Model BM-1600

BM1600

The BM-1600 is a precision brake monitoring system designed to measure brake stopping time (milliseconds) and press RPM/SPM with high accuracy. A high-resolution rotary encoder, driven at a 1:1 ratio by the press crankshaft, ensures precise measurements. Key data such as brake stopping time and machine RPM/SPM are displayed on a bright, easy-to-read LED panel after every cycle, enhancing operator safety and press reliability.

Ordering Guide
Installation Manual

BM-1600 Applications/Categories: Time Based Brake Monitoring

Package Includes: BM-1600 Brake Monitor Controller, E-160 Encoder (CW/CCW rotation capable), 20′ Encoder Cable, Installation and Operation Manual

Features

  • Brake Monitoring: Displays brake stopping time in milliseconds after each stop.
  • RPM/SPM Display: Real-time machine cycle speed during operation.
  • LED Status Indicators: Detailed definitions, causes, and fixes are provided in the supplied installation and operation manual.
    • Green (Ready): All systems are go.
    • Yellow (Brake On): Power to the dual solenoid valve is off.
    • Yellow (Brake Warning): Brake stopping time exceeds the warning setpoint
    • Red (Brake Failure): Stopping time exceeds the brake limit.
    • Red (Drive Failure): Encoder signal interruption detected.
    • Red (Not Ready): System fault or safety relay deactivation.
  • Brake Warning Time and Brake Limit Time Display
  • Built-in 90° and 270° Stop Time Measurement: Initiates a stop signal at the 90° and 270° positions in the downstroke. This information is required to calculate the location of point of operation guarding systems or palm button assemblies.

Design Specifically for the Rigorous Metal Stamping and Forming Industry

  • Compact, front-panel-mounted controller for easy installation and programming.
  • Compatible with OEM systems, retrofits, and rebuilds.
  • Durable, flat-panel design with NEMA 12-rated steel enclosure.
  • Interfaces seamlessly with solid-state or relay-logic press controls.
  • Solid state indicators – no incandescent bulbs that burn out
  • Made in the USA.

Programming and Safety

  • Setpoint Adjustment: Use the secure keyed selector switch and +/- buttons to set warning and failure thresholds (1–999 ms). Changes are locked while the encoder is active for added safety.
  • Non-Volatile Memory: EEPROM storage ensures settings and fault data are retained without battery backup, even during power loss.
  • Dual Safety Relays: Force-guided relays automatically deactivate in fault conditions, preventing further operation until reset.
    • Safety relays are always de-energized when the programming key is not in the Run position.
    • Safety relays are energized when the programming key is in the Run position, as long as there are no faults detected.
    • Only a key turn to the reset position can clear a fault, and the relays de-energize if the key is moved into the reset position without a fault.
  • Motion Detection: Motion detection will be monitored while in the reset position, even if the encoder is turning.

Predictive Maintenance

The BM-1600 enables proactive maintenance by monitoring factors affecting stopping time, such as:

  • Machine speed and tooling weight
  • Clutch and brake wear
  • Air supply to the clutch and counterbalance systems
  • Exhaust restrictions

Advanced Diagnostics

  • Self-diagnostics display error codes for easy troubleshooting.
  • Faults are stored in memory with the last recorded stopping time, simplifying maintenance and reducing downtime.

Compliance

The BM-1600 meets OSHA 29 CFR 1910.217 and ANSI B11.1-2009 (R2020) standards 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, which is required on any press that has a single stroke mode and uses either a two-hand control, light curtain, or type B gate system.

Technical Specifications

Controller

  • Power: 120 VAC ±10%, 50–60 Hz (standard); optional 24 VDC ±10%
  • Power Consumption: 8 watts
  • Operating Temperature: 0–50°C
  • Relays:
    • Safety: Dual self-checking force-guided captive contact safety relays
      • 8A @ 250 VAC resistive for safety relays
      • 4A @ 250 VAC resistive for alarm relay
  • Accuracy: ±1 millisecond
  • Setpoints:
    • Drive Failure: 0.1–2.5 seconds
    • Brake Warning/Failure: 1–999 milliseconds
  • Dimensions:
    • NEMA 12: 8″ H × 7″ W × 4″ D
    • Front Panel Mount: 8″ H × 7″ W × 4″ D

Encoder (Part No. E-160)

  • CW or CCW rotation capable
  • Cable: 20′ supplied standard, optional up to 100′ max
  • Gauge: 20 AWG – 3 connectors plus drain
  • Shaft Loading: Radial: 35 lbs; Axial: 40 lbs
  • Operating Temperature: 0–50°C
  • Dimensions: 5.5″ H × 3.75″ W × 3.56″ D

Ordering Procedure

Model BM 1600 Ordering Procedure
  1. Select BM or BDM for Encoder Style
  2. Specify Mounting Style
    • F: Front Panel Mounting to be installed in an existing control panel
    • C: Stand-alone NEMA 12 (IP 64) steel enclosure.
  3. Specify Controller Input Power
    • 1: 24 VDC
    • 2: 120 VAC, 50-60 Hz
    • 3: 240 VAC, 50-60 Hz
  4. Specify Clutch/Brake Valve Coil Voltage
    • 1: 24 VDC
    • 2: 120 VAC 50-60 Hz
  5. Encoder Connector Cable
    • 20′ (6m) is supplied standard.
    • If additional length is needed, specify in feet (100′ max)

Replacement Parts

  • 11-001 – Metal box enclosure (with gasket)
  • 11-073 – Metal panel mount (with gasket) open frame for brake monitor
  • 20-001 – 1A Slo-Blo glass 3AG fuse
  • 20-022 – 1A Slo-Blo nano SMF 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
  • 52-003 – Computer / Power supply / Relay board (with CPU)
  • 52-084 – Ribbon Cable
  • 52-202 – Encoder board
  • 53-004 – E-1600 Encoder with single-ended shaft (supplied standard)
  • 53-451 – EN-1600D Encoder with double-ended shaft
Ordering Guide
Installation Manual