Electro Cam 5000 User Manual
PLµS® PS-5000 Series
Programmable Limit Switch
Programming &
Installation Manual
October 2001
13647 Metric Rd • Roscoe, IL 61073 USA • 815/389-2620 • FAX 815/389-3304 • 800-228-5487 (U.S.A. and Canada)
Copyright © 2001
All 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
Table of Contents
Section—Introduction
Basic Cam Switch Operation . . . . . . . . . . . . . . . . . . . . . 1-1
Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Model Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Section 2—Dimensions & Component Locations
Controllers with External I/O Module Rack
5001, 5101, 5004, 5104, 5034, 5134 . . . . . . . . . . . . 2-1
Controllers with I/O Modules on Controller Back
5021, 5121, 5024, 5124 . . . . . . . . . . . . . . . . . . . . . . 2-2
Controllers with Built-In Transistor I/O Chips
5011, 5111 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Section 3—Wiring
Logic Terminal Strip Wiring . . . . . . . . . . . . . . . . . . . . . . 3-1
External I/O Racks (5001, 5101, 5004, 5104)
16 Module I/O Rack—Standard . . . . . . . . . . . . . . . . 3-2
16 Module I/O Rack—Analog . . . . . . . . . . . . . . . . . . 3-2
16 Module I/O Rack—M16 Slimline . . . . . . . . . . . . . 3-2
24 & 48 I/O Rack . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
I/O Modules on Controller (5021, 5121, 5024, 5124) . . 3-4
Module Wiring, Outputs . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Sinking/Sourcing Defined . . . . . . . . . . . . . . . . . . . . . . . 3-5
Module Wiring, Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Input Wiring, 3-Wire Sensors . . . . . . . . . . . . . . . . . . . . . 3-5
Built-In Transistor I/O Chips (5011, 5111)
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Output Wiring, Sourcing . . . . . . . . . . . . . . . . . . . . . . 3-7
Output Wiring, Sinking . . . . . . . . . . . . . . . . . . . . . . . 3-8
Output Wiring to PLC . . . . . . . . . . . . . . . . . . . . . . . . 3-9
PS-5X34 Controller & 32 DC Output Rack . . . . . . . 3-10
PS-5X34 Output Rack Layout . . . . . . . . . . . . . . . . 3-11
PS-5X34 Wiring to PLC's . . . . . . . . . . . . . . . . . . . . 3-12
PS-5X34 Output Rack Transistor Array Chips . . . . 3-13
Resolver Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14
Cable for Stainless Steel Resolver . . . . . . . . . . . . . . . 3-15
Encoder Cable Installation . . . . . . . . . . . . . . . . . . . . . . 3-16
Section 4—Programming, Standard Features
Access Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Keyboard Description . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Output Setpoint Programming . . . . . . . . . . . . . . . . . . . . 4-3
Master Level Programming
FCN 0 Programming Enable . . . . . . . . . . . . . . . 4-4
dr Direction of Rotation . . . . . . . . . . . . . . . . 4-4
SF Scale Factor . . . . . . . . . . . . . . . . . . . . . . 4-4
P1 & P2 Keyboard Enable . . . . . . . . . . . . . . . . . . 4-4
tb Time Base for Output Timing . . . . . . . . . 4-5
Enhanced Position/RPM Display Logic . . . . . . . . . . 4-5
dd Display Default . . . . . . . . . . . . . . . . . . . . 4-5
tr Toggle RPM . . . . . . . . . . . . . . . . . . . . . . 4-5
rU rPM Display Update Frequency . . . . . . . 4-6
ct, cS, cA Communications Parameters . . . . . . . . . . 4-6
FCN 6 Output Channel Access . . . . . . . . . . . . . 4-7
FCN 7 Motion ANDing . . . . . . . . . . . . . . . . . . . . 4-8
FCN 8 Subdividing Outputs . . . . . . . . . . . . . . . . 4-9
FCN 9 Enable Inputs and Modes . . . . . . . . . . . 4-9
Setup Level Programming
FCN 1 Motion Setpoints . . . . . . . . . . . . . . . . . . 4-10
FCN 2 Offset . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
FCN 3 Program Number . . . . . . . . . . . . . . . . . 4-10
FCN 4 Speed Compensation, Standard . . . . . 4-12
Speed Compensation, Negative . . . . . 4-12
FCN 5 Timed Outputs . . . . . . . . . . . . . . . . . . . 4-13
Section 5—Programming, Optional Features
Leading Trailing Speed Comp (“-L”)
FCN 0 Speed Comp Type . . . . . . . . . . . . . . . . . 5-1
FCN 4 Leading/Trailing Speed Comp . . . . . . . . 5-1
Analog Output (“-A”)
FCN 1 Analog Offset & High RPM . . . . . . . . . . . 5-2
Outputs Based on Direction of Rotation (“-D”)
Direction ANDing . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Direction Hysteresis . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Gray Code Output (“-G”)
Gray Code Conversion Ladder . . . . . . . . . . . . . . . . . 5-3
FCN 4 Gray Code Speed Comp . . . . . . . . . . . . 5-3
Extra Program Storage (“-F”)
Pulses/Programs Available . . . . . . . . . . . . . . . . . . . 5-4
Program Number Displays . . . . . . . . . . . . . . . . . . . . 5-4
FCN 3 Program Number Changes . . . . . . . . . . 5-5
Viewing/Editing Program . . . . . . . . . . . . . . . . . . . . . 5-6
