Electro Cam Plus PS-6144 Series Programming & Installation Manual Download Page 25

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2-15 Installation & Wiring

Communications Wiring

DB-9F Port

Serial communication to a PLC or other system host is provided through a DB-9 female
connector as shown in Figures 5 & 6. This connector can be wired for RS-232 or RS-485
communications.

RS-485

RS-485 can be used for “multi-drop” networks where more than one controller could be
connected to the system host.

RS-232

RS-232 can connect only a single PS-6144 to a system host.

RS-232/485 Selection

Use the COMMUNICATIONS function to select RS-232 or RS-485 communications.

Figure 15—Communications Wiring

DB-9 Female Connector on Controller

(See Figures 5 & 6 for Location)

RS-232 Cable Wiring

DB-25 (Host) to DB-9F (PS-6144)*

RS-232 Cable Wiring

DB-9 (Host) to DB-9F (PS-6144)*

*Pins 1, 4, 6, 7 and 8 must NOT be connected.
Damage may result from using an off-the-shelf
RS-232 communications cable.

Be sure to follow illustrations, as they are NOT
STANDARD configurations!

Summary of Contents for Plus PS-6144 Series

Page 1: ...PLµS PS 6144 Series Programmable Limit Switch 6000 Series Programming Installation Manual 13647 Metric Rd Roscoe IL 61073 USA 815 389 2620 FAX 815 389 3304 800 228 5487 U S A and Canada ...

Page 2: ... Rights Reserved Neither this document nor any part may be reproduced or transmitted in any form or by any means without permission in writing from the publisher PLµS SLIMLINE and PLµSNET are all registered trademarks of ...

Page 3: ......

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Page 5: ...ications A 3 Factory Defaults A 3 PS 6144 Setpoint Record A 4 Index Section 1 Introduction Mechanical Cam Switches 1 1 Programmable Limit Switches 1 1 PS 6144 Description 1 2 Basic Terminology 1 3 PS 6144 Standard Features 1 3 PS 6144 Optional Features 1 4 Section 2 Installation Wiring General Mounting Wiring 2 1 Mounting Dimensions 2 2 Terminals Components PS 6144 24M17 2 3 PS 6144 24 X16 M09 2 4...

Page 6: ...under no circumstances shall Electro Cam Corp be liable for a Any product damaged or lost in shipment Inspection for damage should be made before acceptance or signing any delivery documents releasing responsibility of the delivering carrier b Product failure or damages due to misuse abuse improper installation or abnormal conditions of temperature dirt or other contaminants as determined at the s...

Page 7: ...hes PS 6144ʼs Resolvers The PS 6144 Programmable Limit Switch uses a resolver see Figure 2 on page 2 instead of a cam to indicate machine position A resolver uses fixed and rotating coils of wire to generate an electronic signal that represents shaft position The resolver is usually coupled to a machine shaft at a 1 1 ratio so that one resolver shaft rotation cor responds to one machine cycle Reso...

Page 8: ...chemicals are used The PS 6144 Series is available in two models the PS 6144 24 X16 M09 and the PS 6144 24M17 Both are described in Figure 3 The PS 6144 24 X16 M09 has 25 total outputs 16 transistor outputs are built into the controller Outputs 17 through 25 can accept AC or DC output modules for driving real world devices such as solenoids valves or glue guns Outputs 24 25 will also accept an ana...

Page 9: ...nding setpoints would take effect Standard PS 6144ʼs can store up to 48 programs The active program can be selected through the keypad display mechanical switches direct PLC interface or serial com munication messages Inputs hardware inputs In addition to accepting a signal from the resolver the PS 6144 can accept up to 16 input signals from mechanical switches relay contacts DC two or three wire ...

Page 10: ...am Memory Depending on the number of outputs used standard controls can store 48 programs consisting of not more than 1258 total output pulses Controls with the F option can store up to 256 programs consisting of not more than 4589 output pulses G Gray Code Output This option provides eight bits of position information on outputs one through eight This gray code output can provide position informa...

Page 11: ...h block Wiring Guidelines Follow normal wiring practices associated with the installation of electronic controls Some guidelines are 1 Route input and output wiring away from high voltage motor drive and other high level control signals 2 Use shielded cables for resolver input transistor output and communication circuits Also shield module output circuits that are driving low current electronic in...

Page 12: ...2 2 Installation Wiring Mounting Dimensions Figure 4 Mounting Dimensions ...

Page 13: ... Auxiliary power output PS 9006 0018 TB 3 Inputs 1 8 PS 9006 0023 TB 4 Resolver connector PS 5300 01 TER TB 5 Keypad port connector PS 9006 0029 TB 6 Module outputs 13 17 PS 9006 0031 TB 7 Module outputs 9 12 PS 9006 0030 TB 8 Power for controller PS 9006 0026 TB 9 Module outputs 1 4 PS 9006 0033 TB 10 Module outputs 5 8 PS 9006 0034 Terminal Block Details 1 Keyed to prevent accidental insertion i...

Page 14: ...27 TB 8 Power for controller PS 9006 0026 TB 9 Transistor outputs 1 8 sinking PS 9006 0019 Transistor outputs 1 8 sourcing PS 9006 0021 TB 10 Transistor outputs 9 16 sinking PS 9006 0020 Transistor outputs 9 16 sourcing PS 9006 0022 TB 11 Power for transistor outputs PS 9006 0017 Terminals Components PS 6144 24 X16 M09 Figure 6 PS 6144 24 X16 M09 Terminals Components Top View Terminal Block Detail...

