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Allen-Bradley 1771-PM User Manual

Allen-Bradley 1771-PM User Manual

Clutch/brake module
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Allen Bradley
Clutch/Brake
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(Cat. No. 1771-PM)
User
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Summary of Contents for Allen-Bradley 1771-PM

  • Page 1 Allen Bradley User Clutch/Brake Module Manual (Cat. No. 1771-PM)

  • Page 2: Table Of Contents

    Table of Contents Introduction ........Chapter Objectives .
  • Page 3 Table of Contents Voting Processor Firmware ......Chapter Objectives ........Operation of Voting Processors .
  • Page 4 Table of Contents Diagnostic Message Codes (Table 7.C) ....7 13 Complete Listing of diagnostic message codes ....7 23 Summary .

  • Page 5: Introduction

    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...

  • Page 6: Terminology

    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...

  • Page 7: Press System Description

    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.

  • Page 8: Figure 2.1

    Chapter 2 Press System Description Figure 2.1 Functional Block Diagram Operator Operator Operator Operator Station Station Station Station No. 1 No. 2 No. 3 No. 4 Allen - Bradley Clutch/Brake Controller - Monitors operator inputs - Monitors shaft position using cam limit switch feedback - Controls the press using solenoid triac outputs Triac Cam Switch...

  • Page 9: Related Safety Documentation

    Chapter 2 Press System Description Related Safety Documentation This manual concentrates on safety considerations relative to the clutch/brake controller. Study this entire manual and all technical documentation provided by the press manufacturer before you install your press system. In addition to local codes and laws, follow the safety requirements detailed in the following publications: OSHA Regulations, Title 29-Labor, Chapter XVII, Section 1910.217, Mechanical Power Presses...

  • Page 10: Clutch/Brake Controller Hardware

    Clutch/Brake Controller Hardware Chapter Objectives 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...
  • Page 11 Chapter 3 Clutch/Brake Controller Hardware Figure 3.1 Overview of a Clutch/Brake Controller Voting Processor A Clutch/Brake Module Remote I/O Chassis A Remote Voting Processor B Clutch/Brake Clutch/Brake Module Communications A-B Programmable Controller Chassis B with Remote I/O Remote I/O Adapter Module Remote Chassis C Remote I/O...
  • Page 12 Chapter 3 Clutch/Brake Controller Hardware Table 3.A Required and Optional Hardware Quantity Item Cat. No. Function Important: (You must use 8 point modules with 2 slot addressing) Required Hardware Clutch/Brake Module 1771 PM Monitors and controls the press Wiring Arm 1771 WB Connections to 1771 PM I/O Chassis...

  • Page 13: Twinaxial Cable Connections

    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.
  • Page 14 Chapter 3 Clutch/Brake Controller Hardware Figure 3.2 Typical Twinaxial Cable Connections Processor/Scanner Blue Terminator Use Twinaxial Cable Shield (cat. no. (cat. no. 1770 -CD) Clear 1770 -XT) for all cable connections. Chassis A Terminal Strip on 1772 - SD, Blue Blue SD2 Remote I/O Scanner/ Shield...

  • Page 15: Multiple Clutch/Brake Controllers

    Chapter 3 Clutch/Brake Controller Hardware Multiple Clutch/Brake Although this manual describes a single clutch/brake controller, you may Controllers 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.

  • Page 16: Interlock Switches

    Chapter 3 Clutch/Brake Controller Hardware Interlock Switches 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.
  • Page 17 Chapter 3 Clutch/Brake Controller Hardware Figure 3.3 Backplane Switch Settings Chassis A and B Backplane Switches Assembly Always OFF Switch Position: 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...
  • Page 18 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.
  • Page 19 Chapter 3 Clutch/Brake Controller Hardware Figure 3.4 Rack Address Switch Setting on 1771 PM Module S W -1 S W - 2 A lw a ys O N (st ar ting M odule G roup 0) A lw ays O F F A lw ays O N (57.6K baud) Rack Addresses Switch Assembly SW-1 Position...

