PROGRAMMABLE LIMIT SWITCHES (PLS) SECTION D — PROGRAMMABLE LIMIT SWITCHES (PLS) Programmable Limit Switch, "The Solid-State Programmable Cam Switch" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2 Stand alone PLS: Touch•PLS, Touchscreen PLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-7 M1020 PLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-13 M1050 PLS Series — M1050, M1050A, M1051, M1051-R10, M1052, & M1053 . . . . . . . . . . . . . . . . . . . . . . . . . . .D-16 M1151 The Incredibly Small PLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-21 M1250 Mini•PLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-24 M1450 Mini•PLS with Advanced Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-24 M1500 Pc•PLS combination PLC and PLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-32 M1750 PLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-35 M1350 Mini•Cam Rotary Cam Switch — Optical Noncontacting Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-40 M1920 PLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-43 PLC/PC Backplane Mounted PLS: M8250 Series PLS BusModules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-47 PC (ISA-Bus) PLS BusModule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-50 800-TEC-ENGR Programmable Limit Switches D-1 www.avg.net SECTION D PROGRAMMABLE LIMIT SWITCH "THE SOLID-STATE PROGRAMMABLE CAM SWITCH" A HISTORICAL PERSPECTIVE Many machines used in automated manufacturing environ- Switch (PLS) to replace the mechanical, cam tripped, limit ments in the early 1970's had rotary cam switches or limit switches. The PLS consists of an absolute-position transducer, switches to sense machine position and used hard-wired relay mounted in place of the rotary cam limit switch, and pro- control panels to control machine operation. Even the smallest grammable electronics mounted in the control panel. With the change in machine control logic required extensive work to advent of the PLS, cam settings can be altered in minutes modify the relay control panel. New control development was instead of hours. Also, cam settings can be optimized by fine- very inefficient since each control logic required custom-built tuning while a machine is in operation. hardware. Further, adjusting a machine's cam settings for a The PLS and PLC combination has been so successfully new set-up required many hours or even days of machine employed in factory automation that it is now standard for down-time. many kinds of machines. The PLS, because of its speed and The mid 70's saw the development of new controls to solve accuracy, controls high-speed machine operations with preci- these problems. Programmable Logic Controllers (PLCs) were sion and can provide the PLC accurate timing, position, or developed to replace the relay control panels and AVG RPM data. The PLC controls slower machine functions and Automation invented an electronic Programmable Limit provides overall machine control. 800-TEC-ENGR Programmable Limit Switches D-2 www.avg.net Since the mid to late 70's, autom0ation control users have Principle of Operation desired to combine the PLS and the PLC into one control. A PLS system consists of a position transducer mounted on a Interfacing absolute-position encoders/resolvers directly to machine's drive shaft and a programmable unit mounted in PLCs has been widely attempted with limited success. The two the machine control panel. In AVG Automation's case, the obstacles to using PLCs for the PLS function are: position transducer is a resolver, which produces analog signals proportional to the shaft position. The position signals are 1. Synchronization of rapidly changing position data to the converted to digital format by an internal ratiometric tracking input scan of a PLC. converter in the programmable unit, displayed on the front 2. Slow scan time of a PLC. panel and compared to the dwell setpoints programmed into The lack of synchronization may result in misreading of the the PLS. When the process cycle reaches these setpoints, out- position information occasionally. AVG Automation solved puts are turned ON or OFF, to start or stop desired functions synchronization problems for PLC users by inventing the PC- during the cycle. Handshake module in 1978. An external PC-Handshake The cam limits or dwells are programmed into the PLS by Module, however, negated the concept of "one control box". thumbwheel settings or simple keyboard entries right from the Even though PLCs have been getting faster and faster, it is control panel. No more climbing to the top of the press to inconceivable for a PLC to be able to handle the desired posi- make cam adjustments which were not only tedious but also tion transducer data rates. For example, even a 5-ms scan time very time consuming. Furthermore, with the PLSs, the fine- allows a top speed of only 33 rpm for 1° resolution. tuning can be done on the fly. In the early 1980's the state of the art in machine control was PLSs today offer many advanced features such as zero offset a combination of a PLS for high-speed response and ease of adjustment, dynamic zeroing and programmable rate offset. set-up and a PLC for control logic and intelligent networking. Zero offset feature allows the operation an easy way of aligning resolver zero to the machine zero. Dynamic zeroing and ModZ It was in the beginning of 1987 when the MacroPLS from allows modification of the zero reference for selected channels AVG Automation with its revolutionary system architecture independent of the actual resolver position. Programmable rate and technology made the industry's desire for "one control offset, ROF, allows automatic adjustment of set points to com- box" a reality. The MacroPLS is the first PLS with ladder logic pensate for machine speed variations. and a math instruction set. With direct high-speed resolver interface and 3K of relay ladder logic repeatable to 100 µs, the The AVG Automation microprocessor-based PLSs uses a MacroPLS was a giant leap into the future. patented DMA technique employing look-up tables to achieve the fastest machine operation in the industry: 20,000 setpoints in 85 µs. 800-TEC-ENGR Programmable Limit Switches D-3 www.avg.net SECTION D 2. Ultrasonic Linear Transducer Position Transducers: An Ultrasonic Linear Transducer provides a means of accurate- 1. Resolver ly measuring linear distance ultrasonically with a minimum of A resolver is a passive position transducer. It works on the mechanical linkages and extra hardware. There are no moving principle of a rotary transformer and consists of one rotor parts and consequently no wear. winding and two stator windings located 90° apart. The