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Toledo Transducers PLS-601 Programmable Limit Switch System

1. AE c Q GACK VIEW OF MABA RESOLVER Figure 3 3A Standard Wiring Diagram Clockwise transducer shaft rotation PLSO01 TRANSDUCER INTERFACE CONNECTOR Figure 3 3B Wiring Diagram Counter clockwise transducer shaft rotation Document 11696 Page 9 PLS 601 User s Manual 3 4 PLS 601 RELAY OUTPUT BOARDS The PLS 601 is available with solid state or electromechanical relay boards Each relay board can contain up to seventeen relays Sixteen of these relays are dedicated for channel Sutputs The remaining relay is dedicated to the MOTION DETECT output A maximum of four relay boards can be interfaced to the control unit providing a total of sixty four relay outputs 3 4 1 Solid State Relay Board The solid state relay board is available with four different types of relays These relays are as follows 120 VAC at 3 Amps 240 VAC at 3 Amps 60 VDC at 3 Amps 200 VDC at 1 Amp All solid state relays are optically isolated and individually fused for safe reliable operation Each relay also has an associated LED to indicate its ON OFF status An additional feature of the PLS 601 is that the internal power supply can drive up to four fully loaded solid state gt relay boards This eliminates the need for an external power supply Figure 3 4 1 shows the layout of the solid state relay board Channel Group Jumpers 16 ERR DCBADCBA H Relay 16 Jumper MD 1 6 7 9 10 11 12 13 14 15 16 00000
2. field the MD LED and output will be ON when the shaft speed is within the MD window and OFF when it is outside of the window If the MF field is greater than the MT field the MD LED and output will be OFF when the shaft speed is within the MD window and ON when it is outside of the window Document 11696 Page 24 PLS 601 User s Manual 4 2 6 MOTION Continued Select MOTION _ Selects the MOTION data entry function New Display 10 MT060 R040 Highlighted character indicates blinking character that can be changed Select DATA 0 9 The numerical value of the selected DATA KEY is displayed in the present cursor position of the MF or MT fields New Display MF 1 10 MT060 R040 Select INC Increments the numerical value at the current cursor location in the MF or MT data fields The value is immediately entered into memory the INC key does not require the use of the ENTER key New Display 210 MT060 R040 Select DEC Decrements the numerical value at the current cursor location in the MF or MT data fields The value is immediately entered into memory the DEC key does not require the use of the ENTER key New Display 10 MT060 R040 Select CLEAR Sets the MF and MT RPM values to 000 New Display MF 00 MT000 R040 Select lt CURSOR Moves the cursor left within the three digit MF or MT fields New Display MF 01 MT060 R040 Select gt CURSOR Moves t
3. New Display PROG 2 P000 R000 4 2 2 TACHOMETER Function The TACHOMETER function is used to display the selected PROGRAM NUMBER PROG the RESOLVER shaft position P in degrees and the RESOLVER shaft speed R in RPM This function does not allow for data entry TACHOMETER DATA Function Select POS TACH Selects the POS TACH function in order to display the current RESOLVER shaft position in degrees and RESOLVER shaft speed in RPM New Display PROG 2 P000 R000 Document 11696 Page 17 PLS 601 User s Manual 4 2 3 SET Function The SET function is used to enter LOBE data into the PLS 601 s memory The SET function will allow single or multiple LOBE data to be entered on any or all of the 64 available channels A total of 3808 LOBES 238 LOBES per channel group per program may be entered The timing and dwell of each LOBE is defined by a FROM position and a TO position The FROM position defines the timing whereas the difference between the FROM and TO positions defines the DWELL SET Function Select SET Selects the LOBE data entry function New Display 1 T Highlighted character indicates blinking character that be changed To enter LOBE data the CHANNEL GROUP must be selected Once the channel group has been chosen the desired channel within the group must be selected The channels are divided into four groups with each group consisting of up to sixteen channels When all channel groups ar
4. Document 11696 Page 40 PLS 601 User s Manual 5 4 8 COPY See Section 4 2 8 5 4 9 SPECIAL FUNCTION F7 See Section 4 2 9 5 4 9 SPECIAL FUNCTION F8 See Section 4 2 10 5 4 11 END See Section 4 2 11 Display P10140 PRG R030 Document 11696 Page 41
5. In data entry mode this is the number 0 key O a Z The SET function is used to enter LOBE data in to the PLS 601 control unit s memory Set allows single or multiple lobes to be entered on any or all of the 64 channels A total of 3808 LOBES 238 LOBES per channel group per program In data entry mode this is the number 1 key SET The OFFSET function is used to display or enter a positive value that is added to the actual resolver angle value This parameter is used to align the resolver zero angle reference point to the actual machine zero angle reference point In brief electrical zero can be adjusted to match that of mechanical zero through the use of the OFFSET value In data entry mode this is the number 2 key OFFSET SCALE The SCALE function is used to display or enter the scale factor parameter into the PLS 601 Control Unit s memory The scale factor is the number of intervals that one complete resolver rotation is divided into In data entry mode this is the number 3 key The MOTION function allows the user to set a window for shaft speed If the resolver shaft speed falls within the defined window criteria the MD LED Motion Detect and Motion Detect outputs will provide visual and electrical feedback depending on how the Motion Detect parameters are programmed into the control unit s memory In data entry mode this is the number 4 key MOTION Document 11696 Page 6 PLS 601 User s Manual 3 2 2 PLS 6
6. gt CURSOR Moves the cursor right in the three digit CHANNEL field of the front panel display Select CLEAR Sets the displayed CHANNEL GROUP to A and the CHANNEL NUMBER to 1 New Display OIF T Select ENTER Selects the displayed CHANNEL GROUP and CHANNEL NUMBER for entry of LOBE DATA Select FUNCTION Terminates the SET function and returns the user to FUNCTION select mode where anyone of the PLS 601 functions can be selected Document 11696 Page 27 PLS 601 User s Manual 4 2 7 TEACH Function Continued ENTERING CHANNEL LOBES After the channel has been selected the LOBE data may be entered If no lobes have previously been programmed for the selected channel the and T fields will display blank characters _ If one or more LOBES already exist for the selected channel the data for the first LOBE will be displayed in the F and T fields NEW CHANNEL LOBE ENTRY Display CH A01 __ T___ Highlighted character indicates blinking character that can be changed Select lt CURSOR Moves the cursor between F and T fields New Display CHA01 F 123 0345 Select ENTER The displayed FROM and TO data fields are entered into memory The cursor is set to the position between the FROM and TO fields and the data is now considered as existing data New Display CHA01 F 12357345 Select NEXT Selects and displays the next LOBE in sequence New Display CHA02F___ T___ The _ in the FROM and TO fie
7. JUMPER OPTION S has been selected See section3 4 1 4 for details of the RELAY 16 JUMPER OPTION Document 11696 Page 35 PLS 601 User s Manual 4 4 CHANNEL STATUS GROUP SELECTION The Channel outputs are divided into four groups of sixteen outputs each designated A01 A16 BO1 B16 CO1 C16 and DO1 D16 The sixteen CHANNEL STATUS LED s display the status of the sixteen Channel outputs in the CHANNEL STATUS GROUP indicated by the GROUP LED s Anytime that the FUNCTION LED is lit the current CHANNEL STATUS GROUP may be changed by using the CURSOR utility keys The right CURSOR key will rotate the CHANNEL STATUS GROUP to the i e A to B to C to D to A while the left CURSOR key will rotate the CHANNEL GROUP to the left i e D to to to Ato D During execution of the SET and TEACH functions the CHANNEL STATUS GROUP is automatically set to the CHANNEL GROUP currently being shown on the alphanumeric display 4 5 ERROR CONDITIONS By selecting RELAY 16 JUMPER OPTION S see Section 3 4 1 Relay 16 can be used to provide a hardware indication that one of the following Control Unit error conditions has occurred TRANSDUCER SIGNAL ERROR CONTROL UNIT MICROPROSSER FAULT LOSS OF AC POWER With the S option selected Relay 16 is held normally closed N C by the Control Unit hardware Should any of the Control Unit errors occur Relay 16 is OPENED to indicate the error condition 4 5 1 TRANSDUCER SIGNA
