Page 1 Allen Bradley Design Clutch/Brake Control System Manual PLC 5 Series (Cat. No. 6556 Pxxxx) ClutchBrake...
Page 2 Reproduction of the contents of this copyrighted publication, in whole or in part, without written permission of Allen-Bradley Company, Inc., is prohibited. Throughout this manual we use notes to make you aware of safety...
Page 3 Summary of Changes Summary of Changes Software Revision 1.3 Wiring Changes Series B Important: Revision 1.3 software cannot be operated on a machine wired for Revision 1.2 (or earlier) software without changing the wiring for power distribution (sheet 1 of 9) and module group 4 (sheet 8 of 9). Summary of Changes We revised this manual to reflect wiring changes and the upgrade to software revision 1.3 as follows:...
Page 4 soc–ii Summary of Changes Software Revision 1.2 Hardware Changes Important: Revision 1.2 software cannot be operated on a machine wired for Revision 1.1 (or earlier) software without this change: You must move the pressure switch from the port line of the clutch/brake valve to the pressure line.
Page 5: Table Of Contents
Table of Contents Summary of Changes ......soc-i Software Revision 1.3 Series B ......soc-i Software Revision 1.2 .
Page 6 Table of Contents Information on Diskette ....... . 1-13 Control System Specifications .
Page 7 Table of Contents Write Ladder Logic ......Chapter Objectives ........Overview of Memory Organization .
Page 8 Table of Contents Set Up or Simulate Rotary Cam Limit Switches ..Chapter Objectives ........Setting Up Position Monitoring Devices .
Page 9 Table of Contents Feedback Timing Diagrams ......Timing Diagrams for Control System Feedback ....Notes .
Page 10 Table of Contents Creating Data Storage Files ......F-11 Directly Creating Data Storage Files ....F-11 Data Storage Created by Assigning Addresses .
Page 11: Using This Manual
(especially with the Allen-Bradley PLC-5 family of processors) an electrical technician skilled in installing electronic equipment Before starting the installation, we suggest that you familiarize Summary of yourself with the information in this manual.
Page 12: Information In The Appendices
P–2 Using This Manual Information in the The last part of the manual contains appendices. Appendix A Appendices contains these descriptions of control system operating modes: inch, and micro-inch single stroke continuous Other appendices include: timing diagram of control system feedback, in Appendix B fault codes to help you debug the control system, in Appendix C operator prompts to help you run the press, in Appendix C class privileges and read/write access by class, in Appendix D...
Page 13: Terms And Abbreviations
Using This Manual P–3 You should become familiar with these abbreviated terms. For Terms and Abbreviations complete definitions of clutch/brake terms, refer to ANSI B11.1-1988 section 3. Category Term Definition Hardware active pin run station wiring that provides a signal to indicate that pairs of run buttons are active, not replaced by dummy plugs (optional feature) brake time a solid state device that monitors press stopping time at any point in the stroke...
Page 14 P–4 Using This Manual Notes Publication 6556 6.5.1 - October 1996...
Page 15: Chapter Objectives
Chapter Overview of the Clutch/Brake Control System Chapter Objectives This chapter acquaints you with the Allen-Bradley clutch/brake control system for part-revolution mechanical stamping presses with a friction clutch/brake mechanism. Topics include: The Application Package Related Safety Documentation Control by Redundant Processors...
Page 16: Typical Hardware (For The Cat. No. 6556 Pxxxk Application Package)
1–2 Overview of the Clutch/Brake Control System Typical Hardware (for the cat. no. 6556 PxxxK Application Package) PLC-5/46 processor (scanner mode, chassis A) PLC-5/26 processor (adapter mode, chassis B) two 1771-A2B 8-slot I/O chassis six 1771-ID16 16-point isolated input modules two 1771-OD16 16-point isolated output modules two 1771-P4S slot power supplies six 700-P400 master control and seal relays...
Page 17: Control By Redundant Processors
Overview of the Clutch/Brake Control System 1–3 Control by The clutch/brake control system uses two independent PLC-5/x6 Redundant Processors processors (Figure 1.1), such as but not limited to: PLC-5/46 processor operating in scanner mode in chassis A PLC-5/26 processor operating in adapter mode in chassis B Both processors monitor all clutch/brake I/O and exchange information regarding machine status.
Page 18: How The Software Controls Your Press
1–4 Overview of the Clutch/Brake Control System How the Software The clutch/brake control system can control the entire press because Controls Your Press you can add your own ladder logic for other press functions. Factory- protected logic for control of the clutch/brake mechanism is stored in locked program files (PF2 and PF16).
Page 19 Overview of the Clutch/Brake Control System 1–5 The Clutch/Brake Application Package includes the clutch/brake code in PF2 and PF16. You program the remaining machine applications (Figure 1.4). Figure 1.4 Example Software Architecture of a Press Control System with Auxiliary Press Functions Slide Adjust Control Die Clamp Control Bolster/Die Cart Control...
Page 20: Protected Memory In Plc 5/X6 Processors
1–6 Overview of the Clutch/Brake Control System Protected Memory in Security PLC 5/x6 Processors When programmed with either version of Rockwell programming software, PLC-5/x6 processors provide enhanced security. Designated program files, such as those storing factory-configured clutch/brake control logic, are locked at the factory. You can read them but you cannot: edit locked program files of a PLC-5/x6 processor restore PLC-5/x6 programs to other PLC-5 processors...
Page 21: Functional Block Diagram
Overview of the Clutch/Brake Control System 1–7 Functional Block Diagram The functional block diagram in Figure 1.5 shows the relationships between various mechanical components of a stamping press and the control system. Figure 1.5 Functional Block Diagram Modes of You select the mode of control system operation with a selector switch. Control System operation In 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.
Page 22: Clutch/Brake Control Functions
1–8 Overview of the Clutch/Brake Control System Clutch/Brake Clutch/brake control functions are summarized in Table 1.A. Control Functions Table 1.A Summary of Clutch/Brake Control Functions Control Function Operating Mode Description...
Page 23: Required Input Switches
Overview of the Clutch/Brake Control System 1–9 Required Input Switches The clutch/brake control system requires input switches. Table 1.B lists representative types. Select the right input switches for your application. Table 1.B Required Input Switches Device Symbol Purpose Type Allen Bradley Type...
Page 24: Choice Of Position Monitoring Devices
If using rotary cam limit switches, we recommend: a pair of Allen-Bradley Cat. No. 803-B94 or 803-P94 If using a resolver, we recommend one of these solutions: AMCI Series 1700 AMCI Resolver, and Absolute Resolver Input Module that plugs into the 1771 I/O chassis NSD VRE–P062 Resolver and VE–2A Single Turn Converter...
Page 25: Internal Timers
Overview of the Clutch/Brake Control System 1–11 Figure 1.6 Shaft Rotation for a 21 ms Response Time of the Clutch/Brake Control System Important: When estimating the braking distance in degrees of rotation, you must add the response time of the control system (Figure 1.6) to the specified downstroke or upstroke braking distance of your press.
Page 26: Options To Suit Your Application
1–12 Overview of the Clutch/Brake Control System Options to Suit To customize the control system to suit your application, we help you: Your Application select your factory-configured options program your clutch/brake interface with ladder-logic commands wire your control system Selecting Factory Configured Options When you purchased your Application Package, you designated factory- configured options by a coded catalog number (6556-Pxxxx) from combinations of these features:...
Page 27: Wiring Your Control System
Overview of the Clutch/Brake Control System 1–13 To program this objective Use these command bits B151/ Wiring Your Control System Your application determines the wiring options to your control system: (We show you how to customize your wiring in chapter 3.) four or fewer run stations micro inch and/or micro inch feedback valve-stem feedback or valves with internal fault detection...
Page 28: Control System Specifications
1–14 Overview of the Clutch/Brake Control System Control System Specifications Type of processor Command bits for clutch/brake logic Type of ac power: Mode selections Type of valves Valve outputs Position monitoring inputs Machine inputs Environmental conditions Number of run stations Response time of C/B control Designed to comply with...
