checking other press functions such as lubrication systems slide adjustmen...

Страница 100: ...sors respectively to 0 and 1 so they can communicate Figure 6 1 You may modify these switch settings if you application requires it Figure 6 1 Setting the DH Station Numbers with SW1 Rear View of PLC...

Страница 101: ...ure 6 2 unless your application requires RS 422A or RS 423 Figure 6 2 Serial port Setting with SW2 Front of Processor Front of Processor Bottom View of PLC 5 26 Processor in Chassis B Bottom View of P...

Страница 102: ...edits 1 slot addressing EEPROM does not transfer processor faults Important Settings for chassis A and B must be identical Set switches by pressing rocker arms Press in OFF side for off and ON side fo...

Страница 103: ...ows Slot Chassis A Chassis B PLC 5 46 PLC 5 26 0 1 Reserved for your use Reserved for your use 2 4 Isolated Input Module 1771 ID16 Isolated Input Module 1771 ID16 5 Isolated Output Module 1771 OD16 Is...

Страница 104: ...s such as a resolver input module This helps segregate dc and ac signals Figure 6 5 Module Locations in Chassis B 1771 ID16 1771 ID16 0 1 2 3 4 5 PLC 5 26 1771 OD16 2 4 6 8 10 12 14 16 18 20 22 24 26...

Страница 105: ...PLC 5 46 in Chassis A Channel 1A for DH Link Channel 1B for Remote I O Channel 1A DH to Programming Terminal 1784 CP6 Cable 1 2 1 2 PLC 5 26 in Chassis B Belden 9463 Configured for Scanner Mode DH St...

Страница 106: ...to N C mode A Unscrew the screw terminals 2 turns B Flip each of the screw terminals from the N O position to the N C position 6 Insert the relay cartridges into the case so the screw terminals now in...

Страница 107: ...bottom zone and open at a point that allows the press to stop at the top anti repeat contacts open during mid upstroke for at least 75ms Position monitor inputs should operate as follows Table 7 A Tab...

Страница 108: ...is On D Near top BCAM and TCAM must be Off while ACAM remains On 180o Important See press manufacturer s recommendations for Near top Zone Bottom On Off settings of ACAM BCAM and TCAM switches 0o Up...

Страница 109: ...te from Figure 7 2 ACAM contacts should remain open for at least two program scans Figure 7 2 Anti Repeat Contacts Up stroke ON span vs Press Speed 200 180 160 30 60 90 0 0 0 OFF Span of Anti repeat C...

Страница 110: ...your application If using rotary cam limit switches follow these steps AMCI resolver connected to an AMCI interface module Figure 7 3 NSD resolver decoder and 1771 IBD input module Figure 7 4 Follow...

Страница 111: ...uts to respective power rails For instructions to do this refer to wiring customization instructions Module Group 2 sheet 2 in chapter 3 of this manual 6 Study the RCLS operation shown in Figure 7 1 a...

Страница 112: ...er Inputs Store Resolver Inputs MOV MOVE Source I 000 0 Dest N155 0 0 Takeover Cam LIM B151 LIMIT TEST CIR Low Limit 170 00 Test N155 0 High Limit 350 Brake Monitor Cam LIM B151 LIMIT TEST CIR Low Lim...

Страница 113: ...51 LIM B151 LIMIT TEST CIR 00 Low Limit 165 00 Test N155 0 High Limit 350 B151 LIM LIMIT TEST CIR 00 Low Limit 170 Test N155 0 High Limit 345 BCam B151 LIM B151 LIMIT TEST CIR 01 Low Limit 5 01 Test N...

Страница 114: ...ding indicator bits in bit file B160 are shown in the following table and in Figure 7 7 While the shaft is in this zone The software sets this bit Top B160 60 Downstroke 61 Near Bottom 59 First Upstro...

Страница 115: ...and TCAM can transition within the same scan or overlap their On states When the software detects any one of the following fault conditions it is designed to turn outputs off and set the corresponding...

