Electro CAM PS-6144 User Manual

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PL µS® PS-6 144 Series

Programmable Limit Switch

6000

PGM:1 RPM:1500 MENU< POS: 180

Series

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)

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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

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Section 1—Introduction

Mechanical Cam Switches .............1-1

Programmable Limit Switches........1-1

PS-6144 Description ......................1-2

Basic Terminology..........................1-3

PS-6144 Standard Features ..........1-3

PS-6144 Optional Features............1-4

Section 2—Installation & Wiring

General Mounting & Wiring ............2-1

Mounting Dimensions.....................2-2

Terminals & Components

PS-6144-24M17 ........................2-3

PS-6144-24-X16-M09 ...............2-4

Controller Input Wiring ...................2-5

Output Wiring .................................2-8

Keypad Wiring................................2-12

DIP Switch Configurations .............2-13

Communications Wiring .................2-15

Resolver Installation .......................2-16

Resolver Dimensions .....................2-17

Resolver Cables.............................2-18

Fuse Tester & Fuse Replacement .2-19

Output Transistor Replacement .....2-20

Section 3—Programming

Keypad Overview ...........................3-1

Menu Tree......................................3-2

Initial Programming ........................3-3

Functions (Alphabetically)

Analog Output ...........................3-4

Analog Quantity.........................3-5

Channel Copy............................3-6

Communications........................3-6

Default Program ........................3-7

Enable Codes............................3-8

Enable Options..........................3-10

Group Position Display..............3-10

Increasing Direction...................3-11

Input Status ...............................3-12

Keyboard Quantity.....................3-12

Main Screen ..............................3-13

Memory Tests............................3-14

Motion ANDing ..........................3-14

Motion Detection .......................3-15

Offset.........................................3-16

Output Enable ANDing ..............3-18

Output Groups...........................3-18

Output Status ............................3-19

Password...................................3-20

Per Channel Enable ..................3-21

Program Copy ...........................3-21

Program Select Mode................3-22

Pulse Copy ................................3-22

Rate Setup ................................3-24

Resolver Type ...........................3-25

RPM Update Rate .....................3-25

Scale Factor ..............................3-25

Setpoint Use..............................3-26

Setpoints ...................................3-26

Shaft Position ............................3-28

Software Version .......................3-28

Speed Compensation................3-28

Speed Comp Mode ...................3-29

Timed Outputs...........................3-30

Toggle RPM ..............................3-30

Section 4—Speed Compensation

Introduction ....................................4-1

Examples .......................................4-2

Leading/Trailing Speed Comp........4-4

Negative Speed Comp ...................4-6

Programming Guidelines................4-6

Section 5—Output Grouping & Modes

Introduction ....................................5-1

Mode 0 ...........................................5-3

Mode 1 ...........................................5-3

Mode 2 ...........................................5-4

Mode 3 ...........................................5-5

Mode 4 ...........................................5-6

Mode 5 ...........................................5-7

Speed Comp & Modes ...................5-8

Section 6—Communications

PLuSNET II Program .....................6-1

Serial Communications Using

Electro Cam Corp. Protocol ...........6-3

Error Codes ....................................6-12

Checksum Calculations..................6-12

Serial Communications Using

Modbus ASCII Protocol..................6-13

Section 7—Troubleshooting

Controller Diagnostics ....................7-1

Keypad Diagnostics .......................7-2

Resolver Troubleshooting ..............7-3

General Troubleshooting................7-4

Fuse Part Numbers ........................7-6

Appendix

Controller Specifications ................A-1

Slimline Module Specifications.......A-2

Transistor Output Specifications ....A-3

Resolver Specifications..................A-3

Factory Defaults .............................A-3

PS-6144 Setpoint Record ..............A-4

Index

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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 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 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 beyond the description on the face hereof. This warranty is in LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED INCLUDING (B UT 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.

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Mechanical Cam Switches

Mechanical Cams The PS-6144 Programmable Limit Switch electronically simulates mechanical cam

switches. A cam switch consists of a roller limit switch whose arm rides on a cam as shown in Figure 1. The cam shaft is driven by a machine at a 1:1 ratio, so that the cam switch turns on and off at specific positions in the machine cycle. Cam limit switches have the following disadvantages:

• The roller, the cam, and the limit switch wear out.

• The machine must be stopped during adjustment.

• On/off patterns are limited, and changing the pattern may require replacement of one cam with another. For example, a cam that switches on and off twice in one revolution would need to be replaced with a different cam if three on/off pulses per revolution were required.

• They cannot run at high speeds because of contact bounce and excessive mechanical wear.

Figure 1—Basic Cam Switch

Programmable Limit Switches

PS-6144’s & Resolvers The PS-6144 Programmable Limit Switch uses a resolver (see Figure 2 on page 2)

instead of a cam to indicate machine position. A resolver uses fixed and rotating coils of wire to generate an electronic signal that represents shaft position. The resolver is usually coupled to a machine shaft at a 1:1 ratio so that one resolver shaft rotation corresponds to one machine cycle. Resolvers have no brushes, contacts, or any frictional moving parts to wear out.

Based on the resolver signal, the PS-6144 Programmable Limit Switch turns electrical circuits, or “Outputs,” on and off, simulating the mechanical roller limit switch. Because the combination PS-6144/resolver system is completely electronic and has no frictional parts, it offers several advantages over mechanical cam switches:

• Long service life with no parts to wear out.

• “On” and “off” points can be adjusted instantly from the keypad; there are no cams to rotate or replace.

• Adjustment is possible with the machine running or stopped.

• Programmable logic allows complex switching functions that are impossible with mechanical cams.

• Operation at speeds up to 3000 RPM.

1-1 Introduction

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Programmable Limit Switches

PS-6144 Controller

PS-6000 Series Keypad/Display

Electro Cam Corp. Foot Mount Resolver With Side/Top Connection

Figure 2—PS-6144 Programmable Limit Switch and Resolver

PS-6144 Description

Controller & Keypad PS-6144 Series Programmable Limit Switches consist of two main components, the

controller and the keypad/display. The controller houses the microprocessor, associated circuitry, and all of the I/O circuits. This eliminates the need for external I/O racks.

A separate 1/4 DIN keypad/display provides a complete user interface from which every aspect of the controller’s operation can be monitored and programmed. Multiple keypads can be connected to a single controller. In addition, when interfaced to a PLC or other computer, the controller can be used without a keypad/display. When properly mounted with the gasket provided, the keypad/display 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.

The PS-6144 Series is available in two models, the PS-6144-24-X16-M09 and the PS6144-24M17. Both are described in Figure 3.

PS-6144-24M17 Controller—Up to 17 Outputs

The PS-6144-24M17 has 17 total outputs:

• Outputs 1 through 17 can accept AC or DC output modules for driving “real world” devices such as solenoids, valves, or glue guns.

• Outputs 16 & 17 will also accept an analog module that generates a control signal proportional to RPM.

Figure 3—PS-6144 Models

1-2 Introduction

PS-6144-24-X16-M09 Controller—Up to 25 Outputs

The PS-6144-24-X16-M09 has 25 total outputs:

• 16 transistor outputs are built into the controller.

• Outputs 17 through 25 can accept AC or DC output modules for driving “real world” devices such as solenoids, valves, or glue guns.

• Outputs 24 & 25 will also accept an analog module that generates a control signal proportional to RPM.

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Basic T erminology

The following terms will be used throughout this manual to explain PS-6144 installation, programming and operation:

Channels Each Channel (CHN) in the PS-6144 controller contains “on” and “off” setpoints for one

360° revolution of the resolver shaft. Channels are one of two types: Output Channels—These channels use a switching transistor or an output module to

turn an external circuit on or off. One or two output channels in a controller may also use an analog output module to generate a control signal that is proportional to RPM.

Group Channels—These channels control the interaction between groups of outputs and an input received from a sensor or other controlling device. See Section 5 for details on Group Channels.

Setpoints “Setpoints” are the points within one rotation of the resolver at which a channel turns on

or off. Setpoints can be programmed into a channel through the keypad/display, or they can be downloaded from a computer or PLC through serial communications. The PS6144 can turn any given channel on and off multiple times within one rotation.

Pulses A “pulse” is the “on” period between the time a channel is turned on and off. The “on”

setpoint is the leading edge of the pulse, and the “off” setpoint is the trailing edge. When multiple pairs of setpoints are programmed into one channel, the channel is said to have multiple pulses.

Programs Suppose that 15 output channels on a cartoner are programmed with setpoints to fold

and glue a certain size carton. These settings could be stored as a “program.” The 15 output channels could then be re-programmed with different setpoints for a different size carton. This second set of setpoints could also be stored as a program. To change carton sizes, an operator could simply activate the correct program, and the corresponding setpoints would take effect.

Standard PS-6144’s can store up to 48 programs. The active program can be selected through the keypad/display, mechanical switches, direct PLC interface, or serial communication messages.

Inputs (hardware inputs) In addition to accepting a signal from the resolver, the PS-6144 can accept up to 16

input signals from mechanical switches, relay contacts, DC two- or three-wire sensors, solid state DC output modules, or PLC DC outputs. The PS-6144 hardware inputs are dedicated to specific functions involving program selection and controlling output channels based on sensor signals.

Groups and Modes Output channels can be combined into “groups”, and each group can be associated

with an input terminal in any of six different “modes” of operation. For example, some modes activate the group only when the corresponding input has signaled that product is present. Glue control is a typical application where outputs are disabled until product is sensed. See Section 5 for details.

PS-6144 Standard Features

Scale Factor The user can program the number of increments per revolution, or “Scale Factor.” For

example, to make the controller display position in degrees, a Scale Factor of 360 is used. For some applications, Scale Factor may be set to define increments in terms of linear distance, such as one increment equals 0.1" of travel. Standard controls have a maximum of 1024 increments per revolution, while “-H” option (high resolution) controls have a maximum of 4096 increments per revolution.

Programming Access Three levels of programming access are provided: Operator, Setup, and Master. Each

level can be assigned a password that must be entered to allow programming at that level. In addition, the Operator and Master levels can be activated on an individual keypad through hardware terminals on the back. Careful use of programming access levels can provide key personnel the flexibility they need in programming the controller, while protecting settings against accidental or unauthorized changes.

1-3 Introduction

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PS-6144 Standard Features (Cont'd)

Speed Compensation Speed compensation advances the setpoints for an output as machine speed increases.

This eliminates the need to manually adjust the setpoints for fixed-response devices when machine speeds are changed. Speed compensation provides greater accuracy, higher production speeds, and reduced downtime for machine adjustment.

Motion ANDing Two speed ranges can be programmed into the controller, and outputs can be ANDed

with either speed range so that they will be disabled unless the machine speed is within the range. A common use for this feature is disabling outputs to glue valves to turn off glue flow if the machine stops.

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 is on, it will remain on for a specified time period, regardless of RPM. If the programmed “off” position is reached before the time period passes, the output will turn off. Timed outputs are used to drive devices such as pneumatic cylinders which require a fixed time to perform a task, regardless of machine speed.

Analog Outputs PS-6144 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 glue pressure as machine speeds change, or to match speeds of other equipment to the machine being controlled by the PS-6144.

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 controller. The program can be printed or edited using the computer. Individual commands may also be sent to the controller to change settings while running.

PS-6144 Optional Features

(-F) Large Program Memory Depending on the number of outputs used, standard controls can store 48 programs

consisting of not more than 1258 total output pulses. Controls with the “-F” option can store up to 256 programs consisting of not more than 4589 output pulses.

(-G) Gray Code Output This option provides eight bits of position information on outputs one through eight.

This “gray code” output can provide position information to a PLC or other electronic control device without the use of expensive PLC accessory cards. The PLC can then make control decisions that do not demand a fast response, while other PLuS outputs directly control devices that must operate accurately at high machine speeds.

(-G10) Gray Code Output This option provides ten bits of position information on outputs one through ten. (-H) High Resolution Controls with this option can divide one resolver revolution into as many as 4096 incre-

ments. Standard controls use 1024 increments maximum. The “-H” Option allows higher Scale Factors to be used. For example, a Scale Factor of 3600 would allow programming in 0.1 degree increments. Or, for an application in which one revolution equals 24" of linear travel, a Scale Factor of 2400 would result in increments equal to .01" of travel.

(-L) Leading/Trailing The “-L” option allows the “on” and “off” edges of output pulses to be Edge Speed Comp speed compensated by different amounts. This option is used for devices whose “on”

and “off” response times are significantly different. High speed gluing is a common application requiring separate leading/trailing edge speed compensation. See Section 4 for details.

(-MSV) Master/Slave Master/Slave resolver mode for multiple controllers used with one resolver. (-MB) Modbus™ Modbus™ ASCII protocol for serial communications. (-V) Vibration Coating Vibration protective coating for extra protection against shock and vibration. (-W) Washdown Boot Keypads with the “-W” option are rated NEMA 4X and are shipped with a clear silicon

rubber boot fitted over and around the keyboard area. In addition to preventing contamination from harsh chemicals, the boot also protects the keyboard from grease, oil, dirt and normal wear that could otherwise shorten the life of the keyboard.

1-4 Introduction

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General Mounting & Wiring

Controller The controller body mounts on a DIN rail as shown in Figure 4.

Keypad/Display Mount the keypad/display to a panel using the four studs on the back of the keyboard.

Enclosures are available from Electro Cam if an appropriate mounting location does not exist.

DIP Switches For convenience, set the DIP switches on the side of the controller and keypad to

their proper positions before mounting the units in a panel. See page 2-13 for DIP

switch information.

Environment 1. Allow space at both sides and the top of controller for terminal blocks to be un-

plugged.

2. Ambient temperature range is 0° to 55°C (32° to 130°F).

3. Locate the controller and keypad away from devices that generate electrical noise, such as contactors and drives.

4. Use the keypad/display gasket provided to prevent contaminants from getting into the cabinet.

Terminal Blocks All terminal blocks can be unplugged from the controller. Each block is keyed so it

cannot be plugged into the wrong socket. All terminals are labelled on each block.

Wiring Guidelines Follow normal wiring practices associated with the installation of electronic controls.

Some guidelines are:

CAUTION

1. Route input and output wiring away from high voltage, motor drive, and other high level control signals.

2. Use shielded cables for resolver, input, transistor output, and communication circuits. Also shield module output circuits that are driving low current electronic input circuits.

3. Ground shielded cables at the PS-6144 end only (except for resolver cable). Use any of the screws on the controller back for grounding.

4. Use appropriate suppression devices where module outputs are directly driving inductive loads.

Power Supply Wiring Connect a 20 to 30 VDC power supply to TB 8 (Fig. 5 or 6). Reversing the polarity will

blow the 1-1/4 amp power fuse. The controller will not be damaged, but you must correct the polarity and replace the fuse before the controller will operate.

To insure electrical noise immunity, connect a good electrical ground to the ground terminal on the power supply terminal block.

Module Mounting A phillips head screw holds each module in place. Individual modules can be removed

and installed without affecting the other modules on the unit.

Disconnect power to the controller before changing modules.

2-1 Installation & Wiring

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Mounting Dimensions

Figure 4—Mounting Dimensions

PGM:1 RPM:1500 MENU< POS: 180

2-2 Installation & Wiring

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Terminals & Components—PS-6144-24M17

Figure 5—PS-6144-24M17 Terminals & Components

Top View

Yellow

Front View

Left Side View

Right Side View

Terminal Block Details

Terminal

Block Function ECC Part #

TB 1 Inputs #9–16 PS-9006-0024 TB 2 Auxiliary power output PS-9006-0018 TB 3 Inputs #1–8 PS-9006-0023 TB 4 Resolver connector PS-5300-01-TER TB 5 Keypad port connector PS-9006-0029 TB 6 Module outputs #13-17 PS-9006-0031 TB 7 Module outputs #9-12 PS-9006-0030 TB 8 Power for controller PS-9006-0026 TB 9 Module outputs #1-4 PS-9006-0033

TB 10 Module outputs #5-8 PS-9006-0034

Keyed to prevent accidental insertion into wrong sockets.

2-3 Installation & Wiring

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Terminals/Components PS-6144-24-X16-M09

Figure 6—PS-6144-24-X16-M09 Terminals & Components

Top View

Y ello w

Front View

Left Side View

Right Side View

2-4 Installation & Wiring

Terminal Block Details

Terminal

Block Function ECC Part #

TB 1 Inputs #9–16 PS-9006-0024 TB 2 Auxiliary power output PS-9006-0018 TB 3 Inputs #1–8 PS-9006-0023 TB 4 Resolver connector PS-5300-01-TER TB 5 Keypad connector PS-9006-0029 TB 6 Module outputs #21–25 PS-9006-0028 TB 7 Module outputs #17–20 PS-9006-0027 TB 8 Power for controller PS-9006-0026 TB 9 Transistor outputs #1–8, sinking PS-9006-0019

TB 10 Transistor outputs #9–16, sinking PS-9006-0020

TB 11 Power for transistor outputs PS-9006-0017

Keyed to prevent accidental insertion into wrong sockets.

Transistor outputs #1–8, sourcing PS-9006-0021

Transistor outputs #9–16, sourcing PS-9006-0022

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Controller Input Wiring

Input Terminals Hardware inputs can be used to select a program of setpoints or activate groups of

outputs based on sensor signals according to mode logic as described in Section 5. The 16 inputs on the PS-6144 are arranged on two terminal strips, TB 1 and TB 3, as

shown in Figure 7. Each input is optically isolated and can be powered from an external DC power source or the Auxiliary Power terminals located on TB 2.

Sinking or Sourcing Each terminal strip TB 1 and TB 3 can be wired to accept sinking or sourcing input

signals, but all eight inputs on that strip will require the same type of signal. Many types of hardware can drive these inputs, including mechanical switches, relay contacts, DC 3-wire sensors, solid state DC output modules, and PLC DC outputs. 2-wire DC sensors can also be used, but may require a load resistor in parallel with the input. Typical wiring diagrams are shown in Figure 7.

Input Functions The following are the input terminals and their corresponding functions:

Program Select (1–8)

The on/off status of these terminals selects which program of setpoints is controlling the outputs. Binary, BCD, or Gray Code formats can drive these terminals as shown in Figure 8.

When all program select inputs are off, the “Default” program will become active as programmed through DEFAULT PROGRAM function.

Group Inputs (9–14)

These inputs work in conjunction with groups of outputs according to mode logic as discussed in Section 5. Typically, photo eyes and other sensors will operate these inputs.

First Cycle Enable (15)

Mode 5 uses this input to allow the first machine cycle to operate the corresponding outputs. See Section 5 for details.

Output Enable (16)

Any of the outputs (except analog) can be ANDed with this input through OUTPUT ENABLE ANDING. Outputs that are ANDed will operate only when this input is on. This can be used in conjunction with Motion ANDing and output modes.

2-5 Installation & Wiring

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Controller Input Wiring (cont’d)

Figure 7—Controller Input Wiring (See Figures 5 & 6 for Terminal Block Locations)

Sourcing Devices

(+VDC is being switched)

Term. Function

1-8 Program Select

9 Group 1 Input 10 Group 2 Input 11 Group 3 Input 12 Group 4 Input 13 Group 5 Input 14 Group 6 Input 15 First Cycle Enable 16 Output Enable

Sinking Devices

(DC common is being switched)

Input Wiring Guidelines

• Voltage from TB 2 will be the same as the voltage supplied to the controller.

• Each input powered from TB 2 will draw 11 mA at 24 VDC. TB 2 is fused at 1/4 amp.

• Inputs will operate with voltages from 10 to 30 VDC.

• An external power supply can be used instead of TB 2 to power inputs.

• A combination of mechanical and solid state devices can be used.

• TB 1 can be wired for sourcing while TB 3 is wired for sinking, and vice versa.

