Electro CAM PS-6244 User Manual

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PLµS™ PS-6244 Series

Programmable Limit Switch

PGM:1 RPM:1500 MENU< POS: 180

Programming &

Installation Manual

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13647 Metric Rd • Roscoe, IL 61073 U.S.A. • 815-389-2620 • FAX 815-389-3304 • 800-228-5487 (USA & Canada)

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

1-2 Introduction

Table of Contents

Section 1—Introduction

Mechanical Cam Switches .............1-5

Programmable Limit Switches........1-5

PS-6244 Description ......................1-6

Basic Terminology..........................1-7

PS-6244 Features ..........................1-8

Section 2—Installation & Wiring

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

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

Terminals & Components

PS-6244-17 ...............................2-3

PS-6244-25 ...............................2-4

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

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

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

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

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

Encoder Wiring...............................2-16

Fuse Tester & Fuse Replacement..2-17

Output Transistor Replacement......2-18

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

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

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

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

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

Increasing Direction...................3-10

Input ANDing .............................3-11

Input Status ...............................3-11

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

Main Screen ..............................3-12

Memory Tests............................3-13

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

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

Section 3—Programming Continued

Offset.........................................3-15

Output Status ............................3-16

Password...................................3-16

Per Channel Enable ..................3-17

Program Copy ...........................3-18

Program Select Mode................3-18

Pulse Copy ................................3-19

Rate Setup ................................3-20

RPM Update Rate .....................3-21

Scale Factor ..............................3-21

Setpoint Use..............................3-22

Setpoints ...................................3-22

Shift Position .............................3-23

Shift Register ANDing ...............3-24

Software Version .......................3-26

Speed Compensation................3-27

Toggle RPM ..............................3-28

Section 4—Troubleshooting

Controller Diagnostics ....................4-1

Keypad Diagnostics .......................4-2

Encoder Troubleshooting ...............4-3

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

Fuse Part Numbers ........................4-6

Section 5—Speed Compensation

Introduction to Speed Comp ..........5-1

Standard Speed Comp...................5-2

Leading/Trailing Speed Comp........5-4

Negative Speed Comp ...................5-5

Speed Comp Guidelines ................5-6

Section 6—PluSNET II™ Communications

Appendix

Controller Specs.............................A-1

Module Specs ................................A-2

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

Index ..................................................I-1

Form to Record Setpoints

1-3 Introduction

WARRANTY

1. Electro Cam Corp. warrants that for a period of twelve (12) months from the date of shipment to the original purchaser, its ne w product to be free from defects in material and workmanship and that the product conforms to applicable drawings and specifications approved by the Manufacturer. This warranty period will be extended on Distributor or OEM orders to a maximum of eighteen months to take into consideration Distributor or OEM shelf time.

2. The remedy obligations of Electro Cam Corp. under this w arranty are e xclusive and are limited to the repair, or at its option, the replacement or refund of the original purchase price of any new apparatus which proves def ective or not in conf ormity with the drawings and specifications. Shipment of the claimed defectiv e product to Electro Cam Corp. shall be at the cost of the consumer. Shipment of the repaired or replacement product to the consumer shall be at the cost of Electro Cam Corp. All claims must be made in writing to Electro Cam Corp., 13647 Metric Road, Roscoe, IL 61073 USA.

3. In no event, and under no circumstances, shall Electro Cam Corp. be liable for: a. Any product damaged or lost in shipment. Inspection for damage should be made before

acceptance or signing any delivery documents releasing responsibility of the delivering carrier.

b. Product failure or damages due to misuse abuse, improper installation or abnormal condi-

tions of temperature, dirt or other contaminants as determined at the sole discretion of Electro Cam Corp.

c. Product failures due to operation, intentional or otherwise, above rated capacities as deter-

mined at the sole discretion of Electro Cam Corp.

d. Non-authorized expenses for removal, inspection, transportation, repair or rework. Nor shall

the manufacturer ever be liable for consequential and incidental damages, or in any amount greater than the purchase price of the equipment.

4. There are no warranties which extend be yond the description on the f ace hereof. This warranty is in LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED INCLUDING (BUT NOT LIMITED T O) ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ALL OF WHICH ARE EXPRESSLY DISCLAIMED. Any legal proceeding arising out of the sale or use of this apparatus must be commenced within (18) months of the date of shipment from the manufacturer.

1-4 Introduction

Mechanical Cam Switches

Mechanical Cams The PS-6244 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-6244’s & Encoders The PS-6244 Programmable Limit Switch uses a quadrature encoder (Figure 2) in-

stead of a cam to indicate machine position. A quadrature encoder uses optical discs to generate streams of pulses that can be processed by the PS-6244. From the encoder signals, the PS-6244 can determine shaft position, direction, and speed. The encoder is usually coupled to a machine shaft at a 1:1 ratio so that one encoder shaft rotation corresponds to one machine cycle. Encoders have no brushes, contacts, or any frictional moving parts to wear out.

Based on the encoder signal, the PS-6244 Programmable Limit Switch turns electrical circuits, or “Outputs,” on and off, simulating the mechanical roller limit switch. Because the combination PS-6244/encoder 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 1500 RPM.

1-5 Introduction

Programmable Limit Switches

Figure 2—PS-6244-24-N16M09 Programmable Limit Switch and Quadrature Encoder

Typical Quadrature Encoder (BEI H25D shown)

Controller

PS-6400 Keypad/Display

PS-6244 Description

Controller & Keypad PS-6244 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.

Figure 3—PS-6244 Models

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 4X standards. A clear silicon rubber boot assembly is available to provide protection for installations where harsh washdown chemicals are used.

The PS-6244 Series is available in two models: the PS-6244-24-M17 and the PS-624424-X16M09 Both are described in Figure 3.

PS-6244-24-N16M09 Controller—Up to 25 OutputsPS-6244-24-M17 Controller—Up to 17 Outputs

The PS-6244-24-M17 has 17 total outputs:

• Outputs 1 through 15 can accept AC or DC output modules for driving “real world” devices such as solenoids, valves, or glue guns.

• Output 16 will accept an AC or DC module, or an analog module that generates a control signal proportional to RPM.

• Output 17 is dedicated to analog output.

1-6 Introduction

The PS-6244-24-N16M09 has 25 total outputs:

• 16 transistor outputs are built into the controller.

• Outputs 17 through 23 can accept AC or DC output modules for driving “real world” devices such as solenoids, valves, or glue guns.

• Output 24 will accept an AC or DC module, or an analog module that generates a control signal proportional to RPM.

• Output 25 is dedicated to analog output.

Basic T erminology

The following terms will be used throughout this manual to explain PS-6244 installation, programming and operation:

Outputs (channels) An “output,” or “output channel,” refers to an external circuit that the PS-6244 controls

based on encoder position or speed. Outputs can be one of two types:

Switching outputs turn circuits on or off. Analog outputs generate a control signal that is proportional to RPM.

Setpoints “Setpoints” are the points within one rotation of the encoder at which an output channel

turns on or off. Setpoints can be programmed into an output channel through the keypad/display, or they can be downloaded from a computer or PLC through serial communications. The PS-6244 can turn any given output on and off multiple times within one rotation.