Page 29: Define Your Control System Characteristics
Chapter Define Your Control System Characteristics Chapter Objectives This chapter helps you complete the design of your Clutch/Brake Control System by specifying design characteristics on a worksheet as follows: verify your factory-configured options assign valves to specific outputs select the type of valve fault detection select input switches select the type of position sensor select command bits for your clutch/brake interface logic...
Page 30: Assign Valves To Specific Outputs
2–2 Define Your Control System Characteristics 2. Assign Valves to Each processor has three pairs of outputs for press valves Specific Outputs (6 outputs per processor, 12 outputs per system). The pairs are: Clutch 1 and Clutch 2 (Clutch and Brake) Auxiliary 1 and Auxiliary 2 Micro-inch 1 and Micro-inch 2 Assign your press valves to specific outputs as follows:...
Page 31: Select The Type Of Position Sensor
Define Your Control System Characteristics 2–3 4. Select the Type of The control system uses dual independent position sensors to monitor Position Sensor the slide position. You select the type of position sensor from: dual rotary cam limit switches (RCLS) dual resolvers (with RCLSs simulated in ladder logic) combination of both Rotary Cam Limit Switches...
Page 32: Record On/Off Positions Of Rotary Cam Limit Switches
2–4 Define Your Control System Characteristics 5. Record On/Off Positions During installation of your rotary cam limit switches, you must set of Rotary Cam Limit the on and off positions of these switches (Figure 2.1). Use the Switches initial on/off positions specified by the press manufacturer. Figure 2.1 Guidelines for Setting the On/Off Positions of the Rotary Cam Limit Switches Set Up or Simulate Rotary Cam Limit Switches as Follows:...
Page 33 Define Your Control System Characteristics 2–5 Table 2.A Command Bits for Your Clutch/Brake Interface To program Program these bits in PF15 this feature Name Address Record the command bits required for your application on the worksheet. We present examples of how to use these bits in chapter 4.
Page 34: Select Other Options
2–6 Define Your Control System Characteristics 8. Select Other Options We provide you with wiring drawings on paper and diskette for ac power: grounded ungrounded Important: Select the type of ac wiring system used for your press. Discard the other set of drawings on paper and diskette to avoid confusion. Other options relate to the way you: wire your control system for application options program ladder logic in PF15...
Page 35: Verify Your Factory Configured Options
Define Your Control System Characteristics 2–7 Configuration Worksheet 1. Verify Your Factory configured Options Do this by inspecting the label on the software diskette in your Application Package and matching it to your order number, such as cat. no. 6556-PA Factory configured Options (by Cat.
Page 36: Record The Type(S) Of Valve Fault Detection
2–8 Define Your Control System Characteristics 3. Record the Type(s) of Valve Fault Detection Important: If using a mix of valves having external and internal fault detection, you must: use valve-stem feedback on all valves with external fault detection simulate valve-stem feedback on valves with internal fault detection Press Valves External Internal...
Page 37: Select Input Switches
Define Your Control System Characteristics 2–9 6. Select Input Switches Record the quantity and locations of your input switches. Device Symbol Purpose Type Qty Location...
Page 38: Select Optional Command Bits For C/B Interface Logic
2–10 Define Your Control System Characteristics 7. Select Optional Command Bits for C/B Interface Logic Select command bits for your clutch/brake interface (PF15). We grouped bits by similar kind. For logic examples, see chapter 4. Important: Some bits are listed more than once, based on usage. Use this Control Bit: At Addr.
Page 39: Select Options That Affect System Wiring
Define Your Control System Characteristics 2–11 8. Select Options That Affect System Wiring Check the ac distribution system wiring you will use: ungrounded _____ (appendix G) , or grounded _____ (appendix H) Important: To avoid confusion from two sets of drawings, remove and/or discard the unused set (printed and electronic versions).
Page 40: Reduce Watchdog Timer Presets As An Option
2–12 Define Your Control System Characteristics 9. Reduce Watchdog Timer Presets as an Option Check the timers you want to change and record shorter presets (in seconds). Timer Preset New Preset...
Page 41: 10. Select Options That Require Programming
Define Your Control System Characteristics 2–13 10. Select Options That Require Programming We give you examples to help you program the following options: Then Refer to Logic...
Page 42 2–14 Define Your Control System Characteristics Notes...
Page 43: Customize The Wiring To Suit Your Application
Chapter Customize the Wiring to Suit Your Application Chapter Objectives In this chapter, we present default configurations of the control system, and show you how to modify them to meet your application requirements. We: list default wiring configurations and modifications you can make explain how to install wiring drawing diskettes on your hard drive explain how to perform the wiring modifications give example figures showing completed modifications...
Page 44: Install Your Wiring Drawing Diskettes
3–2 Customize the Wiring Install Your Wiring We provide you with wiring drawings on diskette so you can install Drawing Diskettes them on your computer and modify them electronically according to the options that you choose for your application. DWG -AutoCAD (release 11.0) DXF - File Interchange Follow this procedure to install your wiring drawings and to select the format that suits your computer.
Page 45: Generalized Instructions To Customize Your Wiring
Customize the Wiring 3–3 Generalized Instructions To customize the wiring drawings to suit your application: to Customize Your Wiring 1. Select the modifications that apply to your application from tables on left-hand pages in this section. 2. Follow the instructions for the modification. Some modifications require that you write ladder logic to replace the function of the deleted wiring, or that you wire an input terminal to a power rail.
Page 46 3–4 Customize the Wiring I/O Module Group 2 (sheet 6 of 9) Ungrounded AC Power For this modification Make these changes And see Replace RCLSs 1. Delete the three pairs of limit switches (RLCSs) at input terminals [ 1 ], [ 3 ], and [ 5 ]. Figure 3.1 with resolvers 2.
Page 47 Customize the Wiring 3–5 Figure 3.1 Replace RCLSs with Ladder Logic (Module Group 2) Figure 3.2 Delete Crowbar Relay Feedback (Module Group 2) CROWBAR RELAY A FEEDBACK (Reserved, Do Not Use) (Reserved, Do Not Use) CROWBAR RELAY B FEEDBACK Figure 3.3 Delete Crowbar Relay (Power Distribution) (Module Group 2) Figure 3.4 Delete Clutch/Brake Air Pressure, Main Motor Forward, and...
Page 48 3–6 Customize the Wiring I/O Module Group 3 (sheet 7 of 9) Ungrounded AC Power For this modification Make these changes Then see Delete run station 1 1. Delete the right run station pushbutton switch wired to input terminal [ 1 ] for chassis A Figure 3.5 and to input terminal [ 3 ] for chassis B.
Page 49 Customize the Wiring 3–7 Figure 3.5 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 Continuous Switch (Module Group 3) (Reserved, Do Not Use)
Page 50 3–8 Customize the Wiring I/O Module Group 4 (sheet 8 of 9) Ungrounded AC Power For this modification Make these changes Then see Use Micro inch Valves With 1. Delete micro inch valve stem limit switches and wiring from input terminals [ 1 ] and [ 3 ]. Figure 3.8 Internal Fault Detection We deleted the wiring (Figure 3.8) and added the label (Reserved, Do Not Use).
Page 51 Customize the Wiring 3–9 Figure 3.8 Delete Valve stem Feedback for Clutch, Auxiliary, and/or Micro inch Valves (Module Group 4) RACK A00 RACK B00 MODULE GROUP 4 MODULE GROUP 4 MICRO INCH 1 FEEDBACK (Reserved, Do Not Use) INPUT 0 INPUT 0 (Reserved, Do Not Use) MICRO INCH 1 FEEDBACK...
Page 52 3–10 Customize the Wiring I/O Module Group 5 (sheet 9 of 9) Ungrounded AC Power For this modification Make these changes Then see Use Valves With No change to output wiring in I/O group 5. Internal Fault Detection 1. Important: Write ladder logic to reset bit B151/20 (Auxiliary Valve Stems Enabled). Figure 4.15 Write ladder logic to reset bit B151/21 (C/B Valve Stems Enabled).