  • Page 20: Setting The Communication Rate

    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.

  • Page 21: Module Placement

    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.
  • Page 22 Chapter 3 Clutch/Brake Controller Hardware Figure 3.6 Module Locations Optional 1771 -OA modules for display of message codes, brake fault, run window and micro inch. Required 1771 -IA modules for module group 3, slot 1 chassis A press inputs chassis A & B module group 5, slot 1, chassis A &...

  • Page 23: Keying

    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 Insert keying bands so that you can install only a 1771-PM module in this slot. 12252 3 14...

  • Page 24: Plc Ladder Programming

    Chapter PLC Ladder Programming Chapter Objectives 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...
  • Page 25 Chapter 4 PC Ladder Programming Figure 4.1 Overview of Clutch/Brake Controller 1771 - PM Chassis Voting A-B Programmable Controller Processor with Remote I/O The firmware in voting processors A and B Press monitors and controls the press. Your ladder diagram program configures and 1771 - PM Chassis...

  • Page 26: Configuration Rungs

    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 Stations 3 and 4 Motion detector feedback Valve stem feedback Air pressure feedback Ungrounded or grounded AC power On the hop...
  • Page 27 Chapter 4 PC Ladder Programming Figure 4.3 Example PLC Configuration Rungs for Bits 01 thru 07 and 14 (PLC 2 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 used...
  • Page 28 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) O0057 O0067 Stations 3 and 4 not used O0057 O0067 Motion detector feedback used O0057 O0067 Valve stem switch feedback used O0057 O0067 Air pressure switch feedback not used...
  • Page 29 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 O:57 O:67 Motion detector feedback used O:57 O:67 Valve stem switch feedback used O:57 O:67 Air pressure switch feedback not used O:57...
  • Page 30 Chapter 4 PC Ladder Programming Matching Configuration Bits and As listed in Table 4.A, backplane switch positions 2 thru 8 correspond Backplane Switches 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.

  • Page 31: Plc Command Rungs

    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 Press enable Stop on top...
  • Page 32 Chapter 4 PC Ladder Programming Figure 4.6 Example PLC Command Rungs for Bits 10 thru 13 (PLC 2 Family) PRESS ENABLE Switch Optional conditions Enable Press Operation STOP-ON-TOP Switch Command Stop-on-top RESET Switch Reset latched messages LAMP TEST Switch Test optional indicators PLC command bits 10 through 13 use conditioned logic.
  • Page 33 Chapter 4 PC Ladder Programming Figure 4.7 Example PLC Command Rungs for Bits 10 thru 13 (PLC 3 and PLC 5/250) PRESS ENABLE Switch Optional conditions I0032 O0057 O0067 Enable Press Operation O0057 O0067 I0032 STOP-ON-TOP Switch Command Stop-on-top O0057 O0067 I0032 RESET Switch...
  • Page 34 Chapter 4 PC Ladder Programming Figure 4.8 Example PLC Command Rungs for Bits 10 thru 13 (PLC 5) PRESS ENABLE Switch Optional conditions I032 O:57 Enable Press Operation O:67 O:57 I032 STOP-ON-TOP Switch Command Stop-on-top O:67 I032 O:57 RESET Switch Reset latched messages O:67 O:57...

  • Page 35: Summary Of Plc Configuration And Command Rungs

    Chapter 4 PC Ladder Programming Summary of PLC Configuration We summarize the bits in module group 7 used for determining and Command Rungs configuration requirements and enabling operator commands (Figure 4.9). Figure 4.9 Functions of PLC Configuration and Command Bits PLC Configuration Bits 17 16 15 14 13 12 11 10 07 06 05 04 03 02 01 00 Output image table word,...

  • Page 36: Monitoring Clutch/Brake Controller Inputs And Outputs

    Chapter 4 PC Ladder Programming Module Group 5, Slot 0 Important: Use module group 5, slot 0 only if your mechanical power Reserved for Micro Inch 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.

  • Page 37: Report Generation

    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...

