Revised: January 31, 2012

• "POWER ON" indicator light
  
• "GUARD" indicator light
  
• "MOTOR ON" (forward) indicator light
  
• "CLUTCH ENGAGED" indicator light
  
• "BRAKE/MOTION FAULT" (check/warning) indicator light
  
• "PRESS MODE" keyed selector switch
  
• "OPERATOR MODE" keyed selector switch
  
• "RESET" button
  
• Brake/motion monitor "TEST" button
  

• Production Counter with keyed reset
  
• Main motor operator station (reversing or non-reversing)
  
• External (front panel) holding cam/auxiliary cam adjustment
  
• "Minimum safe distance/stop time" readout
  
• "Crank Position" readout
  
• Other motor control stations (in larger enclosure)
  
• Custom indicator/fault lights, etc.
  

• "INCH MODE AUTO TOPSTOP" - Removed (switch to left):
          The ram will continue in a continuous motion as long as both RUN buttons are held down. This mode is only recommended when making stop-time measurements or other periodical checks.
  
  
• "INCH MODE AUTO TOPSTOP" - Enabled (switch to right):
          The ram will automatically topstop if both RUN buttons are held down through the topstop position. This prevents the press from cycling unsafely in a continuous type mode while in the INCH mode. It also permits easy topstop positioning before switching to a "run" mode – recommended.
  

• The "OPERATOR MODE" selector switch has no effect while in the INCH mode.
  
• The footswitch cannot be used while in the INCH mode.
  
• The production counter is bypassed while in the INCH mode.
  
• The guard may be active in the INCH mode – depending on the "GUARD BYPASS SELECT" switch position on the Main Control Board.
  

• "GUARD BYPASS SELECT" - Active Always (switch to left):
          The guard is active in all press modes. Both RUN buttons must still be held down until the bottom of the stroke in the SINGLE/2-HAND mode. The guard is still bypassed during the holding cams (upstroke). Required on larger size presses where the rear of the press is accessible and hard to see from the operator.
  
  
• "GUARD BYPASS SELECT" - Bypassed in INCH/2-HAND (switch to right):
          The guard is bypassed in INCH, SINGLE/2-HAND, and CONTINUOUS/2-HAND (hold-down type) modes. Use this position only when the rear of the press is completely mechanically guarded, and the operator has a clear view of the remaining pinch-point area.

• "SINGLE/FOOT MODE SELECT" - Foot-trip (switch to left):
          The footswitch is momentarily pressed to trip the press. The ram will make one full cycle and topstop, providing the guard/s or other stop signal has not been initiated.
  
  
• "SINGLE/FOOT MODE SELECT" - Foot-hold-down (switch to right):
          The footswitch must be held down until the ram reaches the bottom of the stroke. The guard is still active. The holding cams will then take over and carry the ram to topstop position. The guard (in both cases) is bypassed during the upstroke – Recommended by operators who must monitor part position.
  

• 1TB connections are high-voltage (120Vac).
  
• 2TB connections are low-voltage (12Vdc).
  

1. At power-up (after all connections are verified), leave the motor shut off and make sure the flywheel is completely stopped.
   
2. Press the RESET button to clear any fault conditions. Make sure the BRAKE/MOTION FAULT light on the control front panel is off.
   
3. Place your hand on the pulse generator shaft and forcibly try to turn the shaft in both directions. If the BRAKE/MOTION FAULT light on the control front panel comes on, the shaft linkage is too loose or sloppy. Tighten up the linkage and repeat this procedure from step one. The linkage is tight enough when the BRAKE/MOTION FAULT light remains off.
   
4. When using a chain and sprockets, repeat the above procedure at different areas of the cycle to make sure the sprockets are centered on both shafts, each time making sure first that the flywheel is completely stopped. Care should be taken not to exert too much side pressure on the pulse generator shaft, as this could result in shorter pulse generator bearing life.
   

        You may prefer to install sealtite around the pulse generator cable. In this case, the strain-relief connector can be removed from the pulse generator assembly and replaced with a ½" NPT standard sealtite fitting. Re-connect the cable as above between 2TB and the Pulse Generator Assembly. Be careful not to pinch any of the wires between the pulse generator cover and the pulse generator base when replacing the cover. Be sure to re-install the cover gasket to keep the inside dry and clean. See the interconnection drawings for 2TB in the back of this manual for more details.

