How it Works
Gemco
Loading...
2500C
Installation Manual
97 pgs1.92 Mb0

Gemco 2500 Series, 2500R, 2500, 2500C, 2500E Installation Manual

Download
High-Speed Programmable Limit Switch
2500
High-Speed PLS
Series 956
ABSOLUTE PROCESS CONTROL KNOW WHERE YOU ARE... REGARDLESS
INSTALLATION M
2500 Series
2
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
Preface
This manual is for the Installation and Maintenance of the Gemco 2500 Programmable Limit Switch.
AMETEK has checked the accuracy of this manual at the time it was printed. Any comments you may have for the improvement of this manual are welcomed.
AMETEK reserves the right to revise and redistribute the entire contents or selected pages of this manual. All rights to the contents of this manual are reserved by AMETEK.
WARNING: Caution must be taken when adjusting limit outputs!
Disconnect power before servicing. The Gemco 2500 PLS contains no serviceable components other than relays and fuses. Consult factory for repair or replacement.
3
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
Contents
Chapter 1: Introduction .............................4
1.1 Mechanical Cams .................................. 5
1.2 Description .............................................5
1.3 Standard Features ................................. 7
Chapter 2: Hardware Overview ................9
2.1 PLS Module ........................................... 9
2.2 Remote Operator Interface ...................11
2.3 Expansion Modules ..............................11
2.4 Resolver Assembly .............................. 12
2.5 Status Display/Programming Keys ...... 14
2.6 Dimension Drawings ............................16
Chapter 3: Mounting and Wiring ............ 20
3.1 Mechanical Installation ........................20
3.2 Electrical Installation ............................ 21
3.3 Wiring Instructions ............................... 21
Chapter 4: Programming ........................30
4.1 Main Controller Keypad ....................... 30
4.2 Programming Keys Defi ned ................. 31
4.3 Before You Start ..................................32
4.4 Menu Tree ...........................................33
4.5 User and Supervisor Mode Access .....33
Chapter 5: Global Parameters ................ 35
5.1 Quick Start ........................................... 35
5.2 Initialize System ...................................36
5.3 Expansion Boards ...............................37
5.4 Lockout Functions ...............................38
5.5 Scale Factor ........................................39
5.6 Customize Decimal Pt.
(Decimal Location) ...............................40
5.7 Electronic Offset ..................................41
5.8 Motion Detect ......................................42
5.9 Enable Brake Input .............................. 43
5.10 Brake Monitor ....................................43
5.11 Set Fault Clear Option .......................45
5.12 Customize Display ............................. 46
5.13 Defi ne Title Screen ............................47
5.14 Label Outputs ....................................48
5.15 Label Inputs ....................................... 49
5.16 Defi ne User Password ....................... 50
5.17 Defi ne Supervisor Password .............51
5.18 Software Version ...............................52
Chapter 6: Limit Switch Outputs ............53
6.1 Setpoint Data ....................................... 54
Chapter 7: Multiple Program ..................56
7.1 Naming A Program ..............................57
7.2 Editing A Program ................................ 58
7.3 Copying A Program ..............................59
7.4 Accessing A Program ........................... 60
7.5 Initialize Program ................................. 61
Chapter 8: Linear Speed Compensation 62
8.1 Linear Speed Compensation ............... 64
8.2 Minimum Speed Disable ......................65
Chapter 9: Time Based Outputs .............66
Chapter 10: Inputs ................................... 67
10.1 Input Confi guration ............................71
10.2 Input Confi guration for No Input ........73
10.3 Input Confi guration for
Reset to Preset Continuous ...............74
10.4 Input Confi guration for
Reset to Preset Single ....................... 75
10.5 Input Confi guration for
Output Enable One Shot ...................76
10.6 Input Confi guration for
Output Enable Level .......................... 77
10.7 Enable Brake Input ............................ 78
Chapter 11: Die Protection Inputs ..........79
11.1 Applications for Die Protection Inputs 79
11.2 Input Confi guration for
Die Protect Momentary ...................... 82
11.3 Input Confi guration for
Die Protect Maintain ..........................83
11.4 Input Confi guration for
Die Protect Partial ..............................84
Chapter 12: Faults ...................................85
Appendix A: Ordering Information ........89
Appendix B: Specifi cations .................... 90
B.1: Main Controller Specifi cations ............ 90
B.2: Expansion Module Specifi cations ......91
B.3: Remote Operator Interface
Specifi cations ....................................91
4
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
Chapter 1: Introduction
The 2500 PLS is a high speed resolver based Programmable Limit Switch that monitors rotary machine position and provides discrete limit switch outputs. These outputs are updated at a much faster rate than can be accomplished using any conventional PLC.
The single turn resolver is usually coupled to the machine shaft at a 1:1 ratio so that one resolver shaft rotation corresponds to one machine cycle. As the resolver rotates it generates a ratiometric analog signal representing an absolute rotary position. The ratiometric signal is converted to a digital signal at the 2500 PLS. Resolvers have no brushes, contacts, or any frictional parts to wear out.
As the resolver passes through the user programmed dwell settings, the 2500 PLS turns electrical switches, known as outputs, on and off. Outputs can energize solenoids, relays, or solid-state circuitry to control external devices. Because the 2500 PLS is completely electronic and has no frictional parts, it offers several advantages over mechanical cam switches:
• Long life with no parts to wear out.
• Easy to use menu driven displays.
• Setpoints can be adjusted instantly from the controller.
• Adjustments can be made while the machine is running.
• Programmable inputs allow for complex output functions that are impossible with mechanical cams.
• Operating speeds up to 2,000 RPM.
5
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
1.1 Mechanical Cams
The 2500 Programmable Limit Switch electronically simulates mechanical cam switches. A mechanical cam consists of a mechanical limit switch and a roller follower whose roller follower rides on the cam assembly as shown in Figure 1. The camshaft is driven by the machine at a 1:1 ratio so that the cam limit switch turns ON and OFF at specifi c positions in the machine cycle. Cam limit switches have the following disadvantages:
• The roller follower and limit switches wear out.
• The machine must be stopped during adjustment.
• On/off patterns are limited to typically one on and one off per cam. Multiple on and off points require custom cams.
• The mechanical cam switches are typically not installed in an easily accessible location.
• They cannot run at high speeds because of contact bounce and mechanical wear.
1.2 Description
The 2500 is a family of PLS’s that offer unparalleled fl exibility . The main controller is a resolver-based controller that consists of 8 input and 8 output relays, one fault check output relay and one optional brake monitor input relay.
The optional expansion module will provide 8 additional inputs and outputs per module. Up to 7 expansion modules can be driven by the controller for a total of 64 inputs and 64 outputs.
The 2500 PLS uses a unique, easy to understand programming sequence. The traditional number buttons have been
replaced with a rotary knob and the main controller has a 2x24 vacuum fl uorescent display along with 4 pushbutton keys for programming.
The keys have been defi ned as MENU, ÕÖ and . The rotary knob scrolls you easily through the menu drive alphanumeric display. On-line help screens have been added to aid in the setup and troubleshooting of the unit.
System parameters are entered through a scrolling menu, which is accessed through the main display. The rotary knob is used to scroll through the selections and the key is used to select the menu item. The user can view any system value without entering a password. However, if the user wants to change a value, a password is required.
All the parameters are password protected. Once the password is entered, the user will be allowed to edit any value as long as the user does not return to the main display and the program input is in the correct state.
System data such as position, RPM, and brake monitor status will be shown on the main display. This data can be toggled through using the rotary knob.
Figure 1-1:
1980 Rotating Cam Limit Switch
6
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
2500 Stand Alone Main Controller
Cla
ws
on, MI 48017 U.S
.A.