  • Page 38: Summary Of Clutch/Brake Controller Functions

    Chapter 4 PC Ladder Programming Summary of Clutch/Brake You should now be familiar with required and optional PLC ladder Controller Functions 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.
  • Page 39 Chapter 4 PC Ladder Programming Function or Command Operating Mode Description Interrupted stroke Continuous If an operator releases a RUN button during a down stroke, the press stops immediately. If within five seconds of stopping, an operator releases both RUN buttons and presses them again, the press continues the downstroke.

  • Page 40: Voting Processor Firmware

    Chapter Voting Processor Firmware Chapter Objectives This chapter will help you become familiar with: operation of your voting processor firmware operational sequences for controlling your press Operation of Voting Processors A clutch/brake controller has two clutch/brake modules, one in chassis A and the other in chassis B.

  • Page 41: Fault Monitoring

    Chapter 5 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 PM modules remove solenoid power by 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...

  • Page 42: Operation Of Cam Limit Switches

    Chapter 5 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.
  • Page 43 Chapter 5 Figure 5.1 Cam Limit Switch Settings Table 5.A Operation of Cam Limit Switches This In this With these Mode Conditions Provides the PM Module a Signal: Anti Repeat Run on Top Stop Check...

  • Page 44: Clutch/Brake Operating Modes

    Chapter 5 Clutch/Brake Operating Modes 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.
  • Page 45 Chapter 5 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...
  • Page 46 Chapter 5 Figure 5.3 Operational Sequence for Downstroke in Single Mode CAUTION: NOTE:...
  • Page 47 Chapter 5 Figure 5.4 Operational Sequence for Upstroke in Single Mode WARNING: NOTE:...
  • Page 48 Chapter 5 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).
  • Page 49 Chapter 5 Figure 5.5 Operational Sequence for Starting Continuous Mode NOTE:...
  • Page 50 Chapter 5 Figure 5.6 Operational Sequence for First Downstroke in Continuous Mode CAUTION: NOTE:...
  • Page 51 Chapter 5 Figure 5.7 Operational Sequence for First Upstroke and Second Downstroke in Continuous Mode NOTE:...
  • Page 52 Chapter 5 WARNING: NOTE:...

  • Page 53: Connections To Field Wiring Arms

    Chapter Connections to Field Wiring Arms Chapter Objectives This chapter will help you: Connect the field wiring arms of chassis A and B install either ungrounded or grounded 120V AC power distribution Installation Considerations Before continuing, be sure that you configured your clutch/brake controller chassis and modules as shown in chapter 3.
  • Page 54 Chapter 6 Field Wiring Arm Connections Use This Mandatory Figure For These Connections Cam Limit Switch Assemblies 6.10 Main Motor Forward Barrier Guard Stop on top Arm Continuous Mode Select Switch 6.11 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.

  • Page 55: Control Power

    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.

  • Page 56: Crowbar Test Inputs

    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.

  • Page 57: Optional Hardwire Inputs

    Chapter 6 Field Wiring Arm Connections Optional Hardwire Inputs Connect optional hardwire inputs as needed to chassis A and B so voting processors can monitor any of the following inputs: Input Terminal Slot Figure Main Valve Stem 6.2 or 6.6 Motion Detector Air Pressure Auxiliary Valve Stem...

  • Page 58: Internal/External Fault Detection

    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.

  • Page 59: Optional

    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.

  • Page 60: Main Valve Solenoids A And

    Chapter 6 Field Wiring Arm Connections 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): For this wiring And this feature Follow these instructions Single switch Motion detector Connect the jumper between terminal 1 (chassis A)

  • Page 61: Optional Auxiliary Valve Solenoids

    Chapter 6 Field Wiring Arm Connections Optional Auxiliary Valve Use auxiliary valve solenoids when you want to boost the volume of air to Solenoids 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.

  • Page 62: Optional Micro Inch Valve Solenoids

    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.

