The System 2500
Multi-Slide/Four-Slide Control System
Installation and Service Manual

Revised: May 14, 2003

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Introduction Installing the System 1500 Air Null Pressure System
Description of System Cyclestop Limit Switch
Description of Machine Modes Flywheel Motion Sensors
Description of Motor Control Circuits Feed Sensor Inputs
Warranty Troubleshooting
Production Counter Circuit Board Part Numbers
Installation Drawing Part Numbers
Clutch/Brake Valve Connections Replacement Parts

Introduction Top

        The Henry & Wright System 2500 is a complete solid state machine control system designed specifically for Multi-Slide and Four-Slide machines.
        The System 2500 was designed to meet higher production requirements and improved safety standards such as those set down by OSHA. OSHA now considers Multi-Slide and Four-Slide machines as presses in the same category as stamping presses. Therefore, OSHA regulations stated in 1910.217 for metal forming presses, adhere to these machines as well. The System 2500 meets all OSHA requirements for continuous-running/auto-feeding presses.
        Adding the System 2500 to your Multi-Slide/Four-Slide press with an installed clutch/brake unit will enable the press to instantly stop on command. The press can then safely accept various stop commands to provide you with a safer, more flexible means of creating a more productive machine.
        The System 2500 will accept the full range of Multi-Slide/Four-Slide press speeds to above 350 strokes per minute.
        The revised "B" version System 2500 Main Control Board (June 1993) contains some additional features and enhancements to improve safety standards, setup, and production.
        The revised "C" version System 2500 Main Control Board (September 1999) adds more enhancements and in-field flexibility while simplifying installation wiring.
        The "C" version Main Control Board is interchangeable with the "A" and "B" versions for easy in-field upgrades or repairs. The "A" and "B" versions are no longer available. This manual is based on and referenced to the System 2500 containing the "C" version Main Control Board.
        The "C" version Main Control Board contains two flywheel motion sensor inputs and a flywheel motion sensor compare circuit, which eliminates the need for the separate "Flywheel Motion Sensor Compare Board" #550310A2A used with the earlier version Main Control Boards. When replacing a "B" or "A" version Main Control Board with the "C" version, the wires on 2TB from terminals 9 through 13 must all be shifted over (up) one terminal each, because of the added "Flywheel Motion Sensor #2" input. When replacing the older versions with the "C" version, remove the "Flywheel Motion Compare Board", if installed, and reroute the two flywheel sensors wires directly to 2TB 9 and 2TB 10. 1TB terminal block is identical on all three versions and needs no modifications.

Description of System Top

        The basic System 2500 contains two circuit boards in the operator console. These boards are the Main Control Board #550250C1A and the Door Interface Board #550260A1A. The Door Interface Board provides the five front panel indicator lights and a connector for wiring the front panel buttons and selector switch inputs and production counter output. The Main Control Board is the heart of the control system. It contains the 12Vdc-power supply, the input and output quick-disconnect terminals, the control logic circuits, and the Status and Fault Indicator Panel.
        The Main Control Board also contains a built-in, four-input, feed malfunction check circuit with individual LED indicators in the Fault Indicator Panel, and a front panel FEED FAULT light. All four feed sensor inputs are low-voltage (12Vdc), static-current type which are activated when touched to press ground. These inputs will accept any type of hand-fabricated lever, arm, or sensor as well as a device with a dry contact output. All four sensor inputs are prewired to jack inputs on the motor starter enclosure for easy die changing ability or bypassing. See "Feed Sensor Inputs" in this manual for more information.
        A four position keyed selector switch is included to select one of the four MACHINE MODE choices. These are MANUAL SETUP, INCH/SINGLE, OFF, and RUN (continuous) modes. The description of each of these modes is given in detail in the next section.
        Five front panel indicator lights are included with the System 2500 for monitoring different control functions. These are:

        POWER ON
        GUARD
        MOTOR ON
        CLUTCH ENGAGED
        FEED FAULT

        For special requirements, a sixth light can be added to the operator console for "LOW OIL PRESSURE", etc., and connected between 12Vdc and the Auxiliary Stop input at 2TB 1. When 2TB 1 is grounded (to signal a fault), the light will come on, indicating the fault, and the machine will stop.

Auxiliary Light Output Board Option

        The System 2500 Auxiliary Light Output Board #550300A1A provides an external connector for each of the five front panel indicator lights. These five external connections may each be used to operate, directly, a 12Vdc relay coil (200 mills max) or a remote 12Vdc indicator light (200 mills max) for remote status indication.

        A "Ground" terminal is provided on the Auxiliary Light Output Board at 3TB 6 for convenience, to provide a common for all five outputs.
        The POWER ON indicator light (3TB 5) provides a constant +12Vdc power source whenever the control power is on (200 mills max). With the "A" version Main Control Board, this terminal may also be used to supply the 12Vdc-power source required for some proximity sensors that is not available on the "A" version Main Control Board.
        The GUARD light output (3TB 1) is +12Vdc whenever the guard is closed or unobstructed.
        The MOTOR ON light output (3TB 2) is +12Vdc whenever the motor is running.
        The CLUTCH ENGAGED light output (3TB 3) is +12Vdc whenever the clutch is engaged (in the INCH and RUN machine modes).
        The FEED FAULT light output (3TB 4) is +12Vdc only when a feed fault occurs (until reset).

        The Auxiliary Light Output Board is mounted in the operator console above the Main Control Board on the back panel in the two holes provided (above 2TB). The Auxiliary Light Output Board contains a ribbon cable that plugs into the 2RC socket on the Door Interface Board. (The 1RC ribbon cable can also be re-routed to the Auxiliary Light Output Board, and the Auxiliary Light Output Board plugged into the Main Control Board's 1RC socket.) Observe ribbon cable polarity!