rotor An ultrasonic linear transducer consists of an interface control winding is excited with a voltage Vr. As the shaft rotates, the module, a transducer rod and a "doughnut-shaped" magnet. output voltage of the stator windings varies as the sine and An electrical interrogation pulse, generated in the interface cosine of the shaft angle. control module, starts the leading edge of the pulse-width modulation signal. This pulse creates a magnetic field around the conducting element housed inside a magnetorestrictive tube called waveguide. The waveguide, in turn, is enclosed in the nonmagnetic stainless steel tube. The magnetic field from the "doughnut-shaped" permanent magnet, mechanically rep- resentative of machine position, reacts with this generated field producing a mechanical force at right angles to the conducting element. This force causes a twist (torsional strain) which slightly twists the waveguide tube. The twist in the tube pro- duces a torsion wave that is transmitted along the waveguide. The time delay from the interrogating pulse until the travel- ling torsion wave produces a signal in the sensing coil is a direct measurement of the linear position of the "doughnut" magnet. The precise time interval is then converted to digital position inside a linear decoder or a linear PLS. Magnetic fields normally generated by 60 or 400 Hz equip- ment will not affect the operation because these frequencies will be rejected by the narrow bandwidth detection used. Normally, the transducer beam is fixed and the "doughnut" magnet moves with the moving part of the machine. However, the two can be reversed if desired. The relative displacement between the magnet and rod provides the linear position. The ratio of the secondary stator voltages: Note that the angle Ş is no longer a function of the induced absolute Vr, but rather the ratio of Vs1 and Vs2. Therefore, variations in the rotor voltage Vr, frequency and temperature are no longer factors in ratiometric output signal Vs1/Vs2. This results in a highly accurate and repeatable resolver decoder. 800-TEC-ENGR Programmable Limit Switches D-4 www.avg.net Advanages of AVG Automation PLS over Competitive PLSs: Advantages of AVG Automation PLSs over Competitive PLSs Features AVG Automation PLSs Other PLSs Up to 80 outputs in 6" x 4" x 6". 6-48 outputs; factory ordered; Field-expandable to 560 outputs by 1. Number of outputs large overall size adding slave units Only 1 setpoint per channel on most 80 to no limit on 3-digit models; models; some models offer limited 4- and 6-digit models have 21 2. Setpoints per channel multiple setpoints, such as 12 setpoints setpoints per channel per 6 channels Fastest PLS in the market; patented Scan time of a few ms; Some claim µs DMA technique allows processing scan time but in reality operate as time- 3. Response time 20,000 setpoints in 85 µs based rather than position-based For most of PLSs machine shutdown Yes; adjust setpoints in full motion 4. Fine-tuning in motion required to change setpoints Yes, allows quick, automatic Amount of offset required for machine matching of machine zero with 5. Autozero offset zero alignment needs calculation resolver zero 6. Write protect on memory Yes None Connected to high-noise-immune Connected to the noise-susceptible BCD 7. Slave units resolver input output from the master PLS. Field add-on modules for analog or 8. Position output for Must be factory ordered; limited to BCD BCD, Binary, or Gray code; built-in PC- output only; no PC-handshake. external devices handshake Field add-on module for analog or None 9. Tach output digital tach 10. Broken resolver wire Built-in or field add-on accessory Not available on most models; Some depending on model units have factory ordered option detector 11. Optically isolated Plug-in modules or a separate Separate chassis only chassis outputs Portable EEPROM memory modules 12. Portable program allow a preprogrammed module None modules library for multiple program selection Abuse-proof resolver connections; Not short-circuit-proof 13. Resolver connections short- circuit-proof 14. Keyboard Up to 100 programs of160 dual-limits- Some models offer maximum of per-channel. May be remotely programmable and remote programs of a very limited number of selected by PLCs, computers, setpoints. Not necessarily PLC-selectable or BCD switches PLS program selection 800-TEC-ENGR Programmable Limit Switches D-5 www.avg.net SECTION D Advanages of a PLS over Mechanical Limit Swithces: Advantages of a PLS over Mechanical Limit Switches Feature Mechanical Switches Programmable Limit switch (PLS) 0.1° repeatable to arc minutes; 1. Accuracy 5° at best; degrades with time does not degrade with time Very cumbersome and Very simple and accurate limit settings 2. Setup time consuming with keypad or thumbwheel switches Often mounted in inaccessible Mounted on control panel 3. Accessibility locations or in control room 100 rpm max; above this 4. Speed speed contacts bounce Up to 1800 rpm with 1° resolution and accuracy is lost Constant cycling and wear on Very reliable; Resolver shaft 5. Life Expectancy cams as well as switch contacts is the only moving part reduce operational life 6. Dwell Range Minimum 3° to 5° dwell settings Dwell settings as low as 0.10° Often requires adjustment 7. Need for Adjustment Once set never needs adjustment because of mechanical wear 8. Adjustment during Not possible; must stop Setpoints can be fine-tuned machine operation machine to adjust cams with machine in operation Digital shaft position display is extremely 9. Position display No display available useful for set-up and service personnel With varying speed, limits advance 10. Speed Compensation Not available automatically by preprogrammed amount With an external signal, position reference for a group of PLS output channels is reset 11. Mod-Z: Modification Zero Not available to zero while other channels maintain machine position reference Options of EM relays, solid-state 12. Output Options Only electromechanical switches AC or DC relays or logic level outputs compatible with PLCs Higher initial cost, but lower operational 13. Cost Low initial cost cost due to less down-time and increased productivity. Can pay for itself in days Not possible; must use a Modular construction; easily 14. Field Expandable new model for higher field-expandable number of outputs by adding more modules Key-switch lock out against 15. Program security None unauthorized program tampering 16. Speed display Not available Built in tachometer displays shaft RPM Built in motion detector monitors machime 17. Motion Detector Not available over or under speed problems 800-TEC-ENGR