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

point is the leading edge of the pulse, and the “off” point is the trailing edge. When multiple “on” and “off” points are programmed into one output channel, the output 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.” Then, the 15 output channels could 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.

The use of programs can provide tremendous advantages over mechanical cam switches. Standard PS-6244’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 encoder, the PS-6244 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-6244 hardware inputs are dedicated to specific functions involving program selection and controlling output channels based on sensor signals.

1-7 Introduction

PS-6244 Features

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.

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

increases. This eliminates the need to manually adjust the settings for fixed-response devices whenever 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 output channels can be

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

Input ANDing An output channel may be ANDed with one of eight input signals so that the output is

disabled unless the input signal is present.

Shift Register ANDing The PS-6244 includes a shift register that can turn output channels on or off up to 255

revolutions after a signal is applied to Input Terminal 16, Figure 7. The terminal is usually connected to a product sensor.

Analog Outputs PS-6244 controllers can drive up to two analog output modules whose output signal 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-6244.

Serial Communication Using Electro Cam Corp.’s PLuSNET software for IBM-PC compatible computers, the

PS-6244’s programs can be saved to a disk file or loaded from a disk file to the PS-

6244. The programs can be printed or edited using the computer. Individual commands may also be sent to the PS-6244 to change settings while running.

Washdown Boot A clear silicon rubber boot can be supplied that fits over and around the keypad face.

The back of this boot provides sealing between the back of the keypad and the panel. The boot is transparent and pliable, allowing the keypad to be viewed and operated through it. In addition to preventing contamination from harsh chemicals, the boot also protects the keypad from grease, oil, dirt and normal wear that could otherwise shorten its life.

1-8 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 +32° to +130° F (0° to +55°C)

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 encoder, 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-6244 end only (except for encoder 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 TB8 (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

However, 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-6244-24-M17

Figure 5—PS-6244-24-M17 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 Encoder connector PS-9006-0032 TB 5 Keypad 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

Terminals & Components—PS-6244-24-X16M09

Figure 6—PS-6244-24-X16M09 Terminals & Components

Top View

Yellow

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 Encoder connector PS-9006-0032 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

Controller Input Wiring

Input Terminals Hardware inputs can be used to select a program of setpoints, disable keypads, accept

sensor signals, or clear the shift register. The 16 inputs on the PS-6244 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 Following are the input terminals and their corresponding functions:

Channel Enable (1-8)

These terminals accept signals from sensors or from PLC’s. Each output channel on the 6244 can be ANDed with any one of these inputs so that the output is enabled only when a signal is present on the input terminal.

Program Select (9-13)

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. Although standard controllers can store up to 48 programs, not all of these programs can be selected through the Program Select terminals.

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

Shift Register Clear (14)

A signal on this terminal will completely clear the shift register for all output channels.

Keypad Disable (15)

When energized, this terminal disables any keypads connected to the controller. If the controller will be used without any keypads, jumper this terminal so that it is always energized.

Shift Register Input (16)

The leading edge of a signal on this terminal sets a bit in the shift register. See SHIFT REGISTER ANDING for details.

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 Channel Enable

9-13 Program Select

14 Shift Register Clear 15 Keypad Disable 16 Shift Register Input

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 Program Select Table

The BCD format allows standard 1- or 2-digit BCD switches to operate the program select inputs. PLC’s can also output values in BCD. The program number selected can be calculated by adding up the values associated with each of the input terminals that are on. For example, if Input Terminals 9, 11 and 13 are on, Program 15 would be active (10 + 4 + 1).

Please Note:

• Although the PS-6244 can store up to 48 programs, only Programs 1 through 19 can be selected using BCD input. A value larger than 19 will select Program 19.

• Only one of the normal four BCD digits for 10’s is 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.

Binary Program Select Table

The binary format is convenient for PLC program select output signals. The program number selected can be calculated by adding up the values associated with each of the input terminals that are on. For example, if input terminals 9, 11 and 13 are on, program number 21 would be active (16 + 4 + 1).

Please Note:

• Although the PS-6244 can store up to 48 programs, only Programs 1 through 31 can be selected using binary input. A value larger than 31 will select Program 31.

Gray Code Select Table

Input Term: 13 12 11 10 9

Value: 10 8 4 2 1

PGM

Default 0 0 0 0 0

100001 200010 300011 400100 500101 600110 700111 801000 901001

Input Term: 13 12 11 10 9

Value: 16 8 4 2 1

PGM

Default 0 0 0 0 0

1 00001 2 00010 3 00011 4 00100 5 00101 6 00110 7 00111

8 01000

9 01001 10 01010 11 01011 12 01100 13 0 1 1 0 1 14 01110 15 01111

UNITS10's 10'sUNITS

Input Term: 13 12 11 10 9

Value: 10 8 4 2 1

PGM

10 10000 11 10001 12 10010 13 1 0 0 1 1 14 10100 15 10101 16 10110 17 10111 18 11000 19 11001

Input Term: 13 12 11 10 9

Value: 16 8 4 2 1

PGM

16 1 0 0 0 0 17 10001 18 10010 19 10011 20 10100 21 10101 22 10110 23 10111

24 11000 25 11001 26 11010 27 11011 28 11100 29 1 1 1 0 1 30 11110 31 11111

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

Please Note:

• Although the PS-6244 can store up to 48 programs, only Programs 1 through 31 can be selected using gray code input. A value larger than 31 will select Program 31.

Input MSB LSB Term: 13 12 11 10 9

PGM

Default 0 0 0 0 0

100001 200011 300010 400110 500111 600101 700100

801100

901101 10 0 1 1 1 1 11 0 1 1 1 0 12 0 1 0 1 0 13 0 1 0 1 1 14 0 1 0 0 1 15 0 1 0 0 0

Input Term: 13 12 11 10 9

PGM

16 11000 17 11001 18 11011 19 11010 20 11110 21 11111 22 11101 23 11100

24 10100 25 10101 26 10111 27 10110 28 10010 29 10011 30 10001 31 10000

MSB LSB

2-7 Installation & Wiring

Output Wiring

Output Types The outputs available depend on the PS-6244 Model:

Output Model Model Type 6244-24-M17 6244-24-X16M09

Transistor None Outputs 1-16 AC/DC/RR Modules Only Outputs 1-15 Outputs 17-23 AC/DC/RR or Analog Modules Output 16 Output 24 Analog Modules Only Output 17 Output 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 encoder 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-6244-25 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-6244-24-M17

PS-6244-24-X16M09

AC Output

• When other switching devices are in series or parallel with the AC output module, connect a varistor (MOV) across the terminals to prevent module damage from inductive voltage spikes.

• Output modules act like switches; they do not supply power to loads.

Analog Output

• Analog output modules source the analog signal.

• No external supply is required.

• Analog output signals are isolated.

DC Output

Sourcing

Sinking

• Suppress spikes in inductive DC loads with one of the following methods:

Connect a zener diode across the terminals. Turn off time will not be significantly affected. Voltage rating of diode must be greater than the normal circuit voltage. 50 VDC Zener, #EC-9001-5369; 200 VDC Zener, #EC-9001-5388.

Connect a reverse-biased diode across the load. This will increase the turn off time of the load. #EC-9001-4004.