  • Page 63: Electrical Noise Suppression

    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.
  • Page 64 Chapter 6 Field Wiring Arm Connections Figure 6.1 Ungrounded AC Power Connections, Crowbar Test Inputs, and Press Interlock Switch Incoming Disconnect Isolation/ Step Down Transformer 1771-IA Module Group 2 120V Slot 0 To Motor Starters Back Panel Ground Fault Lamps and Ground Bus Text Switches To Earth...
  • Page 65 Chapter 6 Field Wiring Arm Connections Figure 6.2 Connections for Optional Switches on Main Valve Stems, Air Pressure Sensors, and Motion Detectors (Ungrounded AC Power) 1771 IA Module Group 2 Slot 0 Chassis A Remove this jumper when using Motion Detector Switch B.
  • Page 66 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 3 Module Group 2 Slot 0 Slot 1 Chassis A Chassis A Crowbar Relay Auxiliary...
  • Page 67 Chapter 6 Field Wiring Arm Connections Figure 6.4 Connections for Optional Dump and/or Micro inch Valve Solenoids with MOV Surge Suppression (Ungrounded AC Power) For either option For optional Dump Valve For optional Micro-inch Valve 1771 OD 1771 IA 1771 IA Module Group 4 Module Group 4 Module Group 5...
  • Page 68 Chapter 6 Field Wiring Arm Connections Figure 6.5 Grounded AC Power Connections, Crowbar Test Inputs, and Press Interlock Switch Incoming 1771 -IA Module Group 2 Slot 0 Disconnect Isolation/ Step Down Transformer 120V To Motor Starters Back Panel Ground Bus Customer E-stop Contacts...
  • Page 69 Chapter 6 Field Wiring Arm Connections Figure 6.6 Connections for Optional Switches on Main Valve Stems, Air Pressure Sensors, and Motion Detectors (Grounded AC Power) 1771 IA Module Group 2 Slot 0 Chassis A Remove this jumper when using Motion Detector Switch B.
  • Page 70 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 OD 1771 IA Module Group 3 Module Group 2 Slot 0 Slot 1 Chassis A Chassis A Crowbar Relay...
  • Page 71 Chapter 6 Field Wiring Arm Connections Figure 6.8 Connections for Optional Dump and/or Micro inch Valve Solenoids with MOV Surge Suppression (Grounded AC Power) For either option For optional Dump Valve For optional Micro- inch Valve 1771 IA 1771 IA 1771 OD Module Group 4 Module Group 5...

  • Page 72: Cam Limit Switches

    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.
  • Page 73 Chapter 6 Field Wiring Arm Connections Figure 6.9 Connections for Cam Limit Switch Assemblies 1771-IA Module Group 1 Slot 1 Chassis A Top stop check (TCAM) Run-On (RCAM) Cam Limit Switch Assembly A Anti-Repeat (ACAM) Chassis B Top stop check (TCAM) Run-On (RCAM) Cam Limit Switch Assembly B...

  • Page 74: Required Hardwire Inputs

    Chapter 6 Field Wiring Arm Connections Required Hardwire Inputs Connect hardwire inputs in parallel to chassis A and B so each voting processor can monitor the following inputs in parallel: Input Terminal Slot Figure Mode Select Switch 6.10 Main Motor Forward Barrier Guard Stop on top Arm Continuous...
  • Page 75 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 1771 IA Module Group 0 Slot 0 Chassis A...

  • Page 76: Inch Buttons And Plug In Operator Stations

    Chapter 6 Field Wiring Arm Connections Inch Buttons and Plug In Connect the (NC) and (NO) contacts of each INCH button to opposite Operator Stations chassis exactly as shown in Figure 6.11. This allows both voting processors to monitor and cross check both INCH buttons for correct operation.
  • Page 77 Chapter 6 Field Wiring Arm Connections Figure 6.11 Connections for Operator Stations 1 and 2, Dummy Plugs, and Inch Pushbutton Switches 1771 IA Module Group 0 Left Run Ch A- 0 Slot 1 Ch B- 1 Ch A- 2 Left Active Ch A - 0 Left 2L1 Ch A - 1...
  • Page 78 Chapter 6 Field Wiring Arm Connections Figure 6.12 Connections for Operator Stations 3 and 4, and Dummy Plugs 1771-IA Module Group 1 Left Run Ch A- 0 Slot 0 Ch B- 1 Left Active Ch A- 2 Ch A- 0 Left 2L1 Ch A- 1 Right Run...