Phase Mark Registration (“-P”)
Examples and Adjustment Methods . . . . . . . . . . . . . 5-7
Input Information . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
CHN 80 Auto-Center Registration . . . . . . . . . . . . 5-9
CHN 81 Adjust Registration Center . . . . . . . . . . . 5-9
Reversal of Centering Logic . . . . . . . . . . . . . . . . . . 5-10
“OFF” Logic Examples . . . . . . . . . . . . . . . . . . . . . . 5-10
Appendix
Output Grouping & Modes
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Configuration Examples . . . . . . . . . . . . . . . . . . . . . . A-2
Mode 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Mode 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Mode 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Mode 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-8
Mode 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-10
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-12
Communication Port Wiring . . . . . . . . . . . . . . . . . . . . . A-14
Encoder Position vs. Degrees . . . . . . . . . . . . . . . . . . . A-15
60 Pulse Disc—Position vs. Degrees . . . . . . . . . . . . . A-15
Alternate Functions . . . . . . . . . . . . . . . . . . . . . . . . . . A-16
Alt Fcn 1 Transducer Position
Alt Fcn 2 Logic Input Status
Alt Fcn 3 Offset Value
Alt Fcn 4 60 Pulse Disc
Alt Fcn 1002 Keyboard Test
Alt Fcn 1003 LED Display Test
Alt Fcn 1004 Watchdog Timer Test
Alt Fcn 1005 Control Model Info
Alt Fcn 1006 Options & Rev. #
Alt Fcn 7000 Restore Defaults
Alt Fcn 7001 Clear Setpoints
Alt Fcn 7999 EEPROM Test
Remote Display Installation . . . . . . . . . . . . . . . . . . . . . A-17
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . A-18
Index
WARRANTY
1. Electro Cam Corp. warrants that for a period of twelve (12) months from the date of shipment to
the original purchaser, its ne w product to be free from defects in material and workmanship and
that the product conforms to applicable drawings and specifications approved by the Manufacturer. This warranty period will be extended on Distributor or OEM orders to a maximum of
eighteen months to take into consideration Distributor or OEM shelf time.
2. The remedy obligations of Electro Cam Corp. under this w arranty are exclusiv e and are limited to
the repair, or at its option, the replacement or refund of the original purchase price of any new
apparatus which proves def ective or not in conf ormity with the drawings and specifications. Shipment of the claimed defectiv e product to Electro Cam Corp. shall be at the cost of the consumer .
Shipment of the repaired or replacement product to the consumer shall be at the cost of Electro
Cam Corp. All claims must be made in writing to Electro Cam Corp., 13647 Metric Road, Roscoe,
IL 61073 USA.
3. In no event, and 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 condi-
tions of temperature, dirt or other contaminants as determined at the sole discretion of Electro
Cam Corp.
c. Product failures due to operation, intentional or otherwise, above rated capacities as deter-
mined at the sole discretion of Electro Cam Corp.
d. Non-authorized expenses for removal, inspection, transportation, repair or rework. Nor shall
the manufacturer ever be liable for consequential and incidental damages, or in any amount
greater than the purchase price of the equipment.
4. There are no warranties which extend be yond the description on the f ace hereof. This warranty is
in LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED INCLUDING (BUT NOT
LIMITED T O) ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ALL OF WHICH ARE EXPRESSLY DISCLAIMED. Any legal proceeding
arising out of the sale or use of this apparatus must be commenced within (18) months of the date
of shipment from the manufacturer.
Introduction
Basic Cam Switch Operation
A PLµS control’s main purpose is to operate outputs in a
manner that simulates cam switches. The drawing to the
right illustrates the operation of a cam switch. Its function is
to switch the load on and off at the same rotary positions of
the cam shaft during each revolution of that cam shaft. The
rotating cam shaft is driven by a machine at a 1:1 ratio, so
that the on / off positions of the cam switch always match
specific positions in the machine cycle. However, cam limit
switches have the following disadvantages: unreliable
(wear), hard to adjust (machine must be stopped during
adjustment), and they cannot run at high speeds because
of contact bounce and excessive mechanical wear.
PLµS controls overcome these basic cam switch problems.
They have no moving wear parts, they are easy to adjust
from the keyboard with the machine running or stopped,
and they can operate at speeds up to 3000 RPM. They also
add many capabilities far beyond simple cam switch logic.