8. RELAY OUTPUT BOARD connector is a twenty pin male connector used to interface to either a solid state relay board or an electromechanical relay board The pin out of this connector will not be detailed because of the proprietary interface between the PLS 601 and the relay output boards The remaining connectors and their pin out definitions are defined in Figure 3 2 5 Cor munications Interface Connecter Pin 1 Pin 2 RD Pin 3 Pin 4 t Pin 8 RI Rotor 1 Relay Ci tput Board Interface Connector Resalver Inteface Figure 3 2 5 Bottom view of PLS 601 control unit and connector pin out definitions Document 11696 Page 8 PLS 601 User s Manual 3 3 TRANSDUCER CONTROL UNIT INTERFACE CABLE The CONTROL UNIT is interfaced to the TRANSDUCER via a custom made transducer interface cable This cable consist of three individually shielded pairs that has an eight pin female plug connector on one end and a seven pin female MS type connector on the other end The standard transducer interface cable is wired at the factory to provide an INCREASING angular position reading for CLOCKWISErotation of the TRANSDUCER shaft when looking into the END of the shaft The wiring diagram for this cable is shown in Figure 3 3A If an INCREASING angular position reading for COUNTER CLOCKWISE rotation of the TRANSDUCER shaft is desired refer to Figure 3 3B for that wiring diagram O 1 ant N A 10
9. _ _ New Display COPYC FIN TA__ Select ENTER Initiates the COPY for the displayed FROM and TO CANNELS Select FUNCTION Terminates the COPY function and returns the user to FUNCTION select mode where any one of the PLS 601 functions can be selected CHANNEL TO CHANNEL COPY COMPLETION During the CHANNEL to CHANNEL COPY the Control Unit will BLINK the COPY digits one at a time to indicate that the COPY is in progress After the COPY has been successfully completed the Control Unit will display COPY C P U on the alphanumeric display and BLINK only the C Channel digit The SELECTING THE TYPE OF COPY sequence may now be followed see section 4 2 8 COPYING FROM PROGRAM TO PROGRAM For a PROGRAM to PROGRAM COPY the user must specify only the TO PROGRAM the CURRENT PROGRAM is always the FROM PROGRAM data stored by the SET OFFSET SCALE MOTION and TEACH functions are copied from the CURRENT PROGRAM into the TO PROGRAM Note During a PROGRAM to PROGRAM COPY the current TO PROGRAM data is lost Select COPY Selects the COPY program function Select CURSOR Moves the cursor between the three COPY types C Channels P Program and U Unit Choose P New Display COPY C P U Select ENTER Selects the COPY type that is currently being indicated by the cursor New Display F1 TU Document 11696 Page 32 PLS 601 User s Manual 4 2 8 COPY Funct
10. an existing LOBE in memory or in applications which require a large number of LOBES a MEMORY FULL condition may be reached MEMORY FULL will be displayed during the SET or TEACH functions to indicate the MEMORY FULL condition The system will continue with its normal operation but will not allow further entry or modification of LOBES The MEMORY FULL condition may be cleared by pressing the CLEAR key while MEMORY FULL is being displayed The Control Unit will free up room in memory by eliminating any unused LOBES WARNING The process of compressing the memory is very rapid and is not perceptible to the user However during this time the outputs will be frozen at their current states To AVOID MACHINE MALFUNCTION IT IS STRONGLY RECOMMENDED THAT THE OUTPUTS BE DISABLED DURING THIS PROCESS 5 3 SELECTING THE NUMBER OF TURNS MASTER MODE The NUMBER of TURNS is selected in MASTER MODE see 3 2 2 through the use of the SCALE function key The selected TURNS value is used by all four PROGRAMS Control Unit in Master Mode Select SCALE Display TURNS 100 Highlighted character indicates blinking character that can be changed Select DATA 0 9 The numerical value of the DATA KEY i e 0 9 is Displayed in the cursor position of the TURNS field to a maximum value of 100 Document 11696 Page 38 PLS 601 User s Manual 5 3 SELECTING THE NUMBER OF TURNS MASTER MODE continued Select CURSOR Moves the cursor left or r
11. function see Output Enable Connector in Figure 3 4 1 This connector is labeled ENA The ENA pins must be shorted together in order for any of the seventeen solid state relay outputs to be enabled If this connection is opened all seventeen solid state relay outputs will be disabled Document 11696 Page 11 PLS 601 User s Manual 3 4 PLS 601 RELAY OUTPUT BOARDS Continued 3 4 2 Electromechanical Relay Board The electromechanical relay board contains a maximum of seventeen electromechanical relays each rated at 240 VAC at 10 Amps or 30VDC at 10Amps Each relay is configured as SPST providing one normally open contact N O and one normally closed contact N C Figure 3 4 2 shows the layout of the electromechanical relay board Channel Group Jumpers DC Power Source Relay 16 Jumper Enable Relay ic Connectors Connector A ees J C No NO C NC 15 NO G NC NOES nanana 000006 NG GANG annann NO C Ne RO NG Figure 3 4 2 PLS 601 Electromechanical Relay Board 1 Channel Group Jumper Options Electromechanical Relay Board The PLS 601 Control Unit provides sixty four channel outputs that are divided into four groups of sixteen channels each The channels are designated as A01 A16 BO B16 C01 C16 and D01 D16 Up to four electromechanical relay boards each with sixteen relays can be attached to the PLS 601 Control Unit However only one electromechan
12. 0 OO00 8 RRAR RAR MO Songen 5 _ SS o o to tooto tototo HS o tooto totoo MD 1 2 3 4 5 6 7 8 9 10 11 12 13 14 t5 16 ENA Figure 3 4 1 PLS 601 Solid State Relay Board 1 Channel Group Jumper Options Solid State Relay Board The PLS 601 control unit provides sixty four channel outputs that are divided into four groups of sixteen channels each The channels are designated as A01 A16 BO B16 C01 C16 and D01 D16 Up to four solid state relay boards each with sixteen output relays can be attached to the PLS 601 control unit Each board must be assigned to one of four output groups designated as A B C or D This is done by installing the two channel group jumpers in the proper positions on the relay board see Channel Group Jumpers in Figure 3 4 1 The solid state relay board must be configured to match the PLS 601 output group that will drive it Output Group A will drive relay output board A Group B will drive relay output board B and so forth Document 11696 Page 10 PLS 601 User s Manual 3 4 PLS 601 RELAY OUTPUT BOARDS Solid State Relay Board Continued 2 Interface Connectors Solid State Relay Board Each solid state relay output board contains two 20 pin male interface connectors labeled PIOLA and P101B see Interface Connectors in Figure 3 4 1 The PLS 601 Control Unit will connect to P101A through the use of a twenty pin ribbon cable To add additional sol
13. 01 FRONT PANEL USER INTERFACE Continued TEACH The TEACH function allows a user to enter the current shaft position into memory as the FROM or TO position of a LOBE using only the ENTER key In data entry mode this is the number 5 key COPY The COPY function allows the user to copy the stored program data from one channel to another one program to another or from one PLS 601 control unit to another In data entry mode this is the number 6 key The F7 function can be used to implement a special function as required by a specific user s application In data entry mode this is the number 7 key The F8 function be used to implement a special function as required by a specific user s application In data entry mode this is the number 8 key END The END function is used to end data entry for the current program It also allows for the selection of the other programs available for data entry Currently the number of programs available is 1 through 4 In data entry mode this is the number 9 key Each of the above functions will be described in detail later within this manual Utility Keys The utility keys are used in conjunction with the function data keys to increase the ease of entering data into the PLS 601 memory Following is a functional description of each CURSOR CURSOR CURSOR KEYS are used to move the cursor within the various PLS 601 data fields allowing the user to select only those positions at which data ent
14. 6 Page 2 PLS 601 User s Manual 1 0 SCOPE The purpose of this User s Manual is to describe the operation installation and programming of the Toledo Transducer s PLS 601 Programmable Limit Switch It is strongly recommended that this User s Manual be read entirely before placing the PLS 601 into operation Failure to follow the instructions given in this User s Manual may void your PLS 601 warranty Questions regarding any aspect of the PLS 601 should be referred to Toledo Transducers Inc Toledo Transducers Inc 6834 S pring Valley Drive Holland Ohio 43528 Phone 419 867 4170 Fax 419 867 4180 2 0 PROGRAMMABLE LIMIT SWITCH FUNCTIONAL DESCRIPTION A wide variety of industrial applications require that an electrical switch be turned ON and OFF at exactly the same point in each cycle of machine operation The point in the machine cycle that the switch is turned ON is commonly known as the TIMING whereas the length of time that the switch is ON is termed the DWELL TIMING and DWELL can be provided by mounting a mechanical cam on a rotating shaft such that it can make contact with a corresponding electrical switch The portion of the cam that comes into actual contact with the switch is often known as the LOBE The design of the cam must allow the user to be able to set both the TIMING and DWELL of the LOBE Several cam switch assemblies can be placed on the same shaft to provide independent TIMING and DWELL for a number of differ
