M1250, M1450, AND ™ M1451 MINI•PLS u40 Channels in 6.25" x 4.5" x 7.25" compact enclosure u57-85 µs scan time assures high repeatability (M1250) uProgrammable Rate Offset (ROF) for automatic speed compensation (M1450) uDynamic Zeroing—ModZ—to modify the zero point for selected channels (M1450) uEEPROM transportable plug-in output modules make maintenance easy uOptically isolated power or logic outputs uAuto-Zero for zero offset uRugged reliable resolver or ultrasonic linear transducer input uOptional broken-wire detector uPatented + and - keys allow fine-tuning the uOptional serial RS-232C or RS-422A communication setpoints in motion uMulti-Turn available uBuilt-in tachometer and motion detector uBrake Monitor option (M1451) uProgrammable scale factor; resolution up to 4,096 counts-per-turn THE MINI•PLS The MINI•PLS, models M1250, M1450 and M1451, are the signal. This position signal is converted to digital format in the fastest and most versatile PLS family in the market. We call it programmable unit, displayed on the front panel and compared Mini because of the small compact size, but it is big in per- to the dwell setpoints programmed into the PLS. When process formance. cycle reaches these setpoints, outputs are enabled or disabled, starting or stopping desired functions during the cycle. In fact, MINI•PLS is three controls in one: Programmable Limit Switch, Tachometer, and Motion Detector. The power- ABSOLUTE ENCODER ful microprocessor and the revolutionary design make MINI•PLS an extremely compact, fast and versatile solid-state Absolute Positioning With Programmable replacement of electromechanical cam switches. Scale Factor The high accuracy, reliability, operating speed and convenience The resolver as well as the ultrasonic linear transducer provide of operation assure greater efficiencies in manufacturing, help- absolute positioning, that is, the MINI•PLS always gives ing to increase production and reduce cost. TRUE position even upon machine movement after power outage. Further, a programmable scale factor up to 4,095 (res- Principal of Operation olution of 4,096 per turn) is provided to meet the required The MINI•PLS consists of two parts, one being a position system resolution or for direct readout in engineering units. transducer mounted on the machine and the other a program- For linear transducer systems the resolution is predefined as mable unit mounted in the machine control panel. The posi- 1,000 counts-per-inch. tion transducer in this case can be a resolver or an ultrasonic linear transducer, which produces a rotary or linear position 800-TEC-ENGR Programmable Limit Switches D-24 www.avg.net Keyboard Programming Program Stored in Transportable Plug-in Modules The MINI•PLS is fully front panel programmable with con- venient tactile keyboard and yet secure against any unautho- The program setpoints are stored directly in the cam modules rized program changes. Opening of an external user provided in nonvolatile EEROM memory. The information is retained keyswitch inhibits any program changes on the front panel. without power, even when the modules are taken away from the MINI•PLS. This unique feature of program storage in the cam module permits programming of various modules for dif- RUGGED AND RELIABLE ferent jobs or spares, reducing downtime and eliminating eventual errors due to hurried reprogramming at job changes. Single or Multi-turn Resolver or Ultrasonic Also, the cam modules can be programmed at a central place, Linear Transducer Input such as corporate headquarters, and distributed to various The MINI•PLS combines the ruggedness of a brushless plant locations. resolver or noncontacting ultrasonic linear transducer and the reliability of an advanced solid-state control. The rugged, heavy-duty NEMA 13 (IP54) single- or multi-turn resolver can be mounted on a machine in any hostile environment; such as mechanical shock, vibrations, extreme humidity and temperature changes, oil mists, coolants, solvents etc. The pro- grammable control unit can be mounted up to 2500 feet (1000 feet for linear transducer) away in a control panel. The splash-proof oil-tight front plate permits the unit to be installed directly on the machine itself, if so required. The ratiometric converter assures high tracking speed of 1800 rpm and high noise immunity. Modular, Easy to Service Modular 40 Channels in 6.25" x 4.5" x 7.25" compact enclo- sure. The ultra-modern technology used by Autotech has made it possible to house 40 channels in such a small space saving Variety of Plug-In Output Modules enclosure. The system flexibility is further enhanced by the The plug-in cam modules are optically isolated and are avail- modular construction. The unit can be expanded up to 40 able with TTL, PNP or NPN type of logic level outputs. The channels using five modules of eight channels each. A cam sub D connector style on these modules with preassembled module with desired logic level or power