Model EBM-100A
Add-on Brake and Motion Monitor
Designed in
MINIMUM SAFE DISTANCE
Operating Format
For Partial Revolution presses
Installation and Operating Manual

Revised: May 14, 2003

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Introduction Minimum Safe Distance Mounting
System Description Counterbalance Adj. Using the EBM-100A
EBM-100A Features Maintenance
Optional Features Detailed Monitor Description of Operation
Specifications Determining Press Stop Time
Installation Instructions Determining Press Stop Distance
Pulse Generator Shaft Tightness Quick-check Replacement Parts

Introduction Top

        This Manual is for the H&W Controls solid state Brake/Motion Monitor Model EBM-100A, for use with partial revolution power presses. When properly installed and operated, the monitor complies with OSHA regulation 1910.217 (b) (13), requiring partial revolution power press controls to meet fail-safe requirements, and (b) (14) monitoring of brake performance on each press stroke.
        Your overall safety can be insured by thoughtful operation on your part. Observe all the caution and warning precautions in this manual, and labels on the equipment.
        H&W control systems are engineered and manufactured in our plant in Cleveland, Ohio. They have been designed for highly reliable operation and long life, specifically to insure high productivity while meeting safety requirements of the Department of Labor.
        The EBM-100A must be used with a press safety control system. The three solid state outputs in the EBM-100A can be easily interfaced to an existing press control. H&W Controls can provide you with a new press safety control system, if required, such as the System 4000.

CAUTION: Before operating or servicing the EBM-100A, read and study this manual carefully for correct procedures.

System Description Top

Standard System – Components:

  1. Control cabinet (10" x 12" x 6 ¼" deep) Model EBM-100A
  2. Rotary Pulse Generator (with 15' cable) #550750B2
  3. Shock mounts (4) for press mounting #262771B2
  4. Double-bit key (for locking control cabinet) #SZ2531.000

        The EBM-100A Brake/Motion Monitor is designed for rugged industrial use. It is of solid state design incorporating CMOS logic elements. Inputs, outputs, and power supply are well protected from power transients, electromagnetic interference, and voltage fluctuations. The design is tailored to OSHA control reliability requirements, as stated in 1910.217 (b) (13). This requirement is met by incorporating dual channels and/or by use of cross-checking circuitry.
The unique design of the EBM-100A is it's ability to directly convert the press stopping time to MINIMUM SAFE DISTANCE and display the conversion on the front panel display (in tenths of an inch increments). The MINIMUM SAFE DISTANCE (MSD) conversion is also compared with the "MINIMUM SAFE DISTANCE HIGH LIMIT" setting inside the control enclosure. This user-friendly setting permits an instant indication of the press operator station/s and light curtain mounting safety distance requirement.
        The EBM-100A actually monitors the MSD (stopping time) at EVERY clutch disengagement during the press cycle. The MSD reading is automatically calculated per OSHA specifications (stopping time x 63). A factor of one inch (.016 sec.) is automatically added to the MSD conversion to compensate for the clutch valve coil release time. (For ease of installation, the clutch disengage signal is simply taken from the existing control system clutch valve 115Vac. output. The valve coil solenoid produces a back-rush current at disengagement which can delay the disengage signal .016 seconds.)
        The EBM-100A also includes a full 360-degree motion monitoring system used for checking the pulse generator for proper operation. The motion monitor will also shut off the press if the ram suddenly stops during the stroke, to eliminate a die jam-up, broken belts, etc.