2-9 Installation & Wiring

Output Wiring (cont’ d)

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

Model PS-6244-24-N16M09

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-6244-24-P16M09

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.”

2-11 Installation & Wiring

Keypad Wiring

Number of Keypads One or two keypads may be connected to a PS-6244 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

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-6244 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-6244)

RS-232 Cable Wiring

DB-9 (Host) to DB-9F (PS-6244)

2-15 Installation & Wiring

Encoder Wiring

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

nection of the encoder shaft to the machine. The encoder is normally driven at a 1:1 ratio to machine cycles, but this is not true in all applications. Commonly used methods for driving the encoder shaft include flexible couplings, timing belts and pulleys, chains, and sprockets. Insure that the coupling method used is tight enough to minimize backlash without placing excessive side load on the encoder shaft.

If possible, select a location that shelters the encoder from accidental mechanical abuse, lubricants, wash down chemicals or any other liquids.

Encoder Wiring Use shielded cable for wiring the encoder to the PS-6244 controller.

Figure 16—Encoder Connector Wiring

10-Pin Weidmiller TB4

654321

Pin Connection

1 +ENC 2 VREF 3A 4–A 5B 6–B 7Z 8–Z 9 COM

10 Shield

G-+

ñ+Y

2-16 Installation & Wiring

TB4 is EC part# PS-9006-0032. It is keyed to prevent accidental

insertion into the wrong sockets.

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-6244 controllers are shipped with a spare 4A fuse mounted in the test socket.

Figure 17—TR5 Fuse Tester and Fuse Locations

PS-6244-24-M17 PS-6244-24-X16M09

Replacement TR5 Fuse Part Numbers

Rating Function ECC Part # Wickmann Part #

250 mA Power for Inputs (TB 2) PS-9005-0250 1937-035

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

2-17 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-6244-24-N16M09

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-6244-24-P16M09

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 2580 first.

• Replace 2803A if that doesn’t work.

Position Notches Like This

Chips for Outputs 1–8

• Replace 2580 first.

• Replace 2803A if that doesn’t work.

2-18 Installation & Wiring

Replacement Part Numbers

Description ECC Part #

UDN 2580 PS-9011-2580 ULN 2803A PS-9011-2803 DIP Jumper Block PS-9006-0015

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. Using the MOTION ANDING screen, each output channel can be ANDed with either

Motion Level. ANDed outputs will be enabled only when the encoder 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.

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

RPM.

MOTION LEVEL: 1 LO: 30 HI: 1500

Low RPM setpoint

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

RPM.

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.

See Also DEFAULT PROGRAM

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

3-18 Programming

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 encoder 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<

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

  DURATION: 35   COMPLETE<

Example Generate a train of pulses for a Krones Label Check Unit 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

COMPLETE indicates pulses have been generated

3-19 Programming

Pulse Copy (cont’d)

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

  PROGRAM:---<   

  CHANNEL:---<

ON: 0<

 OFF:950<

 COUNT 10<

 DURATION: 50<

  DURATION: 50   EXECUTE<

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 0, then ENT & SEL to go to next screen

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

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

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

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 generated

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

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.

The Main Screen can display the encoder speed in units of Revolutions Per Minute (RPM), Bags Per Minute (BPM), or Cartons Per Minute (CPM). The encoder speed can also be displayed as .5X, 1X, 2X, or 3X actual RPM.

Screen

MPY: 1< DP: 0 DIV: 1 RPM

Multiplier: 0 through 1091

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

Units: RPM, BPM, CPM, IPM

Divider: 1 through 63

3-20 Programming

Rate Setup (Cont'd)

SCALE FACTOR: 360<

Number of increments each revolution is broken into

RPM UPDATE RATE: 1/S<

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

Press the SEL key to toggle display mode or rate. Following is a chart summarizing the relationships between encoder speed, units, and rate multiplier:

If And Then an Is Units Rate Encoder Displayed Are… Is… Speed Of… As…

RPM .5X 100 RPM 50 RPM

1X 100 RPM 100 RPM 2X 100 RPM 200 RPM 3X 100 RPM 300 RPM

BPM .5X 100 RPM 50 BPM

1X 100 RPM 100 BPM 2X 100 RPM 200 BPM 3X 100 RPM 300 BPM

CPM .5X 100 RPM 50 CPM

1X 100 RPM 100 CPM 2X 100 RPM 200 CPM 3X 100 RPM 300 CPM

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 The Scale Factor screen displays the number of increments into which one encoder

revolution is divided. For the PS-6244 special unit, Scale Factor is fixed at 1000.

3-21 Programming

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 programmin 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 channel

<-P-> CH:1<EDG ON: 90 OF: 270

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

• CHN 91 is a special channel used for shift register functions. See “Shift Register ANDing” for details.

Program to view or modif

Pulse mode OFF setpoint

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.

• 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

3-22 Programming

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

Setpoints (cont’d)

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 you enter overlap an existing pulse in the channel, you will see an “Error: Pulse Overlap” message.

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.) You change the Pulse Mode by pressing the SEL key when the cursor points to the Pulse Mode.

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

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.

Shift Position

Menu Path MAIN SCREEN to SETUP MENU to SHIFT POSITION Purpose The Shift Position is the point in the encoder revolution at which the shift register data

shifts. See Shift Register ANDing for details.

SHIFT POS: 850

Programming Use INC and DEC, or the numeric keys and ENT.

Position at which Shift Register will shift.

3-23 Programming

Shift Register ANDing

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

REG ANDING

Background The shift register is a form of electronic memory that sets a “bit” in the zero count of the

register when a signal is applied to Terminal 16, Fig. 7. Afterwards, each time the encoder passes the point programmed through SHIFT POSITION, the register “shifts” the bit to the next higher count. The bit passes along the shift register until, on the 256th shift, the bit is erased.

An output channel can be ANDed with any count in the shift register, so that the channel is enabled only when a bit appears in that count. In this way, output channels can be enabled up to 255 revolutions after Terminal 16 is energized.

Zero Bit is Set

If Terminal 16 is

Energized Within

Channel 91 Window

Count:

1 2 3 4 253 254 255

Bit Shifts Up Once

Each Time Encoder

Passes Shift Position

Bit is Erased On Last Shift

Output Channels

Can Be ANDed with Any

Shift Register Count

Programming This screen allows you to enter the output channel to ANDed with the shift register, and

the shift register count that will enable it.

CHN: 1 SHIFT COUNT: 0

Output Channel to be ANDed Shift Count That Will Enable Output Channel

To select the output channel and the shift register count, use the numeric keys and ENT, or use the INC and DEC keys.

• ANDing an output channel with Count “0” is the same as turning Shift Register ANDing off. The shift register will have no affect on channel operation.

• Any number of output channels can be ANDed to a single shift register count.

• Shift Register ANDing, Input ANDing, and Motion ANDing can be combined for any given output channel.

Input Window A bit is set in Position “0” of the shift register when Terminal 16 of TB 1, Figure 7, is

energized. A special channel, Channel 91, is provided to limit the portion of an encoder revolution during which the signal will be accepted from Terminal 16. A “window” can be programmed into Channel 91 so that a bit is set in the register only if Terminal 16 becomes energized within that window.

