ISB RBPC User manual
Rev. 22
March 2019
P/N: 60 0140 01
RBPC – Resolver Based Press Control
Installation Manual
Complementary to the RBPC User's Manual
Table of contents
1 . Installation Procedure............................................................................................................................................ 3
2 . Installation tips....................................................................................................................................................... 5
2.1 . Front panel mounting..................................................................................................................................... 5
2.2 . Heat considerations....................................................................................................................................... 5
2.3 . Wiring guidelines............................................................................................................................................ 5
2.4 . Grounding essentials..................................................................................................................................... 5
2.5 . Noise considerations...................................................................................................................................... 6
2.6 . Understanding t e fault messages (w at to do?)...........................................................................................6
2.7 . PLS Outputs................................................................................................................................................... 6
3 . System overview.................................................................................................................................................... 7
3.1 . RBPC at first glance....................................................................................................................................... 7
3.2 . Front panel..................................................................................................................................................... 8
3.2.1 . Main mode selector switc ..................................................................................................................... 8
3.2.2 . LED circular array (LCA)........................................................................................................................ 8
3.2.3 . LCD display........................................................................................................................................... 8
3.2.4 . Keypad................................................................................................................................................... 9
3.3 . Rear panel................................................................................................................................................... 10
4 . Connection tables................................................................................................................................................. 11
4.1 . Optional connections................................................................................................................................... 12
5 . Mec anical dimensions........................................................................................................................................ 13
6 . Part c eck list....................................................................................................................................................... 14
7 . Specifications....................................................................................................................................................... 14
8 . Function key......................................................................................................................................................... 14
9 . Outputs................................................................................................................................................................ 14
10 . Troubles ooting................................................................................................................................................. 15
10.1 . Backwards movement detected................................................................................................................. 15
10.2 . Resolver c eck not found........................................................................................................................... 15
10.3 . Brake time exceeded................................................................................................................................. 15
This installation manual is a complement to the RBP User's manual. Please read both documents carefully before
installing and using the RBP
Page 2 of 15
1 Installation Procedure
⚠ IMPORTANT
Before applying power to t e control, make sure t at t e following is connected:
✔ Resolver and proximity switc
✔ J6-9 Top stop switc
✔ J7-4 Aux top stop
✔ J7-5 Aux E-Stop stop
✔ J3-1 Safety lig t curtain input
✔ J3-2 Emergency stop input
T e control as to see t ese inputs, ot erwise faults will be generated and t e setup process will take more time.
Page 3 of 15
STEP1: T e first step is to cut out t e area for t e control
STEP2: Mount t e resolver wit t e spring bracket, t e proximity switc and t e RBPC.
STEP3: Wire t e RBPC as per t e included wiring diagram
STEP4: Put t e mode key-switc in PROG position
STEP5: Clear all t e faults on screen (see section 2.6)
STEP 6: Once t e control states “Press EXIT to Conf.” in t e fourt line of t e display, t en proceed.
STEP 7: Now t e resolver offset must be programmed. Refer to t e Resolver Settings section of t e RBPC User's
Manual for step-by-step instructions.
Page 4 of 15
RESOLVER
RESOLVER CHAIN LINK
PROXIMITY SWITCH AND
MOUNTING BRACKET
Resolver mounted wit a c ain and
sprocket from t e existing cam s aft.
A resolver spring bracket must be
used to avoid damaging t e resolver
due to improper axial load.
T e proximity switc is mounted so t at
it is directly actuated by t e cam of t e
press. T e proximity as to be mounted
so t at it is activated w en t e mac ine
is a t e top dead centre.
Mount t e resolver on t e spring bracket
as s own in t e drawing.
W en t e c ain link is in place, t e
bracket s ould be compressed alf way
in. T is will provide proper load
absorption and will allow an easy removal
of t e c ain if required.
2 Installation tips
2.1 Front panel mountin
T e Front Panel Mounting unit as a sealed front plate and is provided wit four #10-32 bolts for mounting. #10-32
nuts are required to secure t e panel.
2.2 Heat considerations
T e installation enclosure for t e RBPC s ould be at least 76 mm (3”) deep and ave a minimum of 50 mm (2”)
clearance on all sides. No eat producing control or ardware s ould be mounted directly underneat t e RBPC.
