Electrocam: Catalog

PL µ S Controls Div. PS-6000 Series Programmable Limit Switches Available with Modbus™ ASCII Communications 16 DC Logic Level Outputs for Direct Interfacing to PLC's

*Slimline Modules have built-in Fuses & LED's

*17 Plug-In Output Modules for Real World Control of Electro-Mechanical Devices

Controllers can be used with or without Keypad/Display

Plug-In Terminal Blocks Simplify Wiring

*9 Plug-In Output Modules for Real World Control of Electro-Mechanical Devices Dual Resolver Inputs

PS-6144-24-P16M09 Controller DIN Rail Mountable

PS-6344-24-M17 Controller

2-Line Backlit Supertwist LCD Display * Modules sold separately.

Available in AC, DC, Analog & Reed Relay

PS-6400-24-001 Keypad/Display

Compact 1/4 DIN Keypad/Display mounts remotely.

Multiple keypads may be used with one controller.

Description

Benefits

The PLµS PS-6144 Series Programmable Limit Switches are microprocessor based units designed to control machine functions on automated equipment. They can be used as stand-alone controllers, or interfaced to PLC’s in larger automation systems.

Improved Machine Control

The PLµS PS-6344 Programmable Dual Axis Limit Switch is designed to control machine functions on two independent axes. It can also be used as a stand-alone controller, or interfaced to PLC's in larger automation systems.

Typical applications include: ■ ■ ■ ■ ■ ■ ■ ■ ■

Polybag Machines Labelling Machines Can Making Machines Form-Fill-Seal Machines Paper Converting Machines Pick & Place Machines Metal Processing/Stamping Adhesive Application Systems Automatic Assembly Machines

■ ■ ■ ■ ■ ■ ■ ■

Cartoners Case Packers Palletizers De-Palletizers Vision Systems Filling Machines Beverage Fillers High Speed Presses

Features such as automatic speed compensation, combined with fast scan times, enable a PLµS Controller to quickly respond to changes in line speed and product movement, minimizing machine errors and reducing scrap and downtime.

Easier Operator Control By handling complex automation functions under rapidly changing line conditions, PLµS Controllers allow an operator to concentrate on product flow into and out of the line, instead of constantly monitoring the line for malfunctions and manually adjusting setpoints. PLµS Controllers increase operator interface capabilities and contribute to smooth, efficient production.

Faster Changeovers, Greater Flexibility PLµS Controllers can store multiple programs of timing setpoints for solenoids, cylinders, motors, glue guns, and other mechanisms. This allows quick changes in product size or configuration, reducing downtime and improving productivity.

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

PLµ S Controllers Enhance PLC Systems

Figure 1

PL µS Controllers are Fast!

PL µS Controllers Simplify PLC Programming!

As the system in Figure 1 shows, the PLµS monitors the production line every 300 to 500 µsec, approximately 100 times faster than an average PLC with its more extensive programming. Although the PLC does interface directly with the production line, the functions it controls are lower speed, and deals more with the logic functions necessary for machine control.

For high speed, critical functions such as label-to-product registration, the PLµS provides faster control and improved precision, reducing scrap and rejects.

By handling complex functions like speed compensation, timed outputs, and sensor gating, the PLµS controller relieves a programmer of having to write complicated PLC control programming from scratch. The PLC software can simply exchange process variables and control data with the PLµS controller, which handles direct high speed machine control through its own dedicated software.

PLµS Controllers Simplify Operator Interface Design!

Using transistor outputs, the PLµS can signal changes to the PLC within 300 to 500 µsec (as fast as 40 µsec on special models); much faster than the serial communications speed of approximately 50 msec. When product sensors send a signal to the DC input of the PLµS, the PLµS responds to that signal quickly.

Many production lines require an operator to select product sizes or configurations through a keyboard. The 1/4 DIN keypad/display of the PS-6000 can be mounted near the production machinery, giving an operator easy access to critical control functions. The keypad transmits these changes back through the PLµS controller to the PLC, eliminating the need for a PLC system designer to supply custom operator interface software and hardware for PLS functions.

PL µS Controllers have Serial Communications!

Electro Cam Corp. has Systems Experience!

For product changeovers, the PLC can send commands and operating parameters to the PLµS controller to change setpoint programs. This eliminates the need for an operator to manually change programs through the PLµS keyboard.

Our standard PLµS controllers feature extensive capabilities for integration into larger control systems, PLC based or otherwise. We can supply IBM-PC compatible PLuSNet software to facilitate communications between our controllers and a host computer. In addition, we can supply controllers with custom features such as shift-register capability, or the ability to function in non-rotary environments. For information on our systems capabilities, please call our toll free number.

PL µS Controllers have Built-In DC Inputs & Outputs!

PL µS Controllers Save PLC Memory!

The PLµS controller can store many programs containing various setpoints for the production line. The PLC need only select the correct program, and the PLµS will do the rest.

800-228-5487 2

Standard PS-6000 Series Features Analog Output

Timed Outputs

PS-6000 controllers can drive two analog output modules whose output signals will be linearly proportional to RPM. The analog signal level at zero RPM can be programmed, as well as the RPM that corresponds to maximum signal. No measuring equipment is required for initial setup, and calibration is not needed.

Typical uses for the analog output are to control adhesive pressure as machine speeds change, or to match speeds of other equipment to the machine being controlled by the PS-6000.

Timed outputs are programmed like standard outputs to turn “ON” and “OFF” at specific points of resolver rotation. However, once a timed output turns ON, it will remain ON for a specified time period. Timed outputs are used to drive devices such as heat seal bars, spot welders, etc., that require a fixed time to perform a task, regardless of machine speed.

Selectable Scale Factor

Up to 48 programs can be stored in the control’s memory, each containing different setpoints. To change product size or configuration, simply switch program numbers and all of the output settings will change accordingly. Program numbers can be selected by the keypad/display, mechanical switches, PLC DC outputs, or serial communication messages.

The Scale Factor, or number of increments per revolution, can be programmed by the user. Standard controls have a maximum of 1024 increments per revolution, while controls available with an “-H” option have a maximum of 4096 increments per revolution. Scale Factor can be defined to correlate to Real World increments. For example, a controller could be programmed so that one increment of rotation corresponds to 0.1" of travel.

Output Speed Compensation

Serial Communication

Speed compensation allows outputs to compensate for lagging response times of the controlled devices by turning on earlier as machine speeds increase. This eliminates the need to manually adjust output settings whenever machine speeds are changed, allowing high production speeds.

Using Electro Cam Corp.’s PLuSNet software for IBM-PC compatible computers, the controller’s entire program can be saved to a disk file or loaded from a disk file to the control. The program can be printed or edited using the computer. Using MMI software, it is also possible to send individual communication commands to the control, while running, to change settings in the program.

Multiple Programs

Internal High Speed Logic Outputs can be divided into Groups, and each Group can be associated with an input device to perform discrete logic. There are six different modes of operation, or logic functions, that can be selected for each Group. For example, some modes activate the Group only when the input has signaled that product is present. Adhesive control is a typical application where outputs are disabled until product is sensed. Output grouping is a powerful tool in many applications because each Group can be in any of the six modes and operate independently of the other Groups.

Motion Detection Two speed ranges can be programmed into the controller, and specified outputs can then be enabled or disabled, based on the machine speed being within the designated range. This feature can turn off outputs if the machine stops; disable outputs until the machine reaches a minimum speed; or disable outputs if the machine exceeds a specified speed. In adhesive applications, speed range logic is often used to turn off the flow of adhesive if the conveyor carrying products stops.

Certifications are standard.

PS-6000 Series Options Gray Code Position Output, “-G” & “-G10”

Leading/Trailing Edge Speed Comp, “-L”

The “-G” option provides eight bits of position information to a PLC or other electronic control device, eliminating the need for expensive PLC accessory cards. The "-G10" option provides ten bits of position information. This allows the PLC to control non-critical machine functions, while the PLµS directly handles high-speed machine control.

Controls with this option allow the "ON" and "OFF" edges of output pulses to be speed compensated by different amounts.

If a device has “ON” and “OFF” response times that are different, it may be necessary to compensate the “ON” edge by a different amount than the “OFF” edge. This will ensure that the device stays properly synchronized to the machine over a wide range of speeds. High-speed adhesive application is an example that can benefit from this feature.

High Resolution, “-H” Controls with this option can divide the resolver revolution into as many as 4096 increments, while standard controls have a maximum of 1024 increments. The control program allows resolver resolution to be set for any value in the range of 2-4096.

NEMA 4X Keyboard Boot, “-W” Controls with the “-W” option are shipped with a clear silicon rubber boot fitted over and around the keyboard area. The boot provides a good seal between the back of the keyboard and the control panel. The boot is transparent and pliable, allowing the keyboard to be viewed and operated. In addition to preventing contamination from harsh chemicals, the boot protects the keyboard from washdown damage.

Large Program Memory, “-F” Controls with the “-F” option can store up to 256 programs consisting of not more than 4589 output pulses total; standard controls can store up to 48 programs. This additional program storage capability is useful for applications requiring multiple complex programs, or those requiring the storage of more than 48 programs.

Modbus™ ASCII Communication, “-MB” See page 4.

Multiple Controllers Used with One Resolver, “-MSV” See page 5.

3

PS-6000 Series with -MB Option — with Modbus ™ ASCII Communications Description

Benefits

Standard Modbus™ ASCII protocol allows a host computer, Programmable Logic Controller (PLC), intelligent touch panel, or other compatible logic circuitry to easily monitor or modify data within the PS-6000-MB while the machine is in motion.

Improved Machine Control The controller quickly responds to changes in line speed and product movement by combining automatic speed compensation with fast scan times. Modbus serial communications makes it easy to integrate the PLµS controller's high-speed control characteristics into larger control systems.

The control data in the PS-6000-MB is organized as registers and coils, compatible with PLC programming techniques. Registers are used to store control parameters at specific addresses.

Coils represent channel outputs and logic inputs. Through serial communications, coils allow outputs to be forced ON or OFF, and allow inputs to be monitored.

Messaging Capability The PLµS keypad/display can display stored messages or messages received from a host computer. Each message, containing up to 32 characters, is stored in non-volatile EEPROM memory.

The data can be changed by writing to registers, and monitored by reading from registers. All controller data, including position, pulses, RPM, speed compensation, and timed output values, are available through registers.

Mapping Mapping allows the programmer to arrange data into blocks of registers for optimal communication efficiency, giving direct access to specific indexed data items. For example, setpoint values may be mapped into a series of direct access registers in order to display more than one value at once on the host computer.

NOTE: All other features of the -MB version of 6000 series controllers are the same as those for standard PS-6000 series controllers.