Standard Product Features
Basic Cam Switch Operation
The limit switch will turn on and off at
the same cam degree positions every
cam revolution (every machine cycle)
Keyboard/Controller
The keyboard controller is the main component of the PLµS
system. The front keypad and displays provide a complete
user interface from which every aspect of the control’s
operation can be monitored and programmed. When
properly mounted with the gasket provided, the keyboard
meets NEMA 4 standards. A clear silicon rubber boot
assembly is available to provide NEMA 4X protection for
installations where harsh washdown chemicals are used.
Ease of Setup
All output position setpoint values are simply entered
through the numeric keypad. These setpoints can be
adjusted while the machine is running or stopped by using
the increment, decrement, or numeric keys. The keyboard
is also used to synchronize the control’s position to the
machine, eliminating the need to mechanically adjust the
resolver’s shaft position.
Multiple Programs
Depending on the model ordered, up to 64 different
programs, or “job recipes” can be stored in the control’s
memory. This minimizes down time for job change over
because simply changing program numbers makes all of
the output setting changes required. Program numbers can
be changed by mechanical switches; PLC’s (using the
hardware program select inputs); the keypad; or serial
communication messages.
Output Speed Compensation
Speed compensation allows outputs to compensate for the
response time of the controlled devices by turning on earlier
as machine speeds increase. This eliminates the need to
adjust output settings whenever machine speeds are
changed. Using speed compensation often allows higher
production speeds and eliminates the need for output
adjustments.
Motion ANDing
A speed range can be programmed into the controller, and
outputs can then be ANDed with the speed range so that
they will be disabled unless the machine speed is within the
range. This can be used to turn off outputs if the machine
stops; disable outputs until the machine reaches a minimum
speed; or disable outputs if the machine goes above a
specified maximum speed. A common use for this feature
is disabling outputs to glue valves so the flow of glue turns
off if the machine stops.
Timed Outputs
Outputs can be programmed to turn on at the programmed
“on” position and turn off when the specified time elapses,
rather than staying on until an “off” position is reached. The
result is a constant output duration, regardless of machine
speed. The output will turn off when the “off” position is
reached if it hasn’t already timed out. Timed outputs are
used to drive devices which require a fixed time to perform
a task, regardless of machine speed.
1-1 Introduction
Standard Product Features (continued)
Selectable Scale Factor (resolvers only)
The number of increments per revolution (Scale Factor) is
programmed by the user. Standard controls have a
maximum of 1024 increments per revolution and “-H” option
(high resolution) controls have a maximum of 4096
increments per revolution. To make the control operate and
program in degrees, a Scale Factor of 360 is used. In some
applications it is desirable to use a Scale Factor that defines
each increment as a specific distance in engineering units
(ex: 1 inc = .1" of travel).
Output Grouping and Modes of Operation
Outputs can be subdivided into groups and each group
can be associated with an input device. There are five
different modes of operation that can be selected for each
group. For example, some modes allow the group to activate
only when the corresponding input has signaled that product
is present. Glue control is a typical place where outputs
are disabled until product is sensed as being present. For
details, see page A-1.
Optional Product Features
Analog Output, “-A”
Units with this option can output an analog signal that is
linearly proportional to RPM. The analog signal level at
zero RPM can be programmed through the keyboard, as
well as the RPM that corresponds to maximum signal. No
measuring equipment is required for initial setup, and
calibration is not needed. Typical uses are control of glue
pressure as machine speed changes, and speed matching
of other equipment to the machine being controlled.
Outputs Based On Rotation Direction, “-D”
In standard PLµS controllers, outputs will turn ON/OFF
based on resolver position, regardless of which way the
resolver is turning. With the "-D" option, outputs can be
based on resolver rotation direction.
Large Program Memory, “-F”
Depending on the number of outputs ordered, standard
controls can store up to 64 programs consisting of not more
than 1258 output pulses total. Controls with the “-F” option
increase this capacity by storing up to 256 programs
consisting of not more than 4589 output pulses total.
Gray Code Position Output, “-G”
The “-G” option provides eight bits of position information
on the last eight outputs. This “gray code” output can be
connected to a PLC or other electronic control device,
eliminating the need for expensive accessory cards. The
PLC can then make control decisions that do not demand
a fast response, while other PLµS outputs directly control
devices that must operate quickly and consistently.
High Resolution, “-H” (resolvers only)
Controls with this option can divide the resolver shaft
Serial Communication
Serial communication provides an RS-232 and an RS-485
communication port. Using PLµSNET software for IBM
compatible computers, available from Electro Cam Corp.,
the control’s entire program can be saved from the control
to a disk file or loaded from a disk file to the control. The
program can be printed or edited using the computer. It is
also possible to send individual communication commands
to the control, while running, to change settings in the
program. The user must write appropriate software to
communicate at the individual command level.
