Electro Cam Plus PS-6144 Series, Programming & Installation Manual

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1-3 Introduction
Basic Terminology
The following terms will be used throughout this manual to explain PS-6144 installation,
programming and operation:
Channels Each Channel (CHN) in the PS-6144 controller contains “on” and “off” setpoints for one
360° revolution of the resolver shaft. Channels are one of two types:
Output Channels—These channels use a switching transistor or an output module to
turn an external circuit on or off. One or two output channels in a controller may also
use an analog output module to generate a control signal that is proportional to RPM.
Group Channels—These channels control the interaction between groups of outputs
and an input received from a sensor or other controlling device. See Section 5 for details
on Group Channels.
Setpoints “Setpoints” are the points within one rotation of the resolver at which a channel turns
on or off. Setpoints can be programmed into a channel through the keypad/display, or
they can be downloaded from a computer or PLC through serial communications. The
PS-6144 can turn any given channel on and off multiple times within one rotation.
Pulses A “pulse” is the “on” period between the time a channel is turned on and off. The “on”
setpoint is the leading edge of the pulse, and the “off” setpoint is the trailing edge .
When multiple pairs of setpoints are programmed into one channel, the channel is said
to have multiple pulses.
Programs Suppose that 15 output channels on a cartoner are programmed with setpoints to fold
and glue a certain size carton. These settings could be stored as a “program.” The 15
output channels could then be re-programmed with different setpoints for a different size
carton. This second set of setpoints could also be stored as a program. To change carton
sizes, an operator could simply activate the correct program, and the corresponding
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 sensors,
solid state DC output modules, or PLC DC outputs. The PS-6144 hardware inputs are
dedicated to specific functions involving program selection and controlling output chan -
nels based on sensor signals.
Groups and Modes Output channels can be combined into “groups”, and each group can be associated
with an input terminal in any of six different “modes” of operation. For example, some
modes activate the group only when the corresponding input has signaled that product
is present. Glue control is a typical application where outputs are disabled until product
is sensed. See Section 5 for details.
PS-6144 Standard Features
Scale Factor The user can program the number of increments per revolution, or “Scale Factor.” For
example, to make the controller display position in degrees, a Scale Factor of 360 is
used. For some applications, Scale Factor may be set to define increments in terms of
linear distance, such as one increment equals 0.1" of travel. Standard controls have a
maximum of 1024 increments per revolution, while “-H” option (high resolution) controls
have a maximum of 4096 increments per revolution.
Programming Access Three levels of programming access are provided: Operator, Setup, and Master. Each
level can be assigned a password that must be entered to allow programming at that
level. In addition, the Operator and Master levels can be activated on an individual
keypad through hardware terminals on the back. Careful use of programming access
levels can provide key personnel the flexibility they need in programming the controller,
while protecting settings against accidental or unauthorized changes.