Electro-cam 5000 Series User Manual

Programming &Installation ManualOctober 2001PLµS® PS-5000 SeriesProgrammable Limit Switch13647 Metric Rd • Roscoe, IL 61073 USA • 815/389-2620 • F

Controllers with Built-In Transistor I/O Chips2-3 Dimensions & Component LocationsPS-5011PS-5111Detailed View of24 VDC VersionSee page 2-5for Cont

PS-5021PS-5121PS-5024PS-5124PS-5001PS-5101PS-5004PS-5104PS-5034PS-5134Controller Dimensions2-4 Dimensions & Component Locations

PS-5011PS-5111Controller Dimensions2-5 Dimensions & Component Locations

3-1 WiringLogic Terminal Strip(see pp. 2-1 thru 2-3 for location)Program Select Switch and Cable:Pt# PS-4901-01-XXX (XXX=FT)DC power for accessories

3-2 WiringExternal 16 Module I/O Racks: Dimensions & SpecificationsPS-5001PS-5101PS-5004PS-5104End ViewStandard 16 Rack: PS-4100-11-216Analog 16 R

3-3 WiringExternal 24 & 48 Module I/O Racks: Dimensions & SpecificationsPS-5001PS-5101PS-5004PS-5104End ViewNotes:•A Standard module is requir

3-4 WiringSlimline I/O Modules on Controller Back: SpecificationsPS-5021PS-5121PS-5024PS-5124Notes:• A module is required for each Input or Output use

3-5 WiringDC InputModule Wiring—InputsPS-5024PS-5124AC InputSourcing• Input devices can be mechanical contacts or solid state.• The load 10K load resi

3-6 WiringThe output board which contains the output transistor arraychips and the fuse(s) is located under the output boardcover. The pluggable outpu

3-7 WiringBuilt-In Transistor I/O Chips: Output Wiring, SourcingThe output power supplies shown can be internal to theload device being driven. This w

Copyright © 2001All Rights ReservedNeither this document nor any part may be reproduced or transmitted inany form or by any means without permission i

3-8 WiringBuilt-In Transistor I/O Chips: Output Wiring, SinkingThe output power supplies shown can be internal to the loaddevice being driven. This wi

3-9 WiringPLC with Sinking Inputs(A.B. calls these sourcing inputs)PS-5X11 withSinking OutputsPLC with Sourcing Inputs(A.B. calls these sinking inputs

3-10 WiringIntroductionThe PS-5X34 system is available with either 32 or 64 lowcurrent transistor outputs. These systems are intended tobe interfaced

3-11 WiringUser DC Power Input10 - 30 VDC, 4 Amp Max(Sinking outputs switch "-")(Sourcing outputs switch "+")Rack Address Jumper1:

3-12 WiringPS-4100-12-N32Wiring to a PLC with Sinking Inputs(A.B. calls these Sourcing Inputs)Power Supply can beexternal from the PLCNote: PLµS trans

3-13 WiringTransistor Array Chip Layout on PS-4100-12-N32 Sinking Output RackPS-4100-12-P32ULN-2813ULN-2813 ULN-2813ULN-2813UDN-2580UDN-2580UDN-2580UD

3-14 WiringRESOLVER DIMENSIONSResolver Wiring and DimensionsShieldRedGreenBlackBlackWhiteBlackPin A - BlackPin D - RedPin E - BlackPin F - Whi

3-15 WiringSTAINLESS STEEL RESOLVERCable for Stainless Steel Resolver with Terminal Strip ConnectionsPT# PS-5300-02-XXX (XXX = Length in Feet)Connec

3-16 WiringPlug shield spade connector ontoNON-TERM lug if encoder is groundedto the machinePlug shield spade connector ontoTERM lug if encoder is not

4-1 Programming, Standard FeaturesLevels of Programming AccessThe 5000 Series of controls have three levels of programmingaccess. Entry into these lev

Table of ContentsSection—IntroductionBasic Cam Switch Operation . . . . . . . . . . . . . . . . . . . . . 1-1Standard Features . . . . . . . . . . .