15. FI TA__ Select ENTER Initiates the COPY for the displayed FROM and TO CANNELS Select FUNCTION Terminates the COPY function and returns the user to FUNCTION select mode where any one of the PLS 601 functions can be selected SELECTING the CHANNEL NUMBER Select gt CURSOR Move the cursor right within the three digit FROM CHANNEL field until positioned for first blank space on the display New Display COPY C FAQ TA__ Select INC Increments the displayed FROM CHANNEL NUMBER CHANNEL NUMBER depending on the cursor position New Display COPY FA 1 TA__ Select DEC Decrements the displayed FROM CHANNEL NUMBER CHANNEL NUMBER depending on the cursor position New Display COPY 6 __ Select gt CURSOR Move the cursor right to the three digit TO CHANNEL field until positioned at the first blank space on the display New Display COPY FA01 TAJ_ Select INC Increments the displayed FROM CHANNEL NUMBER or CHANNEL NUMBER depending on the cursor position New Display COPY C FA01 TA 0 1 Document 11696 Page 31 PLS 601 User s Manual 4 2 8 COPY Function Continued Select DEC Decrements the displayed FROM CHANNEL NUMBER CHANNEL NUMBER depending on the cursor position New Display COPY 01 Select CLEAR Sets the displayed FROM CHANNEL and TO CHANNEL to A
16. IT TO UNIT COPY COMPLETION During the UNIT to UNIT COPY the Control Unit will BLINK the COPY digits one at a time to indicate that the COPY is in progress After the COPY has been completed the Control Unit will display FINISHED on the alphanumeric display of both SEND and RECEIVE units The FUNCTION LED will be lit allowing the user to select any of the ten PLS 601 functions NOTE The SEND unit may display FINISHED even though a successful COPY has not occurred The true indicator of a successful COPY is when the RECEIVE UNIT displays FINISHED ERROR CONDITIONS RECEIVE UNIT fails to receive data from SEND UNIT A The RECEIVE UNIT will remain in a COPY WAIT state until it receives data from the SEND UNIT If the COPY is not successful the RECEIVE UNIT will remain in the COPY WAIT state indefinitely To remove the RECEIVE UNIT from the COPY WAIT state press any key on the RECEIVE UNIT front panel The RECEIVE UNIT will respond by displaying RECEIVE LINE ERR and lighting the FUNCTION LED The RECEIVE UNIT is placed in COPY WAIT state before the COPY U option is selected in the SEND UNIT Document 11696 Page 34 PLS 601 User s Manual 4 2 8 COPY Function Continued The COPY function and U option must be selected on BOTH units before a SEND or RECEIVE selection is made on either Failure to follow this sequence will result in a RECEIVE LINE ERR being d
17. L ERROR If any of the PLS601 IT Interface Cable wires become disconnected or broken the following error indications will be given by the Control Unit In DISPLAY MODE 1 The message TRANSDUCER ERROR will be placed on the display 2 The OUTPUT DISABLE LED will be lit 3 All PLS601 RE Relay outputs will be dis abled NOTE Relay 16 is disabled regardless of the selected jumper option In PROGRAM MODE 1 POSITION and RPM values will read 000 on the display 2 The OUTPUT DISABLE LED will be lit 3 All PLS601 RE Relay outputs will be disabled NOTE Relay 16 is disabled regardless of the selected jumper option 4 Normal Control Unit programming will be allowed Document 11696 Page 36 PLS 601 User s Manual 4 5 ERROR CONDITIONS Continued 4 5 2 CONTROL UNIT MICROPROCESSOR FAULT In the event of a microprocessor fault the alphanumeric display and Channel outputs are frozen in the State that existed at the time of the failure Because it is implemented in hardware Relay 16 with the RELAY 16 JUMPER OPTION selected can be used to give an indication that the control unit has experienced a microprocessor fault 4 5 3 LOSS OF AC POWER In the event of a loss of AC power the Control Unit will cease all operations The alphanumeric display will become blank and no signals will be output on the Relay and Transducer interface connectors see section 3 2 5 Relay 16 is disabled regardless of the jumper option Because the pro
18. OTION DETECT window The MOTION DETECT output is brought out to the twenty pin male connector that is located on the bottom of the PLS 601 Control Unit 3 2 4 AC DC POWER SYSTEM The AC POWER PLUG offers a safe convenient method of providing AC power to the CONTROL UNIT eliminating the need to connect individual power wires An RFI LINE FILTER provides built in protection against RFI Radio Frequency Interference induced line noise An AC POWER FUSE provides electrical protection for the CONTROL UNIT s electronics The internal DC POWER SUPPLY provides DC power for the CONTROL UNIT as well as up to four solid state relay boards or one electromechanical relay board This eliminates the need for an external power supply 3 2 5 INTERFACE CONNECTORS Three interface connectors are supplied on the standard PLS 601 CONTROL UNIT a TRANSDUCER INTERFACE CONNECTOR a COMMUNICATIONS OUTPUT CONNECTOR and a RELAY OUTPUT BOARD connector These connectors are located on the bottom side of the CONTROL UNIT ENCLOSURE as shown in FIGURE 3 2 5 The TRANSDUCER INTERFACE CONNECTOR is an eight pin male connector used to interface the CONTROL UNIT to the TRANSDUCER Refer to SECTION 3 3 for complete details on the TRANSDUCER INTERFACE The COMMUNICATIONS OUTPUT CONNECTOR is a four pin male connector that provides serial data to the remote display If the CONTROL UNIT is configured for RS232 output the data can interface to an external computer or PLC The
19. T10230 Document 11696 Page 39 PLS 601 User s Manual 5 4 4 OFFSET An asterisk before the OF field indicates that the displayed data must be entered into memory via the ENTER key The INC DEC keys enter data immediately into memory as in the standard unit See Section 4 2 4 for a complete description of OFFSET function Display 10140 02 00024 5 4 5 SCALE asterisk between TN SF fields indicates that the displayed data must be entered into memory via the ENTER key See Section 4 2 5 for a complete description of the SCALE function Display TN 100 1000 Upon entry of anew SCALE FACTOR the SYSTEM RESOLUTION Total TURNS times the SCALE FACTOR is calculated and displayed New Display P10140 RES10000 5 4 6 MOTION An asterisk between the MT and fields indicates that the displayed data must be entered into memory via the ENTER key See Section 4 2 6 for a complete description of the MOTION function 5 4 7 TEACH With the TEACH function the INC DEC keys DO NOT enter immediately into memory The displayed data must always be entered via the ENTER key The dash symbol between the FROM and TO fields will be changed to an asterisk to indicate that the displayed data must be entered into memory See Section 4 2 7 for a complete description of the TEACH function SELECTING THE CHANNEL Display _ ENTERING LOBES Display 01 17140 7102330
20. Toledo Transducers PLS 601 Programmable Limit Switch System User s Manual Rev 1 on the web PLS 601 User s Manual TABLE OF CONTENTS TOFS COPE eS NSD Uk SIE ENG eT 3 2 0 PROGRAMMABLE LIMIT SWITCH FUNCTIONAL 3 3 0 PLS 601 SYSTEM COMPONENTS 1 00 3 TRANSDUCER 3 2 PLS 601 CONTROL UNIT SPECS 3 2 1 ENCLOSUR Eoscsccccccccevsscastescesncevnsosesnseees 3 2 2 FRONT PANEL USER nai S 22A ACPE POWERS a a aa a a e a A T 3 2 5 INTERFACE CONNECTORS riire a eee r ee E AEE EEREN 3 3 TRANSDUCER CONTROL UNIT INTERFACE CABLE es si 3A PLS 601 OUTPUT BOARDS EAEE PAEA teveesdstctsseseeupiasesy 4 0 USING THE PUS 601 vii 3c 008 sce eon ee in ia Si ne ee ae Wea 14 4 17 INSTALLATION esa teeest deat ea aa aa e stu divi AE EEE aR aA E E EAS EREEREER 4 1 1 MOUNTING THE TRANSDUCER 4 1 2 MOUNTING THE CONTROL UNIT 4 1 3 CONNECTING THE RESOLVER TO THE CONTROL UNIT 4 1 4 MOUNTING THE RELAY BOARDS iirinn a n T a 4 1 5 INSTALLING THE AC POWER CORD 4 1 6 POWERING ON THE CONTROL UNIT 4 2 PLES 601 PROGRAMMING acea e E E T EERTE 16 4 2 1 CHANGE PROGRAM NUMBER 4 DSS SCALE PAC VOR E E E ATA ET EEA EE E 4 2 0 MOTION DEFTEG D t
