AMETEK 1995A User Manual
Series 1995A
Gemco
Micro-Set Programmable Limit Switch
®
Installation & Programming Manual
1080 North Crooks Road
Clawson, MI 48017-1097
Phone: (248) 435-0700
FAX: (248) 435-8120
Internet: www.ametekapt.com www.ametek.com
Preface
This manual is for the Installation and Maintenance of the Gemco Series 1995A Micro-Set Programmable
Limit Switch.
Copyright 2000 by AMETEK
All Rights Reserved - Made in the U.S.A.
Version 0.1
AMETEK has checked the accuracy of this manual at the time it was printed. Any comments you may
have for the improvement of this manual are welcomed.
AMETEK reserves the right to revise and redistribute the entire contents or selected pages of this
manual. All rights to the contents of this manual are reserved by AMETEK.
iInstallation & Maintenance Manual
Contents
Chapter 1: Introduction/Description 1
1.1 Programmable Features ....................................................................................................... 1
1.2 General Information ............................................................................................................. 1
1.3 Controller Features and Functions ........................................................................................ 2
Chapter 2: Installation 3
2.1 Mechanical Installation ......................................................................................................... 3
2.2 Electrical Installation ............................................................................................................ 4
2.3 Wiring Instructions ............................................................................................................... 4
Chapter 3: Programming 5
3.1 Security Input ...................................................................................................................... 5
3.2 Initialization.......................................................................................................................... 5
3.3 Scale Factor ........................................................................................................................ 5
3.4 Number of Outputs.............................................................................................................. 6
3.5 Selecting Number of Outputs ............................................................................................... 6
3.6 Multiprogram (Available Only on P Option Units) .............................................................. 6
3.7 Setpoint Formula ................................................................................................................. 7
3.8 Setpoints ............................................................................................................................. 8
3.9 Clear an Existing Setpoint .................................................................................................. 10
3.10 Clear All Setpoints............................................................................................................ 10
3.11 Setpoint Availability ........................................................................................................... 10
3:12 Electronic Offset ............................................................................................................... 11
3.13 Reset-to-Preset ................................................................................................................ 11
3.14 Motion Detector ............................................................................................................... 12
3.15 Power-Up in a Position or RPM ....................................................................................... 13
3.16 Decimal Point Programming .............................................................................................. 13
3.17 Enable/Disable Outputs..................................................................................................... 14
3.18 Linear Speed Offset (Available Only on Option P Units .................................................. 14
3.19 Programming 1995 PLS for Linear Speed ......................................................................... 16
3.20 Minimum Speed Disable ................................................................................................... 16
3.21 Time-Based Outputs (Available Only on Option P Units) ................................................ 17
Chapter 4: Expansion Modules 18
Chapter 5: Fault Check 19
5.1 PLS Output Status on Fault Conditions ............................................................................... 20
Installation & Maintenance Manualii
Chapter 6: Security Inputs 21
Chapter 7: Remote Circular Display 22
7.1 POS/RPM On Remote Circular Display ............................................................................. 22
Chapter 8: Troubleshooting 23
8.1 Preliminary Checks ............................................................................................................ 23
8.2 Transducer Excitation Voltages ........................................................................................... 23
8.3 Electrical Noise and Power Quality Consideration .............................................................. 24
8.4 Grounding ......................................................................................................................... 24
8.5 Incoming Power ................................................................................................................ 24
8.6 Low Level Inputs............................................................................................................... 24
Chapter 9: Specifications 26
9.1 1995 Micro-Set PLS Programmer ..................................................................................... 26
9.2 Mechanical Relay (Single Pole, Double Throw) .................................................................. 26
9.3 AC Solid-State (Single Pole, Normally Open) .................................................................... 26
9.4 DC Solid-State (Single Pole, Normally Open) .................................................................... 27
9.5 1995E Output Expansion Module ...................................................................................... 27
9.6 1995-1446 Remote Circular Display .................................................................................. 27
Chapter 10: Troubleshooting Guide 28
Chapter 11: Wiring Diagrams 31
iiiInstallation & Maintenance Manual
Chapter 1: Introduction/Description
Chapter 1: Introduction/Description
The 1995A Micro-Set is a fully self-contained, single-turn resolver-based programmable limit switch.