3-24 Programming

Shift Register ANDing (cont’d)

Shift Position The point in the encoder revolution at which the register shifts data is programmed

through SHIFT POSITION. When programming Shift Position and the On/Off setpoints for a channel, remember the following:

Don’t Place the Shift Position at the Start of a Pulse

When a pulse starts at the Shift Position, as

500

Shift

Position

220

Output

Channel On at 220 Off at 290

Don’t Let Speed Comp Move a Pulse Onto the Shift Position

shown here, the pulse will be enabled as soon as a bit is shifted into the programmed shift count.

Although the output will function normally on this revolution, a small output spike may occur on the following revolution as the bit is shifted to the next shift count.

Machine at

“Zero” Speed

500

At “Zero” Speed in this example, the output turns on 100 increments after the Shift Position. However, as the machine accelerates, speed compensation advances the setpoints until they overlap the Shift Position. This may split the pulse between two machine cycles. The portion of the pulse following the Shift Position may activate during one cycle, while the portion ahead of the Shift Position may activate during the following cycle.

Shift

Position

100

Output

Channel On at 200 Off at 270

Machine at High RPM

Setpoints Advanced

By Speed Comp

500

Shift

Position

100

The Channel 91 Window is “edge sensitive” to the signal from Terminal 16. The leading edge of the signal must appear in the window for a bit to be set in the register.

Shift Register Clear Energizing Terminal 14 on TB 1, Figure 7, clears all bits from the shift register immedi-

ately.

(continued)

3-25 Programming

Shift Register ANDing (cont’d)

Edge Sensitivity of Channel 91 Window

(Channel 91 programmed “on” at 650, “off” at 750 in this example; Shift Position = 0)

Shift

Position

CHN 91

500

Terminal 16

Leading Edge

On Within Channel 91;

Bit Set at 0 In Register

Leading & Trailing Edges

Bit Set at 0 In Register

Shift

Position

500

Terminal 16

Within Channel 91;

Channel 91 Overlaps Shift Position—Not Recommended!

When Channel 91 overlaps the shift position as

shown here, two problems may occur. One Product, Two Bits: Due to variations in conditions,

sensors sometimes generate more than one pulse for a product. If the product sensor sends a pulse early in the window, that pulse will shift when the encoder reaches the shift position. If the sensor sends a second pulse for the same product after the shift position, a second bit will be set for the same product.

Inconsistent Timing: Some products may appear early in the Channel 91 window, while others appear late. For early products, a bit will be set, then immediately shifted at the shift position. For late products, a bit will be set after the shift position, and a full revolution will occur before the bit shifts to 1.

In most applications, programming Channel 91 to overlap the Shift Position will cause problems.

Shift

Position

CHN 91CHN 91

500

Terminal 16

Leading Edge

On Before Channel 91;

Bit Not Set

Channel 91

On at 900 Off at 100

Shift

Position

CHN 91

500

Terminal 16

Leading & Trailing Edges

Outside Channel 91;

Bit Not Set

First Bit Set

Shift Position

Second Bit Set

500

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.

MAJOR REV:1.75  BASE REV:1.17

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

3-26 Programming

Speed Compensation

)

Menu Path MAIN SCREEN to SETUP MENU to SPEED COMP Background Some devices such as hydraulic 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.

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.

Screen The speed compensation screen shows the Output Channel and the speed compensa-

tion value for that channel.

Output Channel

CH: 1<LE: 10.0   TE: 20.0

To change speed comp values, use the numeric keys or INC and DEC. You can enter values of speed comp in milliseconds without using the decimal point: “12 ENT” will result in a value of 12.0.

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.

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

machine position by the specified number of mSec. It is used when an input sensor is being gated, by the corresponding output channel,

into another control system (PLC, registration control, etc.) Sensor lag can cause an object that is present at the correct position in the cycle to appear late. Negative speed comp can retard the gate signal so the sensor and gate signals are in sync when the object is in the correct position.

Since most sensors have very fast response times, negative speed comp is needed only where the sensor is slow to respond or the machine speeds are high and sensor timing is critical.

It may also be used if there is mechanical "wrap up" present in the machine being controlled. Wrap up will cause machine elements to shift relative to each other as speed increases. This situation may cause an event to happen later in the cycle as the machine goes faster.

Setting Negative Comp Press the +/- key after entering a number but before pressing ENT, or by decrement a

value below zero.

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

3-27 Programming

Toggle RPM

Menu Path MAIN SCREEN to CONFIG MENU to DISPLAY MENU to

TOGGLE RPM

Purpose Toggle RPM is the encoder 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.

TOGGLE RPM: 50

This screen displays the Toggle RPM.

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



3-28 Programming

Controller Diagnostics

CAUTION

Status LED The red Status LED on the controller, Figures 5 & 6, blinks in various patterns to indi-

The controller cannot be repaired in the field. If a unit fails, do not disassemble it. Return it to the factory for replacement.

cate 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.

4-1 Troubleshooting

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

Keypad software revision #. Keypad software revision date. Keypad checksum.

FAULT LED

Fault LED blinks ON one second, OFF one second. Press up or down arrow to return to menu.

PROGRAM ENABLE

1 = E1 jumpered; 2 = E2 jumpered. Press up or down arrow to return to menu.

ADDRESS SWITCHES

COMM PORT

DISPLAY

KEYBOARD

Figure 22—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.

4-2 Troubleshooting

Encoder T roubleshooting

Encoder Type The encoder used with the PS-6244 controller is an incremental quadrature encoder.

The encoder sends three signals to the controller: A, B, and Z, as shown below in Figure 23.

Failure Symptoms Most encoder failures or wiring problems will affect the POS (position) display. Some of

the possible symptoms are listed below:

Pins 1, 2, 3, 5, 9: Failure Before Startup

Position display remains at zero.

Failure During Operation

The display will freeze on the position at the time of circuit break. If the circuit is reconnected before power is turned off, the display will resume incrementing until the zero pulse (Signal “Z”) is received, at which time the display will return to its programmed offset value.

Pin 7: Failure Before Startup

Position display remains at zero.

Failure During Operation

Operation will appear to be unaffected. However, errors in count values may accumulate, and on subsequent startup, the display will remain at zero.

Depending on the type and timing of encoder failure, the machine may continue operating normally until it is turned off. On subsequent startup, the POS (position) display may be “frozen” at zero.

Figure 23—Quadrature Encoder Signals & Controller Pin Connections

10-Pin Weidmiller TB4

Pin Connection

1 +ENC 2 VREF 3A 4–A 5B 6–B 7Z 8–Z 9 COM

10 Shield

Signal

Pulses

Function

Increments position; relationship with "B"

indicates direction.

Increments position; relationship with "A"

indicates direction.

Resets position to "0" once per revolution.

4-3 Troubleshooting

General T roubleshooting

The controller and keypad cannot be repaired in the field. If a unit fails, do not disassemble it. Return it to the factory for replacement.

Problem Possible Solution Controller & keypad dead. 1. Check main fuse shown in Figs. 5 & 6.

2. Check power supply to controller.

Keypad dead, but controller 1. Check wiring between keypad and controller, Figure 12. LED’s are on.

Keypad Fault LED “On” 1. Keypad microprocessor has malfunctioned. Turn the controller off and back on. If the

keypad Fault LED does not go off, return the keypad to the factory.