N
P0197900
R
E
NTE
R
S
CR
OLL
ME
NU
2500 SERIES
P
LS
• 8 Isolated DC Inputs and 8 Solid-State AC or DC Outputs, Expandable to 64 (in groups of 8) using 2500E Expansion Modules
• Rotary Knob with Simple, Menu Driven Programming and Help Menus
• Brake Monitor
• 2 x 24 Vacuum Fluorescent Display
• Panel Mountable
2500R Remote Operator Interface
Clawson,
MI
4801
7 U
.S.A.
NP01
9790
0
R
E
N
TE
R
SCROLL
M
E
N
U
2500 SERIES PLS
• Keypad only, used with 2500C Blind Main Controller Units
• 2 x 24 Vacuum Fluorescent Display
• Panel Mountable, up to 25 feet from Main Controller
• Simple RJ45 Connections to Main Controller
• Rotary Knob, with Scrolling, Menu Driven Programming
2500C Blind Main Controller Units
w
S
D E
C
TR5
V
F 4A 250V
V
S
C
D E
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
DE
S
TR5
w
F 4A 250V
w
TR5
C
V
D E
S
F 4A 250V
D E
S
C
V
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
DE
S
TR5
w
F 4A 250V
INPUT STATUS
OUT6 OUT8OUT7OUT5OUT4
IN8IN7IN5 IN6IN4
OUT1 OUT2 OUT3BK IN
AC POWER 50/60 Hz
INTERNALLY FUSED
100-240 VAC
IN3IN2IN1
GND
L2
L1
2500CBXXXX
2500 SERIES PLS
SERIAL No. >>>>>> D/C >>>>
Clawson, MI 48017 U.S.A.
R
• 8 Isolated DC Inputs and 8 Solid-State AC or DC Ouptuts,
Expandable to 64 (in groups of 8) using 2500E Expansion Modules
• Brake Monitor
• Panel or DIN Rail Mountable
2500E Expansion Modules
w
S
D E
C
TR5
V
F 4A 250V
V
S
C
D E
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
D E
S
TR5
w
F 4A 250V
w
TR5
C
V
DE
S
F 4A 250V
D E
S
C
V
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
DE
S
TR5
w
F 4A 250V
IN4
INPUT STATUS
IN1 IN2 IN3 IN6IN5 IN7 IN8
INTERNALLY FUSED
L1
100-240 VAC
50/60 Hz
AC POWER
GND
L2
OUT4OUT1 OUT2 OUT3 OUT6OUT5 OUT7 OUT8
SERIAL No. >>>>>> D/C >>>>
2500EXXXXX
Clawson, MI 48017 U.S.A.
2500 SERIES PLS
R
• 8 Isolated DC Inputs and 8 Solid-State AC or DC Outputs
• Panel or DIN Rail Mountable
• Up to 7 Expansions Modules can be Driven From the Main
Controller
• Simple Depluggable Connections
2500 PLS confi gurations include:
7
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
1.3 Standard Features
Scale Factor The Scale Factor is the number of increments that the PLS counts through over one rotation of the resolver. For example, a PLS with a Scale Factor of 360 will count from 0 to 359 over one revolution.
Offset
The Offset feature is used to electronically synchronize the PLS displayed position with the actual machine position. Valid values are 0 to (one less than the programmed Scale Factor).
Supervisor Menu
Two levels of programming access are provided: User and Supervisor. In the Supervisor Menu, display screens can be customized and outputs and functions can be locked out. Each level can be assigned a password that must be entered to program the locked out functions. This can provide key personnel the fl exibility they need while protecting settings against accidental or unauthorized changes.
Onboard Help Onboard Help is available from the 2500 PLS 2x24 alphanumeric vacuum fl uorescent display. Each programming screen has easy to follow English programming screens.
Multi-program The Multi-program feature allows the storage of multiple sets of output sequences that are pre-programmed based on various requirements of different jobs. When jobs are changed, the new program is simply called up from the Interface or remote inputs and all outputs
and inputs are automatically set to the new output sequences. The 2500 PLS is capable of storing 15 different programs.
Program Name The Program Name feature allows the user to assign a name to each program.
Program Copy
The Program Copy feature copies all parameters from one program to another. This is useful when inputting data from one program to another where only minor changes are needed.
Brake Monitor The Brake Monitor checks the stopping time of the machine against a selected preset stopping time in milliseconds. A user defi ned output remains energized when the stop time parameters are within tolerance. An excessive stop time will cause the relay to de-energize, which could be used to stop further machine operation.
Motion Detector A programmable Motion Detector output will energize a user selected relay when the transducer speed meets or exceeds the user programmed RPM value.
Fault Check The 2500 PLS offers an on-line Fault Check which provides an automatic, in-process mechanism to verify that all major programmable limit switch functions are operating properly. The fault check output can be energized by activating the fault check enable input. The output is a mechanical relay, which remains energized during normal operation.
8
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
Input Each Input can be confi gured as either a reset to preset input, an output confi guration enable input, or a die protection input.
Output Enabler The output enable input will enable the setpoints for one revolution when the input is activated in a programmed window. The user can program the window.
Reset to Preset The Reset to Preset feature allows the user to reset a pre-defi ned output to any preprogrammed position. This feature can be used to compensate for mechanical slippage. NOTE: Each output has its own independent reset input.
Reset Single Shot
The Reset Single Shot feature allows the user to reset a pre-defi ned output to any pre-programmed position. However, with this feature the output associated with this input waits for the input signal before it allows the output to fi re. Once the input is made, the output will only fi re one time and wait for the next input signal.
Die Protection Die Protection is used in stamping applications where it is necessary to monitor a part as it is progressing through the die. If the part is not detected in the location, an output will signal the press to stop.
Output Enable Output Enable is used in conjunction with an input. If the input is not seen within a programmed range, the output associated with that input will not fi re. Output enables are typically used in gluing applications where if a product is not present, the gluing output does not fi re.
Setpoint Data There are up to eight setpoint pairs available per revolution for each output. The user can add, delete, or change a setpoint in the list. Valid setpoints range from 0 to a value (one less than the current scale factor). For example, if the scale factor is set at 1000, then valid setpoint values range from 0 to 999.
Timed Outputs Time Based outputs are programmed like standard outputs to turn on at a specifi c resolver position and stay on for a programmable amount of time.
Minimum Speed The Minimum Speed Disable will disable the selected outputs when the Disable actual RPM falls below the minimum speed programmed by the user. Valid minimum speed values range from 0 to
2048. A value of zero will disable this feature. The default value is zero.
Linear Speed Linear Speed Compensation allows for setpoints to be adjusted to compensate for mechanical lag at higher speeds. Each output can be programmed with its own adjusted values. The user will program an on offset and an off offset and the RPM that is associated with that offset. The unit will linearize the offset values and adjust the setpoints for that output based on the actual RPM value.
Software Version The software version can be viewed through the Software Version menu item. The version number will follow our standard numbering system with two digits before the decimal indicating major releases and the two digits after the decimal indicating minor releases.
9
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
This section contains mechanical and electrical information on the 2500 PLS main controller, expansion modules, remote operator interface, and resolver assembly. For specifi cations, see Appendix B.
2.1 PLS Module
The 2500 PLS module is an electronic assembly that can be confi gured many different ways. The three main parts are described in Chapter 1. The following are features found on the module:
• A rotary knob replaces the standard number buttons. As the knob is rotated, it helps guide you through the programming process. Convenient help screens guide you through the entire programming process.
• A 2 line x 24 character vacuum fl uorescent display indicates all PLS functions.
• Eight depluggable solid-state output relays are located on the back of the controller. Each output has its own input located on the opposite side of the controller.
• An optional depluggable Brake monitor input relay is located on the back of the controller. This input can be used to determine stopping time of the machine.
• The auxiliary communication port currently supports Modbus ASCII protocol.
