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Electro Cam PLUS PS-5000 Series - User Manual

Electro Cam PLUS PS-5000 Series
81 pages
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Programming &
Installation Manual
January 2006
PL
µ
S
®
PS-5000 Series
Programmable Limit Switch
13647 Metric Rd • Roscoe, IL 61073 USA815/389-2620FAX 815/389-3304800-228-5487 (U.S.A. and Canada)

Table of Contents

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Summary

Introduction

Basic Cam Switch Operation

Explains the function of a cam switch and how PLµS controls simulate it.

Standard Product Features

Details key features like Keyboard/Controller, Ease of Setup, and Multiple Programs.

Optional Product Features

PS-5000 Series Model Summary

Controllers w; External I;O Module Rack

2-1 Dimensions & Component Locations

Provides detailed physical dimensions and component identification for external I/O racks.

Controllers w; I;O Modules on Controller Back

2-2 Dimensions & Component Locations

Details physical dimensions and component locations for controllers with I/O modules on the back.

Controllers with Built-In Transistor I;O Chips

2-3 Dimensions & Component Locations

Shows physical dimensions and component layout for controllers with integrated transistor I/O chips.

Controller Dimensions

2-4 Dimensions & Component Locations

Provides detailed dimensional drawings for various controller models.

Controller Dimensions

2-5 Dimensions & Component Locations

Details dimensions and component layout for PS-5011 and PS-5111 controllers.

Logic Terminal Strip Wiring-Standard Controller

Logic Terminal Strip

Diagram and explanation of the standard controller's logic terminal strip connections.

External 16 Module I;O Racks: Dimensions & Specifications

Standard 16 Rack

Specifications and dimensions for the standard 16-module I/O rack.

Slimline M16 Rack

Specifications and dimensions for the Slimline M16 DIN rail rack.

External 24 & 48 Module I;O Racks: Dimensions & Specifications

Standard 24 Rack

Specifications and dimensions for the standard 24/48 module I/O racks.

Slimline I;O Modules on Controller Back: Specifications

Module Wiring - Outputs

Details wiring configurations for AC, DC Sourcing, DC Sinking, and Analog output modules.

Sinking or Sourcing

Module Wiring-Inputs

Explains wiring for AC and DC input modules, including sinking and sourcing configurations.

Input Wiring, 3-Wire Sensors

Provides wiring diagrams for 3-wire sensors using logic terminal strip power or external supply.

Built-In Transistor I;O Chips: Specifications

Built-In Transistor I;O Chips: Output Wiring, Sourcing

Built-In Transistor I;O Chips: Output Wiring, Sinking

Built-In Transistor I;O Chips: Output Wiring to PLC

PS-5 X34 Controller & 32 DC Output Rack

Introduction

Overview of the PS-5X34 system, its low-current transistor outputs, and capabilities.

Output Rack Configuration

Explains how to configure and connect multiple output racks for 32 or 64 outputs.

PS-5 X34 System: Output Rack Layout

PS-5 X34 System: Wiring to PLCs

PS-5 X34 System: Output Rack Transistor Array Chips

Resolver Wiring and Dimensions

STANDARD RESOLVER CABLES

Details standard resolver cable specifications and wiring.

Foot Mount Resolver - 3;4 Shaft

Provides dimensions and mounting details for 3/4" shaft foot mount resolvers.

Flange Mount Resolver - 3;8 Shaft

Shows dimensions and mounting information for 3/8" shaft flange mount resolvers.

Resolver Wiring and Dimensions

STAINLESS STEEL RESOLVER

Wiring and dimension details for stainless steel resolvers.

Stainless Steel Foot Mount Resolver - 5;8 Shaft

Provides dimensions for 5/8" shaft stainless steel foot mount resolvers.

Encoder Cable Installation

Programming Access Levels

Levels of Programming Access

Describes the three programming access levels: Master, Setup, and Operator.

Logic Terminal Strip

Illustrates hardware connections for program selection and enable functions.

Keyboard Enable Codes for Setup and Operator Access

Explains how to use keyboard codes to access Setup and Operator programming levels.

Keyboard Layout, Keys and Indicators

Function Key and Display

Details the FCN key and how function numbers are accessed and displayed.

Program and Channel Keys

Explains the PGM and CHN keys for program and channel selection.

Value Display, Keys, and LEDs

Describes the POS/RPM display, related keys, and ON/OFF LEDs.

Indicator LEDs

Explains the status indicated by the MOTION, POWER, and CPU LEDs.

Control Keys

Details the function of numeric keys, CLR/CLE, ENT, INC, and DEC keys.

Output Setpoint Programming

Create;Change Setpoints

Guides on creating, changing, and clearing output setpoints using the keypad.

