CM-1805-AS Control Module

CM-1805-AS PART REVOLUTION POWER PRESS CLUTCH/BRAKE CONTROL

NOTE: THIS IS A SUB-PANEL CONFIGURATION ONLY SWITCHES, INDICATOR & ENCLOSURE ARE REQUIRED.

The CM-1805-AS solid state air clutch / brake control module is a self contained sub-panel assembly. The unit was designed to help endusers up-grade their existing press control to help meet O.S.H.A & ANSI Regulation requirements.

The concept behind the CM-1805-AS is to allow manufacturing end-users the ability to retro-fit their current press control system where by utilizing as much of their current control components such as, switches, indicator lights, enclosure, motor starters etc. The module is supplied on a 30H x 24W sub-panel and the units physical dimensions are 14L x 12W.

This small design is essentially a complete dual logic press control incorporating all required operating logic, press control functions and safety features required to help meet Federal Regulations. The system comes standard with an operator display message center to indicate the control status, over 75 messages inform the operator of critical fault conditions, control status conditions and step by step press starting procedures. The system includes a detailed operator user-installation manual and is backed by a full one-year manufacture warranty.

GENRAL DESCRIPTION & FUNCTIONS FOR THE CONTROL MODULE:
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The KTI 9020 series press control and sub-panel modules provide a straight forward solution for the safety and productivity requirements demanded of today’s Metal Forming facilities for part revolution press controls.

The 9020 series offers safe, repeatable operation by incorporating into it’s design Anti-Tie down capability, Anti-Repeat capability, Control component reliability check and a run mode sequential operation fault check feature.

The units base design is a solid-state complete self-checking dual logic microprocessor press control. The control has two independent running channels and a comparison circuit. The preprogrammed dedicated inelastic control system prevents in field alterations by maintenance personnel to alter or jump out the safety features of the control. The control incorporates a control reliable diverse redundant design concept to assure a higher and maintained level of safety and reliability.

CONTROL RELIABILITY “ CONTROL COMPONENT FAILURE”: The 9020 clutch/brake control helps meet OSHA 1910.217 and ANSI B11.1-1988 standards for control reliability. Control reliability standards require that clutch/brake circuits be designed and constructed so that a single failure or fault within the system does not prevent the normal stopping action from being applied to the press when required, or does not create an unintended stroking action, but does prevent initiation of a successive stroke until the failure is corrected.

THE 9020 SOLID STATE PRESS CONTROL: The 9020 series offers safe, repeatable operation by incorporating into it’s design Anti-Tie down and Anti-Repeat capability a control component reliability check and a run mode sequential fault feature. The units base design is a solid-state complete self-checking dual logic microprocessor base control. The control has two independent CPU’s cross checking each function of the controls operation.

OPERATOR MESSAGE DISPLAY: Standard on the 9020 solid state control system is the revolutionary “ Operator Message Display” mounted with the operator controls at a customer designated location on the control panel. The bright back lite alpha-numeric scrolling message display informs the user of any faults, failures and the current operating status of the punch press control system. The messages are in plain English and will give the press operator information quickly and safely. The “Operator Message Display” system is so advanced that it will immediately inform the user of such problems as pressure switch faults, failed output relays, or rotary cam mis-adjustments. The system will also pinpoint internal printed circuit board faults for immediate replacement. This self-diagnostic feature will save many maintenance dollars and will enhance machine uptime measurably due to the units captive troubleshooting ability. Best of all, this information is supplied without even opening the control panel door.

SYSTEM LOGIC AND COMPONENT DIAGNOSTICS: A combination of LED’s and alpha-numeric plain English message display will enhance in-field troubleshooting greatly. The advance design can even troubleshoot itself and advise the user if a printed circuit board is defective and if it needs to be replaced or repaired. The alpha-numeric message display is capable of displaying more than seventy five different message.