Features – EBM-100A Brake/Motion Monitor Top

  1. Monitors press stopping time to check if:
        1. Poor brake performance is causing an increase in stopping time.
        2. Clutch valve is mechanically slow increasing stopping time.
        3. Clogged or dirty exhaust muffler increasing stopping time.
  2. Monitors the MINIMUM SAFE DISTANCE (stopping time) at every clutch disengagement and displays the reading on the front panel.
  3. Warns of an increase in MINIMUM SAFE DISTANCE (stopping time) before the MSD increases to the point of shutting down the press.
  4. Auto-test at power-up tests the brake monitoring circuitry, fault indicators, and outputs, automatically to ensure proper operation. The monitor must be reset manually before the press can be started.
  5. A tamper-proof locking enclosure houses the "MINIMUM SAFE DISTANCE HIGH LIMIT" thumbwheel switches, which provide an instant indication of the press operator station/s and light curtain mounting safe distances to the nearest die pinch-point.
  6. Prevents the "MINIMUM SAFE DISTANCE HIGH LIMIT" setting from being set too high. The high limit setting must be set within 6.3 inches (100 milliseconds) of the actual press stopping time. A "MSD Limit Too High" LED indicator is included for easy troubleshooting.
  7. A TEST button is included to manually test the monitor as follows:
        1. Pressing the TEST button while the clutch is engaged, will test the motion circuitry, fault indicators, and outputs for proper operation. The MSD display readout on the front panel records the MSD.
        2. Pressing the TEST button while the clutch is off, will test the brake circuitry, fault indicators, MSD display, and outputs for proper operation. The front panel MSD display should read "63.0".
  8. A front panel CLUTCH ENGAGED indicator light is included for a safer indication of when the press is cycling.
  9. Dual front panel FAULT indicator lights are included to indicate operation of each circuit channel.
  10. Monitors press motion to check if:
        1. Clutch is slipping or sluggish. The clutch engage time allowed is one second/350 ms. (selectable via "CLUTCH TIME SELECT" switch).
        2. Breakage of press rotary limit switch drive chain or linkage.
        3. A die jam-up occurs at any point during the stroke to the point of slowing down slide (ram) motion to .75 spm /4.5 spm (selectable via "MOTION TIME SELECT" switch).
  11. Full 9 LED Status and Fault indicator panel included inside the enclosure to monitor all inputs and outputs at a glance. Any type of fault is clearly indicated.
  12. Three (3) solid-state control outputs (field replaceable) for fast response times. All three outputs rated at 3 amps maximum at 120Vac each. Two normally open contacts and one normally closed contact. The N.C. contact opens when there is power to the monitor, and BOTH channels are reset, which can be used for an external fault light. Other input/output voltages available upon request at time of purchase. All three output modules are fused for safety.
  13. 120Vac power input. (240Vac power input available upon request.)
  14. Simple installation. The two I/O terminal blocks are labeled for exactly each terminal connection location. A typical installation is done in less than 4 hours.
  15. A motion bypass feature is built in (not easily accessible to the installer for safety reasons) for certain special requirements in the inch/setup press mode. Contact H&W Controls for more information.
  16. Will accept a wide range of press speeds from 5 spm to 350 spm.
  17. Will accept press stopping times up to 1.5 seconds (99.9 inches). (A manual TEST with the clutch off requires the "MINIMUM SAFE DISTANCE HIGH LIMIT" switch setting to be set below 63.0 inches.)
  18. Can be used to accurately adjust the press slide (ram) counterbalance.

Optional Features – EBM-100A Top

  1. "90-Degree TEST" option board #574300A1A. Can be installed at a later date in the field. Selectable "Standard TEST" or "90-degree TEST" modes. Useful features in the "90-Degree TEST" mode...
        1. One person can easily manually TEST the EBM-100A on a fast speed press while the clutch is engaged (to test the motion circuitry). Pressing the TEST button while the clutch is OFF initializes a five-second timer. If the press is cycled during this timeout period, the EBM-100A will automatically "TEST" itself at the next 90-degree crankshaft position.
        2. If the TEST button is pressed with the clutch OFF and the press is NOT cycled within five seconds, the EBM-100A will automatically "TEST" itself (to test the brake circuitry). The MSD front panel display should read "63.0".
        3. If the TEST button is pressed while the clutch is engaged, the EBM-100A will automatically "TEST" itself at the next 90-degree crankshaft position. The press can be cycling in any press mode.
        4. If the TEST button was previously pushed and the press cycled within the timeout period, but the press is stopped for some reason before the next 90-degree position, the "90-degree TEST" will remain in memory until the press is recycled and the 90-degree position is reached, or until reset by pressing the RESET button.
        5. The press is automatically shut off at the 90-degree crankshaft position when "tested" with the "90-Degree TEST" feature, to display the actual MINIMUM SAFE DISTANCE at the most hazardous part of the press cycle per OSHA regulations in 1910.217.
        6. A "90 Degree TEST Active" LED indicator is included on the PC board to indicate the five second timeout period and "90-Degree TEST" memory.