2-6 Installation & Wiring

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Controller Input Wiring (cont’d)

Figure 8—Program Select Terminals for Various Formats

BCD Format

Units10's

Binary Format

Gray Code Format

Input Terminal: 7 6 54321

Value: 40 20 10 8 4 2 1

Program: Default 0000000



1 0000001 2 0000010 3 0000011 4 0000100 5 0000101 6 0000110 7 0000111 8 0001000

9 0001001 10 0010000 11 0010001 12 0010010 13 0010011 14 0010100 15 0010101 16 0010110 17 0010111 18 0011000 19 0011001 20 0 100000 21 0 100001 22 0 100010 23 0100011 24 0100100 25 0 100101 26 0 100110 27 0100111 28 0101000 29 0101001 30 0110000 31 0110001 32 0110010 33 0110011 34 0110100 35 0110101 36 0110110 37 0 110111 38 0111000 39 0111001 40 1000000 41 1000001 42 1000010 43 1000011 44 1000100 45 1000101 46 1000110 47 1000111 48 1001000

Input Terminal: 6 5 4 3 2 1

Value: 32 16 8 4 2 1

Program: Default 000000



1 000001 2 000010 3 000011 4 000100 5 000101 6 000110 7 000111 8 001000

9 001001 10 001010 11 001011 12 001100 13 001101 14 001110 15 001111 16 010000 17 010001 18 010010 19 010011 20 010100 21 010101 22 010110 23 010111 24 011000 25 011001 26 011010 27 011011 28 011100 29 011101 30 011110 31 011111 32 100000 33 100001 34 100010 35 100011 36 100100 37 100101 38 100110 39 100111 40 101000 41 101001 42 101010 43 101011 44 101100 45 101101 46 101110 47 101111 48 110000

Input Terminal: 6 54321

Value: MSB LSB

Program: Default 000000



1 000001 2 000011 3 000010 4 000110 5 000111 6 000101 7 000100 8 001100

9 001101 10 001111 11 001110 12 001010 13 001011 14 001001 15 001000 16 011000 17 011001 18 011011 19 011010 20 011110 21 011111 22 011101 23 011100 24 010100 25 010101 26 010111 27 010110 28 010010 29 010011 30 010001 31 010000 32 110000 33 110001 34 110011 35 110010 36 110110 37 110111 38 110101 39 110100 40 111100 41 111101 42 111111 43 111110 44 111010 45 111011 46 111001 47 111000 48 101000

For BCD, calculate the program selected by adding up the values for each of the inputs that are on. For example, if Inputs 5, 3, and 1 are on, Program #15 is active (10 + 4 + 1).

For Binary, calculate the program selected by adding up the values for each of the inputs that are on. For example, if Inputs 5, 3 and 1 are on, Program #21 is active (16 + 4 + 1).

Electro Cam 8-position Gray Code selector switches are available as accessories for PS6144 and other PLuS controls.

• Only three of the normal four BCD digits for 10’s are used.

• 9 is the largest valid value for the units digit. A units digit combination larger than 9

will set the units digit to 9.

Notes Common to All Three Formats

• Because the standard PS-6144 has 48 programs available, any program select value larger than 48 selects program number 48.

• The Default Program is determined by programming the DEFAULT PROGRAM function, Section 3.

2-7 Installation & Wiring

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Output Wiring

Output Types The outputs available depend on the PS-6144 Model:

Output Model Model Type 6144-24M17 6144-24-X16-M09

Transistor None Outputs 1-16 AC/DC/RR Modules Only Outputs 1-15 Outputs 17-23 AC/DC/RR or Analog Modules Outputs 16 & 17 Outputs 24 & 25

The load device to be driven must match the output type.

Power Output Modules Output modules can directly switch inductive loads and resistive loads that require more

current or voltage than the transistor outputs can supply. The modules do not supply the power for the load; they simply switch it. Each output module has two dedicated terminals and therefore does not share any common signal with the other modules. This allows AC and DC modules to be mixed on the same control. DC modules can be wired to sink or source as shown in Figure 9.

Analog Output Modules Analog output modules generate signals that are proportional to the resolver RPM.

They can be used only in the output positions shown above. Either a 0-10 VDC or 4-20 mA analog module can be used in either module position. ANALOG QTY must be programmed for the number of analog modules installed. An external power supply is not needed because the analog modules get the power they source from the controller. The analog output signal is completely isolated.

Transistor Outputs PS-6144-24-X16-M09 models include 16 transistor outputs to drive the electronic input

circuits of other control devices. The outputs are limited to 30 VDC, 50 mA each and should not be used to control inductive devices such as solenoids, solenoid valves or relays.

The control can be ordered with either sinking or sourcing transistor outputs. Both types require a 10-30 VDC power supply connected to TB 11 to drive the transistor output circuitry. The transistor output fuse will blow if the power supply polarity is incorrect, but the circuitry will not be damaged. See Figs. 17 & 18 for fuse and transistor chip replacement.

Sinking transistor outputs (N16 controls, Figure 10) conduct to the negative terminal of TB 11. Therefore the common for TB 11 and the load must be electrically the same. This may require connecting commons together if the power supplied to TB 11 is not also the load power supply. Electronic counters/ratemeters often fall into this category. The power supply that powers the load does not have to be the same voltage as the transistor power supplied to TB 11.

Sourcing transistor outputs (P16 controls, Figure 11) conduct to the positive power terminal of TB 11. The load is therefore powered from the same supply that is providing the transistor power.

2-8 Installation & Wiring

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Output Wiring (cont’ d)

Figure 9—Wiring for Output Modules

PS-6144-24M17

PS-6144-24-X16-M09

Electro Cam

AC Output

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

• Analog output modules source the analog signal.

• No external supply is required.

• Analog output signals are isolated.

DC Output

Sourcing

Sinking

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 voltage spikes 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.

2-9 Installation & Wiring

Page 18

Output Wiring (cont’ d)

Figure 10—Wiring for Sinking Transistor Outputs (See Figure 6 for Terminal Block Locations)

Model PS-6144-24-N16-M09

Please Note:

• Outputs are rated at 30 VDC, 50 mA.

• Transistor outputs should not be used to switch inductive devices such as solenoids or relays.

• Sinking outputs conduct to the negative terminal of TB 11 when “on.”

• The power supply shown in “Load with Built-In Power Supply” does not have to be the same voltage as the power supply connected to TB 11.

2-10 Installation & Wiring

Page 19

Output Wiring (cont’ d)

Figure 11—Wiring for Sourcing Transistor Outputs (See Figure 6 for Terminal Block Locations)

Model PS-6144-24-P16-M09

Please Note:

• Outputs are rated at 30 VDC, 50 mA.

• Transistor outputs should not be used to switch inductive devices such as solenoids or relays.

• Sourcing outputs conduct to the positive terminal of TB 11 when “on.”

Sinking/Sourcing Defined

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)

2-11 Installation & Wiring

Page 20

Keypad Wiring

Number of Keypads One or two keypads may be connected to a PS-6144 controller as shown in Figure 12.

See Figure 14 for possible system configurations.

Programming Enable The wiring connector on the back of each keypad includes terminals to select Operator

or Master level programming for that keypad. These terminals can be temporarily jumpered during set-up to allow entry of programming access codes, or they can be switched with a variety of devices including mechanical switches, relay contacts, and PLC DC outputs. See ENABLE CODES in the programming section for details on programming access.

If a solid state device will be activating the Programming Enable terminals, that device will determine whether sourcing or sinking wiring should be used. For mechanical devices such as jumpers or key switches, either sourcing or sinking wiring may be used.

Figure 12—Keypad Wiring

Keypad Connector on Controller

Wh Bk Gn

Rd Bk

Programming Enable, Sourcing

Keypad Terminal Block

Bk Wh Bk Gn

Rd Bk

Programming Enable, Sinking

Wh Bk

Rd Bk

2-12 Installation & Wiring

Page 21

DIP Switch Configurations

DIP Switches Each keypad and controller has a DIP switch as shown in Figure 13. For convenience,

set the DIP switches correctly before mounting the units in a panel.

Keypad Settings The address and termination settings on the keypad DIP switch apply to the RS-485

network that connects it to the controller. See Figure 14 for guidelines and sample settings.

Controller Settings The address settings on the controller DIP switch apply to a network connecting the

controller to a PLC or other system host. When the DIP switch is set to zero, the default address programmed through the COMMUNICATIONS function takes affect. Whereas the DIP switches can set a maximum address of “7”, the COMMUNICATIONS function can establish much higher address numbers. These settings are not related to com-

munications with the keypads.

Two sets of termination switches are included on the controller. One set establishes the termination value for an RS-485 network connecting the controller to a PLC or other system host. It does not apply to an RS-232 network. The other termination switches apply to the keypad network. See Figure 14 for guidelines and sample settings.

Figure 13—DIP Switches and Related Communications Networks

NOTE: Both termination switches in a pair must be in the same position.

2-13 Installation & Wiring

Page 22

DIP Switch Configurations (cont’d)

Figure 14—DIP Switch Settings for Typical Systems

One Keypad

Two Keypads, Controller on End

Two Keypads, Controller in Middle

DIP Switch Guidelines Termination: • Termination must be “on” for devices on each end of the chain.

• Termination must be “off” for devices in the middle of the chain.

• Both termination switches in a pair must be in the same position.

Address: • Keypad addresses must be assigned starting with “0” and increasing sequentially.

• The physical location of a keypad in the chain has no relationship to its address.

• During initial programming, the KEYBOARD QTY function must be used to enter the number of keypads in the chain. KEYBOARD QTY can be accessed only through the keypad whose address is “0.”

2-14 Installation & Wiring

Page 23

Communications Wiring

DB-9F Port Serial communication to a PLC or other system host is provided through a DB-9 female

connector as shown in Figures 5 & 6. This connector can be wired for RS-232 or RS485 communications.

RS-485 RS-485 can be used for “multi-drop” networks where more than one controller could be

connected to the system host.

RS-232 RS-232 can connect only a single PS-6144 to a system host. RS-232/485 Selection Use the COMMUNICATIONS function to select RS-232 or RS-485 communications.

Figure 15—Communications Wiring

DB-9 Female Connector on Controller

(See Figures 5 & 6 for Location)

RS-232 Cable Wiring

DB-25 (Host) to DB-9F (PS-6144)*

*Pins 1, 4, 6, 7 and 8 must NOT be connected. Damage may result from using an off-the-shelf RS-232 communications cable.

Be sure to follow illustrations, as they are NOT STANDARD configurations!

RS-232 Cable Wiring

DB-9 (Host) to DB-9F (PS-6144)*

2-15 Installation & Wiring

Page 24

Resolver Installation

General Information Choose a mounting location for the resolver that allows convenient mechanical con-

nection of the resolver shaft to the machine. The resolver is normally driven at a 1:1 ratio to machine cycles, but this is not true in all applications. The shaft can be coupled to the machine using a chain and sprocket, timing pulley and belt, or a direct shaft-toshaft coupling. If a shaft-to-shaft coupling is used, Electro Cam Corp. recommends the use of a FLEXIBLE coupling. Flexible couplings are available through Electro Cam Corp. and are included on the price list.

Turn power to the machine OFF prior to installation!

No provision need be made for physically rotating the resolver shaft with respect to the machine shaft. The PS-6144 can be easily programmed to set any resolver position as the 0° position.

If possible, select a location that shelters the resolver from accidental mechanical abuse, lubricants, washdown chemicals or any other liquids. Most Electro Cam resolvers have a NEMA 4 rating or better, but avoiding contaminants will maximize their reliability and service life.

Figure 16 shows three commonly used Electro Cam resolvers.

Ambient Temperature Electro Cam resolvers have an ambient temperature range of -40° to +125°C (-40° to

+257°F).

Resolver Wiring Cables for non-stainless Electro Cam resolvers are shipped with one end soldered to

the resolver connector. The connector for the other end is mounted on the controller. The shield is connected at both ends of the cable to prevent damage due to electro-

static discharge. If electrical noise problems are suspected when the control is in operation, call Electro Cam Corp. for advice regarding shielding.

The resolver cable used with the stainless steel resolvers (PS-5300-02-XXX) does not have a connector at the resolver end because screw terminals are used inside that resolver. When properly connected, both ends of the cable shield will be connected. If electrical noise problems are suspected when the control is in operation, call Electro Cam Corp. for advice regarding shielding.

Resolver cables supplied by Electro Cam are a special type consisting of three individually twisted/shielded pairs with a common braid shield. This insures that reliable position information is being received by the controller. The use of other cable types could degrade the accuracy of the position signals and make them more susceptible to electrical noise. For these reasons, it is recommended that customers do not make their own resolver cables. Electro Cam will make resolver cables any length up to 1000' and can expedite shipment as required.

2-16 Installation & Wiring

Page 25

Resolver Dimensions

Figure 16 - Electro Cam Corp. Resolvers

Foot Mount

With Rear Connector (shown):

PS-5275-11-ADR

With Side Connector:

PS-5275-11-ADS

Cable:

PS-5300-01-XXX where “XXX” is length in feet.

0.749/

0.747"

19.02/

18.97 mm

Flange Mount

With Rear Connector (shown):

PS-5238-11-ADR

With Side Connector:

PS-5238-11-ADS

Cable:

PS-5300-01-XXX where “XXX” is length in feet.

Stainless Steel

0.375/

0.374"

9.53/

9.50 mm

.625/ .624" dia.

15.88/

15.85 mm

Horizontal Mount

(shown) PS-5262-11-CTG (with right connector) PS-5262-11-CTL (with left connector)

Vertical Mount (Shaft Up)

PS-5262-11-CTG-V (with right connector) PS-5262-11-CTL-V (with left connector)

Cable: PS-5300-02-XXX where “XXX” is length in feet.

For horizontal applications

2-17 Installation & Wiring

Page 26

Resolver Cables

Cable for Resolver with Cannon Connector

PT# PS-5300-01-XXX (XXX = Length in Feet)

Connector - Controller End

PT# PS-5300-01-TER (Weidmuller # BLA7 12822.6)

Green

Black

Red

Black

White

Black

Shield

CAUTION

Shielding Note: Resolver cables made after 3-2-93 have a ring lug on a black shield wire at the resolver end. The ring lug should be attached to one of the resolver connector strain relief screws to protect against static discharge through the resolver cable. In some installations, it may be advisable to disconnect the ring lug to prevent ground loops through the cable shield. Consult Electro Cam if electrical noise problems are suspected.

Cable Type: 3 individually shielded pairs, 22 gauge

Pin B - Green Pin A - Black

Pin D - Red Pin C - Black Pin F - White Pin E - Black

Shield

(see note below)

Shield

Front View

(pin out)

= Not Used

Cable for Stainless Steel Resolver with Terminal Strip Connections

Connector - Controller End

PT# PS-5300-01-TER (Weidmuller # BLA7 12822.6)

GR BK RD

BK WT BK SH

CAUTION

Green Black

Red Black White Black Shield

PT# PS-5300-02-XXX (XXX = Length in Feet)

Cable Type: 3 individually shielded pairs, 22 guage

White Black

Black Red Black Green

Shield

(see note below)

Shielding Note: This type of resolver cable will have a spade lug connected to the shield at the resolver end. The lug should be attached to the grounding stud on the cover plate of the resolver. In some installations, it may be advisable to disconnect the lug to prevent ground loops through the cable shield. Consult Electro Cam if electrical noise problems are suspected.

Connector Inside Resolver

(cable is stripped and tinned at both ends)

WHITE BLK (P/W) WHITE

BLK (P/W) RED

RED BLK (P/W) GREEN

GREEN

2-18 Installation & Wiring

Page 27

Fuse Tester & Fuse Replacement

Fuse Tester Figure 17 shows the location of a fuse test socket and LED which can be used to test

TR5 style fuses. PS-6144 controllers are shipped with a spare 4A fuse mounted in the test socket.

Figure 17—TR5 Fuse Tester and Fuse Locations

PS-6144-24M17

Replacement TR5 Fuse Part Numbers

Rating Function ECC Part # Wickmann Part #

250 mA Power for Inputs (TB 2) PS-9005-0250 19374-035

1 A Power for Transistor Outputs (TB 11) PS-9005-0001 19370-048 4 A Fuse for Output Modules PS-9005-0004 19370-062

PS-6144-24-X16-M09

2-19 Installation & Wiring

Page 28

Output T ransistor Replacement

Check Fuse First If all of the transistor outputs fail to work, check the 1A fuse shown in Figures 17 & 18.

Also check to be sure that a 10–30 VDC power supply is connected to TB 11, Figure 6.

Correct Problems Chips will most likely be damaged by one of two events:

• A short circuit connected to one of the transistor outputs.

• A load exceeding 50 mA connected to one of the transistor outputs. Before replacing a transistor output chip, fix the problem that damaged it.

Proper Placement When replacing a chip, be sure that all of the pins are properly seated in the socket.

Position the notch on the end of the chip as shown below.

Figure 18—Transistor Chip Replacement

TB 11

TB 10

TB 9

PS-6144-24-N16-M09

Sinking Outputs

16 15 14 13 12 11 10 9

8 7 6 5 4 3 2 1

1A Fuse for Transistor Outputs—

If blown, no transistor outputs will work. See Figure 17 for testing.

Empty Socket Holes (2)

Position Notches Like This

Jumper Block & Chip For Outputs 9–16

• Jumper block does not normally need replacement.

Jumper Block & Chip For Outputs 1–8

• Jumper block does not normally need replacement.

TB 11

TB 10

TB 9

PS-6144-24-P16-M09

Sourcing Outputs

16 15 14 13 12 11 10 9

8 7 6 5 4 3 2 1

1A Fuse for Transistor Outputs—

If blown, no transistor outputs will work. See Figure 17 for testing.

Chips for Outputs 9–16

• Replace PS-9011-2580 first.

• Replace PS-9011-2803 if that doesn’t work.

Position Notches Like This

Chips for Outputs 1–8

• Replace PS-9011-2580 first.

• Replace PS-9011-2803 if that doesn’t work.

2-20 Installation & Wiring

Replacement Part Numbers

Description ECC Part #

Replacement Chip-Sourcing PS-9011-2580 Replacement Chip-Sinking PS-9011-2803 DIP Jumper Block PS-9006-0015

Page 29

Keypad Overview

Figure 19—Keypad Keys and Corresponding Functions

Main Screen

• Shows Active Program, RPM, Position, and Group # if applicable.

• See MAIN SCREEN in this Section for details.

• Press SEL key when cursor is on “MENU” to enter Menu Tree (Fig. 20) and initiate programming.

PGM:1 RPM:1500 MENU< POS: 180



Cursor Keys

• Scroll through Menu Tree (Fig. 20).

• Move around within a screen.

• Scroll through setpoints.

ESC, SEL, HLP Keys

• ESC exits from current menu level to pre- vious menu, or aborts numeric entry.

• SEL enters a new menu level; toggles a value; and selects an output group if multiple groups with different offsets are used.

• HLP shows help regarding menu selection and what keys to press. Use this key

if unsure what to do.

INC, DEC Keys

• Increment or decrement a value within a field.

Numeric Keys

• Input numeric values within a field.

• ENT must be pressed to enter the value; entry will flash until ENT is pressed.

• CLR will backspace within an entry prior to pressing ENT.

• ± will convert a positive number to a negative number, or vice versa.

• Hold for rapid scrolling of value.

3-1 Programming

Page 30

Menu T ree

Figure 20—PS-6144 Menu Tree

• Functions are listed alphabetically in Section 3 of this manual starting on page 3-4.

ESC SEL

MAIN SCREEN

PASSWORD SETPOINTS

SETUP MENU

ESC SEL

DEFAULT PROGRAM SPEED COMP TIMED OUTPUTS OFFSET MOTION DETECTION ANALOG OUTPUT

PULSE COPY CHN COPY PGM COPY I/O STATUS MENU

ESC SEL

SYSTEM INFO MENU SETPOINT USE

ESC SEL

CONFIG MENU HARDWARE MENU

ESC SEL

INPUT STATUS OUTPUT STATUS

SOFTWARE VERSION MODEL & OPTIONS

KEYBOARD QTY INCREASING DIR SCALE FACTOR

SHAFT POSITION ANALOG QTY RESOLVER TYPE

PGM SEL MODE

DISPLAY MENU RATE SETUP

ESC SEL

PGM ENABLE MENU ENABLE CODES

ESC SEL

CHN ANDING MENU

ESC SEL

OUTPUT GROUPS

COMMUNICATIONS MENU

TEST MENU MEMORY TESTS

ESC SEL

TOGGLE RPM RPM UPD RATE SPD COMP MODE

GRP POS DISP

PER CHN ENABLE ENABLE OPTIONS SETPOINTS

ESC SEL

DEFAULT PROGRAM SPEED COMP TIMED OUTPUTS OFFSET MOTION DETECT

MOTION ANDING

ANALOG OUTPUTS

OUTP ENAB AND

3-2 Programming

Page 31

Initial Programming

Bench Test To test the PS-6144 prior to installing it, do the following:

1. Plug output modules into the controller beginning with Position 1 on the PS-614424M17, or Position 17 on the 6144-25. See Figure 9.

2. Connect a resolver. See Figure 16.

3. Connect the keypad/display to the controller. See Figure 12.

4. Set the keypad DIP switch to address “0” and termination “on,” as shown in Figure

13. Set switches 6 and 7 on the controller DIP switch to “on,” also shown in Figure

13.

5. Use two jumper wires to enable Master Level programming as shown in Figure 12. Connect one jumper from “+” of the keypad terminal block to “C.” Connect the other jumper from “–” to “E1.” These jumpers will permit access to the entire menu tree shown in Figure 20.

6. Connect DC input power.

When experimenting with the controller, note that the LED on an output module will light when that output channel is turned on. By hand-turning the resolver shaft and watching the module LED’s, you can observe the effects of programming setpoint values. Remember that on a PS-6144-24-X16-M09, outputs 1-16 are transistor outputs. To activate the LED on a module installed in Position 17, enter the setpoint values into Output Channel 17.