Page 53 Customize the Wiring 3–11 Figure 3.10 Delete Auxiliary Valve Outputs (Module Group 5) AUX 1 VALVE (Reserved, Do Not Use) (Reserved, Do Not Use) AUX 1 VALVE AUX 2 VALVE (Reserved, Do Not Use) (Reserved, Do Not Use) AUX 2 VALVE Figure 3.11 Delete Micro inch Valve Outputs (Module Group 5) (Reserved, Do Not Use)
Page 54: Customize A Grounded Ac System
3–12 Customize the Wiring Customize a To customize the wiring of I/O module groups 2-5 to suit your application, Grounded AC System refer General Instructions to Customize Your Wiring (page 3), and follow the instructions below. Instructions and examples are on facing pages. Important: If using ungrounded ac power, go back to the previous section.
Page 55 Customize the Wiring 3–13 Figure 3.13 Replace RCLSs with 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 Clutch/Brake Air Pressure, Main Motor Forward, and Motion Detector Switches (Module Group 2) Publication 6556 6.5.1 - October 1996...
Page 56 3–14 Customize the Wiring I/O Module Group 3 (sheet 7 of 9) Grounded AC Power For this modification Make these changes And see Delete run station 1 1. Delete the right run station pushbutton switch wired to input terminal [ 1 ] for chassis A Figure 3.17 and to input terminal [ 3 ] for chassis B.
Page 57 Customize the Wiring 3–15 Figure 3.17 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 Continuous Switch (Module Group 3) (Reserved, Do Not Use)
Page 58 3–16 Customize the Wiring I/O Module Group 4 (sheet 8 of 9) Grounded AC Power For this modification Make these changes And see Use Micro inch Valves With 1. Delete micro inch valve stem limit switches and wiring from input terminals [ 1 ] and [ 3 ]. Figure 3.20 Internal Fault Detection We removed the wiring (Figure 3.20) and added the label (Reserved, Do Not Use).
Page 59 Customize the Wiring 3–17 Figure 3.20 Delete Valve stem Feedback for Clutch, Auxiliary, and/or Micro inch Valves (Module Group 4) RACK A00 RACK B00 MODULE GROUP 4 MODULE GROUP 4 MICRO INCH 1 FEEDBACK (Reserved, Do Not Use) INPUT 0 INPUT 0 (Reserved, Do Not Use) MICRO INCH 1 FEEDBACK...
Page 60 3–18 Customize the Wiring I/O Module Group 5 (sheet 9 of 9) Grounded AC Power For this modification Make these changes And see Use Valves With No change to output wiring in I/O group 5. Internal Fault Detection 1. Important: Write ladder logic to reset bit B151/20 (Auxiliary Valve Stems Enabled). Write ladder logic to reset bit B151/21 (C/B Valve Stems Enabled).
Page 61 Customize the Wiring 3–19 Figure 3.22 Delete Auxiliary Valve Outputs (Module Group 5) AUX VALVE 1 (Reserved, Do Not Use) AUX VALVE 1 (Reserved, Do Not Use) AUX VALVE 2 (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...
Page 62: Notes
3–20 Customize the Wiring Notes Publication 6556 6.5.1 - October 1996...
Page 63: Write Ladder Logic
Chapter Write Ladder Logic Chapter Objectives To help you write ladder logic to customize the operation of your clutch/brake control system, we present the following information: overview of memory organization for processors A and B data files reserved for control system data how command bits act on control logic in protected memory select from these command bits steps to write ladder logic...
Page 64: Reserved Program And Data Files
4–2 Write Ladder Logic Reserved Program and Allen-Bradley has adopted certain conventions for assigning press-control Data Files functions to specific subroutine files. For standardization, we suggest that you assign subroutine files and corresponding data files for press-control functions in addition to the clutch/brake as listed in Appendix E.
Page 65: Select From These Command Bits
Write Ladder Logic 4–3 Select from These You may program one or more of the following command bits in Command Bits Program File 15 to customize the operation of your press. Your control system will control the clutch/brake mechanism even if you program none of them.
Page 66 4–4 Write Ladder Logic Address ON/OFF States Example Application Example Ladder Logic 2 2 . Important: Important: We designed the clutch/brake code in PF16 with the requirement that you must program most of the command bits with nearly identical logic and hardware conditions for processors A and B. The following table designates which command bits do NOT have that requirement: Logic and Hardware Conditions Can be Different for Processors A and B For These Bits:...
Page 67: Steps To Write Ladder Logic
Write Ladder Logic 4–5 Steps to Write Follow these guidelines when writing ladder logic for your C/B Ladder Logic interface in PF15. We present programming examples afterwards. 1. Install your programming software on your hard drive. Use instructions in the manual that accompanied your software. 2.
Page 68: Programming Command Bits
4–6 Write Ladder Logic Programming We present programming examples for command bits B151/03-B151/29. Command Bits ATTENTION: You are responsible for your own application logic. If using our examples, do so only after modifying them to suit your application. Direct use or misapplication of these examples could result in unexpected machine motion with possible personal injury and/or damage to equipment.
Page 69 Write Ladder Logic 4–7 To start press motion, we recommend that you use the following bits: B151/03 – permit cycle start B151/04 – permit run B151/05 – permit downstroke (or delayed start) Figure 4.1 Example of the Permit Cycle Start Command B151/03 Use this command in single or continuous mode to ensure that the piece is in place before pressing Run buttons to start the press.
Page 70 4–8 Write Ladder Logic Figure 4.4 Example of the Delayed Start Command With B151/05 You can program a delayed start initiated by the AND of part-in-place and all-Run-buttons-pressed. Part |All Active |Run Buttons Permit Place |Pressed Downstroke | I:030 B160 B151 +––––] [––––––––] [–––––––––––––––––––––––––––––––( )–––––+ Figure 4.5...
Page 71 Write Ladder Logic 4–9 Figure 4.7 Example of the Permit Inch Command B151/08 Use the permit inch command to allow inching (used to inch the press to bottom during manual die change in this example). Stop Press at Press at | Bottom Bottom B156...
Page 72 4–10 Write Ladder Logic Figure 4.8 Example Commands to Simulate Inch Buttons B151/09 and Select Remote Inch Mode B151/10 Use these two command bits in an automatic operation. (In this example, they are used to inch the press to bottom.) Important: The main selector switch must be in remote mode.
Page 73 Write Ladder Logic 4–11 Figure 4.10 Example of the Command for Press in Motion B151/12 Use the press in motion command to detect shaft motion with a resolver module in slot zero (at address I:000). Store Resolver Input Angle +–MOV––––––––––––––––– + +––––––––––––––––––––––––––––––––+ MOVE +––| | Source...
Page 74 4–12 Write Ladder Logic Figure 4.11 Example Commands to Select Single Mode B151/13 and Continuous Mode B151/14 from a Remote Selector Use these mode-select command bits to change operating mode from a remote location such as a master controller. Important: The main selector switch must be in remote mode. Line Supervisor Remote Single Stroke Mode...
Page 75: Soft" Clutch And Brake
Write Ladder Logic 4–13 Soft" Clutch and Brake A “soft” clutch/brake provides smoother starting and stopping of press motion. The clutch and brake are activated with a 2-step valve sequence using auxiliary pressure-relief valves in series with the main clutch/brake valves. You preset auxiliary-valve time delays to: provide a brief interval of pressure-relieved slip action turn auxiliary valves ON or OFF for full pressure at time-out You select time-delay presets in the range of 0.1 –...
Page 76 4–14 Write Ladder Logic Figure 4.14 Example Commands to Control Soft" Clutch and Brake Operation B151/16, B151/17, B151/19, and B151/22 Aux Valve 2 Follows Clutch Outputs B151 +–––––––––––––––––––––––––––––––––––––––––––––––––(U)–––––––+ Clutch/Brake |Clutch/Brake Soft Dual Valve 1 |Dual Valve 2 Clutch 926SOL |927SOL Timer O:005 O:005...
Page 77 Write Ladder Logic 4–15 Figure 4.15 Example Commands to Indicate the Absence of Physical Inputs B151/20, B151/21, and Physical Outputs B151/19, B151/22 When customizing your design to omit certain valve hardware wiring, program the following command bits unconditionally to tell the software to ignore corresponding physical inputs that are absent: Program this bit When...
