Electro Cam PLUS PS-6244 Series Manual de usuario

Programming &

Installation Manual

4/99

PLµS™ PS-6244 Series

Programmable Limit Switch

PGM:1 RPM:1500

MENU< POS: 180

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

1-2 Introduction

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

1-3 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

CommunicationsWiring..................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

InitialProgramming.........................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

1-4 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 new product to be free from defects in material and workmanship and

that the product conforms to applicable drawings and specifications approved by the Manufac-

turer. This warranty period will be extended on Distributor or OEM orders to a maximum of

eighteen months to take into consideration Distributor or OEM shelf time.

2. The remedy obligations of Electro Cam Corp.under this warranty are exclusive and are limited to

the repair, or at its option, the replacement or refund of the original purchase price of any new

apparatus which proves defective or not in conformity with the drawings and specifications. Ship-

ment of the claimed defective 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

CamCorp. All claims must bemadeinwriting toElectro CamCorp.,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 car-

rier.

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

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

Cam Corp.

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

mined at the sole discretion of Electro Cam Corp.

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

the manufacturer ever be liable for consequential and incidental damages, or in any amount

greater than the purchase price of the equipment.

4. There are no warranties which extend beyond the description on the face hereof. This warranty is

in LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED INCLUDING (BUT NOT

LIMITEDTO) ANY IMPLIEDWARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PAR-

TICULAR PURPOSE, ALL OF WHICH ARE EXPRESSLY DISCLAIMED. Any legal proceeding

arisingout of the sale oruse of this apparatusmustbe commencedwithin (18) months of thedate

of shipment from the manufacturer.

1-5 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 revolu-

tion would need to be replaced with a different cam if three on/off pulses per revolu-

tion were required.

• They cannot run at high speeds because of contact bounce and excessive mechani-

cal 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 fric-

tional 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.

1-6 Introduction

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, associat-

ed circuitry, and all of the I/O circuits. This eliminates the need for external I/O racks.

A separate 1/4 DIN keypad/display provides a complete user interface from which ev-

ery 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-6244-

24-X16M09 Both are described in Figure 3.

Figure 3—PS-6244 Models

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.

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.

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

Controller

PS-6400

Keypad/Display

Typical

Quadrature Encoder

(BEI H25D shown)

Programmable Limit Switches

1-7 Introduction

BasicTerminology

Thefollowingtermswill be used throughoutthismanualto 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 key-

pad/display, or they can be downloaded from a computer or PLC through serial com-

munications. 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

andglueacertain size carton. Thesesettingscould be stored asa“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 corre-

sponding setpoints would take effect.

Theuseof programs canprovidetremendous advantages overmechanicalcam switch-

es. Standard PS-6244’s can store up to 48 programs. The active program can be se-

lected 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 chan-

nels based on sensor signals.

1-8 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

deviceswhenevermachine speedsarechanged. Speedcompensationprovides 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 usu-

ally connected to a product sensor.

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

belinearly proportionalto RPM.TheanalogsignallevelatzeroRPMcanbeprogrammed,

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.

2-1 Installation & Wiring

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:

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 cir-

cuits. 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 in-

ductive 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 cor-

rect the polarity and replace the fuse before the controller will operate.

Toinsure electricalnoise immunity,connect agood electricalground tothe 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.

CAUTION

2-2 Installation & Wiring

Figure 4—Mounting Dimensions

Mounting Dimensions

PGM:1 RPM:1500

MENU< POS: 180

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