    One of options 2, 3, or 4 may be included in the standard enclosure...

  2. Front panel "STOP TIME Readout" option #554700A2A. The actual press stopping time can be easily figured (in seconds) by dividing the MSD value by 63. This option, however, can be installed at H&W Controls to concurrently display the stopping time and MINIMUM SAFE DISTANCE.
  3. Front panel "CLUTCH ENGAGED TIME Readout" option #554700A3A. The actual press clutch engaged time (from the clutch engaged signal until movement of the slide) is displayed at every clutch engagement.
  4. Front panel "CRANK POSITION Readout" option #554800A1A. The actual press slide (ram) position is displayed in degrees (0 –360). A direction indicator is also included (Fwd/Rev). Accuracy is within 2 degrees when cycling in one direction and 4 degrees when the crankshaft is reversed within the same stroke. A solid state "Forward/Reverse" direction output is also included for special requirements.
  5. A remote readout of the MINIMUM SAFE DISTANCE is possible (up to 250 feet away) by purchasing a second Door Interface Board #574100A1A (enclosure and bezel optional) and a 16 conductor shielded cable assembly.

NOTE: Options 1 and 4 require critical positioning of the Pulse Generator shaft at top-dead-center during installation.

Specifications: Top

Power Requirements: 6 watts @ 120Vac, 1 phase, 60 Hz
102 – 129Vac input voltage range
Temperature: -17 degrees centigrade minimum
40 degrees centigrade maximum
Relative humidity: 80% maximum
Minimum press speed (spm): 2 minimum / 20 minimum (selectable)
Maximum press speed (spm): 350
Maximum clutch engaged time: 1 second / 350 milliseconds (selectable)
Output contact ratings (each): Solid state (field replaceable)
3 amps maximum @ 120Vac
12 – 129Vac voltage range
20 ma minimum load current
80 amps peak 1-cycle surge
Maximum MSD (stopping time): 99.9 inches* (1.58 seconds)
* The MSD HIGH LIMIT switch setting must be less than "63.0" to manually TEST the EBM-100A
"MSD HIGH LIMIT" setting range: Actual press MSD plus 6.2 inches maximum
"STOP TIME" display (optional): 0 – 999 milliseconds
"CLUTCH TIME" display (optional): 0 – 999 milliseconds
"CRANK POSITION" display (optional): 0 – 360 degrees
+/- 2 degrees non-reversing
+/- 4 degrees reversing within same stroke
Pulse Generator shaft diameter: .750 inches
Pulse Generator shaft length: 1.75 inches
Pulse Generator cable length: 15 feet (standard)
Shipping weight: 24 lbs.

Installation Instructions Top

The EBM100A installation consists of four (4) steps...

  1. Mounting the Pulse Generator.
  2. Mounting the EBM-100A control box.
  3. Install wiring...
        1. From Pulse Generator to EBM-100A control box.
        2. From the EBM-100A control box to the press control.
        3. From the EBM-100A control box to the 120Vac power source.
  4. Calibrate the EBM-100A internal switches to press characteristics.

Proceed as follows:

Mount the Pulse Generator.

        The Pulse Generator must be direct coupled to the press crankshaft at a 1:1 ratio. It is recommended that the Pulse Generator be driven from the existing rotary limit switch shaft.

        CAUTION: When installing a coupling or sprocket on the Pulse Generator shaft, DO NOT hammer onto shaft. Photo-optics inside the Pulse Generator may be damaged!