PS-6000-MB System Configuration The Modbus™ ASCII protocol allows the PS-6000-MB Series controller to communicate with various control hardware and software, including: ■

PC's using Microsoft ® Windows™ software such as FactoryLink®, Intellution™, Lookout™, and Wonderware®

■

PC's using DOS software such as Interact™

■

Intelligent Touch Panels

■

PLC's

As the diagram in Figure 2 illustrates, the host computer communicates to the PLµS using Modbus™ ASCII serial communications. The PLµS controller handles high-speed machine functions through direct wiring of inputs and outputs to the machine.

The Modbus serial commands in the PS-6000-MB Series controller allow you to monitor the program, adjust the current program, or change the program through a host computer system.

This allows the flexibility to change product size or configuration quickly and automatically, reducing downtime and improving productivity.

Figure 2

4

PS-6000 Series with -MSV Option Description The -MSV (Master-Slave) option allows up to four controllers to be daisy-chained to one resolver. Controllers with the -MSV option are equipped with a jumper that the user can plug/unplug to configure the unit to be either a master or a slave. The controller comes from the factory jumpered as a master, but can be set to slave status by removing the jumper. Figure 3 shows jumper location:

The wiring of the resolver is daisy-chained to all of the controllers as shown below in Figures 4 & 5. The master controller supplies the reference signal to the resolver and slave units.

The resolver supplies the position information to all units. Only a single unit can be the master. Daisy-chain the power from controller to controller in the same way as the resolver signals.

Connect one of the controllers directly to the power supply.

Power for the other devices in the system should come directly from the power supply. DO NOT power other devices from the wires powering the controllers. This will help reduce the risk of problems associated with EMI and ground loops. Use the standard resolver cable from master to resolver. Use a PS-530005-XXX resolver cable from the master to slave controllers, and from slave to slave.

NOTE: PS-6344 Series Controllers include Master-Slave feature as standard.

All other features of the -MSV version of 6000 series controllers are the same as those for standard PS-6000 series controllers.

Figure 3

Figure 4

Figure 5

5

PS-6X44 Specifications Controller Part Numbers

PS-6144-24-P16M09 (Sourcing† Transistor Outputs) PS-6144-24-N16M09 (Sinking† Transistor Outputs)

PS-6144-24-M17

PS-6344-24-P16M09 (Sourcing† Transistor Outputs) PS-6344-24-N16M09 (Sinking† Transistor Outputs)

PS-6344-24-M17

Electrical Input Voltage

20-30 VDC

20-30 VDC

Input Current

System: 850 mA max. @ 20 VDC. Includes controller, 2 keypads, resolver, 16 transistor outputs, 7 power modules, 2 analog modules, and 16 inputs, all ON. Current will be less at higher voltage.

System: 850 mA max. @ 20 VDC. Includes controller, 2 keypads, resolver, 15 power modules, 2 analog modules and 16 inputs, all ON. Current will be less at higher voltage.

Controller only: 150 mA max. @ 20 VDC

Controller only: 150 mA max. @20 VDC

Controller, Resolver, 1 Keypad: 275 mA max @ 20 VDC

Controller, Resolver, 1 Keypad: 275 mA max @ 20 VDC

EEPROM (no battery required)

EEPROM (no battery required)

Operating Temp.

0° to 55°C (32° to 131°F)

0° to 55°C (32° to 131°F)

Storage Temp.

-40° to 70°C (-40° to 160°F)

-40° to 70°C (-40° to 160°F)

Humidity

95% maximum relative non-condensing

95% maximum relative non-condensing

NEMA Rating

For use on type 1, 4, 4X or 12 enclosure

For use on type 1, 4, 4X or 12 enclosure

Overall Dimensions

See Dimensions (Figures 4 & 5) on page 8.

See Dimensions (Figures 4 & 5) on page 8.

Weight

Controller: 3.5 lbs. (1.6 kg). Keypad/Display: 0.5 lbs.

(0.2 kg)

Controller: 3.5 lbs. (1.6 kg). Keypad/Display: 0.5 lbs.

(0.2 kg)

Brackets accept EN-50035 ("G" profile) or EN-50022 ("Top Hat" profile) DIN rail.

Brackets accept EN-50035 ("G" profile) or EN-50022 ("Top Hat" profile) DIN rail.

Mounts up to 1000' from controller. Up to 2 keypads may be connected to one controller.

Mounts up to 1000' from controller. Up to 2 keypads may be connected to one controller.

DC Inputs

16 DC inputs; can be configured as sinking† or sourcing† in groups of 8. Optically isolated in groups of 8.

16 DC inputs; can be configured as sinking† or sourcing† in groups of 8. Optically isolated in groups of 8.

Input On State Voltage

10-30 VDC

10-30 VDC

Input Current

11 mA @ 24 VDC

11 mA @ 24 VDC

Input Response Times

1 - 2 scans

1 - 2 scans

Real World Outputs

Up to 9 SLIMLINE modules may be plugged into controller. Modules may be any mix of AC, DC, reed relay, & up to 2 analog. All modules optically isolated.

Up to 17 SLIMLINE modules may be plugged into controller. Modules may be any mix of AC, DC, reed relay, & up to 2 analog. All modules optically isolated.

Analog Outputs

Up to two 4-20 mA or 0-10 VDC SLIMLINE analog modules may be plugged into controller. Output proportional to RPM. 12 bit resolution. Update frequency 10 times/ sec (100 msec). Linearity is ±0.3% @ 77°F (25° C). Offset & full scale RPM are programmable.

Up to two 4-20 mA or 0-10 VDC SLIMLINE analog modules may be plugged into controller. Output proportional to RPM. 12 bit resolution. Update frequency 10 times/ sec (100 msec). Linearity is ±0.3% @ 77°F (25° C). Offset & full scale RPM are programmable.

DC (transistor) Outputs

16 sinking † or sourcing†, optically isolated. 30 VDC, 50 mA max. each. Note: Sinking† or sourcing† must be specified on order.

Permanent Memory

Environment

Physical

Mounting Controller Keypad/Display

Inputs

Outputs PS-6144 Series

Outputs PS-6344 Series

†

Outputs are assignable to each resolver.

Outputs are assignable to each resolver.

Specifications continued...

See page 12 for sinking/sourcing definitions.

6

PS-6X44 Specifications (continued) Controller Part Numbers

PS-6144-24-P16M09 (Sourcing† Transistor Outputs) PS-6144-24-N16M09 (Sinking† Transistor Outputs)

PS-6144-24-M17

PS-6344-24-P16M09 (Sourcing† Transistor Outputs) PS-6344-24-N16M09 (Sinking† Transistor Outputs)

PS-6344-24-M17

Operation Scan Time

300 to 500 µsec typical (exact time determined by programming). For higher speeds, interrupt driven versions are available — consult factory.

300 to 500 µsec typical (exact time determined by programming). For higher speeds, interrupt driven versions are available — consult factory.

Position Resolution

10 bits (1024 increments). 12 bits (4096 increments) available with "-H" option.

10 bits (1024 increments). 12 bits (4096 increments) available with "-H" option.

Speed Compensation

Programmed in 0.1 msec steps. 16 individually compensated outputs maximum. Calculations every 10 msec. Special algorithm prevents false firing under rapid acceleration and deceleration. Separate leading/trailing edge compensation available with "-L" option.

Programmed in 0.1 msec steps. 16 individually compensated outputs maximum. Calculations every 10 msec. Special algorithm prevents false firing under rapid acceleration and deceleration. Separate leading/trailing edge compensation available with "-L" option.

Output Timeout

1.0 msec time base (accuracy +1, -0 msec)

1.0 msec time base (accuracy +1, -0 msec)

Number of Timed Outputs

Four maximum

Four maximum

Multiple Programs

48 programs standard (256 available with "-F" option).

48 programs standard (256 available with "-F" option).

Total Pulse Memory

1258 pulses standard (4589 available with "-F" option).

1258 pulses standard (4589 available with "-F" option).

Pulses per Program

512 maximum standard (512 available with "-F" option).

512 maximum standard (512 available with "-F" option).

Pulses per Output

512 maximum standard (512 available with "-F" option).

512 maximum standard (512 available with "-F" option).

Maximum Speed

3000 RPM

3000 RPM

Port Types

1 RS-232 or 1 RS-422/485 — RS-485 can be configured as a "Multi-Drop" network.

1 RS-232 or 1 RS-422/485 — RS-485 can be configured as a "Multi-Drop" network.

Baud Rates

4800, 9600, 19.2K, 38.4K

RS-232/485 Serial Communication

Slimline Output Modules

4800, 9600, 19.2K, 38.4K

Part Numbers

Part Numbers

0-60 VDC, 0-3 amps

EC-ODC060-3

EC-ODC060-3

0-200 VDC, 0-1 amp

EC-ODC200-1

EC-ODC200-1

24-280 VAC rms, 50/60 Hz. 0.02-3 amps

EC-OAC240-3

EC-OAC240-3

Reed Relay

EC-ORR000-0

EC-ORR000-0

Analog, 0-10 VDC

EC-SANL-010V

EC-SANL-010V

Analog, 4-20 mA DC

EC-SANL-420M

EC-SANL-420M

Keypad/Display (Up to 2 keypad/displays can be used with one controller)

Keypad/Display w/Gasket

PS-6400-24-001

Cable, Keypad-to-Controller

PS-6300-01-XXX

Resolvers & Cables

PS-6400-24-001 (XXX = length in feet)

PS-6300-01-XXX

Electro Cam Corp. offers a wide variety of resolver models, shaft sizes, & mounting configurations, including a stainless steel resolver. The cable required depends on the resolver. Contact Electro Cam for details.

Note: Controllers may be used with or without keypad/display. †

See page 12 for sinking/sourcing definitions.

7

(XXX = length in feet)

Electro Cam Corp. offers a wide variety of resolver models, shaft sizes, & mounting configurations, including a stainless steel resolver. The cable required depends on the resolver. Contact Electro Cam for details.

PS-6X44 Controllers & PS-6400 Keypad/Display Dimensions

Figure 3 PS-6400-24-001 Keypad/Display

Figure 4 PS-6144-24-M17 PS-6144-24-P16M09 (Sourcing†) PS-6144-24-N16M09 (Sinking†)

Figure 5 PS-6344-24-M17 PS-6344-24-P16M09 (Sourcing†) PS-6344-24-N16M09 (Sinking†) †

See page 12 for sinking/sourcing definitions.

8

Resolvers The 7-pin resolver connector is supplied as part of the PLµS Programmable Limit Switch Controllers effective with date code 9723. Prior to that date code, connectors were supplied on the resolver cables. Spare 7-pin resolver connectors that plug into controllers may be purchased under part number PS-5300-01-TER. Some resolver configurations are shown below. See Price List (Literature #202) for complete listing.