Operator Station and Guard Mounting: Top
        When a fixed mechanical guard is installed, the distance from the guard to the die pinch-point (the closest pinch-point between the die and operator) is irrelevant, as long as the fixed guard prevents the operator from touching any part of the die. If the fixed guard is removable or opens for setup access, the moveable part must be interlocked to the SYSTEM 4000 (see "Guard/Light Curtain Connections").
        When a light curtain unit is used for guarding, the unit (transmitter and receiver) must be mounted at the MINIMUM SAFE DISTANCE from the die pinch-point area. The press operator station (both RUN buttons) must also be mounted at the MINIMUM SAFE DISTANCE, whether a light curtain is installed or not. Failure to do so may enable the operator to penetrate the die area before the ram has completely stopped, resulting in an unsafe condition.
        The MINIMUM SAFE DISTANCE (MSD) depends on the stopping time of the press. The stopping time is figured using a brake performance tester (such as the H & W Controls #BPT-3B), or, if the optional MSD/Stop Time Readout #554700A1A is installed in the SYSTEM 4000, the press can be cycled once to view the actual MINIMUM SAFE DISTANCE. To determine the MSD, the ram must be stopped at the 90-degree position (half way down) to determine the stopping time at the most dangerous part of the cycle per OSHA requirement.
        Once the stopping time is known (but the MSD is not), the MSD can be easily figured using the following formula...

Stopping Time (seconds) x 63 + 10% = MSD (inches)

The 10% in the formula is to allow for tolerable brake wear.

        The chart below may be used as an alternative to locate the MSD. Follow the correct stopping time up to the "MSD + 10%" line, then to the left to the actual distance in inches...


        Be sure to mount all press operator stations (RUN buttons) and light curtains at or beyond the MINIMUM SAFE DISTANCE of the press. The MSD should be checked periodically (OSHA requires weekly checks) to verify the proper safety distance is less than that of the distance to all RUN buttons and light curtains on the press.

Press Operator Station Connections:

        The Standard Press Operator Station from H&W Controls #555010A1 consists of two guarded RUN buttons, an EMERGENCY STOP button, and an ARMING/TOPSTOP button. These four buttons contain low-voltage logic-reed contacts for optimal performance.
        Multiple Press Operator Stations #555011A1 may be included which require the use of the Multiple Operator Station/Multiple Guard Interface Board #554850A1A for proper operation. When installing multiple press operator stations, use the interconnection drawing #B554851A1 for wire connections, in the back of this manual. In addition to the components on a standard station, each multiple operator station includes extra contacts on both RUN buttons, an ON/OFF keyed selector, and an ON indicator light, which are required for multiple station wiring. For more information on the multiple operator stations, see the "Optional Multiple Operator Station/Multiple Guard Interface" section next in this manual.
        A Standard Press Operator Station #555010A1 is wired directly to 2TB 6 through 10 on the Main Control Board, as shown in the interconnection drawing #B554400D1 in the back of this manual.
        A Press Operator Station #555014A1 using Opto-Touch RUN buttons is wired directly to 2TB 1 and 6 through 10 on the Main Control Board, as shown in the interconnection drawing #B554400D2 in the back of this manual.
        Additional EMERGENCY STOP buttons may be wired in series with the EMERGENCY STOP button provided. Be sure to use low-voltage contacts on all EMERGENCY STOP buttons. All EMERGENCY STOP buttons must be wired to the "Emergency Stop" input at 2TB 9 on the Main Control Board. Do not use 2TB 16 ("Auxiliary Ram Stop") for EMERGENCY STOP buttons as this terminal is not an emergency stop input.
        
DO NOT WIRE MORE THAN ONE "RUN" BUTTON TO EACH OF THE RUN BUTTON INPUT TERMINALS ON THE MAIN CONTROL BOARD!        

        The standard SYSTEM 4000 is designed for a single set of RUN buttons to keep the size and cost down, and for simple installation and troubleshooting. Wiring more than one RUN button to each RUN button input will result in an unsafe condition. The SYSTEM 4000 contains anti-repeat circuits and timing circuits for each RUN button. These circuits will only function properly with one RUN button on each input terminal. (In the case of more than one RUN button installed on each terminal... If one RUN button or set of RUN buttons fails or is held down by some means, the control system would not detect an error. This would free an operator's hand or hands to penetrate the die area pinch-point during motion.)
        When more than one set of RUN buttons are required, use the Multiple Operator Station/Multiple Guard Interface Board #554850A1A. See the next section in this manual.

