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8 Output EASYPack Genesis - Advanced Micro Controls Inc

1. LS Motion ANDing 66 Enable ANDing 66 PLS Groups Screen Group Number ssec 66 Group Mode sees 66 Group Window ON OFF niic eite 66 Group Offset Preset 66 20 Gear Drive Plymouth Ind Park Terryville CT 06786 Tel 860 585 1254 Fax 860 584 1973 http www amci com Chapter 11 Monitoring Machine Operation While the Machine is Running 67 The Main and Status Screens 67 Incrementing Decrementing Setpoints 67 Incrementing Decrementing Advances 68 Error Messages isis ones 69 Transducer Fault 69 nvRAM Error em 69 TABLE OF CONTENTS Notes ADVANCED MICRO CONTROLS INC ABOUT THIS MANUAL Read this chapter to learn how to navigate through the manual and familiarize yourself with the conventions used in it The last section of this chapter highlights the manual s remaining chapters and their targeted audience Audience This manual explains the operation installation and programming of AMCI s EAS YPack Genesis standalone programmable limit switch PLS model number GN3B1 01B 10 It is written for the engineer responsible for incorporating the EASY Pack Genesis into a design as well as the engineer or technician responsible for its actual installation
2. eee 33 View and Edit Modes 54 Group Window 34 Switching Modes 35 OC 2 Password Access Levels 55 Summary Table 34 Setting Passwords sees 56 Mode eerie reip et ea 34 Manipulating Programs 56 Mode T ain hen eode 35 Programming Error Messages 57 Mode 2 3 nti 36 Mode iere teet e 37 Chapter 8 Configuration Dine MR 38 Programming Before You Start Know This 59 Chapter 5 General Installation The Configuration 1 Screen 59 all Scale Factor 4 eere 59 Background uo nose isti bue titre n ra 39 Machine Preset Value 59 Surge EMI Suppression 39 Count Direction 59 Surge Suppression DC Outputs 40 Rate Value 59 Surge Suppression AC Outputs 41 The Configuration 2 Screen 60 Grounding sei iie nooo rre eei rone tt 42 Motion Detector Low Setpoint 60 uester np 42 Motion Detector High Setpoint 60 Power Supply Wattage and Filtering 43 Toggle Speed 60 The Configuration 3 Screen 60 hapter 6 Installing The E k
3. This Group Input transition presets the Group Position and the cycle starts again NOTE 5 You can preset the Group Position multiple times per transducer rotation by programming the Group Window appropriately 20 Gear Drive Plymouth Ind Park Terryville CT 06786 35 Tel 860 585 1254 Fax 860 584 1973 http www amci com 7 53 SPECIFICATIONS Mode 2 Mode 2 is nearly identical to Mode 1 The difference between the two modes is that the outputs assigned to a group in Mode 2 are normally disabled Mode 2 uses the Group Input to preset the group s position to the value programmed into the Group Offset Preset parameter and enable the outputs in the group Typically the Group Input is tied to a sensor that detects the edge of or registration mark on the product This synchronizes the outputs in the group to the product Once the Group Input forces a preset action its state is ignored until the programmed dwell on the Group Window is reached Reaching the programmed dwell on the Group Window also disables the outputs until the Group Input is re activated The outputs can be further conditioned with the LS Enable Input and or the Motion Detector The timing diagram below shows how the Group Input and Group Window are used It shows the Group Position being preset to zero However it can be preset to any value between zero and Scale Factor 1 14 5 One Transducer Turn 4 One Transducer Turn 9 Group Posit
4. The Group Input detects the presence of material and goes active Current begins to flow through the input The outputs begin to cycle A break in the material occurs and the Group Input turns off The outputs are disabled within one millisecond of the transition on the Group Input NOTE gt Mode 3 performs the same function as ANDing the output with the LS Enable Input Mode 3 is most commonly used in two instances 1 The outputs need to be assigned to a group anyway so it s easier to assign Mode 3 to the group and wire the sensor to the Group Input then it is to assign Mode 0 to the group enable the ANDing function for each output and wire the sensor to the LS Enable Input 2 Two sensors are needed to detect the material One input is wired to the Group Input and one to the LS Enable Input In this case the group is placed in Mode 3 and each output is ANDed with the LS Enable Input 20 Gear Drive Plymouth Ind Park Terryville CT 06786 37 Tel 860 585 1254 Fax 860 584 1973 http www amci com Ee SPECIFICATIONS Mode 4 Mode 4 uses the Group Input to enable the outputs for one cycle In order for the outputs to be enabled a pos itive transition inactive state to active on the Group Input must occur during the dwell programmed into the Group Window The outputs are then enabled until the dwell on the Group Window is again reached The Group Input is typically tied to a sensor that detects the prese
5. m 40E ADVANCED ll micRo CONTROLS INC Manual 940 0G010 EASYPack Genesis Programmable Limit Switch GN3B1 01B 10 GENERAL INFORMATION Important User Information The products and application data described in this manual are useful in a wide variety of different applica tions Therefore the user and others responsible for applying these products described herein are responsible for determining the acceptability for each application While efforts have been made to provide accurate information within this manual AMCI assumes no responsibility for the application or the completeness of the information contained herein UNDER NO CIRCUMSTANCES WILL ADVANCED MICRO CONTROLS INC BE RESPONSIBLE OR LIABLE FOR ANY DAMAGES OR LOSSES INCLUDING INDIRECT OR CONSEQUENTIAL DAM AGES OR LOSSES ARISING FROM THE USE OF ANY INFORMATION CONTAINED WITHIN THIS MANUAL OR THE USE OF ANY PRODUCTS OR SERVICES REFERENCED HEREIN No patent liability is assumed by AMCI with respect to use of information circuits equipment or software described in this manual The information contained within this manual is subject to change without notice This manual is copyright 2001 by Advanced Micro Controls Inc You may reproduce this manual in whole or in part for your personnal use provided that this copyright notice is included You may distribute copies of this complete manual in electronic format provided that they are unaltered from the versi
6. s amp HTT 400 1 Shaft Diameter 0 625 0 625 0 375 0 188 0 120 or 0 188 Radial Shaft Loading 400 Ibs max 400 Ibs max 40 Ibs max 8 Ibs max 2 Ibs max Axial Shaft Loading 200 Ibs max 200 Ibs max 20 165 max 4 165 max 1 Ib max Starting Torque 8oz in 25 C 807 25 1 50z in 25 C 0 50z in 25 C 0 1 0z in 25 C Moment of Inertia 4 4 4 4 4 oz in sec 6 25 X10 8 75X10 6 00X10 2 10X10 0 51X10 Weight 4 lbs 4 16 1 Ib 0 7 Ib 0 25 Ib Enclosure NEMA 4 or 4X NEMA 4 NEMA 4 NEMA 13 NEMA 1 Environmental All Transducers Operating Temp Shock Vibration 20 to 125 C 50 G s for 11 milliseconds 5 to 2000 Hz 20 G s Table 4 1 Single Turn Transducer Specifications Outline drawings of our transducers and full spec sheets for our most popular models are available on our website www amci com If you do not have internet access contact AMCI and we ll fax you the information Output Relay Specifications Type Solid state DC Output Solid state AC Output Opto 22 Opto 22 Manufacturer G40DC24 GADAC2A Voltage Range 5 60 Vdc 12 140 Vac Peak Repetitive Voltage 60 Vdc 500 Vac Nominal Current 45 C 3 Adc 3 Aac Nominal Current 70 C 2 Adc 2 Aac Minimum Load Current 0 mAdc 20 mAac Surge Current 5 Adc for 1 sec 80 Apk for 1 cycle Isolation Rating 4000 Vrms 4000 Vrms Leakage Current 1 mA 5 mArms Output Voltage Drop 1 6 Vd
7. t be using it in the System Checkout The uses of the Group Win dow is described starting on page 34 when Group Modes are explained in detail The third line allows you to program the Groups Offset or Preset Value Modes 0 3 and 4 use this as an off set value while Modes 1 and 2 use it as a preset value The fourth line is the usual status information Press 2 ENTER to switch to Group 2 With the cursor now in the Mode field Press 3 ENTER to place the group in Mode 3 Pressing gt twice skips the Group Window on off setpoints and brings you to the Group Offset field Press 3 0 ENTER to enter an offset of thirty degrees Switch to the Status Screen with the STATUS key and look at the state of output 2 Toggle power to the Group 2 Input and note that the output is off unless the Group Input input is powered Finally press MAIN to bring up the main display screen again You ll now see PRG 2 POS 60 RPM 0 that Group 2 position has been added to the screen If you assign limits to 61 POS 60 G2 POS 90 Groups 3 and 4 their positions will be shown on line 3 The Group 2 position equals 90 while the Machine Position and Group 1 posi tion equals 60 This is due to the thirty degree offset you entered above 22 ADVANCED MICRO CONTROLS INC CHAPTER 4 SPECIFICATIONS This chapter contains the full specifications of the eight output EASYPack Genesis Included in it are mechanical electrical and envir
8. Divisor and Decimal Point parameters at their default values Do you need PLS Group Programming functionality If you are using the EAS YPack Genesis as a basic programmable limit switch then the answer is no and you can leave all of the Group Program mable Parameters at their defaults Determine Parameter Values 2 1 2 2 2 3 2 4 2 5 2 6 2 7 If you are using passwords to protect your programming check off the Passwords Enabled box and note where the passwords are kept Determine the basic Transducer Setup Parameters Scale Factor Machine Preset Value and Count Direction Determine the number of outputs you need and their type either normal or timed Determine the on off setpoints for each output If you are not using PLS Group Programming assign all of the out puts to Group 1 Mode 0 If you are using the advanced LS Enable ANDing feature check off which outputs will be ANDed with the input If you are using the advanced Motion ANDing feature determine you Motion Detector LOW HIGH Setpoints and check off which outputs will be ANDed with the motion detector If you are using the advanced feature of machine speed scaling determine the values for the Rate Multiplier Divisor and Decimal Point parameters as well as the Rate Value and Toggle Speed parameters If you are using the advanced PLS Group Programming feature determine the number of groups you will need their modes and the number of
9. gram PRG 1 the present position POS 89 and the present speed RPM 0 If you have a transducer attached you can rotate it to see the position and speed change If you see TRANSDUCER FAULT on the bottom line of the display check your connections and cycle power to the unit Selecting Different Functions Start by pressing the FUNCTION key You will see the red Function LED next to the key come on Repeat edly pressing the FUNCTION key toggles the state of the Function LED When the Function LED is on pressing any of the keys that are both blue and white selects the function on the blue part of the key Pressing any of these keys when the Function LED is off selects the white part of the key This gives the keys the ability to enter data like 1 2 and 3 or select a new function like PRGSEL LIM SW and ADVANCE Throughout this manual when the instructions tell you to do something like press the PRGSEL key it means press the FUNCTION key so the red LED is on and then press key number 1 Creating a New Program Press the PRGSEL key and the display changes to the one shown on the right SELECT PROGRAM with the word SELECT blinking This is the Program Select Screen where 1 you select create copy and delete programs VIEW 89 0 Note the bottom line VI EW 1 means that you are running program 1 but not editing it The other two numbers are the transdu
10. gt S1 53 COS Winding WHT 8 B GRN S1 8 S2 gt S2 S4 SIN Winding GRN S4 B WHT S3 Not Used Not Used Not Used Not Used B color denotes the black wire of the black color pair Figure 6 6 Transducer Input Connector Pinout Transducer Connector Pinouts Figure 6 7 shows the connector pinouts for all AMCI S1 RED S3 BLK RED WHT single transducers that have connectors Note that some BLK WHT AMCI transducers have integral cables or conduit con 2 YEL nections For a complete listing of AMCI transducers 54 BLU without connectors refer to Compatible Transducers starting on page 13 Figure 6 7 Transducer Connector Pinout Transducer Cable Installation Pre assembled and tested cables are available from AMCI The part number for the cable is C1TG x where x is the length in feet Figure 6 8 is the wiring diagram of the C1TG x cable NOTE gt 1 The National Electrical Code cable type used for the transducer cable is Communica tions General Purpose cable Therefore the installation of the cable falls under Article 800 of the National Electrical Code unless your local code or company policy is more restric tive 2 The shields of the transducer cable must be grounded at the EAS YPack only The Shields pin on the Transducer Input Connector is brought to the chassis pin on the power supply connector When installing the cable treat the shield as a signal carry
11. 0 OFFS PRESET ERROR to Scale Factor 1 You re attempting to preset the machine position to a value greater than or PRESET VALUE ERROR equal to the Scale Factor or you a trying to do this while a transducer fault exists The program number you entered while creating or copying a program already PRGM ALREADY IN USE exists or you are attempting to delete the current fannie program SCALE FACTOR ERROR You re attempting to program the Scale Factor to a value less than 2 or greater than 1 000 TOGGLE SPEED ERROR You re attempting to program the Toggle Speed to a value greater than 2 000 Table 7 3 Programming Error Messages 20 Gear Drive Plymouth Ind Park Terryville CT 06786 57 Tel 860 585 1254 Fax 860 584 1973 http www amci com Br PROGRAMMING OVERVIEW Notes ADVANCED MICRO CONTROLS INC CHAPTER 8 CONFIGURATION PROGRAMMING This chapter covers how to program the Transducer Setup Parameters available under the first three Configuration Screens Setting passwords which is done on the fourth Configuration Screen is covered in the previous chapter Before You Start Know This In order to keep the amount of repetition to a minimum the instructions in this chapter assume you re already in Edit Mode Instructions on entering Edit Mode can be found in the View and Edit Modes section found on page 54 If passwords are enabled you must have Master access to program any of the parameters co
12. Chapter e Rate Multiplier 60 Rate DiViSOr ayes ao rok proc 60 Required Power Supply 45 Rate Decima Point 60 Panel Cutout for the EASYPack Genesis 45 Ground BUS ient eene 46 Chapter 9 Basic LS Programming Bonding the Enclosure Door 46 etpoint Screen mounts is LS Number eene 61 Connecting Power eee 47 Limit Switch 62 Transducer Input Connector 48 PLS Group Number 62 Transducer Connector Pinouts 48 LS ON OFF Setpoint Pairs 62 Transducer Cable Installation 48 Entering Multiple Setpoints 62 CITG x Wiring Diagram 49 The LS Advance Screen 63 AMCI Transducer Outline Drawings 49 LS ON OFF Advances 63 AMCI Transducer Mounting 50 VO WINNE 50 Group Input Wiring 50 LS Enable Input 52 Output Wiring eese 52 4 ADVANCED MICRO CONTROLS INC TABLE OF CONTENTS Chapter 10 Advanced LS Programming Before You Start Know This Programming a Timed Limit Switch Output esee LS ANDing Screen
13. GROUPS FUNCTION Key simple toggles the state of the Function LED 7 8 9 SUR AER ENTER SELECT 0 4 Throughout this manual the bi level keys have two names one for when the Function LED is on and one when it is off For example PRGSEL and 1 refer to the same key Figure 7 2 Genesis Keypad NOTE gt These instructions do not constantly remind you to make sure the Function LED is on or off before pressing a key If the instructions give the name of the key that is on the blue level the Function LED must be on before pressing the key The blue level of keys 1 through 9 select the Data Screen to be shown on the display The various Data Screens are introduced in the next section The four arrow keys are used to navigate around the screens The right and left arrows switch between param eters on the display while the up and down keys switch between limit switches when programming parame ters for these outputs Some parameters such a Limit Switch Type have a limited number of values The SELECT key is used to cycle through the values of these parameters The CLEAR key is used to clear fault conditions such as the transducer fault message that appears on line 4 when the unit detects a problem with the transducer connection The ENTER key works the way you d expect Programming changes are not stored in memory until the ENTER key is pressed If
14. Navigating this Manual This manual is designed to be used in both printed and on line formats Its on line form is a PDF document which requires Adobe Acrobat Reader version 4 0 to open it Bookmarks of all the chapter names section headings and sub headings were created in the PDF file to help navigate it The bookmarks should have appeared when you opened the file If they didn t press the F5 key on Windows platforms to bring them up Throughout this manual you will also find green text that functions as a hyperlink in HTML documents Clicking on the text will immediately jump you to the referenced section of the manual If you are reading a printed manual most links include page numbers The PDF file is password protected to prevent changes to the document You are allowed to select and copy sections for use in other documents and if you own Adobe Acrobat version 4 05 or later you are allowed to add notes and annotations Manual Conventions Three icons are used to highlight important information in the manual NOTE gt NOTES highlight important concepts decisions you must make or the implications of those decisions D CAUTION CAUTIONS tell you when equipment may be damaged if the procedure is not followed properly WARNINGS tell you when people may be hurt or equipment may be damaged if the pro cedure is not followed properly The following table shows the text formatting conventions Description Normal Font
15. Output with 60 mS ON OFF Advances 120 RPM 195 T zm 195 0 At this speed the output is turned on and off 29 counts before its programmed setpoints Note that the output turns on before the box reaches the gun Figure 4 5 Automatic Advance Application ADVANCED MICRO CONTROLS INC lt 32 SPECIFICATIONS Ed Limit Switch Parameters continued LS Motion ANDing These parameters are available on the LS Anding Screen The output of each limit switch can be logically ANDed with the state of the Motion Detector See Motion Detector LOW HIGH Setpoints on page 28 for a description of the Motion Detector Each limit switch has a Motion ANDing parameter Motion ANDing prevents associated outputs from firing unless the machine is running at the correct speed The default value of these parameters is off which means that the limit switch is unaffected by the state of the Motion Detector Enable ANDing These parameters are available on the LS Anding Screen The output of each limit switch can be logically ANDed with the state of the LS Enable Input See LS Enable Input on page 12 for a description this input Each limit switch has an Enable ANDing parameter Attaching a sensor to the LS Enable Input for detecting the presence of material and preventing the outputs from firing if the material is not present is a typical use of LS Enable ANDing The default value of these parameters is off which means that the
16. Relays 17 Returns Policy eee IFC Faking a Transducer or 24 Hour Technical Support Number IFC Attaching a Real One usse 17 We Want Your Feedback IFC Applying Power eere 17 About This Manual Initial Display eene 18 Audience 7 Selecting Different Functions 18 Nagata Creating a New Program 18 So NAME 7 Programming a Limit Switch 18 fest CO MCA 8 Viewing I O Status eese 19 cus oben ose 8 Presetting the Position 19 Revision History 8 Wiring the Inputs eee 20 Where EEE cen 8 LS Enable ANDing ast 21 PLS Group Programming 21 Chapter 1 Introducing The ei t ie P EASYPack e enesis Chapter 4 Specifications Overview 9 Transducer Specifications 24 PLS oor I Output Relay Specifications 24 Basic Advanced Features 10 Pro pr nie A d Unit Description 10 Password and Display Parameters 25 Operator Interface d Sam TEE 25 Master Passwords 25 Transducer Input Connector 11 2 Limit Switch Outputs