Description of Machine Modes Top

        MANUAL SETUP Mode is used to manually rotate the slides for setup purposes. The System 2500 is designed to accommodate either a combined clutch/brake unit, or a separate clutch and brake. Two flywheel motion sensors must be installed and wired to the input terminals provided, to utilize this press mode. When the MANUAL SETUP Mode is selected, the motor is automatically shut off. The system then waits for the motor and flywheel to completely stop (via the flywheel motion sensors). When stopped, the clutch/brake output is automatically turned on. The motor is locked off until another MACHINE MODE is selected.
        When a separate clutch and brake are installed, only the brake is energized (released) when the flywheel stops. The clutch output remains off. Henry & Wright recommends installing the flywheel motion sensors in EVERY installation, since, when using a separate clutch and brake, bearing friction can still cause the slides to move until the flywheel is stopped.
        When a combined clutch/brake is installed, more effort is required to manually rotate the slide flywheel since the motor and flywheel are connected through the clutch to the crankshaft (when the brake is released, the clutch is also engaged). On larger size Multi-Slide/Four-Slide presses (size 3 and above), this extra effort may be too great to handle. Henry & Wright can include the System 1500 Air Null Pressure Adjustment System with the System 2500, which will null the air pressure automatically when the MANUAL SETUP mode is selected, to a preset point. This preset point (usually around 32 psi.) centers the piston between the clutch and brake plates so that neither the clutch nor brake is applied, leaving little effort to manually position the slides. When ordered with the System 2500, the Air Null Pressure Adjustment dial is installed on the System 2500 operator console for easy access. The System 1500 also includes the clutch/brake control valve in its valve/transducer assembly for direct connection to the System 2500 clutch/brake output (no other valves are required).
With the clutch/brake output turned on, the flywheel can be easily rotated by hand for accurate slide positioning. When another MACHINE MODE is selected, or the EMERGENCY STOP button is pushed, or the "Auxiliary Stop" input (at 2TB 1) is closed, the clutch/brake output will shut off and lock off. The MACHINE MODE selector must be taken out of the MANUAL SETUP Mode and then placed back in the MANUAL SETUP Mode to re-engage the clutch/brake output. Only when another MACHINE MODE is selected, the motor can be restarted. If the "Auxiliary Stop" input and/or the EMERGENCY STOP button is activated while the MANUAL SETUP Mode is selected, the clutch/brake output will remain off even after the flywheel has stopped. Both the EMERGENCY STOP button and "Auxiliary Stop" input must be deactivated, then the MACHINE MODE selector taken out of and placed back into the MANUAL SETUP Mode before the clutch/brake output will turn back on to release the brake.

        INCH/SINGLE Mode may be used for setup by pressing the RUN button/s to electrically engage the clutch/brake. The motor may be on or off in the INCH/SINGLE Mode. The RUN button/s may be held down to single-stroke the slides. If two RUN buttons are included with the System 2500, both RUN buttons must be pressed concurrently. The slides will cycle-stop automatically.
        The auto cycle-stop feature is designed into the INCH/SINGLE Mode to prevent continuous cycling during setup for safety purposes. For special requirements, this feature can be removed by placing a jumper over the pins at "J2" on the "C" version Main Control Board (inside the operator console).
        A single AUXILIARY JOG button can be included as an option for remote jogging of the slides, effective only in the INCH/SINGLE machine mode. This button can be mounted remotely where the stock is fed in to accommodate a one-person setup. The AUXILIARY JOG button will work with one or two RUN button installations, and with all version Main Control Boards. With a pre-wired system, the AUXILIARY JOG button is pre-wired to the operator console with the length of sealtite determined by the customer. See Drawing #B552300A3 for connections.

        OFF Mode disables any slide movement. The motor may be started and stopped in the OFF Mode. The EMERGENCY STOP button can be used in the OFF mode to shut off the motor.

        RUN Mode is used for production cycling. To initiate the continuous cycle, the ARMING/CYCLESTOP button is first pressed momentarily to initiate a five-second arming timer. The RUN button/s must be pressed during this time period to start the cycle. If two RUN buttons are included with the System 2500, both RUN buttons must be pressed concurrently during the time period.
        The feed malfunction circuits are active in the RUN Mode, which monitor the four feed sensor jack inputs for proper operation.
        The production counter is also active in the RUN Mode, which will advance one count at each cyclestop (slides-out) position.
        The ARMING/CYCLESTOP button can be again pressed momentarily to stop the slides at the next cyclestop (all-slides-out) position.
        The motor must be running to cycle the press in the RUN Mode only. The slides will stop immediately if the motor is stopped during the cycle.
        The perimeter guard, if installed, will stop the slides immediately in the RUN Mode, when interrupted, at any point during the press cycle. For special requirements, the guard input (2TB 12) can be bypassed during the slides-out portion of the cycle by placing a jumper over the pins at "J1" on the "C" version Main Control Board (inside the operator console). A jumper should NOT be placed on "J1" for standard perimeter guarding, since a person could un-safely penetrate the guard during the slide-out portion of the cycle.
        The cyclestop limit switch must be installed and adjusted properly to enable most of the features in the RUN Mode (as well as the auto cycle-stop feature in the INCH/SINGLE Mode). The cyclestop limit switch (at input 2TB 7) is used to detect the cyclestop (all-slides-out) position, advance the production counter, and enable the "Feed Detector" and "Part Ejection" feed sensor jack inputs. Without the cyclestop limit switch installed (or operating properly), the slides can be stopped (immediately) by pressing the RESET button. The EMERGENCY STOP button or motor STOP button can be used also, which will shut off both the motor and slides.
        The RESET button is used to clear any FAULT condition. The "B" and "C" version Main Control Boards include a auto-reset feature at power-up to eliminate having to press the RESET button when powering up the press and System 2500.

Description of Motor Control Circuits Top

        The System 2500 Main Control Board contains four terminals on 1TB for motor control and motor on indication. The four-wire interface can be connected easily to an existing motor starter and motor operator station. However, when Henry & Wright Controls supplies the motor control, the motor control package is completely prewired to the operator console at Henry & Wright with the length of sealtite determined by the customer. The prewiring includes the wiring to the feed sensor jacks on the motor control box, the control transformer for 220/440Vac input, and input/output terminals in the motor control box for quick and simple installation.
        The standard motor control box dimensions from Henry & Wright are 16" x 16" x 6" deep in a Nema type 12 enclosure. A larger box may be required when using a vary-speed drive.
        The Main Control Board contains two field-replaceable relays (REL1 and REL2) for motor control and monitoring. Relay REL2 controls the 120Vac supply to 1TB 1 and 1TB 2 for controlling the motor. This relay will drop out if an emergency stop occurs. Relay REL1 monitors the motor starter coil to determine if the starter is on or off. REL1 coil is wired across 1TB 3 and 1TB 4.

RELAYS REL1 AND REL2 ARE NOT INTERCHANGEABLE!

