Brake Monitor
Model BM-1600

Description

The BM-1600 is a time-based brake monitor that utilizes a high resolution encoder and controller to measure the brake stopping time in milliseconds and also the RPM/SPM of the press. The rotary encoder is attached to the subject machine and is driven on a 1:1 ratio by the power press crankshaft. The brake stopping time of the machine will be displayed on every stop and can be easily read on the bright red light emitting diode (LED) display on the front panel of the unit. The RPM/SPM of the machine will be displayed during the machine cycle.
Individual LED indicators are visible and easily define the existing status of the unit during the press cycle (shown above). All system programming and diagnostics are front panel mounted and controlled which will minimize downtime while enhancing operator safety and press maintenance. All operating mode selections are supervisory controlled by a keyed selector switch which meets all OSHA and ANSI standards for mode selection supervisory control.

To program the Brake Warning Time and the Brake Limit Time set points, the user inserts the programming key into the lock and turns to the desired position (status LED illuminates). By depressing the +/- buttons to the desired time setting and turning the key back to the Run position, the new warning/failure time set points are saved. All errors and time value set points are permanently stored in the EEPROM memory which does not require a battery backup. The user cannot change or re-program the Brake Warning or Brake Limit set points while the encoder is in motion, which is an additional safety feature.

The dual force-guided captive contact safety output relays of the BM-1600 are always de-energized when the programming key is not in the Run position. When the key is in the Run position, the safety output relays are always energized as long as there are no internal or external faults detected. When a fault is detected, it is recorded within the system in non-volatile memory along with the last stopping time. If the power to the Brake Monitor System is removed and re-applied, the last error to occur will come back up and prevent any further use until the programming key is used. Only the key turned to the reset position can clear a fault. If no fault occurred but the programming key is moved into the reset position, the output relays will de-energize as a safety feature. Motion Detection will still be monitored while in the Reset position even if the encoder is turning.

OSHA/ANSI Compliance
The BM-1600 system complies with OSHA code 1910.217 and ANSI Code B11.1-1988 (R1994) for brake monitoring and control reliability standards. The unit will automatically prevent the activation of a successive stroke if the stopping time deteriorates beyond the brake limit set point. Required on any press that has a single stroke mode and uses either a two hand control, light curtain or type B gate system.

Non-volatile EEPROM Memory
All diagnostic faults and brake set points are permanently saved in non-volatile memory which does not require battery backup. Information is retained indefinitely after a power loss or machine shutdown.

Advanced Design
The advanced circuitry and user friendly design on the BM-1600 allows both programming and status monitoring to be performed from the front of the compact panel. There is no need to enter the control panel to adjust switches or thumbwheels which will enhance both safety and productivity.

System Self Diagnostics
Control displays status and system fault codes on the LED display. A detailed definition, cause and cure listing is supplied within each installation and operation manual.

Predictive Maintenance Diagnostic Tool
The unique "brake warning" feature on the BM-1600 allows for predictive maintenance to be scheduled on the machine, which will minimize downtime. Factors which will be monitored and affect stopping time: machine cycle speed, counterbalance air supply, tooling weight, clutch air supply, exhaust restrictions, brake wear adjustment and clutch wear adjustment.

90-degree Stop Built-in
The built-in 90° press stop feature initiates a stop signal at the 90° position in the downstroke. This is required information when calculating the location of point of operation guarding systems or palm button assemblies.

270° Down from Top Stop Test
Allows the press to travel 630° which is 1-3/4 times around. The press will start to stop at the 270º mark. This is used to check for proper counter balance.

Complete Package Supplied
Everything you need to install and operate the BM-1600 is supplied.

• BM-1600 Brake Monitor Controller
• Model E-160 Encoder
• 20' of encoder cable
• Dimensional and technical data
• Installation and operation manual

Features

• Control reliable design
• Dual captive contact safety relays
• Bright red LED display
• Non-volatile EEPROM memory
• Flat unobtrusive design
• Drive failure detection
• Motion detector
• Automatic 90° press stop
• Programming security with keyed selector switch
• Very easy to program and to adjust limits
• System self-diagnostics with display codes
• External diagnostic display
• System status indicators (LED's)
• Solid state indicators - No incandescent bulbs to burn out
• Designed specifically for the rigorous metal stamping/metal forming industry
• Interfaces easily with all types of press controls; solid state or relay logic
• Installs with ease on OEM, Retrofit, or Rebuild projects
• Front panel mount for installation into an existing control panel
• Made in USA

Specifications

Diagnostic Display

Brake Warning Indicator
Yellow light illuminates when the set point is exceeded. Excellent input for the press operator and for maintenance.

Drive Failure
Red LED illuminates when the pulses from the encoder disappear while the brake remains released.

Brake on
Yellow light illuminates when power to the dual solenoid valve drops out.

Ready
Green LED illuminates when all systems are go.

Not Ready
Red LED illuminates when the brake monitor safety relays have dropped out. Example: drive failure, internal failure, etc.

+/- Pushbuttons
The +/- pushbuttons are used to set the time values in milliseconds for the brake warning and the brake limit set points.

System Programming Security and Safety
Keyed selector switch controls:

• Brake Warning Time Set point
• Brake Limit Time Set point
• System Reset
• System Run

Brake Failure Indicator
Red light illuminates when the actual brake stopping time exceeds the programmed brake limit set point.

Stop Time
Displayed in milliseconds after every stop in machine cycle and the red LED is illuminated.

RPM/SPM
Displayed during each press cycle when the red LED is illuminated.

Brake Warning Time
Displayed in milliseconds when the red LED is illuminated.

Brake Limit Time
Set point is displayed in milliseconds when the red LED is illuminated.