17. Shaft Mount Turns Comments seno 1 NEMA I size 11 resolver Leads only no connector Seno 1 NEMA 1 size 11 resolver Leads only no connector FronvSide 1 NEMA 13 wansducer _ HT20S 0 625 Front Side HT 20 with side connector 1 NEMA 4 stainless steel HT 20 w Viton shaft HT 20C 0 625 Front Side 1 Internal terminal plug for resolver connections shaft w Viton shaft seal HT 20K with side connector NEMA 4X hard coat anodized HT 20 stainless steel shaft w Nitrile shaft seal T 20L with side connector NEMA 4 size 25 end connector EMA 4 size 25 end connector Bolt in replace ent for Namco C amp A HT 11B transducers EMA 4 size 25 side connector NEMA 4 size 25 integral 15 foot 3 meter cable HT 20KS 0 625 Front Side HT 20L 0 625 Front Side 1 m seal and 0 5 NPT thread for conduit connection HT 20K 0 625 Front Side NEMA 4X hard coat anodized HT 20 stainless steel Z EE H25 FE 0 375 Flange H25 F1E 0 375 Flange 1 H25 FS 0 375 Flange 1 0 375 Flange Servo Front 125 55 H25 SL 0 375 Servo Front NEMA 4 size 25 integral 15 foot 3 meter cable NEMA 4 Bolt in replacement for Autotech RL100 transducers Also has HT 20 bolt pattern 1 NPT Tron thread for conduit connection Internal terminal strip for resolver connections Same as HT 400 with an AMCI MS connector HT 20 x 0 625 Front HT 20 with
18. Transducer Turn gt Off Setpoint 225 150 RPM Time Out 185 ms 0 4 185 milliseconds 0 At 150 RPM the output turns on a 45 45 12250 turns off 185 milliseconds later at 212 212 At 200 RPM the output turns on at 45 and Transducer Turn off at 225 because the off setpoint was 200 RPM reached before 185 milliseconds expired O age 225 185 milliseconds 267 Figure 4 3 Timed Limit Switch Output ADVANCED MICRO CONTROLS INC SPECIFICATIONS Ed Limit Switch Parameters continued LS ON OFF Setpoint Pairs The ON OFF Setpoint parameters are available on the LS Setpoint Screen The Time Out parameters are available on the LS Timed Screen As implied in the previous section the output is defined One Transducer Turn by an ON Setpoint and an OFF Setpoint which are together called a Setpoint Pair When the ON Setpoint is less than the OFF Setpoint the ja 45 225 di output is on between the two points When programmed ON Setpoint OFF Setpoint this way the output acts as a normally open relay One Transducer Turn When the ON Setpoint is greater than the OFF Setpoint the output is off between the two points When pro grammed this way the output acts as a normally closed 0 des 235 relay OFF Setpoint ON Setpoint gt Setpoints can be programmed to any value Figure 4 4 ON OFF Se
19. You can also fine tune advances while the machine is running using the INC and DEC keys Used to AND the state of limit switch with the Motion Detector and Lo bons ANDING or the LS Enable Input LS Timed TIMED Used to program the Time Out value of a limit switch if it is set up as a Output Timed Limit Switch Status STATUS Used to monitor the status of the LS Outputs and the four Group Inputs Default screen while the machine is running This screen allows you to Main MAIN monitor machine position and speed the present values of the group positions and the currently running program tICONFIG Used to program the Scale Factor Count Direction and Rate Value Configuration 1 parameters as well as preset the Machine Position value T CONFIG Used to i igh Limi i program the Motion Detector Low High Limit Setpoint as well Configuration 2 PREVIOUS NEXT as the Toggle Speed parameter TICONFIG Used to program the Rate Multiplier Divisor and Decimal Point Configuration 3 PREVIOUS NEXT Parameters t CONFIG Used to enable or disable all passwords and set the values for Master Configuration 4 PREVIOUS NEXT Set up and Operator passwords If passwords are enabled only a per son with the MASTER password can access this screen PLS Groups GROUPS 2 Group Mode Group Window and Group Offset Table 7 1 EASYPack Genesis Data Screens t The four Confi
20. corresponds to the LS Enable Input In the figure the LS Enable Input and Group Inputs 1 and 2 are receiving power while Group Inputs 3 and 4 are off Incrementing Decrementing Setpoints While the machine is running the EASY Pack Genesis does not allow you to change the unit s programming However it does allow you to fine tune your setpoints and advances by incrementing or decrementing them This feature uses the INC and DEC keys and is available to all password levels In order to use this feature the unit must be in Edit Mode before you start running the machine Also this feature is only available as long as the ten minute timer has not expired See While the Machine is Run ning above 20 Gear Drive Plymouth Ind Park Terryville CT 06786 67 Tel 860 585 1254 Fax 860 584 1973 http www amci com MONITORING YOUR MACHINE Incrementing Decrementing Setpoints continued To use this feature 1 Put the unit in Edit Mode and start running the machine 2 Switch to the LS Setpoint Screen with the LIM SW key 3 Move the cursor to the setpoint pair you wish to fine tune See The LS Setpoint Screen starting on page 61 if you need information on navigating through the display 4 Figure 11 3 shows an example of a LS Setpoint Screen with the first CH GROUP ONI OFF1 setpoint pair of limit switch 1 set to 10 100 The cursor can be placed 1 N i 10 100 on the On Setpoint the Off Setpoint or the dash between
21. key to move to the next limit switch you have to program Entering Multiple Setpoints Normal limit switches have four ON OFF setpoint pairs per output The unit distinguishes between them by showing the setpoint pair number on the top line of the display When entering setpoint pair 1 the top line will show ON1 OFF1 setpoint pair two shows ON2 OFF 2 etc You can move between the setpoint pairs with the gt and 4 keys NOTE gt 1 If you re not using all of the setpoint pairs leave the unused one at their defaults of 0 0 2 If you are on the fourth OFF Setpoint and press ENTER the display switches to the LS Advance Screen If you want to continue programming setpoints then use either the LIM SW 4 keys to switch back to the LS Setpoint Screen ADVANCED MICRO CONTROLS INC BASIC LS PROGRAMMING 9 The LS Advance Screen The LS Advance Screen is shown in figure 9 2 Access this screen by pressing CH ADVANCES ADVANCE From this screen you can program the ON and OFF Advances for 1 ON OmsOFF Oms each of the eight outputs p MC ME M si alelu 0 Note that all of the data is entered on line 2 On this screen line 3 of the display Figure 9 2 LS Advance shows the mode and position of the group the limit switch 1s assigned to You cannot alter this data from this screen It s programed on the PLS Groups Screen which is covered on page 66 In the following list the number i
22. limit switch is unaffected by the state of the Enable Input Summary Table Parameter Default Limit Switch Type Disabled Disabled Normal Timed ON OFF Setpoints 0 to Scale Factor 1 0 to 9 999 milliseconds 1 millisecond resolution Limit Switch Type must be set to Timed LS Time Out Value ON OFF Advances 0 to 999 milliseconds 1 millisecond resolution Off On means that the state of the output is affected by the state of the Motion Detector Off On On means that the state of the output is affected by the state of the LS Enable Input Table 4 6 Limit Switch Setup Parameters LS Motion ANDing LS Enable ANDing The rest of this chapter describes PLS Group Programming and its Modes If you are not using this feature set all limit switches to Group 1 Mode 0 PLS Group Setup Parameters All PLS Group Parameters are found under the PLS Group Screen Access this screen with GROUPS key Group Mode This parameter defines the function of the Group There are five modes numbered zero through four and they are explained in the next section The Group Mode parameter defaults to zero 20 Gear Drive Plymouth Ind Park Terryville CT 06786 33 Tel 860 585 1254 Fax 860 584 1973 http www amci com ee SPECIFICATIONS PLS Group Setup Parameters continued Group Window Groups that are in Modes 1 2 or 4 make use of a Group Window The window is programmed
23. outputs assigned to each group 20 Gear Drive Plymouth Ind Park Terryville CT 06786 Tel 860 585 1254 Fax 860 584 1973 http www amci com D QUICK START STEP 3 Install Your System Hardware 3 1 Panel cutout and clearance dimensions are given on page 45 3 2 Install the EASYPack Genesis Bond the enclosure and unit to your ground bus Bond all other components as you install them 3 3 If you are using a separate supply for the EAS YPack Genesis install and bond it now 3 4 Install the transducer and transducer wiring Transducer dimensional drawings are on our website and the C1TG x transducer cable drawing in given on page 49 The transducer cable is type CM under the national electrical code Do not install it in conduit with any conductor of electrical light or power circuits Class 1 circuits Non power limited fire protective signaling circuits or other high power wiring 3 5 Wire the outputs Refer to figure 6 9 I O Connector Placement on page 50 for connector pinout Do not run output wiring in the same conduit as the transducer cable 3 6 Install surge suppression on any load switched by a relay in the system This includes loads that are not attached to the EASYPack Genesis 3 7 If you are using the advanced LS Enable ANDing or PLS Group Programming features wire the appropriate inputs Shielded cable is required on all inputs Do not install this wiring in conduit with a branch circuit lighting or
24. position of the group the limit switch is assigned to You cannot alter this data from this screen It s programmed on the PLS Groups Screen which is covered on page 66 In the following list the number in parentheses immediately following the parameter name is the page in the Specifications chapter that describes the parameter LS Number Not a Parameter When you first enter the screen or switch between limit switches with the PREVIOUS NEXT key the cursor moves to the LS Number field This field allows you to select the limit switch number that you want to inspect or program Use the PREVIOUS NEXT A or W keys to cycle through the limit switches You can also jump to a specific output by keying in the number 1 through 8 and pressing ENTER 20 Gear Drive Plymouth Ind Park Terryville CT 06786 61 Tel 860 585 1254 Fax 860 584 1973 http www amci com BASIC LS PROGRAMMING The LS Setpoint Screen continued Limit Switch Type 30 When you enter a LS Number the cursor jumps to the Limit Switch Type field This parameter is cycled through its three values with the SELECT key Its three values are gt disabled gt N Normal gt T Timed NOTE 5 The instructions in this section only cover how to program a Normal limit switch Position on Position off Complete instructions on programming a Timed limit switch are given under Programming a Timed Limit Switch Out
25. the best supply your budget allows When sizing system supplies take into consideration the surge requirements of the components you are attaching to the supply Most devices draw a surge current for a brief time when they power up If your supply cannot accommodate these surge currents the output voltage may momentarily drop when a device turns on causing the EASYPack Genesis and other electronic devices to reset The other thing to consider when choosing a supply is output filtering The better the supply s filtering the better it can absorb noise that may be induced into the power supply wiring 20 Gear Drive Plymouth Ind Park Terryville CT 06786 43 Tel 860 585 1254 Fax 860 584 1973 http www amci com y GENERAL INSTALLATION GUIDELINES Notes 44 ADVANCED MICRO CONTROLS INC CHAPTER 6 INSTALLING THE EASYPACK GENESIS Required Power Supply The EASYPack Genesis draws its power from an external DC supply The output voltage of the supply must be between 18 and 30 Vdc and it must be able to provide a minimum of ten watts of power This translates into roughly 0 4Adc 24Vdc If you are using the supply to power sensors attached to the Group and LS Enable Inputs add in these current requirements before sizing the supply A dedicated power supply can be used for the unit or power can be drawn from a larger system supply NOTE gt If a dedicated supply is used it should be mounted relatively close to the uni
26. them When on a setpoint the INC and DEC keys will change only that setpoint If EL A NO the cursor is on the dash between the setpoints the INC and DEC keys will change both setpoints This has the effect of shifting where the setpoint window occurs without changing its size CAUTION Use care when incrementing and decrementing setpoints 1 Make sure you re changing the correct setpoint pair Figure 11 3 Inc Dec Setpoints 2 If you have multiple setpoint pairs on a limit be aware that the increment decrement feature only changes one setpoint pair at a time so it is possible to increment one set point pair into another Incrementing Decrementing Advances You can fine tune your ON OFF Advances with the INC and DEC keys while the machine is running Like incrementing and decrementing setpoints this feature is available to all password levels In order to use this feature the unit must be in Edit Mode before you start running the machine Also this feature is only available as long as the ten minute timer has not expired See While the Machine is Run ning on page 67 for an explanition of the timer To use this feature 1 Put the unit in Edit Mode and start running the machine 2 Switch to the LS Advances Screen with the ADVANCE key 3 Move the cursor to the advance you wish to fine tune See The LS Advance Screen starting on page 63 if you need information on nav
27. throughout the chapter will alert you to the functionality about to be covered and tell you to go next if you re not interested in the feature Unit Description Figure 1 2 shows the layout of the panels on the EASYPack Genesis controller Note that the unit ships with mating connectors for the Power Input and the Transducer Input connectors These connectors are not shown for clarity The EASYPack Genesis is designed to be mounted on a a panel or enclosure door using its four 8 32 studs A neoprene mounting gasket is included with the unit The recommended panel cutout and mounting method is given in chapter 6 INSTALLING THE EASYPACK GENESIS starting on page 45 TOP RIGHT BOTTOM g 1 ge O m 42 on OT Mz 5 3 3 4 i 5 5 6 6 7 7 8 8 H X P p IE HEJHHEH RESOLVER 91723515483 SERIAL 1 orm OUTPUT RELAYS POWER INPUT AND 8 Places CHASSIS GR
28. value PLS Groups Screen NOTE 5 if you are not using the advanced PLS Group Programming functionality don t change any values available on this screen Figure 10 3 shows the default PLS Groups Screen Note that this screen uses GROUP NUMBER 1 MODEO lines 1 through 3 for entering data WINDOW ON 0 OFF 0 GRP OFFSET PRESET 0 In the following list the number in parentheses immediately after the parameter name is the page in the Specifications chapter that decribes the parameter Figure 10 3 PLS Groups The functionality of each Group Mode is described in the SPECIFICATIONS chapter starting on page 34 Group Number Entered with the numeric keys this parameter can be programmed to any value between 1 and 4 When you change this value the rest of the display updates to show the parameter values of the chosen group Group Mode p 33 Entered with the numeric keys this parameter can be programmed to any value between 0 and 4 Group Window ON OFF Setpoints 34 Entered with the numeric keys these parameters can be programmed to any value between 0 and Scale Fac tor 1 Only Modes 1 2 and 4 actually use the Group Window if you are using Modes 0 or 3 you can leave these fields at their defaults of zero Group Offset Preset p 34 Entered with the numeric keys these parameters can be programmed to any value between 0 and Scale Fac tor 1 Modes 0 3 and 4 use this value as a positive offset from the Ma
29. with a pair of ON OFF Setpoints just like a limit switch output but the Group Window is not an output As explained in the next section Modes 1 and 2 use the Group Window to enable the Group Input and when a group is in Mode 4 the Group Input must be active within the window before the outputs are enabled NOTE gt The Group Window parameter is shown the Groups programming screen regardless of the group s programmed mode Only groups in Modes 1 2 or 4 actually use the window The default values for the Group Window ON OFF Setpoints are zero They can range from zero to Scale Factor 1 Group Offset Preset Groups that are in Modes 0 3 or 4 have a Group Offset which allows you to offset the Group Position from the Machine Position If the Group Offset equals zero then the Group Position will equal the Machine Posi tion Groups in Modes 1 or 2 have a Group Preset When the proper conditions on the input are met a group in one of these two modes will set its group position equal to the value of the Group Preset It does this by gen erating an internal offset that is applied to the Machine Position The Group Offset Preset parameter has a default of zero and range of zero to Scale Factor 1 Summary Table Parameter Default Group Mode 0 to 4 Group Window ON 0 to Scale Factor 1 Only Modes 1 2 and 4 OFF Setpoints use the Group Window 0 to Scale Factor 1 Modes 0 3 and 4 use
30. www amci com EH SYSTEM CHECKOUT PLS Group Programming continued You can accomplish this with the EASYPack Genesis by wiring the material sensor to the Group 2 Input and assigning Modes 1 or 2 to the group These Modes differ slightly in the ways they operate but basically they preset the group s position value when the sensor detects material In our example this synchronizes the limit switches for the fill operation to the position of the box While the machine is operating the Group 2 s posi tion will be adjusted to every new container without affecting the position values of the other two groups With the exception of Mode 0 which doesn t do anything Mode 3 is the easiest to understand When the Group is in Mode 3 the group s input works exactly like the LS Enable Input For the System Checkout we ll put Group 2 in Mode 3 offset the group s position by 30 and view the status of the limit Mode 4 requires the input to become active transition from off to on within a pre programmed window When this occurs the outputs assigned to the group are activated for one cycle Start by pressing GROUPS to bring up the PLS Groups Screen which is shown GROUP NUMBER 1 MODEO on the right WINDOW ON 0 OFF 0 GRP PRESET 0 The top line shows the Group Number and the Mode it s presently in EDIT 2 P 60 RPM 0 The second line allows you to program a Group Window The Group Window is only used in Modes 1 2 and 4 so we won
31. 0 gt Rate Divisor 1 to 63 gt Rate Decimal Point 1 10 100 or 1 000 The unit reports the machine rounded off to the nearest whole number As an example of how the Rate Deci mal Point affects the data assume a speed of 100 RPM a multiplier of 2 a divisor of 3 The table below shows the different machine speeds based on the Rate Decimal Point value RATE DECIMAL POINT VALUE 1 10 100 1 000 Calculated Machine Speed 66 67 6 67 0 67 Reported Machine Speed 67 7 1 0 067 0 Table 4 4 Effect of Rate Decimal Point Values Motion Detector LOW HIGH Setpoints These parameters are available on Configuration Screen 2 They default to zero and each has a range of zero to 2 000 The EASYPack Genesis has a motion detector that functions as a speed based limit switch The motion detector setpoints are always programmed in RPM regardless of the values of the Rate Multiplier Divisor and Decimal Point The setpoints default to zero which disables the motion detector ADVANCED MICRO CONTROLS INC ces SPECIFICATIONS Transducer Setup Parameters continued Motion Detector LOW HIGH Setpoints continued As shown in the figure below if the low speed setpoint is less than the high speed setpoint the motion detec tor will be on when the velocity is between the two setpoints and off at all other speeds If the low speed set point is greater than the high speed setpoint the motion detector will be off when the velocity