21. Y is displayed in the present cursor position of the SCALE FACTOR data field to a maximum value of 1000 Page 23 PLS 601 User s Manual 4 2 5 SCALE Continued SCALE FACTOR Select CLEAR The value of the SCALE FACTOR is set to 1000 and entered into memory The Control Unit automatically returns to FUNCTION select mode after pressing CLEAR New Display SF 1000 P075 R040 Select lt CURSOR Moves the cursor left within the four digit SCALE FACTOR data field of the front panel display New Display SF 1000 P075 R040 Select gt CURSOR Moves the cursor right within the four digit SCALE FACTOR data field of the front panel display New Display SF 000 P075 R040 Select ENTER Stores the new OFFSET value into memory on the display The Control Unit automatically returns to FUNCTION select mode after pressing ENTER Select FUNCTION Pressing the FUNCTION key at any time while in SCALE mode will terminates the SCALE function and returns the user to FUNCTION select mode where any one of the PLS 601 other functions can be selected 4 2 6 MOTION MOTION WINDOW Motion allows the user to set a window for shaft speed and receive an indication that the shaft speed falls within the window via the MD Motion Detect LED and Motion Detect output See section 3 2 5 The window is defined by the MOTION FROM MF and MOTION TO MT values are considered to be WITHIN the window Note If the MF field is less than the
22. an the SCALE FACTOR value If this is attempted the value will automatically be set to zero The following designates the entry of new channel LOBES Document 11696 Page 19 PLS 601 User s Manual 4 2 3 SET Function Continued NEW CHANNEL LOBE ENTRY Display CH 01 __ ___ Highlighted character indicates blinking character that be changed Select DATA 0 9 The numerical value of the selected DATA KEY is displayed in the present cursor position As an example the value of 123 will be entered into the FROM field and the value of 345 will be entered into the TO field New Display CHA01 F 123 1349 Select lt CURSOR Moves the cursor left within the three digit FROM or TO data fields of the front panel display New Display CHAO1 F123 T3 5 Select gt CURSOR Moves the cursor right within the three digit FROM or TO data fields of the front panel display New Display CHA01F 123 1349 Select ENTER The displayed FROM and TO data fields are entered into memory The cursor is set to the position between the FROM and TO fields and the data is now considered as existing data New Display 01 123 7345 Select NEXT Selects and displays the next LOBE in sequence New Display CHA02F___ T___ The _ in the FROM and fields indicates that no LOBE data has been stored for this LOBE If numerical data is present within the FROM and TO fields than data has been previously entered for the LOBE that is displ
23. ay be entered Once programmed the user may quickly and easily instruct the unit to operate under the control of any one of the four separate programs Figure 4 2 1 depicts the front panel of the PLS 601 control unit PROG 1 POOO R000 PROGRAM SET OFFSET SCALE MOTION 0 1 2 3 4 ENTER MASTER 5 6 7 8 9 UTILITY CURSOR CURSOR INC DEC OUTPUT AV1dSIC 123 45 67 8 9 10 11 12 13 14 15 16 CHANNEL STATUS Figure 4 2 1 PLS 601 Front Panel Document 11696 Page 16 PLS 601 User s Manual 4 2 1 PLS 601 CHANGE PROGRAM NUMBER Once the power to the PLS 601 has been applied one of the four programs must be selected by entering the desired program number PROG To accomplish this task make sure the MODE switch is in the PROGRAM position The following describes how to change the PROGRAM number of the PLS 601 CHANGE PROGRAM NUMBER CHANGE PROGRAM NUMBER DISPLAY PROG P000 R000 Highlighted character indicates blinking character that can be changed Select 1 2 3 or4 Blinking character will change accordingly or Select INC Blinking character will INCrement to next value or Select DEC Blinking character will DECrement to next value or Select CLEAR Selects PROGRAM NUMBER 1 New Display PROG 2 P000 R000 Select ENTER Selects the new program number into memory for data entry to begin The FUNCTION LED becomes active and the display prompt for PROGRAM NUMBER stops blinking
24. ayed Select FUNCTION Terminates the SET function and returns the user to FUNCTION select mode where anyone of the PLS 601 functions can be selected Document 11696 Page 20 PLS 601 User s Manual 4 2 3 SET Function Continued MODIFYING EXISTING CHANNEL LOBE DATA Display CH A01 F f 23 T345 Highlighted character indicates blinking character that can be changed Select Select New Display Select New Display Select New Display Select New Display Select New Display Select New Display Document 11696 DATA 0 9 lt CURSOR The numerical value of the selected DATA KEY is displayed in the present cursor position As an example the value of 123 will be entered into the FROM field and the value of 345 will be entered into the TO field Moves the cursor left within the three digit FROM or TO data fields of the front panel display CHA01 F 123 1349 gt CURSOR Moves the cursor right within the three digit FROM or TO data fields of the front panel display 1 23 345 Increments the numerical value at the current cursor location in the FROM or TO data fields If the cursor is between the FROM and TO data fields both FROM and TO data values will be incremented and placed into memory The INC key does not require the use of the ENTER key CHA01 F 23 1345 DEC Decrements the numerical value at the current cursor location in the FROM or TO data fie
25. d of the front panel display OF 00 P075 R040 Moves the cursor right within the three digit OFFSET data field of the front panel display OF 100 P075 R040 The PLS 601 control unit calculates displays and stores the offset value required to set the resolver shaft position to electrical 000 When the CLEAR function is used the offset value is calculated and placed into memory This function will terminate the data entry for the OFFSET value OF 000 P075 R040 Stores the new OFFSET value into memory on the display The Control Unit automatically returns to FUNCTION select mode after pressing ENTER Pressing the FUNCTION key at any time while in OFFSET mode will terminates the OFFSET function and returns the user to FUNCTION select mode where any one of the PLS 601 other functions can be selected The SCALE FACTOR is the number of increments that the CONTROL UNIT divides one complete Transducer shaft rotation into The SCALE function allows the user to enter a SCALE FACTOR FROM 0002 TO 1000 NOTE Upon changing the SCALE FACTOR the Control Unit will re scale all stored LOBE data Care should be taken when changing the SCALE FACTOR as the rescaling of the LOBE data may produce undesirable rounding SCALE FACTOR Select SCALE SCALE DISPLAY SF 000 P075 R040 Highlighted character indicates blinking character that can be changed Select DATA 0 9 Document 11696 The numerical value of the selected DATA KE
26. e active a total of 64 individual channels become available The channels are designated as 01 16 B16 C01 C16 and 01 D16 SELECTING THE CHANNEL GROUP Display 1 T Highlighted character indicates blinking character that can be changed Select INC Increments the active group A B C or D to the next available group value New Display CH 201 T Select DEC Decrements the active group A B C or D to the previous available group value New Display 1 T Select CURSOR Moves the cursor left or right within the three digit CHANNEL field of the front panel display New Display CH F gt used to move CURSOR to the RIGHT CH 01 lt used to move CURSOR to the LEFT Select CLEAR Sets the displayed CHANNEL GROUP to A and the CHANNEL NUMBER to 1 New Display 1 T Select ENTER Selects the displayed CHANNEL GROUP and CHANNEL NUMBER for entry of LOBE DATA Select FUNCTION Terminates the SET function and returns the user to FUNCTION select mode where any one of the PLS 601 functions can be selected Document 11696 Page 18 PLS 601 User s Manual 4 2 3 SET Function Continued SELECTING THE CHANNEL NUMBER Display CH 0 T Highlighted character indicates blinking character that can be changed Select 2 The numerical value of the selected DATA KEY is displayed in the present cursor position In this examp
27. e male AC Power Plug located on the side of the Control Unit enclosure 4 1 6 POWERING ON THE CONTROL UNIT The Control Unit requires a clean stable source of AC Power to operate See SECTION 3 2 for the complete AC Power requirements and specifications of the various Control Unit input power options The male end of the AC Power Cord should be inserted into a standard GROUNDING RECEPTACLE which has been wired to provide the AC Power requirements specified in SECTION 3 2 Document 11696 Page 15 PLS 601 User s Manual 4 2 PLS 601 PROGRAMMING The PLS 601 Control Unit offers four standard programs each consisting of OFFSET SCALE FACTOR MOTION DETECT and LOBE data that is entered by the user via the PLS 601 functions The SCALE FACTOR OFFSET SETPOINT and MOTION DETECT functions require the user to enter data via the FRONT PANEL Parameters can only be entered into the PLS 601 memory when the front panel mode switch is in the PROGRAM position The following sections explain how to enter data into the control unit A typical programming sequence for the PLS 60 Lis as follows e Apply power to the PLS 601 control unit e Turn mode switch to PROGRAM e Enter SCALE values e Enter OFFSET values Enter SET mode or TEACH mode Define MOTION detect window e Perform COPY command if applicable e END programming sequence For each of the PLS 601 functions a BLINKING digit on the display indicates the position of the cursor at which data m