Programming Error Messages

Lists common programming error messages and how to clear them.

Select Channel and View;Clear Setpoints

Instructions for selecting an output channel and viewing or clearing its setpoints.

Master Level Programming, Standard Controls: FCN 0

FCN 0 Programming at the Master Level

Details master level programming for Function 0 features.

dr - Direction of Increasing Rotation

Explains how to set the direction of rotation for transducers.

SF - Scale Factor (Resolver units only)

Describes how to set the scale factor for resolver-based systems.

P1 & P2 Keyboard Enable Codes

Instructions for setting up keyboard enable codes for programming access.

Master Level Programming, Standard Controls: FCN 0 (continued)

dd - Display Default

Configures the default display mode (Auto, Spd, or Pos).

tr - Toggle RPM

Sets the RPM threshold for automatic display switching between position and RPM.

tb - Time Base Used for Output Timing

Selects the time resolution for timed output functions.

Master Level Programming, Standard Controls: FCN 0 (continued)

ct, cS, CA - Communication Parameters

Configures communication type, speed, and address for serial ports.

rU - rPM Display Update Frequency

Sets how often the RPM value is updated on the display.

Viewing; Changing Program Banks

Explains how to view or change active program bank (Pb) settings.

Master Level Programming, Standard Controls: FCN 6 & FCN 7

FCN 6 - Operator Access

Configures which features operators can adjust at the Operator access level.

Setting Output Channel Access

Defines which output channels operators can adjust.

Setting Operator Accessible Functions

Enables or disables specific functions for operator adjustment.

FCN 7 - Motion ANDing of Output Channels

Master Level Programming, PS-5 XX4 Only: FCN 8 & FCN 9

FCN 8 - Subdividing Outputs into Groups

Defines the number of output groups and outputs per group.

FCN 9 - Enable Inputs and Enable Modes

Assigns enable inputs and selects modes for output groups.

Setup Level Programming, Standard Controls: FCN 1, FCN 2, FCN 3

FCN 1 - Motion Setpoints

Sets the low and high RPM values for motion detection.

FCN 2 - Offset

Allows matching the controller position to the machine position.

FCN 3 - Program Number

Manages active programs, banks, and individual program numbers.

Setup Level Programming, Standard Controls: FCN 1, FCN 2, FCN 3

Viewing;Changing Program Number

How to view or change the active program number (Pn) from the keyboard.

Viewing;Changing the Active Program

Explains how to view or change the active program (AP) setting.

Viewing;Changing Program Banks

Details how to view or change the program bank (Pb) setting.

Setup Level Programming, Standard Controls: FCN 4

FCN 4 - Speed Compensation

Enables automatic adjustment of output setpoints based on machine speed.

FCN 4 - Negative Speed Compensation

Allows output channels to lag machine position for timing adjustments.

Setup Level Programming, Standard Controls: FCN 4 & FCN 5

FCN 4 - Negative Speed Comp (continued)

Details programming negative speed compensation values.

FCN 5 - Timed Outputs

Configures outputs to turn off after a specified time duration.

Leading; Trailing Edge Speed Compensation: Option “-L”

FCN 0 Sc - Type of Speed Compensation

Selects standard or leading/trailing edge speed compensation.

FCN 4 - Leading;Trailing Edge Speed Compensation

Programs separate compensation for leading and trailing edges.

Programming the Leading Edge Speed Comp Value

Sets the speed compensation value for the leading edge of output pulses.

Programming the Trailing Edge Speed Comp Value

Sets the speed compensation value for the trailing edge of output pulses.

Analog Output: Option “-A”

FCN 1 Ao, Ah - Analog Output Signal

Configures analog output offset (Ao) and high RPM (Ah).

Programming the Analog Offset

Details how to set the analog offset value for 0-10 VDC or 4-20 mA output.

Programming the Analog Full Scale Signal RPM

Sets the RPM value at which the analog output reaches full scale.

Outputs Based On Direction of Rotation: Option “-D”

Explains how to base output operation on resolver rotation direction.

Speed Compensated Gray Code Output: Option “-G”

Gray Code Position Output

Describes the 8-bit Gray Code output and its relation to position display.

Gray Code Conversion Ladder

Illustrates the ladder diagram for converting Gray Code to Binary.

FCN 4 - Gray Code Speed Compensation

Applies speed compensation to Gray Code outputs as a group.

Extra Program Storage: Option “-F”

Number of Pulses;Programs Available

Explains the increased pulse and program storage capacity with the '-F' option.

Active Program Number Displays

Shows how active program numbers are displayed with RPM or position.

Extra Program Storage: Option “-F” (continued)

FCN 3 Program Number Management

Covers FCN 3 changes, keyboard access, and hardware selection of program numbers.