32. 11 Che p bl 26 Group Inputs esee 12 on P MUN LS Enable Input 12 Transducer Setup Parameters 27 Compatible Relays 12 Scale Factor RE 27 Compatible Transducers 13 a a AA Other EASYPack Family Members 14 Rate Multiplier Divisor and Other Products From AMCI 14 Decimal Point 28 Chapter 2 Quick Start Motion Detector LOW HIGH Decide On Needed Functionality 15 M Determine Parameter Values I5 2 Install Your System Hardware 16 ee 30 Your EASYPack 15 16 LS ON OFF Setpoint Pairs 31 Verify Your System 16 LS ON OFF Advances 31 Fine Tune Your Programming 16 LS Motion ANDing 33 Enable ANDing 33 Summary Table 33 20 Gear Drive Plymouth Ind Park Terryville CT 06786 3 eS Tel 860 585 1254 Fax 860 584 1973 http www amci com TABLE OF CONTENTS Chapter 4 Specifications Chapter 7 Programming Overview continued Using the Display and Keyboard 53 PLS Group Setup Parameters 33 Available Data Screens 54 Group Mode
33. Entered with the numeric keys this parameter can be programmed to any value between 1 and 63 Rate Decimal Point 28 Even though the data is numeric this parameter is limited to the values of 1 10 100 and 1 000 The SELECT key is used to cycle through these values ADVANCED MICRO CONTROLS INC CHAPTER 9 BASIC LS PROGRAMMING This chapter covers how to program normal limit switches This includes ON OFF Setpoints and ON OFF Advances Programming instructions for timed limit switches as well as Motion Detector and or LS Enable ANDing is covered in the next chapter Before You Start Know This In order to keep the amount of repetition to a minimum the instructions in this chapter assume you re already in Edit Mode Instructions on entering Edit Mode can be found in the View and Edit Modes section found on page 54 If passwords are enabled you must enter the Master or Set Up password in order to program any of the parameters covered in this chapter Personnel with the Operator level password cannot program these param eters For the most part entering data on these screens is fairly intuitive Numeric data is entered with the 0 through 9 keys and the values for non numeric data are cycled through with the SELECT key In either case you must press ENTER before new data is accepted The right gt and left 4 arrow keys are used to move the blinking cursor to the next or previous fields on the screen U
34. Font used throughout this manual Emphasis Font Font used the first time a new term is introduced DI SPLAY Highlights text shown on the EASYPack Genesis display KEY Highlights a key to be pressed on the EASYPack Genesis When viewing the PDF version of the manual clicking on the Cross Reference cross reference text jumps you to referenced section 20 Gear Drive Plymouth Ind Park Terryville CT 06786 7 Tel 860 585 1254 Fax 860 584 1973 http www amci com ABOUT THIS MANUAL Trademark Notices EAS YPack and the AMCI logo are trademarks and is a registered trademark of Advanced Micro Controls Inc Adobe and Acrobat are registered trademarks of Adobe Systems Incorporated All other trademarks contained herein are the property of their respective holders Revision Record This manual 940 0G010 is the first revision of the manual It was initially released December 21 2001 Revision History 940 0G010 12 31 2001 Initial Release Where To Go From Here This manual contains information that is of interest to everyone from engineers to operators The table below gives a brief description of each chapter s contents to help you find the information you need to do your job Chapter Title INTRODUCING THE EASYPACK GENESIS Intended Audience Anyone new to the EASYPack Genesis This chapter gives a basic over view of the features available on the unit typical applic
35. Genesis Figure 6 11 Group Input Wiring previous page If you have too many shields to connect to the pin bond them to the enclosure s Ground Bus You can accomplish this by bonding them to one of the unit s mounting studs See figure 6 4 Mounting the EASYPack Genesis on page 47 for instructions on bonding a wire to a stud DO NOT UNDER ANY CIRCUMSTANCES ground both ends of the cable shield Doing so can from a ground loop that can damage the sensor or EASYPack Genesis 20 Gear Drive Plymouth Ind Park Terryville CT 06786 51 Tel 860 585 1254 Fax 860 584 1973 http www amci com Am INSTALLATION Wiring continued LS Enable Input Figure 6 12 shows a simplified schematic of the LS Enable Input This c AC DC input operates at either 110Vac 8 mA ms or 10 30Vdc 10 mA PIN ATTACHED TO Wiring to the LS Enable input is very similar to wiring the Group Inputs NN 8 See figure 6 11 on the previous page for information on wiring DC DOD only if unit is grounded sor to the input Note that Vdc or ground can be attached to either input correctiy pin and the input will still work correctly When wiring the input to accept 110Vac the neutral conductor is typically E attached to one of the pins and the hot conductor is switched through the load to the other A If you cannot ground the shield of the cable at the sensor ground it at
36. Group Window is reached The outputs can be further conditioned by tying them to the LS Enable Inputs and or the Motion Detector The timing diagram below shows how the Group Input and Group Window are used It shows the Group Position being preset to zero However it can be preset to any value between zero and Scale Factor 1 r1 One Transducer Turn 9 One Transducer Group Position 0 0 0 Group Input N Group Window s Limit ON Advance 1 Programmed Setpoints LS2 Limit OFF Advance Actual LS2 ON OFF Points Due To Advance ZA Limit Does Not Fire Figure 4 6 Mode 1 Functional Diagram When the Group Input makes a positive transition current begins to flow through the input the Group Position is set egual to the value of the Group Offset Preset parameter Once the position is preset the Group Input is ignored until the Group Window becomes active Limit Switch 2 turns on immediately because of its ON Advance Note that LS2 cannot fire correctly at this speed when the position is preset because of its advance This edge on the Group Input is ignored because the Group Window dwell has not been reached The Group Input is enabled once the Group window dwell is reached The next positive edge on the Group Input will preset the Group Position Outputs continue to cycle at a rate of once per transducer rotation
37. LED next the FUNCTION Key is on Line JLT JL 2 3 2 pressing one of these keys selects the function listed on the blue level ANDING ae M NEXT A Na DEC NC Es IE SI 2 P i while pressing one of these keys when the Function LED is off selects the function or enters data listed on the white level The GROUPS FUNCTION Key simple toggles the state of the Function LED wA Throughout this manual the bi level keys have two names one for EET o J when the Function LED is on and one when it is off For example PRGSEL and 1 refer to the same key NOTE The instructions do not constantly remind you to make sure the Function LED is on or off before pressing a key If the instructions give the name of the key that is on the blue level the Function LED must be on before pressing the key Figure 1 4 Genesis Keypad The four arrow keys are used to navigate around the screens The right and left arrows switch between param eters on the display while the up and down keys switch between limit switches when programming parame ters for these outputs Some parameters such a Limit Switch Type have a limited number of values The SELECT key is used to cycle through the values of these parameters The ENTER key works the way you d expect Changes to programming are not stored in memory until the ENTER key is pressed If you ch
38. OR ERROR than 63 GROUP ERROR You attempted to program the Group number to zero or greater than four MODE ERROR You attempted to program the Group Mode number greater than four You attempted to program the Group Window OFF Setpoint outside its range GROUP WINDOW OFF ERR of 0 to Scale Factor 1 You attempted to program the Group Window ON Setpoint outside its range of GROUP WINDOW ON ERR 0 to Scale Factor 1 In View Mode instead of Edit Mode or passwords are enabled and your access INCORRECT ACCESS level doesn t permit the operation you re attempting You attempted to program the LS OFF Setpoint outside its range of 0 to Scale LIMIT SWITCH OFF ERROR Factor 1 or you attempted to make the LS OFF Setpoint equal to the LS ON Setpoint while incrementing or decrementing it You attempted to program the LS ON Setpoint outside its range of 0 to Scale LIMIT SWITCH ON ERROR Factor 1 or you attempted to make the LS ON Setpoint equal to the LS OFF Setpoint while incrementing or decrementing it LS GROUP ERROR You attempted to program the PLS Group Number to zero or greater than four You re attempting to program the Motion Detector Low or High Setpoint to a MOTION LIMIT ERROR value greater than 2 000 You re attempting to program the Rate Multiplier to a value of zero or greater MULTIPLIER ERROR than 1 100 You attempted to program the Group Offset Preset value outside its range of
39. OUND EASYPack TRANSDUCER INPUT MOUNTING STUDS GENESIS CONNECTOR 8 32 X 0 5 4 Places Accepts 1 Single Resolver Transducer PRG 1 POS 0 RPM 0 Uses an AMCI C1TG x Transducer Cable G1 POS 45 G2 POS 90 9 SERIAL PORT G3 POS135 G4 POS180 Not Implemented TRANSDUCER FAULT OUTPUTS 1 4 OUTPUTS 5 8 gt E ENABLE INPUT GROUP INPUTS FLUORESCENT DISPLAY 4 Line X 20 Characters KEYPAD Bi Level Keys for Screen Selection and Data Entry FUNCTION LED Figure 1 2 Genesis Layout 10s ADVANCED MICRO CONTROLS INC INTRODUCTION M Unit Description continued Operator Interface Display and Keyboard The operator display provides four lines of text that are twenty charac CONFIGURE 1 OF 4 ters long Figure 1 3 shows a typical Genesis display SF 1000 PRESET 0 gt Line 1 Identifies the screen being displayed DIR CW RATE RPM VIEW 1 90 RPM 0 Lines 2 3 Shows parameters their values Line 4 Displays the unit s status Figure 1 3 Sample Display Usually line 4 displays the current mode View or Edit the number of the current program and the machine s current position and speed This information is replaced with an error message if a problem occurs The keypad is made up of twenty keys that perform various functions Thirteen of the keys are bi level with blue on the top and white on the e ricos PRGSEL ADVANCE bottom When the red Function
40. Places Thru Holes Tapped Holes Grounding Electrode Conductor Grounding Electrode Conductor 8 AWG Wire Minimum Recommended 8 AWG Wire Minimum Recommended WELDED STUD THRU WALL BOLT Figure 6 2 Ground Bus Installation Bonding the Enclosure Door If mounted correctly the body of the enclosure will be bonded to the ground bus through the mounting hard ware However you must install a bonding strap from the door of the enclosure to the ground bus Do not rely on the door s hinge to bond it to the rest of the enclosure The easiest way to ground the door is to run a bolt through the door as shown below and run a bonding wire to the ground bus Scrap Paint Away Both Sides of Enclosure Wall Z Re Star Washers Bolt Two Places Star Washer Tapped Hole u Bonding Wire To Ground Bus 8 AWG Wire Minimum Recommended Figure 6 3 Enclosure Door Bonding The national electrical code specifies the minimum bonding wire size for equipment based on the rating of the overcurrent device in the circuit ahead of the equipment The code states that the size cannot be smaller than 14 AWG However the NEC is concerned with human safety not EMI protection For noise reduction pur poses the larger the bonding wire the better so AMCI strongly recommends stranded 8 AWG for all bond ing wires Once the ground bus is installed and the enclosure is bonded to it you can begin to install equipment in the enclosure and bo
41. SDUCER FAULT If the message is not blinking it means there is an actual fault with the connec tion Check all wiring for opens and shorts and make sure the cable is wired correctly It is sometime easy to cross connect two of the three black wires in the cable All AMCI cables are tested at the factory and are properly wired when shipped but sometimes the Transducer Input connector is taken off the cable before it s pulled through conduit and mis wired when the connector is re attached If you need a wiring diagram refer to CITG x Wiring Diagram found on page 49 If the message is blinking it means the fault can now be cleared If you see the fault appear and start flashing while the machine is running this is most commonly caused by a burst of electrical noise that s injected into the transducer cable or a connection in the cable that has become loose The EASYPack Genesis latches a fault even if it only occurs for a few milliseconds A transducer fault is cleared with the CLEAR key but you have to be in Edit Mode before you can clear it If the message is blinking but you cannot clear it press the EDIT key to make sure you are in the proper mode Operators at all password levels can clear a transducer fault nvRAM Error Figure 11 5 shows an nvRAM Error message All of the unit s parameters are NON VOLATILE MEMORY stored in a battery backed RAM which will hold the values for approximately HAS TO BE INITIALIZED
42. able follow the general guidelines given in chapter 5 in the Wiring section starting on page 42 AMCI Transducer Outline Drawings AMCI offers a broad line of resolver based transducers for use with the EAS YPack Genesis See Compati ble Transducers starting on page 13 Outline drawings for all of these transducers and full spec sheets for our most popular transducers are available on our website www amci com If you do not have internet access contact AMCI and we will fax the information to you 20 Gear Drive Plymouth Ind Park Terryville CT 06786 49 Tel 860 585 1254 Fax 860 584 1973 http www amci com Am INSTALLATION AMCI Transducer Mounting All AMCI resolver based transducers are designed to operate in the industrial environment and therefore require little attention However there are some general guidelines that should be observed to ensure long life gt Limit transducer shaft loading to the following maximums Radial Load Axial Load All 0 625 Shafts 100 lbs 445 N 50 lbs 222 All 0 375 Shafts 30 lbs 133 N 15 Ibs 66 7 N All Other Shafts 11 4 45 N 0 5 16 2 22 N Table 6 1 Transducer Bearing Loads gt Minimize shaft misalignment when direct coupling shafts Even small misalignments produce large loading effects on front bearings Itis recommended that you use a flexible coupler whenever possible A flexible coupler is required for all HT 6 transducers and R11 resolv
43. advance by multiplying the actual machine speed by this ratio Lead Distance Lead Speed Machine Speed Distance AMCI determines the amount of advance with only one parameter by using the fact that speed is the ratio of Distance Time Multiplying Distance Time by the ON OFF Advance in milliseconds yields Distance which is the same value calculated by using the two parameter method NOTE gt When programming the ON OFF Advances total all of the delays associated with the load In the glue gun control example on the following page the ON OFF Advances compensate not only for the activation delay in the glue gun but also for the time it takes the glue to reach the box 20 Gear Drive Plymouth Ind Park Terryville CT 06786 31 Tel 860 585 1254 Fax 860 584 1973 http www amci com ie SPECIFICATIONS Limit Switch Parameters continued LS ON OFF Advances continued In order to illustrate how the LS Advances can be used in a packaging application consider the glue gun application below EASYPack Genesis Glue Gun Controller 25 mS to actuate 35 mS for glue to reach box Box Length 19 5 One Transducer Rotation 0 Positie Length 24 inches HT 20 amp osition Scale Factor 240 Motor 0 1 Count resolution _ LS Output without Advances 20 4508 DEE Soros TI Without advances the output always fires at 15 0 the pro
44. ange a parameter value and then switch to another parameter without press ing the ENTER key the new value will not be stored and the parameter will revert back to its original value Power Input The EAS YPack Genesis requires 24Vdc to operate The Power Input Connector is on the bottom of the unit It has two contacts for power and a third for grounding the chassis Transducer Input Connector When looking at the display the eight pin Transducer Input Connector is located on the right side of the unit The mating connector AMCI part number MS 8P ships with the unit The EASYPack Genesis accepts a sin gle resolver transducer for position feedback Specifications for all of the AMCI transducers that work with the EAS YPack Genesis are listed in the following section Compatible Transducers starting on page 13 Limit Switch Outputs Connectors for the limit switch outputs are the back of the unit Outputs one through four come off the top connector on the back while outputs five through eight come off the bottom Both DC and AC solid state relays can be plugged into the back of the EASYPack Genesis The AMCI part number for the DC relay is KD 6 while the AC relay part number is KA 3 Full specifications of the relays is given in chapter 3 in the section Output Relay Specifications on page 24 20 Gear Drive Plymouth Ind Park Terryville CT 06786 11 Tel 860 585 1254 Fax 860 584 1973 http www amci com IE Nl INTRODUCTION U
45. ations and com patible transducers OUICK START Anyone already experienced in installing or using similar products and wants generalized information to get up and running guickly SYSTEM CHECKOUT Anyone wanting to bench test their unit or troubleshoot an installation SPECIFICATIONS Anyone that needs detailed information on the unit itself This chapter describes all of the unit s parameters their defaults and ranges GENERAL INSTALLATION GUIDELINES Anyone new to installing electronic controls in an industrial environment The chapter includes general information on wiring grounding and surge suppression that is applicable to any controls installation INSTALLING THE EASYPACK GENESIS Anyone that must install an EASY Pack Genesis on a machine Includes information on mounting grounding wiring and surge suppression spe cific to the unit PROGRAMMING OVERVIEW Anyone looking for information on navigating through the displays creat ing copying or deleting programs and using passwords to secure pro grams CONFIGURATION PROGRAMMING Anyone that needs information on programming the transducer setup parameters BASIC LS PRO GRAMMING Anyone that needs information on programming limit switch ON OFF Setpoints and ON OFF Advances ADVANCED LS PROGRAMMING Anyone that needs information on programming the PLS Group function ality MONITORING MACHINE OPERATION Any
46. bus Over time it is possible for bonding connections to loosen or corrode so a redundant grounding connection lessens the likelihood of problems in the future 18Vdc to 30Vdc Isolated Power Supply rh Grounding Strap maybe required by local safety codes Strap can be attached without the concern of forming a ground loop between the supply and Genesis because the negative side of the units power input is isolated from the chassis ground connection ground Bus OOOO 9 Figure 6 5 EASYPack Genesis DC Power Connections 20 Gear Drive Plymouth Ind Park Terryville CT 06786 47 Tel 860 585 1254 Fax 860 584 1973 http www amci com Am INSTALLATION Transducer Input Connector The Transducer Input Connector labeled RESOLVER has eight contacts The mating connector is supplied with the EAS YPack Genesis and also comes on any AMCI pre assembled C1TG x cable you may order The AMCI part number for the mating connector is MS 8P while the Phoenix Contact part number is MC1 5 8 ST 3 81 order number 1803633 Figure 6 6 shows the connector pinout to AMCT s cable colors and indus try standard resolver designations RESOLVER 12 34 5 6 7 8 PIN 1 f Cable Colors Designations B RED R1 RED R2 gt R1 R2 Reference Winding SHIELDS Shields
47. c max 1 6Vac max ON Time 50 microseconds 1 2 cycle max zero voltage Off Time 50 microseconds 1 2 cycle max zero current Table 4 2 Output Relay Specifications 1 The AC relays used by the EASYPack Genesis will only turn on when the instantaneous line voltage passes through zero volts and will only turn off when the instantaneous line current passes through zero amps This occurs twice per cycle or every 8 3 milliseconds when the line frequency is 60 Hz This char acteristic may cause a problem in high speed applications by introducing a random delay of 0 to 8 3 milli seconds but it also effectively eliminates most of the noise that can be generated by switching an AC load 24 ADVANCED MICRO CONTROLS INC SPECIFICATIONS E The remainder of this chapter describes the programmable parameters of the EASYPack Gene sis Tables at the end of each section summarize defaults and ranges for each parameter Programmable Parameters An EAS YPack Genesis is configured by setting its Programmable Parameters Parameters are broken down into four broad categories gt Password and Display Parameters Parameters that set the passwords or only affect the unit s dis play gt Transducer Setup Parameters Parameters that affect the position and rate values calculated by the unit gt Limit Switch Parameters Parameters that affect the limits switch outputs generated by the unit gt Group Setup Parameters Parame