Menu operation Slow on 1. Check KEYBOARD QTY programming. If it is set for two keypads, but only one is keypad display connected, menu operation will be very slow.

COMM FAILURE—HOST TO 1. This message may flash briefly on power-up under normal conditions. KEYBOARD message 2. If the message persists, check keypad wiring connections at keypad and controller,

Figure 12.

3. Check DIP switch settings, Figures 13 & 14.

4. Be sure Input Terminal #15, Figure 7, is not energized.

Programming functions not 1. Programming not enabled. See Figure 12, and also ENABLE CODES for details. accessible.

POS (position) frozen at “0” 1. Encoder or encoder wiring may have failed. Unplug cable at encoder and plug a

spare encoder into the cable. If this solves the problem replace the encoder on the machine. If not, prepare a short encoder cable (Fig. 16), unplug the cable at the controller, and plug the short cable with spare encoder into the controller. If this solves the problem, replace the cable on the machine. See page 4-3 for more.

POS (position) moves opposite 1. Check INCREASING DIR for the correct direction of rotation. to machine direction. 2. Check encoder wiring, Figure 16.

POS (position) does not 1. Verify that OFFSET is correct. Once set, the offset value should not change. If it match machine position. does, check the encoder coupling to be sure it is not loose. Also see “Encoder Trouble-

shooting,” page 4-3. An intermittent encoder connection on controller pins 1, 2, 3, 5, or 9 might cause POS to lag the actual encoder position until the next “zero” pulse (“Z” signal) is received from the encoder.

Serial communications 1. Check COMMUNICATIONS programming to be sure type, baud rate, and address not working are correctly set.

2. Be sure the DIP switches for the PLuS-to-host communications are set correctly as shown in Figure 13.

3. Check communication cable wiring, Figure 2-15.

Outputs cycling regularly at 1. Check that the correct program number is active. incorrect machine positions 2. Check the setpoints of the output(s) in question. Also check SPEED COMP settings.

3. Verify that OFFSET is correct.

Erratic Operation 1. Run the Watchdog Timer test described under MEMORY TESTS in the programming

section of this manual.

2. See “Encoder Troubleshooting,” page 4-3.

(continued)

4-4 Troubleshooting

General T roubleshooting (cont’d)

Analog output not working. 1. Check that ANALOG QTY and ANALOG OUTPUT are programmed correctly.

2. Check that analog output module is located in the correct module position. See Figure 5 or 6.

3. Check correct wiring of analog output.

4. Verify that analog load device is within specifications for the analog module.

5. Try a different analog output module.

Some transistor outputs 1. Check that the correct program number is active. are not working. 2. Use OUTPUT STATUS to see if the controller is activating the output(s) at the correct

position in the encoder revolution. If not, verify that the SETPOINTS are correctly programmed. Other programming that may prevent an output from energizing includes MOTION ANDING, INPUT ANDING, and SHFT REG ANDING.

3. If OUTPUT STATUS shows the output is on, use a meter to see if the output terminal is energized. If so, check the load device and its wiring. If not, go to Step 4.

4. Check the transistor array chips, Figure 17.

All transistor outputs 1. Check that the correct program number is active. are not working. 2. Use OUTPUT STATUS to see if the controller is activating the output(s) at the correct

3. If OUTPUT STATUS shows the output is on, use a meter to see if the output terminal is energized. If so, check the load device and its wiring. If not, check the transistor output fuse, Figure 18. Use the fuse tester built into the controller, Figure 17.

4. Check that 10-30 VDC power is connected to TB 11, Figure 10 & 11.

AC/DC module output 1. Check that correct program number is active. not working. 2. Use OUTPUT STATUS to see if the controller is activating the output(s) at the correct

position in the encoder revolution. If not, verify that the SETPOINTS are correctly programmed. Remember that AC/DC output modules are controlled by Channels 17 through 24. Other programming that may prevent an output from energizing includes MOTION ANDING, INPUT ANDING, and SHFT REG ANDING.

3. If OUTPUT STATUS shows the output is on, but the LED on top of the module does not light, try replacing the module.

4. If the LED on the module lights but the output terminal does not energize, check the fuse built into the top of the module. Use the fuse tester built into the controller, Figure

17.

5. Check that load power is present in the circuit and correctly wired. Remember that modules do not supply power to loads; they simply switch the load circuit on and off.

4-5 Troubleshooting

Fuse Part Numbers

Fuse Description Mfct. Part # Electro Cam Part #

Main Fuse (Figs. 5 & 6) .........................1-1/4 Amp Slo-Blo Glass .... Bussman MDL-1-1/4 ....... PS-9000-4114

Module Fuse.......................................... 4 Amp TR-5........................ Wickmann 19370-K......... PS-9005-0004

Input Fuse (Fig. 17) ............................... 250 mA TR-5 ...................... Wickmann 1937-035 ....... PS-9005-0250

Output Transistor Fuse (Fig. 17) ......... 1 Amp TR-5 ........................ Wickmann 19370 ............ PS-9005-0001

4-6 Troubleshooting

Introduction To Speed Compensation

What Is It? “Speed compensation” refers to the ability of the PS-6244 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, speed compensation can often increase line speeds by as much as 50%.

• Reduced Scrap Rate—Speed compensation maintains the accuracy of critical oper-

ations 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. To perform speed compensation at high machine speeds, the PLC hardware must be extremely fast, and therefore expensive. Integrating a PS-6244 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-6244, 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.

Example Figure 24 on the next page illustrates a simple carton gluing application. A conveyor

moves cartons under 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

5-1 Speed Compensation

Standard Speed Comp (cont’d)

Calculation (cont’d) In the previous example, 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 25 below.

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-6244 will automatically advance the setpoints to maintain the accuracy of the glue bead position.

CAUTION

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!

Figure 24—Simple Application Using Speed Compensation

Figure 25—Speed Compensation at Various Speeds

5-2 Speed Compensation

Standard Speed Comp (cont'd)

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

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.

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

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 26. Convert this ratio to response time and enter it as the speed compensation value.

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 26—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, this shaft would require (0.05/0.006), or

8.3 msec to rotate 0.05°. The speed compensation value is 8.3.

5-3 Speed Compensation

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-6244 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.

Once the second pair of setpoints is established, calculate separate leading and trailing edge speed comp values as shown in Figure 27 on the next page.

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 28—Simple Sensor Gating Scheme

5-4 Speed Compensation

Leading/Trailing Speed Comp (cont’d)

Figure 27—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.

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 28 on the preceeding page 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-6244’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 on programming negative speed comp.

5-5 Speed Compensation

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 29 below 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.

Figure 29—Product Speed Should be Constant Past Controlled Device

5-6 Speed Compensation

PLµSNet II Upload/Download Program (Must use version 2.34 or higher)

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 re-enter 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) Vinyl diskette holder with two diskettes: One containing the PLUSNET.EXE

file, one to store uploaded files.