Programmable Limit Switches D-6 www.avg.net TOUCH•PLS— TOUCHSCREEN PLS A NEW HORIZON IN PROGRAMMABLE LIMIT SWITCHES uTouchscreen PLS and Graphical Operator Interface in One Unit uFive Screen Sizes Available: 5" Color, 6" Monochrome, 8" Color, 9" Monochrome EL, and 10" Color uMost-Advanced PLS with Leading- and Trailing- Edge Speed Compensation uPLS Settings and Machine Data Totally Integrated with Your PLC uProgrammable Graphical Interface to Over 30 Models of PLCs uAngle ON/Angle OFF and Angle/ON/Time OFF uDynamic zeroing upon external command uBroken wire detection u32 PLS Programs uShort-Circuit-Proof Resolver u8 levels of security uSelf Diagnostics uBrake-wear Monitor uOptically Isolated Inputs & Outputs uBuilt-in Motion Detector and Tachometer TOUCH•PLS Touch•PLS is a traditional PLS that's been combined with a Touch•PLS Principle of Operation touchscreen-based Graphical Operator Interface. No longer do The Touch•PLS, as shown in the block diagram, uses two you have to contend with LEDs, switches, pushbuttons, and processors, one for the PLS and the other to manage, display, keypads. Touch•PLS graphically depicts your application, and communicate to the PLC. The PLS processor reads its while providing machine settings and status and production position signals from the resolver mounted on the machine's data. All programming and fine-tuning of the PLS settings shaft. It controls position-based outputs independent of the occurs in a Windows-type environment. While the unit comes interface processor, providing fast repeatable outputs. The PLS with predesigned screens, AVG Automation's µWIN software processor and the interface processor share information using a makes it easy to create or customize screens to suit your partic- 1,024-register shared memory. The dynamic information, such ular application. as position, RPM, and output status, is available to the inter- face processor for display through registers. One size fits all! The interface processor also shares data with the connected You don't need separate PLS and PLC operator interfaces PLC through a second set of 1,024 registers. This arrangement when you use Touch•PLS because it does double duty; serving makes it easy to display data from both the PLC and PLS on as a PLS interface/control as well as an operator interface to one screen. In addition, 32 registers (16 in each direction) are the PLC. There's no need to clutter up your machine's opera- used to exchange time-critical information between the PLS tor panel with several different displays when Touch•PLS does and PLC through the interface processor. These registers can it all! It reduces panel space, which also reduces installation be used to send position, RPM, and output status information costs and hardware costs. to the PLC. 800-TEC-ENGR Programmable Limit Switches D-7 www.avg.net SECTION D pressing a button on a touch screen to select the program cor- responding to the job. Remote selection of PLS programs may also be accomplished by a PLC. Leading- and Trailing-Edge Speed Compensation Touch•PLS features a Speed Compensation (Rate Offset) to compensate for speed variations. The Rate Offset, individually programmable for each channel, is used to advance the PLS settings as a function of the machine speed Pulse Programming Touch•PLS can be fine-tuned while your machine is running. Either or both of the ON and OFF Setpoints can be incre- mented or decremented, or a fixed dwell can be incremented or decremented, as needed. Rugged, Reliable Resolver for Position Angle ON/Time OFF Transducer Touch•PLS can be programmed to have its outputs turned ON The Touch•PLS uses a resolver as a position transducer. Unlike at an angle and turned OFF after a programmed time by touch- incremental encoders, the resolver, along with its noise- ing the screen. For example, Channel 12 can be turned ON at immune ratiometric converter, always gives true machine posi- an angle of 100° and stay ON for a period of 2.45 seconds. tion—even if the machine moved during a power outage. The resolver, due to its construction, is immune to temperature Programmable Functionality: Brake and ModZ and humidity extremes and mechanical shocks and vibrations. Touch•PLS features a dynamic zeroing or ModZ Short-Circuit-Proof Resolver (Modification Zero) to modify the zero reference point, inde- pendent of the actual resolver position. After the PLS receives The Touch•PLS uses AVG Automation's standard short-cir- the ModZ input, the resolver position is reset to zero. cuit-proof resolver circuit. Thus, in case of an accidental short Touch•PLS can also perform Brake Monitoring to satisfy the in the resolver wiring, costly damage to the PLS resolver OSHA requirement. This PLS can be field-programmed to decoder and the resulting downtime is avoided. have Brake Monitoring Functionality (initiated by entering a Broken-Wire Detection Caution and Danger limit). If you do not select Brake The Touch•PLS features a broken resolver-wire detector to Monitoring, the user must select ModZ or the unit defaults to supervise the resolver input signal. The broken-wire detector normal PLS functionality. (If Brake Monitoring is selected, the will signal the fault output if the resolver is missing any signals. unit cannot function as ModZ.) Flexible Group Assignment FEATURES: Touch•PLS's Flexible Group Assignment can be a powerful and useful feature. When it is desirable to control several dif- Highest Processing Speed ferent machines linked to the same drive shaft, output chan- Touch•PLS uses AVG Automation's patented DMA technique, nels may be grouped together into one of five independent which converts the resolver's analog output signal to a digital sections. The base group is always PLS, while the other four form, then compares all the setpoints, and activates all the out- groups (1-4) may be defined as PLS or ModZ type. Each PLS puts in less than a millisecond. The high-speed ratiometric group has its own group offset, while each ModZ group has its resolver-to-digital converter and the microscan time guarantees own ModZ inhibit zone. perfect machine operation at speeds up to 1,800 RPM. Built-in Motion Detector and Tachometer Multiple Program Storage Touch•PLS has a built-in tachometer and motion detector. The Touch•PLS can internally store 32 independent programs The motion detector energizes a relay when the RPM is for different jobs. With a pre-programmed Touch•PLS for dif- between the programmed LOW and HIGH alarm values. ferent product runs, the product change over is as simple as 800-TEC-ENGR Programmable Limit Switches D-8 www.avg.net 8" Color 8-Levels of Password Protection The 8" color model provides 640 x 