        If the "90-Degree TEST" and/or the "CRANK POSITION Readout" options are installed in the EBM-100A, the rotation position of the Pulse Generator shaft is important. As described on the side of the Pulse Generator Assembly #550750B2, the shaft keyway must be at exactly the 12:00 position (in reference to the top of the Pulse Generator) with the press slide (ram) at top-dead-center.
        If the "90-Degree TEST" and/or the "CRANK POSITION Readout" options are NOT installed in the EBM-100A, the rotation position of the Pulse Generator shaft is irrelevant. Without these options, the EBM-100A will operate equally as well using the H&W Controls Pulse Generator #550750A2, which is used with some H&W press safety control systems. The H&W Controls Pulse Generator #550750B2 can be used to replace the "A2" version on these controls.
        Care should be exercised in aligning the Pulse Generator and existing rotary limit switch shafts. Run-out must be compatible with the shaft coupling. Misalignment can damage the generator bearings.
        An alternate method for driving the Pulse Generator is by using a single chain coupled to the existing press rotary limit switch and press crankshaft. In this method, a "Clutch/Motion Fault" will be generated in the event of chain breakage.
Regardless of the drive method chosen, be sure that all fasteners are locked down. See that the Pulse Generator drive chain slack is minimal. Long chains and chains which vary in tightness should be fitted with idlers to take up excess motion.

        CAUTION: Do not under any circumstances mount the Pulse Generator such that its bearings must take an axial load. The bearings are not designed to take end thrust. The Pulse Generator warranty is specifically voided if evidence of axial loading is noted on any returned units.

Pulse Generator Shaft Tightness Quick-Check Top

        Occasional brake faults may occur if the Pulse Generator chain or coupling is too loose or sloppy. A quick check can be made to check the linkage for correct tightness. This check can be done after installation is complete, and the control power is turned on. The motor and flywheel must be stopped.

        BE EXTRA CAREFUL DURING THE CHECK PROCEDURE. THE PROCEDURE REQUIRES THE CONTROL POWER TO BE ON.

        Press the RESET button on the EBM-100A to clear the "Auto-TEST" at power-up. Place your hand on the Pulse Generator shaft and forcibly try to turn the shaft in both directions. The MINIMUM SAFE DISTANCE front panel display should remain at "00.0" inches. If the display advances, the shaft linkage is too loose or sloppy. This check should be done at different parts of the stroke to verify that the linkage (chain sprocket) is not mounted off center on the crankshaft.

Mount the EBM-100A control box.

        Position the control enclosure on the press so that it's FAULT lights and pushbuttons are readily accessible to the pressroom personnel. The standard Pulse Generator cable is 15 feet long but may be extended to 50 feet maximum. Plan the installation so that the Pulse Generator to control box distance does not exceed 15 (50) feet.
        Be sure to use the supplied shock mounts (4) when mounting the EBM-100A control box directly to the press. THE WARRANTY IS VOIDED IF THE CONTROL BOX IS MOUNTED TO THE PRESS WITHOUT THE SUPPLIED SHOCK MOUNTS.
        The control box contains 4 plugged mounting holes on the back of the unit. The control box must be opened to provide access to the mounting holes. Use caution when installing and tightening the nuts and washers on the shock mount studs, so as to not damage the PC board and components. We recommend using a 7/16" deep-well socket with at least a 6-inch extension.
        The shock mounts have a ¼ - 20-threaded stud at both ends for threading directly into a tapped hole in the press. The EBM-100A control box can be slipped over the 4 protruding studs on the shock mounts after hand-tightened in the press holes, and then fastened with a lock washer and nut provided.

Install wiring.

        The Pulse Generator 5 conductor shielded cable must be run in its own conduit if conduit is used. If it becomes necessary to add cable to that supplied with the Pulse Generator, use Consolidated #140356 22 AWG or #2464. Be sure, when splicing in the added length, to connect the shields. Total cable length must not exceed 50 feet.
        Feed the end of the Pulse Generator cable through the cord connector located on the bottom of the EBM-100A control box. Connect the individual leads to 2TB 1 through 5 as shown in the chart below and in the installation drawing #B574500A1.

Pulse Generator Connections to 2TB

Pulse Generator terminal Wire Color EBM-100A
TB 1 Black 2TB 1
TB 2 White 2TB 2
No Connection Shield 2TB 2
TB 3 Red 2TB 3
TB 4 Green 2TB 4
TB 5 Blue 2TB 5

        Run ½ inch conduit from the existing press control to the EBM-100A control box at the hole provided on the bottom. Pull nine (9) #16 AWG wires through the conduit for use as described below (only 7 wires are required if connecting to a single-channel stop circuit).