28. e visual feedback even in dimly lighted areas Mode Keyswitch The mode keyswitch protects the user program data from being changed by unauthorized personnel through the provision of three key selectable modes of operation In Display mode program data can be displayed and verified but not changed In Program mode all standard PLS 601 functions can are enabled allowing the user to enter program data into memory even while the unit is operating In Master mode access is allowed to a set of optional Master functions that are normally required only during system installation and configuration The key can only be removed while the switch is in the display mode position Function Data Keys The FUNCTION key is used to select whether the ten dual purpose function data keys are to be used to select one of the PLS 601 functions or to enter numerical data By pressing the function key the associated function LED will either turn on to indicate function entry mode or turn off to indicate data entry mode While in data mode numerical data 0 through 9 can be entered The ENTER key is used to enter data into non volatile EEPROM memory during ENTER execution of the PLS 601 functions The PLS 601 currently supports the following functions POS TACH The POS TACH function is used to display the selected PROGRAM NUMBER PROG the current resolver angle POSITION P and the current speed of the resolver shaft in RPM R when the function key is active
29. ed in a manner such as to minimize shock vibration as well as axial and radial shaft loading The RESOLVER may be mounted via the standard front face mount or the optional foot type mounting adapter 4 1 2 MOUNTING THE CONTROL UNIT The PLS 601 Control Unit is designed to be mounted in a NEMA type enclosure which is suitable for the ambient environment The enclosure must protect the Control Unit from contamination caused by water oil dust or corrosive gases The Control Unit should not be subjected to excessive amount of mechanical shock or vibration The mounting location should be chosen such as to avoid exposure to significant levels of electromagnetic interference EMI which can be induced by devices such as motor starters and control relays The operating temperature must be maintained between 32 F and 125 F 4 1 3 CONNECTING THE RESOLVER TO THE CONTROL UNIT The Resolver is connected to the PLS 601 Control Unit via the Resolver Control Unit Interface Cable The Cable is a 3 pair individually shielded cable containing an eight pin female plug connector on one end and a seven pin female MS type connector on the other The standard interface cable is wired at the factory to provide an INCREASING angular position reading for CLOCKWISE rotation of the Resolver shaft when looking into the END of the shaft An INCREASING angular position reading during COUNTERCLOCKWISE rotation of the Resolver shaft may be achieved by interchangi
30. elay interface connectors on each unit see section 3 2 5 3 Select the COPY function and U Unit option on BOTH units See section 4 2 8 The OUTPUT DISABLE LED is automatically lit when the 0 option is selected and MUST left on during the COPY 4 Use the CURSOR key to select one unit as the SENDING UNIT SEN and the other unit as the RECEIVING UNIT REC 5 Push the ENTER key on the RECEIVING UNIT to ready it for receipt of the COPY data 6 Push the ENTER key on the SENDING UNIT to initiate the COPY NOTE During a UNIT COPY all program data stored in the RECEIVE UNIT is lost Document 11696 Page 33 PLS 601 User s Manual 4 2 8 COPY Function Continued SELECTING THE SEND AND RECEIVE UNITS Select COPY Selects the COPY program function Select CURSOR Moves the cursor between the three COPY types C Channels P Program and U Unit Choose U New Display copy 8 Select ENTER Selects the COPY type that is currently being indicated by the cursor New Display COPY U SEND REC Select CURSOR Moves the cursor between the SEND and REC fields Designating the SENDING and RECEIVING UNITS Select ENTER Readies the RECEIVE UNIT for receipt of COPY data RECEIVE The R field stops blinking and may become a solid R or a blank Select ENTER Initiates the COPY from the SEND UNIT The S SEND field stops blinking and may become a solid S or a blank UN
31. ent machine functions Each cam switch assembly is commonly known as a CIRCUIT Mechanical cam switches can be very time consuming to set when more than a few circuits are required In addition mechanical cam switches are not practical in applications where the switch must be turned ON and OFF a number of times during a single machine cycle MULTIPLE LOBES A programmable limit switch is a device which overcomes the shortcomings of mechanical cam switches by performing the cam functions electronically rather than mechanically Instead of having to physically adjust the TIMING and DWELL of a number of mechanical cams the programmable limit switch PLS allows a user to enter the TIMING DWELL settings via a keyboard The TIMING and DWELL settings are then stored in a solid state memory and used to control whether the outputs of the electronic switches are turned ON or OFF Because of the relative low cost of today s solid state memories a PLS can readily accommodate applications requiring a large number of circuits each with single or multiple LOBES Document 11696 Page 3 PLS 601 User s Manual 3 0 PLS 601 SYSTEM COMPONENTS The PLS 601 is a state of the art microprocessor based programmable limit switch that allows a user to easily program single or multiple LOBES for a maximum of 16 independent circuits CHANNELS In addition the PLS 601 provides the user with TACHOMETER and MOTION DETECT functions The PLS 601 consists of fo
32. es are required Maximum Number of 3808 238 lobes x 4 channels x 4 groups 3 2 1 ENCLOSURE The CONTROL UNIT ENCLOSURE is constructed of 14 gauge anodized aluminum and is designed for easy access should maintenance or repair be required 3 2 2 PLS 601 FRONT PANEL USER INTERFACE The PLS 601 front panel has been designed for ease of use The front panel utilizes a 16 digit alphanumeric display an operating mode selection keyswitch a positive tactile feel keypad and various LED status indicators Figure 3 2 2 depicts the PLS 601 front panel user interface POOO R000 POS TACH SET OFFSET SCALE MOTION 0 1 2 3 4 ENTER MASTER 5 6 f 8 9 UTILITY CURSOR f CURSOR INC DEC OUTPUT NEXT CLEAR DISABLE 4 AV TdSIC 6 7 8 9 10 11 12 13 14 15 16 CHANNEL STATUS Figure 3 2 2 PLS 601 Front Panel User Interface Document 11696 Page 5 PLS 601 User s Manual 3 2 2 PLS 601 FRONT PANEL USER INTERFACE Continued Each element of the front panel will be discussed in order to give insight into the operation of the PLS 601 unit The description of the front panel elements follows Display The PLS 601 front panel user interface is equipped with a 16 digit alphanumeric display that is used to inspect and or program data fields or operating modes of the unit The display is of the vacuum fluorescent type which provides bright easy to se
33. et Mae is EN ects AA A NE A a 4 2 7 TEACH diss seve ise see ADB CORY 4 219 SPECLATE BU CLION cantentenecdestenitatesce stance 4 2 10 SPECIAL FUNCTION 8 er sees sere see BND EEA EAEE asd slgssnubschst salts fetch stdasaigeogctseestususaa dete 4 3 OUTPUT DISABLE wicca tie iain aul ie Mee di RS Se tee 35 4 4 CHANNEL STATUS GROUP 36 4 5 ERROR CONDITIONS Stee es OM eee ata 4 5 1 TRANSDUCER SIGNAL 4 5 2 CONTROL UNIT MICROPROCESSOR FAULT oy se 4 53 HOSS OR AC POWER AS la Document 11696 Page 1 PLS 601 User s Manual TABLE OF CONTENTS continured 5 0 2105 601 MODDED VY 5 1 ELECTRONIC 5 2 MEMORY FULL CONDITION 5 5 3 SELECTING THE NUMBER OF TURNS MASTER 5 4 USING THE STANDARD FUNCTIONS PROGRAM DISPLAY DA POWERAON E 39 5 4 2 POS TACH 5 4 6 MOTION 5 4 7 TEACH ees a SAS CORY eat vateatiaie iil AEAEE E TEA eda te 5 4 9 SPECIAL FUNCTION ENANA EE ase 5 4 10 SPECIAL FUNCTION F8 a bush ai ga EA D E EE E Document 1169
34. gram data is stored in non volatile EEPROM memory it will not be lost as a result of a loss of AC power Document 11696 Page 37 PLS 601 User s Manual 5 0 PLS 601 MODEL 11 The PLS 601 Model 11 features an Electric Gearbox function that provides multi turn capability for the PLS 601 Model 10 using the standard PLS TR 1 single turn resolver 5 1 ELECTRONIC GEARBOX The ELECTRONIC GEARBOX function allows the user to select the total NUMBER OF TURNS required for the application which can be any number from 1 to 100 As with the standard system the selected SCALE FACTOR determines the resolution of each turn to a maximum of 1000 The total SYSTEM RESOLUTION IS 1000 counts turn for 100 turns or 100 000 turns Because the number of turns is stored in non volatile EEPROM memory the current POSITION is retained during a loss of power to the Control Unit NOTE Following the loss of power the system will resume normal operation providing that the transducer shaft has not rotated more than 1 2 turn 180 degrees in either direction If a 180 degree shaft rotation has occurred during the loss of power the POSITION will be in error and have to be reset The following sections out line the differences between the operation and programming of the Model 10 and Model 11 Control Units 5 2 MEMORY FULL CONDITION The Model 11 Control Unit provides a maximum of 476 LOBES for each of the 4 PROGRAMS When making a modification to
