Allen-Bradley 1771-PM Manual de usuario

User

Manual

Clutch/Brake

Module

(Cat. No. 1771-PM)

AllenBradley

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

Chapter

Objectives

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

Objectives

Of This Manual

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

How To Use This Manual 11

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

Terminology 12

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

Firmware Revision Record 12

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

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

Chapter

Objectives

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

System Components 21

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

Figure 2.1

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

Safety Documentation

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

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

Chapter

Objectives

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

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

the Communication Rate

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

Response Time 311

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

Module

Placement

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

Keying 314

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

PLC

Ladder Programming

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

Chapter

Objectives

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

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

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

Table of Contents

Table of Contentsii

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

Chapter

Objectives

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

Operation

of V

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

Emergency Shut Down 51

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

Fault

Monitoring

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

Operation

of Cam Limit Switches

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

Clutch/Brake Operating Modes 55

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

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

Chapter

Objectives

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

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

est Inputs

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

Optional Hardwire Inputs 65

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

Internal/External

Fault Detection

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

Optional

Valve

Stem Switches,

Motion Detectors, and

Air Pressure Switches 67

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

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

Limit Switches

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

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

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

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

Chapter

Objectives

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

Troubleshooting Considerations and Requirements 71

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

Troubleshooting

with LED'

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

General Troubleshooting Procedure 74

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

Troubleshooting

Hints

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

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

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

Table of Contents iii

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

Complete Listing of diagnostic message codes 723

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

Summary 737

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

Diagnostic diagnostic message codes in T

able 7.C

737. . . . . . . . . . . .

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

I/O FROM /T

O LISTS

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

Chapter 1

11

Introduction

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.

Chapter Objectives

Objectives Of This Manual

How To Use This Manual

Introduction

Chapter 1

12

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.

apress 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)

Terminology

Firmware Revision Record

Chapter 2

21

Press System Description

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.

Chapter Objectives

System Components

Press System Description

Chapter 2

22

Figure 2.1

Functional Block Diagram

Operator

Station

No. 1

Operator

Station

No. 2

Operator

Station

No. 3

Operator

Station

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

Air Supply

Cam

Switch

Assembly

Cam

Switch

Assembly

Shaft at Top Position

Shaft at Bottom Position

Press

Crankshaft

Flywheel

Clutch/Brake Assembly

Cam Switch

Feedback

Inputs

Triac

Outputs

to Main

Solenoids Main Solenoid Valves

Air to Clutch

12245

Press System Description

Chapter 2

23

This manual concentrates on safety considerations relative to the

clutch/brake controller. Study this entire manual and all technical

documentation provided by the press manufacturer before you install your

press system. In addition to local codes and laws, follow the safety

requirements detailed in the following publications:

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

Mechanical Power Presses

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

Mechanical Power Presses, Construction, Care, and Use

NFPA No. 79, Electrical Standard for Metalworking Machine Tools

Related Safety Documentation

Chapter 3

31

Clutch/Brake Controller Hardware

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.

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.

Chapter Objectives

General Hardware

Considerations

Description of your Clutch/Brake

Controller

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