Страница 116: ...tings 029 Forward Transition from Upstroke Software hardware cams did not enter near top zone Press will stop or not run in single or continuous mode Check software cam logic or hardware cams for prop...

Страница 117: ...sition Faults Any of 107 109 detected Press will stop or not run in single or continuous mode Check software cam logic or hardware cams for proper operation or settings 114 ACAM Upstroke ACAM did not...

Страница 118: ...7 12 Set Up or Simulate Rotary Cam Limit Switches Publication 6556 6 5 1 October 1996 Notes...

Страница 119: ...hardware is complete clutch brake wiring is complete control system is in compliance with all applicable standards Otherwise personal injury and or property damage could result This section describes...

Страница 120: ...the Clutch Brake Power Reset button 6 With a voltmeter verify that all press valve outputs have power 120v ac across 115C and 119B 7 Press the E Stop button 8 Visually and with a voltmeter verify tha...

Страница 121: ...four stations Test Run button wiring by observing input LEDs in Module Group 3 Check the OK box after verifying that the LED indication is correct For This Condition In Module Group 3 These Input LED...

Страница 122: ...EDS in Module Group 3 for chassis A and B Check the OK box after verifying that the LED indication is correct For This Condition In Module Group 3 This Input LED is OFF OK In Module Group 3 This Input...

Страница 123: ...umber Term Mod Grp Term 5 AO 005 00 1 2 13 5 AO 005 01 3 2 15 5 AO 005 02 5 N A A 904SOL 5 AO 005 03 7 N A B 905SOL 5 AO 005 04 11 2 7 5 AO 005 05 13 2 11 5 AO 005 06 15 N A A 909SOL 5 AO 005 07 17 N...

Страница 124: ...02 5 4 A 804LS 4 5 4 AI 004 03 5 4 B 805LS 4 7 4 AI 004 04 5 4 A 807LS 4 11 4 AI 004 05 5 4 B 808LS 4 13 For Grounded AC Wiring From Chassis A To Chassis B OK Mod Grp Wire Number Term Mod Grp Term 5...

Страница 125: ...A 925SOL 2 13 5 BO 005 01 3 5 B 926SOL 2 15 5 BO 005 04 11 5 A 931SOL 2 7 5 BO 005 05 13 5 B 932SOL 2 11 5 BO 005 10 21 5 A 936SOL 4 1 5 BO 005 11 23 5 B 937SOL 4 3 From Chassis A To Solenoids Chassis...

Страница 126: ...chapter 7 Otherwise one or more transition faults are designed to shut down the system You can vary the ON OFF times but not the sequence nor overlap of signals This is particularly important during s...

Страница 127: ...roke 8 Repeat steps 3 and 4 This time hold Run buttons for the entire cycle 9 Observe that the press runs through one stroke and stops at the top Continuous Mode with Arm Continuous 1 Place the mode s...

Страница 128: ...tops when you release Run buttons If You Release Run Buttons the Press in first or second downstroke stops immediately in first upstroke stops at the top 8 Bring the press to top by pressing Run butto...

Страница 129: ...tempt to start the press Observe that it will not start and that prompt codes 13 and 93 are indicated 4 Reconnect the main motor forward switch input 5 Remove the switch input from chassis B to repeat...

Страница 130: ...art and run the press 3 Simulate tripping the chain break limit switch as if the chain had broken Observe that the press stops immediately Do this by shorting the chain break input high Short input te...

Страница 131: ...hes the mode selector switch to Remote mode the control system can operate in the following modes when enabled by the corresponding mode select command bit in your ladder logic PF15 remote inch mode B...

Страница 132: ...oth Inch buttons Have you pressed both Inch buttons simultaneously Both processors energize their outputs to actuate the clutch Has the press moved into the near top position Have you released either...