35. haft is used to provide a heavy duty corrosion resistant transducer machine interface A flexible coupling provides mechanical isolation between the transducer shaft and the resolver for increased mechanical reliability Sealed ball bearings are used to maximize transducer life performance and reliability by providing a high quality bearing for the transducer The transducer enclosure contains an integral industrial duty MS type connector for interfacing to the Control Unit The TRANSDUCER may be mounted via the standard front face mount or an optional foot mount adapter for retrofit applications Document 11696 Page 4 PLS 601 User s Manual 3 2 PLS 601 CONTROL UNIT Each CONTROL UNIT consists of an ENCLOSURE INTERNAL ELECTRONICS AC DC POWER SYSTEM and I O INTERFACE CONNECTORS All CONTROL UNITS require a PROGRAMMER for data entry and inspection A PROGRAMMER consists of nineteen tactile feel keys a sixteen character liquid crystal alphanumeric display and a keyswitch for mode selection Each CONTROL UNIT is packaged complete with one AC POWER CORD and two MOUNTING BRACKETS PLS 601 SPECIFICATIONS Power arreire E E S EAE 115Vac 10 1 Phase 60 hertz Operating Temperature seee 32 F to 125 F Storage Temperature 0 F to 150 F Maximum Resolution ossos 1000 counts turn Standard Scan Time 200 microseconds E E E 300 rpm at 1000 counts per turn Consult factory if lower scan tim
36. he cursor right within the three digit or MT fields New Display MF 10 MT060 R040 Select ENTER Stores the new MOTION value into memory on the display The Control Unit automatically returns to FUNCTION select mode after pressing ENTER Select FUNCTION Pressing the FUNCTION key at any time while in MOTION mode will terminate the MOTION function and returns the user to FUNCTION select mode where any one of the PLS 601 other functions can be selected Document 11696 Page 25 PLS 601 User s Manual 4 2 7 TEACH Function The TEACH function allows a user to enter the CURRENT SHAFT POSITON into memory as the FROM or TO position of a LOBE using only the ENTER key TEACH Function Select TEACH Selects the TEACH data entry function New Display OIF T Highlighted character indicates blinking character that can be changed To enter LOBE data the CHANNEL GROUP must be selected Once the channel group has been chosen the desired channel within the group must be selected The channels are divided into four groups with each group consisting of up to sixteen channels When all channel groups are active a total of 64 individual channels become available The channels are designated as 01 16 B16 C01 C16 and 01 D16 SELECTING THE CHANNEL GROUP Display 1 T Highlighted character indicates blinking character that can be changed Select INC Increments the active group A B C
37. ical relay board can be directly driven from the PLS 601 Control Unit s power supply If additional boards are required an external power supply must be used see DC Power Source for details Each board must be assigned to one of four output groups designated as A B C or D This is done by installing the two channel group jumpers in the proper positions on the relay board see Channel Group Jumpers in Figure 3 4 2 The relay board must be configured to match the PLS 601 output group that will drive it Output Group A will drive relay output board A Group B will drive relay output board B and so forth 2 Interface Connectors Electromechanical Relay Board Each electromechanical relay output board contains two 20 pin male interface connectors labeled P101A and P101B see Interface Connectors in Figure 3 4 2 The PLS 601 Control Unit will connect to P101A through the use of a twenty pin ribbon cable To add additional electromechanical relay output boards simply connect P101B of the first or previous relay output board to P101A of the next relay output board Up to four electromechanical relay output boards can be connected to the PLS 601 Control Unit by this interface method 3 Relay Output Connectors Electromechanical Relay Board Each electromechanical relay board contains five 3 pin plug connectors and six 6 pin connectors that provides two output pins and a common for each of the sixteen channels see Relay Output Connectors in Fig
38. id state relay output boards simply connect P101B of the first or previous relay output board to PIOIA of the next relay output board Up to four solid state relay output boards can be connected to the PLS 601 Control Unit by this interface method 3 Relay Output Connectors Solid State Relay Board Each solid state relay board contains four 8 pin plug connectors that provides two output pins for each of the sixteen channels see Relay Output Connectors in Figure 3 4 1 These outputs are normally off until activated by the PLS 601 Control Unit The solid state relay output connectors are labeled through 16 In addition a 2 pin connector is available for the MOTION DETECT function This connector is labeled MD 4 Relay 16 Jumper Options Solid State Relay Board Solid state Relay 16 may be used as one of the standard channel output relays or it may be used as an indication that an error has occurred in the PLS 601 Control Unit To enable solid state Relay 16 as a standard output connect pins and 2 together of J1 see Relay 16 Jumper in Figure 3 4 1 To enable solid state relay 16 as an error indicator connect pins 2 and 3 together of J1 When solid state relay 16 is used as an error indicator it will be active in non error conditions ON and non active in an error condition OFF 5 Output Enable Solid State Relay Board Each solid state relay board has a 2 pin input connector that implements an OUPTUT ENABLE
39. ight within the three digit TURNS field New Display TURNS 10 Select CLEAR The value of the number of TURNS is set to 100 and entered into memory New Display TURNS 100 Select ENTER The displayed number of TURNS is entered into memory Select FUNCTION Pressing the FUNCTION key at any time while in NUMBER of TURNS function will terminate the TURNS function and return the user to FUNCTION select mode where any one of the PLS 601 other functions can be selected 5 4 USING THE STANDARD FUNCTIONS PROGRAM DISPLAY MODES Once the NUMBER of TURNS has been selected in MASTER MODE the ten standard PLS 601 functions can be used in the PROGRAM or DISPLAY MODES The following sections describe the differences between the Model 10 functions as described in Section 4 2 and the Model 11 functions 5 4 1 POWER ON See Section 4 2 1 for a complete description of POWER ON Display P10140 PROG R030 5 4 2 POS TACH See Section 4 2 2 for a complete description of POS TACH Display P10140 PROG1 R030 5 4 3 SET With the SET function the INC DEC keys DO NOT enter data immediately into memory The displayed data must always be entered via the ENTER key The dash symbol between the FROM and TO fields will be changed to an asterisk to indicate that the displayed data must be entered into memory See Section 4 2 3 for a complete description of SET FUNCTION A SELECTING THE CHANNEL Display Noir T B ENTERING LOBES Display A01F10140
40. ion Continued Select DATA 2 4 The numerical value of the selected DATA KEY is displayed in the TO field New Display COPY P F1 T Select INC The displayed value of the TO PROGRAM Is incremented Select DEC The displayed value of the TO PROGRAM is decremented Select CLEAR The displayed value of the TO PROGRAM Is set to _ Select ENTER Initiates the COPY for the displayed FROM and TO PROGRAMS Select FUNCTION Terminates the COPY function and returns the user to FUNCTION select mode where any one of the PLS 601 functions can be selected PROGRAM TO PROGRAM COPY COMPLETION During the PROGRAM to PROGRAM COPY the Control Unit will BLINK the COPY digits one at a time to indicate that the COPY is in progress After the COPY has been successfully completed the Control Unit will display COPY U on the alphanumeric display and BLINK only the C Channel digit The SELECTING THE TYPE OF COPY sequence may now be followed see section 4 2 8 COPYING FROM UNIT TO UNIT In a UNIT to UNIT COPY all the data stored in the four PLS 601 PROGRAMS is copied from one PLS 601 Control Unit to another To perform a UNIT to UNIT COPY the sequence below MUST be followed in the given order 1 Power on both PLS 601 Control Units Neither unit need be connected to a transducer 2 Connect the two PLS 601 Control Units by placing a standard Interface Cable between the R