Viewing;Changing Program Numbers

Guides on viewing/changing program number (Pn), active program (AP), and program bank (Pb).

Extra Program Storage: Option “-F” (continued)

Viewing;Editing Inactive Program

Instructions for viewing or editing programs not currently active.

Phase Mark Registration: Option “-P”

Registration Window Examples and Adjustment Methods

Illustrates registration windows and how to adjust them.

Phase Mark Registration: Option “-P” (continued)

Logic Terminal Strip

Details logic terminal strip functions for phase mark registration.

Input Information

Describes input terminals used for phase mark registration functions.

General Logic Input Information

Provides general information on logic inputs and their behavior.

Phase Mark Registration: Option “-P” (continued)

CHN 80 - Auto-Center Registration

Explains how to automatically center registration windows.

CHN 81 - Display Adjust Registration Center

Details how to monitor and adjust the registration center position.

Phase Mark Registration: Option “-P” (continued)

Automatic Reversal of Centering Logic

Describes how the control handles "off" logic for registration centering.

Output Grouping and Modes

Advantages of Grouping Outputs

Explains the benefits and reasons for grouping outputs together.

How to Program Output Grouping and Modes

Provides step-by-step instructions for programming output groups and modes.

Logic Input Compared to Input Modules

Compares logic terminal inputs with I/O rack input modules.

Output Grouping and Modes I;O Configuration Examples

Example #1

Configuration example for a 9 I/O 5X24 controller with three output groups.

Example #2

Configuration example for a 16 I/O 5XX4 controller with four output groups.

Introduction to Modes

Example Applications that Use Modes

Lists applications and modes for different machine processes.

Details of Mode 0 - Standard Cam Operation

Explains Mode 0 operation where outputs are always enabled.

How to Program Mode 0 Operation

Provides steps for programming Mode 0 operation.

Mode 1 Operation

Details of Mode 1 - Alter Position from Input Signal

Explains Mode 1 operation where position resets to zero on input signal.

How to Program Mode 1 Operation

Provides steps for programming Mode 1 operation, including input windows.

Mode 1 Example Application

Illustrates Mode 1 use for sections with varying phase relationships.

Mode 1 Logic Flow Chart

Mode 2 Operation

Details of Mode 2 - Alter Position and Enable Outputs

Explains Mode 2 operation where outputs are enabled after input signal.

How to Program Mode 2 Operation

Provides steps for programming Mode 2 operation, including input windows.

Mode 2 Example Application

Illustrates Mode 2 use for controlling functions asynchronously.

Mode 2 Logic Flow Chart

Mode 3 Operation

Details of Mode 3 - AND Outputs with Input Signal

Explains Mode 3 where outputs are enabled only when input signal is on.

How to Program Mode 3 Operation

Provides steps for programming Mode 3 operation.

Mode 3 Example Application

Illustrates Mode 3 use for functions requiring a maintained input signal.

Mode 3 Logic Flow Chart

Mode 4 Operation

Details of Mode 4 - Input Signal Required for Output Cycle

Explains Mode 4 where outputs cycle only if input occurs within a specified window.

How to Program Mode 4 Operation

Provides steps for programming Mode 4 operation, including input windows.

Mode 4 Example Application

Illustrates Mode 4 use for punch operation based on part position.

Mode 4 Logic Flow Chart

Error Messages

Programming Errors

Lists programming error messages and their general causes.

System Errors

Details system error messages that disable outputs and require correction.

Specific Error Codes

Explains common error codes like CrASH, EEPROM, Memory, and Pulse Overlap.

Error Messages (Continued)

Programming and Input Errors

Covers errors related to programming not enabled or numbers out of range.

Resolver and Speed Compensation Errors

Details errors like Resolver Fault and too many speed compensated channels.

Error Messages (Continued)

Hardware and Power Errors

Explains errors related to internal hardware, power voltage, and stuck buttons.

Communication Port Information

Details communication port pinouts and RS-232 cable wiring.

Encoder Position Chart; 60 Pulse Disc for Encoder Based Controls

Alternate Functions - Utilities and Hardware Testing

Alternate Functions List

Itemized list of alternate functions for testing and diagnostics.

Remote Display Installation, Wiring and Setup

Dimensioned; Wiring Drawing

Provides wiring diagrams and physical dimensions for the remote display.

Display Operation

Explains how the remote display shows position or RPM values.

Controller; Display Setup

Details necessary FCN 0 settings in the PLµS control for display setup.

Controller Specifications

Transducer Specifications

Input Module Specifications

Analog Output Module Specifications

Transistor Output Specifications

Electro Cam PLUS PS-5000 Series Specifications

General IconGeneral
BrandElectro Cam
ModelPLUS PS-5000 Series
CategorySwitch
LanguageEnglish