M1151 PAK•PLS THE INCREDIBLY VERSATILE PLS FAMILY uSmallest Programmable Limit Switch (PLS); 8 or 16- Outputs in 1.8" x 3.6" x 5.7" housing with NEMA 12 faceplate uIndividual Speed Compensation for each PLS output channel uFour or Eight PLS programs reduce changeover time uSimultaneous display of channel number, ON and OFF setpoints uSimultaneous display of machine speed and position uOptically isolated outputs and inputs enhance system reliability uRugged, reliable resolver as position transducer uSelf-diagnostics help in system troubleshooting uPatented and keys to adjust offset and and maintenance setpoints in full motion uOptional Shift Register PLS Channels uHigh-speed operation, 120 µs (8-channel), 200 µs uOptional Brake Monitor (16-channel) scan time uOptional Dynamic Zeroing ModZ ModeluBuilt-in tachometer and motion detector uSimple creative keyboarduAnalog or Position velocity output options THE M1151 PAK•PLS The PAK•PLS family, since its introduction to the market, has Patented and Keys to adjust Offset and set new standards for speed, precision and reliability. While speed compensations as well as Setpoints, retaining the key features of the PAK•PLS family, the M1151 even in full motion. features an incredibly small size and a simple man-machine Resolver alignment to machine zero as well as fine-tuning the machine interface. Now, AVG Automation has expanded the functions in motion is accomplished through our patented and keys of the M1151 to serve the specialized needs of the industrial which increment or decrement the machine offset or the setpoints. control marketplace. Simultaneous Display of Channel Number, On Smallest PLS and Off Setpoints The state-of-the-art design of the M1151, utilizing surface The large 0.4 ", very-bright LED display provides good visibil- mount technology, makes it possible to package a full-function ity up to 30 feet in plant environments. The user-friendly PLS in a 1.8" H x 3.6" W x 5.7" D cabinet. With 16-Outputs front panel simultaneously displays the correlated parameters in this compact size, the M1151 is the smallest PLS available such as channel number, ON and OFF setpoints or program on the market. The space saving housing (6.5 sq.in. panel number, angle, and rpm allowing a simple and easy-to-under- space) allows a M1151 retrofit to crowded control panels. stand man-machine interface (MMI). Simple Creative Keyboard Individual Channel Speed Compensation The creative engineering from AVG Automation has made it Relays and solenoids, because of their mechanical nature, have possible to program all the PLS functions utilizing only five inherent fixed delays when activating, varying from 10 ms to 30 programming keys. With these five self-explanatory program- ms. A relay with a 10 ms turn on delay will cause as much as a ming keys, the M1151 is extremely simple to program—no 55° shift in operation at 600 rpm. Each channel may be pro- complex key sequence needs to be remembered nor do you grammed with individual speed-dependent advances to compen- need to carry any note cards. sate for fixed delays attributed to relays and solenoids. Speed com- pensation is fully adjustable from 0 to 35.9° advance per 10 rpm. 800-TEC-ENGR Programmable Limit Switches D-21 www.avg.net SECTION D High-Speed Operation, 120 µs Scan Time Brake Monitor The M1151 PAK•PLS can operate up to 1,800 rpm. The 8- The optional M1151 Brake Monitor automatically measures channel unit maintains a repeat accuracy of 120 µs while the the time in ms from an input brake signal until the resolver 16-channel unit has 200 µs scan time. shaft stops rotating. This stopping time is then compared to the programmed Warning Time and Danger Time and the Multiple Program Storage Reduces Down- appropriate Safe, Caution, or Danger output is energized as a Time at Job Changeovers result. The M1151 Brake Monitor is normally applied as an The M1151 PAK•PLS can internally store four or eight independ- indication