41. isplayed on the RECEIVE UNIT 4 2 9 SPECIAL FUNCTION F7 The F7 function key can be used to implement a special function as required by a specific user application 4 2 10 SPECIAL FUNCTION F8 The F8 function key can be used to implement a special function as required by a specific user application 4 2 11 END The END function is used to end data entry for the current PROGRAM and allows selection of any one of the four PLS 601 PROGRAMS for data entry The Transducer shaft POSITION P and the shaft SPEED in RPM R are displayed After entering the PROGRAM NUMBER the FUNCTION LED is lit indicating that one of the ten PLS 601 functions may be selected Select END Selects the END function New Display PROG P140 R030 Select DATA 1 4 The numerical value of the selected DATA KEY is displayed in the PROG field Select INC Increments the displayed PROGRAM NUMBER Select DEC Decrements the displayed PROGRAM NUMBER Select CLEAR Sets the displayed PROGRAM NUMBER to 1 Select ENTER Selects the displayed PROGRAM NUMBER for data entry Turns on the FUNCTION LED 4 3 OUTPUT DISABLE The OUTPUT DISABLE key provides the capability of enabling or disabling the RELAY outputs see section 3 4 without affecting the Channel outputs see section 3 2 5 When lit the associated OUTPUT DISABLE LED indicates that the Relay outputs have been disabled NOTE OUTPUT DISABLE does not disable the Relay 16 output when RELAY 16
42. lay outputs will be disabled 6 DC Power Source Electromechanical Relay Board The internal power supply of the PLS 601 Control Unit is capable of only driving one fully loaded electromechanical relay board Additional boards must be driven from an external power supply To use an external power supply the jumper labeled INT EXT 12VDC must be placed between 2 and 3 see DC Power Source in Figure 3 4 2 The external power supply voltage source must enter the board through the connector labeled 12DC Make sure that the positive voltage of the external supply is attached to the connector pin labeled and that the negative voltage or ground is attached to the connector pin labeled Document 11696 Page 13 PLS 601 User s Manual 4 0 USING THE PLS 601 It is strongly recommended that this portion of the User s Manual be read in its entirety before placing your PLS 601 into operation Failure to follow the instructions given in the following sections may void your PLS 601 warranty 4 1 INSTALLATION ALL PLS 601 ELECTRICAL CONNECTORS MUST CONFORM TO THE NATIONAL ELECTRIC CODE AND ANY LOCAL ELECTRIC CODES IN EFFECT IN THE CASE OF ANY DISCREPANCIES BETWEEN THE ELECTRIC CODES AND THESE INSTALLATION INSTRUCTIONS THE ELECTRIC CODE MUST TAKE PRECEDENT 4 1 1 MOUNTING THE RESOLVER The RESOLVER is designed to be mounted on the target machine and coupled to the target machine shaft The RESOLVER should be mounted and coupl
43. lds If the cursor is between the FROM and TO data fields both FROM and TO data values will be decremented and placed into memory The DEC key does not require the use of the ENTER key 1 23 345 ___ _ ENTER The displayed LOBE is erased from memory allowing for new LOBE data to entered The displayed FROM and TO data fields are entered into memory The cursor is set to the position between the FROM and TO fields and the data is now considered as existing data CHA01F123 T345 Page 21 PLS 601 User s Manual 4 2 3 SET Function Continued MODIFYING EXISTING CHANNEL LOBE DATA Select NEXT Selects and displays the next LOBE in sequence New Display CHA02F___ T___ The _ in the FROM and TO fields indicates that no LOBE data has been stored for this LOBE If numerical data is present within the FROM and TO fields than data has been previously entered for the LOBE that is displayed Select FUNCTION Terminates the SET function and returns the user to FUNCTION select mode where anyone of the PLS 601 functions can be selected 4 2 4 OFFSET The OFFSET is a constant positive adjustment that the CONTROL UNIT adds to the actual Resolver position to produce the shaft POSITION which is displayed and used by the Control Unit functions The OFFSET function allows the user to align the resolver electrical zero and machine mechanical zero reference points The permissible value of
44. lds indicates that no LOBE data has been stored for this LOBE If numerical data is present within the FROM and TO fields than data has been previously entered for the LOBE that is displayed Select FUNCTION Terminates the TEACH function and returns the user to FUNCTION select mode where any one of the PLS 601 functions can be selected Document 11696 Page 28 PLS 601 User s Manual 4 2 7 TEACH Function Continued MODIFYING EXISTING CHANNEL LOBE DATA Display CH 01 9123 1345 Highlighted character indicates blinking character that can be changed Select New Display Select New Display Select New Display Select New Display Select New Display Select New Display Select Document 11696 lt CURSOR Moves the cursor between F and T fields CHA01 F123 345 INC Increments the numerical value at the current cursor location in the FROM or TO data fields If the cursor is between the FROM and TO data fields both FROM and TO data values will be incremented and placed into memory The INC key does not require the use of the ENTER key 1 1 23 346 Decrements the numerical value at the current cursor location in the FROM or TO data fields If the cursor is between the FROM and TO data fields both FROM and TO data values will be decremented and placed into memory The DEC key does not require the use of the ENTER key CHA01 F 123 0345 CLEAR The di
45. le the numerical value of 2 is selected New Display AODF T Select DEC Decrements the displayed CHANNEL NUMBER to the previous value New Display CH 0 T Select INC Increments the displayed CHANNEL NUMBER to the next value New Display AODF T Select CURSOR Moves the cursor left or right within the three digit CHANNEL field of the front panel display Select CLEAR Sets the displayed CHANNEL GROUP to A and the CHANNEL NUMBER to 1 New Display 01 T Select ENTER Selects the displayed CHANNEL GROUP and CHANNEL NUMBER for entry of LOBE DATA Select FUNCTION Terminates the SET function and returns the user to FUNCTION select mode where anyone of the PLS 601 functions can be selected ENTERING CHANNEL LOBES After the channel has been selected the LOBE data may be entered If no lobes have previously been programmed for the selected channel and fields will display blank characters _ If one or more LOBES already exist for the selected channel the data for the first LOBE will be displayed in the F and T fields The PLS 601 allows programming through zero by specifying a FROM field that is larger than the TO field For example if the FROM field is specified as 300 and the TO field is set to 060 the channel output will turn on at 300 remain on through zero and turn off at 060 The PLS 601 will not allow data entry into the FROM or TO fields if the value is greater th
46. ng two of the wires that are brought into the eight pin female connector See SECTION 3 3 for complete wiring details The interface cable may be a maximum length of 2500 feet and should always be routed in such a manner as to avoid exposure to electromagnetic interference EMI Document 11696 Page 14 PLS 601 User s Manual 4 1 3 CONNECTING THE RESOLVER TO THE CONTROL UNIT Continued The seven pin female MS connector is plugged into the mating seven pin male connector located on the rear of the Resolver The eight pin female connector is plugged into the mating eight pin male connector located on the bottom of the PLS 601 Control Unit See SECTION 3 2 5 4 1 4 MOUNTING THE RELAY BOARDS The relay boards are designed to be mounted in a NEMA type enclosure that is suitable for the environment that the boards will operate within The enclosure must be shock mounted and be able to protect the boards from water oil dust and corrosive materials The boards should not be exposed to excessive amounts of mechanical shock or vibration The mounting location should not be exposed to extreme levels of electromagnetic interference EMI that can be induced by devices such as motor starters and control relays The operating temperature of the relay boards has been rated at 32 F to 125 F 4 1 5 INSTALLING THE AC POWER CORD An AC Power Cord is provided with each PLS 601 Control Unit The female end of the Power Cord should be inserted into th
47. or D to the next available group value New Display 1 T Select DEC Decrements the active group A B C or D to the previous available group value New Display CHN01F T Select lt CURSOR Moves the cursor left in the three digit CHANNEL field of the front panel display gt CURSOR Moves the cursor right in the three digit CHANNEL field of the front panel display Select CLEAR Sets the displayed CHANNEL GROUP to A and the CHANNEL NUMBER to 1 New Display OIF T Select ENTER Selects the displayed CHANNEL GROUP and CHANNEL NUMBER for entry of LOBE DATA Select FUNCTION Terminates the TEACH function and returns the user to FUNCTION select mode where any one of the PLS 601 functions can be selected Document 11696 Page 26 PLS 601 User s Manual 4 2 7 TEACH Function Continued SELECTING THE CHANNEL NUMBER Display CH 0 T Highlighted character indicates blinking character that can be changed Select 2 The numerical value of the selected DATA KEY is displayed in the present cursor position In this example the numerical value of 2 is selected New Display AODF T Select DEC Decrements the displayed CHANNEL NUMBER to the previous value New Display CH 0 T Select INC Increments the displayed CHANNEL NUMBER to the next value New Display CH AODF T Select lt CURSOR Moves the cursor left in the three digit CHANNEL field of the front panel display