Optional Multiple Operator Station/Multiple Guard Interface: Top
        The Multiple Operator Station/Multiple Guard Interface Board #554850A1A must be used when installing more than one press operator station. Use only the Multiple Press Operator Station #555011A1 when installing multiple stations. Any number of multiple press operator stations may be installed and wired to the Multiple Operator Station Interface Board per drawing #B554851A1.

Each multiple press operator station includes:

• Two guarded RUN buttons each with a N.C. and N.O. contact
  
• An EMERGENCY STOP button (N.C.)
  
• A continuous ARMING/TOPSTOP button (N.O.)
  
• A keyed Station ON/OFF selector switch with 2-N.C., 2-N.O. contacts
  
• A Station ON indicator light
  

        The Multiple Operator Station Board is used only for the RUN button wiring. The ARMING/TOPSTOP buttons are simply wired in parallel directly to 2TB 10 on the Main Control Board, and the EMERGENCY STOP buttons are wired in series directly to 2TB 9 on the Main Control Board.
        Each RUN button requires two contacts and are wired in series to the Multiple Operator Station Interface Board per drawing #B554851A1. This method permits any number of press operator stations to be wired safely.
        All FRONT operator stations must be connected to the "Front Stations ON" input terminal at 4TB 7 on the Multiple Operator Station Interface Board.
        All REAR operator stations must be connected to the "Rear Stations ON" input terminal at 4TB 8 on the Multiple Operator Station Interface Board.
        If/when ALL operator stations are turned OFF on one side of the press, that side becomes automatically guarded in ALL press modes (through the Multiple Operator Station Interface Board) using a light curtain mounted on that side of the press. This insures that that side of the press is protected at all times, since that side of the press is not in use. It is important that all front and rear stations are wired correctly to their corresponding "Stations ON" input terminal.
        If no REAR stations are installed, leave 4TB 8 empty. If no FRONT stations are installed, leave 4TB 7 empty.
        If multiple operator stations are often selected ON or OFF to accommodate different job setups, it is imperative that light curtains be installed on each side of the press that there are multiple operator stations installed – Even if the press will be cycling in a 2-HAND press mode. This will insure that each side of the press is protected no matter what stations are ON or OFF. The Multiple Operator Station Interface Board includes independent inputs for FRONT and REAR light curtains, which are gated internally with the FRONT and REAR operator station ON/OFF inputs.
        The FRONT light curtain is wired to the FRONT Guard inputs (Ch. #1 and Ch. #2) at 4TB 9 and 10, with the common of both channels wired to 4TB 11.
        The REAR light curtain is wired to the REAR Guard inputs (Ch. #1 and Ch. #2) at 4TB 12 and 13, with the common of both channels wired to 4TB 14.
        If no REAR operator stations are installed, and a fixed mechanical guard is installed on the REAR of the press, but the guard can be opened for setup purposes, the mechanical guard must be interlocked to the REAR guard inputs at 4TB 12 and 13 (install two limit switches on the guard to be used as interlocks). The REAR guard inputs 4TB 12 and 13 can be jumped to ground ONLY if the REAR side of the press is mechanically and permanently guarded or protected, and no REAR operator stations are installed.

DO NOT, UNDER ANY CIRCUMSTANCES, JUMP OUT THE GUARD INPUTS FOR A PARTICULAR SIDE OF THE PRESS, IF THERE ARE MULTIPLE OPERATOR STATIONS INSTALLED ON THAT SIDE OF THE PRESS THAT CAN ALL BE TURNED OFF!        

        * NOTE: Light curtains may not be required IF the press will be cycling ONLY in 2-HAND press mode, and one multiple operator station on each side of the press is permanently wired to be ON (the station ON/OFF keyed selector removed). In this case, jump the station ON/OFF inputs 4TB 7 and 8 to ground and leave the guard inputs at 4TB 9, 10, 12, and 13 open.
        When using the Multiple Operator Station/Multiple Guard Interface Board, wire the multiple operator stations and light curtains only per drawing #B554851A1. Do not wire any RUN buttons or light curtains/guards directly to the 2TB inputs. 2TB 7, 8, 11, and 12 must be wired only to the Multiple Operator Station Interface Board per the interconnection drawing.