Page 15: ...d resistor in parallel with the input Typical wiring diagrams are shown in Figure 7 Input Functions The following are the input terminals and their corresponding functions Program Select 1 8 The on off status of these terminals selects which program of setpoints is controlling the outputs Binary BCD or Gray Code formats can drive these terminals as shown in Figure 8 When all program select inputs ...

Page 16: ... 13 Group 5 Input 14 Group 6 Input 15 First Cycle Enable 16 Output Enable Input Wiring Guidelines Voltage from TB 2 will be the same as the voltage supplied to the controller Each input powered from TB 2 will draw 11 mA at 24 VDC TB 2 is fused at 1 4 amp Inputs will operate with voltages from 10 to 30 VDC An external power supply can be used instead of TB 2 to power inputs A combination of mechani...

Page 17: ...44 1 1 1 0 1 0 45 1 1 1 0 1 1 46 1 1 1 0 0 1 47 1 1 1 0 0 0 48 1 0 1 0 0 0 Units 10 s Input Terminal 7 6 5 4 3 2 1 Value 40 20 10 8 4 2 1 Program Default 0 0 0 0 0 0 0 1 0 0 0 0 0 0 1 2 0 0 0 0 0 1 0 3 0 0 0 0 0 1 1 4 0 0 0 0 1 0 0 5 0 0 0 0 1 0 1 6 0 0 0 0 1 1 0 7 0 0 0 0 1 1 1 8 0 0 0 1 0 0 0 9 0 0 0 1 0 0 1 10 0 0 1 0 0 0 0 11 0 0 1 0 0 0 1 12 0 0 1 0 0 1 0 13 0 0 1 0 0 1 1 14 0 0 1 0 1 0 0 15 ...

Page 18: ...e analog modules get the power they source from the controller The analog output signal is completely isolated Transistor Outputs PS 6144 24 X16 M09 models include 16 transistor outputs to drive the electronic input circuits of other control devices The outputs are limited to 30 VDC 50 mA each and should not be used to control inductive devices such as solenoids solenoid valves or relays The contr...

Page 19: ...llel with the load Most applications will not need the diodes shown above However highly inductive DC loads may damage modules by generating voltage spikes when switched off Suppress these voltage spikes using one of these two methods Connect a Zener diode across the terminals This will not significantly increase the load turn off time Voltage rating of the diode must be greater than the normal ci...

Page 20: ... 24 N16 M09 Please Note Outputs are rated at 30 VDC 50 mA Transistor outputs should not be used to switch inductive devices such as solenoids or relays Sinking outputs conduct to the negative terminal of TB 11 when on The power supply shown in Load with Built In Power Supply does not have to be the same voltage as the power supply connected to TB 11 ...

Page 21: ...evice Sourcing means that when the logic is true and the output or input device is ON the output or input device is providing a DC voltage to the connected device This information is important when interfacing an Electro Cam Corp product with another electronic device If you are using an Electro Cam Corp product input to an Allen Bradley 1746 IN16 sinking input card or similar A B device you have ...

Page 22: ...ming for that keypad These terminals can be temporarily jumpered during set up to allow entry of programming access codes or they can be switched with a variety of devices including mechanical switches relay contacts and PLC DC outputs See ENABLE CODES in the programming section for details on programming access If a solid state device will be activating the Programming Enable terminals that devic...

Page 23: ... DIP switch is set to zero the default address programmed through the COMMUNICATIONS function takes affect Whereas the DIP switches can set a maximum address of 7 the COMMUNICATIONS function can establish much higher address numbers These settings are not related to com munications with the keypads Two sets of termination switches are included on the controller One set establishes the termination ...

Page 24: ...Termination must be off for devices in the middle of the chain Both termination switches in a pair must be in the same position Address Keypad addresses must be assigned starting with 0 and increasing sequentially The physical location of a keypad in the chain has no relationship to its address During initial programming the KEYBOARD QTY function must be used to enter the number of keypads in the ...

Page 25: ...system host RS 232 RS 232 can connect only a single PS 6144 to a system host RS 232 485 Selection Use the COMMUNICATIONS function to select RS 232 or RS 485 communications Figure 15 Communications Wiring DB 9 Female Connector on Controller See Figures 5 6 for Location RS 232 Cable Wiring DB 25 Host to DB 9F PS 6144 RS 232 Cable Wiring DB 9 Host to DB 9F PS 6144 Pins 1 4 6 7 and 8 must NOT be conne...

Page 26: ...ctro Cam resolvers have an ambient temperature range of 40 to 125 C 40 to 257 F Resolver Wiring Cables for non stainless Electro Cam resolvers are shipped with one end soldered to the resolver connector The connector for the other end is mounted on the controller The shield is connected at both ends of the cable to prevent damage due to electrostatic discharge If electrical noise problems are susp...

Page 27: ...53 9 50 mm 625 624 dia 15 88 15 85 mm For horizontal applications Flange Mount With Rear Connector shown PS 5275 11 ADR With Side Connector PS 5275 11 ADS Cable PS 5300 01 XXX where XXX is length in feet Stainless Steel Horizontal Mount shown PS 5262 11 CTG with right connector PS 5262 11 CTL with left connector Vertical Mount Shaft Up PS 5262 11 CTG V with right connector PS 5262 11 CTL V with le...

Page 28: ...problems are suspected Cable for Resolver with Cannon Connector PT PS 5300 01 XXX XXX Length in Feet Cable for Stainless Steel Resolver with Terminal Strip Connections PT PS 5300 02 XXX XXX Length in Feet Connector Controller End PT PS 5300 01 TER Weidmuller BLA7 12822 6 Connector Inside Resolver cable is stripped and tinned at both ends ShieldingNote Thistypeofresolvercablewillhaveaspadelugconnec...