outputs or a separate cable assembly eliminates all field wiring and the related even- chassis with plug-in power relay outputs can be selected to tual wiring errors. Power cam modules are also available with match the application. Parallel BCD position and tach output AC (120 VAC @ 1 A) or DC (10-28 VDC @ 1 A) ratings. modules can be inserted in slots 4 or 5. This modular concept Optional electromechanical relays (10 A) and solid-state AC (3 also permits an easy adoption in field to the future technologi- A) or DC (3 A) relays are mounted on a separate chassis. All cal developments by simply adding new modules to the same these relays are plug-in type for easy field replacement. The basic unit. solid-state relays are optically isolated. Optional parallel BCD position and tach output modules with built-in PC-handshake EEROM TRANSPORTABLE MODULES as well as analog position/tach output modules are available for remote readouts or control devices. No Batteries, Nonvolatile EEROM Memory The scale factor, offset, dwell, and motion detector setpoints are all stored in nonvolatile EEROM memory as they are entered by the user. The information is retained indefinitely after power loss or machine shutdown, eliminating need for back-up batteries and related hazards. 800-TEC-ENGR Programmable Limit Switches D-25 www.avg.net SECTION D Versatile Offset Program Duplication at the Touch of a Button An extremely versatile full-scale programmable offset elimi- When various modules need to be programmed identical, use nates all calculations on the part of the operator, while match- of program duplication key saves time and avoids errors by ing resolver zero to machine zero or while compensating for making fast copies of the original program. Just enter the machine wear and speed changes. After the resolver is mount- ORIGIN slot number, select the COPY slot, press the DUP ed on the machine shaft, all you have to do is align the key, and the program is copied on the corresponding cam machine to a mechanical zero reference, e.g., Top Dead Center module. on a press, and Auto-Zero the MINI•PLS. The resolver offset Write Protect will automatically be calculated and programmed, so that the PNP and NPN type of Cam Modules are shipped with a fac- position display reads zero. If required, a machine offset other tory wired jumper, which enables the modules to receive any than zero can be programmed by direct numerical entry. To program. If Write Protection of the program is required after obtain a precise machine operation, the offset can also be fine- the machine is adequately set up, cutting the jumper will dis- tuned in motion by using + and - keys. able module programming. This feature is especially useful Multiple Setpoints (up to 500) On Each when some of the cam settings should not be accessible to the Channel unauthorized personnel and, once adjusted, need not be All the 40 channels of MINI•PLS can be programmed for changed frequently. Installing the jumper back into place will multiple setpoints without any restrictions. Depending upon enable the module for programming changes, if so required. the scale factor selected, up to 500 dual setpoints can be pro- Multiple Program Selection grammed on each of the 40 channels. Just like an electro- The multiple program selection capability of MINI•PLS mechanical cam switch, the dwell setpoints on MINI•PLS can makes set-up changes for different jobs just as simple as turn- be programmed through zero, e.g., on at 350 ° and off at 10 °. ing a rotary selector switch. Several cam modules can be pre- Built-In Tachometer programmed and wired in parallel. Using an external selector In addition to the normal PLS function as described above, switch, a program corresponding to the job to be performed the MINI•PLS has a built-in tachometer. By pressing the can be selected simply by turning the knob. When TTL-type TACH key, the unit goes in tachometer mode and the display Cam Modules are used, multiple program selection is simply shows shaft speed in RPM. When used with computer con- achieved by using a multiplexing input at terminal 4 of the trols, optional analog or digital BCD Tach output modules Cam Module. can be inserted in slots 4 or 5 to provide shaft speed informa- tion to variable speed drives. ULTRA-FAST Built-In Motion Detector Operation at 1800 RPM (M1250), Adjustable In tachometer mode, a motion detection window with low in Motion and high preset points can be programmed. Direct entry of The high speed ratiometric resolver-to-digital converter and low and high limits together with independent fine-tuning of the micro-scan time of 57-85 µs (M1250) guarantee perfect each limit permits quick programming and in-motion adjust- machine operation at speeds of up to 1800 RPM. In ments. The motion detector status is indicated on front panel MINI•PLS, all the program variables are active in the memory by an indication light and an NPN open collector output is immediately