Guard/Light Curtain Connections: Top
        The SYSTEM 4000 will only cycle in the GUARD or FOOT mode if a light curtain or mechanical guard is installed protecting the die area. Interlock switches on the mechanical guard or the output contacts of a light curtain must be interfaced to the "Guard" inputs at 2TB 11 and 12.
        The "Guard" inputs 2TB 11 and 12 on the Main Control Board are only designed to safely accept guarding on the FRONT side of the press. A FRONT and REAR guard must not be wired in series or parallel to the "Guard" inputs at 2TB 11 and 12. A REAR guard, if required, must be active in ALL press modes, and therefore, must be wired to the Multiple Operator Station/Multiple Guard Interface Board to utilize the individual FRONT and REAR "Guard" inputs - Even if only one press operator station is used. See the previous section in this manual.
        Do not use the Auxiliary Ram Stop input 2TB 16 for a REAR light curtain input. Although it seems this would work, 2TB 16 is not a dual-channel redundant input, as light curtains require for safe operation. 2TB 16 may be used to interlock a fixed mechanical guard on the REAR side when the guard needs to be opened only for setup purposes.

UNDER NO CIRCUMSTANCES SHOULD ANY GUARD INPUT BE JUMPED OUT! This would result in an unsafe condition.        

        The GUARD inputs 2TB 11 and 12 are a single dual-channel input designed to accept the standard dual normally OPEN outputs from most light curtains. Both channel inputs must switch concurrently (within 20 milliseconds of each other) for proper operation. If both channels do not operate together, a MOTION FAULT will occur in the SYSTEM 4000.
        The normally OPEN light curtain output contacts should close when the light curtain is in the green state (powered up and unobstructed).
        H & W Controls recommends using the Dolan-Jenner Safescan 9 light curtain for direct connection to the SYSTEM 4000. The Safescan 9 does not require an external power supply or interface circuits and includes fixed and floating beam blankout. See drawing #B554400D1 or equivalent for light curtain connections.

for proper interface to the SYSTEM 4000. H & W Controls #565024A1A Power Supply/Interface Board is also available, and designed exclusively for interface to the SYSTEM 4000. Both interface boards will safely operate the FGS or MGS light curtain in the "Guard-only" mode, with automatic reset. Both interface boards also contain required "captive-contact" safety relays for safe operation. Below are interconnection drawings for both, the #LCU-ACA and #565024A1A Power Supply/Interface Boards.

can be directly interfaced to the SYSTEM 4000 "Guard" inputs. It's 120Vac power source can be connected to the control power transformer at 1TB 1 and 2. The light curtain is configured to operate in the "Guard-only" mode, as shown below in the interconnection drawing. At power-up, the light curtain must be reset to the "green" state by momentarily breaking the light beam. After this reset, the light curtain will operate as required. Use shielded cable for the low-voltage connections, from the output contacts to 2TB, to reduce electrical noise.


Footswitch Connections: Top
        The Footswitch Assembly #500230A1 may be included with the SYSTEM 4000 for hands-free cycling. The footswitch can only be used in the FOOT mode if guarding has been installed and interlocked to the "Guard" inputs 2TB 11 and 12. A footswitch may be added at anytime in-the-field.
        The H & W Controls footswitch assembly includes an 8ft prewired cable assembly for quick-connection to the SYSTEM 4000 "Footswitch" input at 2TB 14 and any "Ground" terminal.
        The Footswitch Assembly #500230A1 from H&W Controls contains a "kick-plate" in the back of the housing, which must be pushed inward before the foot pedal can be depressed. The footswitch is also fully shielded as a second precaution to accidental tripping.
        If a footswitch is obtained separately, the unit must be fully shielded to prevent accidental tripping. Use the normally OPEN contacts for connection to the Footswitch input 2TB 14 and 2TB 13 (ground).
        See Drawing #B554400D1in this manual for wire connections.

Auxiliary Stop Inputs: Top
        The SYSTEM 4000 includes three normally OPEN Auxiliary Stop inputs (two of which were added to the "D" version Main Control Board – March 2000). These stop inputs and descriptions are:

• Auxiliary Ram Stop (2TB 16) - Stops the ram immediately in any press mode when momentarily closed to press ground. The cycle is inhibited if this input remains closed. (Included on all versions Main Control Boards.)
  