PS-5275-11-ADS Foot Mount

PS-5238-11-ADR Flange Mount

• 3/4" Shaft

• 3/8" or 5/8" Shaft

• Top side, Right side, Left side or Rear connection

• Top side, Right side, Left side or Rear connection

PS-5238-11-SDR Servo Mount

PS-5262-11-CTG Stainless Steel

• 3/8" Shaft

• 5/8" Shaft

• Top side, Right side, Left side or Rear connection

• Left side or Right side connection

PS-5275-051-ADL* Foot Mount Geared

PS-5212-11-SVW Unhoused Servo Mount

• 3/4" Shaft

• .120" Shaft

• 5:1 Gear Ratio

• Standard Size 11

• Top side, Right side or Left side connection *Also available in 10:1 and 36:1 Ratio

9

Resolver Dimensions Foot Mount

With Rear Connector (shown): PS-5275-11-ADR With Side Connector: PS-5275-11-ADS Cable: PS-5300-01-XXX where "XXX" is length in feet.

Flange Mount

With Rear Connector (shown): PS-5238-11-ADR With Side Connector: PS-5238-11-ADS Cable: PS-5300-01-XXX where "XXX" is length in feet.

Stainless Steel

With Right Connector (shown): PS-5262-11-CTG With Left Connector: PS-5262-11-CTL Cable: PS-5300-02-XXX where "XXX" is length in feet.

Unhoused Servo Mount

Size 11, .120" Shaft: PS-5212-11-SVW

Contact the Factory for detailed specifications on other available resolvers.

10

Controller Part Number Breakdown P S - X X X X - X X - X X X(XXX) - X PLuS Part Number OPTIONS

MODEL/DISPLAY SELECTION

F-

Additional setpoint/program storage GGray Code Output (8 bit) G10 - Gray Code Output (10 bit) HHigh Resolution (12 bit-4096) LLeading & Trailing Edge Speed Compensation WWashdown boot

6 - 1/4 DIN LCD Display

TRANSDUCER SELECTION 1 - Resolver Input 3 - 2 Resolver Input

INPUT VOLTAGE 24 - (20 - 30 VDC Input)

MB - Modbus™ communication protocol available for PS-6X44 Models

INPUT/OUTPUT CONFIGURATION 4 - DC Transistor Outputs and/or SLIMLINE Modules on Keyboard/Controller back with input capability

MSV - Multiple Controllers used with one resolver

FUNCTIONS 4 - Output Enable Modes & Standard Features

TYPE & NUMBER OF OUTPUTS M17 17 SLIMLINE AC and/or DC Module Outputs, 2 of which may be analog N16M09 - 16 DC Sinking† Transistor Outputs & 9 SLIMLINE AC and/or DC Module Outputs, 2 of which may be analog P16M09 - 16 DC Sourcing† Transistor Outputs & 9 SLIMLINE AC and/or DC Module Outputs, 2 of which may be analog

Resolver Part Number Breakdown PS - 52 XX - XXX- X X X PLuS Part Number Resolver

HOUSING A C E S

SHAFT SIZE 12 15 20 38 62 75 -

1/8 DIA. 15 mm DIA. 20 mm DIA. 3/8” DIA., 2.06” Bolt Flange 5/8” DIA., 2.25” Bolt Flange 3/4” DIA.

-

Can housing w/flange or foot endbells Stainless steel square housing 74 mm bolt spacing, flange mount Servo mount ( .12 = size 11; .38 - size 25 )

TYPE OF CABLE CONNECTION D T V S

RATIO 11 051 101 361

-

Standard 1:1 (Note: 3rd digit not used on Standard 1:1) Geared 5:1 - Ext. shaft to internal resolver shaft Geared 10:1 - Ext. shaft to internal resolver shaft Geared 36:1 - Ext. shaft to internal resolver shaft

-

Military bayonet style connector Terminal strip with NO conduit entrance No connector, just stripped & tinned wires Sealed connector — screw type

Note: Part # PS-5903-01-001 conduit entrance for terminal strip models sold separately

LOCATION OF CABLE CONNECTION

†

WGR L S -

See page 12 for sinking/sourcing definitions.

11

With stripped & tinned leads Right (120° from top on “A” housings) Rear (not available on Geared Resolver) Left (120° from top on “A” housings) Side (Top)

Typical System(s) Component(s)

Qty.

Part Number

PS-6X44 Controller(s)

(1)

PS-6144-24-P16M09-L

PS-6400 Keypad/Display(s)

(1)

PS-6400-24-001

Keypad-to-Controller Cable(s)

(1)

PS-6300 -01-005

Resolver(s)

(1)

PS-5275-11-ADR

Resolver Cable(s)

(1)

PS-5300-01-010

SLIMLINE Output Modules

(7)

EC-ODC060-3

SLIMLINE Analog Modules

(2)

EC-SANL-010V

†

SINKING or SOURCING ( as pertaining to Electro Cam Corp. products )

Sinking means that when the logic is true and the output (or input device) is ON, the output (or input device) is providing a DC common or ground to the connected device.

Sourcing means that when the logic is true and the output (or input device) is ON, the output (or input device) is providing a +DC voltage to the connected device.

This information is important when interfacing an Electro Cam Corp. product with another electronic device. The terms SINKING / SOURCING are not used in the same context by all manufacturers. If you are using an Electro Cam Corp. product input to an Allen-Bradley 1746-IN16 “sinking” input card* or similar A-B device, you have to supply a +DC voltage to this card, NOT a DC common or ground. In these cases, Sinking is what the card does with the input voltage; sinks it to common or ground. * Other manufacturers include, but not limited to: Koyo (formerly GE Series 1, Texas Instruments, or Siemens SIMATIC PLS’s) that use descriptions similar to Allen-Bradley.

Electro Cam Corp. is highly experienced in supplying automation solutions to a variety of industrial machinery.

For assistance with your application, please call us.

800-228-5487

221 04/98

13647 Metric Rd • Roscoe, IL 61073 USA • Web Site: http://www.electrocam.com • email: ecam@electrocam.com

EC-3000/3400 Series Solid State Rotary Cam Limit Switches Interrupter Discs and Photocouplers Eliminate Contact Wear and Bounce

Internal Degree Wheel and Pointer

Interrupter Discs Seat Tightly on O-Rings.

Easy-to-Adjust with Wrench.

No Cumbersome Lock Screws

Right, Left, or Double-Ended Shaft Configurations Available

Plug-In AC, DC, or Reed Relay Output Modules

Gasketed NEMA 12 Enclosure on EC-3000; NEMA 4X Stainless Steel Enclosure on EC-3400

Heavy-Duty Sealed Ball Bearings

Description

Features

EC-3000 Series and EC-3400 Series Rotary Cam Limit Switches use interrupter discs and photocouplers instead of traditional cams and mechanical limit switches, eliminating contact wear and bounce. They provide on/off control of devices such as glue guns, solenoids, air cylinders, or relays on shaft-driven machinery. Electronic Cam Limit Switches can be used as stand-alone switches, or they can be interfaced to programmable logic controllers (PLC’s) or other logic circuitry.

•

Available with 4, 8, or 12 fused, optically-isolated outputs.

•

Heavy-duty construction for industrial environments.

•

Plug-in modules for AC or DC outputs; replaceable input/ output fuses, easily removed and installed with a needle nose pliers.

•

LED’s indicate output status.

•

EC-3000 units housed in NEMA 12 enclosures; EC-3400 units housed in NEMA 4X stainless steel enclosures.

•

Sealed ball bearings.

•

Internal degree wheel and pointer located on shaft for easy and accurate adjustment.

•

Right, left, or double-ended shaft extensions with a #606 Woodruff key provision; double-ended stainless steel shaft standard with NEMA 4X models.

•

Available options include multi-pulse discs, external degree wheel and pointer, sprocket disengagement clutch, highvibration models, and special shafts.

•

Standard EC-3000 and EC-3400 UL listed, CSA certified; 240 VAC models not UL listed.

Although generally used for applications which do not require setpoint adjustment for speed changes or product changeover, EC-3000 Series and EC-3400 Series switches can accommodate multiple setpoint schemes by assigning groups of interrupters to different product configurations. For product changeover, simply activate the appropriate group of interrupters.

Typical applications for EC-3000 Series and EC-3400 Series switches include cartoners and case packers, palletizers, gluing machines, high-speed presses, automatic assembly, pick and place equipment, and similar machinery.

13647 Metric Rd • Roscoe, IL 61073 USA • 815-389-2620 • FAX 815-389-3304 • 800-228-5487 (USA and Canada)

Theory of Operation Degree Wheel Pointer

Wrench for Cam Adjustment

Degree Wheel Interrupter Disc Halves

Adjustable to Correspond to Machine Zero

The gap, or open window in the interrupter is adjusted by using a wrench to turn the disc halves. Shown below in Figure 2 is a chart showing a few examples of setting “on” times, by adjusting the gap and the DIP switch positions.

Photocoupler

0 to 180 Degree Mode -Light Energized181 to 360 Degree Mode -Dark Energized-

DIP Switch

Disc halves seat tightly to the shaft with O-rings. The discs are easy to adjust with a wrench, requiring no cumbersome locking screws or other devices.

LED Indicator

Figure 1

SWITCH ENERGIZED BY MODE 0° - 180° Light Energized

As shown in Figure 1, each output switch is controlled by two-part interrupter discs which break the beam of light in a photocoupler. If the DIP switch associated with a photocoupler is in the “0° to 180°,” or Light Energized mode, the output will be switched on when the beam is unbroken.

If the DIP switch is in the “181° to 360°,” or Dark Energized mode, the output will be switched on when the interrupter breaks the beam.

Photocoupler Light Beam -PASSING-

ON TIME Fully Adjustable 1° to 180°

EXAMPLE CAM SETTINGS From 0° to 170° ON for 170°

From 45° to 180° ON for 135°

From 90° to 135° ON for 45°

From 312° to 322° ON for 7°

45° 170°

135°

7° "0"

181° - 360° Dark Energized

Photocoupler Light Beam -BLOCKED-

Fully Adjustable 181° to 359°

From 170° to 0° ON for 190°

"0"

From 180° to 45° ON for 225°

"0"

From 135° to 90° ON for 315°

"0"

From 322° to 315° ON for 353°

Figure 2

†

SINKING or SOURCING ( as pertaining to Electro Cam Corp. products )

Sinking means that when the logic is true and the output (or input device) is ON, the output (or input device) is providing a DC common or ground to the connected device.

Sourcing means that when the logic is true and the output (or input device) is ON, the output (or input device) is providing a +DC voltage to the connected device.

This information is important when interfacing an Electro Cam Corp. product with another electronic device. The terms SINKING / SOURCING are not used in the same context by all manufacturers. If you are using an Electro Cam Corp. product input to an AllenBradley 1746-IN16 “sinking” input card* or similar A-B device, you have to supply a +DC voltage to this card, NOT a DC common or ground. In these cases, Sinking is what the card does with the input voltage; sinks it to common or ground. * Other manufacturers include, but not limited to: Koyo (formerly GE Series 1, Texas Instruments, or Siemens SIMATIC PLS’s) that use descriptions similar to Allen-Bradley.

page 2

Standard Models All EC-3000 Series units are housed in NEMA 12 enclosures. All EC-3400 Series units are housed in NEMA 4X stainless steel enclosures. All units have either right, left, or double-ended shaft extensions with a #606 Woodruff Key provision; Nema 4X models have a double-ended stainless steel shaft. The cover plate on the EC-3400 Series units is secured with clamps to avoid contamination.

