System 1500
Air Null Pressure System
Operating Manual

Revised: May 14, 2003

Controls Home | Systems Info | Latest News | Drawings | Helpful Files | Contact Us
Description Adjustment
Valve/Transducer Assembly Mounting System 1500 Technical Data
System 1500 Wiring

Description Top
        The System 1500 is used on a multi-slide/four-slide or other similar machine to null the air pressure to the combination clutch/brake unit. Usually between 30 and 40 psi, this null pressure centers the clutch/brake piston between the brake and clutch plates to release the brake, yet not apply the clutch. The slides then can be easily rotated using the hand wheel for setup purposes, without having to turn the motor and flywheel. This system is particularly useful on larger multi-slide presses.
Mounted Valve/Transducer Assembly
        The System 1500 includes two parts… The Null Pressure Controller #1500-NPC, and the Valve/Transducer Assembly #1500-NPV50 (½") or #1500-NPV75 (¾").
        The Null Pressure Controller will operate on either 115Vac or 230Vac power input. The controller contains a precision potentiometer and vernier scale dial mounted on the front panel, for accurately adjusting the null air pressure to the clutch/brake unit, to an accuracy of better than .1 psi. A locking lever is included on the vernier scale dial to prevent unintentional dial movement. (When included with the System 2500 Multi-Slide Control, the potentiometer and dial are pre-mounted and pre-wired to the System 2500 operator console.) Inside the controller are two quick-disconnect terminal connection blocks for fast installation and service. Each terminal is clearly labeled as to its connection. The Null Pressure Controller is used to control the voltage to the precision transducer on the Valve/Transducer Assembly.
        The Valve/Transducer Assembly is available in two sizes. The #1500-NPV50 is used for ½" NPT air line, and the #1500-NPV75 is used for ¾" NPT air line. The assembly includes a full-pressure/low-pressure clutch/brake-control valve, a shuttle valve, a quick-exhaust valve, a micro-air filter, transducer, and pressure gauge. The assembly also includes a connected 3-foot length of flexible air hose to allow the quick-exhaust valve to be mounted directly to the clutch/brake rotary union. The control valve is specially external-piloted to accommodate the low null air pressure when in the null-adjustment (Manual Setup) mode, which allows the System 1500 to vary the air pressure from almost zero to full line input pressure (80-100 psi). When in the RUN mode, the combination of the control valve and quick-exhaust valve provide a quick stopping time for operator safety.

CAUTION:
        When used on a multi-slide/four-slide machine or other press or machine with a flywheel and a die-pinch-point, the Valve/Transducer Assembly must be connected to the output of a press or machine clutch/brake safety control system, such as the Brandes - System 2500, to meet OSHA safety regulations. The control valve used is not a press safety valve, and is only intended for continuous-cycling, part-revolution machines.

Installation

Valve/Transducer Assembly Mounting Requirements Top

        The Valve/Transducer Assembly must be mounted as close to the clutch/brake rotary union as possible to allow quick exhaust and provide the quickest stopping time as possible (3-feet or less). The 3-foot length of hose included can be shortened as required.
        The assembly must be mounted with the transducer and micro-air filter in the vertical position. The input air line (at the left side of the control valve) should contain a filter/regulator/lubricator (FRL) unit to prolong the life of the valve assembly, and should be sized according to the valve assembly size used. (The micro-air filter included in the assembly is used only for the transducer.)
        Do not attempt to turn or reposition the transducer on the assembly. The transducer will only operate accurately in the installed position.

System 1500 Wiring Top

        The Valve/Transducer Assembly contains three valves, which must be electrically connected to the Null Pressure Controller and the clutch/brake output of a safety control system as follows...

        The white and black wires from the transducer connect directly to the output of the Null Pressure Controller at terminals 2TB 4 and 2TB 5 (black wire to 2TB 5). When included with the System 2500 Multi-Slide Control, the transducer wires connect directly to the output terminals (labeled) in the motor starter box (which are connected to the precision potentiometer on the operator console).
        The "A" (low psi) coil of the control valve (terminals 1 and 2) connect to a switch or relay that supplies 115Vac when the null-adjustment (Manual Setup) mode is selected. The "B" (high psi) coil of the control valve must remain off when in the null-adjustment (Manual Setup) mode.
        The "B" (high psi) coil of the control valve (terminals 1 and 2) connect to the 115Vac-clutch/brake output of a clutch/brake safety control system, such as the System 2500, which only turns on when initiated in the RUN mode. The "A" (low psi) coil of the control valve should remain off while in the RUN mode.
        When using the Null Pressure Controller as a stand-alone system (not interfaced to the System 2500), connect 115Vac or 230Vac to the power input terminals at 1TB 1 through 4, and jumper accordingly. To extend the life of the controller and transducer, this voltage need only be applied when in the null-adjustment (Manual Setup) mode.