480-pixel resolution with Touch•PLS has a password protection feature eight levels deep. 16 colors and a 16 x12 touch-cell grid. Up to eight different passwords that are user-programmable from the touchscreen, allow access to different screens in the Touch•PLS, providing ultimate protection and security of machine settings. Touch•PLS has Choice Of 6 Displays Touch•PLS offers four different types of flat panel touchscreen displays to suit any application and its budget. Except for the size and availability of colors on the screen, all other features remain the same. 5" Color The 5" color LCD model offers 16 colors, high-contrast, 320 x 240-pixel resolution, and an 8 x 6 touch-cell grid. 5" Color The 5" active matrix color LCD model offers 16 bright colors, high-contrast, 320 x 240-pixel resolution, and an 8 x 6 touch- 9" Monochrome EL cell grid. The 9" monochrome electroluminescent model provides 640 x 400-pixel resolution with three shades of amber and an 16 x 10 touch-cell grid. 6" Monochrome The 6" monochrome model provides 320 x 240-pixel resolu- 10" Color tion with three shades of gray and an 8 x 6 touch-cell grid. The 10" color model comes with a bright 640 x 480-pixel reso- lution, 16-color, flat panel display, and 16 x 12 touch-cell grid. 800-TEC-ENGR Programmable Limit Switches D-9 www.avg.net SECTION D Touch•PLS-Total Integration With any PLC µWIN: The Windows-Based On-Line Software Network to Program PLC Screens and Customize PLS Screens Until the advent of Touch•PLS, the only way you communi- cated machine position, speed, or PLS status to your PLC net- Touch•PLS is shipped with preprogrammed screens for PLS work, was through hard-wired discrete outputs from the PLS operation. However, with AVG Automation's µWIN software, to the PLC inputs. As far as the PLS program settings were a user can modify or customize the screens to his or her imagi- concerned, they were simply not available to the PLC. nation. Touch•PLS can communicates to more than 30 different PLCs The µWIN software works with Microsoft Windows 3.11 or and their networks, or through a serial connection, such as A- later. In addition to supporting advanced features like CAD B DH+, A-B Remote I/O, or Profibus. The entire PLS pro- drawing capability, library support, etc., µWIN offers a tool gram can be either uploaded or downloaded to the PLC box of commonly used panel components. The tool box helps through the same bus connection. Hard PLS outputs are also create simple operator panels quickly without drawing. available to activate the machine solenoids directly—freeing A library of several components are available on AVG the PLC's CPU from this task. Automation's web site to save valuable drawing time. Touch•PLS Eliminates the Need for a Separate With µWIN, the user can develop screens off- or on-line. Operator Interface for Your PLC With the off-line feature, the screens can be developed in the Touch•PLS is a complete Graphical Operator Interface for use convenience of your office or remotely, and then downloaded with the PLC in your system. Therefore, you do not need anoth- to the unit. er OI for the PLC if you are using Touch•PLS. It can communi- With the on-line programming feature, you can develop the cate to your PLC, even while performing PLS functions. screens while the Touch•PLS is operating and communicating The OI part of Touch•PLS is more than a pushbutton replace- to the PLC. This allows modifying screens without taking the ment. It offers functionality not possible with other discrete Touch•PLS off line. The program development can be done operator panels. Not only can it replace common panel compo- through a modem, allowing you to change the program on a nents, such as pushbuttons, pilot lights, selector switches, etc. Touch•PLS virtually anywhere in the world. very economically, but you also have complex flexibility. With Touch•PLS, your control panel is never obsolete. Any changes can be made in minutes on-line, off-line, or even remotely. 800-TEC-ENGR Programmable Limit Switches D-10 www.avg.net The operator can't push the wrong button Multiple Language Displays Touch•PLS panels display only the necessary controls that are Touch•PLS units offer a unique multiple languages feature. needed for a particular function, and only when they are need- Today, many production personnel do not speak English as a ed. Thus, not only can the machine's control panel be made first language. Companies are finding they can convey infor- far less cluttered; but, controls that are not needed at that mation to these operators faster, and with less confusion, when moment are simply not available to the operator. This reduces the display is in the operator's native language. Studies have possible operator confusion. And by locking out the operator's shown that in emergency situations, a person reacts fastest in ability to touch the wrong control, using Touch•PLS mini- that person's native tongue. AVG Automation's µWIN pro- mizes or eliminates damage—and the resulting cost—that gramming software enables you to enter display messages in could be caused by introducing inappropriate control signals several different languages. Currently only English and Cyrillic to the machine. character sets are available. This is not to say that µWIN translates English-language phrases into those of other languages—it only recognizes strings of ASCII characters. You can create up to 16 text strings (memory dependent) for each object— each in a differ- ent language. (Please note the more screens and words you use, the more memory you use, and the fewer sets of text strings per object you can create.) To use this feature, a user will design a screen as usual, and enter text strings, where applicable, in as many languages as desired (16 max.). You do not have to design & maintain sepa- rate screens for each language. All your operator has to do is go to the language selection screen and select the language you've already programmed into the Touch•PLS. All screens will then display their messages in the language selected. 