• Resolver input terminals allow connection to a Gemco resolver or compatible equipment.
• Expansion ports allow for further relay expansion. The main controller is capable of driving 64 outputs and inputs.
• Fault check. A mechanical relay output is held closed as long as the PLS is working properly. If the PLS resolver circuitry or microprocessor fails, the relay will open.
• Universal input power. The 2500 PLS can operate over a wide input range, 100 - 240 VAC, 50/60 Hz.
Chapter 2: Hardware Overview
10
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
Clawson, MI 48017 U.S.A.
NP0197900
R
ENTER
SCROLL
MENU
2500 SERIES PLS
w
S
DE
C
TR5
V
F 4A 250V
V
S
C
D E
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
DE
S
TR5
w
F 4A 250V
w
TR5
C
V
D E
S
F 4A 250V
D E
S
C
V
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
DE
S
TR5
w
F 4A 250V
INPUT STATUS
IN8IN7IN5 IN6IN4
100-240 VAC
INTERNALLY FUSED
IN1
50/60 Hz
IN3IN2
AC POWER
GND
L2
L1
OUT4 OUT6OUT5 OUT7 OUT8OUT2 OUT3OUT1BK IN
Figure 2-1: 2500CF Main Controller
Figure 2-2: 2500CB Blind Main Controller
w
S
D E
C
TR5
V
F 4A 250V
V
S
C
D E
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
DE
S
TR5
w
F 4A 250V
w
TR5
C
V
D E
S
F 4A 250V
DE
S
C
V
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
DE
S
TR5
w
F 4A 250V
EXPANSION OUT
INPUT STATUS
OUT6 OUT8OUT7OUT5OUT4
IN8IN7IN5 IN6IN4
OUT1 OUT2 OUT3BK IN
AC POWER 50/60 Hz
INTERNALLY FUSED
100-240 VAC
IN3IN2IN1
GND
L2
L1
2500CBXXXX
2500 SERIES PLS
SERIAL No. >>>>>> D/C >>>>
Clawson, MI 48017 U.S.A.
R
11
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
Clawson, MI 48017 U.S.A.
NP0197900
R
ENTER
SCROLL
MENU
2500 SERIES PLS
The Remote Operator Interface connects to the main controller through an 8-pin Ethernet cable commonly know as an RJ45. Full duplex RS-485 is used to communicate to the main controller. The remote operator interface is made up of a 2x24 vacuum fl uorescent display, along
with four pushbutton keys and a rotary knob for programming. The keys have been defi ned as MENU,
Õ,Ö and . The
2500R Remote Operator Interface can be used with the 2500CB main controller unit. This allows a means of mounting the main controller unit remotely.
2.2 Remote Operator Interface
Figure 2-3: 2500R Remote Operator Interface
2.3 Expansion Modules
The standard 2500 PLS is supplied with 8 inputs and 8 outputs. The system is expandable to 64 inputs and 64 outputs by adding the 2500E Expansion Module. Each expansion module consists of 8 output modules and 8 inputs. These solid-state outputs are an optically isolated barrier between the PLS and the fi eld devices they control. These output modules are also pluggable and either AC or DC relays can be used.
• Panel mount or DIN rail mountable.
• Plug and play cable design.
• Pluggable output relays.
• No increase in update time regardless of number of Expansion Modules.
• LED’s are located next to each input and output. These LED’s specify the state of each input and output.
12
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
Stator 1 Voltage Stator 2 Voltage
90 180 270 360
Ratiometric conversion of the two secondary coil voltages provides absolute position data, and factors out EMI.
w
S
D E
C
TR5
V
F 4A 250V
V
S
C
D E
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
D E
S
TR5
w
F 4A 250V
w
TR5
C
V
DE
S
F 4A 250V
DE
S
C
V
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
D E
S
TR5
w
F 4A 250V
IN4
INPUT STATUS
IN1 IN2 IN3 IN6IN5 IN7 IN8
INTERNALLY FUSED
L1
100-240 VAC
50/60 Hz
AC POWER
GND
L2
OUT4OUT1 OUT2 OUT3 OUT6OUT5 OUT7 OUT8
EXPANSION OUT
SERIAL No. >>>>>> D/C >>>>
2500EXXXXX
Clawson, MI 48017 U.S.A.
2500 SERIES PLS
R
2.4 Resolver Assembly
The resolver assembly consists of a highly accurate and repeatable brushless resolver, housed in an industrial-grade enclosure. Rotary shaft position is calculated from two analog signals that vary as a function of the angular rotation of the input shaft.
The resolver works on the same principle as a rotary transformer to couple power into the rotor. The resolver consists of a two-phase stator and a single-phase rotor. Each stator is positioned 90º apart from each other. The two stators continually provide two different output voltages. Using these two outputs, the PLS performs a ratiometric conversion which factors out electro-magnetic
interference (EMI) and provides an absolute position. See Figure 2-5. This results in a highly accurate and repeatable unit with excellent reliability and infi nite resolution.
The resolver assembly is contained in a rugged NEMA 4 enclosure with a plug-in connector. The input shaft is a 3/4 inch diameter and is made of stainless steel. It is mounted in sealed ball bearings with a radial load rating of 150 lbs. This results in the most rugged duty transducer available for industrial applications. The operating temperature range is -40º C to 125º C. See Figure 2-7 or 2-8 for the resolver dimensions.
Figure 2-4: 2500E Expansion Module
Figure 2-5: Voltages of Stator Coils
13
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
1
.42
2.25
1.08
.7475
.74
90
D
IA.
.75
1.38
.62
2
.5
0
8.5
0
8.0
0
2.12
5.50
4.25
K
E
Y
#6
0
6
W
O
O
D
R
U
F
F
.38
(52.58)
8.88
w/ S
T.
C
ONN
.
2
.50
3.74
2 PLACES
.44 (11.18) DIA. MOUNTING HOLES
8.00 w/
R.A. CONN.
(139.70)
(107.95)
(53.85)
(15.75)
(6
3
.5
0
)
(2
0
3
.2
0
)
(2
1
5.9
0
)
(
2
2
5
.
5
5
)
(203.2
0)
(35.05)
(19.05)
(36.07)
(27
.43
)
(57
.15)
(6
3
.5
0
)
(95.00)
2.07
(9.65)
(1
9.02
)
(18
.99
)
(COSINE)
YELLOW/WHITE
RED/WHITE
2500 PROGRAMMABLE LIMIT SWITCH
TO TERMINALS OF GEMCO
RESOLVER CABLE
SD0508200LX
TRANSDUCER
RESOLVER
BLACK GREEN BLACK
ALPHA CABLE 6053
COLOR CODE
R2
S4
S2
S1
S3
WHITE
BLACK
R1
RED
S1
STATOR
B
F
E
D
C
A
S4 S2
(SINE)
STATOR
ROTOR
R1 R2
S3
BLACK
YELLOW
RESOLVER COLOR CODE
RESOLVER HOUSING
JUMPER INSIDE
BLUE
RED
B
C
D
G
F
A
E
YELLOW
BLUE
RED
BLACK
WHITE
E F
D
C
RED/WHITE
YELLOW
B
A
RESOLVER
Figure 2-6: Reslover Wiring
Figure 2-7: 1986 “A” Style Brushless Resolver
NOTE: Other Gemco resolver assemblies are available. Contact factory for details.