• Auxiliary Continuous Topstop (2TB 17) – Will topstop the ram at the next topstop position (in the CONTINUOUS mode only) when this input is momentarily closed to press ground. This input will not "arm" the continuous cycle as the ARMING/TOPSTOP input does at 2TB 10. The press will only single-stroke in the CONTINUOUS mode, if this input remains closed. (Added to the "D" version Main Control Board – March 2000.)
  

• Auxiliary PAUSE (2TB 18) – Effective in the SINGLE and CONTINUOUS press modes, this input will "pause" the cycle when this input closes, for as long as this input remains closed. The ram will "resume" motion when this input opens, providing any stop signal has not been previously initiated (light curtain interrupted, etc.). If the PAUSE input is closed prior to initiating the cycle, the ram motion will be "suspended" until the PAUSE input opens (providing any stop signal has not been previously initiated). During clutch dis-engagement, the PAUSE input must remain closed for at least the time it takes to completely stop the ram (for the brake "check" circuit to finish), or the motion will not "resume" when the input opens. There is no maximum time limit. (Added to the "D" version Main Control Board – March 2000.)
  

        The Auxiliary Stop inputs are low-voltage low-current inputs, which can safely accept hand-fabricated type sensors, if required. A metal rod or wire can be positioned over the steel stock to create a stock-buckle sensor (assuming the stock is grounded), for example. Use a "Ground" terminal (2TB 15) for the return wire, if using some other type of limit switch, sensor, or output from a monitor or protection device.
        Use only a dry-relay-contact or solid-state current-sync output from an outside device, to any of the Auxiliary stop inputs. Do not apply any outside power source to these terminals!

Control Power Connections: Top
        The SYSTEM 4000 is designed for a standard 120Vac power input, which is connected to 1TB 1 through 3 as shown below...

• 1TB 1 – 120Vac hot lead
• 1TB 2 – Neutral lead
• 1TB 3 – Ground (Internally connected to cabinet ground)

        The SYSTEM 4000 may include a motor control package which, upon request, may or may not be prewired to the SYSTEM 4000. The motor control package from H&W Controls includes a control transformer required for the 120Vac starters and SYSTEM 4000 power source. With the control transformer, the 3-phase 220/440Vac-power source for the motors is all that is required. A prewired motor control package is prewired to 1TB 1 through 7. No further connections are required to these terminals.

Before turning on the control power... verify ALL the connections with the installation drawings in this manual, and possibly, with custom drawings supplied separately by H&W Controls.        

Holding Cam Adjustment: Top
        Incorporated into the SYSTEM 4000 Main Control Board is two sets of rotary thumbwheel switches used for setting the HOLDING CAM ON (bottom return) and HOLDING CAM OFF (topstop) positions. These on-board adjustments from within the control enclosure eliminate the need to re-adjust RLS cams up high on the press, and provide an easy means of topstop re-adjustment for variable speed presses.
        The holding cam settings are adjustable in 1-degree increments from 0-359 degrees. Fault circuits are incorporated into the holding cam circuits to prevent the holding cam settings from being set too high, too low, or illogical. The ON setting must be set lower than the OFF setting. Other Fault circuits monitor the signals from the Pulse Generator Assembly and holding cam circuits for correct operation.
        The holding cam typical settings are as follows:

• HOLDING CAM ON: 160-180 degrees
• HOLDING CAM OFF: 300-350 degrees (depends on press stop time)

        The Holding Cam ON setting is used to set the point at the bottom of the stroke where the guard/s (if installed) become bypassed, and when the ram will continue automatically to topstop position.
        The Holding Cam OFF setting is adjusted to stop the press at top-dead-center position. The guard/s (if installed) will become enabled again at this point (if in a "Guard" or "Foot" mode.
        Two LED's are included on the Main Control Board, which monitor the holding cam circuits. The HOLDING CAMS ON LED (green) monitors the Ch. 1 and Ch. 2 holding cams. The HOLDING CAM FAULT LED (red) indicates either an incorrect HOLDING CAM switch setting, or bad or missing signals from the Pulse Generator Assembly. The "D" version and "E" version Main Control Boards also include LED's above each pulse generator input terminal on 2TB for pulse generator status.
        Optional front panel (external) Holding Cam switches may be included with the SYSTEM 4000 for easier and quicker holding cam ON and OFF adjustment. The front panel cam adjustments are set in the same manor as the on-board cam adjustments. The thumbwheel switches on the Main Control Board are not included when the front panel option is used.