Machine Setup Before installing the PS-6144 on a machine, be sure the DIP switches are properly set

as shown in Figures 13 & 14. After installing the unit, program the following set-up information into the controller before attempting any other programming:

Information Menu Selection Page

Direction of Rotation INCREASING DIR 3-11 Scale Factor SCALE FACTOR 3-25 Shaft Position SHAFT POSITION 3-28 No. of Keypads KEYBOARD QTY 3-12 No. of Analog Outputs ANALOG QTY 3-5 No. of Output Groups OUTPUT GROUPS 3-18 Modes for Output Groups OUTPUT GROUPS 3-18 Group Display Mode GRP POS DISP 3-10 Group Offsets OFFSET 3-16

Once this information is entered, setpoints can be established and modified in the groups and output channels desired. Refer to Section 5 for information on using groups and modes.

3-3 Programming

Page 32

Analog Output

Menu Path MAIN SCREEN to SETUP MENU to ANALOG OUTPUT Purpose Analog output signals are linearly proportional to the resolver RPM. Two types of ana-

log output modules are available: 0-10 VDC and 4-20 mA. This function assigns Offset and High RPM values to output positions for analog mod-

ules.

Screen

ANALOG MODULE: 1< OF: 20 HI: 1500

Analog Module Numbe Analog High RPM

Analog Offset

Module Number The following table shows the relationship between the analog module number on the

screen and the module position on the controller back. See Figure 9 for an illustration of analog module positions.

Module #1 Module #2

Model On Screen On Screen

PS-6144-17 Output #17 Output #16 PS-6144-25 Output #25 Output #24

• Analog characteristics can be programmed for Modules #1 and #2 even if no analog modules are physically mounted on the controller. Programming can be done first, and modules mounted later.

• To program Offset and High RPM for Module #2, be sure the ANALOG QTY function (next page) is set to “2.” If ANALOG QTY is set to “1,” programming for Module #2 will not be available.

• When two analog outputs are used, the two outputs can have different values for Offset and High RPM.

To program Module Number, move the cursor to “Module” and use the numeric keys and ENT.

High RPM Analog High RPM is the resolver speed at which full scale analog output will occur. It is

programmed in whole RPM. When this speed is reached, the analog output signal level will be at full scale (10 VDC or 20 mA). Increasing speed beyond the High RPM will not increase the analog output beyond full scale.

To program High RPM, move the cursor to “Hi” and use the numeric keys and ENT.

3-4 Programming

Page 33

Analog Output (Cont’d)

Offset Analog Offset is the analog signal level that will be output when the resolver is at zero

RPM. This allows the minimum analog signal to be greater than zero volts or 4 mA. Because the analog output module has 4096 increments (12 bits) of signal level available, the offset is specified as the number of increments of signal that should be output at zero RPM. Calculate Analog Offset values as follows:

For 0-10 VDC: (Minimum Signal/10) x 4096 Example: For a 2 VDC minimum signal; Offset = (2/10) x 4096 = 819 For 4-20 mA: ((Minimum Signal - 4)/16) x 4096 Example: For a 5 mA minimum signal; Offset = ((5-4)/16) x 4096 = 256 To program Analog Offset, move the cursor to “Of” and use the numeric keys and

ENT.

Analog Quantity

Menu Path MAIN SCREEN to CONFIG MENU HARDWARE MENU

to ANALOG QTY

Screen

Purpose This screen displays the number of analog outputs that will be programmed into the

controller. The controller can have zero, one or two analog outputs, and each can be offset and

scaled by different values. See ANALOG OUTPUT for details.

Programming Use the numeric keys to enter “0,” “1,” or “2” analog channels. An analog output module

is required to generate an analog output signal.

Channel Copy

Menu Path MAIN SCREEN to SETUP MENU to CHN COPY Purpose Channel Copy allows you to copy all setpoints to another channel in the specified pro-

gram.

Screens The Channel Copy function consists of four screens:

SOURCE PGM:---<

DEST PGM:---<

SOURCE CHN:---<

DST CHN:---<

DEST CHN: EXECUTE<

Programming Use the numeric keys and SEL to enter program numbers.

During programming, the cursor keys allow you to move between the Source and Destination screens to allow you to change values before selecting EXECUTE.

Program containing channels

Program containing channel to be copied

Channel to be copied

Destination channel to be copied to

Move cursor to EXECUTE, then pres SEL to copy program

Communications

Menu Path MAIN SCREEN to CONFIG MENU

to COMMUNICATIONS

Purpose This function sets the communications type, controller address, and baud rate for

communicating with a host computer.

Communications Type: RS-232 or RS-485

Screen

TYPE:485 ADR: 1< BAUD: 9600

Type Use SEL to toggle between RS-232 and RS-485 communications on units shipped with

date code 9549 or newer (default setting is RS 485).

Address The address must be unique for each controller installed on a network. This address is

used by a host computer to identify and send information to a particular controller. A PLuS controller will ignore incoming information if the address field of the communication packet does not match the address of the controller.

The address set through COMMUNICATIONS programming takes effect only when the DIP switch shown in Figure 13 is set to an address value of zero. Whereas the DIP switch can set a maximum address of “7,” the COMMUNICATIONS function can set addresses ranging from 0-255.

Use the numeric keys and ENT to program the address.

Address: 0-255

Baud Rate: 4800, 9600, 19.2Kb, 38.4K

3-6 Programming

Page 35

Communications (Cont’d)

Baud Rate Use SEL to toggle between the available baud rates. The baud rate must match that of

the host computer. Available baud rates are: 4,800; 9,600; 19,200; and 38,400.

Note: Effective with Software Versions 1.97 and higher, the communications screen has been revised as shown below:

TYPE: 232 ADR:1< TRM: ON BR: 9600

Termnination Setting

The termination setting should be ON if TYPE is set to RS-232, or if TYPE is set to RS485 and only one PS-6144 controller is in the multi-drop network. Setting the termina-

tion to OFF in these configurations may cause inaccurate RPM readings.

If multiple PS-6144 controllers are connected in an RS-485 network, termination should be set to OFF on one and only one PS-6144 controller.

The termination setting in this screen is independent of all DIP switch settings. Use the SOFTWARE VERSION function to determine version number.



Default Program

Menu Path MAIN SCREEN to SETUP MENU DEFAULT PROGRAM Background The PS-6144 controller can store up to 48 programs in its memory. The Default Pro-

gram is the program that controls the output channels when terminals 1–8 of TB 3,

Figure 7, are “off.” The Active Program is the program number that is currently controlling the output

channels. If there are program select inputs on TB 3, those inputs will determine the Active Program, and the Default Program will be ignored. If no hardware inputs are “on,” the Default Program will become the Active Program.

For installations where the program select inputs on TB 3 are not used, the Default Program will always be the Active Program.

This function displays the current Default Program and allows you to select a different one.

Screen

Programming Use the numeric keys and ENT to enter or modify the Default Program.

DEFAULT PGM: 0 ACTIVE PGM: 0

Injury and property damage hazard may occur due to changes in machinery operation. Program the Default Program with settings that will eliminate this hazard in the event of sudden activation.

Enter new Default Program throug Numeric Keypad, then press ENT.

Enable Codes

Menu Path MAIN SCREEN to CONFIG MENU

to PGM ENABLE MENU ENABLE CODES

Background The PS-6144 has three levels of programming access: Operator, Setup, and Master in

order of increasing capabilities. Figure 21 lists the menu functions that can be programmed under the various levels of access.

Programming levels can be activated, or “enabled,” by entering a password on the keypad, or by activating Terminals E1 or E2 on the back of the keypad as shown in Figure 12. The first two rows of Figure 21 show which methods can be used to enable the various levels of programming access.

Screen

Operation • Each programming level can have only one code. That code is stored in the controller

Enable Options

Menu Path MAIN SCREEN to CONFIG MENU

to PGM ENABLE MENU to ENABLE OPTIONS

Purpose The Enable Options screen controls Operator Level access to SETUP MENU program-

ming as indicated in Figure 21, note 1.

Screen

SETPOINTS< ENABLE: ON

SETPOINTS or SETUP MENU screen. Scroll through choices with UP and Down cursor keys.

OPERATOR ENABLE: ON/OFF (Toggle with SEL key)

This screen lists the various items in the SETUP MENU, and allows you to turn Operator access to those items on or off.

Access to the “on” items will be available only for those output channels that have been turned ON in PER CHN ENABLE.

Programming Press the Up Cursor and Down Cursor keys to select the function you wish to change.

Press the SEL key to turn Operator access ON or OFF.

Setup Menu Items Access can be turned on or off for the following SETUP MENU items:

SETPOINTS, DEFAULT PROGRAM SPEED COMP OFFSET MOTION DETECT ANALOG OUTPUTS

Group Position Display

Menu Path MAIN SCREEN to CONFIG MENU DISPLAY MENU

to GRP POS DISP

Purpose The Group Position Display determines whether each output group can have its own

position in the machine cycle, or if all groups share one position. Because the position of a group operating in Mode 1 or 2 changes each time the group’s input terminal is energized, GRP POS DISP must be set to EACH if any groups are assigned to

Mode 1 or Mode 2.

Screen

GROUP POSITION DISPLAY: EACH<

Group Position Display Mode: EACH = Each oupu group has its own offset value; ONE = One value of offset is shared by all output groups.

3-10 Programming

Page 39

Group Position Display (Cont’d)

PGM: 1 RPM: 1500 MENU<  POS: 180

Machine Speed Machine Position = Shaft Position + Offset

To enter Menu Tree, press SEL when cursor is here

Active Program

PGM: 1 RPM: 1500 MENU< GRP1: 180

Mode 1 or 2: Position = Preset + change since last reset Mode 0, 3, 4, 5: Position = Shaft Position + Group Offset

Group #: To change, put cursor here and press SEL

To enter Menu Tree, put cursor here and press SEL

The value selected in this screen determines the appearance of the main screen as shown below:

Main Screen— • One Output Group, and GRP POS DISP Set to “One” or “Each”

• Multiple Output Groups, and GRP POS DISP set to “One”

Main Screen— • Multiple Output Groups and GRP POS DISP Set to “Each”

Programming Enter the GRP POS DISP function and press SEL to toggle between “ONE” and “EACH.”

• GRP POS DISP must be set to “EACH” to assign different offsets to groups through OFFSET programming.

• If groups have been assigned different offsets through OFFSET programming, setting GRP POS DISP to “ONE” will immediately change the individual group offsets to the value of Group 1.

Increasing Direction

Menu Path MAIN SCREEN to CONFIG MENU HARDWARE

to INCREASING DIR

Purpose The Increasing Direction screen displays the direction of resolver rotation (CW or CCW

as viewed from the shaft end) that will cause the position display to increase in value.

Screen

INCREASING DIR: CCW<

Direction of resolver shaft rotation (viewed from shaft end) that will cause the postion display to increase in value.

Changing Direction Press SEL to toggle the value of increasing direction. The new value will begin flashing.

This is normally set so the position value increases as the machine turns in its forward direction.

Press the ENT key to confirm your selection.

3-11 Programming

Page 40

Input Status

)

Menu Path MAIN SCREEN to SETUP MENU to I/O STATUS

to INPUT STATUS

The input status screen displays the On/Off status of the DC inputs on Terminal Blocks TB 1 and TB 3, Figure 7.

Screens

Selecting Inputs You may view inputs 1-8 or 9-16. Press SEL to toggle between the two groups of

12345678 INPUT 01001001 1-8<

Input On/Off Status (0=Off, 1=On)

90123456 INPUT 01001001 9-16<

Inputs are numbered 1 through 16, but only 8 inputs are shown at one time. The On/Off status is shown under the input number; 0=Off, 1=On.

inputs.

Input Numbers (1-8)

Input Numbers (9-16

Keyboard Quantity

Menu Path MAIN SCREEN to CONFIG MENU HARDWARE MENU KEYBOARD

QTY

Purpose The Keyboard Quantity screen shows the number of keypads the controller will com-

municate with.

Screen

KEYBOARD QTY: 1<

Number of keyboard/display units attached to controller

The controller will attempt to establish communication with as many keypads as are programmed through this screen. Keypads are assumed to be addressed sequentially, starting at address “0” as shown in Fig. 14.

Keypad “0” You can change the number of keypads shown in KEYBOARD QTY only from the

keypad whose address is “0.”

If KEYBOARD QTY is set to “2,” but only one keypad is physically connected, Menu Tree operation will be very slow. Change KEYBOARD QTY to “1” to restore normal Menu Tree speed.

3-12 Programming

Page 41

Main Screen

PGM: 1 RPM: 1500 MENU<  

Machine position not shown above toggle RPM

PGM: 1 RPM: 1500 MENU< GRP1: 180

Mode 1 or 2: Position = Preset + change since last reset Mode 0, 3, 4, 5: Position = Shaft Position + Group Offset

Group #: To change, put cursor here and press SEL

To enter Menu Tree, put cursor here and press SEL

Two Screens On power-up, or after five minutes of keypad inactivity, the controller will display one of

two main screens:

Main Screen— • One Output Group, and GRP POS DISP Set to “One” or “Each”

• Multiple Output Groups, and GRP POS DISP set to “One”

Active Program

PGM: 1 RPM: 1500 MENU<  POS: 180

To enter Menu Tree, press SEL when cursor is here

Main Screen— • Multiple Output Groups and GRP POS DISP set to “Each”

Active Program The PS-6144 can store up to 48 programs of setpoints. The “Active Program” is the

program currently controlling the output channels.

Machine Speed Machine Position = Shaft Position + Offse

If hardware inputs are being used to select the Active Program, the display will indicate the program selected by the inputs. If all hardware inputs are off, the Active Program will be the Default Program specified through the DEFAULT PROGRAM function. For information on using hardware inputs to select the Active Program, see “Controller Input Wiring” in Section 2.

If hardware inputs are not used, the Active Program will be the program specified through the DEFAULT PROGRAM function.

Machine Speed When the machine is moving, Machine Speed is displayed in user selectable units of

RPM (revolutions per minute), BPM (bags per minute), or CPM (cartons per minute). Machine Speed is displayed as a value which is 1X, 2X, or 3X the resolver RPM. See RATE SETUP for details.

Toggle RPM Machine or Group Position is displayed only when the resolver speed is below the

TOGGLE RPM speed. At higher speeds, Machine Position will be blank. See TOGGLE RPM for programming details.

Entering Menu Tree To enter the Menu Tree from the Main Screen, move the cursor to “MENU” and press

the SEL key.

Memory T ests

Menu Path MAIN SCREEN to TEST MENU to MEMORY TESTS Purpose This menu selection provides three functions that allow you to clear programmed val-

ues from the controller. An additional function tests the controller’s watchdog timer.

Screen

Programming To perform one of the memory test functions, enter the function number using the nu-

Function 7000 Clears all setpoints and configuration settings from the controller’s EEPROM. After

Function 7001 Clears all configuration settings from the controller’s EEPROM. These include all of

Function 7002 Clears all setpoints from the controller’s EEPROM. These include any on/off setpoints

Function 7998 Watchdog Timer Test. The “Watchdog Timer” monitors the operation of the controller’s

MEMORY TESTS FCN:----<

meric keys and press SEL.

clearing the setpoints, the controller will reload the factory default settings listed in the Appendix.

the programming performed through the Setup Menu and Config Menu on the menu tree, Figure 20. When finished, the controller will reload the factory default settings listed in the Appendix.

programmed through SETPOINTS. All other settings will remain intact.

microprocessor and shuts the controller down if any internal malfunction is detected. If the Watchdog Timer fails, the controller may continue to operate. However, any subsequent malfunctions or noise-induced irregularities may go undetected, and the controller may begin to operate erratically.

To test the Watchdog Timer, run Function 7998. If the controller’s Watchdog Timer is working properly, the controller will reset. If Function 7998 does not reset the controller, the Watchdog Timer has failed. Replace the controller immediately and return the faulty unit to the factory.

Enter function here

Failure of controller to pass the watchdog timer test can cause erratic operation, resulting in injury and damage to equipment.

Motion ANDing

Menu Path MAIN SCREEN to CONFIG MENU to CHN ANDING MENU MO-

TION ANDING

Purpose This function is used to tie the operation of output channels to the Motion Detection

levels programmed through MOTION DETECTION. Each output channel may be ANDed with either Motion Detection level. If an output is Motion ANDed, it will turn on only when the resolver RPM is in the range specified for that Motion Detection level, AND the setpoints programmed for that channel are “on.”

Outputs that must always operate, regardless of machine speed, should not be ANDed with a Motion Detection level.

Screen

 CHN: 12 MOTION AND: L1

Channel number Motion ANDing level: L1, L2, or OFF. (Toggle with SEL key)

This screen displays the channel number and the Motion Detection level for Motion ANDing: L1, L2, or OFF. The channel will not be Motion ANDed if the enable is OFF.

3-14 Programming

Page 43

Motion ANDing (Cont’d)

Programming Select a new channel by pressing the INC/DEC keys, or through direct numeric entry

followed by ENT. Press the SEL key to toggle the ANDing to L1, L2, or OFF.

Operation • Any number of output channels can be ANDed to a single Motion Detection level.

• Motion ANDing and Output Enable ANDing can be combined for any given output channel.

• When Motion ANDing is activated for a channel, it will apply to that channel in all programs.

Motion Detector An output channel can be used as a motion detector by programming it to be on at “1”

and off at “1,” and then ANDing it with the desired Motion Level. This will turn the output on constantly as long as the machine speed is within the specified Motion Level range.

Motion Detection

Menu Path MAIN SCREEN to SETUP MENU to MOTION DETECT Background Motion Detection establishes one or two “Motion Levels,” or speed ranges, with low and

high RPM values. These two ranges are independent of each other. Each output channel can be ANDed with either Motion Level. ANDed outputs will be

enabled only when the resolver speed is within the specified speed range. Output channels that are not ANDed will be “on” whenever the machine position is within their programmed setpoints, regardless of machine speed. One use of Motion Levels and Motion ANDing is to turn off devices such as glue guns if the machine stops or jams.

The MOTION DETECTION function is used to establish one or two Motion levels. Once the Motion Levels are programmed, use MOTION ANDING to tie individual output channels to the Motion Levels.

Screen

Programming Use the numeric keys and ENT to change values for Motion Level, Low RPM, and High

Motion Detector An output channel can be used as a motion detector by programming it to be on at “1”

MOTION LEVEL: 1 LO: 30 HI: 1500

Low RPM setpoint

The Motion Detection screen displays the Motion Level, the Low RPM, and the High RPM.

RPM.

and off at “1,” and then ANDing it with the desired Motion Level. This will turn the output on constantly as long as the machine speed is within the specified Motion Level range.

Motion detection leve High RPM setpoint

Offset

)

Menu Path MAIN SCREEN to SETUP MENU to OFFSET Background Because the PS-6144 is a programmable device, it can be set to display a position of

“zero” at any point in the machine cycle. Usually, a machine is jogged to the beginning of a cycle, and the SHAFT POSITION function is set to zero at this point.

In addition, each output group operating in Mode 0, 3, 4, or 5 can be individually “offset” from this SHAFT POSITION through OFFSET programming. This allows the output channels in a group to be set to “zero” at a different machine position than the one that corresponds to “zero” in SHAFT POSITION.

Note: When programming a controller, there must be more than one group defined in the CONFIG MENU in order fro a user to adjust OFFSET for a group in the SETUP MENU.

Setting a group to its own zero position can simplify setpoint programming for output channels by clarifying the relationship between the setpoints and the machine component controlled by the group. For example, suppose that an output group controls a glue head on a cartoning machine. By jogging the machine and viewing POS on the PS-6144 display, you realize that the glue head must turn on at 347° and off at 22° when using the position set through SHAFT POSITION. Since other output channels correlate well with SHAFT POSITION, you don’t want to change it. Instead, using the OFFSET function for this group, you could add 13° to the shaft position so that the glue head would turn on at a group position of 0° and off at 35°. Although the group position has been “offset” by 13°, the gun would still turn on at 347° and off at 22° in terms of shaft position.

For output groups operating in Mode 1 or 2, the group position is reset to a “preset” value whenever the group’s input terminal is energized. This preset is defined through OFFSET programming. Because the reset can occur at any resolver position, the relationship between the position of a group operating in Mode 1 or 2 and the SHAFT POSITION varies.

Units with the gray code output option “-G” generate an 8-bit position signal across Outputs 1 through 8. This gray code position signal always corresponds to the position as programmed through SHAFT POSITION, and is not affected by group positions programmed through the OFFSET function.

Screens OFFSET Screen—Group Mode 0, 3, 4 or 5

Output Group

GRP:1< POS:  0    ABS: 132

OFFSET Screen—Group Mode 1 or 2

Group Position = Shaft Position + ABS Offse Absolute Offset Value for this Group

Output Group

GRP:1< POS: 359    PRE: 30

Group Position = PRE + Change Since Last Reset Group Preset Value (If Group is Mode 1 or Mode 2

3-16 Programming

(continued)

Page 45

Offset (cont’d)

Offset Programming To change the offset for an output group in Mode 0, 3, 4, or 5, first select the group by

moving the cursor to GRP. Use INC or DEC, or the numeric keypad and ENT to select the group.