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

PLuSNET II Program (cont’d)

Sample ASCII Program Copied from PS-6244 Using PLuSNET II

2: 6244 ;Model 3: 197 ;Firmware revision 4: 24 ;Output quantity 5: 5,1 ;Option: -H; High resolution 5: 7,1 ;Option: -A; Analog output 6: 1 ;Default Program 7: 1,400,400 ;Speed comp (.1mS): chn, leading, trailing 7: 3,350,350 ;Speed comp (.1mS): chn, leading, trailing 7: 6,100,100 ;Speed comp (.1mS): chn, leading, trailing 9: 1,90 ;Offset: group#, offset 11: 1,10,3000 ;Motion detection: level#, low rpm, high rpm 11: 2,10,200 ;Motion detection: level#, low rpm, high rpm 16: 1 ;Keyboard quantity 17: 1 ;Direction of increasing rotation: 0=CCW, 1=CW 18: 1000 ;Scale factor 19: 0 ;Shaft offset 20: 0 ;Analog quantity 21: 0 ;Resolver type: 0=ECC, 1=Other 22: 1 ;Program select mode: 0=bin, 1=BCD, 2=Gray 24: 0 ;Time base: 0=1mS, 1=.5mS, 2=.2mS 25: 1,1 ;Termination resistors: grp1 on/off, grp2 on/off 27: 1,1,0,0 ;Rate setup: mpx, div, dec pt, units 28: 50 ;Toggle rpm 29: 1 ;Rpm update rate: 0=1/Sec, 1=2/Sec, 2=10/Sec 30: 0 ;Speed comp mode: 0=Single, 1=L/T 31: 0 ;Group pos display mode: 0=Each, 1=One 32: 1 ;Operator ID number 33: 2 ;Setup ID number 34: 3 ;Master ID number 35: 1;1,1,1,1,1,1,1,1 ;Per chn enable: chns 1-8; chn on/off 35: 2;1,1,1,1,1,1,1,1 ;Per chn enable: chns 9-16; chn on/off 35: 3;1,1,1,1,1,1,1,1 ;Per chn enable: chns 17-24; chn on/off 35: 4;0,0,0,0,0,0,0,0 ;Per chn enable: chns 25-32; chn on/off 36: 1 ;Operator enable: Setpoints 37: 1 ;Operator enable: Default program 38: 1 ;Operator enable: Speed comp 39: 1 ;Operator enable: Timed outputs 40: 1 ;Operator enable: Offsets 41: 1 ;Operator enable: Motion detection 43: 1;0,1,2,0,0,0,0,0 ;Motion ANDing: chns 1-8; chn levels (0=none) 43: 2;0,0,0,0,0,0,0,0 ;Motion ANDing: chns 9-16; chn levels (0=none) 43: 3;0,0,0,0,0,0,0,0 ;Motion ANDing: chns 17-24; chn levels (0=none) 43: 4;0,0,0,0,0,0,0,0 ;Motion ANDing: chns 25-32; chn levels (0=none) 45: 1 ;Output group quantity 46: 1,24,0 ;Output group config: group, #chns, mode 47: 1 ;Enable input quantity 49: 1,1,0,90 ;Pulse: pgm, chn, on, off 49: 1,2,0,90 ;Pulse: pgm, chn, on, off 49: 1,3,0,90 ;Pulse: pgm, chn, on, off 49: 1,4,0,90 ;Pulse: pgm, chn, on, off 49: 1,5,0,90 ;Pulse: pgm, chn, on, off 49: 1,6,0,90 ;Pulse: pgm, chn, on, off 49: 1,7,0,90 ;Pulse: pgm, chn, on, off 49: 1,8,0,90 ;Pulse: pgm, chn, on, off 49: 1,9,0,90 ;Pulse: pgm, chn, on, off 49: 1,10,0,90 ;Pulse: pgm, chn, on, off 49: 1,11,0,90 ;Pulse: pgm, chn, on, off 49: 1,12,0,90 ;Pulse: pgm, chn, on, off 49: 1,13,0,90 ;Pulse: pgm, chn, on, off 49: 1,14,0,90 ;Pulse: pgm, chn, on, off 49: 1,15,0,90 ;Pulse: pgm, chn, on, off 49: 1,16,0,90 ;Pulse: pgm, chn, on, off 49: 1,17,0,90 ;Pulse: pgm, chn, on, off 49: 1,18,0,90 ;Pulse: pgm, chn, on, off 49: 1,19,0,90 ;Pulse: pgm, chn, on, off 49: 1,20,0,90 ;Pulse: pgm, chn, on, off 49: 1,21,0,90 ;Pulse: pgm, chn, on, off 49: 1,22,0,90 ;Pulse: pgm, chn, on, off 49: 1,23,0,90 ;Pulse: pgm, chn, on, off 49: 1,24,0,90 ;Pulse: pgm, chn, on, off

NOTE: Some functions may be listed on printout that are not actually in the unit.

6-2 Communications

PS-6244-24-N16M09 Controller Specs

Electrical

Input Voltage 20 - 30 VDC. Keypad/display is powered from controller. Input Current 500 mA maximum (control only) Power Consumption: 35 VA Permanent Memory: EEPROM (no battery required) Accessory Power Out: 20 - 30 VDC, 250 mA Max (same source and voltage as input power) Safety Compliance: Listed to UL 508 industrial control equipment, file E151636

Environment

Operating Temp: 32° to 131° F (0° to +55° C) Storage Temp: -40° to 160° F (-40° to +7 0° C) Humidity: 95% maximum relative non-condensing UL/NEMA Rating: Keypad/display: 1, 4, 4X, or 12 enclosure

Physical

Overall Dimensions: See Figure 4 Weight: Controller: 3.5 lbs (1.6 kg). Keypad/Display: 0.5 lbs. (0.2 kg)

Mounting

Controller: Brackets accept EN-50035 (“G” profile) or EN-50022 (“Top Hat” profile) DIN rail. Keypad/Display: May be mounted up to 1000' from controller. Multiple keypads may be connected to one

controller.

Inputs

DC Inputs: 8 sinking or sourcing DC inputs, optically isolated. Input On State Voltage: 10-30 VDC Input Current: 11 mA @ 24 VDC Program Select Response: 100 msec (hardware response plus processing time)

Response of All Other Inputs: 1 msec

Outputs

DC (Transistor) Outputs: Outputs #1 through #16 are sinking, optically isolated. Real World Outputs: Outputs #17 through #24 may be any mix of AC, DC, or reed relay Slimline modules. Output

#24 may also be a Slimline analog module. Output #25 must be a Slimline analog module. All modules optically isolated.

Analog Output

Output Types: 4-20 mA or 0-10 VDC, proportional to RPM. Resolution: 12 bit Update Frequency: 10 times/sec (100 msec) Linearity: ±0.2% @ 77° F (25° C) Set-up: Offset & full scale RPM are programmable.