Expanded Operator Access
This feature gives the operator access to motion detection
settings, offset, active program number, and speed
compensation.
NOTE: Serial Communication and Expanded Operator
Access were "-C" and "-E" options prior to date code
9740.
rotation into as many as 4096 increments. Standard
controls have a maximum of 1024 increments.
Leading/Trailing Edge Speed Comp, “-L”
This option allows the “on” and “off” edges of output pulses
to be speed compensated by different amounts. High speed
gluing is a common application where the “on” and “off”
edges of the output signal have to be compensated by
different amounts.
Phase Mark Registration, “-P”
Phase mark registration allows the PLµS control to
determine if a product appears before or after a
programmed timing window. If mis-registration occurs, the
product’s timing can be adjusted manually, or by a PLC or
similar controller interfaced to the PLuS control.
Caustic Washdown Boot, “-W”
The face of the keyboard is rated NEMA 4X (meets NEMA
1, 4, 4X, and 12). For additional protection against caustic
washdown, grease, oil, dirt, and normal wear, a clear
silicone rubber boot is available that fits over and around
the keyboard. The back of the boot provides a good seal
between the back of the keyboard and the control panel.
The boot is transparent and pliable, allowing the keyboard
to be viewed and operated through it. Controls ordered
with the “-W” option are shipped with the boot fitted over
the keyboard. Boots may also be ordered separately and
installed in the field (#PS-4904-99-001).
Remote Display
A remote display which connects to the RS-485 port is
available for units ordered with both the “-C” and “-E”
options. This allows position and RPM information to be
displayed up to 1000 feet away from the controller.
1-2 Introduction
PS-5000 Series Model Summary
PS-5011
PS-5111
Key To Option Selection
PS-5001
PS-5101
PS-5004
PS-5104
PS-5034
PS-5134
Model Output Type Transducer Outputs Programs Modes? Options
PS-5001-10-016 Module Rack Encoder 16 64 no A, F, G, L, P, V, W, 20, 24
PS-5101-10-016 Module Rack Resolver 16 64 no A, F, G, H, L, P, V, W, 20, 24
PS-5001-10-024 Module Rack Encoder 24 48 no F, G, L, V, W, 20, 24
PS-5101-10-024 Module Rack Resolver 24 48 no F, G, H, L, V, W, 20, 24
PS-5001-10-048 Module Rack Encoder 48 24 no F, G, L, V, W, 20, 24
PS-5101-10-048 Module Rack Resolver 48 24 no F, G, H, L, V, W, 20, 24
PS-5004-10-016 Module Rack Encoder 16 64 yes A, F, G, L, P, V, W, 20, 24
PS-5104-10-016 Module Rack Resolver 16 64 yes A, F, G, H, L, P, V, W, 20, 24
PS-5004-10-024 Module Rack Encoder 24 48 yes F, G, L, V, W, 20, 24
PS-5104-10-024 Module Rack Resolver 24 48 yes F, G, H, L, V, W, 20, 24
PS-5004-10-048 Module Rack Encoder 48 24 yes F, G, L, V, W, 20, 24
PS-5104-10-048 Module Rack Resolver 48 24 yes F, G, H, L, V, W, 20, 24
These Models
Use External
I/O Module Racks
20-240 VAC: Change “-10-” to “-20-”.
24-24 VDC: Change “-10-” to “-24-”.
A Analog output proportional to speed
F Additional setpoint/program storage
G Gray code position output
H High resolution, resolver only
L Individual leading/trailing edge speed compensation
P Register mark phasing
U CE mark - requires 24VDC input
V Vibration protective coating
W Washdown Boot
These Models
Use Built-In
I/O Transistor Chips
# of # of Output
PS-5021
PS-5121
PS-5024
PS-5124
These Models
Have I/O Modules
On Controller Back
PS-5011-10-N08 Transistor, Sinking Encoder 8 64 no F, L, V, W, 20, 24
PS-5111-10-N08 Transistor, Sinking Resolver 8 64 no F, H, L, V, W, 20, 24
PS-5011-10-N16 Transistor, Sinking Encoder 16 64 no F, G, L, P, V, W, 20, 24
PS-5111-10-N16 Transistor, Sinking Resolver 16 64 no F, G, H, L, P, V, W, 20, 24
PS-5011-10-P08 Transistor, Sourcing Encoder 8 64 no F, L, V, W, 20, 24
PS-5111-10-P08 Transistor, Sourcing Resolver 8 64 no F, H, L, V, W, 20, 24
PS-5011-10-P16 Transistor, Sourcing Encoder 16 64 no F, G, L, P, V, W, 20, 24
PS-5111-10-P16 Transistor, Sourcing Resolver 16 64 no F, G, H, L, P, V, W, 20, 24
PS-5034-10-032 Transistor, Ext. Rack Encoder 32 32 yes F, G, L, V, W, 20, 24
PS-5134-10-032 Transistor, Ext. Rack Resolver 32 32 yes F, G, H, L, U, V, W, 24
PS-5034-10-064 Transistor, Ext. Rack Encoder 64 16 yes F, G, L, V, W, 20, 24
PS-5134-10-064 Transistor, Ext. Rack Resolver 64 16 yes F, G, H, L, U, V, W, 24
PS-5021-10-M09 Modules on Back Encoder 9 64 no A, F, L, V, W, 20, 24