Offset can be programmed in two ways: Direct Entry—Enter the offset directly by moving the cursor to ABS and entering the

offset value on the numeric keypad, followed by ENT. Group Position—Jog the machine to a position that corresponds to the desired group

position, move the cursor to POS, and enter the group position using the numeric keypad, followed by ENT. For example, jog the machine to a point where the group position should be zero, then press “0” ENT while the cursor is at POS.

• For standard PS-6144 controllers using Electro Cam resolvers, the ABS value will directly show the relationship between the group position and machine 0 (shaft position) in scale factor increments. For example, suppose that SHAFT POSITION is set to machine 0 and SCALE FACTOR is set to 360. If the ABS of a group is 20, its position will always be 20 dgrees ahead of the machine position.

• If groups have been programmed with their own offsets, changing SHAFT POSITION will change all of the group positions at once.

CAUTION

Programming Preset To change the preset for an output group in Mode 1 or 2, first select the group by

Output Enable ANDing

Menu Path MAIN SCREEN to CONFIG MENU to CHN ANDING MENU to

OUTPUT ENABLE ANDING

Purpose Output Enable ANDing allows you to AND any output channels with Input Terminal

#16, Figure 7. A channel ANDed with this terminal will be enabled to turn on at its programmed setpoints only while the terminal is energized.

Screen

Programming Select a new channel by pressing INC/DEC, or using the numeric keys followed by

 CHN: 12< OUTPUT AND: OFF

ENT. Use the SEL key to toggle ANDing on and off.

Channel number Output Enable ANDing: ON or OFF. (Toggle with SEL key)

Output Groups

Menu Path MAIN SCREEN to CONFIG MENU

to OUTPUT GROUPS

Purpose This function allows you to divide output channels into groups, and assign operating

modes to the groups. Operating modes provide a powerful tool for relating output channel operation to sensor signals or other inputs. Incorporating modes into a control system can greatly improve line efficiency, reduce scrap, and improve control accuracy between machine sections at high speeds. See Section 5 for a complete explanation of the uses and applications of operating modes.

Screen

GRP:1 <GRP QTY:2 CHNS: 15 MODE: 3

Selected group number

Number of output groups Enable mode of selected group

Number of channels in selected group

Establishing Groups When dividing outputs into groups, keep these rules in mind:

• Output channels are assigned to groups sequentially. Group 1 will begin with Output 1 and include the specified number of outputs; Group 2 will begin with the next output and continue sequentially for its specified number of outputs; and so on. The last group will automatically include all of the remaining outputs.

• You can establish as many as six groups or as few as one.

• More than one group can be assigned to the same mode.

Grouping Example 1—All Outputs in One Group

Output Includes

Group Outputs Mode

1 1 thru 25 3

Grouping Example 2—Two Groups

Output Includes

Group Outputs Mode

1 1 thru 4 2 2 5 thru 25 0

3-18 Programming

(continued)

Page 47

Output Groups (Cont’d)

)

Grouping Example 3—Three Groups

Output Includes

Group Outputs Mode

1 1 & 2 0 2 3 & 4 4 3 5 thru 25 0

Programming Begin by moving the cursor to GRP QTY and entering the number of groups desired,

followed by ENT. Next, move the cursor to GRP and enter “1” followed by ENT. Move the cursor to CHNS and enter the number of output channels to be included in

Group 1, followed by ENT. Move the cursor to MODE and enter the operating mode for the group from zero to five,

followed by ENT. See Section 5 for an explanation of the operating characteristics of each mode.

Move the cursor back to GRP and repeat these steps for each group to be programmed.

Main Screen When output channels are divided into groups, the appearance of the Main Screen will

change slightly. See MAIN SCREEN for details.

Output Status

Menu Path MAIN SCREEN to SETUP MENU to I/O STATUS

to OUTPUT STATUS

Purpose This screen shows the On/Off state of the output channels, and it allows the outputs to

be forced.

Screens

Both Models, Outputs 1-8

12345678 OUTPUT 01001001 1-8<

Output On/Off Status (O=Off, 1=On)

PS-6344-17, Outputs 9-17

901234567 OUTPUT 0100100AA 9-17<

Analog Modules shown with "A"

PS-6344-25, Outputs 9-25

90123456 OUTPUT 01001000 9-16<

Output Numbers (1-8)

Output Numbers (9-17)

Output Numbers (9-16)

789012345 OUTPUT 0100100AA 17-25<

Analog Modules shown with "A"

If any output positions have been programmed as analog outputs, the On/Off status will show “A” instead of “0” or “1.”

Output Numbers (17-25

3-19 Programming

Page 48

Output Status (Cont’d)

Selecting Outputs Press the SEL key to change the set of outputs displayed. Forcing Outputs Forcing outputs allows you to force an output on or off for diagnostic purposes. This

function is not available on earlier software models. Note: When leaving the Output Status screen, keep in mind that any outputs that have

been forced will return to their originally programmed state.

Programming Press to access Output 1, causing the “0” to blink. Press to turn this output on.

The “0” will change to a “1”. Select other desired outputs by pressing or . If the output is already on, a “1” will be present instead of a “0”. So, the “1” will change to a “0”

when the output is forced. Press to return to output number selection. Outputs will remain forced until you

leave the Output Status screen. Press to access Outputs 9-17 on the PS-6144-17 and Outputs 9-16 or 17-25 on the PS-6144-25.

Password

Menu Path MAIN SCREEN PASSWORD

This screen provides an area to enter a password. It also shows the current programming access level and the status of the Programming Enable terminals on the back of the keypad, Figure 12.

Screen

PASSWORD:****< LEV:NONE INP:OFF

Current programming level (hardware or software)

Enable Levels There are three programming access levels; OPERATOR, SETUP, and MASTER. See Figure 21 for a summary of the programming functions available to the different levels. The codes that correspond to each level are established in the ENABLE CODES screen.

Entering a Password Enter a password through the numeric keypad followed by ENT. As you press the

number keys, the asterisks will be replaced by dashes. If you make a mistake, press CLR to erase the last key you pushed.

If you enter a password that has been programmed through ENABLE CODES, the keypad will function at the corresponding programming level. See ENABLE CODES for a description of the various levels.

If either of the programming enable terminals on the back of the keypad is active when a password is entered, the programming level will be whichever is greater.

PASSWORD:--**< LEV:NONE INP:OFF

Password entry area Keypad programming terminal input statu

Dashes replace asterisks as numbers are entered

3-20 Programming

PASSWORD:****< LEV:MAS INP:OFF

Enable level shown if number matches programmed password value

Dashes change back to asterisks with ENT

Page 49

Password (Cont’d)

Clearing a Password When programming operations are completed, enter a password value of “0,” then ENT

to clear the enable level. If a keypad is left unattended with an active password, the access code will clear after

five minutes of keypad inactivity and the keypad will revert to the “Normal Display” mode shown in Figure 21.

Per Channel Enable

Menu Path MAIN SCREEN to CONFIG MENU to PGM ENABLES

to PER CHN ENABLE

Purpose This screen is used to enable Operator Level access to individual output channels. PER

CHN ENABLE is used in conjunction with the ENABLE OPTIONS screen to assign Operator Level access to selected programming functions.

Screen

CHN: 12< CHN ENABLE: ON

Channel number Per channel enable: ON/OF (Toggle with SEL key)

Channel Select Press the INC/DEC keys, or use the numeric keys and ENT. Enable Toggle Press the SEL key to toggle the enable ON or OFF. See Also ENABLE OPTIONS

Program Copy

Menu Path MAIN SCREEN to SETUP MENU to PGM COPY Purpose Program Copy allows you to copy all of the channels and setpoints from one program to

another. It is often easier to copy an existing program and modify it, than to enter a new program from scratch.

Screens The Program Copy function consists of four screens:

SRC PROGRAM:---<

Program to be copied from

DST PROGRAM:---<

DST PROGRAM: 6<  EXECUTE<

DST PROGRAM: 6  COMPLETE<

Programming Use the numeric keys and SEL to enter program numbers. During programming, the

cursor keys allow you to move between the Source and Destination screens to allow you to change values before selecting EXECUTE.

Destination to be copied to

Move cursor to EXECUTE, then press SE to copy program

COMPLETE indicates program successfully copied

3-21 Programming

Page 50

Program Select Mode

Menu Path MAIN SCREEN to CONFIG MENU HARDWARE

to PGM SEL MODE

Purpose This screen allows you to specify the format for the hardware Program Select inputs on

Terminals 1 through 8 of Terminal Block 3, Figure 7.

Screen

PROGRAM SELECT MODE: BIN<

Hardware Program Select Format: BIN = Binary, GRAY = Gray Code, BCD = Binary Coded Decimal

The Program Select inputs can operate in Binary, BCD, or Gray Code formats as shown in Figure 8.

Use the SEL key to toggle the input format.

Injury and property damage hazard may occur due to changes in machinery operation. If the input signals controlling program selection are lost due to a malfunction, the Default Program will activate. Program the Default Program with settings that will eliminate this hazard in the event of sudden activation.

Pulse Copy

Menu Path MAIN SCREEN to SETUP MENU to PULSE COPY

Purpose Pulse Copy allows you to program a series, or “train” of pulses into a channel without

having to enter the On and Off setpoints for each pulse. The Pulse Copy function prompts you for the beginning and ending setpoints for the pulse train; the number of pulses in the train; and the duration of a pulse. Pulse Copy then divides the designated portion of the resolver cycle into the specified number of pulses, evenly dividing the unused portion of the segment between the pulses.

Screens The Pulse Copy function consists of eight screens:

 PROGRAM:---< 

CHANNEL:---<

ON:---<

 OFF:---<

 COUNT---<

DURATION:---<

DURATION: 35  EXECUTE<

DURATION: 35  COMPLETE<

Program to add pulses to; Enter number, then SEL to go to next screen

Channel to add pulses to; Enter number, then SEL to go to next screen

"On" time of leading edge of first pulse; Enter number, then ENT & SEL to go to next screen

"Off" time of trailing edge of last pulse; Enter number, then ENT & SEL to go to next screen

Total number of pulses to be added; Enter number, then ENT & SEL to go to next screen

Duration of each pulse added; Enter number, then ENT & SEL to go to next screen

Move cursor to EXECUTE, then press SEL to generate pulses. To review values before executing, move cursor to top row and press SEL as needed

COMPLETE indicates pulses have been generated

3-22 Programming

(continued)

Page 51

Pulse Copy (cont’d)

Example Generate a train of pulses as follows:

Pulse On Off

1050 2 100 150 3 200 250 4 300 350 5 400 450 6 500 550 7 600 650 8 700 750 9 800 850

10 900 950 Each pulse is 50 increments wide, separated from the next pulse by 50 increments. Program PULSE COPY as follows:

 PROGRAM:---< 

Program to add pulses to; Enter number, then SEL to go to next screen

CHANNEL:---<

Channel to add pulses to; Enter number, then SEL to go to next screen

ON: 0<

"On" time of leading edge of first pulse; Enter 0, then ENT & SEL to go to next screen

 OFF:950<

"Off" time of trailing edge of last pulse; Enter 950, then ENT & SEL to go to next screen

 COUNT 10<

Total number of pulses to be added; Enter 10, then ENT & SEL to go to next screen

DURATION: 50<

Duration of each pulse added; Enter 50, then ENT & SEL to go to next screen

DURATION: 50  EXECUTE<

Move cursor to EXECUTE, then press SEL to generate pulses.

DURATION: 35  COMPLETE<

Go to SETPOINTS to confirm the pulse train:

<-P-> CH: 1 <EDG ON: 0 OF: 50

COMPLETE indicates pulses have been generate

Move cursor to OF and use arrow keys to review pulse setpoints

3-23 Programming

Page 52

Rate Setup

Menu Path MAIN SCREEN to CONFIG MENU to DISPLAY

RATE SETUP

Purpose The Rate Setup function allows you to configure the RPM display on the Main Screen.

Three parameters can be programmed:

• Units—The Main Screen can label the resolver speed as Revolutions Per Minute (RPM), Bags Per Minute (BPM), Cartons Per Minute (CPM), or Inches Per Minute (IPM).

• Rate—The ratio of actual resolver RPM to displayed RPM. This ratio is a fraction consisting of a multiplier (MPY) over a divider (DIV).

• Decimal Points—The controller divides the Rate by 1, 10, 100, or 1000 to display 0, 1, 2, or 3 decimal places, respectively.

Screen

Multiplier: 0 through 1091

MPY: 1< DP: 0 DIV: 1 RPM

Number of decimal points displayed: 0, 1, 2, or

Units: RPM, BPM, CPM, IPM

Divider: 1 through 63

Following are a few examples of the relationships between multiplier (MPY), divider (DIV), decimal points (DP), actual resolver speed, and displayed resolver speed:

If And And Then And a Is

MPY DIV DP MPY/DIV Resolver Displayed

Is… Is… Is… Is… Speed Of… As…

1 2 0 .5 100 RPM 50 RPM 1 2 1 .5 100 RPM 5.0 RPM 1 2 2 .5 100 RPM .50 RPM 1 2 3 .5 100 RPM .050 RPM 1 1 0 1.0 100 RPM 100 RPM 1 1 1 1.0 100 RPM 10.0 RPM 1 1 2 1.0 100 RPM 1.00 RPM 1 1 3 1.0 100 RPM .100 RPM 2 1 0 2.0 100 RPM 200 RPM 2 1 1 2.0 100 RPM 20.0 RPM 2 1 2 2.0 100 RPM 2.00 RPM 2 1 3 2.0 100 RPM .200 RPM

Programming Units—Move the cursor to the “Units” field and use SEL to toggle between values.

MPY & DIV—Move the cursor to MPY or DIV and use the numeric keys followed by

ENT to enter a value. DP—Move the cursor to DP and use SEL to toggle between values.

3-24 Programming

Page 53

Resolver Type

RPM UPDATE RATE: 1/S<

RPM Update Rate: How often RPM display on main screen is updated; 1/Sec, 2/Sec, or 10/Sec.

SCALE FACTOR: 360<

Number of increments each revolution is broken into

Menu Path MAIN SCREEN to CONFIG MENU to HARDWARE MENU

RESOLVER TYPE

Purpose The PS-6144 can operate with resolvers that have a transformation ratio of .454 or 1.

Standard Electro Cam resolvers have a ratio of .454. Some resolvers made by other manufacturers have a ratio of 1.

Screen

RESOLVER TYPE: ECC<

Pressing the SEL key changes resolver type to OTHER.

RPM Update Rate

Menu Path MAIN SCREEN to CONFIG MENU to DISPLAY

RPM UPD RATE

Purpose The RPM Update Rate is how often the RPM display on the Main Screen is updated.

This rate can be programmed to be 1/Sec, 2/Sec, or 10/Sec.

Screen

Press the SEL key to toggle the selection.

Scale Factor

Menu Path MAIN SCREEN to CONFIG MENU to HARDWARE MENU SCALE

FACTOR

Purpose This function controls the number of increments into which one resolver revolution is

divided. A scale factor of 360 (0 to 359) allows the controller to operate in degrees. A scale factor of 1024 (0 to 1023) allows positions to be programmed more accurately. In some applications the scale factor can be set so each increment equals a unit of linear travel.

Screen

Limits Scale factors range from two to 1024 on standard controllers. For controllers equipped

with the “-H” option, scale factor can be as high as 4096.

Recalculations When the scale factor is changed, all programmed setpoints are recalculated to convert

them to the new scale factor. The keypad/display will be inoperative until the calculations are done.

3-25 Programming

Page 54

Setpoint Use

Menu Path MAIN SCREEN to SETUP MENU to SYSTEM INFO SETPOINT

USE

Purpose This function displays the total number of setpoint On/Off pairs, or “pulses” available for

programming, and the number of pulses that have been programmed.

Screen

TOTAL: 1200  USED: 64

The number of setpoints shown as "Used" is the sum of all pulses that are programmed into all channels of all programs. The "Total" value is the number of pulses that can be stored in non-volatile EEPROM memory. The difference between the two numbers is the number of pulses available for programming.

The number of pulses programmed into all channels of all programs cannot exceed the value displayed as Total.

There are no values that can be changed in this screen.

Total number of pulses available for programming Number of pulses programmed into all channels of all programs

Setpoints

Menu Path MAIN SCREEN to SETPOINTS Screens When SETPOINTS is selected, a preliminary screen specifies the program whose

setpoints will be programmed.

PGM NUMBER: <

The active program is displayed, but any other program can be specified by using the numeric keys or INC and DEC to choose a program, then pressing SEL to move to setpoint programming.

Blank if only 1 pulse in channe

Channel

CH: 1 <EDG ON: 90 OF: 270

ON setpoint

<-P-> indicates multiple pulses in channe

<-P-> CH:1<EDG ON: 90 OF: 270

Program to view or modify

Pulse mode OFF setpoint

Channel to Edit Use the numeric keypad and ENT to select the channel to program.

• Channels 91 through 96 are special channels used for Output Grouping and Modes. See Section 5 for details.

Setpoint Values Use the left and right arrow keys to move between the ON and OFF setpoints.

• If a channel has more than one pulse, you may view the other pulses by pressing the right cursor key when viewing the OFF setpoint, or by pressing the left cursor key when viewing the ON setpoint.

(continued)

3-26 Programming

Page 55

Setpoints (Cont’d)

• If a channel contains no pulses, the ON and OFF setpoints will be “0.”

• If a channel is always on, both the ON and OFF setpoints will be “1.”

CH:1 EDG ON: 0< OF: 0

Adding a Pulse You may add a new pulse to a channel by pressing the SEL key when the cursor points

to either the ON or the OFF setpoint.

CH:1 EDG ON:---< OF:---

The display will change to show blank ON and OFF setpoints; the cursor will point to the ON setpoint. Enter the ON setpoint through the numeric keypad, and then press the ENT key or the right cursor to move to the OFF setpoint. Enter the OFF setpoint through the numeric keypad and then press the ENT key.

Adding Multiple Pulses If ON and OFF setpoints for a pulse are visible on the screen and you press SEL to

program a new pulse, the original pulse will remain in the output channel. If the ON or OFF setpoints entered overlap an existing pulse in the channel, you will see an “Error: Pulse Overlap” message.

ON and OFF setpoints both 0 if no pulse in channel. Both 1 if channel always ON

Enter ON setpoint, then ENT or right cursor to OF. Enter OFF setpoint, then press ENT.

To abort entering a pulse at any time, press ESC.

Changing Setpoints Change a setpoint value with the numeric keys followed by ENT, or with the INC and

DEC keys.

Pulse Modes The Pulse Mode controls how the INC and DEC keys modify setpoints. There are three

modes; EDG (edge), PUL (pulse), and CHN (channel.) Change the Pulse Mode by pressing the SEL key when the cursor points to the Pulse Mode.

In EDG mode, the INC and DEC keys will affect the selected ON or OFF setpoint only. In PUL mode, both ON and OFF setpoints will be incremented or decremented simulta-

neously. In CHN mode, all ON and OFF setpoints for all pulses in the channel will be incremented

or decremented simultaneously.

Deleting a Pulse A pulse may be deleted by making ON equal to OFF, or vice versa. If there is more than

one pulse in the channel, the next pulse will appear in the on/off setpoint area. If the channel has no more pulses, the ON and OFF setpoint will both be zero.

Clearing a Channel To clear a channel of all pulses, enter a new pulse with ON and OFF setpoints of “0.” Channel Always ON A channel may be programmed to be on for a full revolution (always on) by entering a

new pulse with both ON and OFF values equal to “1.”

Record Setpoints Photocopy the form inside of the back cover and use it to write down setpoints for each

program. For most installations, before programming setpoints, it is best to set SHAFT POSI-

TION to zero at the start of a machine cycle. This allows you to jog the machine to various points in the machine cycle where output channels must turn on or off, note these machine positions from the PS-6144 display, and enter them into setpoint programming. Setpoints programmed in this manner will relate directly to the machine position. If setpoints are programmed before SHAFT POSITION is set, and SHAFT POSITION is subsequently changed, the setpoints will no longer correlate with the machine zero position.

The same logic applies if OFFSET will be used for individual output groups. Program the offsets before establishing setpoints for the channels in the groups.

3-27 Programming

Page 56

Shaft Position

)

Menu Path MAIN SCREEN to CONFIG MENU to HARDWARE MENU to

SHAFT POSITION

Purpose Because the PS-6144 is a programmable device, it can be set to display a position of

“zero” at any point in the machine cycle. Usually, the machine is jogged to the beginning of a cycle, and SHAFT POSITION is set to zero at this point. This function eliminates the need to adjust the physical coupling between the machine and resolver in order to change the displayed machine position.

Screen

Programming Use the INC/DEC keys, or the numeric keys followed by ENT to change shaft position.

SHAFT POS:260<

• Set SHAFT POSITION before doing any SETPOINT or OFFSET programming.