48. cer position and tachometer value Press the EDIT key remember to turn on the Function LED first and note that VI EW 1 changes to EDIT 1 You are now in Edit Mode so you can change programmed values Press the SELECT key and note that SELECT changed to NEW Press ENTER followed by 2 ENTER You ll now see two program numbers on the second line and EDI 2 on the bottom line You just created program 2 and are now editing it Programming a Limit Switch Press the LIM SW key The display changes to the LS Setpoint Screen Note GROUP 1 1 that the bottom line still displays the status information This is true for most 1 CH NOT USED screen displays MODE GROUP POS BDIET 2 Pe te Ie 0 The top line is the headings for the data shown on the second line Because limit switch 1 doesn t have any setpoints programmed into it the second line shows CH NOT USED The third line shows some status information for the limit switch You ll see that channel number one is blinking Press the up and down arrow keys and cycle through the eight limit switches When you get back to channel 1 press ENTER and note that the blinking cursor moves to the LS Type field You can also use the gt key to move the cursor Now press SELECT several times and you ll see the value change between three values gt Channel not used N Normal limit switch position on posi
49. ch as enabling the limits only when product is present and positioned correctly By incorporating these modes directly into the EASY Pack Genesis update time on conditioned limit switches is kept to 100 microseconds This means there will be little variance in their actual turn on off positions so your machine can be run at a higher line speed and still produce high quality products Four separate Groups are available on the EASY Pack Genesis controller which means one unit can control up to four different functions on your machine 20 Gear Drive Plymouth Ind Park Terryville CT 06786 9 Tel 860 585 1254 Fax 860 584 1973 http www amci com IE NE INTRODUCTION Basic Advanced Features AMCI knows that many of you will use the EASYPack Genesis as a basic programmable limit switch In order to keep this manual simple for those that are using the unit in this way but still explain all of the features of the unit in an orderly fashion we decided to break down the features of the EASYPack Genesis into two areas gt Basic Features are features needed to get the EAS YPack Genesis operating as a position on position off programmable limit switch with Automatic Advances gt Advanced Features are features that add the position on position off OR time off limits Motion and LS Enable ANDing and group functionality NOTE Where applicable each chapter will cover Basic Features first followed by Advanced Fea tures Notices
50. chine Position Modes 1 and 2 use it as a Preset Value In these two Modes the Group Postion is set equal to this value when the proper input con ditions are met for the Mode 665 ADVANCED MICRO CONTROLS INC 11 MONITORING MACHINE OPERATION This chapter covers how to use the Main and Status Screens to monitor the EASYPack Genesis while the machine is operating and how to use the increment and decrement functions to fine tune limit switch setpoints and advances The chapter finishes with a listing of error messages you may encounter and how to clear them While the Machine is Running The EASYPack Genesis has a built in ten minute timer that is reset to zero every time a key is pressed Ifa key is not pressed for ten minutes the EAS YPack Genesis puts itself into View Mode and switches the display to the Main Screen If you are in Edit Mode and the transducer starts moving the EAS YPack Genesis switches itself to View Mode The unit doesn t switch to the Main Screen It stays in View Mode as long the transducer is rotating and will switch back to Edit Mode if the built in timer has not timed out If the timer has timed out the unit switches the display to the Main Screen and will stay in View Mode The Main and Status Screens The Main Screen accessed with MAIN shows the currently running program the Machine Position and the Machine Speed Two versions of the screen are shown in f
51. chine to be stopped ADVANCED MICRO CONTROLS INC SYSTEM CHECKOUT This chapter is for new users that want to bench test the EASYPack Genesis to become familiar with it Because it assumes you re bench testing the unit installation practices such as grounding a surge suppression are not covered Needed Equipment The following is all you need to walk through the system checkout gt The EASYPack Genesis including the Transducer and Power connectors that shipped with the unit gt A24Vdc power supply that can deliver 0 5A gt A pair of wire cutters and strippers gt Enough wire to connect the supply and unit together fake a transducer connection and power an input A transducer and C1TG x cable from AMCI will make some steps easier but they re not required Output Relays make it easier to check the state of the outputs but again they are not required Optional Relays Even though you don t need them for the bench test install the relays now a A you have them Figure 3 1 shows the relay placement on the back of the TO EASYPack Genesis ae 310297 Faking a Transducer or Attaching a Real One amp l el e If you don t have an transducer and cable you can put wire s slo jumpers on the transducer input connector as shown i
52. de must be sized to handle the inductive surge of the load when it turns off gt Some devices can be ordered with built in fly back diodes or the device manufacturer will offer sup pressors designed specifically for the device These types of devices are strongly recommended gt The fly back diode will slightly increase the device s turn off time by maintaining the magnetic field while it shunts energy back into the device If needed this additional delay can be compensated for by adjusting the LS OFF Advance parameter available on the EAS YPack Genesis ADVANCED MICRO CONTROLS INC lt 40 GENERAL INSTALLATION GUIDELINES Wiring continued Surge Suppression AC Outputs The AC relays used by the EASYPack Genesis will only turn on when the instantaneous line voltage passes through zero volts and will only turn off when the instantaneous line current passes through zero amps This occurs twice per cycle or every 8 3 milliseconds when the line frequency is 60 Hz This characteristic may cause a problem in high speed applications but it also effectively eliminates most of the noise that can be gen erated by switching an AC load However if you are also switching AC loads with hard contacts such as mechanical relays or contactors then you must install a suppression network on the load switched by the hard contacts The two most common suppressors for AC loads are varistors and R C networks gt AMCI strongly suggest
53. e entering Edit Mode You must enter your four digit code As shown in ENTER PASSWORD figure 7 3 the number you enter is displayed as asterisks VLEW 1 P 90 RPM 0 Once your four digit code is keyed in press ENTER Your code is compared to Figure 7 3 Enter Password the three stored in memory and you are granted access rights based on which Screen password you match If you enter the wrong password the display switches to the last screen that you were on in View Mode and flashes NCORRECT ACCESS on the bottom line for two seconds Once again press EDIT to bring up the password screen and try to enter your password a second time NOTE gt Why does the EAS YPack Genesis switch to the last screen and make you wait two seconds instead of just leaving you on the password screen It really slows down someone who s try ing to crack the passwords Password Access Levels The use of passwords is disabled by default If you choose to enable passwords the table below shows what can be programmed based on the password entered when a person switches to Edit Mode Screens Functions Master Set up Operator Select Running Program Yes Yes Yes Create Copy or Delete a Program Yes Yes No Inc Dec Limit Switch Setpoints Yes Yes Yes LS Setpoint Screen Edit View Edit View View Only LS Advance Screen Edit View Edit View View Only LS ANDing Screen Edit View Edit View View Only LS Timed Output Screen Ed
54. e inputs and use the same supply that powers the unit As you wire remember that you will be applying and removing power from the inputs to see how they affect the outputs so make it easy to disconnect power from them later 24Vdc Power Supply DVD Al Sal Pal REP EN EASYPack Genesis BACK Top of Unit Figure 3 3 Wiring Inputs for System Checkout When you re done re apply power to the unit The Configuration I Screen will come back again but you are now in View mode VI EW 2 The unit always powers up in View mode Press the EDIT key to get back into Edit mode ADVANCED MICRO CONTROLS INC gel as SYSTEM CHECKOUT LS Enable ANDing In addition to PLS Group Programming the EAS YPack Genesis can condition limit switches by logically anding them with one or two conditions gt Motion ANDing The state of the output is ANDed with the state of the Motion Detector The Motion Detector is a speed based limit switch It s on between two speeds that you program into the unit Motion ANDing prevents the outputs from firing unless the machine is running at its correct speed gt LS Enable ANDing The state of the output is ANDed with the state of the LS Enable Input A typical packaging application wires the input to a material sensor This prevents the outputs from firing unless material is present Press ANDING and you ll
55. e resolvers with dif ferent electrical specifications for other position feedback applications such as servo control For additional information on these items and the rest of our product lines browse through our website www amci com or contact AMCI or your local AMCI distributor 14 ADVANCED MICRO CONTROLS INC 7 9 QUICK START This chapter can help you get started using the EASYPack Genesis It assumes you are an experienced user with a solid understanding of programmable limit switch functionality and proper installation techniques such as wiring grounding and surge suppression The chapter also contains references to the other sections in this manual where more information can be found If you don t feel you have enough information or background to complete the steps listed here always read the referenced sections before attempting to complete a step STEP 1 Decide On Needed Functionality STEP 2 1 1 1 2 1 3 1 4 1 5 1 6 Passwords Number and type of outputs position on off or timed LS Enable ANDing for any of the outputs Output only fires when LS Enable input is active Motion ANDing for any of the outputs Output only fires when machine is running at the correct speed Do you want the machine speed reported in RPM or a different value such as inches per minute car tons per minute or boxes per minute If the machine speed is reported in RPM you can leave the Rate Multiplier
56. een or more programs defined gt SAVE AS The program number you add must not already exist When created the new program is copy of the currently running program The number of the new program appears on the display unless you already have fourteen or more programs defined gt DELETE The program number you enter must exist and cannot be the presently running program The unit will ask you for confirmation Press SELECT to cycle between YES and NO Pressing ENTER while the display shows YES deletes the program 56 ADVANCED MICRO CONTROLS INC PROGRAMMING OVERVIEW B Manipulating Programs continued As you create new programs their number are added in numeric order to lines 2 FT and 3 of the display Once you enter more than fourteen programs the display 1 3 4 5 6 7 changes to one similar to figure 7 6 where the word MORE is displayed If EU 1 D i T you see this display you can use the W and A keys to cycle through the avail able program numbers Figure 7 6 15 Programs Programming Error Messages The following table is an alphabetical list of error messages you may encounter while programming the EASY Pack Genesis Error message appear on the bottom line of the display for two seconds whenever an error occurs Error Message CHANNEL ERROR You set the LS Number to 0 or 9 Valid Numbers are to 8 You re attempting to program the Rate Divisor to a value of zero or greater DIVIS
57. em EE Output Device Noise can radiate through the load s wiring where it can be n o coupled into other cables around it and the LS Output relay Suppressor may eventually be damaged by high voltage inductive spikes Power Return o Inductive This connection protects the LS Output but nothing else E PH Device Nojse can radiate through the load s wiring where it can be coupled into other cables or into the power supply Noise Suppressor the supply may affect any device powered by it Also if the Power Return suppressor shorts out the load will always receive power Figure 5 1 Installing Surge Suppression Devices Surge Suppression DC Outputs All inductive DC loads require a commutating or fly back diode across the load Inductive DC loads include relays solenoids and DC motors Unlike resistors diodes have a polarity and only conduct current in one direction Therefore care must be taken when installing diodes As shown in the figure below the cathode of the diode which is denoted by the white or black band on one end of the diode must be installed on the positive side of the load If you install the diode backwards it will most likely destroy itself as soon as you apply power to the load DC Load Connection _ Inductive Device LS Output Power In n o COLORED BAND Power Return Figure 5 2 DC Output Surge Suppression The dio
58. ers Wiring Figure 6 9 is the rear view of the EASY Pack Genesis and shows the locations of the output relays and I O wir ing connectors EASYPack Genesis BACK REEE N S A5 ise Hy OUTPUT CONNECTOR lomom OVO osdsg Outputs Al 2 GROUP INPUTS Inputs 1 4 and Input Common LS ENABLE INPUT Input and Shield Connection 3 OUTPUT RELAYS OUTPUT CONNECTOR 00571 KD 6 60Vdc Outputs 5 8 KA 3 120Vac 3A 120Vac 1 5A Motor Rating O i uA E Figure 6 9 I O Connector Placement Group Input Wiring Figure 6 10 shows a simplified schematic of the Group Inputs The Input4 Input3 Input 1 Optocoupler Optocoupler Optocoupler Optocoupler inputs are designed to accept 10 30 Vdc and require 10 mA to activate CZ I m A E f Note that the Input Common Pin is attached to one side of the power gt gt lt gt supply that powers the sensors connected to the inputs gt If your sensors have sourcing outputs then attach the Common pin to power supply ground gt If your sensors have sinking outputs attach the Common pin to Vde of the supply Deos gt Allof your sensors must be sourcing or sinking You cannot attach both types to t
59. es CONFI GURE 4 OF 4 you to the Configuration 4 Screen shown in figure 7 4 The Disable DISABLE PASSWORD Enable Password field will be blinking MASTER 1234 3 Press SELECT as needed to switch the field to ENABLE and press ENTER The cursor switches to the Password Name field Figure 7 4 Password Screen 4 Press SELECT to switch to the Password Name you wish to set Master Set Up or Operator Press ENTER to switch to the Password Value field 5 Enter the new four digit code Any value between 0000 and 9999 is acceptable Press ENTER to store the new value The cursor moves back to the Disable Enable Password field 6 Press gt to move to the Password Name field If needed repeat steps 4 8 5 for the other passwords NOTE 5 If you set two passwords equal to each other the password grants the higher of the two levels For example setting Operator and Set Up passwords to 3333 grants Operator level privileges Manipulating Programs The Program Select Screen shown in figure 7 5 is used to select create copy SELECT PROGRAM and delete programs It is accessed with the PRGSEL key You must be in Edit Mode before you can perform any of these operations If passwords are enabled your access is limited by the password entered Dy l ps 9 0 Figure 7 5 Program Select gt Master and Operator Levels Select Create Copy and Delete functions Screen gt Operator Level Select function
60. ew and Edit Modes 3 Which programming functions that are available to users based on password levels 4 How to enable passwords if you choose to limit programming access 5 How to select create copy and delete programs 6 The error messages you may encounter while programming the unit Using the Display and Keyboard The display provides four lines of text that are twenty characters long CONFIGURE 1 OF 4 Figure 7 1 shows a typical display SF 1000 PRESET 0 gt Line 1 Identifies the screen being displayed DIR CW RATE RPM VIEW 1 90 RPM 0 gt Lines 2 and 3 Shows parameters and their values gt Line 4 Displays the unit s status Figure 7 1 Sample Display Usually line 4 displays the current mode View or Edit the number of the current program and the machine s current position and speed This information is replaced with an error message if a problem occurs The keypad is made up of twenty keys that perform various functions Thirteen of the keys are bi level with blue on the top and white on the e meron EDIT PRGSEL LIM SW ADVANCE bottom When the red Function LED next to the FUNCTION Key is on T JL JL 16 pressing one of these keys selects the function listed on the blue level seit vew ANDING TIMED STATUS while pressing one of these keys when the Function LED is off selects Hw 4 5 6 the function or enters the data listed on the white level The CONFIG
61. g wire connected to the CHASSIS pin of the power supply connector a Any non isolated power supply or sensor attached to the EASY Pack Genesis must be connected to the same chassis ground as the unit to avoid ground loops gt All isolation transformer secondary windings that are ows grounded to conform to local or national codes must be n grounded to the same earth ground as the machine ground EQUIPMENT ENCLOSURE 5 D i AMCI strongly suggests0 the use of a ground bus in the enclosure us SU that houses the EASYPack Genesis As shown in figure 5 3 The ground bus becomes the central grounding point for the enclosure Figure 5 3 Ground Bus System and its equipment The ground bus is directly connected to your grounding electrode system Wiring The most important aspect of wiring is determining the amount of LOW POWER CONDUIT voltage and power carried by the cable and separating low power ME LL cabling from high power cabling Inside of an enclosure separate the two types of cabling with a much physical distance as possible and keep the wiring neat Outside of the enclosure low and high power cabling must be run in separate conduits GROUND BUS Internal to Enclosure Central Grounding Point for all Equipment in Enclosure gt Transducer Cabling Low Power 1 Transducer signals are of low voltage and low power Transducer cable can be installed in conduit along with other l
62. grammed setpoints Trailing Edge of Leading Edge of Previous Box Next Box B Ideally the bead of glue is centered on the box Ideal Glue This is the pattern you will see when the machine Pattern is run at low speeds At low speeds the 60 mS that it takes for the gun Inches0 2 2 17 3 19 5 to activate and the glue to reach the box does not Counts0 22 173 195 greatly affect the position of the glue on the box Pattern at As the speed of the machine increases the distance the 60 Boxes Min box travels during the glue gun delay ends up shifting 60 RPM i j the pattern towards the back of the box At60 RPM the box travels 1 44 in 60 milliseconds so the Inches0 3 64 18 74 19 5 glue pattern is off center by that distance Counts0 36 187 195 Pattern at As the speed of the machine increases further the glue 120 Boxes Min pattern actually falls of the end of the box 120 RPM U L At 120 RPM the box travels 2 88 in 60 milliseconds With 2 2 normal gap the last 0 68 of glue runs off the box Inches 0 5 08 20 18 19 5 Counts 0 51 202 195 LS Output with 60 mS ON OFF Advances 22 ON OFF Setpoint Pai S Spone 0 Er 0 At low speeds the limit still tums on and off at the programmed setpoints LS Output with 60 mS ON OFF Advances 60 RPM 159 195 0 a 195 0 At this speed the output is turned on and off 14 counts before its programmed setpoints so that the glue strip stays centered on the box LS