PS-5121-10-M09 Modules on Back Resolver 9 64 no A, F, H, L, P, U, V, W, 20, 24
PS-5024-10-M09 Modules on Back Encoder 9 64 yes A, F, L, V, W, 20, 24
PS-5124-10-M09 Modules on Back Resolver 9 64 yes A, F, H, L, P, U, V, W, 20, 24
1-3 Introduction
Detailed View of
24 VDC Version
Controllers w/ External I/O Module Rack
PS-5001
PS-5101
PS-5004
PS-5104
PS-5034
PS-5134
2-1 Dimensions & Component Locations
See Page 2-4
for Controller
Dimensions
Controllers w/ I/O Modules on Controller Back
LED
HOLD
DOWN
SCREW
FUSE
4A
Detailed View of
24 VDC Version
PS-5021
PS-5121
PS-5024
PS-5124
See Page 2-4
for Controller
Dimensions
Slimline Modules
TOP
2-2 Dimensions & Component Locations
Detailed View of
24 VDC Version
Controllers with Built-In Transistor I/O Chips
PS-5011
PS-5111
See page 2-5
for Controller
Dimensions
2-3 Dimensions & Component Locations
PS-5001
PS-5101
PS-5004
PS-5104
PS-5034
PS-5134
Controller Dimensions
PS-5021
PS-5121
PS-5024
PS-5124
2-4 Dimensions & Component Locations
PS-5011
PS-5111
Controller Dimensions
2-5 Dimensions & Component Locations
Logic Terminal Strip Wiring—Standard Controller
Logic Terminal Strip
(see pp. 2-1 thru 2-3 for location)
General Logic Input Information
The logic inputs, Terminals 2-7 & 9, are switched by a
current sinking path to Logic Common. They can be switched
by mechanical switches, relays, or NPN transistor outputs.
Logic input terminal voltage is approximately 12 VDC, and
4 mA of current are conducted through the switch to Logic
Common.
Program Select Inputs (Terminals 3, 4, and 5)
These inputs determine which program in the current
program bank is controlling the outputs. When any of these
inputs are connected to Logic Common, they take priority
over the keyboard selected active program (FCN 3). If these
inputs are being used, make sure that the FCN 3 active
program is set to 1. Input combinations are:
PRG # 1 2 3 4 5 6 7 8
SEL 1 off on on off off on on off
SEL 2 off off o n on on on off off
SEL 3 off off off off on on on on
Master Program Enable (Terminal 6)
When the Master Program Enable input is switched to Logic
Common, all programming operations are accessible. A
key switch is commonly used for this input to prevent
unauthorized personnel from accessing the more
complicated features of the control. A temporary jumper can
also be installed for initial programming at the master level,
and then removed when this programming is completed.
Output Group 1 Enable (Re-Zero Input) (Terminal 7)
On standard 5XX1 controls, switching this input to Logic
Common instantly changes the control's position to zero
degrees. The position re-zeroes off of the leading edge of
the signal, but is not held at zero while the input is energized.
When the controller is de-energized, the controller position
will revert to the offset value programmed in FCN 2.
Program Select Switch and Cable:
Pt# PS-4901-01-XXX (XXX=FT)
Program Enable key switch and cable:
PS-4902-01-XXX (XXX=FT)
Input from photo sensor typically
To PLC or other electronic input
Program Enable key switch and cable:
PS-4902-01-XXX (XXX=FT)
DC power for accessories, typically photo sensors.
Terminals 1 and 2 are negative side of this supply
On models PS-5004, 5104, 5024, and 5124 this input is the
enable input for output Group 1. There are four programmable
modes of operation available for enable inputs. For more
information see the Output Grouping and Enable Modes
section in the Appendix.
Motion Detection Output (Terminal 8)
This is a sourcing output signal that is on whenever the
current machine speed is within or equal to the Low and
High RPM setpoints (FCN 1, page 4-7). The circuit is
basically a 12 VDC supply being sourced through a 470
ohm resistor. It is typically connected to PLC inputs or
external solid state output modules. Because the 5000
Series controls have Motion ANDing, any of the standard
outputs can be programmed to be on whenever the motion
logic is on. This is an alternative to the Motion Output when
it is not compatible with an input circuit or if a higher voltage
or current needs to be controlled.
Operator Program Enable (Terminal 9)
When this terminal is switched to Logic Common, access to
programming at the Operator level is enabled. A key switch
can be used to control who can make program changes at
the Operator level. Operator access can also be enabled
through a keyboard enable code number.