Quantity Size Color Wire Use
1 #16 Green Cabinet ground
1 #16 Black 120Vac power hot
1 #16 White 120Vac power common
2 #16 Red Clutch Engaged signal
2 #16 Red Channels 1 & 2 output
2* #16 Red CH 2 output (if separate)
2* #16 Red Output #3 N.C. (optional)
* These wires may not be required depending on requirements.

        Connect two of the red wires to both sides of one of the existing clutch valve coils (120Vac) and connect the other ends to the EBM-100A "Clutch Engaged" input at 1TB 3 and 1TB 4. If a "Clutch Engaged" relay is found in the existing press control (with a 120Vac coil) that relay coil may be used instead of one of the clutch valve coils. 120Vac is required between 1TB 3 and 1TB 4 whenever the clutch is engaged. See Drawing #B574500A1.

        Connect two of the red wires in series with the EMERGENCY STOP circuit in the existing press control. This circuit is usually located in series with the main and counterbalance air pressure switches and Emergency Stop button. Connect the other end of both wires to the EBM-100A control box at 1TB 5 and 1TB 8. A jumper wire is also required between 1TB 6 and 1TB 7. See Drawing #B574500A1.
        If a two channel EMERGENCY STOP circuit is available in the existing press control, break both channel EMERGENCY STOP circuits and reconnect both broke circuits to 1TB 5/6 and 1TB 7/8 respectively. Under normal operating conditions, both channel outputs in the EBM-100A operate concurrently to interrupt both EMERGENCY STOP circuits in the existing press control. Both channel outputs are closed while power is on and a no-fault condition.

        A third normally closed output is available at 1TB 9 and 1TB 10 for optional connections (12V - 129Vac) such as a remote FAULT indicator light, etc. This output is closed during power-down and if either channel faults. The output is open under normal operating conditions.

        Connect the green wire to the cabinet ground stud at both ends. Connect the black wire to 120Vac hot in the existing press control for supply power to the EBM-100A. Connect the other end of the black wire to 1TB 1 in the EBM-100A. Connect the white wire to 120Vac common in the existing press control. Connect the other end of the white wire to 1TB 2 in the EBM-100A.

        The EBM-100A is now installed and can be powered up. BEFORE TURNING ON POWER, verify proper voltages to 1TB 1 and 1TB 2. The complete 1TB terminal block can be unplugged from its socket prior to turning on power to verify the correct voltages without damaging the EBM-100A. Turn the power back off before inserting the 1TB terminal block back in its socket.

Monitor Calibration

Before proceeding with monitor calibration...

  1. Set the heaviest die to be used in the press.
  2. Set the main and counterbalance air pressures.
  3. If the press has an adjustable speed drive, set the speed to maximum used in production.

        Turn on the control power. The EBM-100A should "Auto-TEST" at power-up and the front panel display should read "63.0". At this point, the press should be un-operational. Press the RESET button to clear the "Auto-TEST".
        Cycle the press one stroke. View the MINIMUM SAFE DISTANCE display reading on the front panel, and add 3.1 inches to the value. Enter the added value in the MINIMUM SAFE DISTANCE HIGH LIMIT switch setting on the Main Control Board in the EBM-100A. This will put the MINIMUM SAFE DISTANCE HIGH LIMIT switch setting to its midrange position. Cycle the press a few more times to check the setting. The EBM-100A uses a "window area" that the MSD HIGH LIMIT switch setting must be set in. This "window area" is between the actual MSD reading on the EBM-100A front panel, and this reading plus 6.3 inches (100 milliseconds). Adding 3.1 inches to the actual MSD readout adds a 50-millisecond margin before a fault will occur.
        If a MSD HIGH LIMIT switch setting is detected that is higher than the "window area", the EBM-100A will produce an output fault and turn on LED 5 on the Main Control Board ("MSD Limit Too High"). If a MSD HIGH LIMIT switch setting is detected that is lower than the "window area", the EBM-100A will produce an output fault and turn on LED's 8 and 9 on the Main Control Board (BRAKE FAULT 1 and 2). A warning is sent to both front panel FAULT lights if the actual press MSD equals the MSD HIGH LIMIT switch setting (both FAULT lights will blink on and off until the next disengagement or until reset).