14
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
(T
O
T
AL
C
L
EA
R
AN
C
E
O
F
5.5"
R
E
Q
U
IR
E
D
F
O
R
R
EM
O
V
AL
O
F
M
A
T
IN
G
C
O
N
N
E
C
T
O
R
)
[ ] = DIMENSIONS IN MILLIMETERS
C
O
N
N
EC
TO
R
: M
S3
102
E1
6S-
1P
1/4
-2
0 U
N
C
-2B
.5
0 [1
2
.7
] D
E
EP
(8 P
LAC
E
S)
SE
E K
EY
W
AY
SP
EC
IF
IC
AT
IO
N
S
1.25 [31.8]
.150 [3.8]
1.500
[38.1]
.500 [12.7]
3.250 [82.6]
4.87
[1
23
.7
]
.7
5
0
[1
9
.1]
2.500 [63.5]
2.00
0
[5
0.8
]
1
.0
0
0
[2
5
.4
]
.250 [6.4]
.250 [6.4]
2.000 [50.8]
.6
7
3
[1
7
.1
]
1
.18
0
[3
0.0
]
.6247 .6237
[15.87] [15.84]
Side mount
connec
tor
R
e
a
r m
o
u
n
t
co
n
n
e
cto
r
.6
7
3
[1
7
.1
]
2.50
[63.5]
Clawson, MI 48017 U.S.A.
NP0197900
R
ENTER
SCROLL
MENU
2500 SERIES PLS
Shift Keys: Moves cursor right or left.
Menu Key: Used to access menu driven display.
2 x 24 Alpha Numeric: Vacuum Fluorescent Display.
POS 12345 RPM 2000
Rotary Knob: The Rotary knob is used to scroll and move through the menu driven displays.
Enter Key: Enter must be pressed to enter a value.
Figure 2-8: 1986 “F” Style Brushless Resolver
The 2500 PLS has a 2 line by 24 character vacuum fl uorescent display (VFD), four programming buttons and a rotary knob. The VFD provides
programming and status information. The programming keys and rotary knob are used to program functions and perform basic operations.
Figure 2-9: Main Controller (Front View)
2.5 Status Display/Programming Keys
15
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
Incoming AC Power
Input Status LED’s
Output Status LED’s
Relay Output Fuse
Output Relays AC or DC: Refer to part number Red = DC relays Black = AC relays
Optional Brake Monitor Input Relay
w
S
D E
C
TR5
V
F 4A 250V
V
S
C
DE
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
DE
S
TR5
w
F 4A 250V
w
TR5
C
V
DE
S
F 4A 250V
DE
S
C
V
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
DE
S
TR5
w
F 4A 250V
IN8IN7IN5 IN6IN4
100-240 VAC
INTERNALLY FUSED
IN1
50/60 Hz
IN3IN2
AC POWER
GND
L2
L1
OUT4 OUT6OUT5 OUT7 OUT8OUT2 OUT3OUT1BK IN
SERIAL No. >>>>>> D/C >>>>
Clawson, MI 48017 U.S.A.
2500 SERIES PLS
2500CFXXXX
R
INPUT STATUS
Figure 2-10: Main Controller (Rear View)
The scrolling menu is accessed through the main display by pressing the MENU button. The rotary knob is used to scroll through the selections and the
key is
used to select the menu item. Any system value can be viewed without
entering a password. However, if the user wants to change a value he must enter a password into the system. All the parameters are password protected.
Once the password is entered, the user will be allowed to edit any value as long as the user does not return to the main display and the program input is in the correct state. On-board help is offered for each menu item.
System data such as position, RPM, and brake monitor status will be shown on the main display.
16
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
6.31
7.50
4.73
.54
.13 3.32
3.98
4.50
1.50
5.88.22
.66
6.19
5.31.50
.18 (4 PLACES)
5.88
.22
5.43
6.31 4.50
.90
PANEL CUT OUT
DIMENSIONS
#8-32 UNC-2B (4 PLACES)
Clawson, MI 48017 U.S.A.
NP0197900
R
ENTER
SCROLL
MENU
2500 SERIES PLS
w
S
D E
C
TR5
V
F 4A 250V
V
S
C
DE
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
DE
S
TR5
w
F 4A 250V
w
TR5
C
V
DE
S
F 4A 250V
DE
S
C
V
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
DE
S
TR5
w
F 4A 250V
IN8IN7IN5 IN6IN4
100-240 VAC
INTERNALLY FUSED
IN1
50/60 Hz
IN3IN2
AC POWER
GND
L2
L1
OUT4 OUT6OUT5 OUT7 OUT8OUT2 OUT3OUT1BK IN
SERIAL No. >>>>>> D/C >>>>
Clawson, MI 48017 U.S.A.
2500 SERIES PLS
2500CFXXXX
R
INPUT STATUS
2.6 Dimension Drawings
Figure 2-11: 2500CF Main Controller Dimensions
17
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
w
S
DE
C
TR5
V
F 4A 250V
V
S
C
DE
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250
V
C
V
DE
S
TR5
w
F 4A 250V
w
TR5
C
V
DE
S
F 4A 250V
D E
S
C
V
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
DE
S
TR5
w
F 4A 250V
EXPANSION OUT
INPUT STATUS
OUT6 OUT8OUT7OUT5OUT4
IN8IN7IN5 IN6IN4
OUT1 OUT2 OUT3BK IN
AC POWER 50/60 Hz
INTERNALLY FUSED
100-240 VAC
IN3IN2IN1
GND
L2
L1
6.31
7.50
5.88.22
1.50
4.50
.18
(4 PLACES)
5.31.50
6.19
.66
4.20
3.32 .13
.90
4.506.31
.22
(4 PLACES)
PANEL CUT OUT
(HALF SCALE)
DIMENSIONS
#8-32 UNC-2B
5.43
5.88
.36
OPTIONAL 35MM DIN RAIL MOUNTING HARDWARE
2500CBXXXX
2500 SERIES PLS
SERIAL No. >>>>>> D/C >>>>
Clawson, MI 48017 U.S.A.
R
Figure 2-12: 2500CB Blind Main Controller Dimensions
18
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
6.31
7.50
1.82
2.36
4.50
1.50
5.88.22
6.19
.66
.50 5.31
2500RX
2500 SERIES PLS
SERIAL No. >>>>>> D/C >>>>
Clawson, MI 48017 U.S.A.
NP0197900
R
ENTER
SCROLL
MENU
2500 SERIES PLS
Clawson, MI 48017 U.S.A.
R
.90
4.506.31
.22
(4 PLACES)
PANEL CUT OUT
DIMENSIONS
#8-32 UNC-2B
5.43
5.88
Figure 2-13: 2500R Remote Operator Interface
19
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
w
S
D E
C
TR5
V
F 4A 250V
V
S
C
DE
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
DE
S
TR5
w
F 4A 250V
w
TR5
C
V
DE
S
F 4A 250V
D E
S
C
V
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
DE
S
TR5
w
F 4A 250V
IN4
INPUT STATUS
IN1 IN2 IN3 IN6IN5 IN7 IN8
INTERNALLY FUSED
L1
100-240 VAC
50/60 Hz
AC POWER
GND
L2
OUT4OUT1 OUT2 OUT3 OUT6OUT5 OUT7 OUT8
6.31 4.50 (HALF SCALE)
5.88
5.43
PANEL CUT OUT
.22
.90
DIMENSIONS
#8-32 UNC-2B
(4 PLACES)
3.39
.13
2.51
6.31
7.50 4.50
1.50
6.19
.66
5.88
.22
5.31.50
.18
(4 PLACES)
EXPANSION OUT
.36
OPTIONAL 35MM DIN RAIL MOUNTING HARDWARE
SERIAL No. >>>>>> D/C >>>>
2500EXXXXX
Clawson, MI 48017 U.S.A.
2500 SERIES PLS
R
Figure 2-14: 2500E Expansion Module
20
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
This section describes the installation and wiring of the 2500 PLS family. Changes to these instructions should be made as necessary if special options and/or equipment are used.
The 2500 PLS should be installed in an area free of water spray, corrosive gases, fl ying chips or other foreign matter. The operating temperature should be between 32 and 125 degrees Fahrenheit, with less than 95% relative humidity.