  • Page 79: Optional Binary Display

    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.
  • Page 80 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.
  • Page 81 Chapter 6 Field Wiring Arm Connections Figure 6.13 Connections for Optional Diagnostic Message Display 1771-OA Module Group 5 We recommend Allen-Bradley Small Pilot Lights, Slot 1 Transformer type (cat. no. 800T-PS16R). Chassis A Chassis B 12285 6 29...
  • Page 82 Chapter 6 Field Wiring Arm Connections Figure 6.14 Connections for Brake Fault, Run Window, and Micro Inch Indicators 1771 OA Module Group 3 Slot 1 Chassis A Stop On Top Fault Run Window W recommend Allen Bradley Small Pilot Lights, Transformer type (cat.

  • Page 83: Lamp Test

    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.
  • Page 84 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 for Optional PLC Command Switches Chassis C...

  • Page 85: Troubleshooting

    Chapter Troubleshooting Chapter Objectives 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 Troubleshooting Considerations This chapter explains troubleshooting techniques and refers to previous...
  • Page 86 Chapter 7 Figure 7.1 Module Indicators for Chassis A or B Input Module Indicators PM Module Indicators Output Module Indicators Table 7.A ACTIVE Indicator Number of Blinks 1st Set 2nd Set Problem Correction...
  • Page 87 Chapter 7 Table 7.B I/O RACK FAULT and CBM FAULT Indicators I/O RACK FAULT FAULT Problem Correction or OFF Figure 7.2 Troubleshooting Flowchart for Module Indicators Warning...
  • Page 88 Chapter 7 General Troubleshooting Although the procedure for troubleshooting your clutch/brake controller Procedure varies with each problem, use the following steps as a general procedure: Examine Figure 7.2 and NO TAG. Answer questions in Figure 7.2 and NO TAG until you see a reference to another figure or table.
  • Page 89 Chapter 7 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. 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...

  • Page 90: General Troubleshooting Procedure

    Chapter 7 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: 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...
  • Page 91 Chapter 7 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. 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.

  • Page 92: Display Of Diagnostic Message Codes

    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: If using this...

  • Page 93: Types Of Diagnostic Message Codes

    Chapter 7 Types of Diagnostic Message PM modules detect operational and equipment faults, and indicate Codes 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.
  • Page 94 Chapter 7 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.
  • Page 95 Chapter 7 Re starting the Press You re-start the press with this procedure: When the “OD” message is displayed, press ESTOP to drop the seal relays. Message code “50” is displayed (swingarm power dropout) Press the START button. Press the RESET LATCHED MSG button. Select INCH mode if not already selected.

  • Page 96: Message Code Priority

    Chapter 7 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...