control on metal stamping presses. The brake wear ent programs for different jobs. With a preprogrammed M1151 monitor uses three PLS channels. for different product runs, the product changeover is as simple as Shift Register pressing the MODE and Inc/Dec keys to select the program corre- sponding to the job. Remote selection of PLS programs may be With the Shift Register option, the four shift register channels accomplished by a PLC or an external selector switch. can be thought of as programmable position delays. The Shift Register length (Turns Delay) can be programmed from 1.00 Built-in Tachometer and Motion Detector to 50.00 revolutions of the input shaft. There are two shift The built-in tachometer displays the shaft speed in rpm simul- register modes. The Mode 1 Shift Register emulates a normal taneously with the position display. Additionally, the built-in electronic shift register circuit with a programmable length. To motion detector continuously monitors shaft speed and allows program a shift register channel for Mode 1 operation, pro- the programming of HIGH and LOW rpm limits for the gram a single dwell whose From setpoint is greater than the To motion output. The motion detector status is indicated on the setpoint. The Mode 1 dwell never actually executes; it is a sig- front-panel by an indicator LED. nal for Mode 1 operation. In Mode 1, the input pattern appears at the output after the input shaft has rotated the pro- Optically Isolated Inputs and Outputs grammed Turns Delay revolutions. Optically isolated inputs and outputs are standard to provide The Mode 0 Shift Register acts as a multi-turn ModZ. Mode 0 enhanced noise immunity and ensure operational integrity of can also be programmed with a Turns Delay from 1.00 revolu- the M1151 PAK•PLS in harsh industrial environments. tions to 50.00 revolutions. After a FALSE-to-TRUE input tran- sition, the entire pattern programmed into the Shift Register Internal Diagnostics channel appears at the channel output after the input shaft has The M1151 PAK•PLS has built in circuitry, which continually rotated the Turns Delay number of revolutions. The M1151 monitors the operation of the unit. If any of the six resolver Shift Register model features battery backup of the shift register wires break or short together, the Broken Wire Detect circuitry memory to retain shift register position during power down. will cause a fault condition. A fail-safe fault output is provided which is energized ONLY if the resolver cable is intact, the The shift register memory may be cleared either from the key- customer power supply is present, the line voltage is within board or from an external input. The additional output chan- specifications, and the processor is not in reset. The fault out- nels are programmed as normal PLS outputs. put will de-energize if the M1151 detects any of these faults. Front Panel Selectable Analog Output: Dynamic Zeroing ModZ Position or Tachomenter The M1151 PAK•PLS features optional dynamic zeroing or With the analol option, analog options are front panel selec- ModZ (MODification Zero) to modify the zero reference point table, retrieving the user from ordering specific analog output for selected channels independent of actual resolver position. format or setting DIP swithches. Moreover, if the application Upon receiving an external signal, the resolver position for the requirements change, they can be easily accommodated by selected ModZ channels is reset to zero. Thereafter, the position keying in the appropriate information. is incremented as the resolver rotates and outputs are turned The M1151 unit can provide either position or tachometer in ON or OFF at the programmed limit settings. The ModZ fea- the analog form. The following ranges are available and front ture is ideal for gluing applications, where the glue gun must be panel selectable: activated at certain positions after detection of an upcoming 1. 