PLμS Controls Div.
PS-6000 Series
Programmable Limit Switches
Available with Modbus™ ASCII Communications
*Slimline Modules
have built-in
Fuses & LED's
*9 Plug-In Output Modules for
Real World Control of Electro-Mechanical Devices
DIN Rail
Mountable
16 DC Logic Level Outputs for Direct Interfacing to PLC's
PS-6144-24-P16M09
Controller
2-Line Backlit
Supertwist
LCD Display
*Modules sold separately. Available in AC, DC, Analog & Reed Relay
Controllers can be used with or without Keypad/Display
PS-6400-24-001
Keypad/Display
*17 Plug-In Output Modules for Real World Control of Electro-Mechanical Devices
Plug-In
Terminal Blocks
Simplify Wiring
Dual Resolver
Inputs PS-6344-24-M17
Controller
Compact 1/4 DIN Keypad/Display mounts remotely. Multiple keypads may be used with one controller.
Description
The PLμS PS-6144 Series Programmable Limit Switches are microprocessor based units designed to control machine functions on automated equipment. They can be used as stand-alone controllers, or interfaced to PLC’s in larger automation systems.
The PLμS PS-6344 Programmable Dual Axis Limit Switch is designed to control machine functions on two independent axes. It can also be used as a stand-alone controller, or interfaced to PLC's in larger automation systems.
Typical applications include: |
|
■ Polybag Machines |
■ Cartoners |
■ Labelling Machines |
■ Case Packers |
■ Can Making Machines |
■ Palletizers |
■ Form-Fill-Seal Machines |
■ De-Palletizers |
■ Paper Converting Machines |
■ Vision Systems |
■ Pick & Place Machines |
■ Filling Machines |
■ Metal Processing/Stamping |
■ Beverage Fillers |
■ Adhesive Application Systems |
■ High Speed Presses |
■ Automatic Assembly Machines |
|
Benefits
Improved Machine Control
Features such as automatic speed compensation, combined with fast scan times, enable a PLμS Controller to quickly respond to changes in line speed and product movement, minimizing machine errors and reducing scrap and downtime.
Easier Operator Control
By handling complex automation functions under rapidly changing line conditions, PLμS Controllers allow an operator to concentrate on product flow into and out of the line, instead of constantly monitoring the line for malfunctions and manually adjusting setpoints. PLμS Controllers increase operator interface capabilities and contribute to smooth, efficient production.
Faster Changeovers, Greater Flexibility
PLμS Controllers can store multiple programs of timing setpoints for solenoids, cylinders, motors, glue guns, and other mechanisms. This allows quick changes in product size or configuration, reducing downtime and improving productivity.
13647 Metric Rd • Roscoe,IL 61073 USA •815-389-2620 •FAX 815-389-3304 •800-228-5487 (USA & Canada)
PLμS Controllers Enhance PLC Systems
Figure 1
PLμS Controllers are Fast!
As the system in Figure 1 shows, the PLμS monitors the production line every 300 to 500 μsec, approximately 100 times faster than an average PLC with its more extensive programming. Although the PLC does interface directly with the production line, the functions it controls are lower speed, and deals more with the logic functions necessary for machine control. For high speed, critical functions such as label-to-product registration, the PLμS provides faster control and improved precision, reducing scrap and rejects.
PLμS Controllers have Built-In DC Inputs & Outputs!
Using transistor outputs, the PLμS can signal changes to the PLC within 300 to 500 μsec (as fast as 40 μsec on special models); much faster than the serial communications speed of approximately 50 msec. When product sensors send a signal to the DC input of the PLμS, the PLμS responds to that signal quickly.
PLμS Controllers have Serial Communications!
For product changeovers, the PLC can send commands and operating parameters to the PLμS controller to change setpoint programs. This eliminates the need for an operator to manually change programs through the PLμS keyboard.
PLμS Controllers Save PLC Memory!