Страница 133: ...release Run buttons without stopping the press it continues to the near top position During downstroke releasing a Run button stops the press Figure A 2 To restart the press press the Run buttons Once...

Страница 134: ...roke Have you released a Run button No Yes No Is the press into the upstroke zone Go to R2 Figure A 3 Both processors de energize their outputs to stop the press Have you released then pressed all Run...

Страница 135: ...ssed all Run buttons before the ACAM closes again Have you released a Run button Yes No Yes Yes Yes Yes Both processors de energize their outputs to stop the press in the near top position WARNING If...

Страница 136: ...ontinuous mode with the arming sequence If the slide entered the upstroke zone the first time and your press does NOT have stroke and a half Figure A 6 when both TCAMs come on you may release a Run bu...

Страница 137: ...ure A 4 Typical Operational Sequence to Prepare to Start Continuous Mode Select continuous mode Have you released all Stop on top buttons Is the press configured for Arm Continuous No Is the motor run...

Страница 138: ...e you released all Run buttons Have you pressed the Arm Continuous button Go to R6 Figure A 7 NOTE Releasing a Run button during first downstroke stops the press If the slide has not entered the upstr...

Страница 139: ...processors stop the press Both processors energized their outputs Has the press completed 1 1 2 strokes Have you released all Run buttons Go to R6 Figure A 7 No Yes Have you pressed all Run buttons Ye...

Страница 140: ...h processors de energize outputs to stop the press WARNING If the press coasts past the near top position while braking the brake is faulty and hazardous Repair it immediately NOTE The press strokes c...

Страница 141: ...roke Before BCAMs turn OFF Triac Command ON OFF Triac Feedback ON OFF 0 1 sec Valve Stem Feedback OFF 0 1 sec 1 4 0 3 sec 4 Motion Detector must turn ON before upstroke before Brake montor cams BCAMs...

Страница 142: ...Feedback Timing Diagrams B 2 Publication 6556 6 5 1 October 1996 Notes...

Страница 143: ...elay failed to close C B power will not turn ON Check E Stop relay circuit and operation of input module in slot 2 007 E Stop Relay Weld Fault CRMA relay welded closed C B power is de energized and wi...

Страница 144: ...ill stop or not run in single or continuous mode Check soft cam logic or hard cams for proper operation or settings 034 ACAM Upstroke ACAM did not cycle in upstroke Press will stop or not run in singl...

Страница 145: ...lve and valve wiring 062 Aux Valve Stem 1 Failed to Turn ON Valve failed to energize when output was turned ON Press will not cycle Check valve and valve wiring 063 Aux Valve Stem 1 Failed to Turn OFF...

Страница 146: ...ons and wiring 092 Processor B Station 3 Not Active nor Bypassed Run button failure or improper wiring Prevents single or continuous stroking Check run buttons and wiring 093 Processor B Station 4 Not...

Страница 147: ...or not run in single or continuous mode Check soft cam logic or hard cams for proper operation or settings 125 Spare 126 Brake Monitor Fault On stop on top command the press slid into BCAM zone before...

Страница 148: ...e wiring 147 Clutch Valve 1 Failed to Turn OFF Valve failed to de energize when output was turned OFF C B power is removed Check valve and valve wiring 148 Clutch Valve 2 Failed to Turn ON Valve faile...

Страница 149: ...ess is not in near top position You cannot stroke in single or continuous mode Inch the press to near top position 016 All run buttons are not released The press has stopped and all run buttons are no...

Страница 150: ...ou cannot stroke in single or continuous mode Inch the press to near top position 096 All run buttons are not released The press has stopped and all run buttons are not released You cannot start the p...

Страница 151: ...e outputs are turned off You can use this information to troubleshoot the cause of the shutdown Do this by comparing the status of the snapshot bits with what the status should have been according to...

Страница 152: ...Troubleshooting with Fault Codes Operator Prompts and Snapshot Status Bits C 10 Publication 6556 6 5 1 October 1996 Notes...