0 to 10V 5. -2.5 to 2.5V product. Four ModZ channels, any of which can be used as a 2. -10 to +10V 6. 4 to 20 mA sourcing normal channel, are included in the M1151 ModZ option. 3. 0 to 5V 7. 4 to 20 mA sinking 4. -5 to + 5V 800-TEC-ENGR Programmable Limit Switches D-22 www.avg.net M1151 PAK•PLS SPECIFICATIONS Power Requrirements: Number of ON/OFF Setpoints per channel: AC: 105-135 VAC, 50/60 Hz, 8 W exclusive of load (optional Channel 1: One dual-setpoint 220 VAC) All other channels: Counts per revolution ÷ 2 DC: 11 to 28 VDC, 100 mA. (exclusive of load) Motion Detector: Operating Temperature: -10 °F to +130 °F (-23 °C to +55 °C) Low Setpoint: Up to 998-rpm max. High Setpoint: Up to 999-rpm max. System Resolution: 12 bits Output: P- or N-type, (same as PLS outputs) Scale Factor: Programmable, 16 to 999 Note: Motion, fault and direction outputs will be the same as Offset: Programmable, 0 to full revolution. the PLS outputs ordered. Scan Time for Complete System Execution: (All models: Add 13 Optical Isolation: 1500 V standard on all I/O (except resolver msec for each channel nonzero speed compensation setting.) rms and analog velocity signals) Standard M1151: (All speed compensations 0) Remote Power Relay Outputs: 8-Output units: 120 µs For Cam and Motion outputs requiring higher current 16-Output units: 200 µs ratings, a separate Remote Power Relay chassis AVG M1151 Brake Monitor Option: Automation's part number, ASY-RLYCH-xxxx, can be used. The 8-Output units: 135 µs relay chassis is connected to a unit having N-type outputs 16-Output units: 215 µs using a prewired cable. If Brake Time measurement is active, add 42 µs to normal scan Relay Chassis Input Power: 120 VAC, 50/60 Hz. time. Cable: Prewired with DB15 connector on both ends. M1151 ModZ Option: Relays: Relay chassis is available for EM or solid-state relays. 8-Output units: 185 µs Number of Outputs: 7 or 15 cam outputs plus 1 motion, 1 16-Output units: 265 µs direction, and 1 fault. For each inactive ModZ channel, add 7 µs to above scan time. For each active ModZ channel, add 17 µs to above scan time. Unit Required: N type M1151 Shift Register Option: Electromagnetic relays: 8-Output units: 210 µs (KSD-120C-10A): 120 VAC @ 10 A, SPST, Form C 16-Output units: 290 µs (KSD-A120C-10A): 120 VAC @10 A, SPST, Form A For each Mode 0 Shift Register channel, add 78 µs to above scan Solid State AC relay: time. For each Mode 1 Shift Register channel, add 162 µs to (KSS-120AC-3AMP): above scan time. 24 280 VAC @ 0.23 A, zero cross-over switching Triac output Position Signal: AVG Automation's Series RL100, E7R, E8R, or relay, optically isolated RL101 Resolvers Solid State DC relays: Cable Length between Resolver and M1151: 2,500 ft (762 m), KSS-60VDC-3AMP: 960 VDC @ 3 A, optically isolated shielded KSS-200VDC-1A: 0-200 VDC @ 1 A, optically isolated Resolver Cable: AVG Automation's, CBL-10T22-xxxx INPUTS: Maximum Resolver Shaft Speed: 3,600 rpm Program Enable, Output Enable, External Program Select, Resolver-to-Digital Decoder Tracking Speed: 1,800 rpm ModZ, Shift Register, & Brake Monitor Inputs: For P-type units: OUTPUTS: Enable or TRUE: 11.0 to 28.0 VDC @ 13.5 mA max. or tied to Types Of Outputs: Terminal 9 on the terminal block. (Terminal 9 is internally P: PNP Source Transistor: wired to V for P-type of units) Logic TRUE: Transistor ON, 1.7 V Drop @100 mA s+ Disable or FALSE: 2.0 VDC @ 0.2 mA max. or open circuit Logic FALSE: Transistor OFF, 0.2 mA Leakage @ 50 V For N-type units: N: NPN Sink Transistor: Enable or TRUE: 1.0 VDC @ -3.0 mA max. or tie to Terminal 9 Logic TRUE: Transistor ON, 1.1 V Max. @100 mA on the terminal Block (Terminal 9 is internally wired to Vs- for Logic FALSE: Transistor OFF, 0.1 mA Leakage @ 50 V N-type of units) Number of PLS Outputs: Seven or 15 plus one motion Disable or FALSE: 3.8V DC to 28 VDC Max @ -0.2 mA max. or detector output open circuit. 800-TEC-ENGR Programmable Limit Switches D-23 www.avg.net SECTION D