63. guration Screens are accessed by first pressing the CONFIG key to access the Configuration 1 Screen and then repeatedly pressing the PREVIOUS NEXT key to cycle through the screens View and Edit Modes The display has two modes of operation View Mode and Edit Mode gt View Mode This is the default operating mode The unit power up in View Mode and will switch to this state whenever the transducer is in motion View Mode allows anyone to inspect programmable parameter values but not change them The one exception is the passwords which cannot be inspected while in View Mode For obvious reasons gt Edit Mode Edit Mode allows you to program parameter values If passwords are enabled you will be asked to enter your password before the unit switches to Edit Mode and the parameters you will be allowed to program will be limited by your password ADVANCED MICRO CONTROLS INC 2 PROGRAMMING OVERVIEW a View and Edit Modes continued Switching Modes To enter View Mode simply press the VIEW key The EASYPack will immediately switch to View Mode How you enter Edit Mode depends on whether or not passwords are enabled If passwords are disabled simply pressing the EDIT key switches the EAS YPack to Edit Mode The unit will allow you to program all parameters You have the equivalent of Master level access if passwords were enabled If passwords are enabled the EASYPack Genesis asks you for a password befor
64. he EASY Pack Genesis at the same time e zoo N 1 2 N 3 INPUT COMMON Figure 6 10 Group Input Schematic ADVANCED MICRO CONTROLS INC INSTALLATION 9 I O Wiring continued Group Input Wiring continued Figure 6 11 shows how to connect a three wire source or sink sensor to a Group Input You can use the power supply for the EASYPack Genesis to power the sensors If you do DO NOT connect the negative side of the supply to earth ground chas sis at the sensor Use a continuity tester to verify that the side of the sensor s power is not connected to the body of the sensor before install ing gt DO NOT attach the power supply leads of the sensor to the Power Connector of the EAS YPack Gene sis Connect the sensors directly to your power supply If you make the connection at the EASY Pack Gene sis any noise that may be injected into the sensor cable can be coupled into the unit The shield of a cable is usually grounded where the signal carried by the cable is generated Therefore the shield is usually grounded at the sensor However if you do not have a quality bonding point at the sensor ground the shield at the EAS YPack Genesis If you are using one or two Group Inputs and you are not using the LS Enable Input then ground the shields at the CHASSIS pin of the LS Enable Input Connector See figure 6 9 on the DC Sourci
65. hts of an Operator and can pro gram all of the limit switch parameters The Limit Switch Parameters are defined starting on page 30 gt Master Default 1234 Personnel with Master access can create new programs and program any parameter on the unit 20 Gear Drive Plymouth Ind Park Terryville CT 06786 25 Tel 860 585 1254 Fax 860 584 1973 http www amci com ee SPECIFICATIONS Password and Display Parameters continued Rate Value This parameter is found on Configuration Screen 1 By default the speed of the machine is reported in RPM but it can be scaled to any unit of measure you want See Rate Multiplier Divisor and Decimal Point on page 28 for more information This parameter simply allows you to select what rate units will be shown on the display It does not actually affect any values calcu lated by the unit The choices are RPM revolutions per minute IPM inches per minute CPM cartons per minute BPM boxes per minute Toggle Speed This parameter is found on Configuration Screen 2 The Toggle Speed parameter only affects the display It does not affect any of the outputs When the speed of the machine exceeds the value of the Toggle Speed parameter the position value on the display changes from rapidly changing numbers to The value of the Toggle Speed is affected by the Rate Multiplier Divi sor and Decimal Point parameters See how these parameters affect the reported machine s
66. igating through the display 4 Use the INC and DEC keys to fine tune the advance 5 Run the machine at a different speed to verify that the limit is still firing correctly If it s not then you have one of two problems 1 The delay that you are trying to compensate for is non linear 2 The ON OFF setpoint pair s are not set correctly Run the machine at very low speed when the advances do not make a large difference in where the setpoints fire If the limit is not firing correctly here adjust it with the ON OFF setpoints not the advances If you need further help in determining the correct setpoints and advances for your machine consult our FAQ How do I determine the correct setpoints and advances for my machine found on our website www amci com ADVANCED MICRO CONTROLS INC MONITORING YOUR MACHINE BY Error Messages Other than programming error messages which are covered on page 57 you ll only see two error messages The first is a transducer fault message and the other is a nvRAM non volatile RAM error Transducer Fault The Transducer Fault message occurs whenever there is a problem with the PRG 1 POS 90 RPM transducer connection When this occurs the bottom line of the display shows G1 POS 90 TRANSDUCER FAULT instead of the normal status information Figure 11 4 shows this message on the Main Screen and all other screens are similarly changed Figure 11 4 Transducer Fault Message TRAN
67. igure 11 1 In both screens the top line displays the presently running program the present Machine Position and the present Machine Speed 90 RPM 0 The top screen is the one you ll see if you are not using the advanced PLS Group G2 POS 90 functionality The second line only shows the Group 1 position value Only G3 POSTOU Gu Ae Group 1 is shown because all of the limit outputs are assigned to Group 1 and the Group s position equals the Machine Position because the Group Offset fea Figure 11 1 PLS Groups ture is not being used If you are using PLS Groups then your display may be similar to the bottom screen This screen shows the position values of all four Groups You will only see a Group on this screen if a limit switch is assigned to it Also note that the figure shows four different position values This occurs if you use the Group Offset Preset feature The other screen that shows what s happening while the machine is running is STATUS the Status Screen This screen accessed with the STATUS key shows the OUTPUT present state of the eight outputs and the five inputs The display shows either 0 y a or 1 for each output or input Figure 11 2 Status Screen For outputs the value is zero if it s off and 1 when it s on In figure 11 2 outputs 6 5 and 1 are on while the rest are off For inputs the value equals 1 when the input is powered Inputs 1 through 4 correspond to Group Inputs 1 4 and Input 5
68. ill be the same as the one on the right Press ENTER and the display changes to display the second setpoint pair FROM2 TO2 Normal limit switches can have up to four setpoint pairs Press the W key to switch to limit switch channel 2 Press ENTER twice once to select the channel and once to jump to the LS Type field Using the same basic keystrokes you used to program limit switch 1 pro gram channel 2 as gt LS Type Normal gt Group Number 1 gt From1 50 gt Tot 110 If you have a transducer rotate it until the position equals 90 If you have the relays installed the LED on relay 2 should now be on showing that the limit switch is active Viewing I O Status Press the STATUS key and the display changes to the one shown on the right STATUS This is the Status Screen and it does exactly what its name implies The top OUTPUT line gives the I O numbers line 2 is the status of the outputs and line 3 is the sta EDIT l p ae tus of the inputs Output 2 equals 1 because its presently active Presetting the Position The Machine Preset Value allows you to change the position value without rotat CONFIGURE 1 OF 4 ing the transducer shaft The function is located on Configuration Screen 1 so 360 PRESET 0 press CONFIG to switch to that display As shown on the right the screen con EDIT ae E p tains more that just the preset feature There are four Configuration Screens and
69. ing conductor Do not connect the shield to ground at any junction box or the transducer This will eliminate ground loops that could damage the EAS YPack Genesis 48 ADVANCED MICRO CONTROLS INC INSTALLATION 9 Transducer Cable Installation continued C1TG x Wiring Diagram BLK Ols el S 6 5 4 l2 amp E oh Transducer Connector Module Connector AMCI Part MS 16 Part MS 8P BELDEN 9873 Cable Bendix Phoenix MSTB1 5 8 ST 3 81 For cable lengths greater than 93106 165 15 18 03 63 3 100 30 meters use BELDEN 9730 Figure 6 8 C1TG x Wiring Diagram Article 800 of the National Electrical Code specifies that the transducer cable cannot be installed with the fol lowing wiring gt All conductors of electric light or power circuits gt Class 1 circuits gt Non power limited fire protective signaling circuits Article 800 also states that transducer cable can be installed with Class 2 or Class 3 circuit conductors and other communication cables All of these conductors are for low power low voltage devices such as optical and prox sensors There are listed exceptions to the ban on installing higher power conductors with the transducer cable but AMCI strongly recommends against following these exceptions The NEC is meant to protect individuals from hazardous situations not insure a noise free environment When installing the transducer c
70. int Screen By default each limit switch is disabled This is shown by setting the Limit Switch Type parameter to on the display which is the symbol for disabled Two types of limit switch outputs are available The first type is Normal and as shown in figure 4 2 the limit switch turns on and off based on programmed positions called Setpoints The figure shows an output that turns on at 45 and off at 225 You have four Setpoint Pairs available when the output is configured as a Nor mal limit switch so each Normal limit switch can turn on and off up to four times per turn See LS ON OFF Setpoint Pairs on the following page for a full description of programming the setpoints One Transducer Turn 45 225 Figure 4 2 Normal Limit Switch Output The second type of limit switch is Timed and as the name implies it makes the limit switch act much like a timing relay Figure 4 3 below shows the output of a timed limit switch The limit switch is programmed with a single setpoint pair and a Time Out value In the figure the setpoint pair turns the output on at 45 and off at 225 and the Time Out value is set to 185 milliseconds NOTE gt A timed limit switch has one on condition and two off conditions The on condition is the first setpoint and the off conditions are the Time Out value and the second setpoint The first of the two off condition that is met turns off the output Example On Setpoint 45 One
71. internal x 1 gear ratio HTT 20 1 0 625 Front single turn resolvers single MS connec Redundant single turn resolvers Bolt in replace HTT 400 1 0 625 Front 1 ment for Autotech RL220 transducers Dual AMCI MS connectors on back of transducer B z HT 20LS 0 625 Front Side 1 Z Z NEMA 4 size 25 end connector Z Z 1 1 1 1 1 1 1 1 1 1 Available gear ratios are 2 1 2 5 1 2 77 1 3 1 4 1 4 8 1 5 1 6 1 7 1 8 1 9 1 10 1 12 1 13 1 15 1 16 1 18 1 20 1 24 1 36 1 40 1 50 1 60 1 64 1 100 1 105 1 150 1 180 1 250 1 and 256 1 Additional gear ratios may be available Check our website www amci com for an up to date listing This package contain two resolvers geared 1 1 with the input shaft Most commonly used in systems that man date redundant sensors AMCI can install two different size 11 resolvers in the package per customer require ments Contact AMCI for more information Table 1 2 Compatible AMCI Transducers 20 Gear Drive Plymouth Ind Park Terryville CT 06786 13 Tel 860 585 1254 Fax 860 584 1973 http www amci com IE E INTRODUCTION Other EASYPack Family Members EASYPack is trademarked name for the line of products we designed to ease the task of packaging machine automation The following table lists some of the other products in the EAS YPack family but the line is constantly growing so the list may be incomple
72. ion 0 0 0 i 71 Group Window se ll GG Fl Limit ON Advance 1 Programmed Setpoints LS2 151 Limit OFF Advance Actual LS2 ON OFF Points Due To Advance Limit Does Not Fire Figure 4 7 Mode 2 Functional Diagram D When the Group Input makes a positive transition current begins to flow through the input the Group Position is set equal to the value of the Group Offset Preset parameter Once the position is preset the Group Input is ignored until the Group Window becomes active at its programmed dwell Limit Switch 2 turns on immediately because of its ON Advance Note that LS2 cannot fire correctly at this speed when the position is preset because of its advance 3 This edge on the Group Input is ignored because the Group Window dwell has not been reached The Group Input is enabled and the group s outputs are disabled once the Group Window dwell is reached The next positive edge on the Group Input will preset the Group Position Outputs do not cycle because they have been disabled by the dwell on the Group Window 6 This Group Input transition presets the Group Position and the cycle starts again NOTE 5 You can preset the Group Position multiple times per transducer rotation by programming the Group Window appropriately The figure to the right shows how Mode 2 could be Glue Gun used in a gluing applicat
73. ion The gun s output is in EASYPack Genesis a group in Mode 2 and the prox sensor is wired to Prox Sensor Controler the group s input When the front of the box passes under the sensor the group s position is set the pre J set value zero in this example and the output is HT 20 amp enabled for one box Note that the gun will not fire during the missing box Condition above 0 Position Figure 4 8 Mode 2 Example ADVANCED MICRO CONTROLS INC SPECIFICATIONS y Mode 3 Mode 3 uses the Group Input to enable the outputs in the group The Group Window has no effect and need not be programmed The Group Input is typically tied to a sensor that detect the presence of material The outputs only fire when material is present The outputs assigned to the group will cycle once per transducer rotation and can be further conditioned with the LS Enable Input and or the Motion Detector A group in Mode 3 uses the Group Offset Preset parameter as an offset When the Group Offset Preset equals its default of zero the Group Position equals the Machine Position The timing diagram shows how the Group Input affects the outputs in the group 4 One Transducer a One Transducer Turn Group Position 0 0 0 Group Input LS1 77 9 52 Limit Does Not Fire Figure 4 9 Mode 3 Functional Diagram Outputs do not fire because the Group Input is not active
74. is between the two setpoints and on at all other speeds You can logically AND any limit switch with the state of the motion detector This disables the limit switch output unless the Motion Detector is on Machine Speed RPM 0 I 1 l 500 2000 90 RPM 310 RPM Low Setpoint High Setpoint Machine Speed RPM 1 90 310 RPM High Setpoint Low Setpoint 500 2000 Figure 4 1 Motion Detector Output Summary Table Parameter Default Scale Factor 360 2 to 1 000 Machine Preset Value 0 0 to Scale Factor 1 Count Direction CW CCW clockwise counter clockwise Rate Multiplier 1 to 1 100 Rate Divisor 1 to 63 Rate Decimal Point 1 10 100 or 1 000 Motion Detector Low High Setpoints 0 to 2 000 Table 4 5 Transducer Setup Parameters 20 Gear Drive Plymouth Ind Park Terryville CT 06786 29 Tel 860 585 1254 Fax 860 584 1973 http www amci com E Fl SPECIFICATIONS Limit Switch Parameters The Limit Switch Parameters are distributed across four different screens They are the LS Setpoint Screen LIM SW LS Advances Screen ADVANCE LS ANDing Screen ANDING and LS Timed Screen TIMED When programming a limit switch the unit will automatically switch between these screens while you pro gram Having the functions on separate keys also allows you to quickly jump to the parameter you wish to program Limit Switch Type This parameter is available on the LS Setpo
75. it View Edit View View Only Status Screen This is a View Only Screen Main Screen This is a View Only Screen Configuration 1 Screen Edit View View Only View Only Configuration 2 Screen Edit View View Only View Only Configuration 3 Screen Edit View View Only View Only Configuration 4 Screen Edit View Unavailable Unavailable PLS Groups Screen Edit View Edit View View Only Table 7 2 Screen Access Based on Password Level Basically a Master is able to select create copy or delete programs and program any parameter A Set up level user such a shift supervisor can do everything a Master can do except program Transducer Set up parameters An Operator level user can only select the running program and increment decrement setpoints Note that Operators can only select between programs that already exist they cannot create new programs 20 Gear Drive Plymouth Ind Park Terryville CT 06786 55 Tel 860 585 1254 Fax 860 584 1973 http www amci com Br PROGRAMMING OVERVIEW Setting Passwords The following procedure is for enabling passwords and setting their values 1 Press the EDIT key even if you re already in Edit Mode If you enter Edit Mode without being required to enter a password then passwords are disabled If you are required to enter a password then you must enter the Master password 2 Press CONFIG followed by the NEXT key three times This switch
76. it as Group Offset Preset a position offset value Modes 1 and 2 use it as a position preset value Table 4 7 PLS Group Parameters Mode O Mode 0 does not have any of the additional functionality of the other modes If you only need basic program mable limit switch functionality from some of your outputs assign them all to one group and assign Mode 0 to the group The Group Input for the group is not used and the Group Channel need not be programmed Outputs in the group can still be conditioned by tying them to the LS Enable Input and or the Motion Detec tor Limit Switches will cycle once per transducer rotation The group s Group Offset Preset value is used as an offset value When the Group Offset equals zero the Group Position equals the Machine Position ADVANCED MICRO CONTROLS INC 34 SPECIFICATIONS Ei Mode 1 Outputs that are assigned to a Group in Mode 1 are always enabled to fire This is the primary difference between Modes 1 and 2 Outputs in Mode 2 are normally disabled and fire for only one cycle when the input transitions Mode 1 uses the Group Input to preset the group s position to the value programmed into the Group Offset Preset parameter Typically the Group Input is tied to a sensor that detects an edge or registration mark on the product This synchronizes the outputs in the group to the product Once the Group Input forces a preset action its state is ignored until the programmed dwell on the
77. ition off Up to 4 on off dwells per output Position on Position off OR time off Single on off dwell and on time programmable from 1 to 9 999 milliseconds Automatic Advances Separate On Off Advances available for each output Advance can be programmed from 0 to 999 milliseconds Number of Outputs Eight Each output requires a solid state AC or DC relay Output fuse integral to relay Compatible Output Relays DC KD 6 Opto 22 GAODC 4 or equ AC AMCI KA 3 Opto 22 GAOAC2A or equ Number of Inputs Five Total Four Group Inputs and One LS Enable input Group Inputs DC only Each requires 10 to 30Vdc 10mA to activate LS Enable Input AC DC Requires 110 Vac 8 MA ms OR 10 to 30Vdc 10mA to acti vate Environmental Conditions Operating Temperature 0 to 60 C Relative Humidity 5 to 95 without condensation Storage Temperature 40 to 85 C 20 Gear Drive Plymouth Ind Park Terryville CT 06786 Tel 860 585 1254 Fax 860 584 1973 http www amci com 23 Hz SPECIFICATIONS Transducer Specifications The following table contains mechanical and environmental specifications for all of AMCI s single resolver transducers that are compatible with the EAS YPack Genesis Table 1 2 Compatible AMCI Transducers found on page 13 gives complete part numbers and descriptions of all compatible transducers All HT 20 x Specification All HT 20 s 400 HTT 20 1 All H25 s All R11