Page 78 4–16 Write Ladder Logic Figure 4.17 Example Commands to Select Remote Micro inch Mode B151/24 and Simulate Inch Buttons B151/09 Use these two command bits in an automatic operation. (In this example, they are used to inch the press to bottom.) Important: The main selector switch must be in remote mode.
Page 79 Write Ladder Logic 4–17 Figure 4.19 Example Command to Select Automatic Single stroke Mode from a Remote Selector B151/26 Use this command bit to switch press mode to auto single-stroke from a remote selector. Start the press with bit B151/25 (Figure 4.18).
Page 80: Exchanging Data Between Processors
4–18 Write Ladder Logic Figure 4.21 Example Command to Start Inch Mode After Pressing Inch Buttons B151/28 Use this bit as the last logical condition to start inch motion in combination with pressing Inch buttons manually. Simulate Inch Inch Output Buttons Enabled B156...
Page 81: Using Fault And Prompt Bits
Write Ladder Logic 4–19 For example, if processor A monitors position with resolver inputs and processor B controls all pilot lights for press operational status, processor A could transmit the status of top dead center to processor B as follows (Figure 4.23): Figure 4.23 Example Logic to Exchange Data Over a Scanner/Adapter Channel | Processor A...
Page 82: Programming Shorter Presets For Your Internal Timers
4–20 Write Ladder Logic Figure 4.24 Example Logic to Generate a BCD Fault Number +–FBC––––––––––––––––––––––+ Enable | FILE BIT COMPARE +––(EN)| +–––] [–––––––––––––––––––+ Source #B168:0 +––(DN)| | Reference #B156:0 |––(FD)| | Result #N10:0 |––(IN)| | Cmp Control R6:0 |––(ER)| | Length 160 | | Position | Result Control...
Page 83 Write Ladder Logic 4–21 This is the list of internal timers. The time base is 0.01 second for all timers Timer Preset Your Preset Address...
Page 84: Programming Press Ready To Start Indicators
4–22 Write Ladder Logic Programming Press ready When starting multiple presses in a transfer line, you can program ladder to start Indicators logic in program file PF15 that indicates when the clutch/brake control modes are ready to start (Figure 4.26). Examine the following “ready” bits that tell when permissives are satisfied to start running the press: Bit Name Bit Address...
Page 85 Write Ladder Logic 4–23 The time required to execute the example STI program (Figure 4.27) is about 1/2 ms, so we suggest an STI interrupt interval of about 2 ms. The shorter you make the STI interrupt interval to increase the accuracy of the brake monitor, the less time remains to execute the main program so its overall execution time increases.
Page 86 4–24 Write Ladder Logic Rung 9:12 Starting Brake Angle +MOV–––––––––––––––+ |––] [–––[OSR]––––––––––––––––––––––––––––––––––––––––+–+MOVE +–+–| | |Source I:1.1| | | 0| | | | |Dest N91:4| | | 0| | | | +––––––––––––––––––+ | | Final Brake Angle | +MOV–––––––––––––––+ | | +–+MOVE +–+ | | |Source...
Page 87 Write Ladder Logic 4–25 Rung 9:14 Resolver Angle Change +SUB–––––––––––––––+ |––] [–––––––––––––––––––––––––––+––––––––––––––––––––––+SUBTRACT +–+–| |Source A I:1.1| | | 0| | | |Source B N91:5| | | 0| | | |Dest N91:8| | | 0| | | +––––––––––––––––––+ | | Resolver Angle Change | +LIM–––––––––––––––+ +NEG–––––––––––––––+ | | +–+LIMIT TEST...
Page 88 4–26 Write Ladder Logic Rung 9:16 No Angle Change Brake Time STI Count STI Count +EQU–––––––––––––––+ +SUB–––––––––––––––+ |––] [––+EQUAL +––––––––––––––––––––––––––+–+SUBTRACT +–+–| 34 |Source A N91:7| | |Source A N91:6| | | 0| | | |Source B 100| | |Source B N91:7| | | 0| | | +––––––––––––––––––+...
Page 89 Write Ladder Logic 4–27 Rung 9:18 | Off Mode Last | Confirmed Brake Time B160 +CLR–––––––––––––––+ |––––] [––––––––––––––––––––––––––––––––––––––––––––––+–+CLEAR +–+–| | |Dest N91:1| | | 0| | | | +––––––––––––––––––+ | | Last Brake Angle | +CLR–––––––––––––––+ | | +–+CLEAR +–+ | |Dest N91:3| +––––––––––––––––––+...
Page 90: Programming A Variable Speed Top Stop
4–28 Write Ladder Logic Programming a The purpose of the variable-speed top stop program is to make the Variable speed Top Stop press stop at the top when commanded, regardless of press speed. Requirements of this program are the following: You must use a resolver as a position monitoring device Your program must simulate the action of rotary cam limit switches Your program should adjust the TCAM setting only during...
Page 91 Write Ladder Logic 4–29 Resolver Position | | +–LIM––––––––––––––––––––+ +–LIM––––––––––––––––––––+ | +–+ LIMIT TEST (CIR) +–––+ LIMIT TEST (CIR) +––+ | | | Low Limit 141 | | Low Limit 170 | | | | | | | Test N80:1 | | Test N80:0 | | | |...
Page 92 4–30 Write Ladder Logic Notes...
Page 93: Assigning Passwords To Your Program And Data Files
Chapter Assigning Passwords to Your Program and Data Files Chapter Objectives Program and data files of PLC-5/x6 processors can be protected from unauthorized access by assigning privileges and a password to each of four privilege classes. We have assigned these at the factory. This chapter explains how: we assigned privileges to privilege classes we restricted access to certain program and data files...
Page 94: How We Assigned Privileges To Privilege Classes
5–2 Assigning Passwords to Your Program and Data Files How We Assigned The software is factory–configured for access privileges for security. Privileges to We assigned: Privilege Classes privileges to privilege classes read or read/write access to program and data files Class 1 has all privileges.
Page 95: Data Table Privileges
Assigning Passwords to Your Program and Data Files 5–3 Data Table Privileges We assigned R (read only) or RW (read/write) privileges to classes 1-4 for controlling access to data files. To view the Data Table Privileges screen that allocates these privileges, follow this procedure for 6200 series software (the procedure for AI5 software would be similar): 1.
Page 96: Program File Privileges
5–4 Assigning Passwords to Your Program and Data Files Program File Privileges We assigned R (read only) or RW (read/write) privileges to classes 1-4 for controlling access to program files. To view the Program File Privileges screen that allocates these privileges, follow this procedure for 6200 series software (the procedure for AI5 software would be similar): 1.
Page 97: Communication Channel Privileges
Assigning Passwords to Your Program and Data Files 5–5 Communication Channel Privileges We assigned class 4 as the default privilege class for channel communication, and R (read only) or RW (read/write) privileges to classes 1-4 for controlling channel access. Important: Default class privileges cannot be assigned to scanner or adapter channels;...
Page 98: Assigning Passwords To Classes
Important: Only class 1 privileges include modifying privileges of other classes. The password for class 1 is maintained confidential at the factory. Neither a customer nor any authorized Allen-Bradley sales/service representative can obtain this password. This lets us maintain protection of the factory-configured clutch/brake code.
Page 99: Install And Wire The Clutch/Brake Control System
Chapter Install and Wire the Clutch/Brake Control System Chapter Objectives In this chapter, we assume that the press is ready for installation of its control system. We help you install it with these steps: set jumpers and switches install PLC processors, I/O modules, and power supplies connect PLC processors and programming terminal wire ac power distribution to the controller convert controller OK relay contacts from N.O.
Page 100 6–2 Install and Wire the Clutch/Brake Control System PLC 5/x6 Processors You may set the DH+ station number (channel 1A) for PLC-5/46 and PLC-5/26 processors respectively to 0 and 1 so they can communicate (Figure 6.1). You may modify these switch settings if you application requires it.