Relay REL1 contains a 115Vac coil, and must be plugged into the REL1 socket.
Relay part number: Potter & Brumfield #R10-E1-Z2-115Vac, Allied Controls #T163-2C-115Vac

Relay REL2 contains a 12Vdc coil, and must be plugged into the REL2 socket.
Relay part number: Potter & Brumfield #R10-E1-X2-V185, Allied Controls #TF154-2C-12Vdc

Warranty Top

        This product is warranted by H&W Controls to the original purchaser to be free from defects in material and workmanship under normal use for a period of one year from the date of purchase. If a qualified rebuilder or press manufacturer purchased this product from H&W Controls, this warranty will be forwarded as stated from the original date of purchase from H&W Corporation to and only to the next purchased control user. During the warranty period, and upon proof of purchase, the product will be repaired or replaced with the same or similar model, at H&W Controls option, at H&W Corporation without any charge for either parts or labor. This warranty will not apply if this product has been miswired, misused, abused, or altered.
        All repaired products after one year from the date of purchase, will be warranted by H&W Controls to the sender to be free from defects in material and workmanship under normal use, for a period of 90 days from the date of repair.
        To obtain warranty service, you must take or send the product, postage paid, to H&W Controls with the date of purchase or repair. Due to the possibility of damage or loss, it is recommended when sending the product to H&W Controls, that you package the product securely and send it insured, return receipt requested.
        NEITHER THIS WARRANTY NOR ANY OTHER WARRANTY, EXPRESS OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE, SHALL EXTEND BEYOND THE WARRANTY PERIOD.

Production Counter Top

        The production counter, located on the operator console, will advance one count each stroke in the RUN Mode only. The counter advances when the cycle-stop limit switch opens (at the all-slides-out position). The counter operates off it's own internal batteries (field-replaceable type "N") which will retain the current count if the control power is shut off. Typical battery life is five years. The count RESET button is keyed to prevent unauthorized resets. Count range is from 0 to 999,999.
        The production counter is pre-wired to the 1PL connector on the Door Interface Board. See Drawing #B552300B1 for detailed wiring.

Battery Replacement

        Slide battery cover to the left until the right hand lip disengages and pops out. To reinstall cover, insert left hand lips into case first, push cover to the left until right hand lip drops down and cover snaps back into place.
        To install the batteries, push battery spring clips to the left (toward connector) to completely free the batteries when removing or installing batteries. The batteries must drop in freely. Do not push or force the batteries into place. The conductive rubber battery contacts can be torn from their retaining pins if the batteries are forced in. The batteries are inserted in opposite directions as shown inside the counter.

Installation Top

        AN IMPORTANT TIP… Never run any low-voltage DC wires in the same conduit or sealtite as higher-voltage AC wires, unless the low-voltage wires are in shielded cable and the shield is grounded to the control cabinet.
        1TB terminal connections are all high voltage (120Vac) and 2TB terminal connections are all low voltage (12Vdc).

Motor Control Connections

        The motor control package (usually included with the System 2500) is pre-wired to the operator console at Henry & Wright and to the motor operator station (mounted on the operator console). A step-down transformer is included in the motor control package to provide the 120Vac required to the control system and to provide a single input power source (220/440Vac) for simple installation. See Drawing #B552100B1 for interfacing to an existing motor starter, or for troubleshooting information on the pre-wired package.
        The pre-wired motor control package from H&W Controls also includes pre-wired feed sensor jack inputs (mounted on the motor control box) to the operator console, and labeled terminals in the motor control box for quick and simple installation.

        Terminals 1TB 1 and 1TB 2 supply the 120Vac to the motor control. DO NOT CONNECT ANY OUTSIDE POWER SOURCE TO THESE TERMINALS! The STOP button NC contact connects to the "hot" terminal (1TB 1), and the motor starter overload heaters connect to the "common" terminal (1TB 2).
        1TB 3 and 1TB 4 are wired across the motor starter 120Vac coil. Polarity is irrelevant. When the motor starter coil energizes, 120Vac is applied across 1TB 3 and 1TB 4 to energize the "motor on" relay (REL 1) on the Main Control Board. See Drawing #B552100B1 for connection details.

Clutch/Brake Valve Connections Top

        1TB 7 and 1TB 8 are provided for connecting a clutch/brake control valve. 1TB 7 is the "hot" clutch/brake output, and 1TB 8 is the "common" clutch/brake output. A single-solenoid or dual-solenoid valve will work with a quick exhaust (to shorten the stopping time of the slides as fast as possible). Mount the clutch/brake valve as close to the rotary union as possible and size the airline between the two adequately to provide a fast exhaust.
        When using a combined clutch/brake unit, the System 1500 Air Null Pressure Valve Assembly may be required. This valve assembly includes the clutch/brake control valve. This control valve should be wired to 1TB 7 and 1TB 8. See "Installing the System 1500" section in this manual for details.
        If a separate 24 volt electromagnetic clutch and brake are wired to the System 2500, 1TB 7 and 1TB 8 are left empty. The electromagnetic clutch and brake units are wired to the optional "24Vdc Power Supply and Driver Board" #550270A1. Contact Henry & Wright for more information on this option.

Installing a Separate Pneumatic Clutch and Brake

        When wiring a separate clutch and brake to the System 2500, wire the brake valve to 1TB 7 and 1TB 8, and wire the clutch valve to the optional "Separate Clutch Output Board" #550290A1. The Separate Clutch Output Board can be easily installed in the field, but should be included in the System 2500 operator console when purchased as required.
        The Brake (spring-applied) and the clutch will both turn on and turn off at the same time in the INCH/SINGLE and RUN Modes, using the Separate Clutch Output Board for the clutch. In the MANUAL SETUP Mode, only the brake output will turn on releasing the brake to manually position the slides.
        The Separate Clutch Output Board is plugged into the 2PL connector on the right side of the Main Control Board. Terminals 3 and 4 on the Separate Clutch Output Board are wired to 1TB 8 and 1TB 10 respectively on the Main Control Board to supply the 120Vac for the clutch output. Terminals 1 and 2 on the Separate Clutch Output Board are wired to the 120Vac clutch valve coil.
        When purchased with the System 2500 and motor control package, the Separate Clutch Output Board is installed and pre-wired in the operator console. The separate clutch and brake valve 120Vac outputs are pre-wired to the input/output terminals in the motor control box.
        To install the Separate Clutch Output Board (for repair or replacement), the Main Control Board will need to be tilted up on the right side to be able to plug in the 2PL connector. Simply remove the four screws securing the back-panel and tip the complete panel assembly to install the connector. The connector will be locked in place once the Main Control Board and back-panel are remounted.