4-2 Programming, Standard Features1 - Function Key and DisplayThe FCN Key is used to access the controls functions. TheFCN number accessed will be dis

4-3 Programming, Standard FeaturesNote: When entering multiple pulses, pressENTafter eachCREATE SETPOINTSCLEAR SETPOINTSOutput Setpoint ProgrammingPr

4-4 Programming, Standard FeaturesMaster Level Programming, Standard Controls: FCN 0FCN 0 Programming at the Master Level(Master Program Enable Input

4-5 Programming, Standard FeaturesMaster Level Programming, Standard Controls: FCN 0 (continued)tb - Time Base Used for Output TimingThe timing resolu

4-6 Programming, Standard Features2ndPress CHN key toselect rU3rdPress PULSE key to selectdesired update frequency. 1st If FCN 0not show

4-7 Programming, Standard FeaturesMaster Level Programming, Standard Controls: FCN 6 & FCN 7FCN 6 - Operator Access(Master Program Enable Input MU

4-8 Programming, Standard FeaturesFCN 7 - Motion ANDing of Output Channels(Master Program Enable Input MUST be energized)This function selects which o

4-9 Programming, Standard FeaturesMaster Level Programming, PS-5XX4 Only: FCN 8 & FCN 9Programming the Number of Enable Inputs3rdEnable Input #Sel

4-10 Programming, Standard FeaturesSetup Level Programming, Standard Controls: FCN 1, FCN 2, FCN 3FCN 1 - Motion Setpoints(Setup or Master program ena

4-11 Programming, Standard FeaturesPresent Programnumber shown2ndPress CHN keyto select Pn3rdPress number keys followed byENT to change active

WARRANTY1. Electro Cam Corp. warrants that for a period of twelve (12) months from the date of shipment tothe original purchaser, its new product to b

4-12 Programming, Standard FeaturesSetup Level Programming, Standard Controls: FCN 4FCN 4 - Speed Compensation(Setup or Master program enable must be

4-13 Programming, Standard FeaturesSetup Level Programming, Standard Controls: FCN 4 & FCN 5FCN 4 - Negative Speed Comp (continued)In order to act

5-1 Programming, Optional FeaturesLeading / Trailing Edge Speed Compensation: Option “-L”FCN 0 Sc - Type of Speed Compensation

5-2 Programming, Optional FeaturesAnalog Output: Option “-A”FCN 1 Ao, Ah - Analog Output Signal(Units with "A" option only)The analog

5-3 Programming, Optional FeaturesSpeed Compensated Gray Code Output: Option “-G”Gray Code Position Output -( Units with the "G" Option)Plµ

5-4 Programming, Optional FeaturesExtra Program Storage: Option “-F”Special Alternate Functions have been included in the “F”option to report the tota

5-5 Programming, Optional FeaturesExtra Program Storage: Option “-F” (continued)FCN 3 - Program Number ChangesThe “F” option can store up to 992 uniqu

5-6 Programming, Optional FeaturesExtra Program Storage: Option “-F” (continued)Select Inactive Program Number to beViewed/EditedPress PGM keyPres

5-7 Programming, Optional FeaturesPhase Mark Registration: Option “-P”27090120300Example 1 illustrates the following:CHN 14 - ON @ 290 OFF @ 350CHN

5-8 Programming, Optional FeaturesPhase Mark Registration: Option “-P” (continued)Logic Terminal Strip (see pgs. 2-1 thru 2-3 for location)Terminals 6

Basic Cam Switch OperationBasic Cam Switch OperationA PLµS control’s main purpose is to operate outputs in amanner that simulates cam switches. The dr

5-9 Programming, Optional FeaturesPress number keys 8 1 followed by ENTPhase Mark Registration: Option “-P” (continued)CHN 80 - Auto-Center Regi

5-10 Programming, Optional FeaturesPhase Mark Registration: Option “-P” (continued)Some registration control systems use the “Off” portion ofthe input

Output Grouping and ModesAdvantages of Grouping OutputsPS-5XX4 controls can be subdivided into as many as eightdifferent output groups. Each group can

Appendix A-2Output Grouping and Modes I/O Configuration ExamplesM1M2M3M4M5M6M7M8M9910111213141516123456781817Note: Group 1 Input on Controller Log

Mode Introduction - Mode 0 OperationAppendix A-3Introduction to ModesThe use of modes allows PS-5XX4 controls to performoutput logic which goes be

Mode 1 OperationAppendix A-4Details of Mode 1 -Alter Position from Input SignalAn output group operating in Mode 1 will have its outputsenabled at

Mode 1 Logic Flow ChartAppendix A-5Mode 1 Logic Flow ChartThe flow chart to the right details how Mode 1 operates.The control’s response to any se

Mode 2 OperationAppendix A-6Details of Mode 2 -Alter Position and Enable OutputsAn output group operating in Mode 2 only has its outputsenabled af