Resolver Position Without Offse

Software V ersion

Menu Path MAIN SCREEN to SETUP MENU to SYSTEM INFO

to SOFTWARE VERSION

Purpose The Software Version screen displays the revision number of the firmware contained

within the controller. This information may be useful if the unit needs to be returned for service.

Screen

MAJOR REV:1.75  BASE REV:1.17

There are no values that can be changed in this screen.

Speed Compensation

Menu Path MAIN SCREEN to SETUP MENU to SPEED COMP Background Some devices such as pneumatic cylinders and glue guns require a fixed amount of

time to perform their function. As a machine speeds up, these devices need to be actuated earlier in the cycle in order to complete their action at the required time. Speed compensation automatically advances the On/Off setpoints of specified output channel(s) as the machine speeds up, maintaining proper synchronization at all speeds. See Section 4 for a detailed discussion of speed compensation.

Screens For standard controllers, one value of speed compensation applies to both the ON and

OFF setpoints in a channel The SPEED COMP screen for standard controllers looks like this:

Output Channel

CH: 1<LE:10.0  TE:20.0

For units with the “-L” option (Leading /Trailing edge), the ON and OFF edges in a channel can have different values of speed comp. If SPEED COMP MODE in these models is set to “One,” the same value will apply to both ON and OFF edges, and the screen above will show. If SPEED COMP MODE is set to L/T, Leading/Trailing Edge speed comp is activated, and the following screen appears:

Output Channel

CH:1<SC: 10.5

Leading edge compensation (10 msec shown Trailing edge compensation (20 msec shown)

Speed Compensation (10.5 msec shown

3-28 Programming

Page 57

Speed Compensation (cont’d)

SPEED COMP MODE:ONE

Speed Comp Mode: ONE = Leading/Trailing edge have same speed comp; L/T = Each edge can have a different value of speed comp.

Speed Comp Units Speed compensation is programmed by entering the response time of the output de-

vice in milliseconds (.001 Sec). The output will always turn on this number of msec before the programmed ON position is reached, and turn off this number of msec before the programmed OFF position is reached. As speed increases, the number of degrees of advance will automatically increase to maintain the number of msec of advance.

Programming To change output channels, move the cursor to the channel number and enter a new

one. You may also INC or DEC the channel number. To change speed comp values, use the numeric keys or INC and DEC. To enter tenths

of msec, use the decimal point. When entering even msec, the decimal point is not needed: “12 ENT” will result in a value of 12.0.

Negative Speed Comp Negative values of speed compensation cause an output channel to lag its programmed

machine position by the specified number of msec. See Section 4 for details on applying negative speed compensation.

To program negative speed comp, press the +/- key after entering a number but before pressing ENT. You may also decrement a value below zero.

NOTE: Regardless of the number of outputs available, speed compensation is limited to any 16 of those available outputs.

Speed Comp Mode

Menu Path MAIN SCREEN to CONFIG MENU to DISPLAY MENU to SPD

COMP MODE

Purpose For units with the “-L” option (Leading/Trailing Edge Speed Comp), Speed Comp Mode

determines whether standard or leading/trailing edge speed compensation is in effect.

Screen

When the Speed Comp Mode is ONE, the same value of speed comp is used for both leading and trailing edges.

When the Speed Comp Mode is “L/T”, the leading and trailing edges of a pulse may have different values of speed comp.

Programming Press the SEL key to toggle between ONE and L/T. Press ENT to confirm your selec-

tion.

Timed Outputs

Menu Path MAIN SCREEN to SETUP MENU to TIMED OUTPUTS Purpose Any four outputs can be programmed to time out rather than remain on until an OFF

setpoint is reached. This makes the output duration constant regardless of machine speed. If the OFF setpoint is reached before the specified time has elapsed, the timing will be aborted and the output will turn off immediately.

Once an output times out, it will not turn on until the next ON setpoint is reached. Each timed output can have a unique time delay length.

Outputs are timed in one msec increments up to a maximum of 9999 msec (9.999 seconds).

Screen

Pulse Required A timed output must be programmed with ON and OFF position setpoints in order for

Reverse Rotation If the machine is rotating in the reverse direction, timed outputs will energize when the

CHANNEL: 1 TIME(mS):20

output timing to take effect.

OFF edge of the pulse occurs.

Channel Time duration

Toggle RPM

Menu Path MAIN SCREEN to CONFIG MENU to DISPLAY MENU to

TOGGLE RPM

Purpose Toggle RPM is the resolver speed at which the Position display on the Main Screen will

disappear. At speeds below the Toggle RPM the Position display will be visible; at speeds above the Toggle RPM the Position will not be shown.

Screen

Programming Use the numeric keys and ENT to enter a new value, or use INC and DEC to change an

existing value.

TOGGLE RPM:50

Toggle RPM: Position display on main screen is not shown at speeds above Toggle RPM



3-30 Programming

Page 59

Introduction To Speed Compensation

What Is It? “Speed compensation” refers to the ability of the PS-6144 controller to automatically

advance or retard setpoints in any output channel depending on the speed of the machine. Speed compensation allows devices with fixed response times, such as glue guns, to perform their functions with high accuracy over a wide range of machine speeds. Without speed compensation, a glue bead may tend to “drift” out of position as machine speed increases. By properly programming speed compensation for the output channel controlling the glue gun, the glue bead position can be maintained precisely over the complete range of machine speeds.

Benefits Proper use of speed compensation can provide substantial benefits:

• Increased Productivity—If a machine incorporates components with fixed response

times, the use of speed compensation can often increase line speeds by as much as 50%.

• Reduced Scrap Rate—Speed compensation maintains the accuracy of critical operations such as gluing, thereby reducing rejects, rework, and scrap.

• Simplified PLC Systems—Programming speed compensation into standard motion control equipment such as PLC’s, stepper motors, and stepper motor controls is difficult. In addition, to perform speed compensation at high machine speeds, the PLC hardware must be extremely fast, and therefore expensive. Integrating a PS-6144 into the control system eliminates the need to write custom PLC speed compensation programming, and provides excellent high speed control at a fraction of the hardware cost.

Fixed Response Times Electromechanical components of automated systems often have fixed response times

regardless of the line speed. For example, a glue gun may require ten milliseconds from the time the gun is actuated to the time that glue begins flowing. At the slowest line speed, the gun might need to be triggered when the carton is one inch away, so that the carton arrives under the gun just as glue begins flowing. As the line speed increases and the product travels faster, the lead distance from the carton to the gun must increase in order for the gun, with its fixed response time, to still hit the correct spot on the product. By programming speed compensation into the PS-6144, the timing of glue guns and similar mechanisms can be automatically advanced as speed increases, maintaining proper operation over a wide range of machine speeds.

NOTE: Regardless of the number of outputs available, speed compensation is limited to any 16 of those available outputs.

4-1 Speed Compensation

Page 60

Standard Speed Comp

Example Figure 22 illustrates a simple carton gluing application. A conveyor moves cartons un-

der a glue gun which releases glue onto the flaps. The conveyor is connected through a timing chain and sprocket to a transducer which rotates one revolution for each carton that passes under the gun.

As the transducer dial shows, SHAFT POSITION has been programmed so that the leading edge of the box passes under the gun at 110° and the trailing edge at 360°. Glue begins flowing ten msec after the gun is energized, and it stops flowing ten msec after the gun is de-energized. Once the glue leaves the nozzle, it requires another five msec to travel to the carton. Combining the glue gun response time with the travel time results in a system response time of 15 msec, regardless of line speed.

At very slow, or essentially zero speed, the gun would be energized at a transducer position of 110° and de-energized at 360°. As the line speed increases, however, the gun needs to be energized before 110° to allow the glue to hit the carton in the correct spot. The faster the line speed, the earlier in the transducer cycle the gun must be triggered.

Calculation To calculate the amount of speed compensation required, use the following relation-

ships between the transducer's RPM (revolutions per minute) and degrees of rotation: 1 RPM = 360°/min = 6°/sec = 0.006°/msec,

RPM x 0.006 = deg/msec, thus: @ 100 RPM, the transducer will rotate 0.6°/msec

@ 1000 RPM, the transducer will rotate 6.0°/msec

The gluing system requires 15 msec from the time the gun is energized to the time the glue hits the carton. At 100 RPM, the transducer will rotate 0.6°/msec. Therefore, in the 15 msec response time, the transducer will rotate (15 msec x 0.6°), or 9°. This means the glue gun must be energized at 101°, which is 9° before the box arrives under the gun, and de-energized at 351°. At 1000 RPM, the transducer will rotate (15 msec x 6°), or 90° during the response time, and the gun must be energized at 20° and de-energized at 270°. These values are visually represented in Figure 23.

Figure 22—Simple Application Using Speed Compensation

4-2 Speed Compensation

Page 61

Standard Speed Comp (Cont’d)

Figure 23—Speed Compensation at Various Speeds

Setting Speed Comp In many applications, speed compensation can be set by jogging the line to determine

ON and OFF setpoints at zero speed, then entering the speed compensation value into the controller. In the previous example, the line would be jogged until the leading edge of the box reaches the gun at 110° of transducer rotation. The glue gun output would be set to turn on at this point. Then, the line would be jogged until the trailing edge is under the gun at 360°, and the glue gun output would be set to turn off.

Once these on and off setpoints are entered, the glue system response time of 15 msec would be entered through SPEED COMP programming as described in Section 3. As line speed increases, the PS-6144 will automatically advance the setpoints to maintain

the accuracy of the glue bead position.

CAUTION

Response Time Suppose that in the previous example, the response time was unknown. Unknown To set up the machine, jog a carton through the machine and set the glue gun ON and

Can’t Be Jogged? Some machinery can’t be jogged to determine ON and OFF setpoints. To set up this

When setting speed compensation on a system where zero speed setpoints have been established, always adjust the speed compensation value. Do not adjust the individual output setpoints!

OFF setpoints as described earlier. Then, estimate a response time and enter it into the controller using the SPEED COMP function described in Section 3.

Start the line and run cartons through it at a fixed line speed. Program SPEED COMP to adjust the speed compensation value as required for proper gluing. This can be done while the line is in motion. Once programmed, vary the line speed to confirm proper operation at all speeds, and fine tune the SPEED COMP value if necessary.

type of equipment, start the line, run cartons through it at a fixed line speed, and set the ON and OFF setpoints as required for proper gluing. Write them down for reference in the next step. SPEED COMP should be set to zero.

Next, increase the line speed and adjust the setpoints to restore proper gluing. You might be tempted to enter a speed compensation value to do this. However, since the setpoints were adjusted at the first speed with zero compensation, any change in compensation value now will upset the first pair of setpoints.

Once the second pair of setpoints is established, compare them to the first pair that you wrote down. Establish a ratio of degrees the setpoints advance versus the speed as shown in Figure 24. Convert this ratio to response time and enter it as the speed compensation value.

(continued)

4-3 Speed Compensation

Page 62

Standard Speed Comp (cont'd)

Since the new speed compensation value will affect the ON and OFF setpoints already programmed, you will need to start the line one more time and, at a constant speed, adjust the ON and OFF setpoints for proper gluing. Once set, vary the line speed to confirm that the speed compensation value is accurately adjusting the setpoints over the operating speed range.

Figure 24—Example for Calculating Speed Compensation

RPM Glue On Glue Off Difference

1st Line Speed: 200 73° 156° 83° 2nd Line Speed: 680 49° 132° 83°

Difference in Position: 73° - 49° = 24° Difference in Speed: 680 RPM - 200 RPM = 480 RPM

Speed Compensation Value: Divide difference in position by difference in speed:

24°/480 RPM = 0.05° per 1 RPM

Since a shaft at 1 RPM rotates 0.006°/msec (see page 4-2), this shaft would require (0.05/

0.006), or 8.3 msec to rotate 0.05°. The speed compensation value is 8.3.

Leading Trailing Speed Comp

Leading/Trailing In the previous example, the response time of the glue gun was the same whether

turning on or turning off. While this applies to many systems, some devices have different on/off response times. For these devices, PS-6144 controllers with the “-L” option (Leading/Trailing Edge) provide the ability to program different speed compensation values for the leading and trailing edges of the pulse driving the device.

Setting If the ON and OFF response times are known, jog the line to determine Leading/Trailing ON and OFF setpoints at zero speed. Then enter the speed compensa- Speed Comp tion values through SPEED COMP programming as described in Section 3. When pro-

gramming SPEED COMP, enter the leading edge, or ON response time at the “LE” prompt, and the trailing edge, or OFF response time at the “TE” prompt.

When setting speed compensation on a system where zero speed setpoints have been established, always adjust the speed compensation value. Do not adjust the individual output setpoints!

Response Times If the response times are unknown, jog the line to determine ON and Unknown OFF setpoints at zero speed. Estimate both ON and OFF response times and enter

them through the SPEED COMP function. The leading edge, or “LE” value will control the ON timing, while the trailing edge, or “TE” value will control the OFF timing. Start the line, run product through it at a fixed speed, and adjust each speed compensation value as required for proper gluing. This can be done while the line is in motion. Once programmed, vary the line speed to confirm proper operation at all speeds, and fine tune the SPEED COMP values if necessary.

Can’t Be Jogged? If it is impossible to jog the line, run the line at a fixed speed and set the ON and OFF

setpoints as required with SPEED COMP set to zero for both the leading and trailing edges. Write down the ON and OFF setpoints.

Next, increase the line speed and adjust the setpoints to restore proper gluing. You might be tempted to adjust speed comp values to do this. However, since the setpoints were adjusted at the first speed with zero compensation, any change in compensation value now will upset the first pair of setpoints.

4-4 Speed Compensation

Page 63

Leading Trailing Speed Comp (Cont’d)

Once the second pair of setpoints is established, calculate separate leading and trailing edge speed comp values as shown in Figure 25.

Since the new speed compensation value will affect the ON and OFF setpoints already programmed, you will need to start the line one more time and, at a constant speed, adjust the ON and OFF setpoints for proper gluing. Once set, vary the line speed to confirm that the speed compensation values are accurately adjusting the setpoints over the operating speed range.

Figure 25—Example for Calculating Leading and Trailing Edge

RPM Glue On Glue Off Difference

1st Line Speed: 200 73° 156° 83° 2nd Line Speed: 680 49° 144° 95°

Note that the length of the pulse is 83° at 200 RPM, and 95° at 680 RPM. This means that the leading and trailing edges require different speed compensation values.

Leading Edge: Difference in Position: 73° - 49° = 24°

Difference in Speed: 680 RPM - 200 RPM = 480 RPM Speed Compensation Value: Divide difference in position by difference in speed:

24°/480 RPM = 0.05° per 1 RPM

Since a shaft at 1 RPM rotates 0.006°/msec (see page 4-2), this shaft would require (0.05/0.006), or 8.3 msec to rotate 0.05°. The speed compensation value is 8.3.

Trailing Edge: Difference in Position: 156° - 144° = 12°

Difference in Speed: 680 RPM - 200 RPM = 480 RPM Speed Compensation Value: Divide difference in position by difference in speed:

12°/480 RPM = 0.025°/1 RPM

Since a shaft at 1 RPM rotates 0.006°/msec (see page 4-2), this shaft would require (0.025/0.006), or 4.2 msec to rotate 0.05°. The speed compensation value is 4.2.

4-5 Speed Compensation

Page 64

Negative Speed Compensation

Negative Speed Comp Normal speed compensation advances the setpoints in an output channel to compen-

sate for a fixed response time in the device being controlled. In some applications, however, negative speed compensation is required to retard the setpoints in an output channel. Negative speed compensation is usually found in two situations:

“Wrap-Up” As some machines increase in speed, the drive train at some point between the re-

solver and the product “wraps-up,” or shifts with respect to the resolver. If the wrap-up is proportional to machine speed, negative speed compensation can be used to retard an output channel’s setpoints from the true resolver position, thus maintaining output accuracy.

Sensor Lag While output channels are usually used to switch devices on and off, another use is to

“gate” a sensor into a PLC or other computer. Figure 26 illustrates a basic sensor gating scheme. In the illustration, the signal from the sensor reaches the PLC only when the output channel from the PLS is turned on.

Most sensing devices have very fast response times. However, if a sensor’s response time is slow, its signal will appear later and later in the machine cycle as the machine speeds up. Eventually, the sensor may lag the resolver so much that its signal fails to appear during the window programmed into the PS-6144’s output channel.

Negative speed compensation will correct this problem by causing the output channel to lag its programmed machine position by a specified number of milliseconds. Negative speed compensation is calculated using the same method as standard speed compensation. See SPEED COMP in Section 3 for details.

Figure 26—Simple Sensor Gating Scheme

Speed Comp Guidelines

Device Placement For speed compensation to work most effectively, the device being controlled by the

output channel should be located on the machine in a position where the product is moving past the device at a constant speed. See Figure 27 for an example. In the case of a glue gun, if the gun is ON when the speed is changing, the glue distribution may be inconsistent from carton to carton at varying machine speeds.

Speed Comp & Modes When using Operating Modes as discussed in Section 5, be aware of the effects of

speed compensation on the relationship between the setpoints, the Group Input signal, and the pulse programmed into the Group Channel. Speed compensation will not

affect Group Channels 91 through 96.

Figure 27—Product Speed Should be Constant Past Controlled Device

4-6 Speed Compensation

Page 65

Introduction to Groups & Modes

Input Signals In many industrial applications, the action of a machine component such as a glue gun,

solenoid, or pneumatic cylinder is related to an input signal from a limit switch, sensor, or controller such as a PLC. Input signals are commonly used in two ways:

• Conditional Operation

The device being controlled is allowed to function only if an input signal occurs. A typical example is gluing, where a photoeye senses the presence of a product immediately before gluing should occur. If the product is not present, the glue gun is not enabled to turn on at its programmed setpoints.

• Phase Adjustment

The device being controlled must maintain a certain relationship to other devices on the machine. For example, web converting lines such as disposable diaper machines usually have several machine sections each performing a different operation on a continuous web of material. As line speed increases, the phase relationships between different machine sections are adjusted to compensate for stretching of the web material. To keep a device synchronized within its machine section, a sensor is used to detect a registration mark on a component such as shaft or disk. The sensor signal “resets” the position of the device each revolution, ensuring that the device operates at the correct position on the web of moving material.

Groups & Modes The PS-6144 controller includes powerful programming capabilities that allow output

channels to be linked to input signals from sensors or other devices. Output channels can be divided into as many as six groups, each of which is associated with one of the input terminals on TB 1, Figure 7. Each group can then be assigned to operate in one of six modes which determines the relationship between the channels in the group and the input signals.

Benefits Proper programming of output groups and modes can provide substantial benefits:

• Reduced Waste & Cleanup—By enabling devices such as glue guns to operate

only when a product is present, operating modes conserve glue and reduce mess and cleanup.

• Increased Productivity—When used to compensate for phase adjustments between machine sections, operating modes can improve the high speed accuracy of machine functions, allowing higher machine speeds, better product quality, and reduced scrap.

Typical Applications Details on each of the six PS-6144 operating modes are included later in this section.

Following are a few types of industrial machinery which frequently benefit from the use of operating modes.

Web Converting Machines—Disposable diapers, medical pads, office folders, and similar products. Mode 1 can automatically change the timing of individual machine sections to compensate for changes in phase relationships between sections.

Cartoners & Case Packers—Vacuum, material handling, loading and other functions are usually controlled in Mode 0. Gluing functions are typically controlled in Modes 4 or 5 to prevent glue from being dispensed when containers are not present.

Vertical Form/Fill/Seal Machines—Package handling functions are controlled in Mode 0, while pump or fill functions are handled in Mode 1 to automatically correct for mechanical phase adjustments made between these two sections of the machine. This allows one resolver to do a job that would otherwise require two.

Machines with Multiple Cycle Ratios—Some machines have different sections that run at different cycle ratios per overall machine cycle. For example, one portion of a machine may complete several cycles while another section makes only one cycle. By using Mode 1 or 2, it is possible for some output groups to cycle multiple times while others cycle once.

5-1 Output Grouping & Modes

Page 66

Introduction to Groups & Modes (cont’d)

Group Programming PS-6144 output channels are divided into groups through OUTPUT GROUP program-

ming. Each group is automatically associated with one of the input terminals on TB 1, Figure 7, as well as a special “Group Channel” ranging from Channel 91 to 96. The relationship between groups, input terminals, and group channels is summarized in Fig. 28.

Figure 28—Groups, Input Terminals, & Group Channels

Group Input

Output Terminal Group

Group TB 1, Fig. 7 Channel

1991 21092 31193 41294 51395 61496

When dividing outputs into groups, keep these rules in mind:

• Output channels are assigned to groups sequentially. Group 1 will begin with Output Channel 1 and include the specified number of channels; Group 2 will begin with the next output channel and continue sequentially for its specified number of channels; and so on. The last group will automatically include all of the remaining output channels.

• You can establish as many as six groups or as few as one.

• More than one group can be assigned to the same mode.