48. ry or data modification is desired INC DEC The INC and DEC keys are used to modify existing user data by either v INCrementing or DECrementing the selected data field The NEXT key is used to display the sequence of user LOBE data for the SET NEXT CLEAR and TEACH functions The CLEAR key is used with several of the PLS 601 functions to set a data field to a pre defined value such as zero OUTPUT The OUTPUT DISABLE key provides the capability of enabling or disabling the relay DISABLE outputs of the remote relay output board When the LED is active the output relays are disabled Take note that the channel and motion detect output indicators located on the PLS 601 control unit will continue to display output status even though the outputs are turned off Group and Channel Status LEDs The GROUP and CHANNEL LEDs used in conjunction with each other to give the status of the sixty four independent channel outputs The channel outputs are divided into four groups designated as A B C and D Each group contains sixteen channel outputs The channel outputs per group are represented as channels A01 A16 BO1 B16 C01 C16 and 01 16 The active group LED designate the active channel outputs Document 11696 Page 7 PLS 601 User s Manual Motion Detect LED The MD motion detect LED is used to give the status of the MOTION DETECT output The MD LED is active whenever the resolver shaft speed value RPM falls within the programmed M
49. splayed LOBE is erased from memory and the next LOBE in sequence is displayed 02 8040 060 ENTER The displayed FROM and TO data fields are entered into memory The cursor is set to the position between the FROM and TO fields and the data is now considered as existing data CHA01 F 12357345 NEXT Selects and displays the next LOBE in sequence CHA02F___ T FUNCTION The _ in the FROM and fields indicates that no LOBE data has been stored for this LOBE If numerical data is present within the FROM and TO fields than data has been previously entered for the LOBE that is displayed Terminates the TEACH function and returns the user to FUNCTION select mode where any one of the PLS 601 functions can be selected Page 29 PLS 601 User s Manual 4 2 8 COPY The COPY function allows the user to copy the stored program data from one CHANNEL to another one PROGRAM to another or from one PLS 601 UNIT to another SELECTING THE TYPE OF COPY Select COPY Selects the COPY program function New Display Highlighted character indicates blinking character that can be changed Select CURSOR Moves the cursor between the three COPY types C Channels P Program and U Unit New Display COPY CHU Select ENTER Selects the COPY type that is currently being indicated by the cursor Select FUNCTION Terminates the COPY function and returns the user to FUNCTION select mode where an
50. the OFFSET parameter is in the range from 0 to the FULL SCALE VALUE An AUTO ZERO function is implemented via the CLEAR key that will automatically calculate the offset required to zero the current resolver shaft position Using this function will electrically set the position of the resolver to 000 within the position field P on the PLS 601 front panel display NOTE Changing the OFFSET value causes a corresponding change in the displayed shaft POSITION but does not affect the values of the stored LOBE data The OFFSET function will display the current resolver shaft position within the P data field and the current resolver shaft rotational speed in RPM within the R data field RESOLVER OFFSET Select OFFSET OFFSET DISPLAY 100 P075 R040 Highlighted character indicates blinking character that be changed Select DATA 0 9 The numerical value of the selected DATA KEY is displayed in the present cursor position of the OFFSET data field Select INC Increments the OFFSET value on the display New Display OF 801 P075 R040 Select DEC Decrements the OFFSET value on the display New Display OF 00 P075 R040 Document 11696 Page 22 4 2 4 OFFSET Continued RESOLVER OFFSET Select lt CURSOR New Display Select gt CURSOR New Display Select CLEAR New Display Select ENTER Select FUNCTION 4 2 5 SCALE PLS 601 User s Manual Moves the cursor left within the three digit OFFSET data fiel
51. ur standard components These components are an ANGULAR POSITION TRANSDUCER designed to be mounted on the target machine The CONTROL UNIT that is normally mounted in a NEMA type enclosure APROGRAMMER that provides a keyboard display for data entry and inspection And an INTERFACE CABLE that connects the TRANSDUCER to the CONTROL UNIT An optional INTEGRAL RELAY BOARD is available to handle a variety of external AC or DC loads The TRANSDUCER which utilizes a BRUSHLESS RESOLVER produces an analog signal proportional to the angular position of the machine shaft This signal is sent to the CONTROL UNIT where it is converted to digital format and displayed on the PROGRAMMER During each machine cycle the CONTROL UNIT will turn the CHANNEL outputs ON and OFF in accordance with the user programmed LOBE data The CHANNEL outputs can be used directly or in conjunction with the INTEGRAL SOLID STATE RELAYS 3 1 TRANSDUCER The TRANSDUCER is a single turn rotary position transducer that is used in conjunction with the Control Unit The TRANSDUCER utilizes a BRUSHLESS RESOLVER which eliminates the reliability problems associated with optical encoders or brush type resolvers The brushless resolver is housed in a rugged extruded aluminum enclosure which is anodized to provide a durable finish The enclosure is sealed and gasketed to provide oiltight dust tight NEMA 13 protection for the internal electrical components A 3 4 inch stainless steel input s
52. ure 3 4 2 These outputs are normally closed NC until activated by the PLS 601 Control Unit The electromechanical relay output connectors are labeled NO NC for each of the channels In addition 3 pins are available for the MOTION DETECT function The MD function shares the first three pins of the channel 1 connector Document 11696 Page 12 PLS 601 User s Manual 3 4 PLS 601 RELAY OUTPUT BOARDS Electromechanical Relay Board Continued 4 Relay 16 Jumper Options Electromechanical Relay Board Electromechanical Relay 16 may be used as one of the standard channel output relays or it may be used as an indication that an error has occurred in the PLS 601 Control Unit To enable solid state relay 16 as a standard output connect pins and 2 together of J1 see Relay 16 Jumper in Figure 3 4 2 To enable solid state relay 16 as an error indicator connect pins 2 and 3 together of J1 When solid state Relay 16 is used as an error indicator it will be active in non error conditions ON and non active in an error condition OFF 5 Output Enable Electromechanical Relay Board Each electromechanical relay board has a 2 pin input connector that implements an OUPTUT ENABLE function see Output Enable Connector in Figure 3 4 2 This connector is labeled ENA The ENA pins must be shorted together in order for any of the seventeen electromechanical relay outputs to be enabled If this connection is opened all seventeen electromechanical re
53. y one of the PLS 601 functions can be selected COPYING FROM CHANNEL TO CHANNEL For a CHANNEL to CHANNEL COPY the user must specify the FROM CHANNEL and the CHANNEL All LOBE data stored for the FROM CHANNEL will be copied into the TO CHANNEL Note During a CHANNEL to CHANNEL COPY the current TO CHANNEL LOBE data will be lost The channels are divided into four groups with each group consisting of up to sixteen channels When all channel groups are active a total of 64 individual channels become available The channels are designated as 01 16 B16 C01 C16 and D01 D16 Select COPY Selects the COPY program function New Display Select ENTER Selects the COPY type that is currently being indicated by the cursor New Display COPYC FIN TA__ Select INC Increments the displayed FROM CHANNEL GROUP or TO CHANNEL GROUP depending on the cursor position New Display COPYC F __ TA__ Select DEC Decrements the displayed FROM CHANNEL GROUP or TO CHANNEL GROUP depending on the cursor position Document 11696 Page 30 PLS 601 User s Manual 4 2 8 COPY Function Continued Select CURSOR Moves the cursor left or right within the three digit FROM CHANNEL field and or TO CHANNEL fields New Display COPY TA__ Select CLEAR Sets the displayed FROM CHANNEL and TO CHANNEL to A __ New Display COPYC

Toledo Transducers PLS-601 Programmable Limit Switch System

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