BM-1600 (Rotary Encoder Based)
The BM-1600 is a time-based brake monitor that utilizes a high resolution rotary encoder and controller to measure the brake stopping time in milliseconds and also the RPM 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/ of the machine will be displayed during the machine cycle.
Brake Warning Indicator Drive Failure Brake On Ready Not Ready +/- Pushbuttons Brake Failure Indicator Stop Time RPM/SPM Brake Warning Time Brake Limit Time System Programming Security and Safety • Brake Warning Time Setpoint The BM-1600 is a time based brake monitor that utilizes a high resolution rotary 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. OSHA/ANSI Compliance Non-volatile EEPROM Memory Advanced Design System Self Diagnostics Predictive Maintenance Diagnostic Tool 90º and 270º Stop Time Measurement Built-In Complete Package Supplied • Control reliable design Controller Power Consumption – 8 watts (Relays on) Indicators: NEMA 12 Enclosure Dimensions – Front Panel Mount – 8” (203mm) Height x 7” (178mm) Width x 4” (102mm) Depth Encoder (Part # E-160 — CW or CCW Rotation Capable) 1. Select BM or BDM for encoder style 2. Specify Mounting Style 3. Specify Controller input power 4. Specify Clutch/Brake Valve Coil Voltage 11-001 Metal box enclosure (with gasket) 20-001 1A Slo-Blo glass 3AG fuse 21-053 Encoder Wheel (brass) 26-020 Front panel overlay (BM-1600) 42-001 Software microprocessor chip (specify square or rectangular) 43-004 Encoder cable (20’) 52-002 Display board 53-004 E-1600 Encoder with single-ended shaft (supplied standard)
Yellow light illuminates when the setpoint is exceeded. Excellent input for the press operator and for maintenance.
Red LED illuminates when the pulses from the encoder disappear while the brake remains released.
Yellow LED illuminates when power to the dual solenoid valve drops out.
Green LED illuminates when all systems are go.
Red LED illuminates when the brake monitor safety relays have dropped out (i.e., drive failure, internal failure, etc.)
The +/- pushbuttons are used to set the time values in milliseconds for the brake warning and the brake limit setpoints.
Red LED illuminates when the actual brake stopping time exceeds the programmed brake limit setpoint.
Displayed in milliseconds after every stop in machine cycle and the red LED is illuminated.
Displayed during each press cycle when the red LED is illuminated.
Displayed in milliseconds when the red LED is illuminated.
Setpoint is displayed in milliseconds when the red LED is illuminated.
Keyed selector switch controls:
• Brake Limit Time Setpoint
• System Reset
• System Run
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 setpoints, 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 setpoints are saved. All errors and time value setpoints are permanently stored in the EEPROM memory which does not require a battery backup. The user cannot change or reprogram the Brake Warning or Brake Limit
setpoints 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 reapplied, 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.
The BM-1600 system complies with OSHA code 29 CFR 1910.217 and ANSI Code B11.1-2009 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 setpoint. Required on any press that has a single stroke mode and uses either a two-hand control, light curtain or type B gate system.
All diagnostic faults and brake setpoints are permanently saved in non-volatile memory which does not require battery backup. Information is retained indefinitely after a power loss or machine shutdown.
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.
Control displays status and system fault codes are on the LED display. A detailed definition, cause, and cure listing is supplied within each installation and operation manual.
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, counter-balance air supply, tooling weight, clutch air supply, exhaust restrictions, brake wear adjustment, and clutch wear adjustment.
The built-in 90º press stop feature initiates a stop signal at the 90º and the 270º position in the downstroke. This is required information when calculating the location of point of operation guarding systems or palm button assemblies.
Everything you need to install and operate the BM-1600 is supplied.
• BM-1600 Brake Monitor Controller
• Model E-160 Encoder
• 20′ (6m) of encoder cable
• Dimensional and technical data
• Installation and operation manual
• Dual captive contact safety relays
• Bright red LED display
• Non-volatile EEPROM memory
• Flat unobtrusive design
• Drive failure detection
• Motion detector
• Automatic 90º and 270º 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
Power Requirements – 120 +/- 10% VAC, 50-60 Hz
24 VDC +/- 10% (optional)
Temperature Range – 0º to 50º Celsius
Relay Configuration – Dual self-checking force-guided captive contact safety relays
Relay Contact Rating
8 amps @ 250VAC resistive for safety relays
4 amps @ 250VAC resistive for alarm relay
System Accuracy – +/- 1 millisecond
Setpoints – Drive Failure (1 to 25 tenths of a second)
Brake Warning (1 to 999 milliseconds)
Brake Failure (1 to 999 milliseconds)
Enclosure – NEMA 12 (IP 64) Steel
Brake Fault – Red LED Brake Warning – Yellow LED
Drive Failure – Red LED Brake ON – Yellow LED
Ready – Green LED Not Ready – Red LED
Stop Time Display – Red LED RPM – Red LED
Brake Warning Setpoint – Red LED Brake Limit Setpoint – Red LED
8″ (203mm) Height x 7″ (178mm) Width x 4″ (102mm) Depth
Cable – 20′ (6m) supplied standard; 100’ (30m) max.
Gauge: 20 AWG – 3 connectors plus drain
Rating: 300 VAC @ 60 C
Shaft Loading – Radial: 35 lbs; Axial: 40 lbs.
Temperature Range – 0º to 50º Celsius
Dimensions – 5.5″ (140mm) Height x 3.75″ (95mm) Width x 3-9/16 (90mm)
F ……… Front Panel Mounting to be installed in an existing control panel.
C ……… Stand alone NEMA12 (IP 64) steel enclosure.
1 ………. 24VDC
2 ………. 120VAC 50-60Hz
3 ……….. 240VAC 50-60Hz
1 ………. 24VDC
2 ………. 120VAC 50-60Hz
5. Encoder Connector Cable
20’ (6m) is supplied standard. If additional length is needed, specify in feet. 100’ (30m) max.
11-073 Metal panel mount (with gasket) open frame for brake monitor
20-022 1A Slo-Blo nano SMF fuse
52-003 Computer / Power supply / Relay board (with CPU)
52-084 Ribbon Cable
52-202 Encoder board
53-451 EN-1600D Encoder with double-ended shaft