78. k Genesis as a basic limit switch leave all the limit switches in Group 1 Mode 0 which are the defaults when you create a limit switch and ignore the feature To explain the power of PLS Group Programming consider a Form Fill and Seal machine as an example As the name implies the machine performs three operations 1 The machine forms a container such as a pouch bag or box 2 It fills the container with product such as juice breakfast cereal or pens 3 It seals the container The EAS YPack Genesis can control all three functions by creating three PLS Groups Group 1 contains the limit switches for the form operation Group 2 contains the limit switches for the fill and Group 3 contains the limit switches for the seal Each Group has its own position value which is typically the same as the Machine Position Machine Posi tion is set by the Scale Factor and Machine Preset parameters However with separate positions you can adjust the limit switches of each Group independently of the others Consider the fill operation on our machine which is controlled by Group 2 If there is any variance in the position of the containers when they enter the fill area each container may not fill properly The solution to this problem is sensing the leading edge of the container and synchronizing the fill limit switches to this edge 20 Gear Drive Plymouth Ind Park Terryville CT 06786 21 Tel 860 585 1254 Fax 860 584 1973 http
79. licable along with a description of the problem A RMA number will be issued Equipment must be shipped to AMCI with transportation charges prepaid Title and risk of loss or damage remains with the customer until shipment is received by AMCI 24 Hour Technical Support Number 24 Hour technical support is available on this product For technical support call 860 583 7271 Your call will be answered by the factory during regular business hours Monday through Friday 8AM 5PM EST During non business hours an automated system will ask you to enter the telephone number you can be reached at Please remember to include your area code The system will page one of two engineers on call Please have your product model number and a description of the problem ready before you call We Want Your Feedback Manuals at AMCI are constantly evolving entities Your questions and comments on this manual are both welcomed and necessary if this manual is to be improved Please direct all comments to Technical Docu mentation AMCI 20 Gear Drive Terryville CT 06786 or fax us at 860 584 1973 You can also e mail your questions and comments to techsupport amci com ADVANCED MICRO CONTROLS INC __ TABLE OF CONTENTS General Information Chapter 3 System Checkout Important User Information IFC Needed Equipment 17 Standard Warranty IFC Optional
80. n figure 3 2 below After it s wired plug the connector back into the EAS YPack Genesis When QFY ojo a7 3 you power the unit it will think that the transducer is at 90 OFL olo If you have a transducer and cable plug the cable into the transducer and the a Ce EASYPack Genesis now Figure 3 1 Relay Placement v O st QW 2 Figure 3 2 Faking a Transducer Connection Applying Power The power connector is on the bottom of the unit With the power supply turned off wire the supply to the and pins on the unit s power connector Don t attach a wire to the earth ground pin This pin is for grounding the unit when you install it on your machine Once you ve check over your wiring power up the supply The display should light up in a few seconds If it doesn t remove power immediately and check your wiring again 20 Gear Drive Plymouth Ind Park Terryville CT 06786 17 Tel 860 585 1254 Fax 860 584 1973 http www amci com EH SYSTEM CHECKOUT Initial Display The display should be the same as the picture on the right if its anew unit Ifthe IT unit has been previously programmed your display could be different With none of the limits programmed the display only shows the running pro
81. n parentheses immediately following the parameter name is the page in the Specifications chapter that describes the parameter LS ON OFF Advances p 37 The LS Advances can be set to any value between 0 and 999 milliseconds When you first enter the screen or switch between limit switches with the PREVIOUS NEXT key the cursor moves to the LS Number field This field allows you to select the limit switch number that you want to inspect or program Use the PREVIOUS NEXT A V keys to cycle through the limit switches You can also jump to a specific output by keying in the number 1 through 8 and pressing ENTER There are only two other fields on the screen the ON Advance and OFF Advance Their values are set with the numeric keys and ENTER When you are on the OFF Setpoint and press ENTER the display switches to the LS ANDing Screen If you want to continue programming setpoints then use either the ADVANCE 4 keys to switch back to the LS Advance Screen 20 Gear Drive Plymouth Ind Park Terryville CT 06786 63 Tel 860 585 1254 Fax 860 584 1973 http www amci com H BASIC LS PROGRAMMING Notes ADVANCED MICRO CONTROLS INC 64 CHAPTER 10 ADVANCED LS PROGRAMMING This chapter covers how to program timed limit switches as well as Motion Detector and or LS Enable ANDing PLS Group Programming is also presented Before You Start Know This In order to keep the amount of repetiti
82. nce of material or a registration mark on it In these applications the outputs will only fire when the material is present and positioned correctly The out puts assigned to the group will cycle once per transducer rotation and can be further conditioned with the LS Enable Input or the Motion Detector A group in Mode 4 uses the Group Offset Preset parameter as an offset When the Group Offset Preset equals its default of zero the Group Position equals the Machine Position The timing diagram shows how the Group Input affects the outputs in the group One Transducer Turn 39 4 Group Position 0 0 0 Group Input Group Window it e I 182 2 VS 7 Limit Does Not Fire Figure 4 10 Mode 4 Functional Diagram 14 One Transducer Turn nn A positive transition on the Group Input occurs during the Group Window dwell The outputs are enabled for this one cycle The outputs are disabled on the positive transition on the Group Window during the next turn A positive transition on the Group Input occurs before the dwell on the Group Window The outputs are disabled for this cycle because the material is not correctly positioned ADVANCED MICRO CONTROLS INC _ 707 GENERAL INSTALLATION GUIDELINES This chapter gives general information on installing electronic controls in an industrial environ ment including the importance of proper wiring gr
83. nches per turn and the application require a posi tion resolution of 0 025 inches This translates into a Scale Factor of _ 7 750 inches 1 Count _ SCALE FACTOR 1 Tum X 0 025 inches 310 Counts Turn However programming a Scale Factor of 775 translates into 100 counts per inch of travel 0 01 count Even though 0 01 resolution is overkill for the application the convenience of being able to program other parameters directly in inches may be well worth it Machine Preset Value This parameter is found on Configuration Screen 1 Its range is 0 to Scale Factor 1 and defaults to zero The Machine Preset Value allows you to adjust the position value without physically rotating the transducer s shaft It s most commonly used to zero the transducer position to the physical zero of the machine NOTE gt Many packaging machines reset the position to zero when the leading edge of the product passes a sensor The Machine Preset Value cannot be used to adjust the machine position on the fly If your machine falls into this category consider learning how to use the advanced PLS Pro gramming feature Group Modes 1 and 2 were designed for these types of applications and can simplify your machine design PLS Group Setup Parameters are described starting on page 33 Count Direction This parameter is found on Configuration Screen 1 Its default is clockwise CW and can also be set to counter clockwise CCW The Count Direction
84. nd them to the ground bus as you go ADVANCED MICRO CONTROLS INC INSTALLATION E 9 Mounting the EASYPack Genesis Figure 6 4 shows how to mount the unit in the door or panel Output Relays can be installed before or after the unit 1s mounted A closed cell neoprene gasket ships with the Genesis Before mounting the Genesis in the cutout install the gasket by removing its adhesive backing and adhering it to the back of the unit The top of the figure shows how to fasten three of the studs to the panel or enclosure The bottom shows how to install the grounding lug on stud closest to the power connector EASYPack Genesis E e Door or Panel Neoprene Gasket Adhesive Side Toward Unit 8 32 x 0 40 Stud 4 Places Scrap Paint Around Hole 4 Places 8 Star Washer 3 Places 8 32 Nut 3 Places 8 Star Washer 2 Places Bonding Wire To Ground Bus 8 AWG Bonding Wire Recommended SS P aus Nut Figure 6 4 Mounting the EASYPack Genesis Connecting Power An external 18 to 30Vdc supply typically 24Vdc is required to power the EASYPack Genesis Power con sumption is ten watts This translates into 0 4A 24Vdc The power supply used to power the unit can also be used to power the five inputs if your application requires it NOTE The grounding wire shown in the figure from the Genesis to the ground bus is required even with the bonding wire run from a mounting stud to the ground
85. nectors Figure 6 1 Panel Cutout 20 Gear Drive Plymouth Ind Park Terryville CT 06786 45 Tel 860 585 1254 Fax 860 584 1973 http www amci com Am INSTALLATION Ground Bus A Ground Bus 1s reguired in each enclosure that houses electronic eguipment The ground bus is directly tied to the grounding electrode system of the machine and becomes the central grounding point for the enclosure and all of its equipment Bonding wires are run from the enclosure and each piece of equipment to the ground bus and then a single grounding electrode conductor is run to the system s grounding electrode Each connection must be separate so a ground bus is typically fabricated in house or by the panel shop responsible for wiring the enclosure Figure 6 2 shows various ways to mount the ground bus to an enclosure and how to connect a bonding wire to the bus gt Do not connect two or more lugs to the bus with a single bolt If you do the connection may loosen up over time Bolt 2 Places Star Washer Qu 2 Places Flat Washer 2 Places Star Washer A 2 Places Nut 2 Places g S Tapped Holes P 2 p Bot 7 5 e Thru Holes 4 d 5 Star Washer Tapped Holes 7 Star Washer Enclosure Scrap Paint Away Welded Stud Both Sides of Enclosure Wall Star Washer 2 Places P n Ky s 2 Places Scrap Paint Away From Stud Threads and Enclosure Wall Flat Washer 2
86. ng Material Sensor SENSOR POWER Run a seperate wire from the power supply to each sensor Do Not pull power from the Power Supply Connector of the EASYPack Genesis CABLE SHIELD 10Vdc to 30Vdc j Isolated Power SOURCING abi Can be the MATERIAL same supply that SENSOR powers the unit Grounding Strap maybe gt required by local safety P S98 GROUP INPUT codes C CONNECTOR NNNNO 4321M GROUND SHIELD OF SENSOR CABLE 1 Ground only one end of shield 2 Shield is usually grounded where the signal is generated If a good quality earth ground connection is not available at the sensor the shield can be grounded at the EASYPack Genesis DC Sink Material Sensor SENSOR POWER Run a seperate wire from the power supply to each sensor Do Not pull power from the Power Supply Connector of the EASYPack Genesis CABLE SHIELD 10Vde to 30Vdc Isolated Power SINKING Can be the MATERIAL e same supply that SENSOR I a powers the unit Grounding Strap maybe 080 reguired by local safety GROUP INPUT codes C CONNECTOR NNNNO 4321M GROUND SHIELD OF SENSOR CABLE 1 Ground only one end of shield 2 Shield is usually grounded where the signal is generated If a good quality earth ground connection is not available at the sensor the shield can be grounded at the EASYPack
87. nit Description continued Group Inputs NOTE 5 Group Inputs are only used if you are using the PLS Group Programming advanced feature If you are not using this feature then don t wire anything to the inputs There are a total of four Group Inputs with one input assigned to each of the PLS Groups available on the EASYPack Genesis The exact function of the input depends on the Mode the Group is running LS Enable Input The LS Enable Input can be ANDed to any limit switch output which prevents the output from firing unless input is active If you are not using this feature then do not wire anything to the input Compatible Relays The EASYPack Genesis accepts solid state relays that you must order separately The relays must be com patible with Opto 22 s G4 output relays that use 24Vdc as their logic voltage and have two input pins AMCI sells Opto 22 or compatible relays under our part numbers KD 6 and KA 3 The KD 6 is a DC output relay while the KA 6 is an AC relay Complete specifications of the relays are given in the section Output Relay Specifications found on page 24 Type Solid state DC Output Solid state AC Output Manufacturer Opto 22 Opto 22 Manufacturer s Part G40DC24 G40AC24 Table 1 1 Output Relay Specifications 12 ADVANCED MICRO CONTROLS INC INTRODUCTION E ES Compatible Transducers Table 1 2 lists the AMCI single resolver transducers that are compatible with the EAS Y Pack Genesis unit Model
88. of coupling transient noise into the low power cabling 2 If a conduit containing the transducer cable or input wiring must cross conduit that contains Output Wiring they must cross at right angles gt Power Supply Wiring 24Vdc 1 If you have a separate DC supply for the EASYPack Genesis and possibly its sensors then it is most likely a small one that is mounted in the enclosure with the Genesis In this case AC power for the supply can be routed with the output wiring AC power should never be routed with the transducer or input cabling 2 If you are using a system supply to power the Genesis and the power supply is outside of the enclosure then the 24Vdc supply lines should be run with the output lines if local codes permit gt Other Power Wiring High Power AC amp DC 1 Power Wiring must be kept separate from the transducer and input wiring in order to lessen the possibility of coupling transient noise into the low power cabling 2 If a conduit containing the transducer cable or input wiring must cross conduit that contains Power Wiring they must cross at right angles 3 Whenever possible conduit that contains transducer or input cabling must be kept 1 foot 30 cm away from 120Vac conductors 2 feet 61 cm from 240Vac conductors and 3 feet 91 cm from 480 Vac conductors Power Supply Wattage and Filtering A properly sized power supply is vital to system operation The best guideline that we can give you is to buy
89. on posted by Advanced Micro Controls Inc on our official website www amci com You may incorporate portions of this documents in other literature for your own personal use provided that you include the notice Portions of this document copyright 2001 by Advanced Micro Controls Inc You may not alter the contents of this document or charge a fee for reproducing or distributing it Standard Warranty ADVANCED MICRO CONTROLS INC warrants that all equipment manufactured by it will be free from defects under normal use in materials and workmanship for a period of 1 year Within this warranty period AMCI shall at its option repair or replace free of charge any equipment covered by this warranty which is returned shipping charges prepaid within one year from date of invoice and which upon examina tion proves to be defective in material or workmanship and not caused by accident misuse neglect alteration improper installation or improper testing The provisions of the STANDARD WARRANTY are the sole obligations of AMCI and excludes all other warranties expressed or implied In no event shall AMCI be liable for incidental or consequential damages or for delay in performance of this warranty Returns Policy All equipment being returned to AMCI for repair or replacement regardless of warranty status must have a Return Merchandise Authorization number issued by AMCI Call 860 585 1254 with the model number and serial number if app
90. on to a minimum the instructions in this chapter assume you re already in Edit Mode Instructions on entering Edit Mode can be found in the View and Edit Modes section found on page 54 If passwords are enabled you must enter the Master or Set Up password in order to program any of the parameters covered in this chapter Personnel with the Operator level password cannot program these param eters For the most part entering data on these screens is fairly intuitive Numeric data is entered with the 0 through 9 keys and the values for non numeric data are cycled through with the SELECT key In either case you must press ENTER before new data is accepted The right gt and left 4 arrow keys are used to move the blinking cursor to the next or previous fields on the screen Use these keys to skip over a field if you don t intend to change its value You can also use these keys to switch between screens if you are on the first or last field on the display The PREVIOUS NEXT key can be used to cycle through the eight limit switches When you use this key the cursor automatically moves to the LS Number field on the display The up A and down W arrow keys can also be used to cycle through the eight limit switches Where as the PREVIOUS NEXT key always moves the cursor to the LS Number field of the screen the up and down arrow keys keep you on the same field if the new limit switch is being used If itis unprogrammed the curso
91. one that needs to know how to use the EASYPack Genesis while run ning the machine The chapter includes information on monitoring I O status and error messages you may encounter ADVANCED MICRO CONTROLS INC _ INTRODUCING THE EASYPACK GENESIS This chapter is written for anyone that wants to familiarize themselves with the features of the EASY Pack Genesis the type of applications it was designed for and other products available from you ll need to complete your system Overview The EASYPack Genesis part number is GN3B1 01B 10 is k latest addition to our growing line of standalone programmable limit Easy Pac switch controllers for packaging applications It s a self contained GENESIS unit that accepts a brushless resolver for position feedback and pro vides eight solid state relay outputs and five opto isolated DC inputs on its rear panel This unit is ideally suited for all limit switch applications that require eight or fewer outputs Its small size makes it easy to integrate into packaging machines that don t have a large amount of panel space while its built in display and keypad makes it very simple to setup and operate Typical packaging applications include gt Vertical Form Fill amp Seal Figure 1 1 GN3B1 01B 10 PLS Controller gt Glue Gun Control gt Labelers gt Shrink Wrap machines Limit switches can be programmed to operate in one of two wa
92. only The EASYPack Genesis can store up to 35 programs You can assign any number from 0 to 99 to the pro grams and they do not need to be consecutive Figure 7 5 shows the Program Select Screen with only one program available When you first enter the screen the word SELECT will be blinking Press SELECT to cycle through the values for this field and press ENTER to select the operation you want to perform gt SELECT Changes the running program gt NEW Creates a new program that has all parameter values set to their defaults gt SAVE AS Creates a copy of the current running program gt DELETE Deletes a program The program you select to delete cannot be the current running program After you press ENTER the cursor switches to the program number on the top line Use keys 0 through 9 to enter the correct or new program number If you make a mistake when entering a program number the unit flashes an error message on the bottom line A complete alphabetical list of programming error messages is table 7 3 Programming Error Messages found on the next page gt SELECT The program number you enter must already exist Once its entered the program number on the bottom line of the display 1 in the figure above will change to the new program gt NEW The program number you add must not already exist When created the number of the new pro gram appears on the display unless you already have fourt