3.1 Mechanical Installation
Mounting the 2500 PLS
The 2500 PLS is designed to be panel or DIN-rail mounted. The face of the 2500 can be affected by water and/or oil spray. Provisions should be made to
protect the face of the unit from spraying or splashing.
Panel cutouts, mounting holes and sizes for each component are shown in Chapter 2.
The controller should be mounted in the appropriate panel cutout and securely bolted into place using the four (4) 3/6” diameter mounting holes. A DIN-rail mounting kit is supplied with all blind main controller units and expansion modules for an optional means of mounting. See Fig. 3-1.
NOTE: In instances where the 2500 is being mounted directly on high vibration machinery, care should be taken to isolate the controller from shock load and vibration.
It is always good design practice to mount the controller in the enclosure as far away from the motor starters and control relays as possible to minimize the effects of electromagnetic interference (EMI).
Interconnecting wiring should also be routed to minimize EMI coupling.
To attach DIN-rail to the Expansion Module or Blind Main Controller unit, place the two supplied 8-32 x 5/8” lg. screws through the DIN-rail bracket and fi rmly attach to aluminum plate.
Chapter 3: Mounting and Wiring
21
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
w
S
DE
C
TR5
V
F 4A 250V
V
S
C
D E
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
DE
S
TR5
w
F 4A 250V
w
TR5
C
V
D E
S
F 4A 250V
DE
S
C
V
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
DE
S
TR5
w
F 4A 250V
INPUT STATUS
IN8IN7IN5 IN6IN4
100-240 VAC
INTERNALLY FUSED
IN1
50/60 Hz
IN3IN2
AC POWER
GND
L2
L1
OUT4 OUT6OUT5 OUT7 OUT8OUT2 OUT3OUT1BK IN
Input Power
Mounting the Resolver
The proper mounting of the resolver is critical to ensure the system’s accuracy. There are many resolvers available. See our full line 1986 Reslover Catalog.
A. Standard foot mounted resolvers.
The foot mount resolver should be mounted in an area free of excessive shock and vibration. The resolver should be connected in a 1:1 ratio with the machine.
B. Combination mechanical cam/
resolver systems. Intended as bolt-in replacements to existing switches. The cam/resolver combination unit should be coupled where the existing limit switch is located. Wire and adjust the mechanical cams in accordance with the original manufacturer’s specifi cations and wire the resolver cable to the controller.
NOTE: The 2500 programmable limits are not control reliable for the clutch/ brake circuits. Mechanical cam limits must be used for these circuits.
3.2 Electrical Installation
The 2500 PLS is designed for use in an industrial environment and incorporates extensive transient suppression circuitry. However, the same general installation rules should be followed that are used on all microprocessor-based equipment.
Incoming AC lines should be from a clean power source and lines carrying computer level signals should not be routed in the same conduit as high voltage, transient-producing circuits such
as variable speed drives, welders or DC switching circuits.
The 2500 PLS is only used with a single­turn resolver. Wiring for this system is shown in Figures 3-1 through 3-9. These wiring diagrams are applicable for all standard 2500 PLS’s.
3.3 Wiring Instructions
This section contains pinout diagrams for each connector. The terminal wire size for all connectors is No. 22-12 AWG. For system wiring refer to wiring diagram [E0238000].
Input Power
The 2500 Main Controller and Expansion Modules have a universal input power supply. Input power is 100-240 VAC 50/60 Hz @ 7 watts. This input is internally fused.
22
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
FAULT CHECK RESET SWITCH IS WIRED AS BELOW, AFTER A FAULT OCCURS, THE FAULT
SINKING) DEVICE, CONNECTED SIMILAR TO ABOVE.
NOTE: ALL SWITCHES CAN BE REPLACED BY AN OPEN COLLECTOR (CURRENT
WILL RESUME NORMAL OPERATION.
AND RECLOSED (ENABLED), THE FAULT CHECK RELAY WILL RE-ENERGIZE AND THE OUTPUTS
IS CORRECTED AND THE CUSTOMER SUPPLIED RESET SWITCH IS OPENED (DISABLED)
CHECK RELAY DE-ENERGIZES AND ALL OUTPUT RELAYS DE-ENERGIZE. AFTER THE FAULT
COM
8
(CLOSED)
ENABLE
FLT IN
3
PLS CIRCUITRY AS SHOWN BELOW ONLY IF IT IS REQUIRED. IF A CUSTOMER SUPPLIED
THE USE OF THE FAULT CHECK FEATURE IS OPTIONAL AND SHOULD BE WIRED TO THE
A JUMPER WIRE BETWEEN COM & PGM.
IF NO RUN/SECURITY PROGRAM IS NEEDED (ALWAYS IN PROGRAM MODE) INSTALL
TWO METHODS OF WIRING SECURITY SWITCH
WHEN SWITCH IS CLOSED, PLS CAN BE PLACED IN PROGRAM MODE.
TYPICAL WIRING FOR CUSTOMER SUPPLIED PROGRAM SECURITY SWITCH.
HAS BEEN ACTUATED - CONTINUITY - BETWEEN COM & PGM INPUT.
2500 P.L.S. CANNOT BE PROGRAMMED UNTIL THE PGM INPUT
FAULT CHECK CIRCUIT
COM
8
RUN
PROGRAM (CLOSED)
WHEN SWITCH IS OPEN, PLS WILL BE IN RUN MODE. (ALL FUNCTIONS
PROGRAM SECURITY INPUT
PGM
1
OR
CIRCUITRY AS SHOWN BELOW ONLY IF IT IS REQUIRED. TYPICAL WIRING FOR CUSTOMER
THE USE OF THE ENABLE FEATURE IS OPTIONAL AND SHOULD BE WIRED TO THE PLS
DISABLECOM
82
ENABLE (OPEN)
ENA
ENABLE
OR
OR
CAN BE VIEWED BUT DATA CANNOT BE CHANGED.)
SUPPLIED ENABLE INPUT. WHEN SWITCH IS OPEN, PLS OUTPUTS WILL BE ENABLED. WHEN SWITCH IS CLOSED OUTPUTS WILL BE DISABLED.
+++
---+-
SEL
4
FLT IN
PRG
ENA
12
PRG
COM
8
+--+-+
+-+++
---+-
RESOLVER
INPUTS
SEL
4
FLT IN
PRG
ENA
12
PRG
COM
8
BK/RED
RED
GREEN
BK/WHT
WHITE
BK/GRN
MULTI-PROGRAM SELECT
SINKING INPUTS
+5VDC MAX
ON AT <1VDC @ 5mA
12437865
FAULT CLEAR
ENABLE
PROGRAM SECURITY INPUT
Figure 3-4
Resolver Input
The resolver input has a six position connector (see fi gure 3-3). Attach the pre-wired plug on the resolver cable to the resolver and route the shielded cable through a separate grounded (earth ground) metal conduit to the panel. Connect the mating half terminal block to the 2500 PLS. To change count direction switch green (pin 5) and black of green (pin 6).
NOTE: When extensions to the factory supplied resolver cable are necessary, a junction box should be used to connect the wire leads and cable shields from one cable to the other. The junction box is used to isolate the splices of the connecting wires from outside electrical noises. Ground the cable shields at the controller case only.
Figure 3-3
Program, Fault Clear, Enable and Multi­Program Inputs
When using a cable other than the standard SD0508200, the shield must be tied to Pin 2 (black of red) and must not be tied at the resolver end.
1 2 3 4 5 6 7 8
+--+-+
+
-
RESOLVER
INPUTS
BK/RED
RED
GREEN
BK/WHT
WHITE
BK/GRN
BLACK W/GREEN-S4
GREEN-S2
WHITE-S1
BLACK W/WHITE-S3
BLACK W/RED-RL
RED-RH
1986F
CABLE ASSEMBLY - SD0508200LXX
124365
1 2 3 4 5 6 7 8
OR EQUIVALENT
23
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
The 2500 has eight inputs that are internally tied to the eight outputs. The input connector is a sixteen position connector. Each input can be confi gured as either a reset-to-preset, an output enabler input or a die protection input. Inputs 1 - 8 require a PNP sourcing device type input signal.