Страница 153: ...X Write edit ladder files X X X X Download ladder files X X X X Read ladder files X X X X Upload ladder files X X X X Change processor mode X X X X Force I O X X X Force I O in Sequential Function Ch...

Страница 154: ...RW RW 4 timer RW RW RW RW 5 counter RW RW RW RW 6 control RW RW RW RW 7 integer RW RW RW RW 8 floating point RW RW RW RW 20 bit RW R R R 21 timer RW R R R 150 bit RW RW RW RW 151 bit RW RW RW RW 152 b...

Страница 155: ...ress Do NOT use Read only File Reserved for I O Image Table I 002 I 004 Input words monitored by PF16 I 020 I 025 Scanner cross checking between processors I 026 Scanner word reserved for future use O...

Страница 156: ...dardization we suggest that you program your ladder logic for the control of the clutch brake and other press functions in the program and subroutine files listed below If your application requires ad...

Страница 157: ...l PF30 Bolster Die Cart Control PF31 Automation Device Control PF32 PTO Control PF33 Transfer Electronic Feeder Control PF34 Crossbar Control PF35 Safety Gate Control PF36 Slide Lock Control PF37 Turn...

Страница 158: ...Mapping of Data and Program Files E 4 Publication 6556 6 5 1 October 1996 Notes...

Страница 159: ...anual publication 1785 6 5 12 What is the Program Scan The program scan is the mechanism by which the processor operates It is sequential occurring as fast as 100 times per second Here is what the pro...

Страница 160: ...image table for the corresponding output device 3 Executes Ladder Logic Manipulates data makes decisions and or controls outputs based on the status of inputs according to your ladder logic instructi...

Страница 161: ...k 57 6K baud 3 500 1000 Processor Family Some processor families are faster at executing selected groups of instructions than other processor families Table F B Table F B Comparing Processors for Typi...

Страница 162: ...ntrol such as PID gain computation 500 900 880 1150 Addressing The processor operates faster with direct addressing Other types of addressing take longer Table F D and Table F E Table F D Typical Addi...

Страница 163: ...to 16 bits one word at a time per rung other considerations Program a Faster Response with Special Instructions Rather then trying to minimize program scan time consider responding faster with specia...

Страница 164: ...tions Other considerations for a faster program scan are select a faster processor dedicate an additional processor to critical functions put critical I 0 in the local I O chassis rather than in a rem...

Страница 165: ...outine JSR located anywhere in your ladder logic Subroutine SBR the first instruction in the subroutine file and the target of the JSR instruction directs the processor scan to the subject subroutine...

Страница 166: ...Brake Interface PF15 Clutch Brake Code PF16 Auxiliary Press Function PFxx Automation Function PFyy Figure F 3 Scan of the Allen Bradley Clutch Brake Ladder Program SBR RET Main Program PF2 JSR to SBR3...

Страница 167: ...he current states of output image bits before continuing the program scan updates the remote I O buffer with the current states of the output image bits makes these states immediately available for th...

Страница 168: ...cimal BCD For example 0000 0000 0000 0110 6 I O image status integer I or O S N element a multiple number of words For example timer element 3 words preset accumulated control status bits timer 1 coun...

Страница 169: ...rds or elements from that address down to zero 10 words or down to the next lower assigned address If the next lower assigned address was N7 3 your file at address N7 9 would include six words down to...

Страница 170: ...other example if you assign the address N7 9 to store a word or element the processor opens a file from that address down to zero or down to the next lower assigned address If the next lower address w...

Страница 171: ...ndix or grounded system I O wiring appendix F We present the following wiring drawings for I O racks A00 and B00 for ungrounded system I O wiring See Appendix H for the Grounded System Sheet Title 1 o...

Страница 172: ...Wiring Drawings for an Ungrounded System G 2 Publication 6556 6 5 1 October 1996 Notes...