Page 101 Install and Wire the Clutch/Brake Control System 6–3 Leave the serial-port configuration for channel 0 at default for RS-232C with SW2 (Figure 6.2) unless your application requires RS-422A or RS-423. Figure 6.2 Serial port Setting with SW2 Bottom View of PLC 5/46 Processor in Chassis A Bottom View of PLC 5/26 Processor in Chassis B Front of Front of...
Page 102: Jumper And Switch Settings For I/O Chassis A And B
6–4 Install and Wire the Clutch/Brake Control System Jumper and Switch Settings for I/O Chassis A and B Locate the jumper and switch assembly on the left-hand inside backplane (Figure 6.3). Set them identically in chassis A and B. Figure 6.3 Jumper and Switch Settings for I/O Chassis A and B Leave jumper at the Y"...
Page 103: 1771 Id16 Input Modules
Install and Wire the Clutch/Brake Control System 6–5 1771 ID16 Input Modules These modules have an input filter with a configurable time constant. It is factory set to the faster response time. Leave jumpers JPR1 and JPR2 in their factory-set position. If you need additional information, refer to the Product Data publication 1771-2.189.
Page 104 6–6 Install and Wire the Clutch/Brake Control System We suggest that you use slots 0 and 1 for low-level dc input modules such as a resolver input module. This helps segregate dc and ac signals. Figure 6.5 Module Locations in Chassis B PLC 5/26 1771 1771...
Page 105: Connect Plc Processors And Programming Terminal
Install and Wire the Clutch/Brake Control System 6–7 Connect PLC Processors Connect PLC processors in chassis A and B with Belden 9463 cables, and Programming and the programming terminal with a 1784-CP6 cable (Figure 6.6) Terminal as follows: Figure 6.6 Typical Connections Between Processors PLC 5/46 Configured for...
Page 106: Convert Controller Ok Relay Contacts From N.o. To N.c
6–8 Install and Wire the Clutch/Brake Control System Convert Controller OK The default mode of 700P relay contacts as shipped in this package is Relay Contacts normally open (N.O.). You must convert the contacts to the normally from N.O. to N.C. closed (N.C.) mode.
Page 107: Set Up Or Simulate Rotary Cam Limit Switches
Chapter Set Up or Simulate Rotary Cam Limit Switches Chapter Objectives In this chapter, we help you: set up your position monitoring (RCLS) devices. read status bits in ladder logic to indicate shaft position use transition fault bits to stop the press simulate RCLSs with ladder logic troubleshoot the setup of your RCLSs Setting Up Position...
Page 108 7–2 Set Up or Simulate Rotary Cam Limit Switches Important: Figure 7.1 shows relationships required by control system software. To determine exact settings for actual or simulated limit switches, refer to recommendations provided by the press manufacturer. Important: Any variation from this scheme will cause one or more transition faults where the software is designed to shut down the system.
Page 109 Set Up or Simulate Rotary Cam Limit Switches 7–3 This Turns ON Turns OFF Typical Your RCLS: at a position: at a position: ON OFF: ON OFF: Important: Set the ACAM-off span to the number of degrees (0 ) according to the speed of the press (0-200 strokes per minute) from Figure 7.2.
Page 110: Setup If Using Rotary Cam Limit Switches (Omit If Using Only Resolvers)
7–4 Set Up or Simulate Rotary Cam Limit Switches Setup If Using Rotary Cam If using rotary cam limit switches, follow these steps: Limit Switches (omit if using only resolvers) 1. Set up the cam angles for each RCLS switch assembly as described above.
Page 111: Ladder Logic To Simulate Rotary Cam Limit Switches
Set Up or Simulate Rotary Cam Limit Switches 7–5 Figure 7.3 AMCI Resolver and Interface Module Figure 7.4 NSD Resolver and Converter with 1771 IBD Input Module 4. Repeat step 3 if using dual resolvers. 5. For one or both I/O chassis with a resolver input, remove RCLSs from circuit wiring by jumpering RCLS inputs to respective power rails.
Page 112 7–6 Set Up or Simulate Rotary Cam Limit Switches We present ladder logic to simulate rotary cam limit switches (Figure 7.5). Use software bits TCAM (B151/00), BCAM (B151/01), and ACAM (B151/02) to simulate hardware cams when using resolver or encoder inputs.
Page 113 Set Up or Simulate Rotary Cam Limit Switches 7–7 Figure 7.6 Ladder Logic to Guard Against Reverse motion Faults When Using Resolvers Store Resolver Inputs +–MOV––––––––––––––––– + +––––––––––––––––––––––––––––––––+ MOVE +––| | Source I:000 | | Dest N155:0 | +––––––––––––––––––––––+ TCam B151 +–LIM––––––––––––––––––––+ B151...
Page 114: How Bits Indicate Shaft Position
7–8 Set Up or Simulate Rotary Cam Limit Switches How Bits Indicate The software sets bits to indicate which of six zones the shaft is Shaft Position rotating through during a press stroke. Important: The software reads these zones according to the on/off positions of ACAM, BCAM, and TCAM switches that you set (Figure 7.1) mechanically for hardware switches or that the software reads from resolver inputs if using resolvers to simulate your RCLSs.
Page 115: How Transition Faults Stop The Press
Set Up or Simulate Rotary Cam Limit Switches 7–9 How Transition Faults The software is designed to fault when it sees conditions other than Stop the Press the correct progression of these three rotational zones during a press stroke: Top zone Downstroke Upstroke Important: The software reads these zones according to the on/off...
Page 116: Troubleshoot The Setup Of Your Position Monitoring Devices
7–10 Set Up or Simulate Rotary Cam Limit Switches Troubleshoot the Setup of The processor monitors signals from your position monitoring Your Position Monitoring devices to ensure that the motion: Devices is in the forward direction progresses through the correct sequence of real or simulated cams - downstroke - upstroke - near top...
Page 117 Set Up or Simulate Rotary Cam Limit Switches 7–11 Faults Associated with Processor B B168/ Suggested Message Cause of Fault Effect of Fault How to Correct the Fault...
Page 118: Notes
7–12 Set Up or Simulate Rotary Cam Limit Switches Notes...
Page 119: Test Your Clutch/Brake Control System
Chapter Test Your Clutch/Brake Control System Chapter Objectives Once you have completed the installation and programming of your clutch/brake controller, test it to verify proper operation. We give you the procedures in this chapter for the following: Static Wiring Tests Dynamic tests of operating modes Switch Tests ATTENTION: Before starting this chapter, be sure that:...
Page 120: Crm Relay Test
8–2 Test Your Clutch/Brake CRM Relay Test 1. Power up the system. 2. Visually and with a voltmeter, verify that: – CRMA and CRMB relays are not energized (no ac on wire # 112A) – outputs to all press valves do not have power 3.
Page 121: Crowbar Relay Test (If Using Crowbar Relays)
Test Your Clutch/Brake 8–3 Crowbar Relay Test (If using crowbar relays) 1. Power up the system. 2. Reset the E-Stop circuit by pressing the Control Reset button. 3. Reset control power by pressing the C/B Power Reset button. 4. Verify that crowbar relays are not energized by observing that their output LEDs are OFF at Module Group 5 output 15 in chassis A and B.
Page 122: Test Inch Buttons
8–4 Test Your Clutch/Brake Test Inch Buttons Test Inch-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 In Module Group 3 This Input LED is OFF This Input LED is ON Right hand Inch button pressed.
Page 123: Valves And Valve Feedback
Test Your Clutch/Brake 8–5 Valves and Valve Feedback Test output wiring and input feedback to/from press valves by “ringing out” your I/O connections using the following table. Check the OK? box after verifying each connection. Important: Disconnect one side of each solenoid valve to guard against current flow through solenoids.
Page 124 8–6 Test Your Clutch/Brake From Chassis A To Chassis B Mod Grp Wire Number Term Mod Grp Term AI:004/02 A" 804LS AI:004/03 B" 805LS AI:004/04 A" 807LS AI:004/05 B" 808LS For Grounded AC Wiring From Chassis A To Chassis B Mod Grp Wire Number Term...
