Allen-Bradley ClutchBrake PLC-5 Series

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2–14 Define Your Control System Characteristics

Publication

65566.5.1 - October 1996

Notes

Main Page

Table of Contents5
Using this Manual11
Information in the Appendices12
We've Simplified Your Wiring Documentation12
Terms and Abbreviations13
Chapter Objectives15
The Application Package15
- Software and Documentation15
- Typical Hardware (for the Cat. No. 6556 Pxxxk Application Package)16
Related Safety Information16
Control by Redundant Processors17
How the Software Controls Your Press18
- Organization of Program Files18
- Scanning Program Files18
Protected Memory in PLC 5/X6 Processors20
- Passwords and Levels of Memory Protection20
Functional Block Diagram21
Modes of Control System Operation21
Clutch/Brake Control Functions22
Required Input Switches23
Choice of Position Monitoring Devices24
Control System Outputs24
System Response Time24
Internal Timers25
Options to Suit Your Application26
- Selecting Factory Configured Options26
- Programming Ladder Logic Commands26
- Wiring Your Control System27
Information on Diskette27
Wiring Drawings27
Control System Specifications28
Define Your Control System Characteristics29
Chapter Objectives29
Verify Your Factory Configured Options29
Assign Valves to Specific Outputs30
Select the Type of Valve Fault Detection30
Select the Type of Position Sensor31
- Rotary Cam Limit Switches31
- Resolver31
Record On/Off Positions of Rotary Cam Limit Switches32
Select Input Switches32
Select Command Bits for C/B Interface Logic32
Select Other Options34
Reduce Watchdog Timer Presets (Optional)34
- Verify Your Factory Configured Options35
- Assign Outputs35
- Record the Type(S) of Valve Fault Detection36
- Select the Type and Location of Position Monitors36
- Record On/Off Positions of Rotary Cam Limit Switches36
- Select Input Switches37
- Select Optional Command Bits for C/B Interface Logic38
- Select Options that Affect System Wiring39
- Reduce Watchdog Timer Presets as an Option40
- 10. Select Options that Require Programming41
Customize the Wiring to Suit Your Application43
Chapter Objectives43
How to Customize the Default Wiring43
Install Your Wiring Drawing Diskettes44
Generalized Instructions to Customize Your Wiring45
Customizing an Ungrounded AC System45
Customize a Grounded AC System54
- Notes62
Write Ladder Logic63
Chapter Objectives63
Overview of Memory Organization63
Reserved Program and Data Files64
How Command Bits Act on Control Logic in Protected Memory64
Select from These Command Bits65
Steps to Write Ladder Logic67
Programming Command Bits68
- Soft" Clutch and Brake75
Exchanging Data between Processors80
Using Fault and Prompt Bits81
Programming Shorter Presets for Your Internal Timers82
Programming Press Ready to Start Indicators84
Programming a Brake Monitor (Patent Pending)84
- Selecting the Interrupt Period84
Programming a Variable Speed Top Stop90
Assigning Passwords to Your Program and Data Files93
Chapter Objectives93
What Can Privilege Classes Protect93
How We Assigned Privileges to Privilege Classes94
- Privilege Classes94
- Data Table Privileges95
- Program File Privileges96
- Communication Channel Privileges97
Assigning Passwords to Classes98
Gaining Access to Protected Memory Files98
Install and Wire the Clutch/Brake Control System99
Chapter Objectives99
Set Jumpers and Switches99
- PLC 5/X6 Processors99
- Jumper and Switch Settings for I/O Chassis a and B102
- Keying the Backplane102
- 1771 ID16 Input Modules103
Install PLC Processors, I/O Modules, and Power Supplies103
Connect PLC Processors and Programming Terminal105
Convert Controller OK Relay Contacts from N.O. to N.C106
Wire Your Control System106
Set up or Simulate Rotary Cam Limit Switches107
Chapter Objectives107
Setting up Position Monitoring Devices107
Setup if Using Rotary Cam Limit Switches (Omit if Using Only Resolvers)110
Setup if Using Resolvers (Omit if Using Only Rclss)110
Ladder Logic to Simulate Rotary Cam Limit Switches111
How Bits Indicate Shaft Position114
How Transition Faults Stop the Press115
Troubleshoot the Setup of Your Position Monitoring Devices116
- Notes118
Test Your Clutch/Brake Control System119
Chapter Objectives119
Static Wiring Tests119
- Controller OK Test119
- CRM Relay Test120
- Seal Relay Test120
- Crowbar Relay Test (if Using Crowbar Relays)121
- Test Run Buttons (All Four Stations)121
- Test Inch Buttons122
- Test Stop on Top and Arm Continuous Buttons122
- Test Mode Selector Switch122
- Valves and Valve Feedback123
Dynamic Tests of Operating Modes126
- Inch Mode126
- Single Stroke Mode127
- Continuous Mode with Arm Continuous127
- Continuous Mode with Stroke and a Half128
Switch Tests128
- Air Pressure Switch128
- Main Motor Forward Switch129
- Motion Detector Switch129
- Chain Break Switch130
Description of Operating Modes131
Operating Modes of the Clutch/Brake Controller131
- Off131
- Remote Mode131
- Inch and Micro Inch Modes132
- Single Stroke Mode133
- Continuous Mode136
Feedback Timing Diagrams141
Timing Diagrams for Control System Feedback141
Notes142
Troubleshooting with Fault Codes, Operator Prompts, and Snapshot Status Bits143
Prompts for Operating the Press148
Troubleshooting with Snapshot Status Bits151
- Notes152
Classes of Memory Protection153
Class Privileges153
Read/Write Access by Class153
- Program Files153
- Data Files154
Mapping of Data and Program Files155
Reserved Data Files155
- Reserved Files155
- Useable Data156
Reserved Program Files156
Programming Considerations for PLC 5 Processors159
Purpose of this Appendix159
Program Scan: How the Processor Scans a Program159
- How the Processor Scans the Program160
- The Processor160
Affect Your Ladder Logic Has on the Program Scan160
- Instructions160
- Processor Family160
- Data Format162
- Addressing162
How to Program a Faster Response163
- Program a Faster Response with Special Instructions163
- Scan Logic Only When Needed164
- Other Considerations164
Using Subroutines164
- How Subroutines Are Scanned165
- Using Immediate I/O Instructions167
- Passing Data into and out of a Subroutine167
Working with Data168
- Types of Data168
- Addressing Your Data168
- Creating Data Storage Files169
  - Directly Creating Data Storage Files169
  - Data Storage Created by Assigning Addresses169
Wiring Drawings for an Ungrounded System173
Wiring Drawings183
Wiring Drawings for a Grounded System185
Wiring Drawings185

Allen-Bradley ClutchBrake PLC-5 Series - Page 42

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