Operation

Scan Time: 100-250 microseconds (exact time determined by programming) Position Resolution: 1000 increments Speed Compensation: Programmed in 0.1 msec steps. 16 individually compensated outputs max. Updated ten times

per second. Multiple Programs: 48 programs Total Pulse Memory: 926 pulses Pulses per Program: 512 maximum Pulses per Output: 512 maximum Maximum Speed: 3000 RPM

A-1 Appendix

SLIMLINE Output Module Specifications

AC Outputs Part # EC-OAC240-3

Output Voltage: 24 to 280 VAC Output Current: 3 Amps cont. up to 113° F

1 Cycle Surge: 80 Amps peak Turn On Time: Random (Not 0 Cross) Turn Off Time: 0 Cross (max time: 1/2 cycle) Off State Leakage: 2 mA max Output Voltage Drop: 1.6 Volts max Operating Temp. –22° to +158° F

DC Output, 60 VDC Part # EC-ODC060-3

Output Voltage: 0 to 60 VDC Output Current: 3 Amps cont. up to 113° F

1 Second Surge: 5 Amps Turn On Time: 40 Microseconds Turn Off Time: 140 Microseconds Off State Leakage: 1 uA typical Output Voltage Drop: 1.6 Volts max Operating Temp. –22° to +158° F

2 Amps cont. @ 158° F

DC Outputs, 200 VDC Part # EC-ODC200-1 (Slimline)

Output Voltage: 0 to 200 VDC Output Current: 1 Amp cont. up to 113° F

.5 Amps cont. @ 158° F 1 Second Surge: 5 Amps Turn On: 40 Microseconds Turn Off: 140 Microseconds Off State Leakage: 1 uA typical Output Voltage Drop: 1.6 Volts max Operating Temp. –22° to +158° F

Transistor Outputs Part # PS-9011-2803 (ULN 2803A)

Output Type: Current Sinking (NPN) Output Voltage: 5–30 VDC Output Current: 50 mA cont. max (each output) Input Voltage: 10–30 VDC

Analog Output, 0-10 VDC Part # EC-SANL-010V

Resolution: 12 Bits (4096 Increments) Output Voltage: 0-10 VDC Output Current: 5 mA Max Output Type: Isolated Load Resistance: 2 K Ohm min. Linearity: ±0.2% @ 77° F (25° C)

Analog Output, 4-20 mA Part # EC-SANL-420M

Resolution: 12 Bits (4096 Increments) Output Voltage: 4-20 mA Output Current: 20 mA Max Output Type: Isolated Load Resistance: 275 Ohm max. Linearity: ±0.2% @ 77° F (25° C)

A-2 Appendix

Factory Defaults

Analog Outputs

Quantity: 0 Offset: 0 High RPM: 2000

Communications

Type: RS-485

Baud Rate: 9600 Default Program: 1 Enable Codes

Operator: 1

Setup: 2

Master: 3 Enable Options: ON for all functions Increasing Direction: CCW Input ANDing: OFF Keyboard Quantity: 1 Motion ANDing: OFF Motion Detection: Lo 10 RPM, Hi 3000 RPM both levels Offset: 0 Per Channel Enable: All channels ON Program Select Mode: BIN (Binary) Rate: 1X, RPM RPM Update: 1/S Shift Position: 0 Shift Reg. ANDing: OFF Speed Comp: All channels 0 Toggle RPM: 20 RPM

A-3 Appendix

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A-4 Appendix

Index

Entries in ALL CAPS are programming functions which are arranged alphabetically in Section 3.

Absolute Offset ....................................................... 3-15

Access Codes, Entering.......................................... 3-16

Access Codes, Programming.................................... 3-8

Access Levels ................................. 1-8, 2-12, 3-8, 3-10

Active Program................................................. 3-7, 3-12

Address, DIP Settings ............................2-13, 2-14, 4-2

Address, Programming ............................................. 3-6

Analog High RPM...................................................... 3-4

Analog Modules, Mounting........................................ 2-9

Analog Modules, Specifications ................................A-2

Analog Offset ............................................................ 3-5

ANALOG OUTPUT ................................................... 3-4

Analog Outputs, Intro ................................................ 1-8

ANALOG QTY........................................................... 3-5

Baud Rate................................................................. 3-5

BCD Program Select................................................. 2-7

Binary Program Select .............................................. 2-7

Boot, Washdown ....................................................... 1-8

Channel 91, Shift Register Window........................ 3-22

Channel Enable Input Terminals........................2-5, 2-6

CHN 91, Shift Register Window ..............................3-22

Clear Memory.......................................................... 3-13

Codes, Access .......................................................... 3-8

Communications, Address DIP Settings ........2-13, 2-14

Communications, Baud Rate .................................... 3-5

Communications, Intro .............................................. 1-8

Communications, Programming................................ 3-5

Communications, RS-232/RS-485 .......................... 2-15

Communications, Termination DIP Settings ..2-13, 2-14

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

Components, Layout .......................................... 2-3, 2-4

Controller Diagnostics ............................................... 4-1

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

DEFAULT PROGRAM.............................................. 3-7

Defaults, Factory Settings .........................................A-3

Diagnostics, Controller ..............................................4-1

Diagnostics, Keypad ................................................. 4-2

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

DIN Rail..................................................................... 2-2

DIP Switches, Controller ................................2-13, 2-14

DIP Switches, Keypad.................................... 2-13, 2-14

Direction of Rotation................................................ 3-10

Display, Testing......................................................... 4-2

ENABLE CODES...................................................... 3-8

ENABLE OPTIONS................................................. 3-10

Encoder Direction.................................................... 3-10

Encoder Troubleshooting .......................................... 4-3

Encoder Wiring........................................................ 2-16

Environment, Mounting ............................................. 2-1

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

Fault LED, Keypad .................................................... 4-2

Function 7000 ......................................................... 3-13

Function 7001 ......................................................... 3-13

Function 7002 ......................................................... 3-13

Function 7998 ......................................................... 3-13

Fuse Locations...................................................2-3, 2-4

Fuse Part #’s ..................................... 2-3, 2-4, 2-17, 4-5

Fuse Tester ............................................................. 2-17

Gray Code Program Select ...................................... 2-7

Hardware Inputs ....................................................... 1-8

High RPM, Analog..................................................... 3-4

INCREASING DIR .................................................. 3-10

Input ANDing....................................................1-8, 3-11

INPUT STATUS ...................................................... 3-11

Input Terminals ..................................................2-5, 2-6

Inputs, Introduction.................................................... 1-7

Inputs, Wiring ............................................................ 2-6

KEYBOARD QTY ................................................... 3-12

Keypad Diagnostics .................................................. 4-2

Keypad Disable Terminal ................................... 2-5, 2-6

Keypad Mounting ...................................................... 2-1

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

Keypad, Operation .................................................... 3-1

Keypad, Test ............................................................. 4-2

Keys, Layout ............................................................. 3-1

Keys, Using ...............................................................3-1

LED, Keypad Fault.................................................... 4-2

LED, Status ............................................................... 4-1

Machine Position, Display ...................................... 3-12

Machine Setup, Initial................................................ 3-3

Machine Speed, Display ......................................... 3-12

Main Screen ............................................................3-12

MEMORY TESTS ................................................... 3-13

Memory, Clearing.................................................... 3-13

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

Menu Tree, Entering ............................................... 3-12

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

Modules, Mounting.................................................... 2-1

Motion ANDing .................................................1-8, 3-14

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

Mounting ................................................................... 2-1

Negative Speed Comp ........................................... 3-27

OFFSET (encoder) ................................................. 3-15

Offset, Analog ........................................................... 3-5

Operator Access ..................................................... 3-18

Index I-1

Index (cont’d)

Entries in ALL CAPS are programming functions which are arranged alphabetically in Section 3.