Installing the System 1500 Top

System 1500 Valve/Transducer Assembly (Mounted)         The System 1500 Air Null Pressure System is used to null the air pressure to a combination clutch/brake unit to release both the clutch and brake for manual slide positioning. The System 1500 consists of two parts… The Null Pressure Controller (potentiometer and vernier scale dial pre-installed on the System 2500 operator console at H&W Controls), and the Valve/Transducer Assembly (which includes the clutch/brake operating valve).
        The Valve/Transducer Assembly is available in ½" NPT (#1500-NPV50) and ¾" NPT (#1500-NPV75) airline sizes. The Valve/Transducer Assembly contains four different-type valves and a transducer, which are all pre-assembled at H&W Controls. Two of the valves are electrically engaged. These two valve coils and the transducer must all be wired to independent circuits, as follows…
        The HIGH psi. Control valve coil and the LOW psi. Control valve coil both connect to a MANUAL SETUP relay in series with the clutch/brake output at 1TB 7 and 1TB 8. The MANUAL SETUP relay is a SPDT relay (with a 12Vdc coil) that should be mounted in the motor starter box. The HIGH psi. Control valve coil is connected to the normally CLOSED contact, and the LOW psi. Control valve coil is connected to the normally OPEN contact of the MANUAL SETUP relay. The relay should energize in the MANUAL SETUP mode.
        The two Transducer wires are connected to the AIR NULL PRESSURE potentiometer on the operator console.
        When purchased with the System 2500, the MANUAL SETUP relay, AIR NULL PRESSURE potentiometer, and transducer wiring are all pre-wired to the input/output terminals in the motor starter box. Simply connect the three sets of wires to their corresponding terminals. See Drawing #A552600B1 for wiring details.
        The input air pressure is connected to the tee fitting at the Control valve. The clutch/brake rotary union is connected to the quick-exhaust valve output at the end of the air hose. The air hose should be as short as possible between the quick-exhaust valve and the Control valve to keep the stopping time to a minimum.
        Do not attempt to rotate the transducer on the assembly. The transducer will only work in the position it is mounted in. The transducer must also be mounted vertically with the electrical connector on the left side of the transducer. The transducer will not operate properly (the null air pressure will not be consistent with the NULL AIR PRESSURE dial) if the transducer is not vertical and locked down securely.

System 1500 Operation

        In the INCH/SINGLE and RUN machine modes, the MANUAL SETUP relay is off, which connects the HIGH psi. Control valve coil to the clutch/brake output. When the clutch/brake output energizes, the full airline pressure (around 80 psi.) is sent to the clutch/brake unit.
        In the MANUAL SETUP machine mode, the MANUAL SETUP relay is energized, connecting the LOW psi. Control valve to the clutch/brake output. The clutch/brake output will automatically energize after the motor flywheel comes to a complete stop (via the flywheel motion sensors). This will send the null air pressure to the clutch/brake unit. The null air pressure is adjusted with the NULL AIR PRESSURE dial on the System 2500 operator console, to the point that the clutch/brake piston is centered between the clutch and brake plates (around 30 - 35 psi.). This allows the slides to be manually adjusted easily, by disconnecting the motor and flywheel from the adjustment wheel and slides.

Air Pressure Switch Connections

        1TB 9 and 1TB 10 are provided for wiring to an air pressure switch to monitor the regulated air pressure to the clutch/brake valve. The pressure switch should be adjusted to between 60 and 100 psi. depending on the clutch/brake and press requirements. 1TB 9 and 1TB 10 must be connected together through the air pressure switch to provide the 120Vac to the motor starter circuit and clutch/brake output/s.
        If an electromagnetic clutch and brake are used, jumper 1TB 9 and 1TB 10 together, unless an air pressure switch is desired for monitoring air blow-off, etc. See Drawing #B552100B1 for wiring details.

Cyclestop Limit Switch Top

        A cyclestop limit switch is required in the INCH/SINGLE and RUN machine modes to enable the slides to stop at the all-slides-out position. The cyclestop limit switch is also required in the RUN machine mode to advance the production counter and monitor the FEED DETECTOR and PART EJECTION sensor inputs.
        The cyclestop limit switch connects to 2TB 7. 2TB 8 is used as the "ground" terminal for the common side of the switch. If desired, only one wire may be run to the cyclestop limit switch from 2TB 7, and the other side of the switch connected directly to press ground. Use a limit switch with a contact current rating of 1 amp or less.
        For better performance, use a proximity sensor for the cyclestop limit switch. A proximity sensor requires a 12Vdc power source which can be taken from the System 2500 at 2TB 14 ("C" version) or 2TB 13 ("B" version). When purchased from Henry & Wright, a Banner proximity sensor is supplied (Banner #S18SN6FF50Q and cable #MQDC-415RA), which is the same type as the two flywheel motion sensors supplied from Henry & Wright for easy replacement. The Banner proximity sensor is an infrared light operated sensor with a fixed focal length of 2 inches. The sensor will detect any obstacle or mass within its 2-inch range. This makes for easy mounting and adjustment. The solid state transistor output out-performs a mechanical limit switch contact by eliminating any contact bounce, which may sometimes cause a false FEED DETECTOR or PART EJECTION fault. A quick-disconnect cable (included) provides an easy means of replacing the sensor if it should fail.
        The 15-foot quick-disconnect cable contains four wires that are connected directly to 2TB. The sensor can be connected in the "Standard" or "Alarm Hookup" mode as shown in the charts below. The "Alarm Hookup" mode uses the Auxiliary Stop input at 2TB 1 to monitor the condition of the sensor, and will stop the slides if the sensors light source fails or becomes misaligned.
See Drawing #B552200D1 ("C" version) for wiring details. (Use Drawing #B552200C1 when using a "B" or "A" version Main Control Board.)
Cyclestop Limit Switch Installation

Cyclestop Limit Switch Connections:
Standard Hookup Mode

Sensor Wire Color
Terminal
Brown 2TB 14 ("C" version) (+12Vdc terminal in motor starter cabinet)
Black (NO) 2TB 7 (Cyclestop limit switch terminal in motor starter cabinet)
Blue 2TB 8 (Ground terminal in motor starter cabinet)
White (NC) No connection

Alarm Hookup Mode

Sensor Wire Color
Terminal
Blue 2TB 14 ("C" version) (+12Vdc terminal in motor starter cabinet)
Black (NO) 2TB 7 (Cyclestop limit switch terminal in motor starter cabinet)
Brown 2TB 8 (Ground input terminal in motor starter cabinet)
White (NC) 2TB 1 (Auxiliary Stop input terminal in motor starter cabinet)