        Set the CLUTCH TIME SELECT switch on the Main Control Board to the right position (350 ms) and the MOTION TIME SELECT switch to the correct position (to the left for UNDER 20 SPM and to the right for OVER 20 SPM). Cycle the press. If a CLUTCH/MOTION FAULT is detected (LED's 6 and 7 come on), set the CLUTCH TIME SELECT switch to the left position (1 SECOND) and recycle the press.
        At this time there should be no faults occurring from the EBM-100A while cycling the press. BEFORE PUTTING THE PRESS INTO PRODUCTION, verify the correct MINIMUM SAFE DISTANCE covered in the next section.

        On presses with variable speeds or extreme differences between die weights; if a BRAKE FAULT occurs with a different type setup, the MINIMUM SAFE DISTANCE HIGH LIMIT switch setting may need to be decreased to cover the entire range of variations. Be sure not to add more than 6.2 inches to the actual MSD readout when entering the value into the setting. Also, the switch setting must be set higher than the actual MSD readout on the front panel.

Minimum Safe Distance Mounting Top

        OSHA regulation 1910.217 requires the placement of 2-hand control and presence-sensing devices at a distance from the point of operation, such that an operator cannot reach the point of operation before the press slide (ram) comes to a complete stop.

        The placement of all 2-hand controls (operator stations) and presence-sensing devices (light curtains) must be mounted outside the distance set in the "MINIMUM SAFE DISTANCE HIGH LIMIT" thumbwheel switch setting (not the actual MSD display readout). This ensures a safe operation since the EBM-100A will create a BRAKE FAULT before an unsafe stopping time (minimum safe distance) is reached.
        Verify and, if necessary, reposition all operator stations and light curtains to measure a distance from the nearest die pinch point GREATER than the distance in the "MINIMUM SAFE DISTANCE HIGH LIMIT" switch setting on the Main Control Board.
        The front panel MINIMUM SAFE DISTANCE display readout can be used as an indication of when the actual MSD is approaching its limit.

Counterbalance Adjustment Using the EBM-100A Top

        Because the EBM-100A displays the MINIMUM SAFE DISTANCE at EVERY clutch disengagement, it is possible to use the MSD display readout to accurately adjust the slide (ram) counterbalance air pressure setting.
        Cycle the press in the INCH/SETUP press mode to stop the slide (ram) at the 90-degree (half way down) and 270-degree (half way up) positions. Record both MSD display readings. Both display readings should be close to the same. Adjust the counterbalance air pressure and continue cycling the press to these positions until both readings are close to the same.

THE PRESS SHOULD NOW BE READY FOR PRODUCTION RUNNING.

Maintenance Top

        The following section is a list of maintenance checks to be made on a regular basis. When a problem is recognized, the problem should be corrected by either local maintenance personnel or, if the problem is in the EBM-100A, repaired at H&W Controls before further operation of the press is permitted.

CHECKOUT TEST PROCEDURE

        Auto-TEST at power-up. The MSD (and STOP TIME or CLUTCH ENGAGED TIME if included) display/s should count up to 63.0 and both channel FAULT lamps must light. Attempt to start the press. It must NOT start. Push the RESET button to clear the fault.

AT THE BEGINNING OF EACH SHIFT verify proper Brake/Motion Monitor operation by performing the following tests…

Clutch Disengaged (Testing BRAKE circuitry):

  1. Push the RESET button. The MSD display (and STOP TIME or CLUTCH ENGAGED TIME display if included) must reset to "000" and both channel FAULT lamps must light and then go out when the RESET button is released.
  2. Push the TEST button. The MSD display (and STOP TIME or CLUTCH ENGAGED TIME display if included) must read "63.0" and both channel FAULT lamps must light and stay lit. Attempt to start the press – it must NOT start.
  3. If the "90-degree TEST" option is installed, and the "90-degree TEST" switch position is selected, the EBM-100A will not TEST until after the five second timeout period.

Clutch Engaged (Testing MOTION circuitry):

  1. Push the TEST button. The press must stop and both channel FAULT lamps must light and stay lit. The MSD display (and STOP TIME display if included) count the actual press MSD (if the CLUTCH ENGAGED TIME display is installed, disregard its reading during this test procedure).
  2. the "90-degree TEST" option is installed and the "90-degree TEST" switch position is selected, the press will stop at the next 90-degree slide (ram) position. The display/s and FAULT lights should record as above.
If the EBM-100A does not perform as indicated, DO NOT operate the press until repair is performed.

