AMETEK 1995B User Manual
Series 1995B
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 1995B 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.............................................................................................................. 5
3.5 Selecting Number of Outputs ............................................................................................... 6
3.6 Multiprogram (Available Only on P Option Units) .............................................................. 6
3.7 Setpoint Formula ................................................................................................................. 6
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 Motion Detector ............................................................................................................... 11
3.14 Power-Up in a Position or RPM ....................................................................................... 12
3.15 Decimal Point Programming .............................................................................................. 12
3.16 Enable/Disable Outputs..................................................................................................... 13
3.17 Linear Speed Offset (Available Only on Option P Units .................................................. 13
3.18 Programming 1995 PLS for Linear Speed ......................................................................... 15
3.19 Minimum Speed Disable ................................................................................................... 15
3.20 Time-Based Outputs (Available Only on Option P Units) ................................................ 16
3.21 Brake Monitor Operational Description ............................................................................ 17
Chapter 4: Expansion Modules 20
Chapter 5: Fault Check 21
5.1 PLS Output Status on Fault Conditions ............................................................................... 22
Installation & Maintenance Manualii
Chapter 6: Security Inputs 23
Chapter 7: Remote Circular Display 24
7.1 POS/RPM On Remote Circular Display ............................................................................. 24
Chapter 8: Troubleshooting 25
8.1 Preliminary Checks ............................................................................................................ 25
8.2 Transducer Excitation Voltages ........................................................................................... 25
8.3 Electrical Noise and Power Quality Consideration .............................................................. 26
8.4 Grounding ......................................................................................................................... 26
8.5 Incoming Power ................................................................................................................ 26
8.6 Low Level Inputs............................................................................................................... 26
Chapter 9: Specifications 28
9.1 1995 Micro-Set PLS Programmer ..................................................................................... 28
9.2 Mechanical Relay (Single Pole, Double Throw) .................................................................. 28
9.3 AC Solid-State (Single Pole, Normally Open) .................................................................... 28
9.4 DC Solid-State (Single Pole, Normally Open) .................................................................... 29
9.5 1995E Output Expansion Module ...................................................................................... 29
9.6 1995-1446 Remote Circular Display .................................................................................. 29
Chapter 10: Troubleshooting Guide 30
Chapter 11: Wiring Diagrams 33
iiiInstallation & Maintenance Manual
Chapter 1: Introduction/Description
Chapter 1: Introduction/Description
The 1995B Micro-Set is a fully self-contained, single-turn resolver-based programmable limit switch.
It includes a three-digit LED display, five output relays, and one fault check relay, and it is fully programmable for the following features:
1.1: Programmable Features
Scale Factor There is one scale factor only, permanently set to 360.
Electronic Offset Fully programmable offset to any number with the scale factor.
Motion Detector LS5 can be programmed for either limit switch or motion detect
output.
Expansion Outputs Programmable to accommodate up to 29 circuits.
See Section 1.2: General Information - Software Option P for more options.
1.2: General Information
The 1995B 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 1995B consists of a resolver-based transducer, resolver-to-programmer cable assembly, and the
programmer, which provides five limit switch outputs, one fault check output and one brake monitor
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 twenty-nine 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 1995B PLS was designed for use in rotary and/or rotary-to-linear applications. It incorporates
many features for safe, efficient operation.
The completely self-contained unit can operate up to 29 independent outputs (five standard) based on
the rotary position of the resolver.
Installation and Maintenance Manual
1
Chapter 1: Introduction/Description
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.
Also offered is an on-line brake monitor that checks the stopping time of the machine against a customer
selected preset stopping time in milliseconds, and which can be used to check the stopping distance at
any point in the stroke. A dedicated output remains energized when the stop time parameters are within
tolerance. An excessive stop time will cause the relay to de-energize, which could be used to stop
further machine operation.
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 1995B 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 1995B Micro-Set PLS. Changes to
these instructions should be made as necessary if special options and/or equipment are used.
The 1995B 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 1995B Micro-Set PLS is designed to be panel mounted. The face of the 1995B 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 1995B
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 1995B 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 proper mounting of the resolver transducer is critical to ensure the systems accuracy. There are
two resolver transducers available.
(A) Standard foot mount resolver transducer. The foot mount resolver transducer should be
mounted in an area free of excessive shock and vibration (as is commonly seen by
mounting plates that extend over the edge of the press). The resolver transducer should
be connected in a 1:1 ratio with the crank. If a double-ended cam limit switch is
available, it is preferable to mount off of the rear shaft
NOTE: The Micro-set programmable limits are not control reliable for the clutch/brake circuits.
Mechanical cam limits must be used for these circuits.
Installation and Maintenance Manual
3
Chapter 2: Installation
(B) Combination mechanical cam/resolver systems. Intended as bolt-in replacements to
existing switches. The cam/resolver combination unit should be coupled where the
existing limit switch is located. Wire and adjust the mechanical cams in accordance with
the original press manufacturers specifications and wire the resolver cable to the
controller.
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 1995B PLS is only used with a single-turn resolver. Wiring for this system is shown in Fig. 11-2,
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 1995B 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 1995B PLS at the AC
power terminals on the 24-place connector.
4
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, 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
The 1995B is available only with a 360 degree scale factor, set permanently.
3.4: Number of Outputs
The 1995B comes programmed for five outputs, but it is expandable to 29 outputs. However, when
using a Remote Circular Display, the maximum will be 23 outputs.
Installation and Maintenance Manual
5
Chapter 3: Programming
3.5: Selecting Number of Outputs
Selection of the number of outputs should be done after the system is initialized and , 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 23.
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 five-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.
3.7: Setpoint Formula
Setpoint/Programs = 1467 - 2
6
Number of Programs x A
Installation and Maintenance Manual
Chapter 3: Programming
Where: A = 5 for 5 outputs
= 6 for 11 outputs
= 7 for 17 outputs
= 8 for 23 outputs
= 9 for 29 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
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.
STUPTUO5STUPTUO11STUPTUO71STUPTUO32STUPTUO92
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.
äã
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
-- CIR ON
ENT
-
- ENT-
# of Programs
.
for the capabilities of your unit.
B) Upon entering the above sequence, depressing the key will display the
CIR OFF
maximum amount of setpoints per program.
NOTE: A time-based output uses up three setpoints.
Installation and Maintenance Manual
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
Loading...