as they are entered by the user. This feature per- available at the main terminal block, without occupying any of mits program changes and fine-tuning with machine in full the cam output circuits. In case a remote power relay chassis is motion at 1800 RPM. The + and - keys are especially useful to used an independent motion detector relay is provided on the fine-tune the machine control for maximum productivity. relay chassis. Revolutionary Design Yields Ultra High Speeds Optional Broken Wire Detector The MINI•PLS converts the resolver signal to digital format, The MINI•PLS offers an optional broken wire detector to compares all the setpoints on all the 40 channels and activates supervise the resolver-input signal. The broken wire detector all the outputs in a maximum of 85 µs. This is at least two will signal the missing resolver input, which can occur from a orders of magnitude faster than programmable controllers and loose connection or defective cable. at least one order of magnitude faster than any PLS currently on the market. With one 8-channel module plugged-in, the scan time will be 57 µs. 800-TEC-ENGR Programmable Limit Switches D-26 www.avg.net INTELLIGENT COMMUNICATION VARIETY OF MODELS TO MEET YOUR APPLICATION NEEDS Parallel or serial link Parallel BCD output modules with built-in PC-handshake for Single-Turn Rotary PLS Models easy interface to programmable controllers or remote displays • SAC-M1250-010 is available and can be inserted in slots 4 or 5. The TTL-, • SAC-M1450-300 PNP-, or NPN-types of BCD outputs allow more flexibility • SAC-M1450-MROF for interface to external devices. • SAC-M1450-400 The MINI•PLS Model M1450-300 has been designed to accommodate special modules such as, serial link RS-422A or The model M1250 is the basic MINI•PLS, whereas all the RS-232C, etc. above M1450 models are the advanced versions of the single- turn rotary PLS. The single turn MINI•PLS is an absolute Consult factory for availability of special modules. position programmable limit switch that uses a resolver as input and has built-in tachometer and motion detector. M1450 MINI•PLS The model M1250 offers an ultra fast response time of 57 µs. ADVANCED FEATURES The M1450 Models offer rate offset (ROF) and dynamic zero- ing (ModZ) as standard features. Serial communication RS- Programmable Rate Offset, ROF, for Automatic 232C or RS-422A is provided on the model M1450-300. The Speed Compensation model M1450-MROF features programmable multiple rate The M1450 MINI•PLS features a rate offset to compensate offsets (up to 19), while the model M1450-400 is a high reso- for speed variations. This rate offset represents a positive num- lution PLS (up to 4096 counts-per-revolution) ber that varies linearly with RPM. This number is added to the resolver position and is used to advance the PLS settings as Linear PLS with Single-Turn Resolver a function of the machine speed. Depending upon the selected Model SAC-M1450-M10 model, you can program a single rate offset value for a group This is a semiabsolute position programmable limit switch that of 8 channels on a cam module or different rate offset values uses a single-resolver as input and has a maximum resolution for up to 16 individual channels. of 4096 counts-per-revolution. This model is a multi-turn unit Dynamic Zeroing, ModZ that keeps track of number of revolutions and accumulates its The M1450 MINI•PLS features dynamic zeroing or ModZ position as the resolver shaft rotates. The maximum read out is (Modification Zero) to modify the zero reference point for 999,999. The position is retained on loss of power provided selected group of channels independent of the actual resolver the resolver shaft is not rotated more than 180 degrees while position. Upon receiving an external signal, the resolver posi- power is off. A preset input is provided to enter a preset num- tion for the selected ModZ channels is reset to zero. Thereafter ber into the memory as a reference position. The ModZ trig- the position is incremented as the resolver rotates forward and ger and ModZ enable inputs allow ModZ functions for up to outputs are turned on and off at the programmed limit set- three cam modules. Speed compensation is also provided for tings. This feature is ideal for gluing applications, where the all cam modules installed. glue-gun must be activated at a certain position after the Single-Turn Rotary PLC with Brake Wear detection of an upcoming product. Depending upon the Monitor selected model, you can operate up to 4 ModZ cam modules Model SAC-M1451-010 or 32 outputs. Model M1451-010 PLS is an absolute position resolver which accepts input from a single-turn Resolver. It combines a PLS, tach, and motion detector and features a built-in broken-wire detector. It also has MODZ, speed compensation and brake- wear monitoring capability. At 1800 RPM the micro-scan time is rated 450-905 µs. 800-TEC-ENGR Programmable Limit Switches D-27 www.avg.net SECTION D