2.3 Wirin uidelines
•T e RBPC must be powered from a dedicated 120 V AC line wit an appropriate fuse and power switc .
•Do not wire any ot er devices in series wit wit t e AC power input of t e RBPC (J3-3), suc as air or oil
pressure switc es, counterbalance, die block or any ot er monitoring switc es.
•If ot er s ut-off monitoring devices like t ose mentioned above are required, t ey s ould be wired in line wit
t e E-Stop monitoring input of t e RBPC (J3-2.).
•T e lig t curtain input (J3-1) and E-stop input (J3-2) of t e RBPC are not safety-related and can only be used
for monitoring purposes.
•Do not install 12 V or 24 V wiring in t e same conduits or raceways as t e mac ine ig voltage wiring,
including motor wiring.
•Connect all t e inputs, outputs, resolver and proximity switc es before applying power.
•Appropriate transient suppressor devices must be connected (in parallel) to eac solenoid of t e clutc safety
valve and as close as possible to t e solenoid terminals (see V1 & V2 in figure below). Suitable suppressor
devices can be ordered from ISB (e.g. P/N 56000502).
2.4 Groundin essentials
A proper grounding is essential to t e RBPC operation. Please observe t e following grounding guidelines w en
wiring t e RBPC:
•Use a t ick grounding wire to connect t e c assis GND terminal of t e RBPC to t e eart ground point in t e
control panel.
•T e enclosure itself s ould ave a good eart ground connection. A separate 1.5 mm2 (16 AWG) or t icker
ground wire is essential.
•A star was er s ould be used toget er wit a mounting bolt to ensure a good electrical connection between t e
RBPC c assis and t e enclosure.
•Before finis ing t e installation, measure t e electrical reistance of t e ground wiring to ensure t at it complies
wit t e local electrical codes and regulations.
Page 5 of 15
Figure 1: Connection of transient suppressor devices
CLUTCH DUAL
SAFETY VALVE
V2
V1
2.5 Noise considerations
All motor starters, contactors or any ot er inductive or noise generating devices s ould be mounted in eit er a
separate control panel or in a separate section of t e RBPC enclosure, at least 305 mm (12”) away.
W en t e RBPC is mounted in an enclosure or a control panel, use separate conduit entrances for low voltage
wiring and 120 V AC wiring.
2.6 Understandin the fault messa es (what to do?)
T e faults in t e RBPC are generated one at a time. If a fault occurs, t e fault as to be corrected first and t en it
as to be reset on t e main screen. T e faults are generated and stored like a deck of cards, one on top of anot er.
If multiple faults ave occurred t en once t e first fault is cleared t e next one will appear instantly after t e first. All
errors are saved in memory. If a power down occurs t ose same faults will re-appear t e next time t e control
powers up. Please refer to Appendix 1 in t e RBPC User’s Manual for a detailed listing and explanation of all faults
messages.
2.7 PLS Outputs
In order to cover a wider range of applications wit t e standard configuration, t e PLS outputs of t e RBPC are
factory equipped wit general purpose electromec anical relays. However, it is important to note t at t e service
life of electromec anical relays is inversely proportional to t e load current and to t e number of operations; t at is,
t e greater t e number of cycles t at an electromec anical relay is actuated and t e ig er t e current t roug its
contacts, t e s orter its service life.
T is wear mec anism can be particularly significant w en t e PLS outputs are programmed to operate at relatively
ig speeds (e.g. > 100 cycles per minute), as t ese operating conditions can lead to a premature failure of t e
relay w ic , ultimately, must be replaced.
To address t is problem, ISB recommends t e use of optional solid-state relays, w ic , aving no moving parts,
provide a longer lifetime and trouble free operation.
However, unlike t eir electromec anical counterparts, w ic can be used in a wider range of applications, solid-
state relays must be selected according to t e specific loading conditions (AC or DC, voltage and current) of eac
particular application. Please use t e information in t e table below to select and order optional ISB solid-state
relays:
ISB Part number Description
22 0240 00 Solid-state relay, AC output, 1 A @ 250 V AC (black colour)
22 0242 00 Solid-state relay, DC output, 1 A @ 60 V DC (red colour)
Please also note t at t e load ratings of t e solid-state relays is lower t an t e standard relays provided wit t e
RBPC.