Page 29: ...ollers are shipped with a spare 4A fuse mounted in the test socket Rating Function ECC Part Wickmann Part 250 mA Power for Inputs TB 2 PS 9005 0250 19374 035 1 A Power for Transistor Outputs TB 11 PS 9005 0001 19370 048 4 A Fuse for Output Modules PS 9005 0004 19370 062 Replacement TR5 Fuse Part Numbers Figure 17 TR5 Fuse Tester and Fuse Locations PS 6144 24M17 PS 6144 24 X16 M09 ...

Page 30: ... the socket Position the notch on the end of the chip as shown below Figure 18 Transistor Chip Replacement 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 PS 6144 24 N16 M09 Sinking Outputs PS 6144 24 P16 M09 Sourcing Outputs TB 11 TB 10 TB 9 Jumper Block Chip For Outputs 9 16 Jumper block does not normally need replacement Jumper Block Chip For Outputs 1 8 Jumper block does not normally need replacement E...

Page 31: ...what to do Numeric Keys Input numeric values within a field ENT must be pressed to enter the value entry will flash until ENT is pressed CLR will backspace within an entry prior to pressing ENT will convert a positive number to a negative number or vice versa INC DEC Keys Increment or decrement a value within a field Hold for rapid scrolling of value Figure 19 Keypad Keys and Corresponding Functio...

Page 32: ...ENU SCALE FACTOR SHAFT POSITION ANALOG QTY RESOLVER TYPE INCREASING DIR PGM SEL MODE DISPLAY MENU RATE SETUP TOGGLE RPM RPM UPD RATE SPD COMP MODE GRP POS DISP COMMUNICATIONS MENU PGM ENABLE MENU ENABLE CODES PER CHN ENABLE ENABLE OPTIONS SETPOINTS SPEED COMP TIMED OUTPUTS OFFSET MOTION DETECT ANALOG OUTPUTS CHN ANDING MENU MOTION ANDING OUTP ENAB AND OUTPUT GROUPS TEST MENU MEMORY TESTS DEFAULT P...

Page 33: ...ed on By hand turning the resolver shaft and watching the module LEDʼs you can observe the effects of programming setpoint val ues Remember that on a PS 6144 24 X16 M09 outputs 1 16 are transistor outputs To activate the LED on a module installed in Position 17 enter the setpoint values into Output Channel 17 Machine Setup Before installing the PS 6144 on a machine be sure the DIP switches are pro...

Page 34: ...r The following table shows the relationship between the analog module number on the screen and the module position on the controller back See Figure 9 for an illustration of analog module positions Module 1 Module 2 Model On Screen On Screen PS 6144 17 Output 17 Output 16 PS 6144 25 Output 25 Output 24 Analog characteristics can be programmed for Modules 1 and 2 even if no analog modules are phys...

Page 35: ... 4 20 mA Minimum Signal 4 16 x 4096 Example For a 5 mA minimum signal Offset 5 4 16 x 4096 256 To program Analog Offset move the cursor to Of and use the numeric keys and ENT See Also OUTPUT STATUS Analog Quantity Menu Path MAIN SCREEN to CONFIG MENU HARDWARE MENU to ANALOG QTY Screen Purpose This screen displays the number of analog outputs that will be programmed into the controller The controll...

Page 36: ...The address set through COMMUNICATIONS programming takes effect only when the DIP switch shown in Figure 13 is set to an address value of zero Whereas the DIP switch can set a maximum address of 7 the COMMUNICATIONS function can set addresses ranging from 0 255 Use the numeric keys and ENT to program the address Channel Copy Menu Path MAIN SCREEN to SETUP MENU to CHN COPY Purpose Channel Copy allo...

Page 37: ...6144 controller can store up to 48 programs in its memory The Default Program is the program that controls the output channels when terminals 1 8 of TB 3 Figure 7 are off The Active Program is the program number that is currently controlling the output channels If there are program select inputs on TB 3 those inputs will determine the Active Program and the Default Program will be ignored If no ha...

Page 38: ...numbers that will be used as passwords to enable the Operator Setup and Master levels Use the SEL key to toggle between enable levels Use the numeric keys followed by ENT to assign codes Operation Each programming level can have only one code That code is stored in the controller and applies to all keypads connected to that controller If a code is entered into a keypad that has a programming enabl...

Page 39: ...n View View View View Model Options View View View View Config Menu Hardware Menu Keyboard Qty Program2 Increasing Dir Program Scale Factor Program Shaft Position Program Analog Qty Program Resolver Type Program Pgm Sel Mode Program Display Menu Rate Setup Program Toggle RPM Program RPM Update Program Spd Comp Mode Program Grp Pos Disp Program Pgm Enable Menu Enable Codes Program Per Chn Enable Pr...

Page 40: ...e 1 Screen SETPOINTS ENABLE ON SETPOINTS or SETUP MENU screen Scroll through choices with UP and Down cursor keys OPERATOR ENABLE ON OFF Toggle with SEL key This screen lists the various items in the SETUP MENU and allows you to turn Operator access to those items on or off Access to the on items will be available only for those output channels that have been turned ON in PER CHN ENABLE Programmin...

Page 41: ...POS DISP must be set to EACH to assign different offsets to groups through OFFSET programming If groups have been assigned different offsets through OFFSET programming setting GRP POS DISP to ONE will immediately change the individual group offsets to the value of Group 1 See Also OFFSET SHAFT POSITION OUTPUT GROUPS MAIN SCREEN Increasing Direction Menu Path MAIN SCREEN to CONFIG MENU HARDWARE to ...