For input wiring examples, see Fig. 3-12.
The Main Controller and Expansion Modules are available with any combination of solid-state AC or DC ouput relays. The Main Controller has one extra optional solid-state Brake Monitor input relay. This relay is located in the far left relay slot and is only used for brake monitoring. This twenty-place connector contains limit switch 1 - 8 solid-state relay outputs, the optional Brake Monitor input and the Fault Check output relay. For output or brake monitor input wiring, see Fig. 3-13 & 3-14.
LIMIT SWITCH OUTPUTS
COMM
AUX
DISPLAY
BRAKE
INPUT
FAULT
CHECK
RES
TRM
3
--
+8+
7
+
+
6
5
+
4
--
+
+2+1+
+
BK F.C.IN
87651516 14 1013 1112 9181920 17
SOLID STATE RELAY OUTPUTS. RELAY TYPES SPECIFIED IN THE PART NUMBER.
OUTPUTS
21
34
FAULT CHECK SEE NOTES
*
90-140VAC
BRAKE MONITOR INPUT
OPTO 22 P/N: G4IAC5
AMETEK P/N: 04523125
LIMIT SWITCH OUTPUTS
COMM
AUX
DISPLAY
BRAKE
INPUT
FAULT
CHECK
RES
TRM
3
--
+8+
7
+
+
­6
5
-
+
4
-- -
+-+2+1+-+
-
BK F.C.IN
NOT USED ON MODEL 2500CF. ONLY USED W/BLIND UNIT MODELS.
The remote operator interface connects to the Main Controller through an 8-pin Ethernet cable (part# SD0530100), commonly know as an RJ45. A full duplex RS485 is used to communicate to the Main Controller.
Figure 3-5
Figure 3-6
Figure 3-7
+--+-+
+-+++
---+-
RESOLVER
INPUTS
SEL
4
FLT IN
PRG
ENA
12
PRG
COM
8
BK/RED
RED
GREEN
BK/WHT
WHITE
BK/GRN
INPUTS 1-8
>1.5mA @ 10V
SOURCING DEVICE 10-30VDC ON AT
>4.0mA @ 30V
1 2 3 4 5 6 7 8
Inputs 1-8
Output Relays & Optional Brake Monitor Input
Remote Operator Interface
24
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
LIMIT SWITCH OUTPUTS
COMM
AUX
DISPLAY
BRAKE
INPUT
FAULT
CHECK
RES
TRM
3
--
+8+
7
+
+
­6
5
-
+
4
-- -
+-+2+1+-+
-
BK F.C.IN
RESISTOR JUMPER
RS-485 TERMINATION
COMMUNICATIONS PORT
RS-485 AUXILLARY
The auxillary RS485 communication port uses a standard RJ11 connector. The communication port has not been defi ned at this time, consult factory.
The standard 2500 PLS is supplied with 8 inputs and 8 outputs. The system is expandable to 64 inputs and 64 outputs by adding the 2500E Expansion Module. Each expansion module consists of 8 output modules and 8 inputs. Simple depluggable cable assemblies
Figure 3-8
NOTE: Connect from Expansion Out of main controller to Expansion In on expansion module.
Figure 3 - 9
Clawson, MI 48017 U.S.A.
NP0197900
R
ENTER
SCROLL
MENU
2500 SERIES PLS
Depluggable Expansion Cable
Part Number SD0528500LX
X = Length in feet 1 & 6 ft length available.
Expansion Module
Expansion Module
Main Controller
Expansion Out
Expansion In
Expansion Out
Expansion In
w
S
DE
C
TR5
V
F 4A 250V
V
S
C
D E
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
DE
S
TR5
w
F 4A 250V
w
TR5
C
V
DE
S
F 4A 250V
DE
S
C
V
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
DE
S
TR5
w
F 4A 250V
IN4
INPUT STATUS
IN1 IN2 IN3 IN6IN5 IN7 IN8
INTERNALLY FUSED
L1
100-240 VAC
50/60 Hz
AC POWER
GND
L2
OUT4OUT1 OUT2 OUT3 OUT6OUT5 OUT7 OUT8
SERIAL No. >>>>>> D/C >>>>
2500EXXXXX
Clawson, MI 48017 U.S.A.
2500 SERIES PLS
R
w
S
DE
C
TR5
V
F 4A 250V
V
S
C
DE
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
D E
S
TR5
w
F 4A 250V
w
TR5
C
V
DE
S
F 4A 250V
DE
S
C
V
TR5
w
F 4A 250V
w
C
V
DE
S
TR5
F 4A 250V
C
V
DE
S
TR5
w
F 4A 250V
IN4
INPUT STATUS
IN1 IN2 IN3 IN6IN5 IN7 IN8
INTERNALLY FUSED
L1
100-240 VAC
50/60 Hz
AC POWER
GND
L2
OUT4OUT1 OUT2 OUT3 OUT6OUT5 OUT7 OUT8
SERIAL No. >>>>>> D/C >>>>
2500EXXXXX
Clawson, MI 48017 U.S.A.
2500 SERIES PLS
R
Auxillary Com Port
Expansion Connections
connect from expansion to expansion or the Main Controller.
25
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
Figure 3-9
Main Wiring Diagram
L
I
M
I
T
S
W
I
T
C
H
O
U
T
P
U
T
S
C
O
M
M
A
U
X
D
I
S
P
L
A
Y
B
R
A
K
E
I
N
P
U
T
F
A
U
L
T
C
H
E
C
K
R
E
S
T
R
M
3
--
+
8
+
7
+
+
­6
5
-
+
4
-- -
+
-
+
2
+
1
4
+
8
--
+
7
-
+
6
+
5
-
+
+
+
--
32
-
+
1
-
R
E
S
O
L
V
E
R
I
N
P
U
T
S
S E L
4
F L T
I
N
P R G
E N A
12
P R G
C O M
8
B K /
R E D
R E D
G R E E N
B K /
W H T
W H I
T E
B K /
G R N
+
-
+
-
B
K
F
.
C
.
I
N
B
L
A
C
K
W
/
G
R
E
E
N
-S
4
G
R
E
E
N
-
S
2
W
H
I
T
E
-S
1
B
L
A
C
K
W
/W
H
I
T
E
-S
3
B
L
A
C
K
W
/R
E
D
-R
L
R
E
D
-
R
H
N
O
T
U
S
E
D
O
N
M
O
D
E
L
2
5
0
0
C
F
.
O
N
L
Y
U
S
E
D
W
/B
L
IN
D
U
N
IT
M
O
D
E
L
S
.
1986F
C
A
B
L
E
A
S
S
E
M
B
L
Y
-
S
D
0
5
0
8
2
0
0
L
X
X
M
U
L
T
I
-
P
R
O
G
R
A
M
S
E
L
E
C
T
S
IN
K
IN
G
IN
P
U
T
S
+
5
V
D
C
M
A
X
O
N
A
T
<
1
V
D
C
@
5
m
A
IN
P
U
T
S
1
-8
>
1
.
5
m
A
@
1
0
V
S
O
U
R
C
IN
G
D
E
V
I
C
E
1
0
-
3
0
V
D
C
O
N
A
T
12437865
87651
5
1
6
1
4
1
0
1
3
1
1
1
2
9
1
8
1
9
2
0
1
7
S
O
L
ID
S
T
A
T
E
R
E
L
A
Y
O
U
T
P
U
T
S
.