Cyclestop Limit Switch Adjustment

        The cyclestop limit switch is mounted on one of the crankshafts and is adjusted to open at the all-slides-out position. The switch or sensor must close for at least 20 milliseconds just before the all-slides-out position. The opening of the switch or sensor contact signals the machine to cyclestop, if the ARMING/CYCLESTOP button was pushed during the cycle (in the RUN mode). The adjustment position of this switch or sensor depends on the stopping time of the machine. Re-adjustment of the switch or sensor may be needed to stop the slides at the all-slides-out position.
        The closing portion of the switch (or when the proximity sensor is detecting mass) will bypass the GUARD input at 2TB 12 if a jumper is placed on jumper pins "J1" for special requirements ("C" version). When "J1" is left open (standard), the GUARD input is always active in the RUN mode. The point that the cyclestop limit switch/sensor closes is irrelevant when "J1" is open (although it must close for at least 20 milliseconds). If jumper pins "J1" are shorted ("C" version), do not adjust the cyclestop limit switch/sensor so that it is closed (detecting mass) during the slide-in stroke!
        When using the Banner proximity sensor, mount the sensor through a bracket or hole so that the end of the sensor is just over 2 inches away from the crankshaft, and that the mass or cam hub will enter the 2-inch range as it rotates. Once the control is powered up, the sensor can be checked for proper alignment by making sure the yellow indicator light on the sensor glows brightly when the mass or cam hub is present, and that the light goes out completely when leaving the mass or hub. Another way to verify alignment is to watch the production counter as the machine cycles, to make sure the count advances one count each stroke. If the counter advances multiple counts each stroke, the problem is most likely that the cyclestop limit switch/sensor is mounted too close to the crankshaft, or the cyclestop limit switch/sensor is picking up other masses on the crankshaft.

Flywheel Motion Sensors Top

        Two flywheel motion sensors are mandatory for the MANUAL SETUP Mode when installing a combined clutch/brake unit, and are recommended when using a separate clutch and brake. When selecting the MANUAL SETUP Mode, the System 2500 must be sure that the motor and flywheel are completely stopped before turning on the clutch/brake output. The flywheel motion sensors are used for this purpose.
        The two sensors are mounted through holes on the flywheel guard to detect holes or indents in the flywheel as the flywheel rotates. The sensors are wired directly to 2TB 9 and 2TB 10 on the Main Control Board ("C" version). 2TB 11 can be used as the common ground for both inputs. When using the "A" or "B" version Main Control Board, the Flywheel Motion Switch Compare Board #550310A2A is required to compare the two flywheel sensors. See the next section in this manual.
        If a separate clutch and brake are used, the flywheel motion sensors are not mandatory, but are recommended for safe setup. The slides can still rotate caused by the flywheel bearing friction, even though the clutch is off. If the flywheel motion sensors are NOT required, simply leave 2TB 9 and 2TB 10 open on the Main Control Board ("C" version).

        CAUTION: With 2TB 9 and 2TB 10 open, the brake will release as soon as the MANUAL SETUP Mode is selected (regardless of the flywheel rotating).        
Flywheel Motion Sensor Installation         For quick and simple installation and troubleshooting, two Banner Proximity Sensors are used for the flywheel motion sensors. They are the same types used for the cyclestop limit switch (three altogether). The Banner sensors #S18SN6FF50Q and cables #MQDC-415RA are wired as shown below ("C" version). The "Alarm Hookup" mode uses the Auxiliary Stop input at 2TB 1 to monitor the condition of the sensor, and will stop the slides if the sensors light source fails or becomes misaligned.
        See Drawing #B552200D1 ("C" version) for wiring details. (Use Drawing #B552200C1 when using a "B" or "A" version Main Control Board.)

Flywheel Motion Sensor Connections ("C" version):
Standard Hookup Mode

Flywheel sensor cable wires:
Connections:
Flywheel sensor #1 BROWN wire
Flywheel sensor #2 BROWN wire
2TB 14 (+12Vdc terminal in motor starter cabinet)
Flywheel sensor #1 BLACK wire 2TB 9 (Flywheel Sensor #1 terminal in motor starter cabinet)
Flywheel sensor #2 BLACK wire 2TB 10 (Flywheel Sensor #2 terminal in motor starter cabinet)
Flywheel sensor #1 BLUE wire
Flywheel sensor #2 BLUE wire
2TB 8 (Ground terminal in motor starter cabinet)
Flywheel sensor #1 WHITE wire
Flywheel sensor #2 WHITE wire
No connection

Alarm Hookup Mode

Flywheel sensor cable wires:
Connections:
Flywheel sensor #1 BLUE wire
Flywheel sensor #2 BLUE wire
2TB 14 (+12Vdc terminal in motor starter cabinet)
Flywheel sensor #1 BLACK wire 2TB 9 (Flywheel Sensor #1 terminal in motor starter cabinet)
Flywheel sensor #2 BLACK wire 2TB 10 (Flywheel Sensor #2 terminal in motor starter cabinet)
Flywheel sensor #1 BROWN wire
Flywheel sensor #2 BROWN wire
2TB 8 (Ground terminal in motor starter cabinet)
Flywheel sensor #1 WHITE wire
Flywheel sensor #2 WHITE wire
2TB 1 (Auxiliary Stop input terminal in motor starter cabinet)

Flywheel Motion Sensors Adjustment

        The two sensors are positioned through holes in the flywheel guard, and each adjusted to less than 2 inches of the flywheel. When a hole or indent passes by each sensor (as the flywheel rotates), each sensor's focal length should be greater than 2 inches. The amount of holes or indents in the flywheel is irrelevant, as long as there is at least one per rotation. The mounting position of both sensors (from each other) is also irrelevant.
        The position of both sensors and the amount of senses-per-cycle are not important, as long as both sensors are operating and sense at least once per rotation. The use of two sensors is required only for safety purposes (in case one sensor fails).

Flywheel Motion Sensors Operation

        The "C" version Main Control Board contains a built in compare circuit to monitor the two flywheel motion sensors. The "A" and "B" versions require the Flywheel Motion Compare Board #550310A2A described in the next section.
        Under normal operation, the compare circuit monitors both flywheel motion sensor inputs for pulses up to 1 second apart, in the MANUAL SETUP Mode. The flywheel is considered stopped when the pulses become longer than 1 second apart. After the flywheel is considered stopped, the brake will release.
        Both flywheel motion sensor inputs are continuously monitored in all machine modes for concurrent operation. If the two flywheel motion sensor inputs become opposite (do not work concurrently) for more than 6 seconds, the MANUAL SETUP Mode brake release is locked out in memory. When the MANUAL SETUP Mode is selected, LED 13 will light on the Main Control Board (signaling a bad motion sensor), and the brake will not release until the RESET button is pressed. However, the second flywheel motion sensor will still be monitoring flywheel motion. The compare circuit will continue to fault again, until the bad sensor is adjusted or replaced. The continued faults will be evident by the operator by having to constantly press the RESET button when entering the MANUAL SETUP Mode. Check and replace the bad flywheel motion sensor as soon as possible.