Page 125 Test Your Clutch/Brake 8–7 From Chassis B To Solenoids & Chassis A OK? Mod Grp Wire Number Term Mod Grp Term BO:005/00 A" 925SOL BO:005/01 B" 926SOL BO:005/04 A"931SOL BO:005/05 B"932SOL BO:005/10 A"936SOL BO:005/11 B"937SOL From Chassis A To Solenoids & Chassis B OK? Mod Grp Wire Number Term...
Page 126: Dynamic Tests Of Operating Modes
8–8 Test Your Clutch/Brake Dynamic Tests of This section tests ladder logic in PF15 for press operation in these modes: Operating Modes inch single-stroke continuous, started by arm-continuous or stroke-and-a-half Important: We assume that you have downloaded your ladder programs with 6200 Software (Revision 4.4 or later) into processors A and B.
Page 127: Single Stroke Mode
Test Your Clutch/Brake 8–9 Single stroke Mode 1. Select inch, and inch the press to the top. 2. Place the mode selector switch in single-stroke mode. 3. Press and hold Run buttons for more than 1/2 stroke. 4. Observe that the press cycles and stops on top. 5.
Page 128: Continuous Mode With Stroke And A Half
8–10 Test Your Clutch/Brake Continuous Mode with Stroke and a half 1. Place the mode selector switch in continuous mode. 2. Press and hold Run buttons for 1-1/2 strokes before releasing them. 3. Observe that the press continues to cycle. 4.
Page 129: Main Motor Forward Switch
Test Your Clutch/Brake 8–11 4. Reconnect the air pressure switch input to chassis A (step 1). 5. Remove the switch input from chassis B to repeat the test. wire # AI:002/15 module group 2 terminal 33 6. Attempt to start the press. Observe it will not start and that fault codes 39 and 119 are indicated.
Page 130: Chain Break Switch
8–12 Test Your Clutch/Brake 5. Remove the switch input from chassis B to repeat the test. wire # AI:002/17 module group 2 terminal 37 6. Start the press and observe that it stops before reaching bottom. 7. Reconnect the switch input to chassis B (step 5). Chain Break Switch 1.
Page 131: Description Of Operating Modes
Appendix Description of Operating Modes Operating Modes of the You can select any one of the following operating modes with the Clutch/Brake Controller mode selector switch: Remote Inch Micro-inch Single stroke Continuous stroking When an operator selects OFF, the control system is designed to turn off all outputs to press valves.
Page 132: Inch And Micro Inch Modes
A–2 Description of Operating Modes Inch and Micro inch Modes Before entering single or continuous mode, use inch or micro-inch mode to jog the press to the near-top position to set up the machine. Use micro-inch mode only if your press is equipped with a separate micro-inch drive.
Page 133: Single Stroke Mode
Description of Operating Modes A–3 Single Stroke Mode Single stroke mode is designed to stroke the press once, from top to bottom to top, with the concurrent use of all active run buttons. Once the press reaches the takeover cam (TCAM), operators can release Run buttons without stopping the press it continues to the near-top position.
Page 134 A–4 Description of Operating Modes Figure A.2 Typical Operational Sequence for Downstroke in Single Mode Select single mode. Is the motor running forward? Have you released all Run buttons since the previous stroke? Have you pressed all Run buttons concurrently? (see table below) Have you released a Run button? Both processors energize their...
Page 135 Description of Operating Modes A–5 Figure A.3 Typical Operational Sequence for Upstroke in Single Mode Have you released all Run buttons before the ACAM closes again? Upstroke continues regardless of releasing Run buttons. Both processors Have you pressed all Run buttons Has either processor detected de energize their outputs before the ACAM closes again?
Page 136: Continuous Mode
A–6 Description of Operating Modes Continuous Mode When you want to run your press continuously, ready the press as follows for starting from any position in the press cycle: select continuous mode press the arm continuous button (Figure A.4) if you have this feature press all active Run buttons within 5 seconds (within the preset time) In first downstroke, releasing a Run button stops the press (Figure A.5).
Page 137 Description of Operating Modes A–7 Figure A.4 Typical Operational Sequence to Prepare to Start Continuous Mode Select continuous mode. Is the motor running forward? Have you released all Stop on top buttons? Is the press configured for Arm Continuous? Go to R4. Go to R5.
Page 138 A–8 Description of Operating Modes Figure A.5 Typical Operational Sequence for Arm Continuous in Continuous Mode Have you released all Run buttons? Have you pressed the Arm Continuous button? Have you pressed Has the Arm Continuous all Run buttons? timer timed out? Both processors energized their outputs.
Page 139 Description of Operating Modes A–9 Figure A.6 Typical Operational Sequence for Stroke and a half in Continuous Mode Have you released all Run buttons? Have you pressed all Run buttons? Both processors energized their outputs. Has the press completed Have you released a Run button, 1 1/2 strokes? or has a stop condition occurred? Both processors...
Page 140 A–10 Description of Operating Modes Figure A.7 Typical Operational Sequence To Stop Continuous Stroking Both processors allow continuous stroking regardless of releasing Run buttons. Have you pressed a Stop on top button? The stroke continues until the press reaches the top. Has the PLC received a stop on top command? Is the press in the...
Page 141: Feedback Timing Diagrams
Appendix Feedback Timing Diagrams Timing Diagrams for We define the controller’s feedback response time for these signals: Control System Feedback triac and valve-stem feedback (where valve-stem feedback pertains to main, auxiliary, and/or micro-inch valves with external fault detection) motion detector feedback When PLC-5/x6 processors command triacs ON or OFF, they check that feedback signals (triac, valve stem, and motion detector) have turned ON or OFF in the order shown and within the times shown.
Page 142: Notes
B–2 Feedback Timing Diagrams Notes Publication 6556 6.5.1 - October 1996...
Page 143: Troubleshooting With Fault Codes, Operator Prompts, And Snapshot Status Bits
Appendix Troubleshooting with Fault Codes, Operator Prompts, and Snapshot Status Bits Troubleshooting Whenever a PLC-5/x6 processor detects a fault, it sets a corresponding with Fault Codes bit Bit File 168 in the data table. We list the conditions that for which the software is designed to detect and signal a fault.
Page 144 C–2 Troubleshooting with Fault Codes, Operator Prompts, and Snapshot Status Bits B168/ Suggested Message Cause of Fault Effect of Fault How to Correct the Fault Processor A Station 3 Run button held too long before Press will not start a stroke in Release, then press run buttons Tiedown pressing other Run button.
Page 145 Troubleshooting with Fault Codes, Operator Prompts, and Snapshot Status Bits C–3 B168/ Suggested Message Cause of Fault Effect of Fault How to Correct the Fault At Rest On switching to run, the software The press will not run in single Check prompts for reasons why press Run Button Tiedown detected a held run button.
Page 146 C–4 Troubleshooting with Fault Codes, Operator Prompts, and Snapshot Status Bits Faults Associated with Processor B B168/ Suggested Message Cause of Fault Effect of Fault How to Correct the Fault Processor B Remote I/O link (channel 1B) failed. C/B power is de energized. Check remote I/O cable to chnl 1A.
Page 147 Troubleshooting with Fault Codes, Operator Prompts, and Snapshot Status Bits C–5 B168/ Suggested Message Cause of Fault Effect of Fault How to Correct the Fault 108* Forward Transition Software/hardware cams did not Press will stop or not run in Check soft cam logic or hard cams from Downstroke enter upstroke.
Page 148: Prompts For Operating The Press
C–6 Troubleshooting with Fault Codes, Operator Prompts, and Snapshot Status Bits B168/ Suggested Message Cause of Fault Effect of Fault How to Correct the Fault 138* Aux Valve 1 Valve failed to energize Press will not cycle. Check valve and valve wiring. Failed to Turn ON when output was turned ON.
Page 149 Troubleshooting with Fault Codes, Operator Prompts, and Snapshot Status Bits C–7 Prompts Associated with Processor A B169/ Suggested Message Cause of the Prompt Condition Effect of Prompt Condition How to Correct the Condition 000 Spare E Stop actuated E stop button was pressed, or CRM and seal relays opened.
