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.

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
   

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.
    

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.
   

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.

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.
   

        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.

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.
   

        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.

        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 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.

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.
   

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.
   

        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.

        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.

        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