Flywheel Motion Compare Board ("A" and "B" versions)

        The Flywheel Motion Compare Board #550310A2A is required when using the "A" or "B" version Main Control Board. The part numbers for each version are as follows…

        The "A" version Main Control Board is part #550250A1A
        The "B" version Main Control Board is part #550250B1A
        The "C" version Main Control Board is part #550250C1A

        The flywheel motion sensors operation is the same as described in the previous section. The two flywheel motion sensors are wired to the compare board. The output of the compare board is wired to the "Flywheel Motion Switch Input" at 2TB 9 on the Main Control Board ("A" or "B" version). The compare board contains a "Bad Motion Switch" LED for fault indication.
        A space is provided in the System 2500 operator console (all versions) for the compare board mounting, above 2TB (top left). A "Flywheel Motion Sensor Kit" is available for upgrades with the "A" or "B" version Main Control Board. The kit (#2500FMSC) contains the following…
        (2) Banner Proximity Sensors #S18SN6FF50Q
        (2) Banner 15 foot cables #MQDC-415RA
        (2) Cord connectors for a ½ inch knockout hole #265295A1
        (1) Flywheel Motion Compare Board #550310A2A
        (1) Board mounting hardware
Flywheel Motion Compare Board
        See Drawing #B552200C1 for installation or replacement details.

Perimeter Guarding

        A normally open guard input is provided at 2TB 12 ("C" version) (2TB 11 on "A" or "B" version) on the Main Control Board for wiring a mechanical guard interlock switch or light curtain output contact. The input must close when the interlock and guard are closed, or when the light curtain is on and in the green state. 2TB 13 ("C" version) (2TB 12 on "A" or "B" version) or press ground can be used for the common side of the interlock switch or output contact. On pre-wired controls, the guard input is located on the terminal strip in the motor control cabinet (pre-wired to 2TB). A GUARD indicator light is provided on the console top panel, which monitors the guard input. The indicator light and guard input are only effective in the RUN machine mode. The GUARD indicator light will remain lit in both setup modes (the guard input bypassed) to provide access to the machine for setup purposes.
        The guard input is designed for perimeter type guarding around the machine area. A jumper (J1) is provided on the Main Control Board ("C" version) to bypass the guard input (when jumped), in the RUN machine mode, while the Cyclestop limit switch is closed (during the slide-out stroke). Jumper J1 should only be jumped for special requirements. Jumper J1 should not be jumped when using the guard input for standard perimeter guarding around the machine, to keep the guard active during the complete cycle.
        If no interlock signal is connected to 2TB 12 ("C" version), then 2TB 12 must be jumped to 2TB 13 (ground) to enable the RUN machine mode (the guard input terminal jumped to ground in the motor control cabinet). See Drawing #B552200D1 ("C" version) or Drawing #B552200C1 ("A" or "B" version) for connection details.

Feed Sensor Inputs Top

Feed Sensor Jack Inputs         Four feed sensor inputs are included in the System 2500 for die and stock monitoring. The four jack inputs are designed to utilize any type of normally open, hand-fabricated sensing device which touches machine ground to initiate the feed input or fault. The inputs are low-voltage, static current type to accept even un-insulated sensors safely. The feed sensor inputs are only effective in the RUN machine mode.
        The four sensor inputs are located at 2TB 2 through 2TB 5 on the Main Control Board (all versions). On pre-wired systems, the four inputs are pre-wired to jacks on the motor starter cabinet. Four plugs are included with the System 2500 for utilizing the jack inputs. Extra plugs (part #500704A4) can be purchased from Henry & Wright for quick changeovers or added equipment. Each sensor wire is connected to the center pin in its plug, then plugged into the corresponding jack input. The common of each feed sensor input can be either connected to machine ground or to the outside sleeve of its plug (ground). In certain cases, such as stock buckle, no ground connection is needed, because the metal stock is normally grounded and will activate a hand-fabricated bar type sensor when touched by the metal.
        Two of the sensor inputs are momentary type (if either one is activated, the machine will stop) and two are pulsed type inputs (each must receive a "sense" pulse each stroke or the machine will cyclestop). Each jack input (feed sensor) is used for a different function as described below...

        End of Stock input (at 2TB 2) will cyclestop the slides when this terminal (jack input) touches machine ground through the cyclestop (all-slides-out) position. The "End of Stock Fault" LED in the FAULT indicator panel on the Main Control Board and the FEED FAULT light on the operator console will light and remain lit when this fault occurs. Press the RESET button to clear the fault condition. This input (jack) is left open when not used.

        Stock Buckle input (at 2TB 3) will instantly stop the slides when this terminal (jack input) momentarily touches machine ground. The "Stock Buckle Fault" LED in the FAULT indicator panel on the Main Control Board and the FEED FAULT light on the operator console will light and remain lit when this fault occurs. Press the RESET button to clear the fault condition. This input (jack) is left open when not used.

        Feed Detector input (at 2TB 4) is a pulsed type input. When a plug is plugged into this jack input, the sensor MUST touch machine ground momentarily at least once each cycle, before the cyclestop (all-slides-out) position, to sense the feed advance system. If this input remains open or closed (no pulse) for a complete cycle, the slides will cyclestop, and the "Feed Detector Fault" LED in the FAULT indicator panel on the Main Control Board and the FEED FAULT light on the operator console will light and remain lit. Press the RESET button to clear the fault condition.
        If this input is NOT used, the input must be jumped out to cycle the machine in the RUN mode. 2TB 4 must be jumped to 2TB 7. On pre-wired packages (standard), the jack input on the motor control cabinet will automatically jumper out the input when the plug is unplugged from the Feed Detector jack (through the shunt terminal on the jack to 2TB 7). This will permit the machine to cycle.

        Part Ejection input (at 2TB 5) is a pulsed type input. When a plug is plugged into this jack input, the sensor MUST touch machine ground momentarily at least once each cycle, before the cyclestop (all-slides-out) position, to sense the part ejection system. If this input remains open or closed (no pulse) for a complete cycle, the slides will cyclestop, and the "Part Ejection Fault" LED in the FAULT indicator panel on the Main Control Board and the FEED FAULT light on the operator console will light and remain lit. Press the RESET button to clear the fault condition.
        If this input is NOT used, the input must be jumped out to cycle the machine in the RUN mode. 2TB 5 must be jumped to 2TB 7. On pre-wired packages (standard), the jack input on the motor control cabinet will automatically jumper out the input when the plug is unplugged from the Part Ejection jack (through the shunt terminal on the jack to 2TB 7). This will permit the machine to cycle.

        See Drawing #B552200D1 ("C" version) or Drawing #B552200C1 ("A" or "B" version) for connection details.