Five standard EC-3000 Series and four standard EC-3400 Series models are available: Model EC-3004/EC-3404 EC-3008/EC-3408 EC-3012/EC-3412

Outputs 4 8 12

Standard Shafts* Right, left, or double Right, left, or double Right, left, or double

* See dimensional drawings for shaft illustrations.

Special shafts can be supplied. Please enclose shaft drawing and specs with your order. All NEMA 4X units are ONLY available in double-ended shafts.

Model EC-3004-10-ARO

Options Pulse Generating Discs Multi-output pulse generating discs are an option offered for applications requiring multiple outputs per revolution.

These discs are most often used to generate timing pulses for tachometers, motion detection, glue stitching, or wherever multi-pulse signals are required. Glue stitching patterns on carton and case sealing equipment is an example of an application that benefits from pulse generating discs.

Standard pulse discs are available with 1, 2, 3, 4, 6, 7, 10, 16, 20, 32, 60, and 64 slots per revolution, allowing for quick changeover. Pulse generating discs must be ordered with the unit. The discs are factory mounted on the cam shaft, and each disc replaces one set of adjustable cams.

See Publication 107B for more detailed information.

Sprocket Disengagement Clutch The sprocket disengagement clutch is essential in situations where the shaft needs to be easily disconnected from the sprocket without removing the chain. The clutch not only allows for disengagement of one station of the machine to check operation without jogging the entire machine, but it simplifies the adjustment of the rotary cam limit switch. The clutch automatically locks back in the home position after one revolution. The clutch has a 3/4 inch bore with the provision for a #606 Woodruff key. There are five standard and numerous special sprockets available. See Publication 108B for more detailed information.

External Degree Wheel and Pointer An internal degree wheel and pointer is included with each EC-3000 and EC-3400 unit for reference during cam adjustment. To visually determine shaft position without removing the cover, an optional external degree wheel and pointer is available. This option must be ordered with the unit, and requires a double-ended shaft for mounting.

Specify mounting on left- or right-hand shaft (see mounting dimensions), and clockwise or counterclockwise rotation as viewed from end of shaft.

CFX for High Shock / Vibration For extremely high shock or vibration, such as punch press applications, a CFX option may be needed on the EC-3000 or EC-3400 units. The CFX option adds clear conformal coating on both sides of the printed circuit board and removable jumpers replace the DIP switch. The jumpers eliminate the possibility of intermittent connection to the DIP switch or the accidental changing of the DIP switch setting through shock or vibration.

CF for Highly Contaminating Environments For highly contaminating environments, the CF option may be ordered with the EC-3000 units. The CF option adds clear conformal coating to both sides of the printed circuit board. This option is standard on all EC-3400 units.

page 3

Mounting and Shaft Connection The shaft can be coupled to the machine using a chain and sprocket, timing pulley and belt, or a direct in-line shaft-to-shaft coupling.

If a shaft-to-shaft coupling is used, Electro Cam Corp. recommends the use of a flexible coupling. Flexible couplings available through Electro Cam Corp. are listed on the Rotary Cam Switch Price List, Lit. #111.

Using a solid coupling with shaft misalignment greater than 0.005" (T.I.R.) may damage the unit. Because of tolerance stackups, this will require shimming of the individual unit to its mounting surface.

Specifications Max Speed:

3000 RPM, clockwise or counterclockwise rotation

Max Phase Shift: 1°/1000 RPM Ambient Temp:

0° to 60°C (32° to 140°F)

Input Voltage:

120 VAC (108 to 132 VAC), 50 or 60 Hz. 12 VDC, 24 VDC or 240 VAC units available

Input Power:

EC-3004/EC-3404 EC-3008/EC-3408 EC-3012/EC-3412

Shaft:

3/4" diameter shaft extensions. The shaft is rated at 32,000 PSI yield and necked down to 0.500" internally. Power transmission through shaft should be based on these figures.

Max Side Load:

100 lbs. at speeds up to 1800 RPM / 200 lbs. at speeds up to 500 RPM

Bearing Life:

10 years (87,660 hours) continuous running with 75 lbs. side load at 1000 RPM Note: Consult factory if higher speeds or larger loads are required.

Enclosures:

EC-3000—NEMA 12 steel housing EC-3400—NEMA 4X stainless steel housing

Printed Circuit Board:

Net Weight:

3 VA Max 6 VA Max 6 VA Max

EC-3000—conformal coating on top only EC-3400—conformal coating on top and bottom EC-3004/EC-3404: EC-3008/EC-3408: EC-3012/EC-3412:

9.0 lbs.

13.5 lbs.

15.0 lbs.

4.0 kg 6.1 kg 6.8 kg

Output Module Specifications The EC-3000 Series and the EC-3400 Series units offer plug-in modules for DC, AC, and Reed Relay outputs. One output module must be purchased for each output desired. For further information, please consult the factory.

DC Output:

EC-ODC5, Red

AC Outputs:

EC-OAC5A-11, Black/Gray

Output Voltage:

0 to 60 VDC

Output Voltage:

24 to 132 VAC

Output Current:

1.0 Amp @ 35°C (95°F) Derate 35.7 mA/°C above 35°C (95°F)

Output Current:

0.8 Amp @ 35°C (95°F) Derate 50 mA/°C above 35°C (95°F)

DC Output:

EC-ODC5A, Red

Reed Relay:

EC-ORR5, White

Output Voltage:

0 to 200 VDC

Output Type:

Reed Relay Contacts

Output Current:

0.5 Amp Derate .018 amp/°C above 45°C (113°F)

DC Rating:

0 to 24 VDC 0 to 100 mA DC (resistive loads only)

AC Rating:

0 to 120 VAC 0 to 30 mA AC (resistive loads only)

page 4

Terminal and Component Identification The following three drawings are component layouts.

EC-3400 Series Units All EC-3400 Series units have the same component layout as the EC-3000 Series units except a stainless steel doubleended shaft extension and stainless steel enclosure with clamps to secure the cover are standard.

Figure 3 EC-3004 Unit

1 1/16" Dia. Hole (For 3/4" Conduit)

Figure 4 EC-3008 Unit

0° to 180° 181°

0° to

to 360°

1

181° 5

180° to 360° 6

1 1/16" Dia. Hole (For 3/4" Conduit)

Figure 5 EC-3012 Unit

Degree Wheel and Pointer

Interrupter Discs

Left-Hand Shaft Extension Shown DIP Switches

Indicator Lights

1 2 3 4 L

11121314

19 202122

6 7 8 9 L

15161718

23 24 25 26

1/4 Amp Input Fuse EC-9000-0250

Output Modules EC-OAC5A-11 for AC EC-ODC5 for DC EC-ODC5A for DC EC-ORR5 Reed Relay

3 Amp Output Fuses EC-9000-0003 120 VAC Input Terminals

Output Terminal s Wireway

1 1/16" Dia. Hole (For 3/4" Conduit)

page 5

Mounting Dimensions - EC-3004, EC-3008 & EC-3012 Right-Hand or DoubleEnded Shaft Extension

0.75" 19.1 mm

G

0.750/0.748" 19.05/19.00 mm

L H

Left-Hand Shaft Slotted for Woodruff Key #606 (Customer Supplied)

F E D

(4) Holes 0.31" Dia. 7.9 mm

J

K

1 1/16" Dia. Hole (For 3/4" Conduit) 4.38" 111.3 mm

2.07" 52.6 mm

2.75" 69.9 mm

B

C

A

Figure 6 EC-3004, EC-3008 & EC-3012

EC-3004

EC-3008

EC-3012

A

7.50" (190.5 mm)

9.50" (241.3 mm)

11.50" (292.1 mm)

B C

6.00" (152.4 mm) 3.00" (76.2 mm)

8.00" (203.2 mm) 3.38" (85.9 mm)

10.00" (254.0 mm) 5.00" (127.0 mm)

D E

1.94" (49.3 mm) 6.75" (171.5 mm)

2.50" (63.5 mm) 8.75" (222.3 mm)

2.50" (63.5 mm) 10.75" (273.1 mm)

F G

6.25" (158.8 mm) 0.88" (22.4 mm)

8.25" (209.6 mm) 1.25" (31.8 mm)

10.25" (260.4 mm) 1.25" (31.8 mm)

H J

4.00" (101.6 mm) 6.25" (158.8 mm)

6.00" (152.4 mm) 8.25" (209.6 mm)

6.00" (152.4 mm) 8.25" (209.6 mm)

K L

6.00" (152.4 mm) 1.88" (47.8 mm)

8.00 (203.2 mm) 2.25" (57.2 mm)

8.00" (203.2 mm) 2.25" (57.2 mm)

Table 1 EC-3004, EC-3008 and EC-3012 Dimensions

Mounting Dimensions - NEMA 4X Units Figure 7 EC-3404

1-1/16" Dia. Hole (For 3/4" Conduit)

J

H G E

F

1-1/16" Dia. Hole (For 3/4" Conduit)

2.07" 52.6 mm

D

Table 2 EC-3408 & EC-3412 Dimensions

C B A

Figure 8 EC-3408 & EC-3412

EC-3408

EC-3412

A B

9.50" (241.3 mm) 8.00" (203.2 mm)

11.50" (292.1 mm) 10.00" (254.0 mm)

C D

3.38" (85.9 mm) 2.56" (65.0 mm)

5.00" (127.00 mm) 2.75" (69.9 mm)

E F

1.00" (25.4 mm) 5.25" (133.4 mm)

1.50" (38.1 mm) 7.25" (184.2 mm)

G H

8.75" (222.3 mm) 8.25" (209.6 mm)

10.75" (273.1 mm) 10.25" (260.4 mm)

J

8.00" (203.2 mm)

10.00" (254.0 mm)

Input Wiring 1

2

3

6

7

4

8

L1

9

The terminal block shown is for an EC-3004 unit or

Upper Terminals

L2

120 VAC (108 to 132 VAC)

Lower Terminals

EC-3404 unit. Other models will contain more blocks.

Figure 9

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

Output modules available for the EC-3000 and EC-3400 Series units include DC, AC, and Reed Relay. An output module is required for each output being used. Refer to page 4 for further module information. Module signals are isolated from one another, allowing AC and DC modules to be mixed on the same control.

DC Output Module Wiring DC output modules can be wired to sink† or source† load circuit.

Diode--EC-9001-4004 Upper Terminal

AC Output Module Wiring AC output modules are wired with the load connected to the lower terminal of the output module, while the external power supply is connected to the upper terminal.