800-TEC-ENGR Programmable Limit Switches D-11 www.avg.net SECTION D TOUCH•PLS SPECIFICATIONS Power Requirements: INPUTS/OUTPUTS: 5" Color and 6" Models: 24 VDC @ 18 W Electrical Specifications: 8" Color Model: 24 VDC, 24 W I/O Power Input: 20 to 30 VDC @ 100 mA + user's loads 9"Amber EL Model: 115/230 VAC <40 VA or 24 VDC <40 VA 10" Color Model: 120 VAC ±10%, 50-60 Hz, @ 1 A or N-Channel Sinking I/O 24 VDC @ 1.25 A Output Logic Levels: Operating Temperature: Logic TRUE: MOSFET ON, 0.2 V Max. @ 100 mA 5" Models: 32 to 122 °F (0 to 50 °C) Logic FALSE: MOSFET OFF, 0.05 mA leakage @ 30 V 6" and 8" Models: 32 to 104 °F (0 to 40 °C) Max. Current per Output: 600 mA 9" Model: 32 to 140 °F (0 to 60 °C) Max. Current per Card: 2 A 10" Model: 32 to 113 °F (0 to 45 °C) Output Isolation: 1,500 V Position Resolution: 1 part in 1,000 Input Logic Levels: (consult factory for higher resolution) Logic FALSE: 6-30 VDC Update Time: 1.5 msec Logic TRUE: 0-1.5 VDC Input Isolation: 1,500 V PROGRAMMABLE PARAMETERS: Scale Factor: Programmable from 16 to 999, common to all PLS P-Channel Sourcing I/O setup Output Logic Levels: Position Offset: Programmable to full scale factor value, Logic TRUE: MOSFET ON, 0.5 V Drop @ 100 mA common to all PLS setup Logic FALSE: MOSFET OFF, 0.05 mA leakage @ 30 V Number of PLS ON/OFF Setpoints: 112 per PLS setup Max. Current per Output: 600 mA Number of PLS Setups: 32 Max. Current per Card: 2 A Speed Compensation: Leading and Trailing edge, Output Isolation: 1,500 V programmable in scale factor units per 100 RPM, up to full- Input Logic Levels: scale factor value. Each PLS output (channel) has its own Logic TRUE: 6-30 VDC speed compensation Logic FALSE: 0-1.5 VDC Motion Detector: LOW and HIGH motion limits, common to all Input Isolation: 1,500 V PLS setups, programmable from 0-999 RPM Brake Monitor: Caution and Danger Limit, Stopping time 9.99 sec. max. Number of PLS outputs: 16 Dynamic Zero or ModZ Input or Brake Input: Resolution Touch Shades/ Enclosure Display Size Modification Zero on the fly with an external input (edge (pixels) Cells Colors Ratings triggered) or brake input Color (Active) 5" 320 x 240 8 x 6 16 NEMA 4 Serial Communication: Via RS-485A port Color 5" 320 x 240 8 x 6 16 NEMA 4 Broken Resolver Wire Detection: Indication for broken wire in I/O Status Monochrome 6" 320 x 240 8 x 6 3 NEMA 4, 4X Color 8" 640 x 480 16 x 12 16 NEMA 4 RESOLVER INTERFACE: Position Transducer: Resolver, AVG Automation Series RL100, Amber EL 9" 640 x 400 16 x 10 3 NEMA 4X RL101, E7R, and E8R. Color (Active) 10" 640 x 480 16 x 12 16 NEMA 4X Resolver Cable: CBL-10T22-CXXX or CBL-10T22-MXXX Resolver Decoder: Ratiometric, tracks resolver shaft angle up to 1,800 RPM. Cable Length: 2,500 ft. max., shielded, twisted-pair. 800-TEC-ENGR Programmable Limit Switches D-12 www.avg.net M1020 PROGRAMMABLE LIMIT SWITCH THE SIMPLE, LOW-COST REPLACEMENT FOR CAM/LIMIT SWITCHES uProgrammable Limit Switch (PLS) at the cost of cam/limit switches uDetachable operator interface for program security uIncreased machine productivity uProgrammable production rate counters uFine tuning in motion uProgrammable zero offset M1020-PLS AVG Automation, your Programmable Limit Switch (PLS) mounted on the machine shaft, simply align the machine to a specialist, has now made it possible to simply obsolete electro- mechanical zero reference and enter the required offset num- mechanical cam/limit switches! In spite of numerous limitations, ber to read zero. such as cam bounce, limited life, and high maintenance, Programmable Limit Settings industrial use of electromechanical switches has continued due The "ON/OFF" setpoints for each output can be programmed to their low cost. The M1020-PLS from AVG Automation has simply by the touch of a key from the front panel. The AVG broken down the last barrier…the price. It offers solid-state reli- Automation patented key sequence in the M1020-PLS is ability at the cost of electromechanical cam switches. incredibly simple and easy to use. Principle of Operation Fine-Tuning in Motion The M1020-PLS consists of two parts, one being a position An additional advantage of the M1020-PLS is that you can transducer (resolver) mounted on the machine shaft and the fine-tune your limit settings while the machine is running. other a programmable unit mounted in the machine control This increase in machine productivity pays for the PLS within panel. The resolver produces an analog signal proportional to months. the shaft position that is converted to digital format by a ratio- metric converter inside the programmable unit. This position Programmable Production Rate Indicator is then displayed on the front of the PLS panel and compared In the "TACH" mode, the M1020-PLS displays the machine to the dwell setpoints programmed into it. When the process shaft speed in RPM. However, in this mode, a production rate cycle reaches these setpoints, outputs are enabled or disabled, factor can be programmed to display parts manufactured per resulting in starting or stopping desired functions during the minute. cycle. Programmable Zero Offset Key selects the function to be programmed, while MODE The M1020-PLS allows for quick initial setup, while matching the display shows each function's current values. "machine zero" to "resolver zero" or compensating for Key selects the parameter to be programmed, while machine-wear-induced speed changes. After the resolver is the location of the decimal points indicates which parameter is selected. 800-TEC-ENGR Programmable Limit Switches D-13 www.avg.net SECTION D Keys adjust the parameter value, Program Enable Input DEC INC while the display indicates all The M1020-PLS allows another level of security against unau- current parameter values. thorized programming changes. In addition to the detachable programmer, you need a contact closure at the back of the Key selects the next programmed setpoint RECALL M1020 to enable programming. for the display. Rugged, Reliable for Hostile Environments The M1020-PLS combines the ruggedness of a brushless MODULAR,EASY TO SERVICE resolver and the reliability of an advanced solid-state control. The rugged, heavy-duty, NEMA 13 (IP54)-rated resolver can Low Maintenance be mounted on a machine shaft in hostile environments, such Unlike an electromechanical limit switch that requires periodic as mechanical shock, vibration, extreme humidity and temper- maintenance and often at places that are hard to reach, the ature changes, oil mist, coolant sprays, solvents, etc., and the M1020-PLS requires no maintenance and has no mechanical programmable control unit, M1020-PLS, can be mounted up cams/contacts to wear out. In addition, the plug-in output to 2,500 ft. away in a control panel The splash-proof, oil-tight relays are easily field replaceable. front plate permits the unit to be installed directly on the machine itself, if so required. The ratiometric converter used in the M1020-PLS assures high noise immunity and short-cir- cuit-proof resolver wiring. Fully Absolute Position Unlike some other attempts to replace cam switches with incremental encoders, and/or counter modules in a PLC, the M1020-PLS maintains one crucial feature of cam switches…it is totally absolute. The M1020-PLS will give you reliable limit settings, irrespective of