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.

        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.

        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.

        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.

        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.

        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.

        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).

        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.

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.

        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.)