⚠WARNING: Exceeding t e maximum ratings of t e solid-state relays may cause permanent damage
to t e device and may also lead to damage to t e internal circuitry of t e RBPC
Page 6 of 15
3 System overview
3.1 RBPC at first lance
T e RBPC Resolver Based Press Control is a full clutc control wit t e following features:
•Punc Press and Press Brake control modes.
•Built-in brake monitor t at displays stopping time & stopping angle
•Automatically compensates to stop press at top of stroke even wit varying press speed or die weig t.
•Multi-colour LED circular display array s ows press position and displays PLS & Die protection settings.
•Built-in PLS C annels (4), eac wit 4 dwell settings t at are angle on / angle off and include a maximum time
setting and speed compensation feature.
•Built-in Die protection c annels (4), eac wit multiple dwell inputs t at are universally programmable for
function and stop type.
•Additional PLS and die protection c annels available using external circuit boards.
•Built-in 300 jobs storage capability. Eac job stored will contain press parameters suc as operating mode, PLS
settings, die protection settings, brake settings, counter info and muc more!
•Multi-level password protection; Operator level, set-up level, and supervisor level.
•Numerous built-in counters; total strokes, batc , quality, total faults, running time, etc.
•Fault messages and working conditions recording. Fault codes, our meters, last stopping times and a variety of
ot er faults are stored internally for troubles ooting, etc.
•Message center wit 4-line LCD prompts operator and display user information and settings.
•Durable keypad, 27 keys.
•Standard built-in operating modes; Inc , Single Stroke, Continuous, Auto Single Stroke and Timed inc .
•Standard built-in actuating modes; 2 and controls (2 sets), electric foot switc (2) Kwik-Trip, PSDI Mode 1, and
PSDI Mode 2.
•All modes selectable t roug keypad.
•All electrical connections made from t e back of t e panel using plug-in terminal blocks.
•Compact design is easy to install and user friendly.
•Contains many features t at are normally found in ig -end controllers.
Page 7 of 15
3.2 Front panel
3.2.1 Main mode selector switch
T e main selector switc is used to select t e RUN/Program and OFF modes of t e control. T is feature is used for
supervisory purposes. T e unit can be locked out by putting t e key switc in OFF mode and removing t e key.
T e key is also used to lock out programmable features of t e unit during operation.
3.2.2 LED circular array (LCA)
T is is a circular visual interface to allow t e user to know t e angular position of t e w eel of t e mac ine. It also
s ows t e angles in PLS and DIE protection settings. See t e RBPC User’s Manual for furt er details.
3.2.3 LCD display
T e Press control screen s ows ow t e mac ine is operated. It provides t e following information to t e user:
•Current Strokes per minute
•Angular position of t e cranks aft
•Current operation mode
•Current Actuating mode
T e message line at t e bottom of t e LCD screen is used for:
•S owing messages w en an action is required from t e user
•S owing warning and fault messages
T e control tells you ow to operate and run t e mac ine, also it will tell you exactly w at fault as occurred if
anyt ing goes wrong wit t e operation of t e press.
Page 8 of 15
3.2.3.1 Main screen fi ure
3.2.4 Keypad
T e 27-key keypad provides “hot keys” for direct and easy access to t e desired functions. All jobs and settings are
keyed in using t is durable keypad.
Page 9 of 15
3.3 Rear panel
T e rear panel of t e RBPC looks like t is. T e connector positions mig t be different depending on t e version on
t e RBPC. All connections are made to t e appropriate connector directly to t e back of t e panel. T e Die
Protection Inputs2 and t e PLS outputs2 require extra ardware to be purc ased from ISB.
At t e top of t e back panel t ere are eig t relays. T e first four small relays to t e left are t e PLS output relays
and t e four large relays on t e rig t are t e output relays for t e load.
Page 10 of 15
PLS outputs1
Die protection
Inputs1
Inputs1
(palm, FS etc)
Inputs2
(palm, FS etc)
Communications
TIA-232
Resolver
Power (90-250 V AC/DC)
Main outputs
PLS outputs 2
Die protection
Inputs 2
DIP-switc
(for ISB)
Lig t curtain and
valve reference (V)
LEDs description
table
Extra power/GND
Power/fault
LEDs
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