  • Page 97: Processing Diagnostic Message Codes

    Chapter 7 Processing Diagnostic Message If you want to maintain a record of diagnostic message codes or process Codes 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...
  • Page 98 Chapter 7 Table 7.C Diagnostic Message Codes Associated with the "0D" Message Code MISCELLANEOUS MESSAGES TYPE PROBLEM CORRECTIVE ACTION CODE...
  • Page 99 Chapter 7 MISCELLANEOUS MESSAGES (cont'd) TYPE PROBLEM CORRECTIVE ACTION CODE...
  • Page 100 Chapter 7 STATION MESSAGES TYPE PROBLEM CORRECTIVE ACTION CODE...
  • Page 101 Chapter 7 TYPE PROBLEM CORRECTIVE ACTION CODE DOWNSTROKE MESSAGES UPSTROKE MESSAGES BRAKE OR MOTION DETECTOR MESSAGES...
  • Page 102 Chapter 7 BRAKE OR MOTION DETECTOR MESSAGES (cont'd) TYPE PROBLEM CORRECTIVE ACTION CODE...
  • Page 103 Chapter 7 BRAKE OR MOTION DETECTOR MESSAGES (cont'd) TYPE PROBLEM CORRECTIVE ACTION CODE CAM LIMIT SWITCH TRANSITION TO DOWNSTROKE MESSAGES CAM LIMIT SWITCH DOWNSTROKE MESSAGES...
  • Page 104 Chapter 7 CAM LIMIT SWITCH TRANSITION TO NEAR BOTTOM ZONE MESSAGES TYPE PROBLEM CORRECTIVE ACTION CODE CAM LIMIT SWITCH NEAR BOTTOM ZONE MESSAGES...
  • Page 105 Chapter 7 CAM LIMIT SWITCH NEAR BOTTOM ZONE MESSAGES (cont'd) TYPE PROBLEM CORRECTIVE ACTION CODE CAM LIMIT SWITCH UPSTROKE MESSAGES CAM LIMIT SWITCH TRANSITION TO NEAR TOP ZONE MESSAGES...
  • Page 106 Chapter 7 CAM LIMIT SWITCH TRANSITION TO NEAR TOP ZONE MESSAGES (cont'd) TYPE PROBLEM CORRECTIVE ACTION CODE DIAGNOSTIC MESSAGES...

  • Page 107: Complete Listing Of Diagnostic Message Codes

    Chapter 7 Complete Listing of The complete diagnostic message table is divided into sections and diagnostic message codes subsections common to a device, operating condition, or hardware condition to assist your troubleshooting. When a diagnostic condition is detected and a message code is displayed, look for the problem in the section/subsection in which the message code is tabulated.
  • Page 108 Chapter 7 Table 7.D Diagnostic Messages Type of Message Code Type Diagnostic Message (figure References) Code Press Operation Inhibited Station 1...
  • Page 109 Chapter 7 Type of Message Code Type Diagnostic Message (figure References) Code Station 2...
  • Page 110 Chapter 7 Type of Message Code Type Diagnostic Message (figure References) Code Station 3...
  • Page 111 Chapter 7 Type of Message Code Type Diagnostic Message (figure References) Code Station 4 Inch button...
  • Page 112 Chapter 7 Type of Message Code Type Diagnostic Message (figure References) Code Valve Stem Inputs Not Configured Downstroke Fault...
  • Page 113 Chapter 7 Type of Message Code Binary Type Code Diagnostic Message (figure References) Upstroke Fault Fault in Set up for Continuous Mode Faulty Brake or Motion Detector...
  • Page 114 Chapter 7 Type of Message Code Binary Type Code Diagnostic Message (figure References) Faulty Cam Limit Switch Near Top Position Transition to Downstroke...
  • Page 115 Chapter 7 Type of Message Code Binary Type Code Diagnostic Message (figure References) Downstroke Transition to Near Bottom Zone Near Bottom Zone...
  • Page 116 Chapter 7 Type of Message Code Binary Type Code Diagnostic Message (figure References) Transition to Upstroke Upstroke Transition to Near Top Zone...
  • Page 117 Chapter 7 Type of Message Code Binary Type Code Diagnostic Message (figure References) Triac Fault...
  • Page 118 Chapter 7 Type of Message Code Binary Type Code Diagnostic Message (figure References) Fault in Valve Stem Feedback...
  • Page 119 Chapter 7 Type of Message Code Binary Type Code Diagnostic Message (figure References) Hardware or Cable Fault...
  • Page 120 Chapter 7 Type of Message Code Binary Type Code Diagnostic Message (figure References) Micro inch Diagnostic Codes...