Mode 2 Logic Flow ChartAppendix A-7The control’s response to any set of conditions can bedetermined by stepping through the flow chart blocks usin

Mode 3 OperationAppendix A-8Details of Mode 3 -AND Outputs with Input SignalAn output group operating in Mode 3 will have the samecharacteristics

1-2 IntroductionSelectable Scale Factor (resolvers only)The number of increments per revolution (Scale Factor) isprogrammed by the user. Standard cont

Mode 3 Logic Flow ChartAppendix A-9Mode 3 Logic Flow ChartPower UpOutputs DisablednoyesGroup EnableInput On?Outputs Enabled1234The flow chart to t

Appendix A-10Mode 4 OperationDetails of Mode 4 -Input Signal Required for Output CycleAn output group operating in Mode 4 only has its outputsenab

Mode 4 Logic Flow ChartAppendix A-11Mode 4 Logic Flow ChartTASKDECISIONPower UpOutputs DisabledGroupPosition withinWindow?noyesnoInput SignalLeadi

Appendix A-12Error MessagesTwo types of errors may be displayed:Programming Programming error messages indicate that a programming attempt was i

Appendix A-13Error Messages (Continued)E4-ProProgramming Not Enabled A programming change was attempted when the corresponding level of programmi

FAtL intInternal Run Error There is a hardware problem with internal circuitry. All outputs will be disabled.Solution: Call Electro Cam for return aut

60 59.161 60.562 61.964 63.365 64.766 66.168 67.570 68.971 70.372 71.774 73.175 74.576 75.978 77.380 78.881 80.282 81.684 83.085 84.486 85.888 87.289

Alternate Functions - Utilities and Hardware TestingAppendix A-16Alternate functions test and/or display the hardware statusof the control or p

Remote Display Installation, Wiring and SetupDimensioned / Wiring Drawing12345R-R+T-T+V+V-SH(Back View)3. Red - Data +4. Black - Data -5. Green - S

Controller SpecificationsElectrical24 VDC 20-30 VDC120 VAC 50/60 Hz: 108 - 132 VAC240 VAC 50/60 Hz: 216 - 264 VACPower Consumption: 35 VAPermanent Mem

1-3 IntroductionPS-5000 Series Model SummaryPS-5021PS-5121PS-5024PS-5124These ModelsHave I/O ModulesOn Controller BackPS-5001PS-5101PS-5004PS-5104PS-5

Transducer SpecificationsENCODER(S)Operating Temp: 0° to 50°C (32° to 122°F)Storage Temp: -40° to 50°C (-40° to 122°F)Operating Humidity: 95% Relative

Reed Relays: EC-ORR5 (Standard)Output Type: N/O Reed Relay ContactsContact Rating: 10VA maximum(DC resistive load)Switching Volts: 0 V to 200 V, DC or

Analog Output Module Specifications0-10 VDC: EC-ANLG-010V (Standard)EC-SANL-010V (Slimline)Resolution: 12 Bits (4096 increments)Output Voltage: 0-10 V

Input Module SpecificationsAppendix A-22DC Inputs: EC-IDC5 (Standard)EC-IDC032 (Slimline)Input Voltage: 10-32 VDCInput Current: 34 mA maximum (@3

Transistor Output SpecificationsAppendix A-23Sinking Transistor Outputs (PS-5X11, N08 and N16)Output Type: Current Sinking (NPN)Output Voltage:

IndexCommunications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6cA, Communication Address . . . . . . . . . . . . . . . . 4-6cS, Comm

IndexFCN 0All ControllersDirection of Increasing Rotation (dr) . . . . . . . . 4-4Display Default (dd) . . . . . . . . . . . . . . . . . . . . . 4-5

Motion ANDing (FCN 7) . . . . . . . . . . . . . . . . . . . . . . 4-8Motion DetectionSetpoints (FCN 1) . . . . . . . . . . . . . . . . . . . . . . .

“tr” (FCN 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5Transistor OutputReplacement . . . . . . . . . . . . . . . . . . . .

Controllers w/ External I/O Module Rack2-1 Dimensions & Component LocationsPS-5001PS-5101PS-5004PS-5104PS-5034PS-5134Detailed View of24 VDC Versio

800-228-5487 (U.S.A. and Canada) • Web Site: www.electrocam.com • email: [email protected] IN U.S.A 252 10/01

2-2 Dimensions & Component LocationsPS-5021PS-5121PS-5024PS-5124Controllers w/ I/O Modules on Controller BackLED HOLDDOWN SCREWFUSE4ASlimline Mo