12 VDC Power Output (Terminal 10)
The 12 VDC accessory power supply is regulated and
capable of supplying up to 150 mA. It is protected by a 1/4
amp fuse which is located just below the Logic Terminal
strip. This supply is intended to be used for electronic
sensors or other electronic circuitry. It should not be used to
power relays or any other inductive devices. Logic Common
(terminals 1 or 2) is the negative side of this 12 VDC supply.
3-1 Wiring
External 16 Module I/O Racks: Dimensions & Specifications
Standard 16 Rack: PS-4100-11-216
Analog 16 Rack: PS-4100-11-316-A (for “-A” Option Only)
PS-5001
PS-5101
PS-5004
PS-5104
End View
Notes:
•A Standard module is required for each Input or
Output used. See Appendix for module specs.
• AC and DC modules can be mixed as needed.
• Input modules can be used only with 5004 and 5104
units.
• Output modules act like switches; they do not
supply power to loads.
• Position 16 of Analog racks is dedicated to analog
output and will not work with other modules. If an
analog module is used, it must be installed in
position 16.
• Odd Terminals: (+) or hot
Even Terminals: (-) or load
Slimline M16 Rack
Foot Mount Rack: PS-4100-11-M16-F
DIN Rail Rack: PS-4100-11-M16-D
End Views
Foot Mount (-F)
DIN Rail (-D)
Notes:
•A Slimline module is required for each Input or Output used.
See Appendix for module specs.
• AC and DC modules can be mixed as needed.
• Input modules can be used only with 5004 and 5104 units.
• Output modules act like switches; they do not supply
power to loads.
• Analog modules may be installed in position 16 only.
• Module Fuses: 4 Amp, #PS-9005-0004
(Wickman 19370-K)
• “A” Terminals: (-) or load
“B” Terminals: (+)or hot
3-2 Wiring
External 24 & 48 Module I/O Racks: Dimensions & Specifications
Standard 24 Rack: PS-4100-12-224
PS-5001
PS-5101
PS-5004
PS-5104
End View
Configuration for 48 I/O System
Notes:
•A Standard module is required for each Input or
Output used. See Appendix for module specs.
• AC and DC modules can be mixed as needed.
• Input modules can be used only with 5004 and 5104
units.
• Output modules act like switches; they do not
supply power to loads.
• Either 25 pin connector can be used to connect the
rack to the controller. The other connector ties to a
second rack for 48 I/O as shown below.
• Odd Terminals: (+) or hot
Even Terminals: (-) or load
3-3 Wiring
Slimline I/O Modules on Controller Back: Specifications
Back View of Controller Body
PS-5021
PS-5121
PS-5024
PS-5124
Notes:
• A module is required for each Input or Output used. See
Appendix for module specs.
• AC and DC modules can be mixed as needed.
• Input modules can be used only with 5024 and 5124 units.
• Output modules act like switches; they do not supply power
to loads.
• Analog modules may be installed in Position 9 only, and
only on units ordered with option “-A”.
• Module Fuses: 4 Amp, #PS-9005-0004 (Wickman 19370-K)
• Odd Terminals: (+) or hot
Even Terminals: (-) or load
Module Wiring - Outputs
AC Output
Odd or
Even or
• Most applications will not need the varistor or R-C suppressor shown
above. However, when other switching devices are in series or parallel
with the AC module, voltage spikes may damage the module. Use one
of the following two methods to suppress voltage spikes.
• For infrequent switching, connect a varistor (MOV) across the terminals.
• For continuous switching, wire an R-C suppressor in parallel with the
load.
Analog Output
• Control must have Option “-A” to use analog output module.
• Analog output modules source the analog signal.
• Analog output signals are isolated.
• Caution: Do not apply external voltage to an analog module or you will
damage it.
DC Output
Sourcing
PS-5X04
PS-5X21
PS-5X24
Odd or
Even or
Sinking
Odd or
Even or
• 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 loads 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 circuit voltage.
• Connect a reverse-biased diode across the load. This may increase the
load turn off time.
PS-5X01
3-4 Wiring
Sinking or Sourcing (as pertaining to Electro Cam Corp. products)
Sinking means that when the logic is true and the output (or input device) is ON, the output (or input device)
is providing a DC common or ground to the connected device.
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 to supply a +DC voltage (Electro Cam Corp.
to this card, NOT a DC common or ground. In these cases,
*Other manufacturers include, but not limited to: Koyo (formerly GE Series 1, Texas Instruments, or Siemens SIMATIC PLS’s) that use descriptions
similar to Allen-Bradley.
Sinking
is what the card does with the input voltage; sinks it to common or ground.
Sourcing
output)
Module Wiring—Inputs
AC Input
• Input devices can be mechanical contacts or solid state.
• The load 10K load resistor shown may be needed if the AC input device
has off-state leakage, such as a solid state triac.