The PLμS controller can store many programs containing various setpoints for the production line. The PLC need only select the correct program, and the PLμS will do the rest.
PLμS Controllers Simplify PLC Programming!
By handling complex functions like speed compensation, timed outputs, and sensor gating, the PLμS controller relieves a programmer of having to write complicated PLC control programming from scratch. The PLC software can simply exchange process variables and control data with the PLμS controller, which handles direct high speed machine control through its own dedicated software.
PLμS Controllers Simplify Operator Interface Design!
Many production lines require an operator to select product sizes or configurations through a keyboard. The 1/4 DIN keypad/display of the PS-6000 can be mounted near the production machinery, giving an operator easy access to critical control functions. The keypad transmits these changes back through the PLμS controller to the PLC, eliminating the need for a PLC system designer to supply custom operator interface software and hardware for PLS functions.
Electro Cam Corp. has Systems Experience!
Our standard PLμS controllers feature extensive capabilities for integration into larger control systems, PLC based or otherwise. We can supply IBM-PC compatible PLuSNet software to facilitate communications between our controllers and a host computer. In addition, we can supply controllers with custom features such as shift-register capability, or the ability to function in non-rotary environments. For information on our systems capabilities, please call our toll free number.
800-228-5487
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Standard PS-6000 Series Features
Analog Output
PS-6000 controllers can drive two analog output modules whose output signals will be linearly proportional to RPM. The analog signal level at zero RPM can be programmed, 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 for the analog output are to control adhesive pressure as machine speeds change, or to match speeds of other equipment to the machine being controlled by the PS-6000.
Multiple Programs
Up to 48 programs can be stored in the control’s memory, each containing different setpoints. To change product size or configuration, simply switch program numbers and all of the output settings will change accordingly. Program numbers can be selected by the keypad/display, mechanical switches, PLC DC outputs, or serial communication messages.
Output Speed Compensation
Speed compensation allows outputs to compensate for lagging response times of the controlled devices by turning on earlier as machine speeds increase. This eliminates the need to manually adjust output settings whenever machine speeds are changed, allowing high production speeds.
Internal High Speed Logic
Outputs can be divided into Groups, and each Group can be associated with an input device to perform discrete logic. There are six different modes of operation, or logic functions, that can be selected for each Group. For example, some modes activate the Group only when the input has signaled that product is present. Adhesive control is a typical application where outputs are disabled until product is sensed. Output grouping is a powerful tool in many applications because each Group can be in any of the six modes and operate independently of the other Groups.
Certifications are standard.
Timed Outputs
Timed outputs are programmed like standard outputs to turn “ON” and “OFF” at specific points of resolver rotation. However, once a timed output turns ON, it will remain ON for a specified time period. Timed outputs are used to drive devices such as heat seal bars, spot welders, etc., that require a fixed time to perform a task, regardless of machine speed.
Selectable Scale Factor
The Scale Factor, or number of increments per revolution, can be programmed by the user. Standard controls have a maximum of 1024 increments per revolution, while controls available with an “-H” option have a maximum of 4096 increments per revolution. Scale Factor can be defined to correlate to Real World increments. For example, a controller could be programmed so that one increment of rotation corresponds to 0.1" of travel.
Serial Communication
Using Electro Cam Corp.’s PLuSNet software for IBM-PC compatible computers, the controller’s entire program can be saved to a disk file or loaded from a disk file to the control. The program can be printed or edited using the computer. Using MMI software, it is also possible to send individual communication commands to the control, while running, to change settings in the program.
Motion Detection
Two speed ranges can be programmed into the controller, and specified outputs can then be enabled or disabled, based on the machine speed being within the designated range. This feature can turn off outputs if the machine stops; disable outputs until the machine reaches a minimum speed; or disable outputs if the machine exceeds a specified speed. In adhesive applications, speed range logic is often used to turn off the flow of adhesive if the conveyor carrying products stops.