Page 150 C–8 Troubleshooting with Fault Codes, Operator Prompts, and Snapshot Status Bits Prompts Associated with Processor B B169/ Message Cause of the Prompt Condition Effect of Prompt Condition How to Correct the Condition Spare E Stop actuated E stop button was pressed, or CRM and seal relays opened.
Page 151: Troubleshooting With Snapshot Status Bits
Troubleshooting with Fault Codes, Operator Prompts, and Snapshot Status Bits C–9 Troubleshooting with The primary means of troubleshooting the clutch/brake control Snapshot Status Bits system is by means of reading fault codes and operator prompts as presented earlier in this appendix or in the Operator’s Guide, publication 6556-6.9.1 for PLC processors.
Page 152: Notes
C–10 Troubleshooting with Fault Codes, Operator Prompts, and Snapshot Status Bits Notes Publication 6556 6.5.1 - October 1996...
Page 153: Classes Of Memory Protection
Appendix Classes of Memory Protection Class Privileges We have assigned privileges to four classes of memory protection. Class 1 has access to all processor functions. The password for class 1 is kept confidential at the factory. We show you how to assign your own passwords to classes 2-4 in chapter 5.
Page 154: Data Files
D–2 Classes of Memory Protection Data Files File Type Class 1 Class 2 Class 3 Class 4 output input status timer counter control integer floating point timer 150 bit 151 bit 152 bit 160 bit 162 timer 163 block transfer 164 integer 165 control 166 integer...
Page 155: Mapping Of Data And Program Files
Appendix Mapping of Data and Program Files Reserved Data Files We designed the software using selected data files. Some of these files are locked. We present this information with two purposes: overall mapping of data reserved for the control system useable data for your application Reserved Files When mapping your data table for controlling press operations,...
Page 156: Useable Data
E–2 Mapping of Data and Program Files Useable Data When writing ladder logic for your control system, you may write to the following data files for their intended purpose: Use These Files: For: B150:0 Programmable output bits in PF15 B151:0, 1 Programmable command bits in PF15 B152 Other bits for you to use in PF15...
Page 157 Mapping of Data and Program Files E–3 Processor A Processor B PF21 Spare PF22 Auto die Change Sequencer PF23 Main Motor Control PF24 Inch Motor Control PF25 Counter Balance Air Control PF26 Cushion Air Control PF27 Die Clamp Control PF28 Slide Adjust Control PF29 Cushion Stroke Adjust Control PF30 Bolster/Die Cart Control PF31 Automation Device Control...
Page 158 E–4 Mapping of Data and Program Files Notes Publication 6556 6.5.1 - October 1996...
Page 159: Programming Considerations For Plc 5 Processors
Appendix Programming Considerations for PLC 5 Processors Purpose of this Appendix The purpose of this appendix is to help you make correct decisions when writing ladder logic for controlling machine functions. We divided this guide into these sections: Program Scan: How the Processor Scans a Program What Affect Does Your Ladder Logic Have on Program Scan? How to Program a Faster Response What are Subroutines and Why Use Them?
Page 160: How The Processor Scans The Program
F–2 Programming Considerations for PLC-5 Processors How the Processor Scans the Program The Processor: 1. Monitors Inputs Monitors the status of input devices by means of input modules. (The off/on or analog signal of each input appears as a corresponding 0/1 or BCD bit pattern in the input image table.) 2.
Page 161 Programming Considerations for PLC-5 Processors F–3 Table F.A Typical Execution Times for Selected Instructions for PLC 5/11, 20, 30 Processors Type of Instruction If False (approx s) If True (approx s) relay, such as examine, energize, latch, and unlatch timer and counter arithmetic, such as add, subtract, multiply, divide 4 - 12 trig functions, such as sin, cos, tan,...
Page 162: Data Format
F–4 Programming Considerations for PLC-5 Processors Data Format The processor operates faster when you use integer data as compared with floating-point data (Table F.C). Table F.C Comparing Data Types for Typical If True" Execution Times for Selected Instructions for PLC 5/11, 20, 30, 40, 80 Processors Type of Instruction Integer Floating point...
Page 163: How To Program A Faster Response
Programming Considerations for PLC-5 Processors F–5 Table F.E Typical Additional Instruction Execution Times for Various Types of Addressing for PLC 5/11, 20, 30, 40, 60, 80 Processors For This Type of Address With This Type of Data Add for Each Operand indexed integer 1 us...
Page 164: Scan Logic Only When Needed
F–6 Programming Considerations for PLC-5 Processors Scan Logic Only When Needed Use program control instructions to reduce program scan time with these techniques: program a jump forward (or back) to avoid scanning portions of your ladder logic not required under certain programmed conditions program a jump to a subroutine (and a return) when you require intermittent use of a block of ladder logic.
Page 165: How Subroutines Are Scanned
Programming Considerations for PLC-5 Processors F–7 How Subroutines Are Scanned Subroutines are accessed from your main program file or from other subroutines (nested) by means of these instructions (Figure F.2): Jump To Subroutine (JSR) – located anywhere in your ladder logic Subroutine (SBR) –...
Page 166 F–8 Programming Considerations for PLC-5 Processors You may add subroutines to the clutch/brake ladder program. For example, the program scan for the following program files is shown in Figure F.3. Main Program, PF2 Call Subroutines, PF3 Clutch/Brake Interface, PF15 Clutch/Brake Code, PF16 Auxiliary Press Function, PFxx Automation Function, PFyy Figure F.3...
Page 167: Using Immediate I/O Instructions
Programming Considerations for PLC-5 Processors F–9 With subroutine programming, you can: update critical I/O within the subroutine with immediate I/O instructions pass data into and out of a subroutine Using Immediate I/O Instructions Immediate I/O instructions are output instructions that, when enabled, interrupt the program scan to update a specified word of I/O image table.
Page 168: Working With Data
F–10 Programming Considerations for PLC-5 Processors Working With Data Understanding the types of data that your processor handles and how your processor stores them may help you: conserve memory achieve a faster processor data scan Types of Data The types of data that your processor handles depend on the processor, but essentially falls into three categories: bit, word, and element.
Page 169: Creating Data Storage Files
Programming Considerations for PLC-5 Processors F–11 Creating Data Storage Files You create data storage files in two ways: by directly creating data storage files each time you assign an address to an instruction Good programming techniques suggest that you keep data storage areas as small as possible to minimize scan time and avoid wasting memory storage.
Page 170 F–12 Programming Considerations for PLC-5 Processors For example, if your first assigned timer in your program has the address T4:99, the processor allocates storage for timers T4:99 down to T4:0 whether you use them or not. Since each timer address uses three words (timers are 3-word elements), your timer address of T4:99 has created a 300 word data storage file.
Page 171 Appendix Wiring Drawings for an Ungrounded System Wiring Drawings The wiring option of your Clutch/Brake Application Package included either one of two choices: ungrounded system I/O wiring (this appendix), 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.
Page 172 G–2 Wiring Drawings for an Ungrounded System Notes Publication 6556 6.5.1 - October 1996...
Page 173: Wiring Drawings For An Ungrounded System
Wiring Drawings for an Ungrounded System G–3 440 VAC FROM CUSTOMER FROM CUSTOMER 01–01 01–25 CLUTCH BRAKE TRANSFORMER–1KVA #12 AWG BLK #12 AWG BLK 01–02 01–26 H2 H4 01–03 01–27 01–04 01–28 103L1 103L2 01–05 01–29 10CCB 105L1 105L2 01–06 01–30 GROUND GROUND...
Page 174 G–4 Wiring Drawings for an Ungrounded System 1771–ID16 120VAC ISOLATED INPUT 01–09 01–09 01–24 01–24 06–01 RACK A00 105L1 105L2 119B 115C MODULE GROUP 2 TAKEOVER CAM LIMIT SW. – 602LS AI:002/00 L2–0 INPUT 0 06–02 ANTIREPEAT CAM LIMIT SW. – 603LS AI:002/01 L2–1 INPUT 1...