  • Page 121: Summary

    Chapter 7 Type of Message Code Binary Type Code Diagnostic Message (figure References) Summary Now that you have read this chapter, you should have a general idea of how to safely troubleshoot your press system. This chapter showed you how to interpret the diagnostic diagnostic message codes and status indicators of your clutch/brake controller.
  • Page 122 Chapter 7 Type of Message Code Binary Type Code Diagnostic Message (figure References) Other Cam Limit Switch Faults General Faults Configuration Error...
  • Page 123 Chapter 7 Type of Message Code Binary Type Code Diagnostic Message (figure References) Motion Detector and Pressure Switch Faults...

  • Page 124: Bit Monitoring Addresses

    Appendix Bit Monitoring Addresses Use the addresses in the following tables to monitor press operation. Address digits a, b, and c are rack address digits. Assign them as required by your application. For PLC–2/20, –2/30 processors, rack addresses are 1 thru 7. For PLC–3 processors, rack addresses are 00 thru 77. Refer to Rack Addresses of Chassis A and B, chapter 3.10 for further information.
  • Page 125 Appendix A Bit Monitoring Address Module Group 0 Slot 0, 1771-IA, Figure 6.10 Addresses Term. Function PLC-2/30 PLC-3 Chassis Chassis Selector switch OFF position 1a0/00 1b0/00 10ab0/00 10ac0/00 Selector switch INCH position 1a0/01 1b0/01 10ab0/01 10ac0/01 Selector switch SINGLE position 1a0/02 1b0/02 10ab0/02...
  • Page 126 Appendix A Bit Monitoring Address Module Group 1 Slot 0, 1771-IA, Figure 6.12 Addresses Term. Function PLC-2/30 PLC-3 Chassis Chassis Station 3 left RUN (NC) contacts 1a1/00 10ab1/00 right RUN (NC) contacts 1b1/00 10ac1/00 Station 3 right RUN (NO) contacts 1a1/01 10ab1/01 left RUN (NO) contacts...
  • Page 127 Appendix A Bit Monitoring Address Module Group 2 Slot 0, 1771-IA, Figures 6.1 and 6.2 or 6.5 and 6.6 Addresses Term. Function PLC-2/30 PLC-3 Chassis Chassis Input from Main Valve Stem (NO) Switch A* 1a2/00 10ab2/00 Switch B* 1b2/00 10ac2/00 Input from Motion Detector (NO) Contacts A* 1a2/01...
  • Page 128 Appendix A Bit Monitoring Address Module Group 3 Slot 0, 1771-OD, Figure 6.3 or 6.7 Addresses Term. Function PLC-2/30 PLC-3 Chassis Chassis 1 & 2 Triac 0 for Main Solenoid A 1a3/00 1b3/00 10ab3/00 10ac3/00 3 & 4 Triac 1 for Main Solenoid B 1a3/01 1b3/01 10ab3/01...
  • Page 129 Appendix A Bit Monitoring Address Module Group 4 Slot 0, 1771-OD, Figure 6.4 or 6.8 Addresses Term. Function PLC-2/30 PLC-3 Chassis Chassis 1 & 2 Triac 6 for Dump Solenoid A 1a4/00 1b4/00 10ab4/00 10ac4/00 3 & 4 Triac 7 for Dump Solenoid B 1a4/01 1b4/01 10ab4/01...
  • Page 130 Appendix A Bit Monitoring Address Module Group 5 Slot 0, 1771-IA, Figure 6.4 or 6.8 Addresses Term. Function PLC-2/30 PLC-3 Chassis Chassis Selector Switch MICRO-INCH position 1a5/00 1b5/00 10ab5/00 10ac5/00 Input from Micro-inch valve stem 1a5/01 1b5/01 10ab5/01 10ac5/01 Input from Micro-inch pressure switch 1a5/02 1b5/02 10ab5/02...
  • Page 131 Appendix I/O FROM /TO LISTS In the following tables of from/to lists, we use the notation CGST to designate field wiring arm terminals, where C = chassis A or B S = slot number G = module group T = terminal number For example, a connection to chassis A, module group 3, slot 1, terminal 12 would be designated A3112.