93. onmental specifications of the unit as well as the specifications of the compatible AMCI trans ducers and output relays This chapter concludes with descriptions of the programmable parameters their defaults and range of values System Location NEMA 12 enclosure recommended NEMA Rating Front panel is washdown tight NEMA 4 when properly mounted The rest of the unit is NEMA 1 Required Panel Space Front panel dimensions are 5 00 square Behind the panel unit requires a clearance area of 6 00 square to a minimum depth of 4 00 for installation and removal of connectors and output relays Power Requirements 18 to 30Vde 10 watts 24Vdc 400 mA nominal Compatible Transducers Any AMCI single resolver transducer Position Resolution Programmable from 2 to 1 000 counts per turn Position can be preset to any value within its range from the keyboard Tachometer Range 0 to 2 000 RPM Speed value can be scaled to any other engineering unit such as boxes per minute inches per minute etc Limit Switch Update Time 100 microseconds Limit Switch On Off Resolution 1 part in 1 000 counts per turn 0 36 indepen dent of programmed position resolution Program Input Built in keyboard and display Program Storage EEPROM memory 100 000 write cycles mini mum Number of Available Programs Recipes 35 Number of available programs is indepen dent of the size of the programs Available Output Type Position on Pos
94. or Negative High Resistance Lower surge current through relay contacts Low Capacitance to charge capacitor Positive Table 5 1 R C Network Trade offs In general capacitor values range from 0 1 to 1 0 uF and resistor values range from 150 to 680 ohms Higher transient voltage spike Negative The easiest way to specify a R C network is by following the recommendations of the load s manufacturer Most manufacturers have tested and specify standard R C networks and many sell networks that are designed to integrate with their products If you cannot get help from your load s manufacturer feel free to contact AMCI for assistance 20 Gear Drive Plymouth Ind Park Terryville CT 06786 41 Tel 860 585 1254 Fax 860 584 1973 http www amci com GENERAL INSTALLATION GUIDELINES Grounding Proper grounding is the single most important consideration for a safe installation Proper grounding also ensures that unwanted electrical currents such as those induced by electromagnetic noise will be quickly shunted to ground instead of flowing throughout the machine gt All ground connections must be permanent and continuous to GROUND BUS provide a low impedance path to earth ground for induced MP did noise currents Enclosure and ALL of its Equipment gt The chassis of the EAS YPack Genesis must be connected to j chassis ground through its mounting in an enclosure and 55 with a groundin
95. other high power wiring STEP 4 Program Your EASYPack Genesis 4 1 If needed create a new program with the PRGSEL key 4 2 Program all of the needed parameters under the CONFIG key Use the NEXT key to cycle through the four configuration screens 4 3 Program the limit switch setpoints using the LIM SW key Use the four arrow keys to move between parameter values and limit switch numbers Each limit switch has four setpoint pairs Unused pairs are displayed as On 0 Off 0 It s possible to switch to the ON OFF Advances screen or ANDing screen with the left or right arrow keys If you do this use the other arrow key to switch back to the setpoint screens If you are not using the PLS Group Programming advanced feature leave the group number at its default of 1 4 4 If you are using the ON OFF Advances feature you can program them now with the ADVANCE key or later determine their values when the machine is being setup 4 5 If you are using the LS Enable ANDing or Motion ANDing advanced features program them using the ANDING key 4 6 If you are using the PLS Group advanced feature program their parameters using the GROUPS key STEP 5 Verify Your System Setup 5 1 Run your machine to verify basic operation STEP 6 Fine Tune Your Programming 6 1 The INC and DEC keys can be used to fine tune limit switch setpoints and advances while the machine is running 6 2 Changing all other parameter requires the ma
96. ounding and surge suppression If you are responsible for installing the EASYPack Genesis make sure you are familiar with these practices and follow them when installing the unit This chapter is presented as a tool in the hopes of avoiding common installation prob lems It is not a substitute for the safety practices called out in local electrical codes or in the United States the National Electrical Code published by the National Fire Protec tion Association If any conflicts exist local and national codes must be followed t is the responsibility of the user to determine what installation practices must be followed to conform to all local and national codes Background AMCI has extensively tested the EASYPack Genesis both in the lab and in the field under a wide range of conditions to see how the unit reacts to an adverse environment This includes testing the unit after intention ally installing it incorrectly The results of our testing is the following list of areas that must be addressed when engineering your system The order of the list shows the areas that have the largest impact on system operation first 1 Surge Suppression 2 Grounding 3 Wiring 4 Power Supply Wattage and Filtering This list also shows the first areas that should be investigated if your installation experiences problems Surge EMI Suppression NOTE gt All inductive devices in the system such as motors motor starters contactors relays and
97. ow power cabling such as communication cables and low power ac dc I O lines It cannot be installed in conduit with ac power lines or high power ac dc lines EASYPack GENESIS 2 The shield of the cable must be grounded at the unit only If you must splice the transducer cable it must be done in a 4 EQUIPMENT ENCLOSURE grounded junction box When splicing treat the shield as a signal carrying conductor Do not connect the shield to earth Mounted to Enclosure Door ground at the junction box or transducer Ideally the three shields in the cable are also kept isolated from each other in HIGH POWER CONDUIT the junction box as well AC DC Output and Power Cabling gt Input Cabling Low Power DC amp AC Figure 5 4 Typical Enclosure 1 The Group Inputs are low power DC inputs and cabling from the sensor to the input must be shielded Follow the two guidelines given above for Transducer Cabling DC Input cabling and the transducer cable can be installed in the same conduit 2 The LS Enable Input can be powered with 120 Vac or 12 24Vdc Follow the two guidelines given above for Transducer Cabling If it s AC powered it must without exception be shielded 42 ADVANCED MICRO CONTROLS INC GENERAL INSTALLATION GUIDELINES Wiring continued gt Output Wiring High Power AC amp DC 1 Output Wiring must be kept separate from the transducer and input wiring in order to lessen the possibility
98. parameter sets the direction the transducer shaft must rotate in order to produce increas ing counts The default is CW which means that the position count will increase if the transducer shaft is rotating clockwise when looking at the shaft This parameter accurately reflects the count direction if the cable is wired to the CI TG x Wiring Diagram found on page 49 of this manual NOTE gt It is possible to reverse count direction by reversing the connections of the green black pair in the transducer cable 20 Gear Drive Plymouth Ind Park Terryville CT 06786 27 Tel 860 585 1254 Fax 860 584 1973 http www amci com m SPECIFICATIONS Transducer Setup Parameters continued Rate Multiplier Divisor and Decimal Point These parameters are available on Configuration Screen 3 The default value for all three parameters is 1 Their ranges are given below These three parameters allow you to scale the machine speed reported by the EAS YPack Genesis When they are left at their defaults of 1 the Genesis reports the machine speed in RPM By programming these parame ters you can have the machine speed value scaled to boxes per minute inches per minute or any other mean ingful value The EAS YPack Genesis reports the machine speed based on the following formula Speed RPM MULTIPLIER MACHINE SPEED RATE DIVISOR RATE DECIMAL POINT The ranges of the three parameters are gt Rate Multiplier 1 to 1 10
99. parameters to their default values This includes erasing all limit switch programming data Machine Preset Value 27 Entering this parameter works differently then all others It s set with the numeric keys but when ENTER is pressed the EASYPack Genesis asks you for confirmation If you want to preset the Machine Position sim ply press ENTER If you made an error and don t want to preset the Machine Position then press SELECT to change the display to NO and then ENTER Count Direction 27 The Count Direction value is cycled between clockwise CW and counter clockwise CCW with the SELECT key Rate Value 26 The Rate Value field is cycled through its four values of RPM IPM CPM and BPM with the SELECT key 20 Gear Drive Plymouth Ind Park Terryville CT 06786 59 Tel 860 585 1254 Fax 860 584 1973 http www amci com a CONFIGURATION PROGRAMMING The Configuration 2 Screen The Configuration 2 Screen is shown in figure 8 2 Access this screen by press CONFI GURE 2 OF 4 ing CONFIG followed by NEXT From this screen you can program the Motion de AO m Detector Low and High Setpoint and Toggle Speed parameters SPEED 0 EDIT 6 In the following list the number in parentheses immediately after the parameter Figure 8 2 Configuration 2 name is the page in the Specifications chapter that decribes the parameter Motion Detector Low Se
100. peed starting on page 28 The default value of 0 disables this feature The range of this parameter is 0 to 2 000 Summary Table Parameter Default Password Enable Disabled Disabled Enabled Operator Password 1111 0000 to 9999 Setup Password 2222 0000 to 9999 Master Password 1234 0000 to 9999 Rate Value RPM RPM IPM CPM BPM Toggle Speed 0 0 to 2 000 Table 4 3 Password and Display Parameters ADVANCED MICRO CONTROLS INC _ 26 SPECIFICATIONS Ei Transducer Setup Parameters The Transducer Setup Parameters define the Machine Position and Machine Speed These two values are used by the limit switches to determine their on off state All Transducer Setup Parameters are found under the Configuration Screens Access these screen with CONFIG key and cycle through them with the PREVIOUS NEXT key Scale Factor This parameter is found on Configuration Screen 1 Its range is 2 to 1 000 and defaults to 360 This parameter allows you to program the position resolution of the transducer by setting the number of counts per turn Setting the Scale Factor to 360 yields one count per degree of rotation The Machine Posi tion is defined by the Scale Factor and the Machine Preset Value see below The position data ranges from 000 to Scale Factor 1 A well thought out Scale Factor value can greatly simplify the rest of your programming For example consider a machine that moves product along at 7 750 i
101. pts 1 or 2 resolver inputs and conditions its outputs Module to fire only when an input is active NX3BIC ControlNet 8513 functionality in a din rail mounted product with a ControlNet interface NX3AIP ProfiBus NX3BIC with Profibus interface instead of ControlNet NX3AIEB Ethernet IP NX3BIC with Ethernet interface instead of ControlNet Table 1 3 EASYPack Family Members Other Products From AMCI AMCI has been serving the industrial automation sector since 1985 and we have a broad range of other prod ucts that are used in the packaging machine market DURACODERS Absolute Analog or Incremental encoders that replace the fragile glass disk and sen sitive optics with an industrial resolver The size 25 DuraCoders are drop in replacements for similar sized optical encoders STEPPER MOTION Our line of stepper products that includes motors drives and indexers Stepper motor systems offer low cost motion control for many packaging machines gt PLC PLUG IN MODULES AMCI offers a broad range of PLC plug in modules for most major PLC brands including A B ControlLogix SLC500 and 1771 I O GE Fanuc 90 70 and 90 30 and Modicon Quantum Modules include resolver LDT and SSI interfaces programmable limit switches and regis tration control modules RESOLVER TRANSDUCERS AMCTis the only company in the market place to manufacturer its own resolvers Not only do we make the resolvers for our own products we also produc
102. put found on page 65 PLS Group Number When you program the Limit Switch Type to Normal or Timed the cursor jumps to the PLS Group Number field NOTE 5 1 If you are not using the advanced PLS Group Programming feature leave this field at its default value of 1 2 If you are using the advanced PLS Group Programming feature then set this field with the numeric keys to assign the limit to the proper group The field can be set to any value from one to four LS ON OFF Setpoint Pairs p 31 ON and OFF Setpoints can be set to any value between zero and Scale Factor 1 The next field on the screen is the LS ON Setpoint It can be changed by entering a new value with the numeric keys and pressing ENTER or using the INC and DEC keys If you increment or decrement the field the parameter is updated every time a key is pressed so there s no need to press the ENTER key Once you ve set the ON Setpoint the next field is the dash between the ON and OFF setpoints With the cur sor here pressing the INC or DEC keys changes the ON and OFF setpoints together This shifts where the output turns on and off but keeps the size of the window the same gt To skip this field just press gt or ENTER The OFF Setpoint is set in the same manner as the ON Setpoint using the numeric keys and pressing ENTER or the INC and DEC keys If you are using only one setpoint pair for the limit you can use the PREVIOUS NEXT
103. r jumps to the LS Number field If you encounter an error message while going through these instructions and you can t figure out why refer to table 7 3 Programming Error Messages found on page 57 for an alphabetical list of all programming error messages and their causes Programming a Timed Limit Switch Output For the most part programming a Timed limit switch is identical to programming a Normal limit switch The only difference is the number of ON OFF Setpoint pairs available While a Normal limit switch has four pairs a Timed limit switch only has one Programming the setpoint pair is covered in the The LS Setpoint Screen starting on page 61 Set the Limit Switch Type field to Once you have the setpoint pair programmed press TIMED to switch to the LS CH TIMED OUTPUT Timed Output Screen You will have to switch to the correct limit switch number i DURATI ON by using the PREVIOUS NEXT A or W keys to cycle through the limit re UN switches You can also jump to a specific output by keying in the number 1 through 8 and pressing ENTER Figure 10 1 LS Timed Output If the output is programmed as a Normal limit switch then the second line of the display will only show the LS Number field If the output is programmed as a Timed limit switch the display will be similar to figure 10 1 Once you enter the LS Number the cursor moves to the Time Out field Enter the value of the Time Out parameter wi
104. s R C networks for all AC applications A varistor is a solid state device that turns on and conducts when the voltage across its terminals exceeds its rated value Herein lies the problem with using a varistor as an AC suppressor The voltage problem must be generated before the varistor responds In our testing we have found that hard contacts will still arc when a varistor is placed across the AC load This arcing is due to the fact that the breakdown voltage of the air between the contacts when they first open can be less than the rated voltage of the varistor If the instanta neous AC voltage applied to the contacts is above the breakdown voltage of air but less than the rated voltage of the varistor the contacts will arc On the other hand an R C network acts as a low pass filter instantaneously dampening fast transients when they occur The main drawback of R C networks is that they are harder to correctly specify than varistors Varistors only require you to specify breakdown voltage and power dissipation ratings R C networks require you to balance the need of suppression when the contacts open against the amount of surge current the relay can tolerate when the contacts close Table 5 1 shows the trade offs you must be aware of when specifying R C networks When Contacts Close When Contacts Open Low Resistance Higher surge current through relay contacts ower transient voltage spike Positive High Capacitance to charge capacit
105. se these keys to skip over a field if you don t intend to change its value You can also use these keys to switch between screens if you are on the first or last field on the display The PREVIOUS NEXT key can be used to cycle through the eight limit switches When you use this key the cursor automatically moves to the LS Number field on the display The up A and down W arrow keys can also be used to cycle through the eight limit switches Where as the PREVIOUS NEXT key always moves the cursor to the LS Number field of the screen the up and down arrow keys keep you on the same field if the new limit switch is being used If it is unprogrammed the cursor jumps to the LS Number field If you encounter an error message while going through these instructions and you can t figure out why refer to table 7 3 Programming Error Messages found on page 57 for an alphabetical list of all programming error messages and their causes The LS Setpoint Screen The LS Setpoint Screen is shown in figure 9 1 Access this screen by pressing CH GROUP ON1 OFF1 LIM SW From this screen you can program the Limit Switch Type and LS ON RE 0 0 OFF Setpoints for each of the eight outputs If you are using PLS Group func M tionality you also assign each limit switch to a Group from this screen Figure 9 1 LS Setpoint Note that all of the data is entered on line 2 On this screen line 3 of the display shows the mode and
106. see the screen shown on the right This screen doesn t TT show the status of the inputs but instead shows whether or not the limit switch 1 OFF OFF is affected by the input Right now limit switch 1 is not tied to either of the ST e ANDing inputs Press gt twice to move the cursor to the LS Enable field Press SELECT to change its value to ON and press ENTER The display changes to the LS Setpoint Screen NOTE 5 When you re on the last field of the screen and press ENTER the display automatically switches to the next screen It may seem confusing now but it makes data entry much faster when you start entering a full program With the LS Enable input now tied to LS1 the limit switch will not be on unless the input is powered Switch to the Status Screen with the STATUS key and look at the state of output 1 Toggle power to the LS Enable input and note that the output is off unless the LS Enable input is powered This is not to say the output is on whenever the input is powered With the limit switch programmed to be on between the positions of 30 and 70 the output will only be on when the position is between these two values and the LS Enable input is active PLS Group Programming So far the manual has only told you two things about PLS Groups 1 They allow you to group together limit switches and condition them with specific functions useful in packaging applications 2 If you re using the EASYPac