R
E
L
A
Y
T
Y
P
E
S
S
P
E
C
IF
IE
D
IN
T
H
E
P
A
R
T
N
U
M
B
E
R
.
S
E
E
M
A
N
U
A
L
F
O
R
W
IR
I
N
G
D
E
T
A
IL
S
.
O
U
T
PU
T
S
>
4
.0
m
A
@
3
0
V
2 1
34
F
A
U
L
T
C
H
E
C
K
S
E
E
N
O
T
E
S
*
9
0
-
1
4
0
V
A
C
B
R
A
K
E
M
O
N
IT
O
R
I
N
P
U
T
O
P
T
O
2
2
P
/N
:
G
4
IA
C
5
A
M
E
T
E
K
P
/N
: 0
4
5
2
3
1
2
5
O
R
E
Q
U
IV
L
E
N
T
F
A
U
L
T
C
L
E
A
R
E
N
A
B
L
E
P
R
O
G
R
A
M
S
E
C
U
R
I
T
Y
I
N
P
U
T
R
E
S
IS
T
O
R
J
U
M
P
E
R
R
S
-4
8
5
T
E
R
M
I
N
A
T
I
O
N
C
O
M
M
U
N
IC
A
T
IO
N
S
P
O
R
T
R
S
-4
8
5
A
U
X
IL
L
A
R
Y
A
26
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
M
A
C
H
I
N
E
S
H
O
U
L
D
B
E
W
I
R
E
D
S
O
T
H
A
T
D
E
-
E
N
E
R
G
I
Z
I
N
G
F
A
U
L
T
C
H
E
C
K
R
E
L
A
Y
W
I
L
L
I
M
M
E
D
I
A
T
E
L
Y
S
T
O
P
M
A
C
H
I
N
E
.
I
F
N
O
F
A
U
L
T
C
H
E
C
K
N
E
E
D
E
D
-
D
O
N
O
T
C
O
N
N
E
C
T
A
N
Y
W
I
R
I
N
G
T
O
F
A
U
L
T
C
H
E
C
K
I
N
P
U
T
(
F
L
T
I
N
)
A
N
D
D
O
N
O
T
W
I
R
E
F
A
U
L
T
C
H
E
C
K
R
E
L
A
Y
I
N
T
O
M
A
C
H
I
N
E
R
U
N
C
I
R
C
U
I
T
.
N
O
T
E
:
A
L
L
S
W
I
T
C
H
E
S
C
A
N
B
E
R
E
P
L
A
C
E
D
B
Y
A
N
O
P
E
N
C
O
L
L
E
C
T
O
R
(
C
U
R
R
E
N
T
S
I
N
K
I
N
G
)
D
E
V
I
C
E
,
C
O
N
N
E
C
T
E
D
S
I
M
I
L
A
R
T
O
A
B
O
V
E
.
R
E
C
O
M
M
E
N
D
E
D
W
I
R
I
N
G
O
F
F
A
U
L
T
C
H
E
C
K
R
E
L
A
Y
(
C
)
1
(
N
O
)
2
C
O
M
8
(
C
L
O
S
E
D
)
E
N
A
B
L
E
F
L
T
I
N
3
T
H
E
U
S
E
O
F
T
H
E
F
A
U
L
T
C
H
E
C
K
F
E
A
T
U
R
E
I
S
O
P
T
I
O
N
A
L
A
N
D
S
H
O
U
L
D
B
E
W
I
R
E
D
T
O
T
H
E
P
L
S
C
I
R
C
U
I
T
R
Y
A
S
S
H
O
W
N
B
E
L
O
W
O
N
L
Y
I
F
I
T
I
S
R
E
Q
U
I
R
E
D
.
I
F
A
C
U
S
T
O
M
E
R
S
U
P
P
L
I
E
D
F
A
U
L
T
C
H
E
C
K
R
E
S
E
T
S
W
I
T
C
H
I
S
W
I
R
E
D
A
S
B
E
L
O
W
,
A
F
T
E
R
A
F
A
U
L
T
O
C
C
U
R
S
,
T
H
E
F
A
U
L
T
C
H
E
C
K
R
E
L
A
Y
D
E
-
E
N
E
R
G
I
Z
E
S
A
N
D
A
L
L
O
U
T
P
U
T
R
E
L
A
Y
S
D
E
-
E
N
E
R
G
I
Z
E
.
A
F
T
E
R
T
H
E
F
A
U
L
T
I
S
C
O
R
R
E
C
T
E
D
A
N
D
T
H
E
C
U
S
T
O
M
E
R
S
U
P
P
L
I
E
D
R
E
S
E
T
S
W
I
T
C
H
I
S
O
P
E
N
E
D
(
D
IS
A
B
L
E
D
)
A
N
D
R
E
C
L
O
S
E
D
(
E
N
A
B
L
E
D
)
,
T
H
E
F
A
U
L
T
C
H
E
C
K
R
E
L
A
Y
W
I
L
L
R
E
-
E
N
E
R
G
I
Z
E
A
N
D
T
H
E
O
U
T
P
U
T
S
W
I
L
L
R
E
S
U
M
E
N
O
R
M
A
L
O
P
E
R
A
T
I
O
N
.
I
F
N
O
R
U
N
/S
E
C
U
R
I
T
Y
P
R
O
G
R
A
M
I
S
N
E
E
D
E
D
(
A
L
W
A
Y
S
I
N
P
R
O
G
R
A
M
M
O
D
E
)
I
N
S
T
A
L
L
A
J
U
M
P
E
R
W
I
R
E
B
E
T
W
E
E
N
C
O
M
&
P
G
M
.
E
N
A
B
L
E
T
H
E
U
S
E
O
F
T
H
E
E
N
A
B
L
E
F
E
A
T
U
R
E
I
S
O
P
T
I
O
N
A
L
A
N
D
S
H
O
U
L
D
B
E
W
I
R
E
D
T
O
T
H
E
P
L
S
C
I
R
C
U
I
T
R
Y
A
S
S
H
O
W
N
B
E
L
O
W
O
N
L
Y
I
F
I
T
I
S
R
E
Q
U
I
R
E
D
.
T
Y
P
I
C
A
L
W
I
R
I
N
G
F
O
R
C
U
S
T
O
M
E
R
S
U
P
P
L
I
E
D
E
N
A
B
L
E
I
N
P
U
T
.
W
H
E
N
S
W
I
T
C
H
I
S
O
P
E
N
,
P
L
S
O
U
T
P
U
T
S
W
I
L
L
B
E
E
N
A
B
L
E
D
.
W
H
E
N
S
W
I
T
C
H
I
S
C
L
O
S
E
D
O
U
T
P
U
T
S
W
I
L
L
B
E
D
I
S
A
B
L
E
D
.
F
A
U
L
T
C
H
E
C
K
C
I
R
C
U
I
T
C
O
M
8
R
U
N
P
R
O
G
R
A
M
(
C
L
O
S
E
D
)
P
G
M
1
O
R
D
I
S
A
B
L
E
C
O
M
82
E
N
A
B
L
E
(
O
P
E
N
)
E
N
A
O
R
O
R
T
O
M
A
C
H
I
N
E
R
U
N
C
O
N
T
R
O
L
2
5
0
0
P
L
S
C
A
N
N
O
T
B
E
P
R
O
G
R
A
M
M
E
D
U
N
T
I
L
T
H
E
P
G
M
I
N
P
U
T
H
A
S
B
E
E
N
A
C
T
U
A
T
E
D
-
C
O
N
T
I
N
U
I
T
Y
-
B
E
T
W
E
E
N
C
O
M
&
P
G
M
I
N
P
U
T
P
R
O
G
R
A
M
S
E
C
U
R
I
T
Y
I
N
P
U
T
T
Y
P
I
C
A
L
W
I
R
I
N
G
F
O
R
C
U
S
T
O
M
E
R
S
U
P
P
L
I
E
D
P
R
O
G
R
A
M
S
E
C
U
R
I
T
Y
S
W
I
T
C
H
W
H
E
N
S
W
I
T
C
H
I
S
C
L
O
S
E
D
,
P
L
S
C
A
N
B
E
P
L
A
C
E
D
I
N
P
R
O
G
R
A
M
M
O
D
E
.