Removing/Installing the PC Boards

        If it becomes necessary to remove a PC board for repair, do NOT disconnect any wires from their terminals. All the terminal blocks inside the EBM-100A are quick-disconnect type and can be removed simply by pulling the terminal block connector straight out from its header.
        The Main Control Board also contains a 26-conductor ribbon cable, which must be unplugged from its connector before removing the board.
        The STOP TIME or CLUTCH ENGAGED TIME option boards are plugged in via a 16 conductor ribbon cable only. The ribbon cable is plugged into the STOP TIME READOUT connector (2RS) on the Door Interface Board. Use caution when removing/inserting the connector. The pins can easily bend or break off. The connector is removed by sliding the rubber clamp over to the side, and pulling the connector straight out from the plug while rocking SLIGHTLY from side to side.
        DO NOT ATTEMPT TO REMOVE OR INSTALL ANY PC BOARDS WITH THE POWER ON!

Detailed Monitor Description of Operation Top

        The H&W Controls Model EBM-100A Brake/Motion Monitor is an add-on type control for partial revolution presses with an existing clutch/brake control system (such as the H&W System 4000 Stamping Press Control with a built-in brake/motion monitor). The EBM-100A continuously monitors press motion during clutch engagement and after clutch disengagement (as long as power is supplied to the control). Any press motion detected while the clutch is disengaged is converted directly to MINIMUM SAFE DISTANCE automatically (using the formula described in OSHA regulations 1910.217). The converted value is then displayed on the EBM-100A front panel, and is compared with the setting in the MINIMUM SAFE DISTANCE HIGH LIMIT thumbwheel switches on the Main Control Board. If the value (distance) exceeds the setting in the thumbwheel switches, the EBM-100A will BRAKE FAULT. Any type of fault generated in the EBM-100A will turn off all three outputs (OPEN outputs 1 and 2, and CLOSE output 3), turn on both front panel FAULT lights, and turn on the corresponding LEDs on the Main Control Board.
        While the clutch is engaged, the EBM-100A monitors press slide (ram) motion to check for correct operation of the Pulse Generator (and existing RLS) and to shut off the press if the slide (ram) suddenly stalls during the stroke. A CLUTCH ENGAGED indicator light on the front panel is provided as an added safety precaution.
        A circuit is included to prevent the MINIMUM SAFE DISTANCE HIGH LIMIT thumbwheel switches from being set too high (which would override the operation of the brake monitor). The switches must be set in a "window" set by the actual press MSD (display reading) and that distance plus 6.3 inches. This "window" of 6.3 inches equals a stop time of 100 milliseconds.
        The front panel FAULT lights (Channel 1 and Channel 2) indicate three different conditions as described on the front label. Under normal conditions, both lights will flash on momentarily, at each clutch disengagement until slide motion stops. This provides an indication of the brake monitor functioning. Both FAULT lights will blink on and off continuously after a clutch disengagement if the MINIMUM SAFE DISTANCE display reading equals the MINIMUM SAFE DISTANCE HIGH LIMIT switch setting on the Main Control Board. This indicates that a BRAKE FAULT is close to occurring. (This function can be verified by simply setting the thumbwheel switches the same as the current value in the front panel MSD display readout.) Both FAULT lights will lock on when either a BRAKE FAULT or a MOTION FAULT occurs, or when the RESET button is held in (this prevents the RESET button from being jumpered out).
        Four green LEDs are included on the Main Control Board to monitor the Pulse Generator signals (LEDs 1 and 2), the RESET button (LED 3), and the TEST button (LED 4). LEDs are also included inside the Pulse Generator Assembly to monitor each of its three outputs for troubleshooting. These LEDs are accessed by removing the pulse generator top cover (the Pulse Generator top cover can also be removed to remove the Pulse Generator PC board for servicing, without having to disconnect the entire Pulse Generator mounting and linkage). Five other red LEDs are included on the Main Control Board to indicate the MINIMUM SAFE DISTANCE HIGH LIMIT switch setting too high (LED 5), CLUTCH/MOTION FAULT channels 1 and 2 (LED's 6 and 7), and BRAKE FAULT channels 1 and 2 (LED's 8 and 9). LED's 8 and 9 also come on if the RESET button is held in or disconnected.
        The monitoring circuitry is dual crystal controlled for accuracy and reliability. Two LEDs are included on the front panel (in the MSD display) for indicating a TEST READING and MSD LIMIT EXCEEDED (over 99.9 inches). The MINIMUM SAFE DISTANCE display reading is rounded off to the nearest tenth of an inch.