Brake/Motion Monitor: Top
        The System 4000 Main Control Board contains a 360-degree Brake/Motion Monitor system. The independent Brake and Motion Monitors consistently monitor the clutch and brake through the entire stroke.

        The Motion Monitor is active while the clutch is engaged in the SINGLE and CONTINUOUS press modes. This monitor is bypassed in the INCH press mode to allow for slow "inching" of the ram while the flywheel is slowing down, if the motor is shut off (used mainly for setup on higher speed presses).
        The Motion Monitor is used to monitor ram movement while the clutch is engaged to protect the die, flywheel belts, and motor during a "stalled" condition by shutting off the clutch. A stall could result from a die jam-up, frozen bearing, low shut-height, etc. The clutch outputs are instantly shut off if the ram slows below 12/5 strokes-per-minute while the clutch is engaged.
        The Motion Monitor is also used to monitor the operation of the Pulse Generator. This eliminates the requirement of a chain-break switch on the Pulse Generator Assembly, since a motion fault will occur if the Pulse Generator stops during clutch engagement.
        The front panel Brake/Motion FAULT light coming ON and the main motor remaining ON distinguish a "Motion Fault".

Clutch/Motion Time Adjustment: Top
        The Motion Monitor's FAULT setting can be adjusted to either 12 or 5 strokes-per-minute by the MOTION TIME SELECT switch on the Main Control Board ("D" version – March 2000). Presses over 20 strokes-per-minute (spm) should use the right switch position "OVER 20 SPM" to provide a quicker response time. Presses under 20 spm should use the left switch position "UNDER 20 SPM". Presses under 8 spm may require a modified Main Control Board from H & W Controls. The standard SYSTEM 4000 Main Control Board will accept press speeds from 8 to 800 spm.
        The Motion Monitor circuit also monitors the clutch engage time of the press, and will shut off the clutch outputs if the clutch does not engage within a selected time period. This may occur with low air pressure or worn clutch plates, etc. Once motion begins, the clutch monitor drops out, and the motion monitor takes over. The Clutch Engage Fault time can be adjusted to either "1 second" or "350 ms" (milliseconds), by the CLUTCH TIME SELECT switch on the Main Control Board ("D" version – March 2000). Presses with a slow clutch engage time will require the left switch position ("1 second"). Other presses should use the right switch position ("350 ms") to provide a quicker response time in shutting off the clutch outputs.

        The Brake Monitor is required by OSHA to monitor the stopping time of the brake during clutch disengagement, and inhibit further operation if the safe stopping time is exceeded. A faulty or worn brake could allow the operator to penetrate the die pinch-point area before the ram comes to a complete stop.
        The H&W Control's Brake Monitor continually monitors the brake in ALL press modes, during and after every clutch disengagement through the complete 360-degree cycle. The only time the brake monitor is not active is while the clutch is engaged.
        The front panel Brake/Motion FAULT light coming ON and the main motor shutting OFF distinguish a "Brake Fault".
        The brake monitor's stop-time adjustment is adjusted with the ALLOWABLE STOPPING TIME potentiometer on the Main Control Board. If this time adjustment is set too low, or the set stop-time is exceeded, a BRAKE FAULT will occur at clutch disengagement. See the next section on "Stopping Time Adjustment".
        A TEST button is included with the SYSTEM 4000 used to test the Brake Monitor and outputs to the clutch and motor control. When the TEST button is pushed the clutch (if engaged), and all motor control should turn off, and the Brake/Motion FAULT light on the control front panel should light and remain lit. Push the RESET button to clear any faults or tests.
        The Brake Monitor contains self-checking circuitry, which momentarily flashes the Brake/Motion FAULT light on the control front panel, during each clutch disengagement. During this momentary flash, the brake monitor is comparing the stop time of the press with the ALLOWABLE STOPPING TIME adjustment. The next cycle is inhibited until this flash ("check") is completed, to allow the brake monitor to fully function. Turning the ALLOWABLE STOPPING TIME adjustment up higher than is required, will prolong the cycle inhibit, and hence, decrease production. If the press stop-time is within the ALLOWABLE STOPPING TIME adjustment, the Brake/Motion FAULT light will go back off, enabling the press to be re-cycled. Bottom line... The ALLOWABLE STOPPING TIME adjustment should be set as low as possible, without creating a Brake Fault.
        A brake fault WARNING indication is included on the "D" version Main Control Board (March 2000). If the press stop-time is within 2-degrees of a BRAKE FAULT, the Brake/Motion FAULT light on the control front panel will continually "blink" on and off after the "check" period at each clutch disengagement. This is only an indication of a near Brake Fault, and the press will still cycle as normal.