System 1500 Stand-alone Schematic

        When the System 1500 is purchased with the System 2500 Multi-Slide Control, labeled output terminals are provided for all three valve coils in the motor starter box. For reference on connections to the System 2500 or troubleshooting, see Drawing #A552600B1 or "The System 2500 Service and Installation Manual".

Adjustment Top

        The vernier-scale dial is adjusted for the correct "null" air pressure to the combination clutch/brake unit, which will center the piston between the clutch and brake plates to release both the clutch and brake. The "null" air pressure is usually a very close tolerance around 32-35 psi, and depends on the clutch/brake characteristics. Once properly set, selecting the MANUAL SETUP mode will automatically center the piston between the clutch and brake, and enable the hand wheel to be easily rotated. Re-adjustment of the null air pressure may be periodically required as the clutch characteristics change.
        Adjustment is done in the MANUAL SETUP mode by increasing the pressure (turning the 11-turn dial clockwise) until the brake just releases. If the motor and flywheel rotate when the hand wheel is rotated, decrease the pressure (counter-clockwise) until the clutch releases. Each full rotation of the dial is equal to 10 psi. The number in the dial "window" is the "tens" digit and the numbers on the dial itself are the "ones" digit. Full range (with 100-psi air pressure input) is 0 to 100 psi, although no more than 40 psi should be required.
        A locking lever is located on the side of the dial. The lock must be released (moved up) to adjust the null pressure. Once adjusted, place the lever in the down position to lock the setting, to help stabilize the setting under vibration or if bumped.

System 1500 Technical Data Top

WARNING:
        This system shall only be used on machines that operate in a fully guarded mode. The clutch/brake control valve used is NOT a press safety valve, and is only intended for continuous-cycling machines. The installer and machine owner must make sure that all applicable Federal and State OSHA regulations and requirements, and any industry requirements are followed before the machine is put in service.

System 1500 Air Schematic and Block Diagram

PLEASE NOTE:
        Machine controls are to be modified and/or updated when this system is to be used. It is required when MANUAL SETUP mode is selected that:

  1. Main motor be de-energized, and be prevented from being energized. The flywheel must be stopped before MANUAL SETUP mode can be made available.
  2. Normal operation shall not be permitted while the "A" (low psi) control valve coil is energized.

DESCRIPTION OF MODES…

        NORMAL MODE:

  1. The "A" (low psi) control valve coil is de-energized, and inhibited from being energized.
  2. The "B" (high psi) control valve coil is controlled by the machine safety control.
  3. The main motor is controlled by the machine safety control.
  4. The Null Pressure Controller (#1500-NPC) is de-energized.
  5. Normal air pressure is used (80-100 psi).
MANUAL SETUP MODE:

  1. The Main motor is de-energized, and inhibited from being energized.
  2. The flywheel is to be stopped.
  3. Power is supplied to the Null Pressure Controller (#1500-NPC).
  4. The "A" (low psi) control valve coil is energized.
  5. The "B" (high psi) control valve coil is de-energized, and inhibited from being energized.
  6. Null pressure is applied to the clutch/brake to allow manual setup.
CAUTION:
        When MANUAL SETUP mode is selected, any vertical slides or rams that are not at bottom-dead-center may drift, and any motions that are spring-loaded may drift. If cushions are used, they may cause sudden movement.

NOTES:

  1. Air supply input is to be between 80 and 100 psi (not to exceed 100 psi).
  2. Air must be filtered to remove particulate and water. A 20-micron filter or better is recommended.
  3. Air line from the shuttle valve to the quick-exhaust valve (clutch/brake rotary union) is to be 3 feet long maximum, and properly sized for the clutch/brake used.
  4. The Valve/Transducer Assembly must be mounted with the transducer and micron filter in the upright position.
CALIBRATION:
        The transducer contains a SPAN and a ZERO adjustment screw on its side. These are pre-calibrated at our factory before shipment for correct voltage-to-psi conversion, and should not be tampered with.

Top

H&W CONTROLS
A Division of Henry & Wright Corporation
739 East 140th Street - Cleveland, OH 44110
Phone: 216-851-3750 Fax: 216-851-3970

H&W Controls 2000
All Rights Reserved