W
H
E
N
S
W
I
T
C
H
I
S
O
P
E
N
,
P
L
S
W
I
L
L
B
E
I
N
R
U
N
M
O
D
E
.
(
A
L
L
F
U
N
C
T
I
O
N
S
C
A
N
B
E
V
I
E
W
E
D
B
U
T
D
A
T
A
C
A
N
N
O
T
B
E
C
H
A
N
G
E
D
.)
T
W
O
M
E
T
H
O
D
S
O
F
W
I
R
I
N
G
S
E
C
U
R
I
T
Y
S
W
I
T
C
H
S
E
E
M
A
N
U
A
L
F
O
R
I
N
P
U
T
P
O
W
E
R
W
I
R
I
N
G
D
E
T
A
I
L
S
.
I
N
P
U
T
P
O
W
E
R
B
)
I/O
M
O
D
U
L
E
A
C
O
U
T
P
U
T
2
4
-
2
8
0
V
A
C
A
)
I
/O
M
O
D
U
L
E
D
C
O
U
T
P
U
T
5
-
6
0
V
D
C
T
H
IS
D
E
V
IC
E
C
A
N
B
E
S
U
P
P
L
IE
D
W
IT
H
T
H
E
S
E
O
U
T
P
U
T
D
E
V
IC
E
S
:
P
A
R
T
N
o
. 0
4
5
2
3
1
2
6
P
A
R
T
N
o
. O
4
5
2
3
1
2
7
C
O
N
N
E
C
T
IO
N
S
T
O
P
.C
. O
U
T
P
U
T
M
O
D
U
L
E
S
3
4
2
1
R
D
C
O
U
T
P
U
T
M
O
D
U
L
E
A
M
E
T
E
K
P
/N
:
0
4
5
2
3
1
2
6
A
M
P
L
I
F
I
E
R
c
F
U
S
E
O
P
T
O
2
2
P
/N
: G
4
O
D
C
5
O
P
T
O
2
2
P
/N
: G
4
O
A
C
5
A
A
M
E
T
E
K
P
/
N
: 0
4
5
2
3
1
2
7
L
O
A
D
O
R
L
O
A
D
4
A
C
O
U
T
P
U
T
M
O
D
U
L
E
3
2
F
U
S
E
1
C
I
R
C
U
I
T
c
R
L
O
A
D
L
O
A
D
O
R
V
A
C
Z
E
R
O
V
O
L
T
A
G
E
L
E
D
L
E
D
C
O
N
T
R
O
L
L
E
D
I
N
T
E
R
N
A
L
L
Y
B
Y
2
5
0
0
P
L
S
C
O
N
T
R
O
L
L
E
D
I
N
T
E
R
N
A
L
L
Y
B
Y
2
5
0
0
P
L
S
*
*
*
C
O
M
M
U
T
A
T
I
O
N
D
I
O
D
E
M
U
S
T
B
E
U
S
E
D
O
N
I
N
D
U
C
T
I
V
E
L
O
A
D
S
.
T
Y
P
I
C
A
L
L
Y
,
U
S
E
D
I
O
D
E
I
N
4
0
0
5
.
Drawing # E0238000
27
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
Enable / Disable Outputs
The use of the enable feature is optional and should be wired to the PLS circuitry as shown below only if it is required. Typical wiring for customer supplied
Figure 3 - 11
DISABLE
8
COM
(OPEN)
ENABLE
OR
ENA
2
PROGRAM SECURITY INPUT
ON AT <1VDC @ 5mA
MULTI-PROGRAM SELECT
-
+
+
--
+
PRG
8
COM
4
SEL
21
ENA
PRG
FLT IN
5876 43 12
FAULT CLEAR
+5VDC MAX
SINKING INPUTS
ENABLE
INPUTS
+
---
+
+--+
+
BK/RED
RESOLVER
BK/GRN
WHITE
BK/WHT
GREEN
RED
1 2 3 4 5 6 7 8
enable input. When the switch is open, PLS outputs will be enabled. When the switch is closed, outputs will be disabled.
28
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
Input Wiring Guidelines
• An external power supply must be used to power inputs.
• Inputs will operate with voltages from 10 - 30VDC.
• Each input will draw 4.0mA max.
• A combination of mechanical and solid state devices can be used.
• Each input is optically isolated.
• With mechanical switches, you can either break to + or - input.
• Each input is optically isolated and does not share a common.
• Voltage must be present across + and - terminals for input to turn on.
-
+
8
+
-7­6
+
Inputs Terminal Strip
4
+
-5--
+3+
-
2
-
+1+
3 wire DC Sensor w/ PNP Output
+
Customer Supplied 10-
30VDC
Power Supply
-
Connect to + terminal of inputs 1-8
PLC Sourcing Module or other
Connect to + terminal of inputs 1-8
Connect to + terminal of inputs 1-8
Switch or Relay Contact
Whisker Sensor Note: For whisker sensor
applications take power supply + to + of input terminal & - of power supply to frame of machine.
Sourcing PNP Devices + VDC is being switched
Figure 3 - 12
Control Input Wiring
29
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
Outputs Terminal Strip
Across LS1-8 +,­outputs
Note: L1 or L2 can be broken with the solid state output relay.
AC OUTPUT
24-280VAC 3 AMP MAX.
LIMIT SWITCH OUTPUTS
8+7
+
5
6
+4+
+3+
--
+
12
+
INBK
+
INPUT
BRAKE
F.C.
+
CHECK
FAULT
Neutral
L2
Hot
L1
Load
Limit Switch Outputs 1-8
Load
DC OUTPUT
5-60VAC 3 AMP MAX.
+VDC
DC
Common
+
Sourcing
Load
DC
Common
Sinking
+
+VDC
*
*
Limit Switch Outputs 1-8
Figure 3 - 13
Figure 3 - 14
* Commutation diode must be used on inductive loads Typically, use IN4005
LIMIT SWITCH OUTPUTS
8+7
+
5
6
+
RES
COMM
AUX
TRM
4
+
+3+
--
+12+
INBK
+
INPUT
BRAKE
DISPLAY
F.C.
+
CHECK
FAULT
L1 L2
Brake Input 90-140VAC from Presses Brake/Clutch Solenoid
Note: The Brake Monitor input looks for a loss of input voltage. When the brake monitor’s input voltage drops out, the 2500 starts a high speed counter. This counter continues to count until the resolvers comes to a stop.
Control Output Wiring
Brake Monitor Input Wiring
30
1080 N. Crooks Road • Clawson, MI 48017 • 800.635.0289 • Fax 248.435.8120 • www.AMETEKAPT.com
Clawson, MI 48017 U.S.A.
NP0197900
R
ENTER
SCROLL
MENU
2500 SERIES PLS
Shift Key Left
Menu Key
2 x 24 Alpha Numeric: Vacuum Florescent Display.
POS 12345 RPM 2000
Shift Key Right
Rotary Knob
Enter Key
Chapter 4: Programming
This chapter provides detailed descriptions and instructions for programming all 2500 PLS functions. A complete list of functions, with a brief explanation, can be found in Chapter One: Standard Features.
Figure 4-1: Programming Keys
4.1 Main Controller Keypad
Figure 4-1 calls out the 2500’s display, rotary knob and programming keys. Following this fi gure are descriptions of these keys and how they work, as well as a short tutorial on how to use the keys and rotary knob.
Loading...
+ 67 hidden pages
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use