Page 175 Wiring Drawings for an Ungrounded System G–5 1771–ID16 120VAC ISOLATED INPUT 06–24 06–24 06–24 RACK B00 06–25 105L2 119B 105L1 MODULE GROUP 2 TAKEOVER CAM LIMIT SW. – 626LS BI:002/00 INPUT 0 L2–0 06–26 ANTIREPEAT CAM LIMIT SW. – 627LS BI:002/01 INPUT 1 L2–1...
Page 176 G–6 Wiring Drawings for an Ungrounded System 06–48 1771–OD16 120VAC ISOLATED INPUT 07–01 RACK A00 105L1 105L2 RIGHT RUN STATION #1 702PB MODULE GROUP 3 105L1 AI:003/00 RIGHT RUN STATION #1 N.O. – 702PB 07–02 L2–0 INPUT 0 AI:003/01 LEFT RUN STATION #1 BUTTON N.C. – 703PB 07–03 L2–1 INPUT 1...
Page 177 Wiring Drawings for an Ungrounded System G–7 07–24 1771–ID16 120VAC ISOLATED INPUT 07–25 RACK B00 105L1 105L2 MODULE GROUP 3 LEFT RUN STATION #1 N.O. – 703PB BI:003/00 07–26 INPUT 0 L2–0 RIGHT RUN STATION #1 BUTTON N.C. – 702PB BI:003/01 07–27 INPUT 1...
Page 178 G–8 Wiring Drawings for an Ungrounded System 06–48 07–48 06–24 1771–ID16 120VAC ISOLATED INPUT 119B 08–01 RACK A00 115C MODULE GROUP 4 105L2 BO:005/10 MICRO INCH 1 FEEDBACK L2–0 INPUT 0 09–36 08–02 BO:005/11 MICRO INCH 2 FEEDBACK L2–1 INPUT 1 09–37 08–03 VALVE STEM CLUTCH 1 –...
Page 179 Wiring Drawings for an Ungrounded System G–9 07–48 08–24 08–24 06–48 1771–ID16 120VAC ISOLATED INPUT RACK B00 08–25 105L1 105L2 115C MODULE GROUP 4 119B MICRO INCH 1 FEEDBACK AO:005/10 09–12 INPUT 0 L2–0 08–26 MICRO INCH 2 FEEDBACK AO:005/11 09–13 INPUT 1 L2–1...
Page 180 G–10 Wiring Drawings for an Ungrounded System 1771–OD16 120VAC ISOLATED OUTPUT 09–01 RACK A00 08–48 08–48 MODULE GROUP 5 105L1 115C AO:005/00 L1–0 OUTPUT 0 CLUTCH 1 VALVE TO 06–32 09–02 AO:005/01 L1–1 OUTPUT 1 CLUTCH 2 VALVE TO 06–33 09–03 CLUTCH 1 –...
Page 181 Wiring Drawings for an Ungrounded System G–11 1771–OD16 120VAC ISOLATED OUTPUT 09–25 RACK B00 08–48 08–48 MODULE GROUP 5 105L2 119B BO:005/00 OUTPUT 0 L1–0 CLUTCH 1 VALVE TO 06–08 09–26 BO:005/01 OUTPUT 1 L1–1 CLUTCH 2 VALVE TO 06–09 09–27 BO:005/02 OUTPUT 2...
Page 182 G–12 Wiring Drawings for an Ungrounded System Notes Publication 6556 6.5.1 - October 1996...
Page 183: Wiring Drawings
Appendix Wiring Drawings for a Grounded System Wiring Drawings The wiring option of your Clutch/Brake Application Package included either one of two choices: grounded system I/O wiring (this appendix), 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.
Page 184 H–2 Wiring Drawings for a Grounded System Notes Publication 6556 6.5.1 - October 1996...
Page 185: Wiring Drawings For A Grounded System
Wiring Drawings for a Grounded System H–3 440 VAC FROM CUSTOMER FROM CUSTOMER 01–01 01–25 CLUTCH BRAKE TRANSFORMER–1KVA #12 AWG BLK #12 AWG BLK 01–02 01–26 H2 H4 01–03 01–27 01–04 01–28 103L1 103L2 01–05 01–29 10CCB 105L1 105L2 01–06 01–30 #14 AWG GREEN GROUND...
Page 186 H–4 Wiring Drawings for a Grounded System 1771–ID16 120VAC ISOLATED INPUT 01–09 01–09 RACK A00 06–01 108L1 105L2 MODULE GROUP 2 TAKEOVER CAM LIMIT SW. – 602LS AI:002/00 L2–0 INPUT 0 06–02 ANTIREPEAT CAM LIMIT SW. – 603LS AI:002/01 L2–1 INPUT 1 06–03 BRAKE MONITOR CAM LIMIT SW.
Page 187 Wiring Drawings for a Grounded System H–5 1771–ID16 120VAC ISOLATED INPUT 06–24 RACK B00 06–25 105L2 MODULE GROUP 2 TAKEOVER CAM LIMIT SW. – 626LS BI:002/00 INPUT 0 L2–0 06–26 ANTIREPEAT CAM LIMIT SW. – 627LS BI:002/01 INPUT 1 L2–1 06–27 BRAKE MONITOR CAM LIMIT SW.
Page 188 H–6 Wiring Drawings for a Grounded System 06–48 06–24 1771–OD16 120VAC ISOLATED INPUT 07–011.5 RACK A00 105L2 108L1 RIGHT RUN STATION #1 702PB MODULE GROUP 3 AI:003/00 RIGHT RUN STATION #1 N.O. – 702PB 07–02 L2–0 INPUT 0 AI:003/01 LEFT RUN STATION #1 BUTTON N.C. – 703PB 07–03 L2–1 INPUT 1...
Page 189 Wiring Drawings for a Grounded System H–7 07–24 1771–ID16 120VAC ISOLATED INPUT 07–25 RACK B00 105L2 MODULE GROUP 3 LEFT RUN STATION #1 N.O. – 703PB BI:003/00 07–26 INPUT 0 L2–0 RIGHT RUN STATION #1 BUTTON N.C. – 702PB BI:003/01 07–27 INPUT 1 L2–1...
Page 190 H–8 Wiring Drawings for a Grounded System 07–48 01–24 07–24 1771–ID16 120VAC ISOLATED INPUT 08–01 RACK A00 105L2 115E 108L1 MODULE GROUP 4 BO:005/10 MICRO INCH 1 FEEDBACK L2–0 INPUT 0 09–36 08–02 BO:005/11 MICRO INCH 2 FEEDBACK L2–1 INPUT 1 09–37 08–03 VALVE STEM CLUTCH 1 –...
Page 191 Wiring Drawings for a Grounded System H–9 08–24 1771–ID16 120VAC ISOLATED INPUT RACK B00 08–25 105L2 MODULE GROUP 4 MICRO INCH 1 FEEDBACK AO:005/10 09–12 INPUT 0 L2–0 08–26 MICRO INCH 2 FEEDBACK AO:005/11 09–13 INPUT 1 L2–1 08–27 VALVE STEM CLUTCH 1 – 804LS AI:004/02 08–04 INPUT 2...
Page 192 H–10 Wiring Drawings for a Grounded System 1771–OD16 120VAC ISOLATED OUTPUT 09–01 RACK A00 08–24 08–08 08–48 MODULE GROUP 5 108L1 115E 105L2 AO:005/00 L1–0 OUTPUT 0 09–02 TO 06–32 CLUTCH 1 VALVE AO:005/01 L1–1 OUTPUT 1 09–03 TO 06–33 CLUTCH 2 VALVE L1–2 OUTPUT 2...
Page 193 Wiring Drawings for a Grounded System H–11 1771–OD16 120VAC ISOLATED OUTPUT RACK B00 09–25 09–23 MODULE GROUP 5 105L2 CLUTCH 1 – 925SOL BO:005/00 L1–0 OUTPUT 0 09–26 TO 06–08 CLUTCH 1 VALVE CLUTCH 2 – 926SOL BO:005/01 L1–1 OUTPUT 1 09–27 TO 06–09 CLUTCH 2 VALVE...
Page 194 H–12 Wiring Drawings for a Grounded System Notes Publication 6556 6.5.1 - October 1996...

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