        It is imperative that all press operator stations and light curtains protecting the perimeter of the press be mounted outside the distance set in the MINIMUM SAFE DISTANCE HIGH LIMIT thumbwheel switches. The front panel MINIMUM SAFE DISTANCE display readout is only a reference of the "current" minimum safe distance.

Determining Press Stop Time from the MINIMUM SAFE DISTANCE Top

        If the STOP TIME display readout (optional) is not included in your EBM-100A, the press stop time (in seconds) can be easily figured using the MINIMUM SAFE DISTANCE display readout. Simply divide the actual minimum safe distance (MSD display readout) by "63*".

FORMULA:

        Press MSD 4 63 = Press STOP TIME

EXAMPLE:

        12.2 inches (actual press MSD) 4 63 = .193 seconds STOP TIME

* The value 63 is derived from OSHA in regulation 1910.217.

Determining Stop Distance (Angle) from the Press STOP TIME Top

        The STOP TIME can be used to determine the angle the crankshaft travels in stopping. The stopping angle can be calculated from the following formula... (RPM is the crankshaft speed, and K is a factor supplied by the clutch/brake manufacturer reflecting variations in friction of the linings accounting for the non-linearity of the braking action. 1.5 appears as a good average.)

FORMULA:

        3 4 K x RPM x STOP TIME (seconds) = Stopping Distance (degrees)

EXAMPLE:

        (If K = 1.5, RPM = 60, STOP TIME = 300 milliseconds)

        [3 4 1.5 = 2] x 60 x .300 = 36 degrees Stop Distance

EBM-100A Replacement Parts Top

EBM100A Brake/Motion Monitor (Including key and 4 shock mounts)
550750B2 Pulse Generator Assembly ("B" version) with 15 foot cable
550700B2A Pulse Generator PC Board Assembly ("B" version) (field replaceable)
574100A1A EBM-100A Main Control Board Assembly
574200A1A EBM-100A Door Interface/Display Board Assembly
501201A1 ¼ amp slow-blow fuse (F1)
500248A1 AC input module, 90 – 140Vac, (MOD 1) #G4IAC15
500249A1 AC output module, N.O., 12 – 129Vac, (MOD 2/3) #G4OAC5
500250A1 AC output module, N.C., 24 – 280Vac, (MOD 4) #G4OAC5A5
1754504 Removable connector, 5 wire terminal
1754601 Removable connector, 10 wire terminal
SZ2531.000 Door key, double bit
500876A5 Hex standoff, ¾ inches long, #6-32 (Main Control Board)
500876A2 Hex standoff, 3/8 inches long, #6-32 (Door Interface/Display Board)
265651A1 Lamp, 14.4 volt - 100 ma, #1813
500364A2 Lamp cap, amber (CLUTCH ENGAGED)
500364A4 Lamp cap, red (FAULT 1 and 2)
800T-XD1R Contact block, logic read, N.O. (TEST button)
800T-XD2R Contact block, logic read, N.C. (RESET button)
800T-A9 Push button, yellow (TEST button)
800T-A2 Push button, black (RESET button)
262771B2 Shock mount, ¼ - 20, 11.5 lbs. shear, 44 lbs. compression
501270A6 Cable, foil shielded, 6 conductor, 22 gauge (Pulse Generator)

Optional PC Boards

554300A1A "90-Degree TEST" PC Board Assembly (field replaceable)
554700A2A "STOP TIME Readout" PC Board Assembly
554700A3A "CLUTCH ENGAGED TIME Readout" PC Board Assembly
554800A1A "CRANK POSITION Readout" PC Board Assembly

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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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