Страница 173: ...23 01 24 01 25 01 26 01 27 01 28 01 29 01 30 01 31 01 32 01 33 01 34 01 35 01 36 01 37 01 38 01 39 01 40 01 41 01 42 01 43 01 44 01 45 01 46 01 47 01 48 PRI SEC H1 H3 H2 H4 X2 X1 119B 105L1 TO 06 01 9...

Страница 174: ...1 13 CRM POWER FEEDBACK INPUT 14 35 36 L2 14 INPUT 16 INPUT 15 39 37 L2 16 L2 15 38 40 INPUT 11 INPUT 10 INPUT 13 INPUT 12 33 31 27 29 L2 12 L2 13 34 32 L2 11 L2 10 30 28 INPUT 7 21 23 25 17 19 INPUT...

Страница 175: ...005 01 AO 005 00 AO 005 05 BRAKE MONITOR CAM LIMIT SW 628LS ANTIREPEAT CAM LIMIT SW 627LS TAKEOVER CAM LIMIT SW 626LS 105L2 06 24 BI 002 01 BI 002 02 AO 005 04 BI 002 00 L2 7 L2 10 L2 11 L2 12 21 INPU...

Страница 176: ...01 5 7 3 1 105L2 105L1 105L2 105L2 RIGHT RUN STATION 1 N O 702PB LEFT RUN STATION 1 BUTTON N C 703PB STATION 1 ACTIVE PIN LEFT INCH BUTTON N C 719PB RIGHT INCH BUTTON N O 718PB CONTINUOUS SETUP BUTTON...

Страница 177: ...8 26 RIGHT RUN STATION 1 BUTTON N C 702PB RIGHT RUN STATION 2 BUTTON N C 705PB RIGHT RUN STATION 3 BUTTON N C 709PB STATION 3 ACTIVE PIN LEFT RUN STATION 4 N O 714PB STATION 2 ACTIVE PIN STATION 1 ACT...

Страница 178: ...005 10 STROKE MODE SINGLE REMOTE CHANGE A A A A MODE SEL SW 809SS VALVE STEM DUMP 2 AUXILIARY 808LS VALVE STEM AUXILIARY 1 807LS VALVE STEM CLUTCH 2 805LS DIE 09 37 09 36 MICRO INCH 1 FEEDBACK MICRO...

Страница 179: ...AO 005 11 AO 005 10 FROM 08 17 VALVE STEM AUXILIARY 2 808LS VALVE STEM AUXILIARY 1 807LS VALVE STEM CLUTCH 2 805LS MICRO INCH 1 FEEDBACK MICRO INCH 2 FEEDBACK VALVE STEM CLUTCH 1 804LS 09 12 09 13 NOT...

Страница 180: ...OUTPUT 12 OUTPUT 13 OUTPUT 14 OUTPUT 15 OUTPUT 16 OUTPUT 17 L1 4 L1 5 L1 6 L1 7 NOT USED L1 10 L1 11 L1 12 L1 13 NOT USED L1 14 L1 15 L1 16 L1 17 NOT USED 115C 08 48 CLUTCH 2 905SLO AUXILIARY VALVE 2...

Страница 181: ...UTPUT 4 L1 0 L1 1 L1 2 L1 3 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 39 37 35 33 31 29 27 25 23 21 19 17 15 13 11 9 7 5 3 1 CONTROLLER OK 941CR NOT USED OUTPUT 3 OUTPUT 2 BO 005 03 OUTP...

Страница 182: ...Wiring Drawings for an Ungrounded System G 12 Publication 6556 6 5 1 October 1996 Notes...

Страница 183: ...or ungrounded system I O wiring appendix G We present the following wiring drawings for I O racks A00 and B00 for grounded system I O wiring See Appendix G for the Ungrounded System Sheet Title 1 of...

Страница 184: ...Wiring Drawings for a Grounded System H 2 Publication 6556 6 5 1 October 1996 Notes...