+VDC Upper Terminal

Load Zener Diode-EC-9001-5369 (51 VDC) EC-9001-5388 (200 VDC)

Lower Terminal

Lower Terminal

Load Varistor EC-9001-1010 (120 VAC) Power EC-9001-2020 (240 VAC) Supply

Load

DC COM R-C Suppressor EC-9001-2000 (120 VAC or 240 VAC)

Figure 10 - Sinking† Output Figure 12

Most applications will function properly without the varistor or R-C suppressor shown in the wiring diagram above. However, when other switching devices are in series or parallel with the AC output module, voltage spikes may damage the module. If necessary, use one of the following two methods to suppress voltage spikes.

• For infrequent switching, connect a varistor (MOV) across the terminals. †

Figure 11 - Sourcing Output Most applications will function properly without the diodes shown in the wiring diagrams above. However, highly inductive DC loads may damage modules by generating voltage spikes when switched off. This type of inductive load may need to be suppressed by a diode. If necessary, use one of the following two methods to incorporate a diode into your circuit.

• Connect a Zener diode across the terminals. This will not significantly increase the load turn-off time. The voltage rating of the diode must be greater than the normal circuit voltage.

• Connect a reverse-biased diode across the load. This may increase the load turn-off time. †

See page 2 for sinking/sourcing definitions.

• For continuous switching, connect an R-C suppressor in parallel with the load.

Upper Terminal Lower Terminal

PLC Input

Load Power Supply

Resistor EC-9001-5010 (5 Watt, 10K Ohm)

Figure 13 Most applications will function properly without the resistor shown in the wiring diagram above. However, it may be necessary to add the resistor if the load is affected by the module's off-state leakage of 2 mA maximum. Keep in mind that a resistor across a PLC input card may speed up the response time of that PLC input.

103 6/98 13647 Metric Rd • Roscoe, IL 61073 USA • Web Site: www.electrocam.com • email: ecam@electrocam.com

PLµ S Controls Div. PL-1746 Series PLµS® Plug-In Modules for the Allen-Bradley SLC-500 PLC

PL-1746-C01

PL-1746-C02

PL-1746-C03

The PLµS PL-1746 Series Plug-In Modules for AllenBradley PLC’s, incorporate advanced PLS functions in a 1746 I/O module package.

PL-1746-C04

In addition to providing precise control of events based on rotary position, these modules incorporate high speed control logic and automatic speed compensation, independent of the PLC scan. Output Groups and High Speed Logic Modes move beyond standard PLS functionality to give the user powerful tools that solve control problems accurately and at high speeds.

The PLµS Plug-In Modules provide 12 bit absolute position, and accurate control of functions at high speeds, based on rotary position input. They complement the control capabilities of the PLC by performing tasks that typically must occur much faster than a normal PLC scan cycle.

Programming of the PL-1746 modules may be done through the backplane or through the Electro Cam Corp. model 6400 keypad/display.

PL-1746 Series Features 12 bit Resolution

Leading/ Trailing Speed Compensation

2 Analog Backplane Outputs

8 Sinking/ Sourcing DC Inputs

32 Solid State Relay Output via I/O Rack

C01

❄

❄

❄

❄

❄

C02-E1

❄

❄

❄

❄

❄

❄

C02-R1

❄

❄

❄

❄

❄

❄

C03-E1

❄

❄

❄

❄

❄

❄

C03-R1

❄

❄

❄

❄

❄

❄

C04

❄

❄

❄

PL-1746 Model

6 Sinking DC Outputs Onboard

6 Sourcing DC Outputs Onboard

2 Analog Outputs

Onboard Display

❄

❄

Encoder Based

Resolver Based

❄ ❄ ❄ ❄

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

❄ ❄

Standard PL-1746 Series Features ■ Non-Volatile Memory - configurations

■ Automatic leading & trailing edge speed

■ Output Groups and Operating Modes

- allows high speed logic to be done in the PLS, separate from the PLC scan.

(Up to 4096 increments per revolution)

compensation - to advance/retard output channel timing to compensate for ON/OFF delay in valves and other devices.

■ Able to connect up to 2 Electro Cam

■ 48 available programs - active pro-

■ 2 levels of motion detection - to enable/

Corp. Model 6400 keypad/displays for remote adjustment.

grams selected through the backplane or via the Electro Cam Corp. 6400 series keypad/display.

disable speed critical machine functions.

■ Ability to access user selected param-

■ 4 timed outputs for controlling time criti-

eters while operating in an Allen-Bradley remote I/O chassis.

saved when power is interrupted.

■ Absolute position with high resolution

■ Complete module status available

cal functions initiated by position.

through the backplane.

PL-1746-C01 Plug-In Module ■ Up to 32 PLS output channels avail-

able through 1746 backplane. All channels are available to use either with the Electro Cam Corp. I/O rack (High Speed/Real World), or any 1746 discrete output module.

LED Display

The PS-4108-13-L08 and PS-4108-13-L16 I/O racks provide inputs, analog outputs, and digital power outputs (requiring SLIMLINE™ solid state relays) for the PL-1746-C01 PLµS plug-in modules.

Keypad/Display

■ Real world, high speed I/O available

via either an 8 input/8 output, or an 8 input/16 output external DIN mount rack.

Power Input

■ Up to 32 digital plus 2 analog outputs

available.

(Requires two racks, 16 I/O per rack)

I/O Rack (optional)

Resolver

■ SLIMLINE™ module outputs: AC, DC

PS-4108-13-L08 & PS-4108-13-L16 I/O Racks

PL-1746-C01

Resolvers Electro Cam Corp. Resolvers are designed for rugged industrial applications.

They feature dual bearing construction (except the 5212 model), and come in a variety of mounting styles and shaft sizes. Some resolver configurations are shown here.

See Price List (Lit. #202) for complete listing of part numbers and specifications.

PS-5275-11-ADS Foot Mount

PS-5238-11-ADR Flange Mount

• 3/4" Shaft

• 3/8" or 5/8" Shaft

• Top side, right side, left side or rear connection

• Top side, right side, left side

2

or rear connection

PL-1746-C02/C03 Plug-In Module ■ 6 real world DC outputs, and 8 DC inputs mounted on the front of

the PL-1746 module.

(-C02 = sourcing† outputs, -C03 = sinking† outputs)

LED Display

■ Up to 32 PLS output channels available through the 1746 back-

plane.

Inputs

Resolver or Encoder

■ 2 analog values based on speed, available through the backplane.

These are "tunable" to a specific machine speed range.

Optional Features

Power Input Outputs

■ Incremental Encoder input.

Keypad/Display

■ Shift register with 256 shifts.

■ Output assignment allowing the user to choose which six (6)

channels are the real world power outputs.

PL-1746-C02/C03

All other features of the PL-1746-C02/C03 models are the same as those for standard PL-1746 series modules.

PL-1746-C04 Plug-In Module ■ Up to 32 PLS output channels available through the 1746 back-

Keypad/Display

plane.

■ 2 analog outputs available through the backplane.

Power Input

All other features of the PL-1746-C04 model are the same as those for standard PL-1746 series modules.

Resolver

PL-1746-C04

PS-5275-051-ADL Foot Mount Geared

PS-5262-11-CTG Stainless Steel

PS-5238-11-SDR Servo Mount

• 3/4" Shaft

• 5/8" Shaft

• 3/8" Shaft

PS-5212-11-SVW Unhoused Servo Mount

• 5:1 Gear Ratio

• Left side or right side

• Top side, right side,

• .120" Shaft

• Top side, right side or

connection

left side or rear connection

• Standard size 11

left side connection • Available in ratios 2:1 thru 36:1 (Consult Factory for availability)

†

3

See page 4 for sinking/sourcing definitions.

Plug-In Module Part Number Breakdown P L - X X X X - XXX - X X - X

Plug-In Module Typical Systems Component(s)

Qty.

Part Number

PL-1746-C01 System

PL = Plugs into backplane Utilizes Allen-Bradley technology.

TYPE TRANSDUCER R - Resolver E - Encoder

PLATFORM TYPE 1746 = SLC 500

NUMBER OF TRANSDUCERS

SUB-CATEGORY C01 = Display, 32 Real World I/O with External I/O racks

1 = One

C02 = Display, Built-in 8 Inputs and 6 Sourcing† DC Outputs, 1.5 A

OPTIONS

C01 Plug-In Module

(1)

Resolver

(1)

PL-1746-C01-R1 PS-5275-11-ADR

Resolver Cable

(1)

PS-5300-01-010

Keypad/Display

(1)

PS-6400-24-001

Keypad-to-controller cable(s)

(1)

PS-6300-01-005

I/O Rack

(1)

PS-PS-4108-13-L08

I/O Rack Cable

(1)

PS-4308-10-005

SLIMLINE™ Output Modules

(16)

EC-ODC060-3

SLIMLINE™ Analog Modules

(2)

EC-SANL-010V

S = Shift Register & Output assignment feature

C03 = Same as C02, except with Sinking† outputs

PL-1746-C02 System (C03 for †Sinking)

C04 = No Display, No Real World I/O

C02/C03 Plug-In Module

Resolver Part Number Breakdown PS - 52 XX - XXX- X X X-X

(1)

PL-1746-C02-R1

Resolver

(1)

PS-5275-11-ADR

Resolver Cable

(1)

PS-5300-01-010

Keypad/Display

(1)

PS-6400-24-001

Keypad-to-controller cable(s)

(1)

PS-6300-01-005

(1)

PL-1746-C04-R1

PL-1746-C04 System C04 Plug-In Module Resolver

(1)

PS-5275-11-ADR

Resolver Cable

(1)

PS-5300-01-010

Keypad/Display

(1)

PS-6400-24-001

Keypad-to-controller cable(s)

(1)

PS-6300-01-005

PLµS Part Number Resolver SHAFT SIZE 12 15 20 38 62 75 -

1/8 DIA. 15 mm DIA. 20 mm DIA. 3/8” DIA., 2.06” Bolt Flange 5/8” DIA., 2.25” Bolt Flange 3/4” DIA.

HOUSING A - Can housing w/flange or foot endbells.

C - Stainless steel square housing.

E - 74 mm bolt spacing, flange mount S - Servo mount (.12 = size 11; .38 = size 25 )

†

Sinking means that when the logic is true and the output (or input device) is ON, the output (or input device) is providing a DC common or ground to the connected device.

TYPE OF CABLE CONNECTION RATIO 11 - Standard 1:1 (Note: 3rd digit not used on Standard 1:1) 021 - Geared 2:1 - Ext. shaft to internal resolver shaft thru 361 - Geared 36:1 - Ext. shaft to internal resolver shaft Various ratios available, contact Factory.

D - Military bayonet style connector T - Terminal strip with NO conduit entrance V - No connector, just stripped & tinned wires S - Sealed connector — screw type

Sourcing means that when the logic is true and the output (or input device) is ON, the output (or input device) is providing a +DC voltage to the connected device.

Note: Part # PS-5903-01-001 conduit entrance for terminal strip models sold separately.

