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 [phone] • 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 new 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 warranty are exclusive 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 defective or not in conformity with the drawings and specifications. Shipment of the claimed defective 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 conditions 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 determined 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 beyond the description on the face hereof. This warranty is in LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED INCLUDING (BUT NOT LIMITED TO) 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.

Basic Cam Switch Operation

The limit switch will turn on and off at the same cam degree positions every cam revolution (every machine cycle)

Standard Product Features

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.

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.

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

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-5001 These Models

PS-5101 Use External

PS-5004 I/O Module Racks

PS-5104

PS-5034

PS-5134

	PS-5011	These Models
		Use Built-In
	PS-5111
		I/O Transistor Chips

Key To Option Selection

20-240 VAC: Change “-10-” to “-20-”. 24-24 VDC: Change “-10-” to “-24-”.

A Analog output proportional to speed

FAdditional setpoint/program storage

GGray code position output

HHigh resolution, resolver only

L Individual leading/trailing edge speed compensation P Register mark phasing

UCE mark - requires 24VDC input

VVibration protective coating

WWashdown Boot

PS-5021 These Models

PS-5121 Have I/O Modules

PS-5024 On Controller Back

PS-5124

				# of	# of	Output
	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
	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

Controllers w/ External I/O Module Rack

Detailed View of

24 VDC Version

PS-5001

PS-5101

PS-5004

PS-5104

PS-5034

PS-5134

See Page 2-4 for Controller Dimensions

2-1 Dimensions & Component Locations

Controllers w/ I/O Modules on Controller Back

PS-5021

PS-5121

PS-5024

PS-5124

Detailed View of

24 VDC Version

See Page 2-4 for Controller Dimensions

Slimline Modules

TOP

	LED	HOLD	FUSE
		DOWN
			4A
		SCREW

2-2 Dimensions & Component Locations

Controllers with Built-In Transistor I/O Chips

PS-5011

PS-5111

Detailed View of

24 VDC Version

See page 2-5 for Controller Dimensions

2-3 Dimensions & Component Locations

Controller Dimensions

PS-5001

PS-5101

PS-5004

PS-5104

PS-5034

PS-5134

PS-5021

PS-5121

PS-5024

PS-5124

2-4 Dimensions & Component Locations

Controller Dimensions

PS-5011

PS-5111

2-5 Dimensions & Component Locations

Logic Terminal Strip Wiring—Standard Controller

Logic Terminal Strip

(see pp. 2-1 thru 2-3 for location)

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

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	on	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.

On models PS-5004, 5104, 5024, and 5124 this input is the enableinputforoutputGroup1.Therearefourprogrammable 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

Notes:

End Views

• A Slimline module is required for each Input or Output used.

Foot Mount (-F)

DIN Rail (-D)

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

PS-5001

Standard 24 Rack: PS-4100-12-224	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.

• 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

Configuration for 48 I/O System

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	DC Output	PS-5X01
			PS-5X04
		Sourcing	PS-5X21
			PS-5X24

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.

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.

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. Sourcing output) to this card, NOT a DC common or ground. In these cases, Sinking is what the card does with the input voltage; sinks it to common or ground.

*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.

Module Wiring—Inputs

AC Input

DC Input

PS-5024

Sourcing

PS-5124

• 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.

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.

Input Wiring, 3-Wire Sensors

Using Logic Terminal Strip Power Supply (pg. 3-1)

Various

Sourcing

Sinking

Models

• For controllers using input/output modules.

•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 External Power Supply & Terminal 7

• 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

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-4300-04- XXX, 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.

3-6 Wiring

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.

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.

3-7 Wiring

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.

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.

3-8 Wiring

Built-In Transistor I/O Chips: Output Wiring to PLC

PS-5011

PS-5111

PS-5X11 with

PLC with Sinking Inputs

Sinking Outputs

(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).

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.

PS-4100-12-X32-X Dimensioned Drawing

			DIN Rail Mount*
1/2" (13mm)		Foot Mount	3"
			(76mm)
	9"	2-1/2"
	(229mm)		2-13/16"
		(64mm)
	1/4" (6mm)		(72mm)
7/8"
(22mm)
C		3-1/8"
L		(79mm)

	0.168" (4.3mm)	Brackets (2) on	DIN Rail	DIN Rail
	For #8 Screw		EN 50022
		Foot Mount Version (-F) Only
				EN 50035

*DIN Rails must be ordered separately

Output Rack Configuration

Control systems requiring 32 or fewer outputs will need only	To PS-5X34 Control
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.

3-10 Wiring

PS-5X34 System: Output Rack Layout

Sinking Output Rack Pt#: PS-4100-12-N32

Each 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)

Sourcing Output Rack Pt#: PS-4100-12-P32

Each Output can Source 10-30 VDC, 100 mA Max

PLμS Power LED

On when PLμS control is powered up and connected to rack

Output Terminals

25-32

E.C. Pt#: PS-9006-0014

(unpluggable)

Output Terminals

17-24

E.C. Pt#: PS-9006-0013

(unpluggable)

					Rack Address Jumper
					1: Channels 1-32
					2: Channels 33-64
					3: Unused
					4: Unused
					(Jumper shown in position 1)
					Transistor Array Chips
				X	(socketed for field replacement)
					E.C. Pt#: PS-9011-2803
					Generic Pt#: ULN-2803
					Output Terminals 1-8
					E.C. Pt#: PS-9006-0011
					(unpluggable)
Y		X	Y		Transistor Array Chips on
	X				Sourcing Output Racks
					(socketed for field replacement)
					E.C. Pt#: PS-9011-2580
					Generic Pt#: UDN-2580

	Y	OR
		Dip Jumper Blocks on
		Sinking Output Racks
		E.C. Pt#: PS-9006-0015
Y X	X Y	Output Terminals 9-16
		E.C. Pt#: PS-9006-0012
		(unpluggable)
		User DC Power Input
F1	F2	10 - 30 VDC, 4 Amp Max
		(Sinking outputs switch "-")
		(Sourcing outputs switch "+")
		User DC Power Fuses
User Power LED		4 Amps (F1= "+", F2="-")
On when user power applied to rack		E.C. Pt#: PS-9005-0004
(will NOT be on if user power fuse is blown)		Wickman Pt#: 19370-K

3-11 Wiring

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

(A.B. calls these Sinking Inputs)

PS-4100-12-P32

Note: PLμS transistor output rack and PLC MUST both be connected to the same DC common.

PLC

Power Supply can be external from the PLC

3-12 Wiring