REDUNDANT CAPTIVE CONTACT SAFETY RELAYS: The 9020 incorporates redundant safety relays to assure safety if a control output relay should fail. The system utilizes safety relays which have force-guided contacts. This is a configuration where the contacts are not mechanically locked together so that if one set of contacts weld, the other contacts can change state. If one should fail, the control shuts down and the message display will identify which relay has faulted and what state the relay should be in ( on/off ).

PART STROKE PROVISION WITH INDICATOR: If the press control is in “ Single-stroke “ or “ Continuous” mode of operation and the press stops before the completion of a full stroke, The Part Stroke Provision is activated. The control will automatically switch to “ inch “ mode and the palm buttons must be used to return the ram to the top of the stroke. When back at top the control automatically switches back to the original operational mode setting and the operator may resume normal production. The Part Stroke Provision improves productivity and safety significantly by eliminating the need for the operator to make mode selections adjustments on interrupted strokes.

MICRO-INCH FEATURE STANDARD: The 9020 control features a micro inch mode. This mode allows the end user to slowly in set increments to inch the ram down during setup. Typically during die set up it is required to inch the ram down to allow and adjust for proper shut height adjustment and setting. Hardware is required such as , a key-selectable on-off micro-inch control, labeled as MICO-INCH MODE.

BAR MODE FEATURE STANDARD: The bar-mode operation feature allows the manual rotation of the flywheel with the clutch engaged for die setting. This is an extremely useful and time saving feature which ads in die setup and shut-height confirmation prior to press operation. This feature is standard in the 9020 press control and 9020 control modules. Hardware is required such as, a key-selectable on-off switch, bar mode indicator light and a bar mode engagement push button switch with enclosure.

GROUND INTACT CIRCUIT STANDARD: The 9020 Control features a ground check intact circuit. Required by OSHA and ANSI regulation this circuit continuously monitors the integrity of the presses earth ground condition. A ground signal from the press’s frame is required at all time to a dedicated input terminal. Under any condition in all modes of operation if this signal is lost the control will instantly shutdown. Under a fault condition the operator message display will indicate the fault condition.

VALVE DETEC TION CIRCUIT STANDARD: The 9020 control module features a clutch air valve-monitoring mode. This feature when activated in combination with a clutch valve, which offers electrical position contacts will continuously, monitors the activation time frame of the clutch valve when energized. If the clutch valve fails to change state in either direction within a predetermine time frame the control will automatically shut the press down and turn the main drive motor off and display the fault condition on the operator message display.

E-STOP OUTPUT CONTROL RELAY: The 9020 control features a supplied output relay dedicated for interconnection for controlling of an E-Stop conditions of external systems. This relay energizes when the control is in the run mode and de-energizes under the condition that the control is commanded to E-Stop or the control comes out of the run mode condition. This output relay is not a dry contact it supplies 120Vac when energized.

PRESSURE SWITCH MONITORING STANDARD: The 9020 Control features two detected pressure switch stop input connections. Pressure switch 1 and pressure switch 2. These inputs are intended to be used to monitor the press air supply. Typically pressure switch one is used to monitor the main air supply/clutch pressure. Pressure switch two is typically use to monitor air pressure for the counter balance operation. These inputs are required to be held high (on) for control operation. In the event that one or both pressure switch fault the control shuts down and displays the fault condition on the operator message display.

CHAIN BREAK DETECTION FEATURE STANDARD: The 9020 control features chain break detection. This feature continuously monitors the mechanical connection of the rotary cam limit switch to the press’s crankshaft. In the event that the connecting chain or belt breaks the control will automatically shutdown and indicate the fault condition.

ENERGY CONSERVATION FEATURE STANDARD: The 9020 control features an energy conservation-monitoring mode. With the control in the run mode and with the main flywheel motor running, the system monitors the activity of the press. In the event that the press remains idle for more than 30 minutes, The press control system automatically shuts down the system and turns off the main flywheel drive motor, whereby conserving on electrical energy.

