Electro CAM PS-6144 User Manual
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)
Copyright © 2001
All Rights Reserved
Neither this document nor any part may be reproduced or transmitted in
any form or by any means without permission in writing from the publisher.
®
, PLµS®, SLIMLINE®, and PLµSNET® are all registered trademarks of
Table of Contents
Section 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
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.
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
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.
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
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
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
Mounting Dimensions
Figure 4—Mounting Dimensions
PGM:1 RPM:1500
MENU< POS: 180
2-2 Installation & Wiring
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
1
Keyed to prevent accidental insertion into wrong sockets.
-
1
2-3 Installation & Wiring
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
1
Keyed to prevent accidental insertion into wrong sockets.
Transistor outputs #1–8, sourcing PS-9006-0021
Transistor outputs #9–16, sourcing PS-9006-0022
-
1
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
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
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
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
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
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
-
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
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
Bk
Rd Bk
Programming Enable, Sourcing
Keypad
Terminal Block
Keypad
Terminal Block
--
Bk Wh Bk Gn
Rd Bk
Programming Enable, Sinking
-
-
Bk
Wh Bk
Rd Bk
Gn
2-12 Installation & Wiring
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
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
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
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
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
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
GR
Black
BK
Red
RD
Black
BK
White
WT
Black
BK
Shield
SH
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)
A
B
C
J
XX
E
D
= Not Used
X
H
X
G
K
X
F
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
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
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
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
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
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
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
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