Страница 185: ...6 01 27 01 28 01 29 01 30 01 31 01 32 01 33 01 34 01 35 01 36 01 37 01 38 01 39 01 40 01 41 01 42 01 43 01 44 01 45 01 46 01 47 PRI SEC H1 H3 H2 H4 X2 X1 108L1 TO 06 01 941CR CONTROLLER OK CRMB TO 06...

Страница 186: ...CLUTCH BRAKE POWER FEEDBACK CLUTCH BRAKE AIR PRESSURE 01 13 CRM POWER FEEDBACK INPUT 14 35 36 L2 14 INPUT 16 INPUT 15 39 37 L2 16 L2 15 38 40 INPUT 11 INPUT 10 INPUT 13 INPUT 12 33 31 27 29 L2 12 L2...

Страница 187: ...T SW 628LS ANTIREPEAT CAM LIMIT SW 627LS TAKEOVER CAM LIMIT SW 626LS BI 002 01 BI 002 02 AO 005 04 BI 002 00 L2 7 L2 10 L2 11 L2 12 21 INPUT 10 INPUT 12 INPUT 11 25 23 NOT USED INPUT 7 19 17 22 26 24...

Страница 188: ...RUN STATION 1 N O 702PB LEFT RUN STATION 1 BUTTON N C 703PB STATION 1 ACTIVE PIN LEFT INCH BUTTON N C 719PB RIGHT INCH BUTTON N O 718PB CONTINUOUS SETUP BUTTON N O 720PB LEFT RUN STATION 4 BUTTON N C...

Страница 189: ...ACTIVE PIN LEFT RUN STATION 4 N O 714PB STATION 2 ACTIVE PIN STATION 1 ACTIVE PIN LEFT RUN STATION 3 N O 710PB LEFT RUN STATION 2 N O 707PB LEFT RUN STATION 1 N O 703PB BI 003 04 AI 003 05 BI 003 06...

Страница 190: ...10 STROKE MODE SINGLE REMOTE CHANGE A A A A MODE SEL SW 809SS VALVE STEM AUXILIARY 2 808LS VALVE STEM AUXILIARY 1 807LS VALVE STEM CLUTCH 2 805LS DIE 09 37 09 36 MICRO INCH 1 FEEDBACK MICRO INCH 2 FEE...

Страница 191: ...TCH 2 805LS MICRO INCH 1 FEEDBACK MICRO INCH 2 FEEDBACK VALVE STEM CLUTCH 1 804LS 09 12 09 13 NOT USED INPUT 7 INPUT 10 INPUT 11 19 23 21 17 INPUT 6 15 20 L2 10 L2 1124 22 L2 7 L2 6 18 16 NOT USED INP...

Страница 192: ...PUT 14 OUTPUT 15 OUTPUT 16 OUTPUT 17 L1 4 L1 5 L1 6 L1 7 NOT USED L1 10 L1 11 L1 12 L1 13 NOT USED L1 14 L1 15 L1 16 L1 17 NOT USED 115E 08 08 CROW BAR RELAY 918CR SEAL RELAY 919CR 08 24 108L1 09 25 A...

Страница 193: ...37 35 OUTPUT 14 31 29 OUTPUT 13 OUTPUT 12 27 25 NOT USED NOT USED L1 6 16 L1 11 24 L1 10 22 L1 7 18 20 L1 5 14 L1 4 12 10 L1 3 8 L1 0 2 L1 2 6 L1 1 4 OUTPUT 6 15 OUTPUT 11 OUTPUT 10 23 21 OUTPUT 7 17...

Страница 194: ...Wiring Drawings for a Grounded System H 12 Publication 6556 6 5 1 October 1996 Notes...

Страница 195: ...uador Egypt El Salvador Finland France Germany Greece Guatemala Honduras Hong Kong Hungary Iceland India Indonesia Ireland Israel Italy Jamaica Japan Jordan Korea Kuwait Lebanon Malaysia Mexico Nether...

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