Page 42: ... one keypad is physically connected Menu Tree operation will be very slow Change KEYBOARD QTY to 1 to restore normal Menu Tree speed KEYBOARD QTY 1 Number of keyboard display units attached to controller Input Status Menu Path MAIN SCREEN to SETUP MENU to I O STATUS to INPUT STATUS The input status screen displays the On Off status of the DC inputs on Terminal Blocks TB 1 and TB 3 Figure 7 Screens...

Page 43: ...hrough the DEFAULT PROGRAM function Machine Speed When the machine is moving Machine Speed is displayed in user selectable units of RPM revolutions per minute BPM bags per minute or CPM cartons per minute Machine Speed is displayed as a value which is 1X 2X or 3X the resolver RPM See RATE SETUP for details Toggle RPM Machine or Group Position is displayed only when the resolver speed is below the ...

Page 44: ... setpoints and configuration settings from the controllerʼs EEPROM After clearing the setpoints the controller will reload the factory default settings listed in the Appendix Function 7001 Clears all configuration settings from the controllerʼs EEPROM These include all of the programming performed through the Setup Menu and Config Menu on the menu tree Figure 20 When finished the controller will r...

Page 45: ...t of each other Each output channel can be ANDed with either Motion Level ANDed outputs will be enabled only when the resolver speed is within the specified speed range Output channels that are not ANDed will be on whenever the machine position is within their programmed setpoints regardless of machine speed One use of Motion Levels and Motion ANDing is to turn off devices such as glue guns if the...

Page 46: ...2 when using the position set through SHAFT POSITION Since other output channels correlate well with SHAFT POSITION you donʼt want to change it Instead using the OFFSET function for this group you could add 13 to the shaft position so that the glue head would turn on at a group position of 0 and off at 35 Although the group position has been offset by 13 the gun would still turn on at 347 and off ...

Page 47: ...s set to 360 If the ABS of a group is 20 its position will always be 20 dgrees ahead of the machine position If groups have been programmed with their own offsets changing SHAFT POSITION will change all of the group positions at once It is usually best to set SHAFT POSITION to the desired zero position in the machine cycle before programming individual group offsets If groups have been programmed ...

Page 48: ...g modes into a control system can greatly improve line efficiency reduce scrap and improve control accuracy between machine sections at high speeds See Section 5 for a complete explanation of the uses and applications of operating modes Screen Establishing Groups When dividing outputs into groups keep these rules in mind Output channels are assigned to groups sequentially Group 1 will begin with O...

Page 49: ...rogrammed Main Screen When output channels are divided into groups the appearance of the Main Screen will change slightly See MAIN SCREEN for details See Also MAIN SCREEN OFFSET GRP POS DISP Output Status Menu Path MAIN SCREEN to SETUP MENU to I O STATUS to OUTPUT STATUS Purpose This screen shows the On Off state of the output channels and it allows the outputs to be forced Screens If any output p...

Page 50: ...evel will be whichever is greater Output Status Contʼd Selecting Outputs Press the SEL key to change the set of outputs displayed Forcing Outputs Forcing outputs allows you to force an output on or off for diagnostic purposes This function is not available on earlier software models Note When leaving the Output Status screen keep in mind that any outputs that have been forced will return to their ...

Page 51: ...e ON OFF Toggle with SEL key Channel Select Press the INC DEC keys or use the numeric keys and ENT Enable Toggle Press the SEL key to toggle the enable ON or OFF See Also ENABLE OPTIONS Program Copy Menu Path MAIN SCREEN to SETUP MENU to PGM COPY Purpose Program Copy allows you to copy all of the channels and setpoints from one program to another It is often easier to copy an existing program and ...

Page 52: ... number of pulses to be added Enter number then ENT SEL to go to next screen DURATION Duration of each pulse added Enter number then ENT SEL to go to next screen DURATION 35 EXECUTE Move cursor to EXECUTE then press SEL to generate pulses To review values before executing move cursor to top row and press SEL as needed DURATION 35 COMPLETE COMPLETE indicates pulses have been generated Program Selec...

Page 53: ...go to next screen ON 0 On time of leading edge of first pulse Enter 0 then ENT SEL to go to next screen OFF 950 Off time of trailing edge of last pulse Enter 950 then ENT SEL to go to next screen COUNT 10 Total number of pulses to be added Enter 10 then ENT SEL to go to next screen DURATION 50 Duration of each pulse added Enter 50 then ENT SEL to go to next screen DURATION 50 EXECUTE Move cursor t...

Page 54: ...n multiplier MPY divider DIV decimal points DP actual resolver speed and displayed resolver speed If And And Then And a Is MPY DIV DP MPY DIV Resolver Displayed Is Is Is Is Speed Of As 1 2 0 5 100 RPM 50 RPM 1 2 1 5 100 RPM 5 0 RPM 1 2 2 5 100 RPM 50 RPM 1 2 3 5 100 RPM 050 RPM 1 1 0 1 0 100 RPM 100 RPM 1 1 1 1 0 100 RPM 10 0 RPM 1 1 2 1 0 100 RPM 1 00 RPM 1 1 3 1 0 100 RPM 100 RPM 2 1 0 2 0 100 R...

Page 55: ...increment equals a unit of linear travel Screen Limits Scale factors range from two to 1024 on standard controllers For controllers equipped with the H option scale factor can be as high as 4096 Recalculations When the scale factor is changed all programmed setpoints are recalculated to convert them to the new scale factor The keypad display will be inoperative until the calculations are done RPM ...

Page 56: ...e program whose setpoints will be programmed The active program is displayed but any other program can be specified by using the numeric keys or INC and DEC to choose a program then pressing SEL to move to setpoint programming continued Channel to Edit Use the numeric keypad and ENT to select the channel to program Channels 91 through 96 are special channels used for Output Grouping and Modes See ...