It includes a three-digit LED display, six output relays, and one fault check relay, and it is fully programmable for the following features:
1.1: Programmable Features
Scale Factor Two scale factors to choose from either 360 or 1,000. On units
with P option software, the scale factor is permanently set to
360.
Electronic Offset Fully programmable offset to any number with the scale factor.
Reset-to-Preset Reset value is programmable to any number within the scale factor.
Motion Detector LS6 can be programmed for either limit switch or motion detect
output.
Expansion Outputs Programmable to accommodate up to 30 circuits.
See Section 1.2: General Information - Software Option P for more options.
1.2: General Information
The 1995A Micro-Set is a fully self-contained, microcomputer-based Programmable Limit Switch
(PLS) with a convenient keypad for programming each independent output circuit to open or close at
the desired settings. This system allows precise position control of rotary motion.
A 1995A consists of a resolver-based transducer, resolver-to-programmer cable assembly, and the
programmer, which provides six limit switch outputs and one fault check output. The optional output
expansion modules will add six additional limit switch outputs per module, and up to four expansion
modules can be driven by the programmer, for a total of thirty limit switch outputs.
The single-turn resolver transducer generates a ratiometric analog signal representing an absolute rotary
position. This ratiometric signal is converted to a digital signal at the Micro-Set. A microprocessor
calculates and/or converts these signals based on user-programmed data.
As the transducer passes through the preprogrammed dwell settings, the programmer outputs can
energize solenoids, relays, or solid-state circuitry to control external circuits.
The 1995A PLS was designed for use in rotary and/or rotary-to-linear applications. It incorporates
many features for safe, efficient operation.
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1
Chapter 1: Introduction/Description
The completely self-contained unit can operate up to 30 independent outputs (six standard) based on
the rotary position of the resolver.
It offers an on line fault check which provides an automatic, in-process mechanism to verify that all
major programmable limit switch functions are operating properly. The fault check output can be
energized by activating the fault check enable input. The output is a mechanical relay with 1 N.O. and 1
N.C. contact, which remains energized during normal operation.
A programmable motion detect output will energize a relay when the transducer speed meets or
exceeds the customer-preprogrammed RPM value.
SOFTWARE OPTION P ENHANCES THE SYSTEM BY OFFERING:
n Multiple Programs - Allow storage of job setups for future use. This saves time
spent reprogramming and lessens the chance of programming errors when tooling is
changed.
n Speed-Induced Offsets - On many variable speed machines, the limit switch outputs
have to be adjusted when the speed increases or decreases. This option automatically
adjusts specified circuits based on speed.
n Time-Based Outputs - Specified outputs can be programmed to turn on based on
position and turn off based on time (0.01 - 9.99 seconds).
1.3: Controller Features and Functions
The controller is housed in an all metal case that can be panel mounted. The controller consists of a
keypad, a CPU Board, and a Power Supply I/O Board.
The following features are found on the 1995A Micro-Set.
n Display A (3) three-digit LED readout and a 10-place bar graph are provided.
The LED readout displays current angular position and/or RPM and
programming details, while the bar graph shows fault check, program
status, and limit status.
NOTE: The Bar graph will not display expansion board relay status.
n I/O Mechanical relays, AC solid-state, and DC solid-state relays are
available, and any combination can be specified. The example in the
catalog shows three AC and three DC solid-state relays being specified. There is a fixed price adder for any combination of relays other
than all mechanical (6M). The fault check relay will always be a
mechanical relay regardless of the type of output relays specified.
See Chapter 9: Specifications.
2
Installation and Maintenance Manual
Chapter 2: Installation
Chapter 2: Installation
This section describes the installation and wiring of a standard 1995A Micro-Set PLS. Changes to
these instructions should be made as necessary if special options and/or equipment are used.
The 1995A Micro-Set should be installed in an area free of water spray, corrosive gases, flying chips
or other foreign matter. The operating temperature should be between 32 and 125 degrees Fahrenheit,
with less than 95% relative humidity.
2.1: Mechanical Installation
Mounting the 1995 Micro-Set PLS
The 1995A Micro-Set PLS is designed to be panel mounted. The face of the 1995A can be affected
by water and/or oil spray. Provisions should be made to protect the face of the unit from spraying or
splashing.
