AMETEK 1995L User Manual

Series 1995L

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 1995L Micro-Set Programmable Limit Switch.

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 Multi-Program (Only Available on P Option Units) ............................................................. 7

3.9 Setpoints ............................................................................................................................. 8

3.10 Clear an Existing Setpoint .................................................................................................. 9

3.11 Clear All Setpoints .............................................................................................................. 9

3.12 Setpoint Availability ............................................................................................................ 9

3:13 Electronic Offset ............................................................................................................... 10

3.14 Reset-to-Preset ................................................................................................................ 10

3.15 Motion Detector ............................................................................................................... 11

3.16 Power-Up in a Position or RPM ....................................................................................... 12

3.17 Decimal Point Programming .............................................................................................. 12

3.18 Enable/Disable Outputs..................................................................................................... 13

Chapter 4: Expansion Modules 14

Chapter 5: Fault Check 15

5.1 PLS Output Status on Fault Conditions ............................................................................... 16

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Chapter 6: Security Inputs 17

Chapter 7: Troubleshooting 18

7.1 Preliminary Checks ............................................................................................................ 18

7.2 Electrical Noise and Power Quality Consideration .............................................................. 18

7.3 Grounding ......................................................................................................................... 18

7.4 Incoming Power ................................................................................................................ 19

7.5 Low Level Inputs............................................................................................................... 19

Chapter 8: Specifications 20

8.1 1995 Micro-Set PLS Programmer ..................................................................................... 20

8.2 Mechanical Relay (Single Pole, Double Throw) .................................................................. 20

8.3 AC Solid-State (Single Pole, Normally Open) .................................................................... 20

8.4 DC Solid-State (Single Pole, Normally Open) .................................................................... 21

8.5 1995E Output Expansion Module ...................................................................................... 21

Chapter 9: Troubleshooting Guide 22

Chapter 10: Wiring Diagrams 25

iiiInstallation & Maintenance Manual

Chapter 1: Introduction/Description

The 1995L Micro-Set is a fully self-contained, 0 - 10 Volt input 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 Valid Scale Factor are 2 to 1,000.

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 1995L 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 linear motion.

A 1995L consists of an LTD (Linear Displacement Transducer) , LDT 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 position input into this PLS is a 0 to 10 VDC analog signal usually provided by a Gemco LDT. The 0 to 10 volts is generated by the LDT over its active stroke. The PLS will read out position directly in inches if the scale factor entered is the active stroke of the LDT (in inches).

The LDT generates a 0 to 10 Volt D.C. analog signal representing an absolute Linear position. This Analog signal is converted to a digital signal at the Micro-Set. A microprocessor calculates and/or converts these signals based on user-programmed data.

Installation and Maintenance Manual

Chapter 1: Introduction/Description

As the LDT passes through the preprogrammed dwell settings, the programmer outputs can energize solenoids, relays, or solid-state circuitry to control external circuits.

The 1995L PLS was designed for use in linear applications. It incorporates many features for safe, efficient operation.

The completely self-contained unit can operate up to 30 independent outputs (six standard) based on the linear position of the LDT.

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 LDT speed meets or exceeds the customer-preprogrammed 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 Reset-to-Preset-Allows an external input i.e. prox switch to reset the PLS to a

preprogrammed value.

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 1995L Micro-Set.

n Display A (3) three-digit LED readout and a 10-place bar graph will show

current Linear position, programming details and output 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 8: Specifications.

Installation and Maintenance Manual

Chapter 2: Installation

This section describes the installation and wiring of a standard 1995L Micro-Set PLS. Changes to these instructions should be made as necessary if special options and/or equipment are used.

The 1995L 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 1995L Micro-Set PLS is designed to be panel mounted. The face of the 1995L 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 1995L 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 1995L 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. Coupling methods should minimize backlash and be in accordance with the system accuracy required.

Installation and Maintenance Manual

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 1995L PLS is designed to be used with a Gemco 0 to 10 Volt Analog LDT. Wiring for this system is shown in Fig. 10-1, Fig. 10-2 and Fig. 10-3; Chapter 10: Wiring Diagrams. This wiring diagram is applicable for all standard 1995 PLSs.

2.3: Wiring Instructions

Attach the pre-wired plug on the LDT cable to the LDT and route the shielded cable through a separate grounded (earth ground) metal conduit to the panel and connect the mating half terminal block to the 1995L 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 60Hz - should be connected to the 1995L PLS at the AC power terminals on the 24-place connector.

Installation and Maintenance Manual

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 6: Security Inputs. 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 1995L Valid Scale Factors are 2 to 1,000.

To program the scale factor, the following procedures must be followed:

1) Unit must be in the Program mode.

2) Depress - Desired Scale Factor -

CIR#- 1- 8 0

ENT

NOTE: Display will read from 0 to 1 less than Scale Factor.

Installation and Maintenance Manual

Chapter 3: Programming

3.4: Number of Outputs

The 1995L comes programmed for six outputs, but it is expandable to 30 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

1) Valid numbers for are and .

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.

Installation and Maintenance Manual

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