power outages, machine movement during a power outage, as well as during severe electrical noise! Detachable operator interface for Program A PLS AT THE COST OF CAM/LIMIT Security and Cost Savings SWITCHES ($500)* Once the setpoints are programmed using the front-panel-pro- An innovative design and AVG Automation's fully automated gramming interface, you can detach it from the main unit, 100,000 sq.ft. manufacturing facility with the latest in state- making the program inaccessible to any unauthorized person- of-the-art surface-mount equipment, have now made it possi- nel. While this feature makes the M1020-PLS tamper-proof, it ble to provide you with a programmable electronic cam/limit also saves you money by using the same programmer to pro- switch at the cost of electromechanical cam/limit switches. At gram various other AVG Automation PLSs in your plant. less than $500.00 for eight cam outputs, the M1020-PLS offers all the advantages of a solid-state programmable device with the same degree of product reliability as any other AVG Autotech PLS, and yet at no penalty cost. * OEM Quantities 800-TEC-ENGR Programmable Limit Switches D-14 www.avg.net M1020 PLS SPECIFICATIONS GENERAL: CONTROL INPUT: Power Requirements: AC Power: 105-135 VAC, 60Hz, 45W Program Enable: Needs to be tied to common (common pin is provided) to Operating Temperature: -10 °F to +130 °F (-23 °C to +55 °C) enable programming. Programming is disabled if this input is System Resolution: 10 Bits left open. Scale Factor: Fixed, 359 Types of Outputs: Offset: Programmable, 0 to 359 8 PLS outputs, activated according to the user-entered Scan Time: Setpoint Dependant (430 µs max.) setpoints (1 setpoint per channel). The available output types Position Signal: AVG Automation's Series RL100, E7R, E8R, or are: RL101 resolvers Electromechanical SPST relay: Cable Length Between Resolver and M1020: 2500 ft. (762 m) 10 A, resistive, continuous @ 120 VAC shielded Solid-state relays: Resolver-to-Digital Decoder Tracking Speed: 380 RPM with 1° 1. AC output: 120 VAC @ 3 A Resolution ON time: < 3 ms after zero cross OFF time: At zero cross Leakage: 2.1 mA @ 120 VAC 2. DC output: Up to 60 VDC @ 3 A ON time: 5 µs OFF time: 35 µs Leakage: 0.29 mA @ 15 VDC 3. DC output: Up to 200 VDC @ 1 A ON time: 15 µs OFF time: 100 µs Leakage: < 0.01 mA @ 30 VDC Panel Cutout 800-TEC-ENGR Programmable Limit Switches D-15 www.avg.net SECTION D M1050 PLS THE HIGH-PERFORMANCE SELF-CONTAINED PROGRAMMABLE LIMIT SWITCH Includes Power Output Relays in the Same Chassis uEight PLS Outputs, Motion Output, and Fault Output in compact chassis. No external power relay chassis or customer power supply needed. (Selected models do not use relay rack, except for expansion greater than 8 outputs.) uEight PLS programs can be remotely or keyboard selected to simplify job changeover uBuilt-in speed compensation for all PLS outputs uAll inputs and outputs fully isolated uBuilt-in self diagnostics uSimple creative keyboard uRugged, reliable, resolver as position transducer, can be mounted upto 2500 ft (762 m) away uSetpoints-per-program – 8-channel units—80 uPatented and keys for fine-tuning, even with – 16-channel units—160 machine in full motion uProgrammable resolution from 17-1000 divisions- uHigh-speed operation, 100 µs scan time per-revolution uBuilt-in tachometer and Motion Detector uSimultaneous display of program number, channel number, ON and OFF setpoints, and output statusuBrake Monitor Option M1050-PLS AVG Automation's PLS and Mini-PLS families have continu- Simultaneous display of related parameters ally set the standard for speed, precision, reliability, and prod- for easy understanding uct features in the Programmable Limit Switch (PLS) market- In the normal operating mode, the large, 0.56" (14.2 mm) place. While retaining the key features and high-standards of numerical display indicate the selected PLS program number, other AVG Automation products, the M1050 combines 10 the selected channel number, and the current resolver RPM power outputs, fault detection and indication, eight user- and position. When programming PLS setpoints, the display defined PLS programs, and simple, easy-to-learn program- shows the program number, selected channel number, and the ming, in one compact unit with a NEMA 12 front panel. In selected ON and OFF setpoints. addition, each of the eight PLS programs supports up to 80 In all modes, bright easy-to-read bar graph displays the TRUE ON/OFF setpoint pairs for 8-channel units, or 160 for 16- output status of all eight or 16 PLS outputs, as well as the channel units, which may be used in any combination per fault relay status, the motion output status, and the external eight output channels. Included is a fault output which indi- program select enable input status. cates on the display the source of the fault for fast, easy trou- bleshooting and a motion detector which energizes when the resolver is rotating between the HIGH and LOW user-pro- grammed limits. 800-TEC-ENGR Programmable Limit Switches D-16 www.avg.net Powerful, Easy-to-Learn, Human-Machine High-Speed Operation Interface The M1050 PLS can operate upto 1800 RPM while maintain- AVG Automation's human factors engineering has made it ing a timing accuracy of less than 100 µs. possible to program all PLS functions with only five front Multiple Program panel keys and a smart front panel display: Storage Makes Job Changeover Easy Key selects the function to be programmed, while The M1050 PLS can store up to MODE the display shows each function's current values eight independent, user-defined PLS programs for different Key selects the parameter to be programmed, while machine setups. The M1050 is the location of the decimal point indicates which easily configured to accept either parameter is selected front panel or external PLC- compatible input to select a program. Keys adjust the parameter value, INC DEC while the display indicates all Built-In Speed Compensation for All PLS current parameter values Outputs The M1050 PLS features a rate offset to compensate for speed Key selects the next programmed setpoint RECALL variations. This rate offset represents a positive number that for the display varies linearly with RPM. The rate offset is added to the resolver position and is used to advance the PLS settings as a With these five self-explanatory programming keys, program- function of the machine speed. In M1050, the rate offset can ming the M1050 is extremely simple. No long complex key be programmed in Scale Factor units per 10 or 100 rpm, sequences to remember. depending on model, up to full Scale Factor value. Patented and Keys for Fine-Tuning Built-In