Page 57: ...all ON and OFF setpoints for all pulses in the channel will be incremented or decremented simultaneously Deleting a Pulse A pulse may be deleted by making ON equal to OFF or vice versa If there is more than one pulse in the channel the next pulse will appear in the on off setpoint area If the channel has no more pulses the ON and OFF setpoint will both be zero Clearing a Channel To clear a channel...

Page 58: ... activated and the following screen appears Shaft Position Menu Path MAIN SCREEN to CONFIG MENU to HARDWARE MENU to SHAFT POSITION Purpose Because the PS 6144 is a programmable device it can be set to display a position of zero at any point in the machine cycle Usually the machine is jogged to the beginning of a cycle and SHAFT POSITION is set to zero at this point This function eliminates the nee...

Page 59: ... machine position by the specified number of msec See Section 4 for details on applying negative speed compensation To program negative speed comp press the key after entering a number but before pressing ENT You may also decrement a value below zero NOTE Regardless of the number of outputs available speed compensation is limited to any 16 of those available outputs Speed Comp Mode Menu Path MAIN ...

Page 60: ...ulse Required A timed output must be programmed with ON and OFF position setpoints in order for output timing to take effect Reverse Rotation If the machine is rotating in the reverse direction timed outputs will energize when the OFF edge of the pulse occurs Toggle RPM Menu Path MAIN SCREEN to CONFIG MENU to DISPLAY MENU to TOGGLE RPM Purpose Toggle RPM is the resolver speed at which the Position...

Page 61: ...ent such as PLC s stepper motors and stepper motor controls is dif ficult In addition to perform speed compensation at high machine speeds the PLC hardware must be extremely fast and therefore expensive Integrating a PS 6144 into the control system eliminates the need to write custom PLC speed compensation programming and provides excellent high speed control at a fraction of the hardware cost Fix...

Page 62: ... the line speed increases however the gun needs to be energized before 110 to allow the glue to hit the carton in the correct spot The faster the line speed the earlier in the transducer cycle the gun must be triggered Calculation To calculate the amount of speed compensation required use the following relationships between the transducer s RPM revolutions per minute and degrees of rotation 1 RPM ...

Page 63: ...hen estimate a response time and enter it into the controller using the SPEED COMP function described in Section 3 Start the line and run cartons through it at a fixed line speed Program SPEED COMP to adjust the speed compensation value as required for proper gluing This can be done while the line is in motion Once programmed vary the line speed to confirm proper operation at all speeds and fine t...

Page 64: ...oints have been established always adjust the speed compensation value Do not adjust the individual output setpoints Response Times If the response times are unknown jog the line to determine ON and Unknown OFF setpoints at zero speed Estimate both ON and OFF response times and enter them through the SPEED COMP function The leading edge or LE value will control the ON timing while the trailing edg...

Page 65: ...Line Speed 680 49 144 95 Note that the length of the pulse is 83 at 200 RPM and 95 at 680 RPM This means that the leading and trailing edges require different speed compensation values Leading Edge Difference in Position 73 49 24 Difference in Speed 680 RPM 200 RPM 480 RPM Speed Compensation Value Divide difference in position by difference in speed 24 480 RPM 0 05 per 1 RPM Since a shaft at 1 RPM...

Page 66: ... usually found in two situations Wrap Up As some machines increase in speed the drive train at some point between the re solver and the product wraps up or shifts with respect to the resolver If the wrap up is proportional to machine speed negative speed compensation can be used to retard an output channel s setpoints from the true resolver position thus maintaining output accuracy Sensor Lag Whil...

Page 67: ...modes which determines the relationship between the channels in the group and the input signals Benefits Proper programming of output groups and modes can provide substantial benefits ReducedWaste Cleanup By enabling devices such as glue guns to operate only when a product is present operating modes conserve glue and reduce mess and cleanup Increased Productivity When used to compensate for phase ...

Page 68: ...ut channel and continue sequentially for its specified number of channels and so on The last group will automatically include all of the remaining output channels You can establish as many as six groups or as few as one More than one group can be assigned to the same mode Grouping Example 1 All Outputs in One Group Includes Group Input Output Output Terminal Group Group Channels TB 1 Fig 7 Channel...

Page 69: ...utomatically adjust phase relationships between machine sections It can also be used in applications where some machine sections run multiple cycles per resolver revolution Details The group position resets at the leading edge of the input terminal signal regardless of how long the terminal is on Once a reset occurs the input terminal has no effect until it is de energized and the leading edge of ...

Page 70: ...ts are disabled the input terminal is armed and the group position is the same as the value programmed in SHAFT POSITION Section 3 Figure 29 Mode 1 Example Application Three sections of an adjustable phase converting machine are controlled by a single PLuS controller and resolver Groups 1 2 and 3 all operate in Mode 1 The position of each group is reset to the preset value when the group s sensor ...

Page 71: ... of the output channels have completed their functions but before the input terminal will be energized Mode 3 Operation Description Outputs in a group assigned to Mode 3 are on only while their programmed setpoints are on AND the corresponding input terminal is energized If the input is off all of the outputs in the group will be off regardless of setpoint programming See Figure 28 for input termi...

Page 72: ... as shaft rotates the on edge of the pulse will disable the outputs If the shaft is rotating in the reverse direction position decreasing as shaft rotates the off edge of the pulse will disable the outputs MOTION ANDING and OUTPUT ENABLE ANDING can be used with outputs in a Mode 4 group The machine position for a Mode 4 group can be set through OFFSET programming Figure 31 Mode 3 Example Applicati...

Page 73: ...Description Mode 5 operation is similar to Mode 4 operation with the following differences In Mode 4 the leading edge of the input terminal signal must occur within the pulse programmed into the group channel In Mode 5 the group outputs will be enabled if any portion of the input signal occurs within the pulse If the machine stops the group outputs will be disabled immediately This prevents an ope...