107. sole noids must have surge suppression devices installed across their coils This includes all devices that share a power supply with the EASY Pack Genesis have wiring in the unit s enclosure or wiring that is run in the same conduit as wiring connected to the unit DC loads are typically suppressed with a flyback diode while AC loads are typically suppressed with a RC network or varistor gt RC Networks are the preferred suppressor for AC loads 20 Gear Drive Plymouth Ind Park Terryville CT 06786 39 Tel 860 585 1254 Fax 860 584 1973 http www amci com GENERAL INSTALLATION GUIDELINES Surge EMI Suppression continued The figure below show where surge suppression devices should be placed in the circuit Acceptable Connection inductive acceptable connection supresses noise at its source The Powerin ES Output Device wiring that connects the load to the power supply and contacts n o will not radiate noise when the load is switched and noise will Suppressor not be coupled into the power supply Power Return Un Acceptable Connection 1 Inductive This connection protects the power supply and LS output but Powerin E Output TYL Device allows noise to radiate through the load s wiring where it can n o be coupled into other cables around it Suppressor Power Return PE Inductive This connection protects the power supply but nothing else po
108. t If a system sup ply is used this supply must not be used to switch large inductive loads such as relays or sole noids without proper surge suppression devices installed on these loads See Surge EMI Suppression on page 39 for additional information on installing surge suppression devices Some customers have contacted us to request a power supply recommendation We re hesitant to make such a recommendation because there are many reputable power supply vendors and we don t want to imply that a specific supply must be used with our products With that said AMCI has used the SOLA SDN 5 24 100 power supply in most of its testing It is a small DIN rail mountable 24Vdc 5A supply Panel Cutout for the EASYPack Genesis The EAS YPack Genesis is designed to be mounted on a panel or the door of an enclosure Figure 6 1 shows the required panel cutout to mount the unit gt Maximum panel thickness is 0 150 inches gt Behind the panel the unit requires a clearance area of 6 00 square to a minimum depth of 4 00 for installation and removal of connectors and output relays gt All edges must be deburred before installing the unit 4 500 2 250 9 4 188 E ENLIA 0 125 max radius 4 Places Outline of EASYPack Genesis 6 0 square area needed to a depth of 4 0 for installation and removal of relays and con
109. te For the latest information on all of our products browse through our website www amci com Model Interface Number Type Description 16 output EASYPack Genesis Nearly identical to the 8 output EASYPack Standalone Genesis described in this manual the 16 output version also includes 2 veloc ity based analog outputs and a 256 bit shift register SLC 500 The same functionality as the 8 output EASYPack Genesis in a plug in module Module for the A B SLC 500 controller The 8511 has 16 limit switch outputs that are available to the processor over the backplane The same functionality as the 8 output EASYPack Genesis in a plug in module SLC 500 for the A B SLC 500 controller The 8512 has 16 limit switch outputs which Module are available over the backplane and 8 available off a relay board attached to its front panel The same functionality as the 8 output EASYPack Genesis in a plug in module 8513 SLC 500 for tne A B SLC 500 controller The 8513 has 16 limit switch outputs avail Module able over the backplane and 16 available off a relay board attached to its front panel Two velocity based analog outputs are also available 8523 SLC 500 The same functionality as the 8513 but it uses a quadrature encoder for posi Module tion feedback instead of a resolver 8213 ControlLogix A plug in module for the ControlLogix backplane with the same functionality Module as the 8513 2742 18 1771 I O This eight output PLS acce
110. ten years This is our vendor s specification and it is actually based on such things as environmental temperature amount of time the unit is powered etc BATTERY RAM FAULT Figure 11 5 nvRAM Error This error is cleared with the CLEAR key A working transducer must be attached before the error can be cleared This error occurs for one of three reasons 1 The battery is dead If this message occurs on every power up then a dead battery is the most likely cause Contact AMCI for assistance 2 There was an inadvertent power outage while the unit was storing information It only takes a few microseconds to update the information in the nvRAM but the error can occur in this way 3 A very large burst of electrical noise occurred near the unit or was coupled into it through the transducer or I O wiring The most common cause of this fault is actually number three because of problems with grounding and surge suppression This fault screen is one that you should hardly ever see so if you see it on a regular basis con sider it a symptom of a problem with the machine that must be addressed 20 Gear Drive Plymouth Ind Park Terryville CT 06786 69 Tel 860 585 1254 Fax 860 584 1973 http www amci com ADVANCED MICRO CONTROLS INC 20 GEAR DRIVE TERRYVILLE CT 06786 T 860 585 1254 F 860 584 1973 WWW AMCI COM LEADERS IN ADVANCED CONTROL PRODUCTS
111. ters that set the Mode and other values for each of the four groups Password and Display Parameters All of the password and display parameters are available under the Configuration Screens These screens are accessed with CONFIG key and cycled through with the PREVIOUS NEXT key Password Enable This parameter is found on Configuration Screen 4 which is only displayed under the following conditions gt Passwords are disabled and the unit is in Edit Mode gt Passwords are enabled and the user has entered the Master level password to enter Edit Mode This parameter globally enables or disables the three passwords available on the EASYPack Genesis By default the passwords are disabled Operator Set Up amp Master Passwords These parameters are found on Configuration Screen 4 which is only displayed under the following condi tions gt Passwords are disabled and the unit is in Edit Mode gt Passwords are enabled and the user has entered the Master level password to enter Edit Mode When passwords are enabled the EASY Pack Genesis has three levels of password access Passwords are four digits long and range from 0000 to 9999 They have the defaults listed below which should be changed if they are used gt Operator Default 1111 Operators can select the running program and fine tune limit switch set points with the increment decrement function SetUp Default 2222 Set up personnel have all of the access rig
112. th the numeric keys and press ENTER The range of values is 0 to 9 999 milliseconds When you do the display switches to the LS Setpoint Screen 20 Gear Drive Plymouth Ind Park Terryville CT 06786 65 Tel 860 585 1254 Fax 860 584 1973 http www amci com 10 ADVANCED LS PROGRAMMING LS ANDing Screen If you have decided to use the state of the Motion Detector and or the LS Enable FI Input to condition the state of your limit switches the LS ANDing Screen is 1 OFF OFF MODE 0 GROUP POS 89 where you associate the inputs with the outputs Figure 10 2 shows the default EDIT 1 P 89 RPM 0 screen for output 1 Figure 10 2 LS ANDing Once you call up the screen you may have to switch to the correct limit switch number Do this with the PREVIOUS NEXT A or W keys to cycle through the limit switches or jump to a specific output by keying in the number 1 through 8 and pressing ENTER LS Motion ANDing p 33 When you enter a LS Number the cursor jumps to the LS Motion ANDing field This parameter is cycled between OFF and ON with the SELECT key Once you set its state press ENTER to accept the value Enable ANDing p 33 After you enter a value for the LS Motion ANDing parameter the cursor moves to the Enable ANDing field You can also use the right left arrow keys to move to the cursor This parameter is cycled between OFF and ON with the SELECT key Once you set its state press ENTER to accept the
113. the Optocoupler CHASSIS pin of the connector DO NOT ground both ends of the shield Figure 6 12 LS Enable Input Schematic Output Wiring You have a choice between AC or DC outputs when ordering the solid state relays for the EAS YPack Genesis Relay specifications can be found on page 24 in the section Single Turn Transducer Specifications Figure 6 9 I O Connector Placement found on page 50 shows the placement of the relays and the pinout of the out put connectors The connectors are also labeled on the unit When installing the cabling for the outputs all local and national codes must be followed Additionally gt Keep as much physical space as possible between output wiring and input wiring within the enclosure gt Do not place output wiring in a conduit with input wiring If you are using inputs you should have at least two conduits connected to the enclosure One conduit for the inputs and a second for power and the outputs Of course additional conduits may be necessary for your application Finally all inductive loads on the machine require surge suppressors especially those that are switched with mechanical relays Refer to Surge EMI Suppression starting on page 39 for additional information ADVANCED MICRO CONTROLS INC 825 PROGRAMMING OVERVIEW This chapter covers 1 How to use the keyboard to navigate the screens available on the EASYPack Genesis 2 How to switch between Vi
114. tion off gt Timed limit switch Position on Position or time off ADVANCED MICRO CONTROLS INC SYSTEM CHECKOUT Programming a Limit Switch continued When the display shows press ENTER The display changes tothe one on the right 1 1 4 0 0 MODE 0 GROUP POS 89 Now the PLS Group Number is blinking PLS Group Programming is an EDIT 2 P 89 RPM 0 advanced feature that we re not going to use right now If you re using the EASYPack Genesis as a basic limit switch you probably won t be using it either In a nutshell PLS Group Programming lets you combine limit switch outputs into groups and then further condition their outputs with additional logic For now we ll just leave all of the limit switches in Group 1 Note on the third line MODE 0 This is the value of the Group Mode parameter for Group 1 Mode 0 does not apply any addi tional logic to the group and the outputs fire based only on their on off setpoints Press the gt key to move to the first setpoint Enter a value of 30 by pressing CH GROUP FROM1 TO1 3 0 ENTER The cursor is now on the dash between the On and Off Set i qp o 30 70 points With the cursor at this position you can use INC and DEC to change T LM E the value of both setpoints which changes where the output fires but not the size of its on window For now press ENTER to move to the second setpoint When you press 7 0 the display w
115. tpoint p 28 Entered with the numeric keys this parameter can be programmed to any value between 0 and 2 000 Motion Detector High Setpoint 28 Entered with the numeric keys this parameter can be programmed to any value between 0 and 2 000 NOTE 5 if the Low Setpoint is less than the High Setpoint the output of the Motion Detector will be on between the setpoint speeds If the Low Setpoint is greater than the High Setpoint the output of the Motion Detector is off between the two setpoints If the setpoints are equal the Motion Detector will never be on The state of the Motion Detector is important if you are using the Motion ANDing feature of the EASY Pack Genesis Toggle Speed p 26 Entered with the numeric keys this parameter can be programmed to any value between 0 and 2 000 The Configuration 3 Screen The Configuration 3 Screen is shown in figure 8 3 Access this screen by press CONFI GURE 3 OF 4 ing CONFIG followed by pressing NEXT twice From this screen you can pro Dy a gram the Rate Multiplier Divisor and Decimal Point parameters ae a RPM 1 0 In the following list the number in parentheses immediately after the parameter name is the page in the Specifications chapter that decribes the parameter Figure 8 3 Configuration 3 Rate Multiplier p 28 Entered with the numeric keys this parameter can be programmed to any value between 1 and 1 100 Rate Divisor 28
116. tpoints between zero and Scale Factor 1 The Scale Factor parameter is described on page 27 gt Normal Limit Switches have four setpoint pairs They can be programmed to turn on and off up to four times per turn gt Timed Limit Switches have one setpoint pair and a Time Out value The Time Out value has a default of zero milliseconds a range of zero to 9 999 milliseconds and a resolution of one millisecond LS ON OFF Advances These parameters are available on the LS Advances Screen They default to zero have a range of 0 to 999 milliseconds and a resolution of one millisecond Limit Switch ON OFF Advances compensate for fixed delays in the system by turning the outputs on or off in advance of their programmed setpoints as a function of shaft speed An example on the following page shows how ON OFF Advances are used ON OFF Advances are programmed in milliseconds With the default value of zero milliseconds the limits turn on and off based solely on shaft position Each limit switch has a separate ON Advance and OFF advance Two advances are available for those cases when a load takes a different amount of time to activate than to deactivate AMCI is aware of some companies that use two values to specify their speed compensation values These two values are typically called something similar to Lead Speed and Lead Distance Their controllers use the ratio of these values Lead Distance Lead Speed to determine the amount of
117. vered in this chap ter For the most part entering data on these screens is fairly intuitive Numeric data is entered with the 0 through 9 keys and the values for non numeric data are cycled through with the SELECT key In either case you must press ENTER before new data is accepted The right gt and left 4 arrow keys are used to move the blinking cursor to the next or previous fields on the screen Use these keys to skip over a field if you don t intend to change its value If you encounter an error message while going through these instructions and you cannot figure out why refer to table 7 3 Programming Error Messages found on page 57 for an alphabetical list of all programming error messages and their causes The Configuration 1 Screen The Configuration 1 Screen is shown in figure 8 1 You access this screen by CONFI GURE 1 OF 4 pressing CONFIG From this screen you can program the Scale Factor Count spy 900 PRESET Direction and Rate Value parameters as well as preset the Machine Position EU ur E ig E n a In the following list the number in parentheses immediately after the parameter name is the page in the Specifications chapter that describes the parameter Figure 8 1 Configuration 1 Scale Factor p 27 Entered with the numeric keys this parameter sets the number of counts per turn and can be programmed to any value between 2 and 1 000 NOTE gt Programming the Scale Factor resets all other
118. w both of the limit switches should be on Press the STATUS key to verify this As a final step press MAIN to bring up the main display screen again It should be the same as the one on the right 61 POS 60 You ll notice it has changed a little since we started the system checkout Line two now contains G1 POS 60 This is the Group 1 Position value If you re using the EAS YPack Genesis as a basic limit switch without the PLS Group Programming feature you can safely ignore this value it should always be the same as the machine position shown on the top line If you are using PLS Group Programming each group that has at least one limit switch assigned to it will have its position shown on the display The EAS YPack Genesis has the ability to offset the group positions from each other so they may be different from the machine position shown on the top line and from each other NOTE 5 if you do not press a key for ten minutes the EAS YPack Genesis switches to the main display and enters View Mode The rest of this chapter introduces some EASYPack Genesis Advanced features specifically LS Enable ANDing and Group Modes If you re not interested in these features you can stop the system checkout now Wiring the Inputs In order to continue the system checkout you ll have to wire up two inputs as shown in figure 3 3 One is the LS Enable input and the other is the input for Group 2 Turn off power before wiring th
119. you change a parameter value and then switch to another parameter without press ing ENTER the new setting will not be stored and the parameter will revert back to its original value The PREVIOUS NEXT key is used to cycle through the limit switch numbers or the four Configuration Screens 20 Gear Drive Plymouth Ind Park Terryville CT 06786 53 Tel 860 585 1254 Fax 860 584 1973 http www amci com Br PROGRAMMING OVERVIEW Using the Display and Keyboard continued The INC and DEC keys are used to fine tune limits by adjusting one or both setpoints one count at a time or by adjusting the advances one millisecond at a time The EDIT and VIEW keys are used to switch between the unit s two operating modes When the transducer is rotating the EASYPack Genesis automatically switches to View Mode Available Data Screens Table 7 1 lists the data screens available on the eight output EAS YPack Genesis and the keys used to access them A brief description of common usage is also given Screen Name Access Key Description Program Select PRGSEL Used to select the running program or create copy or delete them Used to program the Limit Switch Type assign the limit to a group LS Setpoint LIM SW and program its ON OFF Setpoints You can also fine tune setpoints while the machine is running using the INC and DEC keys Used to program the ON OFF Advances for the limit switch outputs LS Advances ADVANCE
120. you cycle through them with the PREVIOUS NEXT key The first three Configuration Screens configure the posi tion and tachometer data calculated from the resolver transducer Scale Factor Count Direction Motion Detector and Rate Multipliers are examples of these parameters The fourth Configuration Screen is for passwords From this screen you enable or disable the three different passwords as well as set their actual values Right now the Scale Factor value is blinking but we don t want to change the number of counts per turn so press gt to move to the PRESET field 20 Gear Drive Plymouth Ind Park Terryville CT 06786 19 Tel 860 585 1254 Fax 860 584 1973 http www amci com EH SYSTEM CHECKOUT Presetting the Position continued NOTE Get in the habit of using the 4 and gt keys to switch between fields on the display Using ENTER can cause problems For example if you want to change the Count Direction DI R value and you press ENTER right now you ll get there but you ll also preset your position value to zero Try it if you want and then press lt to get back to the Preset field Preset the position to 60 by pressing 6 0 ENTER Three things happen when you press ENTER 1 The cursor moves to the Count Direction field 2 The Preset field goes back to its default value of zero 3 As shown on the last line of the display your position value changes to 60 P 60 Right no
121. ys gt Position on position off Equivalent to mechanical cams gt Position on position off OR time off Similar to timer relays In addition to having two types of limit switch outputs the EAS YPack Genesis also includes gt Automatic Advances that allow you to compensate for fixed delays in your system as your line speed changes By programming in the fixed delays of each output load the unit automatically adjusts when outputs fire A typical use of Automatic Advances is glue gun control which keeps the placement of glue consistent as line speed changes gt Motion Detector that functions as a speed based limit switch The state of the Motion Detector can be ANDed with any of the limit switches so their outputs only fire when the machine is running at the desired speeds gt LS Enable input is an AC DC input Any of the limit switches can be ANDed with this input When associated with this input the limit switches only fire when the input is active The features listed above make the EAS YPack Genesis a programmable limit switch that is capable of han dling many applications but the unit s most powerful feature is PLS Group Programming PLS Group Programming PLS Group Programming allows you to group together limit switches and condition them with one of five predefined logical functions These logical functions are called Modes and each Mode is designed to per form a specific function useful in packaging applications su

8 Output EASYPack Genesis - Advanced Micro Controls Inc

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