Grouping Example 1—All Outputs in One Group

Includes Group Input

Output Output Terminal Group

Group Channels TB 1, Fig. 7 Channel Mode

1 1 thru 25 9 91 0

Grouping Example 2—Two Groups

Includes Group Input

Output Output Terminal Group

Group Channels TB 1, Fig. 7 Channel Mode

1 1 thru 4 9 91 2 2 5 thru 25 10 92 0

Grouping Example 3—Three Groups

Includes Group Input

Output Output Terminal Group

Group Channels TB 1, Fig. 7 Channel Mode

1 1 & 2 9 91 0 2 3 & 4 10 92 4 3 5 thru 25 11 93 0

Mode Assignments During OUTPUT GROUP programming, each group is assigned any one of six modes

of operation that control the interaction between the group, its input terminal, and its group channel. Detailed discussions of each operating mode follow.

5-2 Output Grouping & Modes

Page 67

Mode 0 Operation

Description Output channels in a group assigned to Mode 0 function normally and are not affected

by the corresponding input terminal or group channel.

Details • MOTION ANDING and OUTPUT ENABLE ANDING can be used with outputs in a

Mode 0 group.

• The machine position for a Mode 0 group can be set through OFFSET programming, Section 3.

Mode 0 Programming During OUTPUT GROUP programming, group together output channels that should

remain unaffected by Modes, and assign them Mode 0.

Mode 1 Operation

Description Outputs in a group assigned to Mode 1 are always enabled to turn on at their pro-

grammed setpoints. However, when the corresponding input terminal is energized, the machine position for the group immediately resets to the “Preset” value programmed through the OFFSET function, Section 3. Once the position is reset, the input terminal will have no effect until it is turned off and the resolver reaches the leading edge of a pulse programmed into the corresponding group channel. See Figure 28 for input terminal and group channel assignments.

Applications This mode can be used to automatically adjust phase relationships between machine

sections. It can also be used in applications where some machine sections run multiple cycles per resolver revolution.

Details • The group position resets at the leading edge of the input terminal signal, regardless

of how long the terminal is on.

• Once a reset occurs, the input terminal has no effect until it is de-energized and the leading edge of a pulse in the corresponding group channel re-arms the terminal.

• When the position of a group resets, the position of the corresponding group channel also resets.

• On start-up, the input terminal is armed and the group position is the same as the value programmed in SHAFT POSITION, Section 3. On power-down, the group’s current position setting will be lost.

• Either edge of a pulse in the group channel can re-arm the input terminal. If the resolver shaft is rotating in the forward direction (position is increasing as shaft rotates) the “on” edge of the pulse will re-arm the terminal. If the shaft is rotating in the reverse direction (position decreasing as shaft rotates), the “off” edge of the pulse will re-arm the terminal.

• Each program in the controller can have different setpoints for output channels and the corresponding group channel.

• MOTION ANDING and OUTPUT ENABLE ANDING can be used with outputs in a Mode 1 group.

(continued)

5-3 Output Grouping & Modes

Page 68

Mode 1 Operation (Cont’d)

Figure 29—Mode 1 Example Application

Three sections of an adjustable phase converting machine are controlled by a single PLuS controller and resolver. Groups 1, 2 and 3 all operate in Mode 1. The position of each group is reset to the “preset” value when the group’s sensor detects the registration mark on the shaft for the corresponding machine section. This keeps the electrical control signals properly synchronized to the mechanical devices in each section when phase adjustments are made.

One resolver provides the position information needed for all sections of the machine, regardless of their phase relationship.

Mode 1 Programming See Figure 28 for input terminal and group channel assignments.

1. Program OUTPUT GROUPS, Sect. 3, to establish groups and modes.

2. Program the “Preset” value for each Mode 1 group using OFFSET, Section 3.

3. Jog the machine to the point where the group input terminal will energize. Using this point as a reference, program setpoints into the output channels in the group.

4. Program a pulse in the group channel to re-arm the input terminal.

Mode 2 Operation

Description Outputs in a Mode 2 group are disabled until the

corresponding input terminal is energized. The outputs are then enabled to turn on at their programmed setpoints, and the group position immediately resets to the value programmed through the OFFSET function, Section 3. The leading edge of a pulse in the corresponding group channel disables the group’s outputs and re-arms the input terminal.

Applications This mode is used where products may not be

evenly spaced and the group outputs should cycle only when a product has been sensed.

Details • Outputs are enabled and the group position

resets at the leading edge of the input terminal signal, regardless of how long the terminal is on.

• Once a reset occurs, the input terminal has no

effect until it is de-energized and the leading edge of a pulse in the corresponding group channel re-arms the terminal.

• When the position of a group resets, the position of the corresponding group chan-

nel also resets.

• On power-up, outputs are disabled, the input terminal is armed, and the group posi-

tion is the same as the value programmed in SHAFT POSITION, Section 3.

5-4 Output Grouping & Modes

Page 69

Mode 2 Operation (Cont’d)

• Each program in the controller can have different setpoints for output channels and the corresponding group channel.

• MOTION ANDING and OUTPUT ENABLE ANDING can be used with outputs in a Mode 2 group.

Figure 30—Mode 2 Example Application

Two glue heads at different locations on the conveyor are controlled independently by a single PLuS controller and resolver. The spacing between parts being glued is random.

The sensors are connected to the input terminals for the corresponding groups. When a sensor detects a product, it resets the corresponding group position to the “preset” values and enables the group outputs to turn on the glue guns at the correct setpoints.

When parts are not present, the outputs will be inactive.

Mode 2 Programming See Figure 28 for input terminal and group channel assignments.

1. Program OUTPUT GROUPS to establish groups and modes.

2. Use OFFSET to program the “Preset” value for any Mode 2 groups.

3. Jog the machine to the point where the group input terminal will energize. Using this

point as a reference, program setpoints into the output channels in the group.

4. Program a pulse in the group channel to disable the output channels and re-arm the

input terminal. This pulse must be after all of the output channels have completed their functions, but before the input terminal will be energized.

Mode 3 Operation

Description Outputs in a group assigned to Mode 3 are

on only while their programmed setpoints are on AND the corresponding input terminal is energized. If the input is off, all of the outputs in the group will be off, regardless of setpoint programming. See Figure 28 for input terminal channel assignments.

Applications Use this mode where outputs should be ac-

tive only while a sensor or limit switch is on.

Details • The group channel for a group operating in

Mode 3 has no effect.

• Each program in the controller can have different setpoints for output channels in the group.

• MOTION ANDING and OUTPUT ENABLE ANDING can be used with outputs in a Mode 3 group.

• The machine position for a Mode 3 group can be set through OFFSET programming.

(continued)

5-5 Output Grouping & Modes

Page 70

Mode 3 Operation (Cont’d)

Mode 3 Programming See Figure 28 for input terminal assignments.

1. Program OUTPUT GROUPS to establish groups and modes.

2. Use OFFSET to program the absolute offset value for any Mode 3 groups.

3. Program setpoints into the output channels in the group. Remember that the output channels in Mode 3 will be enabled only while a signal is applied to the group terminal.

Figure 31—Mode 3 Example Application

In this illustration the glue head will operate only while the photo eye sees the top edge of a carton. Gluing will stop on crushed or improperly erected cartons when the eye loses sight of the top edge.

Mode 3 operation eliminates the need to hardwire photoeyes and other sensors in series with the corresponding controller outputs. Instead, the sensor is “ANDed” with the output through Mode 3 programming.

Mode 4 Operation

Description For a group in Mode 4, outputs will be enabled to

turn on at their programmed setpoints for one machine cycle if the corresponding input terminal turns on within a pulse programmed into the group channel. Outputs will be disabled at the start of the next pulse in the group channel. See Figure 28 for input terminal and group channel assignments.

Applications Use this mode to check the presence and correct

positioning of a product before enabling the outputs for this machine cycle.

Details • The leading edge of the signal from the input ter-

minal must occur during the pulse in the group channel. If the leading edge occurs before the pulse, the outputs will not be enabled.

• Each program in the controller can have different

setpoints for output channels and the corresponding group channel.

• Either edge of a pulse in the group channel can disable the outputs. If the resolver

shaft is rotating in the forward direction (position is increasing as shaft rotates) the “on” edge of the pulse will disable the outputs. If the shaft is rotating in the reverse direction (position decreasing as shaft rotates), the “off” edge of the pulse will disable the outputs.

• MOTION ANDING and OUTPUT ENABLE ANDING can be used with outputs in a

Mode 4 group.

• The machine position for a Mode 4 group can be set through OFFSET programming.

5-6 Output Grouping & Modes

Page 71

Mode 4 Operation (Cont’d)

Mode 4 Programming See Figure 28 for input terminal and group channel assignments.

1. Program OUTPUT GROUPS to establish groups and modes.

2. Use OFFSET to program the absolute offset value for any Mode 4 groups.

3. Jog the machine to the point where the group input terminal will energize. Program a pulse in the group channel that will turn on a little earlier than this point, and off a little later. The shorter the pulse, the narrower the portion of the machine cycle in which the input signal will enable the outputs.

4. Program setpoints into the output channels in the group. Remember that the leading edge of the pulse in the group channel will disable the output channels in the group.

Figure 32—Mode 4 Example Application

The glue gun will be enabled for one machine cycle only if the sensor detects the leading edge of a carton during the pulse programmed in the group channel. If a carton is missing or incorrectly positioned, the glue gun will not activate.

Mode 4 operation is appropriate for flight bar conveyors, rotary index tables, and similar types of machinery.

Mode 5 Operation

Description Mode 5 operation is similar to Mode 4 operation,

with the following differences:

• In Mode 4, the leading edge of the input terminal

signal must occur within the pulse programmed into the group channel.

In Mode 5, the group outputs will be enabled if any portion of the input signal occurs within the pulse.

• If the machine stops, the group outputs will be

disabled immediately. This prevents an operation such as gluing from continuing if the machine stops while the glue gun is on.

• If the machine is stopped and the group’s input

terminal is “on,” energizing the First Cycle Enable terminal #15 on TB 1, Fig. 7, will re-enable the outputs. This allows the operation to be completed on a product that was in process when the machine stopped.

Details See Figure 28 for input terminal and group channel assignments.

• Regardless of its programmed “off” point, the pulse in the group channel will end as

soon as any of the outputs in the group turn on.

• Each program in the controller can have different setpoints for output channels and

the corresponding group channel.

• MOTION ANDING and OUTPUT ENABLE ANDING can be used with outputs in a

Mode 5 group. Use MOTION ANDING to prevent the First Cycle Enable terminal from re-activating the outputs while the machine is stopped.

• The machine position for a Mode 5 group can be set through OFFSET programming.

5-7 Output Grouping & Modes

Page 72

Mode 5 Operation (cont’d)

Figure 33—Mode 5 Example Application

The glue gun will be enabled for one machine cycle if the sensor sees a carton during the pulse programmed into the group channel. If a carton is missing, the glue gun will not activate.

If the line stops, the glue gun will be disabled immediately. To re-enable the glue gun on the same machine cycle, depress the push-button while the product sensor is “on.”

Note: Sensor must be active after stopping.

Mode 5 Programming See Figure 28 for input terminal and group channel assignments.

1. Program OUTPUT GROUPS to establish groups and modes.

2. Use OFFSET to program the absolute offset value for any Mode 5 groups.

3. Jog the machine to the point where the group input terminal will energize. Program a pulse in the group channel that will be on during any portion of the input terminal signal. The smaller the overlap between the input signal and the group channel pulse, the narrower the portion of the machine cycle in which the input signal will enable the outputs.

4. Using the start of the overlap from Step 3 as a reference point, program setpoints into the group output channels. Don’t overlap the setpoints with the group channel pulse programmed in Step 3.

Speed Compensation & Modes

Speed Compensation Speed compensation will affect individual channels in an output group as programmed

through SPEED COMP. However, speed compensation will not affect the group channels, 91 through 96.

When using speed compensation and modes together, be aware that speed compensation may shift an output channel’s setpoints into a pulse programmed in the group channel, or into the position in which an input signal will occur. Depending on the Mode and the arrangement of setpoints, speed compensation may produce unexpected results.

5-8 Output Grouping & Modes

Page 73

PLµsNet II Upload/Download Program

Description PLµSNet II is a DOS program that will run on most IBM-PC compatible computers.

When the serial port of the PC is connected to a PLµS Programmable Limit Switch, PLµSNet II can transfer programming values between the computer and the controller in either direction. PLµSNet II includes its own communications software with selection of baud rate, PLµS controller address, and the computer’s COM port. No other communication software is needed.

Functions PLµSNet II provides two main functions: Uploading a controller’s complete set of pro-

gramming values from the controller to an ASCII file on the PC; and downloading the contents of an ASCII from a computer to the PLµS controller. PLµSNet II also provides a text editor to view and change the contents of an ASCII file.

Applications Hard Copy Reference—Using PLµSNet II, a PLµS controller’s programming can be

saved as an ASCII file and printed out for reference. The printout can be used to study line operation or to program other PLµS controllers in the plant.

Archival Storage—The ASCII file containing a PLµS controller’s programming can be stored on a hard drive or floppy disk. In the event of accidental alteration or erasure of the controller’s programming, PLµSNet II can be used to download the ASCII file to the controller to restore normal operation.

Programming Multiple Units—If several PLµS controllers will have the same values, one controller can be programmed correctly and its setpoints uploaded to a PC using PLµSNet II. The programming can then be downloaded to the other PLµS controllers, eliminating the need to manually reenter setpoints for each controller.

Modify Programming—Once a program has been saved as an ASCII file, it can be studied and edited to create other versions of the program.

Contents The PLµSNet II Communications Software Program includes these materials:

(1) Introduction sheet. (1) One disk containing the PLUSNET.EXE file.

Cable To use PLµSNet II, a serial communications cable is required to connect the PLµS

controller to an IBM compatible personal computer. This cable can be purchased from Electro Cam Corp., or it can be built by the customer using the wiring information shown in the PLµS Programming and Installation Manual.

Installation Copy the PLUSNET.EXE file to the desired directory on the PC. Operation Connect the PC and the PLµS controller with a communications cable and turn both

units ON. Start PLUSNET.EXE from the DOS command line, or from a DOS window within

Microsoft Windows. The menus in the program are self-explanatory.

6-1 Communications

Page 74

PLuSNET II Program (cont’d)

Sample ASCII Program Copied from PS-6144 Using PLµSNET II

6-2 Communications

Page 75

Serial Communications Using Electro Cam Corp. Protocol (Standard 6144 Units)

Background PS-6144 controllers include programming that allows them to accept and respond to a

set of serial commands issued by a system host such as a PLC or other computer. The commands can interrogate the PS-6144 for operating and control data, and they can also change programming values within the PS-6144.

Serial communications are initiated when the system host sends a command to the PS-

6144. The PS-6144 processes the command and sends a reply to the host. Modbus ASCII protocol is available (see page 6-16).

Syntax All commands are sent and received as ASCII character strings in the following syntax.

Do not include spaces between fields. Command from Host: STX ADR CMD <DTA> CSM ETX

Reply from PLuS: ACK or NAK <DTA> CSM ETX

No. of

Field Characters Description

STX 1 Start of text. The PLuS uses “!” for this character. ADR 2 hex Address of PLuS controller on network (0-255) CMD 2 hex Command number. Commands are listed later in this chap-

ter.

DTA n hex The number and type of data elements is determined by the

command, reply, or the error.

All data is sent and received in hex.

CSM 2 hex Checksum. The method by which the PS-6144 calculates

the checksum is described later in this chapter. When the host sends a command, it must include a checksum calculated in the same way so that the PS-6144 can check the command for communication errors. The host should also use this calculation method to analyze the reply from the PS-6144 for possible communication errors.

ETX 1 End of text. The PLuS uses a carriage return, or <CR>, for

this character ACK 1 Positive acknowledge. The PLuS uses the letter “A” for ACK. NAK 1 Negative acknowledge, or error condition. The PLuS uses

the letter “N” for NAK. A list of error replies are included later

in this section. The specified number of ASCII characters must be sent for each field. Include leading

zeroes if the data in a field is less than the field length. The control will also include leading zeroes in its replies.

6-3 Communications

Page 76

Serial Commands

Description The PS-6144 controller recognizes a set of 95 commands. Some of these commands

involve testing and diagnostic functions performed at the factory. Because these commands are of little use in field installations, they are not included in the following pages. For information on the complete command set, contact the factory.

The commands are grouped by general function. In the syntax shown for each command and reply, the characters used for STX, ETX, ACK, and NAK are substituted, as listed on the previous page.

The commands are listed in hex.

CMD (hex) Name Function

04 Hello Are you there?

Cmd: ! ADR 04 CSM <CR> Reply: A <CR>

Supervisory Commands

Status Commands

06 Com Stop Stop operation & idle; changes will be written directly to

EEPROM with no other action taken.

Cmd: ! ADR 06 CSM <CR> Reply: A <CR>

07 Checksum Sets new checksums in EEPROM.

Cmd: ! ADR 07 CSM <CR> Reply: A <CR>

08 Start Resume operation.

Cmd: ! ADR 08 CSM <CR> Reply: A <CR>

09 Reset Create hard reset through watchdog.

Cmd: ! ADR 09 CSM <CR> Reply: A <CR>

0A RPM Current RPM.

Cmd: ! ADR 0A CSM <CR> Reply: A XXXX CSM <CR>

where “XXXX” = current RPM in hex.

6-4 Communications

38 Shaft Pos Shaft position.

Put: ! ADR 38 P XXXX CSM <CR> Reply: A <CR>

Get: ! ADR 38 G CSM <CR> Reply: A XXXX CSM <CR>

where “XXXX” is the shaft position in hex.

0B Grp Pos Current position.

Cmd: ! ADR 0B XX CSM <CR> Reply: A YYYY CSM <CR>

where “XX” is the group number minus one. “YYYY” is that group’s position in hex.

Page 77

Serial Commands (cont’d)

CMD (hex) Name Function

Configuration Commands

56 Kbd Qty Number of keypads connected.

Put: ! ADR 56 P XX CSM <CR> Reply: A <CR>

Get: ! ADR 56 G CSM <CR> Reply: A XX CSM <CR>

where “XX” = number of keypads connected.

0D Setup ID Setup ID code.

Put: ! ADR 0D P XXXX CSM <CR> Reply: A <CR>

Get: ! ADR 0D G CSM <CR> Reply: A XXXX CSM <CR>

where “XXXX” = Setup Enable Code in hex.

0E Operator ID Operator ID code.

Put: ! ADR 0E P XXXX CSM <CR> Reply: A <CR>

Get: ! ADR 0E G CSM <CR> Reply: A XXXX CSM <CR>

where “XXXX” = Operator Enable Code in hex.

58 Master ID Master ID code.

Put: ! ADR 58 P XXXX CSM <CR> Reply: A <CR>

Get: ! ADR 58 G CSM <CR> Reply: A XXXX CSM <CR>

where “XXXX” = Master Enable Code in hex.

0F User Pgm User programming enable/disable.

Put: ! ADR 0F P XX <00 or 01> CSM <CR> Reply: A <CR>

Get: ! ADR 0F G XX CSM <CR> Reply: A <00 or 01> CSM <CR>

where “XX” is the channel number minus 1, in hex. “00” = disable, and “01” = enable.

10 Motion Enab Motion detection on/off for a specified output channel.

Put: ! ADR 10 P XX <00, 01, or 02> CSM <CR> Reply: A <CR>

Get: ! ADR 10 G XX CSM <CR> Reply: A <00, 01, or 02> CSM <CR>

where “XX” is the channel number minus 1, in hex. “00” = L1 & L2 off; “01” = L1 on; “02” = L2 on.

6-5 Communications

Page 78

Serial Commands (cont’d)

CMD (hex) Name Function

Configuration Commands

(cont’d)

12 Inc Direction Direction of increasing rotation.

Put: ! ADR 12 P <00 or 01> CSM <CR> Reply: A <CR>

Get: ! ADR 12 G CSM <CR> Reply: A <00 or 01> CSM <CR>

where “00” = CCW, and “01” = CW

13 Scale Factor Scale factor.

Put: ! ADR 13 P XXXX CSM <CR> Reply: A <CR>

Get: ! ADR 13 G CSM <CR> Reply: A XXXX CSM <CR>

where “XXXX” = scale factor in hex.

48 Lo Limit Motion detection low limit.

Put: ! ADR 48 P <00 or 01> YYYY CSM <CR> Reply: A <CR>

Get: ! ADR 48 G <00 or 01> CSM <CR> Reply: A YYYY CSM <CR>

where “YYYY” = low limit RPM in hex. “00” = Level 1, “01” = Level 2.

49 Hi Limit Motion detection high limit.

Put: ! ADR 49 P <00 or 01> YYYY CSM <CR> Reply: A <CR>

Get: ! ADR 49 G <00 or 01> CSM <CR> Reply: A YYYY CSM <CR>

where “YYYY” = high limit RPM in hex. “00” = Level 1, “01” = Level 2.

17 Time Delay Delay value for Timed Output channels.

Put: ! ADR 17 P XX YYYY CSM <CR> Reply: A <CR>

Get: ! ADR 17 G XX CSM <CR> Reply: A YYYY CSM <CR>

where “XX” is the channel minus 1, in hex, and “YYYY” is the delay in msec, in hex.