Page 74: ... in Step 3 Speed Compensation Modes Speed Compensation Speed compensation will affect individual channels in an output group as programmed through SPEED COMP However speed compensation will not affect the group channels 91 through 96 When using speed compensation and modes together be aware that speed compensation may shift an output channel s setpoints into a pulse programmed in the group channel...

Page 75: ... In the event of accidental alteration or erasure of the controller s programming PLµSNet II can be used to download the ASCII file to the controller to restore normal operation Programming Multiple Units If several PLµS controllers will have the same values one controller can be programmed correctly and its setpoints uploaded to a PC using PLµSNet II The programming can then be downloaded to the ...

Page 76: ...6 2 Communications PLµSNET II Program cont d Sample ASCII Program Copied from PS 6144 Using PLµSNET II ...

Page 77: ...255 CMD 2 hex Command number Commands are listed later in this chapter DTA n hex The number and type of data elements is determined by the command reply or the error All data is sent and received in hex CSM 2 hex Checksum The method by which the PS 6144 calculates the checksum is described later in this chapter When the host sends a command it must include a checksum calculated in the same way so ...

Page 78: ...ion 04 Hello Are you there Cmd ADR 04 CSM CR Reply A CR 06 Com Stop Stop operation idle changes will be written directly to EEPROM with no other action taken Cmd ADR 06 CSM CR Reply A CR 07 Checksum Sets new checksums in EEPROM Cmd ADR 07 CSM CR Reply A CR 08 Start Resume operation Cmd ADR 08 CSM CR Reply A CR 09 Reset Create hard reset through watchdog Cmd ADR 09 CSM CR Reply A CR 0A RPM Current ...

Page 79: ...r Enable Code in hex 58 Master ID Master ID code Put ADR 58 P XXXX CSM CR Reply A CR Get ADR 58 G CSM CR Reply A XXXX CSM CR where XXXX Master Enable Code in hex 0F User Pgm User programming enable disable Put ADR 0F P XX 00 or 01 CSM CR Reply A CR Get ADR 0F G XX CSM CR Reply A 00 or 01 CSM CR where XX is the channel number minus 1 in hex 00 disable and 01 enable 10 Motion Enab Motion detection o...

Page 80: ... CR where YYYY low limit RPM in hex 00 Level 1 01 Level 2 49 Hi Limit Motion detection high limit Put ADR 49 P 00 or 01 YYYY CSM CR Reply A CR Get ADR 49 G 00 or 01 CSM CR Reply A YYYY CSM CR where YYYY high limit RPM in hex 00 Level 1 01 Level 2 17 Time Delay Delay value for Timed Output channels Put ADR 17 P XX YYYY CSM CR Reply A CR Get ADR 17 G XX CSM CR Reply A YYYY CSM CR where XX is the cha...

Page 81: ...ts used Put ADR 4B P XX CSM CR Reply A CR Get ADR 4B G CSM CR Reply A XX CSM CR where XX is the number of analog outputs used XX can be 00 01 or 02 1C Analog Analog values Put ADR 1C P XX YYYY ZZZZ CSM CR Reply A CR Get ADR 1C G XX CSM CR Reply A YYYY ZZZZ CSM CR where XX is the channel minus one in hex YYYY is the Offset from 0 to 4095 converted to hex ZZZZ is the High RPM in hex 1D Grp Qty Outpu...

Page 82: ...p number minus one YY is the number of output channels in that group in hex 21 Mode Mode for the specified output group Put ADR 21 P XX YY CSM CR Reply A CR Get ADR 21 G XX CSM CR Reply A YY CSM CR where XX is the group number minus one YY is the operating mode from zero to five 47 Output Enab Output Enable ANDing on or off for specified channel Put ADR 47 P XX 00 or 01 CSM CR Reply A CR Get ADR 4...

Page 83: ...nus one ZZZZ and TTTT are the on and off points of the pulse respectively All values are in hex 25 Add Spt Adds a setpoint Cmd ADR 25 XX YY ZZZZ TTTT CSM CR Reply A CR where XX is the program number minus one and YY is the channel number minus one ZZZZ and TTTT are the on and off points of the pulse respectively All values are in hex 26 Del Spt Deletes a setpoint Cmd ADR 26 XX YY ZZZZ TTTT CSM CR ...

Page 84: ...am number minus one and YY is the channel number minus one ZZZZ and TTTT are the current on and off points of the pulse respectively MM specifies the scope of the change 00 is the off edge 01 is the on edge 02 is both edges of the pulse and 03 is all edges of all pulses in the channel All values are in hex 30 Def Disp Default display on start up Put ADR 30 P XX CSM CR Reply A CR Get ADR 30 G CSM C...

Page 85: ...ADR 2C P 00 or 01 CSM CR Reply A CR Get ADR 2C G CSM CR Reply A 00 or 01 CSM CR where 00 disabled 01 enabled 2D En Act Pgm Active Program enable at operator level Put ADR 2D P 00 or 01 CSM CR Reply A CR Get ADR 2D G CSM CR Reply A 00 or 01 CSM CR where 00 disabled 01 enabled 2E En Spd Cmp Enable Speed Comp programming at operator level Put ADR 2E P XX 00 or 01 CSM CR Reply A CR Get ADR 2E G XX CSM...

Page 86: ...0 1 2 2 48 50 50 53 48 69 48 56 48 48 49 57 48 49 50 50 821 decimal 821 decimal FCCB hex therefore Checksum CB String sent to controller 02250E0800190122CB CR Error Codes Error Replies If a command sent to the PS 6144 cannot be processed for any reason the controller sends a reply in the following format N error code CSM CR The error codes are listed below Code Name Meaning 00 OK Processed ok 01 B...