FLYWHEEL DRAG BRAKE FEATURE STANDARD: The 9020 control features and optional output dedicated for the use of a flywheel drag brake. On many presses a flywheel drag brake is used to reduce the wind down time or zero RPM’s of the flywheel when the motor is turned off. Typically this brake is no more than an air cylinder with a brake pad mounted to the cylinder’s shaft. An electrically controlled air solenoid valve is used to control the on and off state airflow to the cylinder. When the control system is on the solenoid is de-energized (no airflow to brake cylinder). When the control is turned off the output energizes turning on the brake solenoid valve, which engages the drag brake.

SLIDE ADJUSTMENT INPUT FEATURE STANDARD: The 9020 Control features a slide adjustment input. With presses that are configured with a motorized ram shut height adjustment control this feature disables ram motion initiation when turned on. Typically a key selector switch is used to turn on and off the motorized controlling feature. A dry contact on the selector switch or a dry contact on the motor control starter is required to signal the control that this feature is in use. When the control receives this indication the control system prevents any initiation motion of the ram, this is true for all modes of operation. The operator message display center will indicate that the slide adjustment control is activated.

DIE BLOCK INPUT FEATURE STANDARD: The 9020 Control features a die block receptacle input. Under OSHA and ANSI regulations it is required that during maintenance, when working in the die area, that the ram be block from movement in the event of any downward movement. Die blocks are typically a bar mechanism, which is inserted between the ram and bolster to prevent movement. The bar has and attached chain with a plug receptacle to ensure that if the bar is in use the press control will not be allowed to function. Once maintenance is complete the bar is removed and the plug reinserted into the die block receptacle. The die block receptacle is typically located at a position where the chain length will not allow the bar to be in the press die area when plug in. When the die block is unplugged from its receptacle the control will shutdown allowing no initiation of the press. The operator message display will indicate the fault condition.

LUBE PUMP MONITORING FEATURE STANDARD: The 9020 Control features a lubrication-monitoring input. Typically mechanical power presses utilizes a recycling lubrication system whereby, lubrication (oil) is pumped to various mechanical points of the press and than recollected cleaned and returned to the pump’s reservoir tank for re-circulation. A lubrication pump is used to pull from the reservoir and feed the various locations of the press. Normally, on the lubrication side of the pump a PSI gauge reading of approximately 20 to 60 Lbs. is typical. Utilizing a pressure switch on the lubrication side of the pump the pressure can be monitored for lower lube detection. If the pressure in the lubrication system drops below the setting of the pressure switch a fault is generated and the press is shutdown.

PULSE LUBE CONTROL OUTPUT FEATURE STANDARD: The 9020 Control features an automatic pulse lube output control relay. Some presses are equipped with a grease lubrication system. These systems typically function pneumatically, whereby the grease system is a system which requires air pressure to force the lubrication to predetermine points of the press. Commonly a electrical solenoid valve is used to control the on/off state of the air. The 9020 control offers a designated output control relay for the operation of the controlling grease solenoid. With the control in the run mode of operation with the press running (active motion) the control will automatically energize the output control relay to pulse every 30 seconds, with a pulse duration of 2 seconds.

TIME BASED BRAKE MONITOR STOP FEATURE: The 9020 Control features a dedicated stop input for the use of a external time base brake monitor control system. A brake monitor system monitors the stopping time each time the press comes to a stop. If the brake monitoring system detects a brake fault condition it generates a stop signal. This stop signal can be connected to the 9020 press control system, which will under a fault condition stop the press and indicate a brake fault stop on the message display center. This allows the operator to determine the stop fault condition in a short amount of time.

DIE PROTECTION SYSTEM STOP FEATURE: The 9020 Control features a dedicated stop input for the use of a external die protection control system. A die protection system monitors a variety of die forming conditions. In the event that this system detects a fault condition it generates a stop condition. This stop signal can be connected to the 9020 press control system, which will under a fault condition stop the press and indicator a die protection system fault stop on the message display center. This allows the operator to determine the stop fault condition in a short amount of time.

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