Auxiliary Stop Input

        A low-voltage auxiliary stop input is located at 2TB 1 on the Main Control Board. This input will instantly stop the slides in any machine mode at any time, when connected to machine ground (or any "Ground" terminal on 2TB). 2TB 1 can be used for an overload monitor output or other device that must instantly stop the slides under certain conditions. The Auxiliary Stop input is a low-voltage, static current input, that can be safely used with a hand-fabricated bar or sensor, if required. With a pre-wired System 2500, the Auxiliary Stop terminal is pre-wired to the motor starter cabinet I/O terminals. If not used, leave this terminal empty.
        See Drawing #B552200D1 ("C" version) or Drawing #B552200C1 ("A" or "B" version) for connection details.

Control Power Connections

        A control transformer is included with a pre-wired System 2500 to provide a single 220/440Vac power input. The control transformer provides the 110Vac necessary for the System 2500, motor control, and clutch/brake valve. The 110Vac is pre-wired to 1TB 5 and 1TB 6 on the Main Control Board. The only power required is the motor voltage 3-phase connection to the top of the disconnect switch in the motor starter cabinet. The motor also needs to be connected to the heater terminals at the bottom of the starter in the motor starter cabinet.

        WARNING! Make sure the primary windings on the control transformer (in the motor starter cabinet) are jumped for the correct incoming voltage BEFORE powering up. The control transformer primary and secondary fuses also need to be verified for correct size, per the voltage required. Also, verify the motor starter heaters for correct size.

        If the System 2500 is not pre-wired, a 3 amp, 110-125Vac source is required. Connect the hot lead (black wire) to 1TB 5, and connect the common lead (white wire) to 1TB 6. A ground lead (green wire) is also required from the System 2500 operator console to the grounded motor starter cabinet.

Installation is Complete!

Troubleshooting Top

        The System 2500 is designed primarily towards the ease of troubleshooting. Most of the time spent during a control repair is contained in troubleshooting. The 12 LED Status and Fault Indicator Panel along with the 5 front panel indicator lights can quickly trace the control or machine malfunction to a specific area. These indicators are the keys to troubleshooting the System 2500. The condition and sequence of these indicators will be discussed in this section.

Fault LED's

        NOTE: All Fault LED's must be off to cycle the press.

        Auxiliary Stop input LED #7 will light as long as the Auxiliary Stop input (2TB 1) is connected to machine ground (or any "Ground" terminal on 2TB). Check the auxiliary device connected to 2TB 1, or remove any wires to 2TB 1 to verify.

        End of Stock LED #8 will light and remain lit until reset, if the End of Stock input (2TB 2) is connected to press ground (or any "Ground" terminal on 2TB) through the cyclestop position in the RUN mode. See the Feed Sensor Inputs section in this manual.

        Stock Buckle LED #9 will light and remain lit until reset, if the Stock Buckle input (2TB 3) is momentarily connected to machine ground (or any "Ground" terminal on 2TB) in the RUN mode. See the Feed Sensor Inputs section in this manual.

        Feed Detector Fault LED #10 will light and remain lit until reset, if the Feed Detector input (2TB 4) does NOT pulse (touch machine ground, or any "Ground" terminal on 2TB) at least once each stroke in the RUN mode. 2TB 4 must be connected to 2TB 7 if NOT used, usually through the jack shunt connector. See the Feed Sensor Inputs section in this manual.

        Part Ejection Fault LED #11 will light and remain lit until reset, if the Part Ejection input (2TB 5) does NOT pulse (touch machine ground or any "Ground" terminal on 2TB) at least once each stroke in the RUN mode. 2TB 5 must be connected to 2TB 7 if NOT used, usually through the jack shunt connector. See the Feed Sensor Inputs section in this manual.

        Flywheel Not Stopped LED #12 is only effective in the MANUAL SETUP mode. This LED will light when the MANUAL SETUP mode is first selected, and remain lit until the motor and flywheel have come to a complete stop. The Flywheel Motion Sensor inputs at 2TB 9 and 2TB 10 ("C" version) monitor the flywheel rotation by pulsing (touching machine ground or any "Ground" terminal on 2TB) until the flywheel has stopped. The brake will not release until BOTH Flywheel Motion Sensor inputs stop pulsing. If the brake releases immediately when the MANUAL SETUP mode is selected, then both of the flywheel motion sensors are not working, misaligned, or not connected.
        When using the "A" or "B" version Main Control Board, the two Flywheel Motion Sensors should be connected to the "Flywheel Motion Compare Board", and the output of this board connected to 2TB 9. When no flywheel motion sensing is used with the "A" or "B" version Main Control Board, 2TB 9 must be grounded to release the brake in the MANUAL SETUP mode and LED #12 will remain lit in the MANUAL SETUP mode until 2TB 9 is grounded.
        See the Flywheel Motion Sensors section in this manual.

        Bad Flywheel Motion Sensor LED #13 ("C" version) is effective in all machine modes. This LED will light when the two Flywheel Motion Sensor inputs (2TB 9 and 2TB 10) do NOT work concurrently for more than 6 seconds. In other words, if one of the sensor inputs is pulsing (sensing flywheel motion) and the other sensor input is not, for more than 6 seconds, this LED will light and remain lit until reset. While this LED is lit, the brake will not release in the MANUAL SETUP mode, although, the compare circuit and LED will be active in all machine modes, for troubleshooting.
        When using the "A" or "B" version Main Control Board, the "Bad Motion Sensor" LED is located on the "Flywheel Motion Compare Board" (if installed).

Status LED's

        NOTE: All Status LED's are normally off. Each LED should light when its corresponding button is pressed.

        RUN #1 Button LED #1 will light when the RUN #1 button is pressed. Check the normally open switch contact, 1PL connector, and ribbon cable from the Door Interface Board.

        RUN #2 Button LED #2 will light when the RUN #2 button is pressed. Check the normally open switch contact, 1PL connector, and ribbon cable from the Door Interface Board. (A single RUN button system will operate both RUN buttons LED's together).

        Arming/Cyclestop Button LED #3 will light when the ARMING/CYCLESTOP button is pressed. Check the normally open switch contact, 1PL connector, and ribbon cable from the Door Interface Board.

        Emergency Stop Button LED #4 will light when the EMERGENCY STOP button is pressed. Check the normally closed switch contact, 1PL connector, and ribbon cable from the Door Interface Board for a loose or broken connection.

        Reset Button LED #5 will light when the RESET button is pressed. Check the normally closed switch contact, 1PL connector, and ribbon cable from the Door Interface Board for a loose or broken connection.