Page 87: ...sing controller data via dedicated registers specific indexed data items can be accessed through the 240 data display registers This is done by map ping a specific indexed data element to a data display register a data display register is assigned to represent a pulse speed comp value etc Once an indexed data element is mapped it can be accessed either through the data display register or through ...

Page 88: ...nnel Index 40288 Analog Offset 40289 Analog High RPM Gray Code Speed Compensation 40290 Gray Code Speed Comp Discrete Elements Inputs 10001 10016 DC Inputs Outputs 00001 00100 Channel Outputs ORing and NOT ANDing 00101 00200 Channel ORing 00201 00300 Channel NOT ANDing Special Purpose 00301 00400 Special Purpose 00301 Global Unforce 00302 Pulse Register Enable 00303 Create New Pulse 00304 Move Bot...

Page 89: ... Speed Comp Display Mode 40325 Group Position Display Mode Password ID Numbers 40326 Operator ID 40327 Setup ID 40328 Master ID Per Channel Enable 40329 Per Channel Enable Index 40330 Per Channel Enable Operator Function Enable 40331 Operator Function En able Bitmask Motion ANDing 40332 Channel Index 40333 Motion Enable Level Output Enable ANDing 40334 Output Enable Index 40335 Output Enable Group...

Page 90: ...to increment feature on index registers This feature allows sequential reading of indexed values without changing the index register Inputs 10001 10016 DC Inputs These points represent the status of the DC inputs Outputs 00001 00100 Channel Outputs These coils represent the status of the channel outputs Forcing these coils directly will set clear the appropriate ORing and ANDing coils as required ...

Page 91: ...ing 40261 Pulse Mapping Read write Values 17 255 General Purpose register used for mapping the On and Off values for the pulse specified by the index registers Two registers will be used the first will contain the On value the second will contain the Off value 40262 Total Pulse Count Read write Values 0 n Returns the total number of pulses for all channels Writing a value of 0 to this register wil...

Page 92: ...r is reset to 1 when the Program Index Register is changed 40266 Pulse Index Read write Values 1 n Contains the current pulse number for pulse access This register is reset to 1 when the Program Index Register or Channel Index Registers are changed 40267 Pulse On Read write Values 0 Scale Factor 1 Pulse On Value 40268 Pulse Off Read write Values 0 Scale Factor 1 Pulse Off Value 40269 New On Read w...

Page 93: ...ay on after it has bee turned on Offset 40279 Offset Mapping Read write Values 17 256 General purpose register used for mapping Group Offset values 40280 Group Index Read write Values 1 6 Group index for offset values 40281 Group Offset Read write Values 0 Scale Factor 1 Offset value for the specified group Note that this value is a PRESET value for groups in modes 1 or 2 Motion Detection 40282 Mo...

Page 94: ... Values 1 2 Analog channel index for analog offset and high RPM values 40288 Analog Offset Read write Values 0 4095 Analog output at 0 RPM 40289 Analog High RPM Read write Values 0 3000 RPM at which analog output is 4095 Gray Code Speed Compensation 40290 Gray Code Speed Comp Read write Values 0 n 1mS In controllers equipped with the G option the Gray code bit pattern is speed compensated by this ...

Page 95: ...sing Direction Read write Values 0 CCW 1 CW Specifies the direction of rotation of the resolver viewed from the shaft end that will result in an increasing numerical display of position 40307 Scale Factor Read write Values 2 1024 4096 with H Option Scale factor used for pulse position and offset programming 40308 Shaft Position Read only Values 0 Scale Factor 1 Returns the current resolver shaft p...

Page 96: ...6000 s with 5144A Input Board Display Configuration 40317 Default Display Read write Values 0 RPM 1 Position 2 Auto Select Specifies Pos Rpm display mode only applicable on 5XXX controllers 40318 Rate Multiplier Read write Values 1 1091 RPM rate multiplier 6000 controllers only 40319 Rate Divisor Read write Values 1 63 RPM rate divisor 6000 controllers only 40320 Rate Decimal Point Position Read w...

Page 97: ...to enable the Setup access level for programming 40328 Master ID Read write Values 0 n Specifies the Master ID number used to enable the Master access level for programming Per Channel Enable 40329 Per Channel Enable Index Read write Values 1 Max Channel Number Channel index for the Per Channel Enable register 40330 Per Channel Enable Read write Values 0 No Operator access 1 Operator access enable...

Page 98: ...nes the number of channels in the output group specified by the Group Index Register 40339 Group Mode Read write Values 0 5 Defines the operating mode for the output group specified by the Group Index Register Note that groups in mode 0 do not need or have an enable input Run Time Control 40340 Stop Control Read write Values 0 Running 1 Stopped When PLuS is STOPPED changes written to registers do ...

Page 99: ...rs and coils will reflect the forced conditions 40370 40379 ORing Bits Read Write Values 0 65535 Each register represents the status of 16 ORing bits The least significant bit of the register corresponds to the lowest numbered output When a 1 is present in an outputs bit position the output will be forced ON The OUTPUT STATUS register will reflect the forced condition 40380 40389 ANDing Bits Read ...

Page 100: ...the data needed for the special function Pulse Copy This function will add a series of pulses to a specific program and channel Register Use 40001 1 Pulse Copy 40002 Program number 40003 Channel number 40004 Beginning on value of pulse envelope 40005 Ending off value of pulse envelope 40006 Number of pulses within envelope 40007 Duration width of each pulse within envelope Registers 40004 and 4000...