  • Page 132 Appendix B I/I/O From/To Lists I/O From/To List for Figure 6.3 Auxiliary Valve Solenoids (Ungrounded AC Power) From From A214 A306 A301 A214 B214 A301 A303 A215 B215 A303 A305 A216 A308 A305 A307 A216 B216 A306 Auxiliary Valve Solenoid A A217 B217 A306...
  • Page 133 Appendix B I/O From/To Lists I/O From/To List for Figure 6.5 Micro-Inch Valve Solenoids (Ungrounded AC Power) From From A401 A500 Micro-inch Position on Selector Switch (figure .12) A401 A403 A500 B500 A403 A405 A501 Micro-inch Valve Stem Switch A405 A407 A502 B504...
  • Page 134 Appendix B I/I/O From/To Lists I/O From/To List for Figure 6.6 3L1 Power, Crowbar Test, and Press Interlock Inputs (Grounded AC Power) From A203 A204 Crowbar as (NO) contact A206 B206 A20B B203 B204 Crowbar B (N)) contact B206 Press Interlock Switch B20B I/O From/To List for Figure 6.7 Main Solenoids, Crowbar and Seal-in Relays...
  • Page 135 Appendix B I/O From/To Lists I/O From/To List for Figure 6.9 Dump Valve Solenoids (Grounded AC Power) From From A401 A410 B410 A401 A403 A411 B411 A402 B401 A412 B412 A042 A413 B413 A402 A410 A404 B403 A414 Switch on Dump Valve Stem A A404 A41B...
  • Page 136 Appendix B I/I/O From/To Lists I/O From/To List for Figure 6.11 Cam Limit Switches From A115 Brake Monitor Cam Limit Swich A A116 Run-on Cam Limit Switch A A117 Anti-repeat Cam Limit Switch A A11B B115 Brake Monitor Cam Limit Switch B B116 Run-on Cam Limit Switch B B117...
  • Page 137 Appendix B I/O From/To Lists I/O From/To List for Figure 6.13 Operator Station 1 From A010 Left RUN button (NC) contact) A011 Right RUN button (NO) contact A012 Left Active jumper connection A016 Left INCH button (NC) contact A017 Right INCH button (NO) contact A01B B010 Right RUN button (NC) contact...
  • Page 138 Appendix B I/I/O From/To Lists I/O From/To List for Figure 6.15 Operator Station 3 From A100 Left RUN button (NC) contact) A101 Right RUN button (NO) contact A102 Left Active jumper conection A10B B100 Right RUN button (NC) contact B101 Left RUN button (NO) contact B102 Right Active jumper conection...
  • Page 139 Appendix B I/O From/To Lists I/O From/To List for Figure 6.18 Diagnostic Message Display From A51A A510 Output indicator for bit 10 A511 Output indicator for bit 11 A512 Output indicator for bit 12 A513 Output indicator for bit 13 A514 Output indicator for bit 14 A515...
  • Page 140 Appendix B I/I/O From/To Lists I/O From/To List for Figure 6.20 Connections for PC Command Switches From C213 Barrier Guard (NO) switch contact C214 Reset Latched Messages (NO) switch C215 Stop-on-top (NO) switch contact C216 Lamp Test (NO) switch contact C21B NOTE: We have chosen rack 3, module group 2 for the address of this module in remote I/O chassis C.
  • Page 141 Index Symbols **Empty**, hardware coniderations, press, inch mode, installation considerations, addresses, bit monitor, interlock switches, bottom zone, keying, 3 14 braking distance, 3 12 lamp test, 6 31 cable connections (twinaxial), load resistors, cam limit switches, 6 20 anti-repeat, run-on, chassis A and B, Manual, how to use, objectives, chassis C,, lamptest,...
  • Page 142 Index I–2 panel, system components, rack address, report generation, 4 14 response time, 3 12 rungs, terminator resistor, Terminology, top position, triac, sequential turn on, 3 11 safety troubleshooting documentation, considerations, requirements, example, seal relay, procedure, single mode, solenoid valves auxiliary, dump, unique rack address,...

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