LOCATION OF CABLE CONNECTION WGRL S -

SINKING or SOURCING

( as pertaining to Electro Cam Corp. products )

With stripped & tinned leads Right (120° from top on “A” housings) Rear (not available on Geared Resolver) Left (120° from top on “A” housings) Side (Top)

This information is important when interfacing an Electro Cam Corp. product with another electronic device. If you are using an Electro Cam Corp. product input to an Allen-Bradley 1746IN16 “sinking” input card* or similar A-B device, you have to supply a +DC voltage (Electro Cam Corp. Sourcing output) to this card, NOT a DC common or ground. In these cases, Sinking is what the card does with the input voltage; sinks it to common or ground. * Other manufacturers include, but not limited to: Koyo (formerly GE Series 1, Texas Instruments, or Siemens SIMATIC PLS’s) that use descriptions similar to Allen-Bradley.

OPTION V - Vertical Mount Note: Only required for vertical mounting of PS-5262-11-CTX Models.

4

Resolver Dimensions Foot Mount

With Rear Connector (shown): PS-5275-11-ADR With Side Connector: PS-5275-11-ADS Cable: PS-5300-01-XXX where "XXX" is length in feet.

0.749/ 0.747" 19.02/ 18.97 mm

Flange Mount

With Rear Connector (shown): PS-5238-11-ADR With Side Connector: PS-5238-11-ADS Cable: PS-5300-01-XXX where "XXX" is length in feet.

0.375/ 0.374" 9.53/ 9.50 mm

Stainless Steel .625/ .624" dia.

15.88/ 15.85 mm

Horizontal Mount (shown): PS-5262-11-CTG (with right connector) With Left Connector: PS-5262-11-CTL Vertical Mount (Shaft up) PS-5262-11-CTG-V (with right connector) PS-5262-11-CTL-V (with left connector) Cable: PS-5300-02-XXX where "XXX" is length in feet.

For horizontal applications

Unhoused Servo Mount

Size 11, .120" Shaft: PS-5212-11-SVW

Contact the Factory for detailed specifications on other available resolvers.

5

PL-1746 Specifications Plug-In Module Part Numbers

PL-1746-C01-R1

PL-1746-C02-E1-S PL-1746-C02-R1 PL-1746-C03-E1-S PL-1746-C03-R1

PL-1746-C04-R1

Electrical Input Power

20-30 VDC. Keypad/display is powered from controller.

20-30 VDC. Keypad/display is powered from controller.

Backplane Power

5VDC @ 500 mA max.

5 VDC @ 500 mA max.

5VDC @ 500 mA max.

I/O Power

20-30 VDC, 80 mA + 150 mA per keypad + 230 mA per rack.

20-30 VDC @ 90 mA max. + 150 mA per PS-6400 keypad

20-30 VDC @ 80 mA max. + 150 mA per PS-6400 keypad (include power supply warning).

Example: Total = 840 mA with 2 keyboards and 2 racks.

Certain types of power supplies employ a self protection feature called current fold back limiting. The inrush currents of the high efficiency switching regulators may cause power supplies to enter current limit mode. Power supplies with current fold back limiting should be sufficient to supply three times the steady state current of the system.

Certain types of power supplies employ a self protection feature called current fold back limiting. The inrush currents of the high efficiency switching regulators may cause power supplies to enter current limit mode. Power supplies with current fold back limiting should be sufficient to supply three times the steady state current of the system.

Inrush current @ 30v, 40 amps max. for 600 µs (2 keyboards, 2 racks)

Permanent Memory

EEPROM (no battery required)

EEPROM (no battery required)

EEPROM (no battery required)

Operating Temp.

0° to 55°C (32° to 131°F)

0° to 55°C (32° to 131°F)

0° to 55°C (32° to 131°F)

Storage Temp.

-40° to 70°C (-40° to 160°F)

-40° to 70°C (-40° to 160°F)

-40° to 70°C (-40° to 160°F)

Humidity

95% maximum relative non-condensing

95% maximum relative non-condensing

95% maximum relative non-condensing

NEMA Rating

Keypad/Display: NEMA 4

Keypad/Display: NEMA 4

Keypad/Display: NEMA 4

PLµS Module: 0.5 lbs (0.2 kg)

PLµS Module: 0.5 lbs (0.2 kg)

PLµS Module: 0.5 lbs (0.2 kg)

Keypad/Display: 0.5 lbs. (0.2 kg)

Keypad/Display: 0.5 lbs. (0.2 kg)

Keypad/Display: 0.5 lbs. (0.2 kg)

Controller

Mounts in SLC-500 chassis.

Mounts in SLC-500 chassis.

Mounts in SLC-500 chassis.

Rack

Brackets accept EN-50035 (“G” profile) or EN-50022 (“Top Hat” profile) DIN Rail

Keypad/Display

Mounts up to 1000’ from controller. 0 0 to 2 keypads may be connected to one controller.

Mounts up to 1000’ from controller. 0 0 to 2 keypads may be connected to one controller.

Mounts up to 1000’ from controller. 0 0 to 2 keypads may be connected to one controller.

Environment

Physical Weight

Mounting

Inputs on Rack DC Inputs

8 sinking† or sourcing† DC inputs, optically isolated (1st rack only).

Input ON State Voltage

10-30 VDC

Input Current

11 mA @ 24 VDC

Response

2 µs max.

Outputs on Rack

†

Real World Outupts

Up to 16 SLIMLINE™ modules may be mounted on the rack. Modules may be any mix of AC, DC, and reed relay. All modules (except reed relay) optically isolated.

Analog Output

Up to 2 SLIMLINE™ analog output modules may be mounted on the rack in addition to the 16 digital modules.

See page 4 for sinking/sourcing definitions.

6

Specifications continued...

PL-1746 Specifications (continued) Plug-In Module Part Numbers

Outputs On Rack

PL-1746-C01-R1

PL-1746-C02-E1-S PL-1746-C02-R1 PL-1746-C03-E1-S PL-1746-C03-R1

PL-1746-C04-R

(cont’)

Output Types

4-20 mA or 0-10 VDC, proportional to RPM

Resolution

12 bit

Update Frequency

10 ms

Linearity

±0.3% of full scale @ 25°C (77°F)

Set-up

Offset & full scale RPM are programmable

Inputs on Module DC Inputs

8 DC inputs, optically isolated, sinking† or sourcing† in banks of 4.

Input ON State Voltage

20-30 VDC

Input Current

11 mA @ 24 VDC

Response

2 µs max.

Outputs on Module 6 DC outputs @ 1.5A each, 20-30V

Real World Outputs

Note: -C02 all outputs are SOURCING† -C03 all outputs are SINKING†

Analog Output

Analog outputs accessible through backplane only; they are proportional to RPM.

Resolution

12 bit

Update Frequency

10 ms

Set-up

Offset & full scale RPM are programmable

Operation Scan Time

Less than 1000 µs typical (exact time Less than 1000 µs typical (exact time determined by programming). determined by programming)

Less than 1000 µs typical (exact time determined by programming).

Position Resolution

12 bits (4096 increments)

12 bits (4096 increments)

12 bits (4096 increments)

Speed Compensation

Programmed in 0.1 msec steps. 16 individually compensated outputs max. Updated 5 times per second. Separate leading/trailing edge compensation standard.

Programmed in 0.1 msec steps. 16 individually compensated outputs max.

Separate leading/trailing edge compensation standard.

Programmed in 0.1 msec steps. 16 individually compensated outputs max.

Updated 5 times per second. Separate leading/trailing edge compensation standard.

Output Timeout

1.0 ms time base (accuracy: +1,-0 ms)

1.0 ms time base (accuracy: +1,-0 ms) 1.0 ms time base (accuracy: +1,-0 ms)

Number of Timed Outputs

Four maximum

Four maximum

Four maximum

Multiple Programs

48 programs standard

48 programs standard

48 programs standard

Total Pulse Memory

1252 pulses standard

1252 pulses standard

1252 pulses standard

Pulses per Program

512 maximum standard

512 maximum standard

512 maximum standard

Pulses per Output

512 maximum standard

512 maximum standard

512 maximum standard

Maximum Speed

3000 RPM. Note: Pulses generated with Pulse

3000 RPM.

3000 RPM. Note: Pulses generated with Pulse Train command are not included in pulses per program or pulses per output counts.

Train command are not included in pulses per program or pulses per output counts.

†

See page 4 for sinking/sourcing definitions.

7

Copyright © 2000 All Rights Reserved 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

This product incorporates patented technology which is licensed by Allen-Bradley Company, Inc. A-B has not technically approved, nor does it warrant or support this product. All warranty and support for this product and its application is provided solely by Electro Cam Corp.

SLC-500 is a trademark of Allen-Bradley Company.

299 08/00

13647 Metric Rd • Roscoe, IL 61073 USA • Web Site: http://www.electrocam.com • email: ecam@electrocam.com

PLµS Controls Div. PS — 4256 / 4456 ABSOLUTE GRAY CODE ENCODER

PS-4256/4257 (NEMA 12)

PS-4456/4457 (NEMA 4X)

Easily Interfaced to PLCs Using Standard Digital DC Inputs Or Directly to Gray Code Modules*

Features

General Information

■ ■ ■ ■

Sinking† or Sourcing† Output — The encoders are available with Sinking† or Sourcing† outputs. Be sure to order the type that is compatible with the control's input circuits. The use of fast response DC inputs is recommended to minimize missed fast pulsing encoder outputs.

Absolute 8 Bit Output Rugged Construction 3/4" Shaft with Ball Bearings NEMA 12 or NEMA 4X

Applications ■ ■ ■ ■ ■

*

Packaging Machines Pick and Place Operations Assembly Machines Food Processing Equipment Indexing Equipment

A-B 1771-DL or Similar type modules

NEMA 4X Option — The NEMA 4X version of the encoder includes a stainless steel enclosure and shaft, double sealed ball bearings, and conformal coating on both sides of the internal circuit board. This version should be ordered for applications which involve washdowns, high humidity or corrosive atmospheres.

†

See page 7 for sinking/sourcing definitions

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

Why 8 Bit Gray Code?

When wiring an encoder to the PLC, the most important thing to remember is which output is the MSB (Most Significant Bit) and which is the LSB (Least Significant Bit). If the order is reversed, or the output wiring is out of order (transposed wires), the value that you create in the PLC register will not sequence properly.

Absolute Position Decoding — The 8 Bit Gray Code

MSB and LSB are digits of the binary number. An understanding of the different number systems used by logic controllers (binary, hex, decimal, etc.) is essential to know what these codes signify.

8 Bit Resolution (256 increments) — The revolution of

signal always represents the current position of the encoder shaft. The PLC cannot get out of sync with the present encoder position — not even when the encoder shaft is turned while power is off to the controller.

the encoder shaft is divided into 256 uniform increments.

Each increment is 1.4 degrees wide, which allows any machine position to be known within ±0.7 degrees. This is appropriate resolution for many applications, especially when PLC scan times are taken into account (@ 60 RPM, a 10 mSec scan time equates to 3.6 degrees of motion between scans).

■ Gray Code is a cyclic or reflected binary code, specifically designed for positioning information. In a Gray Code number only one-digit changes at a time. In a binary number, going from one number to the next may have many of its digits change.