PS-6000 Series Options
Gray Code Position Output, “-G” & “-G10”
The “-G” option provides eight bits of position information to a PLC or other electronic control device, eliminating the need for expensive PLC accessory cards. The "-G10" option provides ten bits of position information. This allows the PLC to control non-critical machine functions, while the PLμS directly handles high-speed machine control.
High Resolution, “-H”
Controls with this option can divide the resolver revolution into as many as 4096 increments, while standard controls have a maximum of 1024 increments. The control program allows resolver resolution to be set for any value in the range of 2-4096.
Large Program Memory, “-F”
Controls with the “-F” option can store up to 256 programs consisting of not more than 4589 output pulses total; standard controls can store up to 48 programs. This additional program storage capability is useful for applications requiring multiple complex programs, or those requiring the storage of more than 48 programs.
Leading/Trailing Edge Speed Comp, “-L”
Controls with this option allow the "ON" and "OFF" edges of output pulses to be speed compensated by different amounts. If a device has “ON” and “OFF” response times that are different, it may be necessary to compensate the “ON” edge by a different amount than the “OFF” edge. This will ensure that the device stays properly synchronized to the machine over a wide range of speeds. High-speed adhesive application is an example that can benefit from this feature.
NEMA 4X Keyboard Boot, “-W”
Controls with the “-W” option are shipped with a clear silicon rubber boot fitted over and around the keyboard area. 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. In addition to preventing contamination from harsh chemicals, the boot protects the keyboard from washdown damage.
Modbus™ ASCII Communication , “-MB”
See page 4.
Multiple Controllers Used with One Resolver, “-MSV”
See page 5.
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PS-6000 Series with -MB Option
— with Modbus ™ ASCII Communications
Description
Standard Modbus™ ASCII protocol allows a host computer, Programmable Logic Controller (PLC), intelligent touch panel, or other compatible logic circuitry to easily monitor or modify data within the PS-6000-MB while the machine is in motion.
The control data in the PS-6000-MB is organized as registers and coils, compatible with PLC programming techniques. Registers are used to store control parameters at specific addresses. Coils represent channel outputs and logic inputs. Through serial communications, coils allow outputs to be forced ON or OFF, and allow inputs to be monitored.
The data can be changed by writing to registers, and monitored by reading from registers. All controller data, including position, pulses, RPM, speed compensation, and timed output values, are available through registers.
NOTE: All other features of the -MB version of 6000 series controllers are the same as those for standard PS-6000 series controllers.
Benefits
Improved Machine Control
The controller quickly responds to changes in line speed and product movement by combining automatic speed compensation with fast scan times. Modbus serial communications makes it easy to integrate the PLμS controller's high-speed control characteristics into larger control systems.
Messaging Capability
The PLμS keypad/display can display stored messages or messages received from a host computer. Each message, containing up to 32 characters, is stored in non-volatile EEPROM memory.
Mapping
Mapping allows the programmer to arrange data into blocks of registers for optimal communication efficiency, giving direct access to specific indexed data items. For example, setpoint values may be mapped into a series of direct access registers in order to display more than one value at once on the host computer.
PS-6000-MB System Configuration
The Modbus™ ASCII protocol allows the PS-6000-MB Series controller to communicate with various control hardware and software, including:
■PC's using Microsoft® Windows™ software such as FactoryLink®, Intellution™, Lookout™, and Wonderware®
■ PC's using DOS software such as Interact™
■ Intelligent Touch Panels
■ PLC's
As the diagram in Figure 2 illustrates, the host computer communicates to the PLμS using Modbus™ ASCII serial communications. The PLμS controller handles high-speed machine functions through direct wiring of inputs and outputs to the machine.
The Modbus serial commands in the PS-6000-MB Series controller allow you to monitor the program, adjust the current program, or change the program through a host computer system. This allows the flexibility to change product size or configuration quickly and automatically, reducing downtime and improving productivity.
Figure 2
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