Output Modules, General .......................................... 2-8

Output Modules, Specifications.................................A-2

Output Modules, Wiring............................................. 2-9

OUTPUT STATUS .................................................. 3-16

Output Transistors, General...................................... 2-8

Output Transistors, Replacement ........................... 2-18

Output Transistors, Wiring .............................2-10, 2-11

Outputs...............................................................1-7, 2-8

Outputs, Analog ..........................................1-8, 2-8, 3-4

PASSWORD, Entering ........................................... 3-16

PER CHN ENABLE................................................. 3-17

PGM SEL MODE .................................................... 3-18

PLC, Wiring Input from.............................................. 2-6

PLC, Wiring Output to ....................................2-10, 2-11

PluSNet II Communications ...................................... 6-1

Position, Machine Setup ......................................... 3-15

Position, Machine, Display ......................................3-12

PROGRAM COPY .................................................. 3-18

Program Enable, Jumper Info ................................... 4-2

Program Enable, Wiring ..........................................2-12

Program Select ......................................................... 3-7

Program Select Formats ........................................... 2-7

Program Select Mode ............................................. 3-18

Program Select Terminals............................2-5 thru 2-7

Program, Active, Display......................................... 3-12

Programming Access, Enable Options ................... 3-10

Programming Access, Functions .............................. 3-9

Programming Access, General ................................. 1-8

Programming, Defaults .............................................A-3

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

Programs, General.................................................... 1-7

PS-6244-17 Description ............................................ 1-6

PS-6244-25 Description ............................................ 1-6

PULSE COPY ......................................................... 3-19

Pulses ....................................................................... 1-7

Pulses, Programming.............................................. 3-22

RATE SETUP ......................................................... 3-21

RPM UPDATE......................................................... 3-21

RPM vs. Position, Display .......................................3-28

RPM, Toggling, Display........................................... 3-28

RS-232 ......................................................................3-5

RS-485 ......................................................................3-5

Setpoints, Clearing.........................................3-13, 3-23

Setpoints, Defined..................................................... 1-7

Setpoints, Deleting ..................................................3-23

Setpoints, Program Copy ........................................ 3-18

Setpoints, Pulse Copy............................................. 3-19

Setpoints, Pulse Modes .......................................... 3-23

Setpoints, Pulses .................................................... 3-22

SHIFT POSITION........................................... 3-23, 3-25

SHIFT REG ANDing......................................... 1-8, 3-24

Shift Register Clear Terminal ............................. 2-5, 2-6

Shift Register Input Terminal.............................. 2-5, 2-6

Shift Register Programming ....................................3-24

Shift Register, Channel 91 ...................................... 3-25

Sinking, Input Wiring ................................................. 2-6

Sinking, Output Wiring .............................................. 2-8

SOFTWARE VERSION.................................... 3-26, 4-2

Sourcing, Input Wiring............................................... 2-6

Sourcing, Output Wiring ............................................2-8

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

Specifications, Module ..............................................A-2

Speed Compensation, Defined ..........................1-8, 5-1

Speed Compensation, Leading/Trailing ....................5-4

Speed Compensation, Negative ......................3-27, 5-5

Speed Compensation, Programming ...................... 3-27

Speed Compensation, Standard ...............................5-2

Speed, Machine, Display ........................................ 3-12

Status LED ................................................................4-1

Status, Inputs .......................................................... 3-11

Status, Output ......................................................... 3-16

Terminal Block Part #’s......................................2-3, 2-4

Terminal Block, Keypad .......................................... 2-12

Terminal Blocks, Controller .........................2-1, 2-3, 2-4

Terminals, Input .................................................2-5, 2-6

Termination, Communications .......................2-13, 2-14

Testing, Initial ............................................................3-3

Timer, Watchdog, Test............................................ 3-13

TOGGLE RPM ........................................................ 3-27

Transistor Outputs, General...................................... 2-8

Transistor Outputs, Wiring ............................. 2-10, 2-11

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

Troubleshooting .................................................4-4, 4-5

Version, Software ............................................ 3-26, 4-2

SCALE FACTOR .................................................... 3-21

Sensors, Input, Wiring............................................... 2-6

Serial Communications, General .............................. 1-8

SETPOINT USE...................................................... 3-22

SETPOINTS............................................................ 3-22

Setpoints, Adding .................................................... 3-22

Setpoints, Always “On”............................................ 3-23

Setpoints, Changing................................................ 3-23

Washdown Boot ....................................................... 1-8

Watchdog Timer, Test............................................. 3-13

Wiring, General ......................................................... 2-1

Wiring, Inputs ............................................................ 2-6

Wiring, Keypads ...................................................... 2-12

Wiring, Output Modules............................................. 2-9

Wiring, Output Transistors ............................. 2-10, 2-11

Wiring, Power Supply................................................ 2-1

Index I-2

PLuS 6244 Setpoint Record Date:

PLuS Program #:_______ Description: ________________________________________________________

ANDed With…

Motion Shift Speed

CHN On Off Input # Level # Count Comp Other Comments (multiple pulses, etc.)

1 ____ ____ ____ ____ ___ ______ __________________________________ 2 ____ ____ ____ ____ ___ ______ __________________________________ 3 ____ ____ ____ ____ ___ ______ __________________________________ 4 ____ ____ ____ ____ ___ ______ __________________________________ 5 ____ ____ ____ ____ ___ ______ __________________________________ 6 ____ ____ ____ ____ ___ ______ __________________________________ 7 ____ ____ ____ ____ ___ ______ __________________________________ 8 ____ ____ ____ ____ ___ ______ __________________________________

9 ____ ____ ____ ____ ___ ______ __________________________________ 10 ____ ____ ____ ____ ___ ______ __________________________________ 11 ____ ____ ____ ____ ___ ______ __________________________________ 12 ____ ____ ____ ____ ___ ______ __________________________________ 13 ____ ____ ____ ____ ___ ______ __________________________________ 14 ____ ____ ____ ____ ___ ______ __________________________________ 15 ____ ____ ____ ____ ___ ______ __________________________________ 16 ____ ____ ____ ____ ___ ______ __________________________________ 17 ____ ____ ____ ____ ___ ______ __________________________________ 18 ____ ____ ____ ____ ___ ______ __________________________________ 19 ____ ____ ____ ____ ___ ______ __________________________________ 20 ____ ____ ____ ____ ___ ______ __________________________________ 21 ____ ____ ____ ____ ___ ______ __________________________________ 22 ____ ____ ____ ____ ___ ______ __________________________________ 23 ____ ____ ____ ____ ___ ______ __________________________________ 24 ____ ____ ____ ____ ___ ______ __________________________________ 25 ____ ____ ____ ____ ___ ______ __________________________________

Analog Outputs

Output Channel #: _____ ¬ 4-20mA ¬ 0-10 VDC Offset: ____ High RPM:______ Output Channel #: _____ ¬ 4-20mA ¬ 0-10 VDC Offset: ____ High RPM:______

Global Settings

Motion Detection Levels: L1: _____ RPM L2:______ RPM Shift Position: ________ Offset: ______________ Comments: ___________________________________________________________________________________

____________________________________________________________________________________________ ____________________________________________________________________________________________

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