Panel cutouts, mounting holes, and sizes for each component are shown on Pages 6 and 7 of the 1995A
catalog section.
The controller should be mounted in the appropriate panel cutout and securely bolted into place using
the four (4) 3/16" diameter mounting holes.
NOTE: In instances where the 1995A is being mounted directly on a mechanical stamping press, care
should be taken to isolate the controller from shock load and vibration.
It is always good design practice to mount the controller in the enclosure as far away from the motor
starters and control relays as possible to minimize the effects of electromagnetic interference (EMI).
Interconnecting wiring also should be routed to minimize EMI coupling.
Mounting the Transducer
The transducer should be mounted securely to the machine in such a manner so as to minimize shock
and vibration. The transducer should be coupled to the moving machine member, thus reducing
excessive axial and radial loads. Coupling methods should minimize backlash and be in accordance
with the system accuracy required.
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3
Chapter 2: Installation
2.2: Electrical Installation
The Micro-Set is designed for use in an industrial environment and incorporates extensive transient
suppression circuitry. However, the same general installation rules should be followed that are used on
all microprocessor-based equipment. Incoming AC lines should be from a clean power source and
lines carrying computer level signals should not be routed in the same conduit as high voltage, transientproducing circuits such as variable speed drives, welders or DC switching circuits.
The 1995A PLS is only used with a single-turn resolver. Wiring for this system is shown in Fig. 11-3,
Chapter 11: Wiring Diagrams. This wiring diagram is applicable for all standard 1995 PLSs.
2.3: Wiring Instructions
Attach the pre-wired plug on the resolver transducer cable to the transducer and route the shielded
cable through a separate grounded (earth ground) metal conduit to the panel. Connect the mating half
terminal block to the 1995A PLS. Be sure the shield wire is connected to Pin 1 of the 16-place
connector.
When extension to the factory supplied cable is necessary, a junction box should be used to connect the
wire leads and the cable shields from one cable to the other. The cable shield should be grounded at the
1995 Micro-Set only.
AC line voltage - 115V AC + 10% 50-60 Hz - should be connected to the 1995A PLS at the AC
power terminals on the 24-place connector.
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Installation and Maintenance Manual
Chapter 3: Programming
Chapter 3: Programming
3.1: Security Input
The security input is often referred to as the Run/Program input. This input is located on the 16-place
terminal strip and is discussed in Chapter 4: Expansion Modules. This input prevents unauthorized
changes to the programmed functions. With the unit in the Program mode, all functions of the controller can be programmed. With the unit in the Run mode, all setpoints, reset-to-preset, motion detect
and other operational functions can be verified, but the programmed information cannot be changed.
3.2: Initialization
The following key commands should be entered on the
keypad to clear all programmed data upon installation and PRIOR to programming. This sequence
clears all programmed data. All operating parameters must be reprogrammed after using this initialization function.
CIR#- 9- 9 5
--
ENT
3.3: Scale Factor
NOTE: Programming of the desired scale factor or the number of outputs will delete all programmed
data held in memory. Therefore, these should be the first steps in your setup procedure.
The 1995A is available with two scale factors: 360 or 1,000.
To program the scale factor, the following procedures must be followed:
1) Unit must be in the Program mode.
2) Depress
CIR#- 3- 6 0
-or-
CIR#- 9- 9 9
--
--
ENT
ENT
NOTE: ON UNITS WITH SOFTWARE OPTION P, THE SCALE FACTOR IS
PERMANENTLY SET AT 360.
Installation and Maintenance Manual
5
Chapter 3: Programming
3.4: Number of Outputs
The 1995A comes programmed for six outputs, but it is expandable to 30 outputs. However, when
using a Remote Circular Display, the maximum will be 24 outputs.
3.5: Selecting Number of Outputs
Selection of the number of outputs should be done after the desired scale factor is entered, and before
any other programming is done. See Chapter 4: Expansion Modules.
A) To program the number of outputs desired, the unit must be in the Program mode, then depress
. The unit will then show the number of circuits previ-
CIR#- 1- 7 7
ously stored. To change the number of outputs desired, enter the number of relays in multiples
of six and depress .
--
ENT
ENT
1) Valid numbers for are and
. Remember, if using a Remote Circular Display, the maximum number of
30
outputs is 24.