Stopping Time Adjustment: Top
        Use the ALLOWABLE STOPPING TIME potentiometer on the Main Control Board to adjust the stop-time allowed, before a Brake Fault occurs. Set the "Allowable Stopping Time" as follows…

• Set the press speed at the fastest speed used.
• Set the heaviest die used in production in the press.
• Set air pressure settings at maximum pressure used in production.
• Set the PRESS MODE selector to INCH mode.
• Make sure the ram is set at or close to top-dead-center.
• Set the ALLOWABLE STOPPING TIME to minimum (15 ms).
• Cycle the press to the 90-degree crank position (half way down).
• If a BRAKE FAULT occurs, turn up the potentiometer slightly, push RESET, restart the motor, and repeat the above procedure.
• When a BRAKE FAULT does not occur, the correct ALLOWABLE STOPPING TIME is set.

        When adjusting the ALLOWABLE STOPPING TIME, the press is disengaged at the 90-degree crank position, which is usually the point of the longest stop-time.
Continued use of any press will eventually cause an increase in stopping time as the brake linings wear, or the springs weaken. If BRAKE FAULTS eventually start to occur, it is wise to first check the brake assembly and linings, before simply increasing the ALLOWABLE STOPPING TIME setting. After all, the whole reason for the brake monitor is to monitor the brake!

Brake Monitor Testing Procedure: Top
        At the beginning of each shift, verify proper Brake Monitor operation by performing the following tests…

1. With the press stopped, push the TEST button. The front panel "Brake/Motion FAULT" light must light and remain lit, and the motor must shut off. Attempt to start the press – It must not start.
2. Push the RESET button. The front panel "Brake/Motion FAULT" light should go off. The motor can be restarted.
3. With the press cycling, push the TEST button. The press must stop and the motor must shut off. The front panel "Brake/Motion FAULT" light must light and remain lit.
4. Push the RESET button. The front panel "Brake/Motion FAULT" light should go off. The motor can be restarted, and the press can be recycled.

Optional - Auxiliary Cams: Top
        The Auxiliary Cam Boards #554900A1A and #554900A2A are designed for the SYSTEM 4000 auxiliary cam requirements. The standard 12" x 14" control enclosure can accommodate one Auxiliary Cam. Up to 10 Auxiliary Cams may be used in the SYSTEM 4000, using larger enclosures.
        Each Auxiliary Cam is adjusted with thumbwheel switches, in the same manor as the Holding Cams on the Main Control Board. Adjustment is set in one-degree increments, from 0-359 degrees. Separate settings control the cam ON and cam OFF positions. Each cam board will operate one ON/OFF transition per stroke. Accuracy is better than 2-degrees. Making sure the SYSTEM 4000 Pulse Generator shaft keyway is adjusted exactly as specified can optimize the accuracy of the cam settings.
        As with the Holding Cam settings, FAULT check circuits are incorporated into each Auxiliary Cam Board. If a cam fails, the ram will be stopped and inhibited until RESET. Circuits are also included, to prevent the cam settings from being set too high or illogical. The ON setting must be set at least 2-degrees lower than the OFF setting on each cam board. Each cam board must turn on and turn off every press stroke, or the cam will FAULT. "FAULT" and "Cam ON" LED's are included on each cam board for easy identification.

        The Auxiliary Cam Board #554900A1A is a relay-output version Auxiliary Cam. Each cam board contains 1-N.O. and 1-N.C. isolated output contact, capable of 120Vac at 3 amps maximum. Surge suppression and arc protection are built into each cam board for long contact life and low electrical noise. The N.C. output contact can be used when a cam is required to be closed over top-dead-center. The ON and OFF settings are then set in reverse (since the ON setting must be set lower than the OFF setting).
        Example: To turn a cam ON at 270 degrees and OFF at 45 degrees… Adjust the ON setting to 045 and the OFF setting to 270, then use the N.C. output.


        The Auxiliary Cam Board #554900A2A is a solid-state-output version Auxiliary Cam with a 12Vdc-sourcing output. This version is recommended for interfacing to electronic feed systems, or PLC inputs, since any contact "bounce" is eliminated. TB1 and TB2 terminals are not used in this version. Use terminals 3 (output) and 4 (ground) only.