Error Free Decoding — Only one of the bits changes state when the encoder shaft rotates, eliminating the need for sophisticated latching and/or handshaking circuitry between the encoder and the PLC. Standard DC input cards are used to interface with the encoder. The only special programming needed is 8 exclusive-ORed (XOR) ladder rungs.

The cyclic change is created by the relationship of the 8 pulse disks that turn the encoder OFF and ON. (See Figure 6, page 6.)

■ Most Significant Bit refers to the binary code (Gray Code) digit that is on the far left when written out. This digit changes the least as the binary number goes from 0 to 255.

■ Least Significant Bit refers to the binary code (Gray Code) digit that is on the far right when written out. This digit changes the most as the binary number goes from 0 to 255.

RPM / Response Considerations When machine speed rises above a certain level, several factors need to be considered:

The operating speed and resolution required of the application must be considered when interfacing the Gray Code encoder directly to a PLC or other control device. The scan speed and/or hardware response will cause delays that can reduce the overall system response and resolution. Where full 8 bit resolution is required at higher speeds, the use of an Electro Cam PLµS (Programmable Limit Switch) is recommended.

■ What is the scan time of the PLC program?

■ What is the response time of the input module?

■ What is the integer value that is being used, and is it dependent on several of the least significant bits?

Values might not be true for certain fast response PLC inputs.

Faster response times are dependent on hardware.

Scan Time / Maximum RPM / Degrees Per Scan Scan Time 1 mSec 5 mSec 10 mSec 15 mSec

Max RPM 234 46 23 15

Deg / Scan @ 30 RPM 0.18 0.9 1.8 2.7

Deg / Scan @ 100 RPM 0.60 3.0 6.0 9.0

Scan Time 20 mSec 25 mSec 30 mSec 40 mSec

Max RPM 11 9 7 5

Deg / Scan @ 30 RPM 36 4.5 5.4 7.2

Deg / Scan @ 100 RPM 12.0 15.0 18.0 24.0

The table above indicates the maximum RPM that the encoder can be turning for all 256 positions to be decoded each revolution for the corresponding scan time.

Exceeding the indicated RPM will result in encoder shaft positions being skipped by the control. It is acceptable to skip encoder positions when 8 bit resolution is not required. Worst case output response = 2 Scans + Hardware response.

Figure 1 processor will not see that bit (or combination of bits). If the input module's response time is longer than the bit, or bits on time, the module will not react to the input. All of these factors show up as non-sequencing position values, or outputs that are not performing properly.

Refer to the above chart to compare machine RPM to the values listed on the chart. If speed exceeds the value, the PLC will not "see" certain Gray Code values. Miscalculation of the output value will occur.

If a bit is on for 30 µSec, and the scan time is 10 mSec, the 2

Decoding Gray Code?

The Ladder Programming examples shown below apply for all Gray Code Encoder models. The examples show how to convert the 8 Bit Gray Code output signal (G0-G7) of the encoder to a binary number (B0-B7) during each scan of the PLC. The value of the Binary result will always be in the range of 0 - 255 because the 8 bit encoder divides each revolution into 256 uniform increments. Ladder rungs which follow the conversion can compare the rotary position value to known positions for control of machine devices that must operate at specific positions within the overall machine cycle. The rotary position of

the machine cycle can also be used to gate input sensors and shift register functions.

Models DDN & DDP

Model DDH

B7

B7

G6

B6

G5

B6

G5

B5

G4

B5

G4

B4

B3 B4

G3

B4

G3

B3

G2

B3

G2 G1

B2

G1

B2

G0

B1

G0

B7

G6

B6

G5

B6

G5

B5

G4

B5

G4

B5

B4

B7

G6

B7

G6

B6

G5

B6

G5

B5

G4

B5

G4

B4

G3

B4

G3

B3

G2

B3

G2

B2

G1

B2

G1

B4

G3

B4

G3

B3

G2

B3

G2

B2

B2

G1

B2

G1

B4

G6

B7

G6

B6

G5

B6

G5

B5

G4

B5

G4

B1

G0

B1

B1

G0

B1

B2

B1

B4

G3

B4

G3

B3

G2

B3

G2

B2

G1

B2

G1

B4

B2

B1

B0

G0

B1

G0

G0

B1

G0

DRAWING L-3

DRAWING L-2

B5

B3

B0

B0

DRAWING L-1

B5

B7

B3

B1

B0 B1

G6

B3

B1 B2

B7

B6

B6

B6

B5

B7 G7

G7

G7

B6

CLOCKWISE ROTATION

B7

B7

G7

G6

COUNTER-CLOCKWISE ROTATION

COUNTER-CLOCKWISE ROTATION

CLOCKWISE ROTATION

B7

Converting Gray Code to Binary involves a sequence of "Exclusive OR" operations. It is simple to program this same conversion logic in other programming languages besides ladder logic. In addition to decoding the rotary position of the encoder, controls with arithmetic capability can be programmed to perform direction reversal, position offset and re-zero functions, as well as convert the position value to degrees for ease of monitoring and setup.

DRAWING L-4

Use a limit test function to program a pulse in the PLC. The limit test uses a test reference (in this case the integer register that the Gray Code is going into), and compares it to see if it is between a lower limit and an upper limit. If the integer value is between the lower limit (ON setpoint), and the upper limit (OFF setpoint), the rung is true and an output is turned on. If the integer value does not fall between the upper and lower limits, the rung is false, and nothing happens.

For every output pulse to occur, a different limit test must be programmed with the appropriate limits. Reminder: The limit values are position values, not degrees.

PLC Output LIM Limit Test Low Lim Test High Lim

O:2.0 ( ) 0

107 107 < N7:0 0< 128 128 < 3

Gray Code — Error Free Decoding The Gray Code chart below (Figure 2) shows the bit patterns that are used to represent all 256 encoder positions.

It can be seen on this chart that from any position to any adjacent position, only 1 bit changes state. This ensures that the encoder inputs can be read by the control at any point in time (even during a transition) without error.

Refer to the table below to understand the relationship between the increment (integer), degrees and binary numbers. Use this table as a guide for setup and troubleshooting your Gray Code system.

■ INC (increment) column represents the integer value to which the Gray Code is equal. The increments are 0 to 255 (256 total) that repeat or cycle. (At 255, the next number change is 0, increment to 255, then repeat the cycle over again).

Consider the following comparison to Binary Code: INC

DEG

GRAY CODE

BINARY

127 128

178.6 180.0

01000000 11000000

01111111 10000000

■ DEG (degree) column represents the actual degree position that the Gray Code is indicating.

■ Gray Code column shows the Gray Code value for that particular position. This Gray Code binary number is the same as the Gray Code inputs status, 1 = ON and 0 = OFF.

When Gray Code advances from increment 127 to 128, only 1 of the 8 bits changes state — bit 8. When Binary Code advances from increment 127 to 128, all 8 bits change states. Sampling the Binary bits during this transition could result in a very large decoding error. Sampling the Gray Code bits during this transition would yield either 127 or 128, depending only on bit 8.

Because the Gray Code value is also a graphic representation of the input status, it is an invaluable tool in checking the position or troubleshooting.