        Cyclestop Limit Switch LED #6 will light when the cyclestop limit switch closes during each cycle (while 2TB 7 is connected to machine ground, or any "Ground" terminal on 2TB). This LED will stay off if the cyclestop limit switch is not installed or disconnected. Check the normally open limit switch contact and wiring to 2TB 7.
If a Banner sensor is used for the cyclestop sensing, make sure the sensor's power wire is connected to +12Vdc and the sensor is adjusted properly. LED #6 will blink erratically (sometimes multiple times during each stroke) if the cyclestop limit switch sensor is misadjusted. See the Cyclestop Limit Switch section in this manual.

Front Panel Indicator Lights

        The five front panel indicator lights can help in locating a control or machine malfunction. Each of these indicators is described in this section. Understanding the normal operation and condition of each of these indicators will greatly increase your knowledge and troubleshooting ability of the System 2500.

        POWER ON indicator light monitors the +12Vdc power supply. The power supply is self-contained on the System 2500 Main Control Board. The power supply is supplied from the 110Vac input at 1TB 5 and 1TB 6, through fuse F2 on the Main Control Board.

        GUARD indicator light monitors the Guard input at 2TB 12 ("C" version) (or 2TB 11 "A" or "B" version) on the Main Control Board. The GUARD indicator light and Guard input are bypassed in both setup modes, and the indicator light will stay lit in either setup mode, regardless of the Guard input's condition.
        If jumper pins "J1" ("C" version) are jumped, the Guard input and GUARD indicator light will also be bypassed while the cyclestop limit switch is closed. The GUARD indicator light will stay lit while the cyclestop limit switch is closed, regardless of the Guard input's condition. Adjust the cyclestop limit switch so that the limit switch is only closed during the slide-out portion of the cycle. See the "Cyclestop Limit Switch" section, or remove jumper "J1" to enable the Guard input.
        If no guard is installed (it is recommended to guard the entire press perimeter), then 2TB 12 ("C" version) (or 2TB 11 "A" or "B" version) must be jumped to machine ground, or any ground terminal on 2TB, for the machine to cycle in the RUN mode.

        MOTOR ON indicator light must be lit to cycle the press in the RUN mode. If the motor cannot be started in the INCH or RUN modes, check Fuse F1 on the Main Control Board. Also check the Motor Control relay REL 2 on the Main Control Board to make sure it is plugged into it's socket and energized. If the motor starts, but the MOTOR ON indicator light does not light, check to make sure the Motor On relay REL 1 on the Main Control Board is plugged into it's socket and energized. The coil of REL 1 (at 1TB 3 and 1TB 4) should be wired directly across the motor (forward) starter 110Vac coil.

        CLUTCH ENGAGED indicator light will light whenever the clutch/brake output (1TB 7) is on. If the indicator light lights but the clutch does not engage, there may be a valve or mechanical problem. Note that the indicator light does not light in the MANUAL SETUP mode when the clutch/brake output is turned on to release the brake. This is because the motor and flywheel are completely stopped and cannot be started in the MANUAL SETUP mode, so there is no slide motion.

        FEED FAULT indicator light will light when there is one of four feed faults in the RUN mode. The FEED FAULT light monitors the feed sensor inputs at 2TB 2 through 2TB 5 on the Main Control Board. If any feed fault occurs, this indicator light will light and remain lit until reset by pressing the RESET button. All feed monitor circuits are bypassed in both setup modes. The machine will not cycle while the FEED FAULT indicator light is lit. See the Feed Sensor Inputs section in this manual for details on each of the feed sensor inputs.
        NOTE: The "Feed Detector" and "Part Ejection" sensor inputs must be jumped to 2TB 7 if not used. On pre-wired systems, these two sensor input "shunt" terminals on their jacks are wired to 2TB 7, so the sensor inputs will be automatically bypassed when the plug is unplugged from it's jack. Check the jack for an internal bad connection between the shunt and the center pin - replace the jack.

Quick-Disconnect Terminal Blocks

        1TB and 2TB on the Main Control Board are quick-disconnect type terminal blocks which can be pulled straight out from their sockets without removing any connected wires. The Main Control Board can be removed quickly and easily for servicing or replacement. The wires will remain connected to their appropriate terminals to eliminate confusion of marking or retracing each wire.
        1RC ribbon cable needs to be unplugged also, to remove the Main Control Board. Care should be taken when unplugging this connector. The pins on the connector can bend or brake off, if too much side motion is exerted while unplugging or inserting 1RC. To remove the connector, move the rubber strap to one side, and gently and slightly rock the connector vertically while pulling away from the Main Control Board. You can also insert a small screwdriver between the connector and socket (at the top and bottom) to pry the connector out evenly. When inserting the connector, make sure to line up the pins with the socket. The connector can be inserted one row off, which will not allow any operation.

Circuit Board Part Numbers Top

550250C1A Main Control Board ("C" version)
550250B1A Main Control Board ("B" version)
550250A1A Main Control Board ("A" version)
550260A1A Door Interface Board
550270A1A Electromagnetic 24Vdc Power Supply and Driver Board
550280A1A Separate Clutch Output Board (110Vac pneumatic)
550300A1A Auxiliary Indicator Light Output Board
550310A2A Flywheel Motion Compare Board ("A" or "B" versions)

Drawing Part Numbers Top

B552100B1 1TB (110Vac) Interconnection Drawing (standard)
B552100B2 1TB (110Vac) Interconnection Drawing (vary-drive)
B552200D1 2TB (12Vdc) Interconnection Drawing ("C" version)
B552200C1 2TB (12Vdc) Interconnection Drawing ("B" or "A" version)
B552300A3 Auxiliary INCH/SINGLE JOG Button connections
B552300B1 Door Interface Board 1PL connections (pre-wired)
B552600B2 System 1500 Air Null Pressure Circuit Interface

Replacement Parts Top

262651A1 Indicator light bulb, 14V, #1813
500012A1 F2 - Slow-blow fuse, ¼ amp
500109A1 REL 2 - Motor Control Relay (12Vdc coil)
500245A2 REL 1 - Motor Forward Relay (110Vac coil)
501201A3 F1 - Slow-blow fuse, 3 amp
501774A2 Indicator light cover, amber
501774A3 Indicator light cover, green
501774A4 Indicator light cover, red
800T-N246G Button cap, green mushroom
800T-N246Y Button cap, yellow mushroom
800T-N247R Button cap, jumbo, red mushroom
800T-XAR Contact block, logic reed, NO/NC
800T-XD1R Contact block, logic reed, NO
800T-XD2R Contact block, logic reed, NC
S18SN6FF50Q Banner proximity switch
MQDC-415RA Banner proximity switch cable

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

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