Input Wiring, 3-Wire Sensors
Using Logic Terminal Strip Power Supply (pg. 3-1)
Sourcing
DC Input
Sourcing
PS-5024
PS-5124
Sinking
• Input devices can be mechanical contacts or solid state.
• 12 VDC power is available from the controller’s logic terminal strip. See
page 3-1 for details.
Various
Sinking
Models
• For controllers using input/output modules.
Using External Power Supply & Terminal 7
• Module wiring applies only to controllers using input/output modules.
• Using sensor to switch terminal 7 can be done for any PS-5000 Series
controller. See page 3-1 for details.
• Using sensor to switch terminal 7 can be done for any PS-5000 Series
controller. See page 3-1 for details.
3-5 Wiring
Built-In Transistor I/O Chips: Specifications
PS-5011
PS-5111
The output board which contains the output transistor array
chips and the fuse(s) is located under the output board
cover. The pluggable output terminal strips plug into receptacles that are mounted to the output board The only time
it will be necessary to remove the output board cover is
when an output fuse is blown or a transistor array chip is
damaged.
Output Transistor Array Chips:
Each group of 8 output transistors is contained in a single 18
pin transistor array chip. If one or more of these transistors
becomes damaged, the chip can simply be unplugged from
the socket and replaced. Note that Sinking and Sourcing
output boards do not use the same transistor array chip.
Output Fuses:
Each group of 8 outputs (1 transistor array chip) is protected
by a 1 Amp plug in fuse. This fuse will blow if the DC power
polarity is incorrectly wired to the “+” and “-” terminals on the
output terminal strip. On the sourcing output versions this
fuse will also blow if the total amount of current being
3-6 Wiring
conducted by that group of 8 outputs exceeds 1 Amp. If a
fuse blows, all 8 of the outputs in that group will be inoperative until the fuse is replaced.
Output Cables:
Pluggable screw terminal strips are used to connect the
transistor outputs to the load device. Therefore, no special
connectors are needed for output wiring. However, shielded
cable is recommended (Electro Cam part #: PS-4300-04XXX, 2 cables required for systems with more than 8
outputs) to maximize immunity to electrical noise. The
shield should be connected to the grounding screw located
on the back panel just above the output terminal strips. The
shield should be unconnected at the load end of the cable.
Also, the cable should be kept away from other electrical
wiring, especially control wiring involving solenoids, relays,
contactors, and motors.
Built-In Transistor I/O Chips: Output Wiring, Sourcing
PS-5011
PS-5111
The output power supplies shown can be internal to the
load device being driven. This will normally be the case
when connecting to PLC's.
The loads connected to outputs 1-8 must all be powered
from the same power supply.
The loads connected to outputs 9-16 must all be powered
from the same power supply.
The same power supply can be used to power all 16 outputs
by paralleling the wiring between the “+” and “-” terminals
on the PLµS output terminal strips.
3-7 Wiring
The load power supply must be connected to both the “+”
and “-” terminals on the output terminal strip(s).
The unpluggable output terminal strips are keyed so they
can only be plugged into the correct receptacle.
Use shielded cable(s) for output wiring. Electro Cam 10
conductor cable part number PS-4300-04-XXX (XXX=length
in feet) is recommended. Two cables required for 16 output
units.
Built-In Transistor I/O Chips: Output Wiring, Sinking
PS-5011
PS-5111
The output power supplies shown can be internal to the load
device being driven. This will normally be the case when
connecting to PLC's.
More than 1 power supply can be used to power loads within
each group of 8 outputs. Only one of the power supplies
used within the group can have its positive side connected
to the “+” terminal of the corresponding 5011 output terminal
strip. The common of each power supply used within a
group of 8 outputs must be connected to the “-” terminal of
the output terminal strip.
3-8 Wiring
The same power supply can be used to power all 16 outputs
by paralleling the wiring between the “+” and “-” terminals on
the 5011 output terminal strips.
Both the “+” and “-” terminals on the output terminal strip(s)
must be connected to a load power supply.
The unpluggable output terminal strips are keyed so they
can only be plugged into the correct receptacle. Do not force
when plugging them in.
Use shielded cable(s) for output wiring. Electro Cam 10
conductor cable part# PS-4300-XXX (XXX=length in feet) is
recommended. Two cables required for 16 output units.
Built-In Transistor I/O Chips: Output Wiring to PLC
PS-5011
PS-5111
PS-5X11 with
Sinking Outputs
PLC with Sinking Inputs
(A.B. calls these sourcing inputs)
Power Supply can be
external from the PLC.
PS-5X11 with
Sourcing Outputs
PLC with Sourcing Inputs
(A.B. calls these sinking inputs)
Power Supply can be
external from the PLC.
3-9 Wiring
PS-5X34 Controller & 32 DC Output Rack
Introduction
The PS-5X34 system is available with either 32 or 64 low
current transistor outputs. These systems are intended to
be interfaced directly to PLCs or other control devices with
low level DC inputs.