18 Default Pgm Default program.

Put: ! ADR 18 P XXXX CSM <CR> Reply: A <CR>

Get: ! ADR 18 G CSM <CR> Reply: A XXXX CSM <CR>

where “XXXX” is the Default Program minus 1, in hex.

6-6 Communications

Page 79

Serial Commands (cont’d)

CMD (hex) Name Function

Configuration Commands

(cont’d)

1A Spd Cmp Mode Standard or Leading/Trailing mode.

Put: ! ADR 1A P <00 or 01> CSM <CR> Reply: A <CR>

Get: ! ADR 1A G CSM <CR> Reply: A <00 or 01> CSM <CR>

where “00” = Standard, “01” = Leading/Trailing

1B Spd Cmp Val Speed comp value.

Put: ! ADR 1B P XX YYYY ZZZZ CSM <CR> Reply: A <CR>

Get: ! ADR 1B G XX CSM <CR> Reply: A YYYY ZZZZ CSM <CR>

where “XX” is the channel minus 1, in hex. “YYYY” is the value in tenths of a msec for the leading edge, and “ZZZZ” is the value for the trailing edge. For standard speed comp, “YYYY” = “ZZZZ”. “Y” and “Z” values are hex.

4B Analog Qty Number of analog outputs used.

Put: ! ADR 4B P XX CSM <CR> Reply: A <CR>

Get: ! ADR 4B G CSM <CR> Reply: A XX CSM <CR>

where “XX” is the number of analog outputs used. “XX” can be 00, 01, or 02.

1C Analog Analog values.

Put: ! ADR 1C P XX YYYY ZZZZ CSM <CR> Reply: A <CR>

Get: ! ADR 1C G XX CSM <CR> Reply: A YYYY ZZZZ CSM <CR>

where “XX” is the channel minus one, in hex. “YYYY” is the Offset from 0 to 4095, converted to hex. “ZZZZ” is the High RPM in hex.

1D Grp Qty Output group quantity.

Put: ! ADR 1D P XX CSM <CR> Reply: A <CR>

Get: ! ADR 1D G CSM <CR> Reply: A XX CSM <CR>

where “XX” is the number of output groups, from one to six.

4A Offset Mode One offset for all groups, or individual offset for each group.

Put: ! ADR 4A P <00 or 01> CSM <CR> Reply: A <CR>

Get: ADR 4A G CSM <CR> Reply: A <00 or 01> CSM <CR>

“00” = Each; “01” = One.

6-7 Communications

Page 80

Serial Commands (cont’d)

CMD (hex) Name Function

Configuration Commands

(cont’d)

1E Grp Offset Output group offset value.

Put: ! ADR 1E P XX YYYY CSM <CR> Reply: A <CR>

Get: ADR 1E G XX CSM <CR> Reply: A YYYY CSM <CR>

where “XX” is the group number minus 1. “YYYY” is the offset value for that group, in hex.

3C Shaft Offset Shaft position offset.

Put: ! ADR 3C P XXXX CSM <CR> Reply: A <CR>

Get: ! ADR 3C G CSM <CR> Reply: A XXXX CSM <CR>

where “XXXX” is the shaft offset in hex.

1F Grp Chn Qty Number of channels in a specified output group.

Put: ! ADR 1F P XX YY CSM <CR> Reply: A <CR>

Get: ! ADR 1F G XX CSM <CR> Reply: A YY CSM <CR>

where “XX” is the group number minus one. “YY” is the number of output channels in that group, in hex.

21 Mode Mode for the specified output group.

Put: ! ADR 21 P XX YY CSM <CR> Reply: A <CR>

Get: ! ADR 21 G XX CSM <CR> Reply: A YY CSM <CR>

where “XX” is the group number minus one. “YY” is the operating mode, from zero to five.

47 Output Enab Output Enable ANDing on or off for specified channel.

Put: ! ADR 47 P XX <00 or 01> CSM <CR> Reply: A <CR>

Get: ! ADR 47 G XX CSM <CR> Reply: A <00 or 01> CSM <CR>

where “XX” is the channel number minus one, in hex. “00” = ANDing “off”; “01” = ANDing “on”.

4D Pgm Sel Mode Program select terminals use Binary, Gray Code, or BCD format.

Put: ! ADR 47 P <00, 01, or 02> CSM <CR> Reply: A <CR>

Get: ! ADR 47 G CSM <CR> Reply: A <00, 01, or 02> CSM <CR>

“00” = Binary; “01” = Gray Code; “02” = BCD.

6-8 Communications

Page 81

Serial Commands (cont’d)

CMD (hex) Name Function

Setpoint Commands

22 Spt Count Return number of pulses.

Cmd: ! ADR 22 CSM <CR> Reply: A XXXX CSM <CR>

where “XXXX” is the total number of pulses in hex. Includes all pulses in all channels and programs in the controller.

23 Wipe Spt Deletes all pulses from EEPROM.

Cmd: ! ADR 23 CSM <CR> Reply: A <CR>

24 Get Spt Return program, channel, and on/off points for the specified

pulse.

Cmd: ! ADR 24 XXXX CSM <CR> Reply: A XX YY ZZZZ TTTT CSM <CR>

where “XXXX” is the number of the pulse in hex. Pulses are numbered starting at Channel 1, Program 1, Position 0. As the transducer rotates through a complete cycle, each pulse encountered is numbered sequentially. After one cycle, the pulses in Channel 2 are numbered, and so on.

In the reply, “XX” is the program number of the specified pulse, minus one. “YY” is the channel number, minus one. “ZZZZ” and “TTTT” are the “on” and “off” points of the pulse, respectively. All values are in hex.

25 Add Spt Adds a setpoint.

Cmd: ! ADR 25 XX YY ZZZZ TTTT CSM <CR> Reply: A <CR>

where “XX” is the program number minus one, and “YY” is the channel number minus one. “ZZZZ” and “TTTT” are the “on” and “off” points of the pulse, respectively. All values are in hex.

26 Del Spt Deletes a setpoint.

Cmd: ! ADR 26 XX YY ZZZZ TTTT CSM <CR> Reply: A <CR>

27 Mod Spt Modifies one edge of a setpoint.

Cmd: ! ADR 27 XX YY ZZZZ TTTT MM NNNN CSM <CR> Reply: A <CR>

where “XX” is the program number minus one and “YY” is the channel number minus one.

“ZZZZ” and “TTTT” are the current “on” and “off” points of the pulse, respectively.

“MM” is the edge to be modified: “00” is the “off” edge, “01” is the “on” edge.

“NNNN” is the new value for the specified edge. All values are in hex.

6-9 Communications

Page 82

Serial Commands (cont’d)

CMD (hex) Name Function

Setpoint Commands

(cont’d)

28 Inc Spt Advances one edge of a pulse, both edges, or all pulses in a

channel, by one scale factor increment.

Cmd: ! ADR 28 XX YY ZZZZ TTTT MM CSM <CR> Reply: A <CR>

where “XX” is the program number minus one, and “YY” is the channel number minus one.

“ZZZZ” and “TTTT” are the current “on” and “off” points of the pulse, respectively.

“MM” specifies the scope of the change: “00” is the “off” edge; “01” is the “on” edge; “02” is both edges of the pulse; and “03” is all edges of all pulses in the channel. All values are in hex.

29 Dec Spt Retards one edge of a pulse, both edges, or all pulses in a

channel, by one scale factor increment. Cmd: ! ADR 29 XX YY ZZZZ TTTT MM CSM <CR> Reply: A <CR>

where “XX” is the program number minus one, and “YY” is the

channel number minus one.

“ZZZZ” and “TTTT” are the current “on” and “off” points of the

pulse, respectively.

“MM” specifies the scope of the change: “00” is the “off” edge;

“01” is the “on” edge; “02” is both edges of the pulse; and “03” is

all edges of all pulses in the channel. All values are in hex.

Display Commands

30 Def Disp Default display on start-up.

Put: ! ADR 30 P XX CSM <CR> Reply: A <CR>

Get: ! ADR 30 G CSM <CR> Reply: A XX CSM <CR>

where “XX” is the display mode: “00” is Speed, “01” is Position,

and “02” is Auto.

31 Tog RPM Toggle RPM speed.

Put: ! ADR 31 P XXXX CSM <CR> Reply: A <CR>

Get: ! ADR 31 G CSM <CR> Reply: A XXXX CSM <CR>

where “XXXX” is the toggle RPM speed in hex.

57 Rate Setup Multiplier and units for RPM display.

Put: ! ADR 57 P XX YY CSM <CR> Reply: A <CR>

Get: ! ADR 57 G CSM <CR> Reply: A XX YY CSM <CR>

“XX” is the multiplier: “01” = 1X; “02” = 2X; “03” = 3X; “04” = .5X.

“YY” = units: “00” = RPM; “01” = BPM; “02” = CPM

6-10 Communications

Page 83

Serial Commands (cont’d)

CMD (hex) Name Function

Special Commands

2A Key Press Adds a value to the keyboard buffer; just like pressing a key.

Cmd: ! ADR 2A XX CSM <CR> Reply: A <CR>

where “XX” is the key number in hex. See “Keypad Diagnostics” in Section 7 for a method to determine the key number for each key on the keypad.

2B En Mot Spt Enable “Motion ANDing” programming at operator level.

Put: ! ADR 2B P <00 or 01> CSM <CR> Reply: A <CR>

Get: ! ADR 2B G CSM <CR> Reply: A <00 or 01> CSM <CR>

where “00” = disabled, “01” = enabled.

2C En Offset Enable “Offset” programming at operator level.

Put: ! ADR 2C P <00 or 01> CSM <CR> Reply: A <CR> Get: ! ADR 2C G CSM <CR> Reply: A <00 or 01> CSM <CR>

where “00” = disabled, “01” = enabled.

2D En Act Pgm “Active Program” enable at operator level.

Put: ! ADR 2D P <00 or 01> CSM <CR> Reply: A <CR>

Get: ! ADR 2D G CSM <CR> Reply: A <00 or 01> CSM <CR>

where “00” = disabled, “01” = enabled.

2E En Spd Cmp Enable “Speed Comp” programming at operator level.

Put: ADR 2E P XX <00 or 01> CSM <CR> Reply: A <CR>

Get: ! ADR 2E G XX CSM <CR> Reply: A <00 or 01> CSM <CR>

where “XX” is the channel number minus 1, in hex. “00” = disabled, “01” = enabled.

2F En Timed Out Enable “Timed Output” programming at operator level.

Put: ! ADR 2F P XX <00 or 01> CSM <CR> Reply: A <CR>

Get: ! ADR 2F G XX CSM <CR> Reply: A <00 or 01> CSM <CR>

where “XX” is the channel number minus 1, in hex. “00” = disabled, “01” = enabled.

6-11 Communications

Page 84

Error Codes

Error Replies If a command sent to the PS-6144 cannot be processed for any reason, the controller

sends a reply in the following format: N <error code> CSM <CR> The error codes are listed below.

Code Name Meaning

00 OK Processed ok. 01 BAD BUFFER Buffer not correct. 02 NOT OUR ADDRESS To someone else. 03 BAD COMMAND Illegal command. 04 BAD DATA Illegal data. 05 NOT IN MOTION Can’t do while running. 06 TOO MANY TIMERS Too many timers for time base. 07 NOT AN OPTION Option not on unit. 08 NOT STOPPED Can’t do this unless STOPPED.

09 BAD FORMAT Bad input or output format string. 0A TIMEOUT Timeout error. 0B BAD KEY Illegal key value. 0C FLASH ERROR Flash programming error. 0D BAD PROGRAM# Illegal program number. 0E BAD CHANNEL# Illegal channel number.

0F KEYBOARD CONFLICT Conflict with keyboard activity.

Checksum

Calculating Checksum The PS-6144 calculates checksums in four steps:

1. Add the ASCII values of the command string, not including STX (!) or ETX (<CR>).

2. Make the decimal value from Step 1 negative.

3. Convert the value from Step 2 to hex.

4. Use the two least significant digits from Step 3. The following examples will clarify how Checksums are calculated:

Example 1—Command 0A: Request RPM from Controller #1

Command: !010A<CSM><CR> Checksum Calculation:

0 1 0 A | | | |

48+49+48+72 = 217(decimal)

–217 decimal = FF27 hex; therefore: Checksum = 27 String sent to controller = !010A27<CR>

Example 2—Command 25: Add Pulse to Control #2

Pulse Values: Program 15, Output Channel 9, “On” at 25, “Off” at 290 Command: !02250E0800190122<CSM><CR> Checksum Calculation:

6-12 Communications

0 2 2 5 0 E 0 8 0 0 1 9 0 1 2 2 | | | | | | | | | | | | | | | | 48+50+50+53+48+69+48+56+48+48+49+57+48+49+50+50 = 821(decimal)

–821 decimal = FCCB hex; therefore: Checksum = CB String sent to controller = !02250E0800190122CB<CR>

Page 85

Serial Communications Using Modbus ASCII Protocol (PS-6144-MB Units)

Data Organization

This section describes the internal data structure of PLuS controllers, and how this data may be accessed via serial communications. The data has been organized as a series of "Coils" and "Registers" compatible with PLC programming techniques. You access and/or change the data within a PLuS controller by forcing coils ON or OFF, and by reading and writing register data.

A PLuS Controller can be completely programmed via the serial interface. All controller data, such as pulses, speed compensation, timed output values, etc., are available as registers. Configuration data, such as the direction of rotation, number of keyboards, number of analog outputs, etc., is also available as register data. The controller is programmed by writing to these registers. Data is monitored within the controller by reading from these registers.

Note: The ability of the EEPROM to retain data is reduced after 100,000 write cycles. Do not set up routines that constantly write data to the EEPROM's.

Mapping

In addition to accessing controller data via dedicated registers, specific indexed data items can be accessed through the 240 data display registers. This is done by "mapping" a specific indexed data element to a data display register; a data display register is assigned to represent a pulse, speed comp value, etc. Once an indexed data element is mapped it can be accessed either through the data display register or through the dedicated register.

Modbus

Mapping is useful when displaying more than one instance of an indexed data element at once. For instance, speed compensation is accessed via three registers; 1) a channel index, 2) a leading edge value, and 3) a trailing edge value. This means that the values of speed compensation for all channels can be accessed, but only one at a time. To display more than one value of speed compensation at once, simply map the values to a series of data display registers.

You must define how many mappings are available through the Map Limit register.

Modbus ASCII protocol is used for serial communications.

Set host controller communication parameters to 7 data bits, 2 stop bits, no parity.

Limit the number of consecutive registers or coils read to 32.

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Page 86

Quick Reference

Discrete Elements

Inputs

10001 - 10016 DC Inputs

Outputs

00001 - 00100 Channel Outputs

ORing and NOT ANDing

00101 - 00200 Channel ORing 00201 - 00300 Channel NOT ANDing

Special Purpose

00301 - 00400 Special Purpose

00301 Global Unforce 00302 Pulse Register Enable 00303 Create New Pulse 00304 Move Both Edges of Pulse 00305 Move All Pulses in Channel 00314 NAK Bad Address Reads 00315 Execute Special Function 00316 Auto Increment

Pulse Programming (Cont.)

40264 Program Index 40265 Channel Index 40266 Pulse Index 40267 Pulse On 40268 Pulse Off 40269 New On 40270 New Off

Default Program

40271 Default Program

Speed Compensation

40272 Speed Comp Mapping 40273 Channel Index 40274 Leading Edge Comp 40275 Trailing Edge Comp

Timed Outputs

40276 Timed Output Mapping 40277 Channel Index 40278 Time Delay

Offset

Registers

Special Purpose & Data Display

40001 Message and Special Func-

tion (16 registers)

40017 Data Display (240 registers)

RPM

40257 RPM

Position

40258 Position Mapping 40259 Position Index 40260 Position

Pulse Programming

40261 Pulse Mapping 40262 Total Pulse Count 40263 Channel Pulse Count

40279 Offset Mapping 40280 Group Index 40281 Group Offset

Motion Detection

40282 Motion Detection Mapping 40283 Channel Index 40284 Low Motion Detection RPM 40285 High Motion Detection RPM

Analog Output

40286 Analog Output Mapping 40287 Channel Index 40288 Analog Offset 40289 Analog High RPM

Gray Code Speed Compensation

40290 Gray Code Speed Comp

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Page 87

Quick Reference

Mapping Registers

40296 Map Limit 40297 Map Quantity 40298 Map Store 40299 Map Recall

Model Information

40300 Model 40301 Revision 40302 Output Quantity 40303 Option Index 40304 Option

Hardware Configuration

40305 Keyboard Quantity 40306 Increasing Direction 40307 Scale Factor 40308 Shaft Position 40309 Shaft Offset 40310 Analog Quantity 40311 Resolver Type 40312 Program Select Mode 40313 Gray Level 40314 Time Base 40315 Termination Resistor One 40316 Termination Resistor Two

Display Configuration

40317 Default Display 40318 Rate Multiplier 40319 Rate Divisor 40320 Rate Decimal Point Position 40321 Rate Units 40322 Toggle RPM 40323 RPM Update Rate 40324 Speed Comp Display Mode 40325 Group Position Display Mode

Password ID Numbers

Per Channel Enable

40329 Per Channel Enable

Index

40330 Per Channel Enable

Operator Function Enable

40331 Operator Function

Enable Bitmask

Motion ANDing

40332 Channel Index 40333 Motion Enable Level

Output Enable ANDing

40334 Output Enable Index 40335 Output Enable

Group Programming

40336 Group Quantity 40337 Group Index 40338 Channel Quantity 40339 Group Mode

Run Time Control

40340 Stop Control 40341 EEPROM Checksum 40342 EEPROM Changed

The following registers are not supported by early versions of Modbus Controllers.

Active Program

40343 Active Program

I/O Control

40350 - 40359 Input Status 40360 - 40369 Output Status 40370 - 40379 ORing Bits 40380 - 40389 ANDing Bits

40326 Operator ID 40327 Setup ID 40328 Master ID

Communications

40390 Type (RS485/RS232) 40391 Baud Rate 40392 Address

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Page 88

Discrete I/O

Inputs

10001 - 10016 DC Inputs

These points represent the status of the DC inputs.

Outputs

00001 - 00100 Channel Outputs

These coils represent the status of the channel outputs. Forcing these coils directly will set/ clear the appropriate ORing and ANDing coils as required. The Channel Output Coil status before OR/ANDing is determined by setpoints, group modes, speed compensation, motion ANDing, enable input ANDing, timed outputs, and resolver fault status.

ORing and NOT ANDing

00101 - 00200 Channel ORing

Setting these coils to '1' will force the corresponding Channel Output Coil ON.

00201 - 00300 Channel NOT ANDing

Setting these coils to '1' will force the corresponding Channel Output Coil OFF.

Channel Status

Ladder Diagram Example of ORing/ANDing Coils

Special Purpose

00301 - 00400 Special Purpose

301 Global Unforce

Clears all OR and NOT AND coils when set from '0' to '1' (edge active).

302 Pulse Register Enable

When '1', this coil enables the creation of new pulses through writes to the New Off Register. When this coil is '0', writes to New Off Register do not create a new pulse.

303 Create New Pulse

Creates a new pulse defined by the New On and New Off registers when set from '0' to '1' (edge active). This coil is ignored if coil 302 is '1'.

304 Move Both Edges of Pulse

When '1', this coil will cause both edges of a pulse to move when either the leading or trailing edge is changed by '1' (incremented or decremented).

305 Move All Pulses in Channel

When '1', this coil will cause all edges of all pulses in a channel to move when either the leading or trailing edge is changed by '1' (incremented or decremented).

314 NAK Bad Address Reads

When '1', this coil will cause the controller to NAK attempted reads to non-existent registers. When this coil is '0', reads to non-existent registers return a value of zero.

315 Execute Special Function

Executes the special function defined by the contents of the Special Purpose Registers (40001-40017) when set from '0' to '1'.

316 Auto Increment

When '1', this coil enables the auto increment feature on index registers. This feature allows sequential reading of indexed values without changing the index register.

6-16 Communications

OR Coil

112

AND Coil

212

Channel Output

012

Note: The "Pulse Register Enable" coil (#302) is intended for mass downloads.

When a pulse is created using this mode, the new pulse does not appear in the channel until the unit is power cycled. This enables pulses to be added faster in a batch type situation. When pulses need to be created and take effect immediately, "Create New Pulse" coil (#303) should be used instead. "Pulse Register Enable" coil (#302) should be set to 0. A pulse created with "Create New Pulse" coil will take effect immediately and not require the unit to be power cycled.

Page 89

Registers

Special Purpose & Data Display

40001 Special Function (16 registers)

The first 16 registers (001 - 016) are used for entering data used by the special functions.

40017 Data Display (240 registers)

These registers (017 - 256) are used by the Mapping functions to display individual instances of indexed data.

RPM

40257 RPM

Read only Returns the current RPM.