Tachometer and Motion Detector in Motion The built-in tachometer and motion detector are accurate to 1 All programmed values, except Scale Factor and the PLS pro- rpm and are updated over 68 times per second to provide fast, gram number, can be adjusted with the machine running, accurate indication and detection of rotary motion. The making fine-tuning of job parameters easy. Two fully isolated motion detector is programmed to energize a power relay out- supervisory inputs prevent accidental or unauthorized program put when the machine's RPM falls between the low or under- changes. speed limit and the high or over-speed limit. The motion detector output status is always indicated on the front panel. Channel Number Built-In Fault Detector “On” Setpoint The fault output is normally energized when the M1050 PLS Program is operating properly and the resolver wiring is intact. If an “Off” Setpoint Number internal M1050 fault is detected, or the power fails, or one or more of the resolver wires is broken or disconnected, the fault output will de-energize. Under fault conditions all PLS out- Status puts and the motion output will de-energize. Indicators Motion Brake Monitor Option and Fault The M1050 Brake Monitor measures the time it takes to bring 5-Button Indicators Keypad a rotating machine shaft to a full stop. If the shaft fails to stop within specified safety limits, Caution or Danger outputs are turned OFF. If the shaft stops safely in time, the Safe output turns ON. 800-TEC-ENGR Programmable Limit Switches D-17 www.avg.net SECTION D M1051-R10: Rugged, Reliable Resolver as Position Transducer Standard M1051, 16-channel PLS with sockets The M1050 combines the ruggedness of a brushless resolver for electromechanical relays. Both, NO/NC con- and reliability of an advanced solid-state control. The rugged, tacts are available. heavy-duty NEMA 13 (IP54) resolver can be mounted on a M1052: "Glue Gun Control" PLS—In addition to per- machine shaft in any hostile environment, such as mechanical forming normal PLS functions, the M1052 has a shock, vibration, extreme humidity and temperature changes, built-in Glue Gun Control. It has channels 1-5 oil mists, coolants, solvents, etc. And the programmable con- controlled by three Enable Inputs and a First trol unit, M1050, can be mounted up to 2500 ft. away in a Cycle Reset Input. This allows Programmable control panel. The splash proof, oil-tight front plate permits Enabling or Disabling of up to five glue guns the unit to be installed directly on the machine itself, if based on three external inputs detected during a required. The ratiometric converter assures high-tracking speed programmable window as well as resolver speed. of 1800 RPM and high-noise-immunity. Thus, a packaging machine equipped with a M1052 PLS can handle a variety of different Fully Isolated Inputs and Outputs packages on the same line. The M1052 PLS also All M1050 inputs and outputs are fully isolated from user has 16 programs as well as program duplication. power sources to provide The program selection is either from front panel outstanding electrical noise or external digital input. It also has an optional 4- immunity in harsh industrial 20 mA programmable Analog tach or eight addi- environments. tional NPN sinking outputs. The M1052 PLS has the capability of having different speed compensa- APPLICATION tion values for leading and trailing edges of PLS outputs. Other standard features of the M1052 SPECIFIC SOFTWARE PLS include: built-in motion detector and tach, FOR DIFFERENT pulse programming, and supervisory controls. INDUSTRIES M1053: "Registration Control" PLS—In addition to per- The M1050 Series of Programmable Limit Switches, is the forming normal PLS functions, the M1053 PLS most versatile family of PLSs on the market. In addition to the has a built-in registration control. Channels 15 standard 8-channel PLS (M1050A) and 16-channel PLS and 16 provide programmable pulses (proportion- (M1051), AVG Automation offers industry-specific PLS mod- al to error signal) that advance or retard the drive els that have unique features customized for that industry. motor to remain synchronized with a registration mark on the package enclosure. This mark is M1050A: Eight built-in power outputs, Brake Monitor or detected by an external sensor and fed into the ModZ, individual speed compensation, built-in M1053 PLS. Other features of this PLS include: motion detector and Tach, Pulse programming, programmable reference position; programmable supervisory controls, eight programs with external LOW and HIGH correction limits, programma- program selection. ble pulse width in ms; programmable frequency of M1051: Eight built-in power outputs, eight NPN (sink- registration outputs; individual channel speed ing) outputs, Brake Monitor or ModZ, built-in compensation, built-in motion detector and tach, motion detector and Tach, eight programs with pulse programming and supervisory controls. external program selection, individual speed com- pensation for PLS outputs with four channels hav- CUSTOMISED VERSION TO MEET ing 16 speed compensation zones, five PLSs in one unit with flexible group assignment, Angle- YOUR APPLICATION: ON/Time-OFF, Pulse programming, supervisory AVG Automation is continuously developing new software for controls, and an RS-422A/RS-485A port for serial different industries. For further information regarding qualify- communication. ing applications, call the factory. 800-TEC-ENGR Programmable Limit Switches D-18 www.avg.net M1050 SERIES PLS SPECIFICATIONS Power Requirements: 105-135 VAC, 50/60 Hz, 20 W or Optional Brake Wear Monitor Limits: M1050A and M1051, 220-260 VAC, 50/60 Hz, 20 W (option) Two, one Caution and one Danger. Programmable from 0 to 9.99 seconds Operating Temperature: -10 °F to +130 °F (-23 °C to +55 °C) RESOLVER INTERFACE: PROGRAMMING: Position transducer: Single-Turn Resolver, AVG Automation Series RL100, E7R, E8R, RL101, or equivalent. Number of PLS Programs: M1050A, M1051, M1053: Eight selectable from keyboard Cable Length between Resolver and M1050 Series: 2500 ft or externally via three program-selected inputs (PS0-PS2). (762 m) max., shielded M1050-M10: 60 programs with 8 channel outputs or 30 Resolver Cable: AVG Automation CBL-10T22-XXX programs with 16 channel outputs Maximum Resolver Shaft Speed: 3600 RPM M1052: 16 selectable from keyboard or externally via 5 Resolver Decoder: Ratiometric, tracks resolver shaft angle to program selected inputs (PS0-PS3 and EP) 1800 RPM PLS Setpoints: M1050-M10: 256 per PLS program for 60 total programs or CONTROL INPUTS: 512 per PLS program for 30 total programs. Electrical specifications: (All