Page 101: ...for a second followed by one or more quick blinks off the controller is experiencing internal errors The specific error is indicated by the number of off blinks One Off Blink Corrupt RAM Two Off Blinks Checksum error indicating EPROM corruption Three Off Blinks System error Four Off Blinks System error If any of the above four patterns occur power cycle the control If the pattern occurs again remo...

Page 102: ...umpered as shown a string of plus signs will scroll across the display When either jumper is removed the scrolling will stop Figure 34 Keypad Communications Port Test Setup Unique key ID appears here when any key is pressed Keypad software revision Keypad software revision date Keypad checksum 15 REV 1 00 CS 024B 07APR94 Fault LED blinks ON one second OFF one second Press up or down arrow to retur...

Page 103: ...ately be disabled until the resolver is re connected Press ESC to clear the error message Note that ESC will clear the message and restore access to keypad programming even if the resolver has not been re connected Follow this procedure to troubleshoot electrical problems 1 Verify that the electrical connections at each end of the resolver cable are secure 2 Disconnect the cable at the controller ...

Page 104: ... the keypad Once the calculations are complete contact will be re established Press ESC to clear any remnants of the error message Programming functions not 1 Programming not enabled See Figure 12 and also ENABLE CODES for details accessible ERROR Analog 1 This is a non fatal error indicating the controller s internal analog chip is not working Malfunction A bad or missing analog module will not c...

Page 105: ...tion If not verify that the SETPOINTS are correctly pro grammed Other programming that may prevent an output from energizing includes MOTION ANDING and OUTPUT ENABLE ANDING 3 If OUTPUT STATUS shows the output is on use a meter to see if the output terminal is energized If so check the load device and its wiring If not check the transistor output fuse Figure 18 Use the fuse tester built into the co...

Page 106: ... Cam Part Main Fuse Figs 5 6 1 1 4 Amp Slo Blo Glass Bussman MDL 1 1 4 PS 9000 4114 Module Fuse 4 Amp TR 5 Wickmann 19370 062 PS 9005 0004 Input Fuse Fig 17 250 mA TR 5 Wickmann 19372 035 PS 9005 0250 Output Transistor Fuse Fig 17 1 Amp TR 5 Wickmann 19370 048 PS 9005 0001 ...

Page 107: ...ourcing P16 optically isolated Sinking or sourcing must be specified on order Outputs PS 6144 24 M17 Real World Outputs Up to 17 Slimline modules may be mounted on controller Modules may be any mix of AC DC reed relay and up to two analog All modules optically isolated Analog Output Output Types 4 20 mA or 0 10 VDC proportional to RPM Resolution 12 bit Update Frequency 10 times sec minimum Lineari...

Page 108: ... Part EC ODC200 1 SLIMLINE Output Voltage 0 to 200 VDC Output Current 1 amp DC below 45 C 113 F Above 45 C derate 18 mA C 10 mA F Turn On 50 µs maximum Turn Off 50 µs maximum Off State Leakage 1 µA maximum Operating Temp 30 C to 70 C 22 to 158 F Analog Output 0 10 VDC Part EC SANL 010V Resolution 12 Bits 4096 Increments Output Voltage 0 to 10 VDC Output Current 10 mA maximum Load Resistance 1 K Oh...

Page 109: ...er only 30 arc minutes combined with R D converter in controller Linearity specials 3 to 10 arc minutes resolver only 7 to 14 arc minutes combined with R D converter in controller Note A resolver s linearity errors are repeatable at all positions of its 360 degree rotation Therefore once appropriate setpoints are established machine performance is consistent every cycle Factory Defaults Analog Out...

Page 110: ...___________________________ 17 _____ _____ _____ _____ _____ _____ _____ ______ ________________________________ 18 _____ _____ _____ _____ _____ _____ _____ ______ ________________________________ 19 _____ _____ _____ _____ _____ _____ _____ ______ ________________________________ 20 _____ _____ _____ _____ _____ _____ _____ ______ ________________________________ 21 _____ _____ _____ _____ _____...

Page 111: ...ttings 2 13 2 14 Communications Baud Rate 3 6 Communications Introduction 1 4 6 1 Communications Serial 6 3 Communications Wiring 2 15 Communtications PLµSNET II 6 1 Components Layout 2 3 2 4 Controller Diagnostics 7 1 Controller Specifications A 1 Copy Program 3 21 Copy Pulse 3 22 D Default Program 3 7 Defaults Factory Settings A 3 Diagnostics Controller 7 1 Diagnostics Keypad 7 2 Dimensions 2 2 ...

Page 112: ...ction 5 1 Output Groups Programming 3 19 5 2 Output Modules General 2 8 Output Modules Specifications A 2 Output Modules Wiring 2 9 Output Status 3 19 Output Transistors General 2 8 Output Transistors Replacement 2 20 Output Transistors Specifications A 3 Output Transistors Wiring 2 10 2 11 Outputs Analog 1 4 2 8 3 4 Outputs Timed 1 4 3 30 P Password Entering 3 20 Per Channel Enable 3 21 PLµSNET I...

Page 113: ...Comp Mode 3 29 Speed Compensation 3 28 Speed Compensation Modes 5 8 Speed Compensation Definition 1 4 4 1 Speed Compensation Guidelines 4 6 Speed Compensation Leading Trailing 1 4 3 28 4 4 Speed Compensation Negative 3 29 4 6 Speed Display Machine 3 13 Status Input 3 12 Status LED 7 1 Status Output 3 19 T Terminal Block Keypad 2 12 Terminal Block Part s 2 3 2 4 Terminal Blocks Controller 2 1 2 3 2...

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Page 116: ...800 228 5487 U S A and Canada Web Site www electrocam com email ecam electrocam com PRINTED IN U S A 256 9 14 ...

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