NOTE: If a number is entered that is not a multiple of six, the unit will store the next multiple of six.
CIR#- 1- 7 7
--
ENT
6 12 24 18
,,,,
3.6: Multiprogram (Available Only on P Option Units)
The Multiprogram feature allows the storage of multiple sets of output sequences that are
preprogrammed based on the various requirements of different tooling. When dies or tooling are
changed, the new program is simply called up on the keypad and all outputs are automatically set to the
new output sequences. The number of available programs will vary based on the number of output
limits and the number of setpoints programmed on each limit. A typical six-limit system with one ON
and one OFF setpoint per output will be capable of storing twenty programs in memory
A setpoint is one CIR ON or CIR OFF entry. The following formula shows the relationship
between the number of output relays, the number of programs, and the number of setpoints available
per program.
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Installation and Maintenance Manual
3.7: Setpoint Formula
Setpoint/Programs = 1467 - 2
Number of Programs x A
Where: A = 5 for 6 outputs
= 6 for 12 outputs
= 7 for 18 outputs
= 8 for 24 outputs
= 9 for 30 outputs
Setpoints are in whole numbers (drop decimal).
Example: 12 outputs relays with 10 programs:
S.P. = 1467 -2 = 24.45 - 2 = 22 Setpoints/Program
10 x 6
Chapter 3: Programming
The following table shows the relationship between the number of outputs, the number of programs, and
the number of setpoints per program. The table only shows a few of the many combinations that are
possible. Before programming outputs, it is advisable to verify that enough setpoints are available, otherwise
the number of programs may need to be reduced. A setpoint is one CIR ON or CIR OFF entry.
STUPTUO6STUPTUO21STUPTUO81STUPTUO42STUPTUO03
352/1242/1702/1181/1161/1
21/0252/993/534/497/2
9/6281/2142/843/525/3
6/6321/7181/0142/703/5
1/797/7241/3102/852/6
Number of program Resulting in number of setpoints per program.
Programming 1995 PLS for Multiprogram
A) Specify the number of programs desired, unit must be in the Program mode. Depress
See above table
CIR#- 7- 7 0
for the capabilities of your unit.
äã
-- CIR ON
ENT
-
- ENT-
# of Programs
.
B) Upon entering the above sequence, depressing the key will display the
maximum amount of setpoints per program.
NOTE: A time-based output uses up three setpoints.
Installation and Maintenance Manual
CIR OFF
7
Chapter 3: Programming
C) will display the total number of setpoints available for use in
D) To display the active program, depress .
NOTE: Program 0 is the first program. If 10 programs were previously selected using Code 770,
CIR# 7- 7- -2 ENT-
the currently selected active program.
CIR# - 7 To change programs, with the unit in the Program mode, depress
.
(0 thru Highest Program Number)
there will be programs 0-9.
-
ENT
7 1
-
ENT-
3.8: Setpoints
Programming New Setpoints
A) Unit must be in the Program mode.
B) Select a limit switch circuit for programming. Depress .
The circuit number selected cannot exceed the number of output relays specified earlier using
CIR# 177. See Section 3.5: Selecting Number of Outputs.
CIR#
--(1 thru 30) -
ENT
-
C) Depress . The will set the selected relay turn-on
point.
D) Depress . . This will set the selected relay turnoff
point.
1) On units where time-based circuits have been selected, the will be the
E) Multiple ON and OFF setpoints can be programmed on each circuit. All decimal points will
flash when more than one setpoint exists on the selected circuit.
F) An LS (Limit Switch) may not have the same value for both the ON point and the OFF point.
If a value is entered that is already a setpoint for that LS, only the new one will be used. For
example: If LS1 had an ON point at 100 and an OFF point of 100 was entered, the ON point
at 100 would be deleted, and the OFF point would then take its place. Assuming that these
were the only setpoints, the output would turn ON at 0 and OFF at 100.
The programmable limits are programmed based on dwell on and dwell off locations. The dwell
on typically represents the location at which a selected limit turns on and the dwell off represents the
location at which the limit turns off. The position locations for the dwell on and dwell off are based
CIR ON- (Desired Pos)
CIR OFF- (Desired Pos)
time interval that the relay will be active once the ON setpoint has been reached.
ENT
ENT
CIR OFF
8
Installation and Maintenance Manual
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