8 Bit Gray Code Table INC

DEG

GRAYCODE

INC

GRAYCODE

DEG

GRAYCODE

INC

DEG

GRAYCODE

INC

DEG

GRAYCODE

INC

DEG

0 1 2 3 4

0.0 1.4 2.8 4.2 5.6

00000000 00000001 00000011 00000010 00000110

45 46 47 48 49

63.3 64.7 66.1 67.5 68.9

00111011 00111001 00111000 00101000 00101001

90 91 92 93 94

126.6 128.0 129.4 130.8 132.2

01110111 01110110 01110010 01110011 01110001

135 136 137 138 139

189.8 191.3 192.7 194.1 195.5

11000100 11001100 11001101 11001111 11001110

180 181 182 183 184

253.1 254.5 255.9 257.3 258.8

11101110 11101111 11101101 11101100 11100100

225 226 227 228 229

316.4 317.8 319.2 320.6 322.0

10010001 10010011 10010010 10010110 10010111

5 6 7 8 9

7.0 8.4 9.8 11.3 12.7

00000111 00000101 00000100 00001100 00001101

50 51 52 53 54

70.3 71.7 73.1 74.5 75.9

00101011 00101010 00101110 00101111 00101101

95 96 97 98 99

133.6 135.0 136.4 137.8 139.2

01110000 01010000 01010001 01010011 01010010

140 141 142 143 144

196.9 198.3 199.7 201.1 202.5

11001010 11001011 11001001 11001000 11011000

185 186 187 188 189

260.2 261.6 263.0 264.4 265.8

11100101 11100111 11100110 11100010 11100011

230 231 232 233 234

323.4 324.8 326.3 327.7 329.1

10010101 10010100 10011100 10011101 10011111

10 11 12 13 14

14.1 15.5 16.9 18.3 19.7

00001111 00001110 00001010 00001011 00001001

55 56 57 58 59

77.3 78.8 80.2 81.6 83.0

00101100 00100100 00100101 00100111 00100110

100 101 102 103 104

140.6 142.0 143.4 144.8 146.3

01010110 01010111 01010101 01010100 01011100

145 146 147 148 149

203.9 205.3 206.7 208.1 209.5

11011001 11011011 11011010 11011110 11011111

190 191 192 193 194

267.2 268.6 270.0 271.4 272.8

11100001 11100000 10100000 10100001 10100011

235 236 237 238 239

330.5 331.9 333.3 334.7 336.1

10011110 10011010 10011011 10011001 10011000

15 16 17 18 19

21.1 22.5 23.9 25.3 26.7

00001000 00011000 00011001 00011011 00011010

60 61 62 63 64

84.4 85.8 87.2 88 6 90.0

00100010 00100011 00100001 00100000 01100000

105 106 107 108 109

147.7 149.1 150.5 151.9 153.3

01011101 01011111 01011110 01011010 01011011

150 151 152 153 154

210.9 212.3 213.8 215.2 216.6

11011101 11011100 11010100 11010101 11010111

195 196 197 198 199

274.2 275.6 277.0 278.4 279.8

10100010 10100110 10100111 10100101 10100100

240 241 242 243 244

337.5 338.9 340.3 341.7 343.1

10001000 10001001 10001011 10001010 10001110

20 21 22 23 24

28.1 29.5 30.9 32.3 33.8

00011110 00011111 00011101 00011100 00010100

65 66 67 68 69

91.4 92.8 94.2 95.6 97.0

01100001 01100011 01100010 01100110 01100111

110 111 112 113 114

154.7 156.1 157.5 158.9 160.3

01011001 01011000 01001000 01001001 01001011

155 156 157 158 159

218.0 219.4 220.8 222.2 223.6

11010110 11010010 11010011 11010001 11010000

200 201 202 203 204

281.3 282.7 284.1 285.5 286.9

10101100 10101101 10101111 10101110 10101010

245 246 247 248 249

344.5 345.9 347.3 348.8 350.2

10001111 10001101 10001100 10000100 10000101

25 26 27 28 29

35.2 36.6 38.0 39.4 40.8

00010101 00010111 00010110 00010010 00010011

70 71 72 73 74

98.4 99.8 101.3 102.7 104.1

01100101 01100100 01101100 01101101 01101111

115 116 117 118 119

161.7 163.1 164.5 165.9 167.3

01001010 01001110 01001111 01001101 01001100

160 161 162 163 164

225.0 226.4 227.8 229.2 230.6

11110000 11110001 11110011 11110010 11110110

205 206 207 208 209

288.3 289.7 291.1 292.5 293.9

10101011 10101001 10101000 10111000 10111001

250 251 252 253 254

351.6 353.0 354.4 355.8 357.2

10000111 10000110 10000010 10000011 10000001

30 31 32 33 34

42.2 43.6 45.0 46.4 47.8

00010001 00010000 00110000 00110001 00110011

75 76 77 78 79

105.5 106.9 108.3 109.7 111.1

01101110 01101010 01101011 01101001 01101000

120 121 122 123 124

168.8 170.2 171.6 173.0 174.4

01000100 01000101 01000111 01000110 01000010

165 166 167 168 169

232.0 233.4 234.8 236.3 237.7

11110111 11110101 11110100 11111100 11111101

210 211 212 213 214

295.3 296.7 298.1 299.5 300.9

10111011 10111010 10111110 10111111 10111101

255

358.6

10000000

35 36 37 38 39

49.2 50.6 52.0 53.4 54.8

00110010 00110110 00110111 00110101 00110100

80 81 82 83 84

112.5 113.9 115.3 116.7 118.1

01111000 01111001 01111011 01111010 01111110

125 126 127 128 129

175.8 177.2 178.6 180.0 181.4

01000011 01000001 01000000 11000000 11000001

170 171 172 173 174

239.1 240.5 241.9 243.3 244.7

11111111 11111110 11111010 11111011 11111001

215 216 217 218 219

302.3 303.8 305.2 306.6 308.0

10111100 10110100 10110101 10110111 10110110

40 41 42 43 44

56.3 57.7 59.1 60.5 61.9

00111100 00111101 00111111 00111110 00111010

85 86 87 88 89

119.5 120.9 122.3 123.8 125.2

01111111 01111101 01111100 01110100 01110101

130 131 132 133 134

182.8 184.2 185.6 187.0 188.4

11000011 11000010 11000110 11000111 11000101

175 176 177 178 179

246.1 247.5 248.9 250.3 251.7

11111000 11101000 11101001 11101011 11101010

220 221 222 223 224

309.4 310.8 312.2 313.6 315.0

10110010 10110011 10110001 10110000 10010000

Figure 2 4

INC

DEG

GRAYCODE

Wiring

Figure 3

Dimensions NEMA 12

NEMA 4X

Figure 4

5

Figure 5

Specifications General

NEMA 4X

Ambient Temp.

0 - 60 Degrees C

0 - 60 Degrees C

Enclosure

JIC - 16 Ga Steel

JIC - 16 GA Stainless

Shaft Dia. / Material

3/4" Stainless Steel

3/4" Stainless Steel

Bearings

3/4" Sealed Ball Bearing

3/4" Double Sealed Ball

Conformal Coating

Component Side of PCB

Both Sides of PCB

Electrical

Sourcing†

Input Voltage

12 - 30 VDC

12 - 30 VDC

Output Voltage

12 - 30 VDC

3 - 30 VDC

Output Current (each bit) Output Logic Type

†

NEMA 12

50 mA High True

Sinking†

50 mA Low True or High True

See page 7 for sinking/sourcing definitions

The 8 Bit Gray Code Encoder Output Chart (Figure 6) shows the transitions of each of the 8 bits as the encoder rotates from 0 to 360 degrees. The output bits are phased so that only one bit changes state at each of the 256 increments.

The pulse disc which operates bit 0 (least significant) has 64 uniformly spaced slots, bit 1 has 32 uniformly spaced slots, bit 2 has 16 uniformly spaced slots, and so on. The 8 bit output of the encoder is always one of the 256 bit patterns shown in the table on page 4 (Figure 2) and always represents the current position of the encoder shaft. For this reason, the control cannot get out of sync with the encoder. High speed count cards that use incremental encoders are NOT absolute and require marker pulses, or other reference signals, for position synchronization.

Figure 6 6

Encoder Part Numbers 1000 RPM MAX PS - 4256 - 12 - DDP

2000 RPM MAX PS - 4257 - 12 - DDP

Output Type Sourcing† †

NEMA Rating 12

PS - 4256 - 12 - DDN

PS - 4257 - 12 - DDN

Sinking (Low True)*

12

PS - 4256 - 12 - DDH

PS - 4257 - 12 - DDH

Sinking† (High True)*

12

†

PS - 4456 - 12 - DDP

PS - 4457 - 12 - DDP

Sourcing

4X

PS - 4456 - 12 - DDN

PS - 4457 - 12 - DDN

Sinking† (Low True)*

4X

PS - 4456 - 12 - DDH

PS - 4457 - 12 - DDH

†

Sinking (High True)*

4X

* High True = Current Flow Low True = No Current Flow

Accessories PS - 4300 - 03 - XXX (XXX = Length in Feet): 10 Conductor #22 gauge shielded (foil and braid) cable for use with encoders. Cut to specified length, stripped, tinned, connectors attached to shield.

EC - 8001 - XXX - XXX (X's for pitch and # of teeth): Sprocket disengagement clutch allows encoder to be rotated without turning the chain which drives the encoder. Call for more information.

†

SINKING or SOURCING (as pertaining to Electro Cam Corp. products)

Sinking means that when the logic is true and the output (or input device) is ON, the output (or input device) is providing a DC common or ground to the connected device.

Sourcing means that when the logic is true and the output (or input device) is ON, the output (or input device) is providing a +DC voltage to the connected device.

This information is important when interfacing an Electro Cam Corp. product with another electronic device. If you are using an Electro Cam Corp. product input to an Allen-Bradley 1746-IN16 “sinking” input card* or similar A-B device, you have to supply a +DC voltage (Electro Cam Corp. Sourcing output) to this card, NOT a DC common or ground. In these cases, Sinking is what the card does with the input voltage; sinks it to common or ground. * Other manufacturers include, but not limited to: Koyo (formerly GE Series 1, Texas Instruments, or Siemens SIMATIC PLS’s) that use descriptions similar to Allen-Bradley.

7

Electro Cam Corp. is highly experienced in supplying automation solutions to a variety of industrial machinery.

For assistance with your application, please call us.

800-228-5487

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PS-2252-12-TP1 Net Forward Encoder Interface The PS-2252-12-TP1 Net Forward Encoder Interface (NFEI) accepts inputs from the A and B channels of a standard quadrature encoder. The NFEI outputs a pulse for each forward direction transition of the encoder, but reverse direction transitions result in no pulses. Furthermore, following reverse movement, no output pulses result from forward movement until the encoder position exceeds the furthermost forward position reached before the reverse movement. The NFEI rejects jitter resulting from mechanical oscillation at a transition point of the encoder with the system at a zero average velocity. Note: If more than 65,535 consecutive reverse encoder transitions are made, an Overflow output on the NFEI is activated indicating that the reverse counter has lost track of reverse transitions. A reset input allows clearing the reverse counter in order to restart.

Inputs Channel A, Channel B: Standard Quadrature encoder A and B channels.

Reset: Resets internal reverse counter when high-level.

Outputs Out 0: High-going pulse indicates forward increment of encoder.

Overflow: High level indicates overflow of internal 16-bit reverse counter.

Voltage Levels Channel A & B Inputs: 5-15 VDC. Reset Input On voltage: Optically isolated, 4.0 VDC min @ 10 mA. Out 0 & Overflow Outputs: 7406 open collector.

VOL = 0.4V max @ IOL = 16 mA. VOH = 30V max.

Timing Time Between Encoder Channel Edges: 17 microseconds minimum.

Reset Input Pulse Width: 50 microseconds minimum.

Output Pulse Width: 20 microseconds minimum.

Configuration CW/CCW: Dip switch sets forward rotation direction.

1st switch ON = CW. 1st switch OFF = CCW. Switches 2-6 are not used.

Power Supply Supply Voltage: 11-15 VDC. Supply Current: 90 mA @ 12 VDC. Environment Operating Temperature: 0° to 55°C (32° to 131°F) Storage Temperature: -40° to 70°C (-40° to 160°F) Humidity: 95% maximum relative non-condensing.

Mounting Brackets accept EN-50035 (''G'' profile) or EN-50022 (''Top Hat'' profile) DIN rail.

EN-50035 (''G'' profile) included.

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Internal Encoder Count Mechanical oscillation of the encoder is properly tracked by the NFEI as long as the minimum time between encoder channel edges is within specification, as illustrated below.

For Example:

A

A quadrature encoder with 1000 pulses/revolution has 4000 edges revolution If this encoder revolves at 800 rev/min:

B

800 rev . 1min . 4000 edges = 53,333 edges min 60 sec 1 rev sec

17 microseconds minimum

This implies 18.75 microseconds edge Thus, the upper speed limit for a 1000 rpm quadrature encoder is 800 rpm.

Installation Connect the NFEI using the Terminal Block Wiring illustration below.

CHN A (from encoder)

CHN B (from encoder)

Overflow Out 0

+11-15 VDC IN

Shield

Common

Not Used

Reset

Reset Input, Sourcing

R

C

Reset

Reset

Reset Input Common

Reset Input Common

-

S

Reset Input, Sinking

+

O

B

A

Mechanical Switch

R

C

S

- +

O

B

R

C

S

- +

O

B

A

Mechanical Switch

A

OR

Solid State Switch PNP Transistor

OR

Solid State Switch NPN Transistor

Troubleshooting Symptom: Output does not turn on with encoder movement. a. Verify that the voltage on the + and - terminals of the NFEI terminal block is between 11 and 15 VDC. b. Verify with oscilloscope that proper encoder signals (per Internal Encoder Count illustration) are present at the Chn A and Chn B terminals of the NFEI terminal block, and that the voltage levels are TTL compatible (logic 0 less than 0.8 v and logic 1 greater than 2.0 v). If not, there is a problem with the encoder or encoder cable. If the encoder signals are proper, the problem is internal to the NFEI, and the NFEI should be exchanged. c. Verify that the configuration DIP switch setting agrees with the actual direction of encoder movement. If the Overflow output is at a TTL high level, then the encoder has moved more than 65,535 counts in the reverse direction, and the internal reverse count logic of the NFEI will not be accurate. Move encoder to “0” position and reset NFEI. d. Verify with oscilloscope the status of the Out 0 terminal on the NFEI terminal block. If, after the reverse counts have been counted out, there are pulses when the encoder moves in the configured direction, then the problem is not in the NFEI.

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