The 32 transistor output rack(s) used with PS-5X34 controls
can be DIN rail mounted (-D) or foot mounted (-F) and are
available with Sinking or Sourcing outputs.
Systems that require 32 or fewer outputs will only need one
of the transistor output racks. Systems requiring more than
32 outputs need two transistor output racks daisy chained
together (see rack configuration section below).
PS-4100-12-X32-X Dimensioned Drawing
1/2" (13mm)
9"
(229mm)
7/8"
(22mm)
1/4" (6mm)
The PS-5X34 controller incorporates the same keyboard
and features that other PS-5000 controls use. Because of
the large number of outputs being controlled, the number of
programs stored in a 32 output controller is 32, and the
number of programs in a 64 output controller is 16.
This control has PS-5XX4 capabilities (output grouping and
modes) and includes an RS-232/485 communications port.
Outputs can be subdivided into as many as 8 groups, and
the position of each of these groups can be offset individually.
Because the rack transistor outputs cannot be configured
as inputs, the only enable input available is the "Output
Group Enable 1" input located on the logic strip. Output
Group 1 can operate in any output mode, all other groups
must operate in Mode 0 only.
DIN Rail Mount*
Foot Mount
2-1/2"
(64mm)
3"
(76mm)
2-13/16"
(72mm)
C
L
0.168" (4.3mm)
For #8 Screw
*DIN Rails must be ordered separately
Brackets (2) on
Foot Mount Version (-F) Only
Output Rack Configuration
Control systems requiring 32 or fewer outputs will need only
1 PS-4100-12-X32 transistor output rack. The "Rack
Address Jumper" must be plugged into position 1. This will
configure the outputs to be channels 1-32. 1 rack cable (Pt#
PS-4300-02-XXX) will be needed to connect the rack to the
controller.
Control systems requiring more than 32 outputs will need 2
PS-4100-12-X32 transistor output racks. The "Rack Address
Jumpers" must be plugged into position 1 on one of the
racks, and position 2 on the other. Output channel numbers
will be assigned as shown in the illustration to the right. 2
rack cables (Pt# PS-4300-02-XXX) will be needed: one to
connect the controller to the first rack and the other to
connect the two racks.
3-1/8"
(79mm)
DIN Rail
EN 50022
To PS-5X34 Control
DIN Rail
EN 50035
3-10 Wiring
PS-5X34 System: Output Rack Layout
Sinking Output Rack Pt#: PS-4100-12-N32 Sourcing Output Rack Pt#: PS-4100-12-P32
Each Output can Source 10-30 VDC, 100 mA MaxEach Output can Sink 3-30 VDC, 100 mA Max
DB 25 Connectors (Female)
Connect to PLuS controller or another rack
(these connectors can be used interchangeably)
Output Terminals
25-32
E.C. Pt#: PS-9006-0014
(unpluggable)
PLµS Power LED
On when PLµS control is powered up
and connected to rack
Rack Address Jumper
1: Channels 1-32
2: Channels 33-64
3: Unused
4: Unused
(Jumper shown in position 1)
Transistor Array Chips
(socketed for field replacement)
X
E.C. Pt#: PS-9011-2803
Generic Pt#: ULN-2803
Output Terminals 1-8
E.C. Pt#: PS-9006-0011
(unpluggable)
Transistor Array Chips on
Y
X
Y
X
Sourcing Output Racks
(socketed for field replacement)
E.C. Pt#: PS-9011-2580
Generic Pt#: UDN-2580
Output Terminals
17-24
E.C. Pt#: PS-9006-0013
(unpluggable)
F1
X
Y
F2
Y
X
User Power LED
On when user power applied to rack
(will NOT be on if user power fuse is blown)
3-11 Wiring
Y
OR
Dip Jumper Blocks on
Sinking Output Racks
E.C. Pt#: PS-9006-0015
Output Terminals 9-16
E.C. Pt#: PS-9006-0012
(unpluggable)
User DC Power Input
10 - 30 VDC, 4 Amp Max
(Sinking outputs switch "-")
(Sourcing outputs switch "+")
User DC Power Fuses
4 Amps (F1= "+", F2="-")
E.C. Pt#: PS-9005-0004
Wickman Pt#: 19370-K
PS-5X34 System: Wiring to PLCs
Wiring to a PLC with Sinking Inputs
(A.B. calls these Sourcing Inputs)
PS-4100-12-N32
Note: PLµS transistor output
rack and PLC MUST
both be connected to
the same DC positive.
PLC
Power Supply can be
external from the PLC
Wiring to a PLC with Sourcing Inputs
PS-4100-12-P32
(A.B. calls these Sinking Inputs)
Note: PLµS transistor output
rack and PLC MUST
both be connected to
the same DC common.
PLC
3-12 Wiring
Power Supply can be
external from the PLC
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