Position

40258 Position Mapping

Read/write Values: 17 - 256 Specifies the general purpose register used to display the position for the output group specified by the Group Index Register.

40259 Position Index

Read/write Values: 1 - 6 Specifies the output group whose position is displayed in the Position Register.

40260 Position

Read only Values: 0 - ( Scale Factor - 1 ) returns the current position for the output group specified by the Group Index Register.

Pulse Programming

40261 Pulse Mapping

40262 Total Pulse Count

40263 Channel Pulse Count

40264 Program Index

Read/write Values: 17 - 255 General Purpose register used for mapping the On and Off values for the pulse specified by the index registers. Two registers will be used; the first will contain the On value, the second will contain the Off value.

Read/write Values: 0 - n Returns the total number of pulses for all channels. Writing a value of '0' to this register will erase all pulses. You can only write to this register when the Stop register is '1'.

Read only Values: 0 - n Returns the number of pulses in the channel defined by the index registers below.

Read/write Values: 0 - Max Program Number Contains the current program number for pulse access. Writing to this register resets the Channel Index Register and the Pulse Index Register to '1'. When this register is '0', the current active program is used for setpoint access and for mapping (setpoints mapped with a program index of '0' will automatically change when the active program changes).

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Page 90

Registers (Cont'd)

Pulse Programming (Con'td)

40265 Channel Index

Read/write Values: 1 - Max Channel Number Contains the current channel number for pulse access. Writing to this register resets the Pulse Index Register to '1'. This register is reset to '1' when the Program Index Register is changed.

40266 Pulse Index

Read/write Values: 1 - n Contains the current pulse number for pulse access. This register is reset to '1' when the Program Index Register or Channel Index Registers are changed.

40267 Pulse On

Read/write Values: 0 - ( Scale Factor - 1 ) Pulse On Value.

40268 Pulse Off

Read/write Values: 0 - ( Scale Factor - 1 ) Pulse Off Value.

40269 New On

Read/write Values: 0 - ( Scale Factor - 1 ) New Pulse On Value. Writing to this register loads the On setpoint of a new pulse for the program and channel specified by the index registers above.

40270 New Off

Read/write Values: 0 - ( Scale Factor - 1 ) New Pulse Off Value. Writing to this register loads the Off setpoint of a new pulse for the program and channel specified by the index registers above. The pulse is stored when the Off value is written if the Pulse Register Enable Coil is set to '1'; otherwise the pulse is stored when the Create New Pulse Coil is changed form '0' to '1' (edge active).

Default Program

40271 Default Program

Read/Write. Values: 1 - Max program number Defines the program that will be active if no hardware program select inputs are active.

Speed Compensation

40272 Speed Comp Mapping

Read/Write Values: 17 - 255 General purpose register used for mapping speed compensation values. Two registers will be used; the first will contain the leading edge value, the second will contain the trailing edge value.

40273 Channel Index

Read/Write Values: 1 - Max Channel Number Channel index for speed comp values.

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Page 91

Registers (Cont'd)

Speed Compensatin (Cont'd)

40274 Leading Edge Comp

Read/Write Values: 0 - n (.1mS) Specifies the leading edge speed comp value.

40275 Trailing Edge Comp

Read/Write Values: 0 - n (.1mS) Specifies the trailing edge speed comp value.

Timed Outputs

40276 Timed Output Mapping

Read/write Values: 17 - 255 General purpose register used for mapping timed output values.

40277 Channel Index

Read/Write Values: 1 - Max Channel Number Channel index for time delay values.

40278 Time Delay

Read/write Values: 0 - n (1mS) Specifies the maximum time in milliseconds that a channel may stay on after it has bee turned on.

Offset

40279 Offset Mapping

40280 Group Index

40281 Group Offset

Motion Detection

40282 Motion Detection Mapping

40283 Channel Index

Read/write Values: 17 - 256 General purpose register used for mapping Group Offset values.

Read/write Values: 1 - 6 Group index for offset values.

Read/write Values: 0 - ( Scale Factor - 1 ) Offset value for the specified group. Note that this value is a PRESET value for groups in modes 1 or 2.

Read/write Values: 17 - 255 General purpose register used for mapping low and high motion detection values. Two registers will be used; the first will contain the low motion detection rpm value, the second will contain the high motion detection rpm value.

Read/write Values: 1, 2 Motion detection level index for high and low motion detection values.

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Page 92

Registers (Cont'd)

Motion Detection (Cont.)

40284 Low Motion Detection RPM

Read/write Values: 0 - n Motion detection low limit for the level specified by the index register.

40285 High Motion Detection RPM

Read/write Values: 0 - n Motion detection high limit for the level specified by the index register.

Analog Output

40286 Analog Output Mapping

Read/write Values: 17 - 255 General purpose register used for mapping analog offset and high RPM values. Two registers will be used; the first will contain the analog offset value, the second will contain the high RPM value.

40287 Channel Index

Read/write Values: 1, 2 Analog channel index for analog offset and high RPM values.

40288 Analog Offset

Read/write Values: 0 - 4095 Analog output at 0 RPM.

40289 Analog High RPM

Read/write Values: 0 - 3000 RPM at which analog output is 4095.

Gray Code Speed Compensation

40290 Gray Code Speed Comp

Read/write Values: 0 - n (.1mS) In controllers equipped with the "-G" option, the Gray code bit pattern is speed compensated by this amount.

Mapping Registers

40296 Map Limit

Read/write Values: 0 - 256 Sets the maximum number of data mappings.

40297 Map Quantity

Read/write Values: 0 - 256 Returns the number of data mappings active in the controller. NOTE: Writing a '0' to this register will delete all data mappings!

40298 Map Store

This register is only for use by utility programs.

40299 Map Recall

This register is only for use by utility programs.

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Page 93

Registers (Cont'd)

Model Information

40300 Model

Read only Returns the PLuS model number (5144, 6144, etc.).

40301 Revision

Read only Returns the major software revision.

40302 Output Quantity

Read only Returns the number of output channels (8, 9, 16, 17, 25, etc).

40303 Option Index

Read/write Values: 1 - n Used as index for reading installed controller options through the Option Register.

40304 Option

Read only Values: 0 - n Returns installed controller options as specified through the Option Index Register. A value of '0' at index '1' means no options are installed.

Hardware Configuration

40305 Keyboard Quantity

Read/write Values: 1, 2 Number of keyboards attached to PS-6000 controller.

40306 Increasing Direction

Read/write Values: 0 = CCW, 1 = CW Specifies the direction of rotation of the resolver (viewed from the shaft end) that will result in an increasing numerical display of position.

40307 Scale Factor

Read/write Values: 2 - 1024 (4096 with "-H" Option) Scale factor used for pulse, position, and offset programming.

40308 Shaft Position

Read only Values: 0 - ( Scale Factor - 1 ) Returns the current resolver shaft position, including the shaft offset.

40309 Shaft Offset

Read/write Values: 0 - ( Scale Factor - 1 ) Offset that is added to raw resolver position to make Shaft Position.

40310 Analog Quantity

Read/write Values: 0, 1, 2 Specifies the number of analog modules active.

40311 Resolver Type

Read/write Values: 0 = Electro Cam, 1 = Other Specifies type of resolver attached to controller.

40312 Program Select Mode

Read/write Values: 0 = Binary, 2 = BCD, 1 = Gray code Specifies how the program select inputs determine the active program.

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Page 94

Registers (Cont'd)

Hardware Configuration (Cont'd)

40313 Gray Level

Read/write Values: 0 = Positive True, 1 = Negative True On controllers equipped with the "-G" Option, this register specifies the logic level of the Gray code bit pattern.

40314 Time Base

Read only Values: 0 = 1mS, 1 = .5mS, 2 = .2mS Returns the timer interrupt rate.

40315 Termination Resistor One

Read/write Values: 0 = Off, 1 = On Termination resistor On/Off RS485 port; keyboard port for 6000's, RS485 Communication port for 5144's.

40316 Termination Resistor Two

Read/write Values: 0 = Off, 1 = On Termination resistor On/Off for RS232/RS485 port; communication port for 6000's with 5144A Input Board.

Display Configuration

40317 Default Display

Read/write Values: 0 = RPM, 1 = Position, 2 = Auto Select Specifies Pos/Rpm display mode; only applicable on 5XXX controllers.

40318 Rate Multiplier

Read/write Values: 1 - 1091 RPM rate multiplier; 6000 controllers only.

40319 Rate Divisor

Read/write Values: 1 - 63 RPM rate divisor, 6000 controllers only.

40320 Rate Decimal Point Position

Read/write Values: 0 - 3 RPM decimal point position; 6000 controllers only.

40321 Rate Units

Read/write Values: 0 = RPM, 1 = BPM, 2 = CPM, 3 = IPM RPM display units; 6000 controllers only.

40322 Toggle RPM

Read/write Values: 0 - n Specifies RPM which will cause position display to blank (6000 series) or to change from Position to RPM (5000 series).

40323 RPM Update Rate

Read/write Values: 0 = 1/Sec, 1 = 2/Sec, 2 = 10/Sec Rate at which the RPM display is updated.

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Page 95

Registers (Cont'd)

Display Configuration

40324 Speed Comp Display Mode

Read/write Values: 0 = One, 1 = L/T Specifies whether speed comp values are displayed as one value for both leading and trailing edges, or as a value for each.

40325 Group Position Display Mode

Read/write Values: 0 = Each, 1 = One Specifies whether the positions for output groups are individually displayed, or if they are displayed as one value for all groups. Output group positions can only be displayed as one if none are in mode 1 or mode 2 (rezero modes).

Password ID Numbers

40326 Operator ID

Read/write Values: 0 - n Specifies the Operator ID number used to enable the Operator access level for programming.

40327 Setup ID

Read/write Values: 0 - n Specifies the Setup ID number used to enable the Setup access level for programming.

40328 Master ID

Read/write Values: 0 - n Specifies the Master ID number used to enable the Master access level for programming.

Per Channel Enable

40329 Per Channel Enable Index

Read/write Values: 1 - Max Channel Number Channel index for the Per Channel Enable register.

40330 Per Channel Enable

Read/write Values: 0=No Operator access, 1=Operator access enabled Specifies whether channel data can be modified under the Operator access level (0=no, 1=yes). Channel data such as speed comp and timed output values can be individually enabled per channel for operator access through this register.

Operator Function Enable

40331 Operator Function Enable Bitmask

Read/write Values: 0 - 0FFFFH Bit mask which specifies which programming functions the operator may perform. Bit 0: Pulse on/off values. Bit 1: Default program. Bit 2: Speed compensation. Bit 3: Timed outputs. Bit 4: Offsets. Bit 5: Motion detection. Bit 6: Analog offset & high rpm.

6-23 Communications

Page 96

Registers (Cont'd)

Motion ANDing

40332 Channel Index

Read/write Values: 1 - Max Channel Number Channel index for the Motion Enable Level Register.

40333 Motion Enable Level

Read/write Values: 0 = Off, n = Motion Detection Level Specifies the motion detection level used for a channel.

Output Enable ANDing

40334 Output Enable Index

Read/write Values: 1 - Max Channel Number Channel index for the Output Enable register.

40335 Output Enable

Read/write Values: 0=Channel not ANDed, 1=Channel ANDed Specifies whether a channel is ANDed with the Enable Input.

Group Programming

40336 Group Quantity

40337 Group Index

40338 Channel Quantity

40339 Group Mode

Run Time Control

40340 Stop Control

40341 EEPROM Checksum

Read/write Values: 1 - 6 Specifies the number of output groups.

Read/write Values: 1 - 6 Group index for Channel Quantity and Group Mode Registers.

Read/write Values: 0 - n Defines the number of channels in the output group specified by the Group Index Register.

Read/write Values: 0 - 5 Defines the operating mode for the output group specified by the Group Index Register. Note that groups in mode '0' do not need (or have) an enable input.

Read/write Values: 0 = Running, 1 = Stopped When PLuS is STOPPED, changes written to registers do not update the checksum in EEPROM memory. Changes are faster when unit is stopped, but you must read from the Checksum Register when changes are complete to establish a valid checksum. Writing a '1' value to this register will place the PLuS in STOPPED mode. Writing a '0' to this register will restart the PLuS via a watchdog timer reset.

Read only Returns the current checksum of EEPROM memory. If computed checksum of EEPROM memory does not match the current value (i.e. if changes were made while unit STOPPED), a new value will be written to EEPROM memory.

6-24 Communications

Page 97

Registers (Cont'd)

Run Time Control (Cont'd)

40342 EEPROM Changed

Read only Values: 0 = no change, 1 = changed. A value of '1' in this register means that the EEPROM has been changed (through the keyboard) since the last time this register was read. Reading this register sets it to '0'.

Active Program

40343 Active Program

Read/Write. Values: 1 - Max program number Returns to program currently active; determined either by hardware inputs or by the value of the default program. If hardware inputs are active, writes to this register will change the default program, but the active program will not change.

I/O Control

40350 - 40359 Input Status

Read Only. Values: 0 - 65535 Each register represents the status of 16 inputs.

40360 - 40369 Output Status

Read/Write. Values: 0 - 65535 Each register represents the status of 16 outputs. The least significant bit of the register corresponds to the lowest numbered output. Writing to one of these registers will force 16 outputs. The ORing and ANDing registers (and coils) will reflect the forced conditions.

40370 - 40379 ORing Bits

Read/Write. Values: 0 - 65535 Each register represents the status of 16 ORing bits. The least significant bit of the register corresponds to the lowest numbered output. When a '1' is present in an outputs' bit position, the output will be forced ON. The OUTPUT STATUS register will reflect the forced condition.

40380 - 40389 ANDing Bits

Read/Write. Values: 0 - 65535 Each register represents the status of 16 ANDing bits. The least significant bit of the register corresponds to the lowest numbered output. When a '1' is present in an outputs' bit position, the output will be forced OFF. The OUTPUT STATUS register will reflect the forced condition.

Host Communications Setup

40390 Communication Type (RS485/RS232)

Read/Write. Values: 0/1 (0=RS485, 1=RS232) Determines the communication type used by the controller. This register may only be written to when the controller is stopped (via the STOP CONTROL register).

40391 Communication Baud Rate

Read/Write. Values: 2/3/4/5 (2=4800, 3=9600, 4=19200, 5=38400) Determines the baud rate used by the controller. This register may only be written to when the controller is stopped (via the STOP CONTROL register).

6-25 Communications

Page 98

Registers (Cont'd)

Host Communications Setup (Cont'd)

40392 Communication Address

Read/Write. Values: 1-255 Determines the address used by the controller. This register may only be written to when the controller is stopped (via the STOP CONTROL register).

NOTE: If the three address switches on the input board are all UP (address 7), the controller will be automatically configured to be RS232, 9600 baud, address 1. Use this feature to enable communications with a controller if no keyboard is available or if you are unsure of the communication parameters currently in use.

Special Functions

Overview

Special functions are used to implement features not directly defined by the standard registers. Special functions are executed by loading the special purpose registers (40001-40016) with data, and then bringing the Execute Special Function Coil (00315) from '0' to '1'.

The data loaded into the special purpose registers is dictated by the special function being performed; each different special function will define the number and use of the special purpose registers.

Register 40001 will define the special function to be performed; registers 40002-40016 will hold the data needed for the special function.

Pulse Copy

This function will add a series of pulses to a specific program and channel. Register Use:

Registers 40004 and 40005 define the on and off values of the envelope pulse that will be divided into a series of smaller pulses.

Register 40006 contains the number of pulses that the envelope pulse will be divided into. Register 40007 contains the duration of each of the smaller pulses. This function will not be completed if the envelope pulse would overlap any other pulse in the speci-

fied program and channel, or if the count and duration values would result in overlapping pulses within the envelope pulse.

Once the registers have been loaded, bring the special purpose coil number 315 from '0' to '1'. The command will be acknowledged when pulse programming is complete. Special purpose coil number 315 must be made '0' before this function can be used again.

EEPROM Clearing

40001: 1 (Pulse Copy) 40002: Program number. 40003: Channel number. 40004: Beginning on value of pulse envelope. 40005: Ending off value of pulse envelope 40006: Number of pulses within envelope. 40007: Duration (width) of each pulse within envelope.

This function will clear various areas of EEPROM memory. Register Use:

6-26 Communications

40001: -3 (EEPROM Clearing) 40002: EEPROM Clearing Function Number:

7000: Clear all EERPOM memory. 7001: Clear configuration memory. 7002: Clear setpoint memory.

Page 99

Controller Diagnostics

CAUTION

Status LED The yellow Status LED on the controller, Figures 5 & 6, blinks in various patterns to

The controller cannot be repaired in the field. If a unit fails, do not disassemble it. Return it to the factory for replacement.

indicate the controller status.

Normal Operation

The Status LED blinks on and off rapidly.

Keypad Not Connected

If the controller is powered without a keypad connected, the LED blinking pattern will be “off” for one second, followed by four quick “on” blinks.

Internal Errors

If the LED blinking pattern is “on” for a second, followed by one or more quick blinks “off,” the controller is experiencing internal errors. The specific error is indicated by the number of “off” blinks:

One “Off” Blink—Corrupt RAM Two “Off” Blinks—Checksum error indicating EPROM corruption. Three “Off” Blinks—System error. Four “Off” Blinks—System error.

If any of the above four patterns occur, power cycle the control. If the pattern occurs again, remove the controller from service and return it to the factory.

Five “Off” Blinks—Internal error; possibly noise problems. Six “Off” Blinks—Internal error; possibly noise problems.

If either of these two patterns occur, check for loose connections and fix any obvious noise problems. If the problem persists, remove the controller from service and return it to the factory.

7-1 Troubleshooting

Page 100

Keypad Diagnostics

CAUTION

Keypad Fault LED If the Fault LED on the keypad lights, turn the controller off and back on. If the keypad

Keypad Diagnostics The 6400 Keypad includes a series of diagnostics that show the status of various key-

The keypad cannot be repaired in the field. If a unit fails, do not disassemble it. Return it to the factory for replacement.

Fault LED does not go off, the keypad microprocessor has malfunctioned. Return the keypad to the factory.

pad functions. To start the diagnostics, turn the controller off, then restart the controller while pressing any key on the keypad.

Unique key ID# appears here when any key is pressed.

15 REV 1.00 CS:024B 07APR94

FAULT LED

PROGRAM ENABLE

Keypad software revision #. Keypad software revision date. Keypad checksum.

Fault LED blinks ON one second, OFF one second. Press up or down arrow to return to menu.

1 = E1 jumpered; 2 = E2 jumpered. Press up or down arrow to return to menu.

ADDRESS SWITCHES

COMM PORT

DISPLAY

KEYBOARD

Figure 34—Keypad Communications Port Test Setup

When the COMM PORT diagnostic is run with keypad terminals W, X, Y, and Z jumpered as shown, a string of “plus” signs will scroll across the display. When either jumper is removed, the scrolling will stop.

Shows keypad DIP switch address setting. Press up or down arrow to return to menu.

Tests communication. Press up or down arrow to return to menu.

Complete character set scrolls across both lines. Press up or down arrow to return to menu.

Displays unique key# for each key pressed. Press hidden key on face below HLP key to exit.

7-2 Troubleshooting

Electro CAM PS-6144 User Manual

Table of Contents

WARRANTY

Mechanical Cam Switches

Programmable Limit Switches

PS-6144 Description

Basic T erminology

General Mounting & Wiring

Mounting Dimensions

Controller Input Wiring

Output Wiring

Keypad Wiring

DIP Switch Configurations

Communications Wiring

Resolver Installation

Resolver Dimensions

Resolver Cables

Fuse Tester & Fuse Replacement

Output T ransistor Replacement

Keypad Overview

Menu T ree

Initial Programming

Analog Output

Analog Quantity

Channel Copy

Communications

Default Program

Enable Codes

Enable Options

Group Position Display

Increasing Direction

Input Status

Keyboard Quantity

Main Screen

Memory T ests

Motion ANDing

Motion Detection

Offset

Output Enable ANDing

Output Groups

Output Status

Password

Per Channel Enable

Program Copy

Program Select Mode

Pulse Copy

Rate Setup

Resolver Type

Scale Factor

Setpoint Use

Setpoints

Shaft Position

Software V ersion

Speed Compensation

Speed Comp Mode

Timed Outputs

Toggle RPM

Standard Speed Comp

Negative Speed Comp Normal speed compensation advances the setpoints in an output channel to compen-

Speed Comp Guidelines

Mode 0 Operation

Mode 1 Operation

Mode 2 Operation

Mode 3 Operation

Mode 4 Operation

Mode 5 Operation

PLµsNet II Upload/Download Program

Serial Communications Using Electro Cam Corp. Protocol (Standard 6144 Units)

Serial Commands

Supervisory Commands

Status Commands

Configuration Commands

Setpoint Commands

Display Commands

Special Commands

Error Codes

Checksum

Serial Communications Using Modbus ASCII Protocol (PS-6144-MB Units)

Data Organization

Mapping