        Installation of each Auxiliary Cam requires the 1RC ribbon cable to be plugged into the 1RC socket on the Main Control Board, or preceding Auxiliary Cam Board. The Door Interface Board 1RC ribbon cable plugs into the last Auxiliary Cam Board on the left. The blue wire at the bottom of each Auxiliary Cam Board (Topstop Sync) must also be plugged into 2TB 5 on the Main Control Board, or daisy-chained over to the next Auxiliary Cam Board "Topstop Sync" terminal. If the blue wire is not connected to one or more Auxiliary Cam Boards, the unconnected boards will FAULT at the first topstop position.

Optional - 6, 12, 18 Channel Die Monitoring: Top
    The optional 6-channel Die Monitor Board #554950A1A can be used with ALL version System 4000 Main Control Boards through the "E1" version. Use the Die Monitor Board #554950A2A with the "E2" version Main Control Board. The mounting holes are identical to the Auxiliary Cam Board mounting for easy installation or upgrade. Up to three Die Monitor Boards may be used providing a total of 18 die-monitoring channels.
    Also available is the Die Monitor Indicator Board #554955A1A which provides 6 remote (front panel) FAULT lights. The Indicator Board plugs into the remote indicator socket provided on the Die Monitor Board. The Die Monitor Board can be used with the Remote Indicator Board, or as a stand-alone internal die monitor. The Die Monitor Board contains on-board FAULT LEDs for internal visual fault indication when the Remote Indicator Board is not included.
    Each Die-Monitoring channel can be programmed as required for "Immediate Stop", "Topstop", or "Cyclic" sensing, and monitored either "Inside Window" or "Outside Window". A "Window" input is included with each channel which may or may not be used depending on the application. When required, a "Window" input may be wired directly to an available Auxiliary Cam Board for easy and accurate window adjustment. 
    A "Window" input is used when its sensor must only be "seen" during a portion of the press cycle, and ignored during the rest of the cycle. The "Inside Window / Outside Window" switch can reverse the effect of its "window" input just as switching the contact of the "Window" input cam from normally open to normally closed. 
    All sensor and window inputs are low-voltage, low-current, current sync type which can accommodate most types of sensors including hand-fabricated designs. All inputs on this board are "made" when touched to press ground or one of the "Ground" terminals provided. Outputs are provided with +12Vdc reference voltage required for use with proximity type sensors (current-sync type - 200 milliamps max.). As in a typical case with "Stock Buckle", a sensor input can be wired directly to a steel bar or grid just above the stock (isolated from press ground) with a single wire. If the conductive stock touches the grid, a "Stock Buckle" fault will occur. In this case, the corresponding channel program switch would be set to the "Stop" position (left) to enable an immediate stop condition when the fault occurs. 
   

    Some typical connections to the Die Monitor Board are shown on the Interconnection Drawing #B554950A1 in the back of this manual. 

Optional – Separate Clutch & Brake Valve Connections with Adjustable Delays:

When separate air valves with time delays between them are required for the clutch and brake, the “Separate C/B Driver Board” #554270A1A is required. This board contains four output modules (two for each the clutch and brake) with individual LED indicators and individually fused and suppressed for protection.
            This board provides solid switching of the clutch and brake valves, with an adjustable time delay for “Clutch Engagement” and for “Apply Brake” of 0 – 300 milliseconds each.
            A 500 millisecond auto-cutoff is incorporated into the brake circuit for added safety, in case of any failure. If this failure should occur, the “Brake Engage Delay Fault” LED will light and prevent any further press operation until reset.
            A “Delay Mode” switch is included on the “Separate C/B Driver Board” to allow “Delay Always” or “No INCH Delay”. When the control is placed in INCH Mode, the delay between the clutch and brake will be automatically removed when “No INCH Delay” is selected and the clutch and brake will work concurrently as if parallel wired.
            As an option, inputs are provided at 5TB for connection to physical switches which monitor the clutch and brake for absolute engagement and disengagement. These inputs can be used in conjunction with the time delays if desired; otherwise both time delays are set to “0”. LED’s are included above each switch input to monitor switch activity. If these switch inputs are not used, 5TB 1 and 5TB 2 must be jumpered together. See Drawing #B554270A for details.