Inputs) M1050A: 80 per PLS Program, 640 total, 80 setpoints in a Optical Isolation: 1500 V program can be assigned to the eight PLS outputs in any Input impedance: 1800 Ω manner. Logic levels: M1051, M1053: 160 per PLS program, 1280 total. TRUE: 1 to 28 VDC sourcing M1052: 120 per PLS program, (60 for channels 1-8 and 60 FALSE: 0 to 0.8 VDC for channels 9-16) 1920 total. Enable EN1, EN2, EN3: Scale Factor: M1052: TRUE enables selected channel (1 to 5). M1050A, M1051, M1052, M1053: Programmable from 16 Program Enable (PE): When TRUE, enables Programming, and to 999, common to all PLS programs (resolution 17 to 1000 (if EP input is also TRUE) External Program Number Select counts/turn). Program Enable 2 (PE2): M1050-M10: Programmable from 2.56" (65.0 mm) to 40.00" M1051: When TRUE, enables setpoint and setup (1016 mm) per resolver revolution. Maximum machine travel (scale factor, offset, program number, etc.) = 16 x scale factor. Scale factor is common to all PLS Output Enable (OE): When TRUE, PLS Channel outputs programs. enabled,(Both, Fault and Motion always enabled) Offset: Fault Check Enable (FCE): When TRUE, disables PLS and M1050A, M1051, M1052, M1053: Programmable from 0 Motion Detector Outputs whenever Resolver Broken Wire to Scale Factor Value, common to all PLS programs. Fault or M1050-M10, M1051 internal fault occurs. M1050-M10: Programmable from 0 to 16 x Scale Factor Registration Control (RC): Value, common to all PLS programs. M1053: On FALSE to TRUE transition, the resolver position is Speed Compensation: captured and used for error calculations. M1050A: Programmable in Scale Factor units-per-100 rpm, Operator Pushbuttons (PB1 and PB2): up to full Scale Factor value. M1053: On FALSE to TRUE transitions, PB1 increments ref., M1051: Programmable in Scale Factor Units-per-100 rpm, retarding the timing of the motor while PB2 decrements ref., up to full scale factor value. Each PLS channel has its own advancing the timing of the motor. speed compensation. 16 speed compensation zones for First Cycle Inputs (FCI) and Enable Inputs (EN1-EN3): channels 1-4. M1052: Channels 1 to 5 can be individually associated with M1052: Programmable leading and lagging speed either of the enable inputs EN1 to EN3. This association is compensation for channels 1-5. Each speed compensation is user programmable from the keypad. Any channel 1 to 5 programmable in increments of 1 ms. with an enable (EN1-EN3) programmed into it is also M1053: Programmable in Scale Factor units-per-10 rpm, up controlled by the first cycle input and the programmed new to full Scale Factor value ÷10. Each of the first 8 PLS channels cycle position. (1-8) has its own speed compensation. Brake Input (BI): When TRUE, starts Brake Monitor Operation. Motion Detector Setpoints: Two, one LOW and one HIGH, (For details, consult factory.) common to all PLS programs. Programmable from 0 to 999 Supervisory (SUP): rpm. M1050-M10: When TRUE, all programming modes enabled. Registration Pulse Width Resolution: When FALSE: only default, program number change, and M1053: 14.7 ms setpoint modes enabled. Low Motion Enable: Modified Zero (ModZ): M1052: Low Motion Enable, common to channels 1-5 M1050A, M1051, M1050-M10, M1053: On FALSE to associated with enable inputs EN1, EN2, EN3. Programmable TRUE transition, the resolver position is captured and used to from 0 to 999 zero the position for that cycle. New Cycle Position: All ON: M1052: Programmable from 0 to scale factor value. M1050-M10: When TRUE, all output channels are Common to channels 1-5 associated with enable inputs EN1, energized. When FALSE, outputs are normal PLS control. EN2, EN3. 800-TEC-ENGR Programmable Limit Switches D-19 www.avg.net SECTION D Electromechanical SPDT Relay: SCAN TIME: (SAC-M1051-R10) basic unit) Scan time varies with speed compensation programming. 10 A resistive continuous @ 120 VAC Models M1050A, M1051: 100-500 µs Solid-State Relay: (SAC-M1050-8Sx basic unit) Models M1052, M1053: 500-1500 µs. 1. AC output: 120 VAC @ 3 A; OUTPUTS: ON time: <3 ms after zero cross; Unregulated Voltage Out (VO): Current Limited, unregulated OFF time: At zero cross; 12 VDC for use with M1050-M10, M1051 inputs ONLY. Not for Leakage: 2.1 mA @ 120 VAC external sensor power. 2. DC output: Up to 60 VDC @ 3 A; Fault Output: Detects resolver broken wire and M1050-M10, ON time: 5 µs; OFF time: 35 µs; M1051, M1052, M1053 internal faults Leakage: 0.29 mA @ 15 VDC Electromechanical relay (Form C) output; 10 A resistive max. 3. DC output: Up to 200 VDC @ 1 A; @ 120 VAC ON time: 15 µs; Without Fault: Relay remains energized OFF time: 100 µs; With Fault: Relay de-energized Leakage: <0.01 mA @ 30 VDC Motion Output: EM relay (Form C) output; 10 A resistive max. @ 120 VAC. Relay energized whenever resolver RPM is within programmed motion low- and high-limits Number of PLS Outputs: M1050-M10: 1-8 Normal PLS in 60 total program configuration. 1-16 Normal PLS in 30 total program configuration. M1050A: 8 M1051, M1052: 16 M1053: Channels 1-14 are normal PLS. Channel 15 is the retarding registration output. Channel 16 is the advancing registration output. Types of Outputs: 800-TEC-ENGR Programmable Limit Switches D-20 www.avg.net 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 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 Linear PLS with Multi-turn (Dual) Resolver Choice of Front-Panel, Back-Panel, or NEMA 12 (IP52) Enclosure Mounting Models SAC-M1450-D64, SAC-M1450-D128 The basic MINI•PLS unit with its sealed front plate is The multi-turn (dual) resolver MINI•PLS models D64 and designed for front panel mounting. It has T- (5 V, TTL), P-, D128 resolve the position of a rotary shaft up to 4096 counts- or N-type (50 V DC @ 100 mA) outputs for light loads or PC per-turn. These systems, utilizing dual resolvers with built-in interface. For higher voltages and currents, Power Cam precision gear train, are fully absolute and keep track of the Modules or remote power output chassis are available. The shaft position as well as number of turns, regardless of power MINI•PLS can also be purchased in a back panel mount ver- failure, up to 64 and 128 turns respectively. sion with built-in power relay output chassis. This back panel model can be mounted either inside the user control panel or Linear PLS with Ultrasonic Transducer in a NEMA 12 (IP52) enclosure available from AVG Model SAC-M1450-LTO Automation. The linear MINI•PLS, model LTO, decodes the linear move- ment with 0.001" resolution and up to 108" of travel. This unit utilizes an ultrasonic transducer to monitor the linear position of a machine by the movement of a 1.3" (33.02 mm) 3 diameter magnet ring over a / " (9.53 mm) diameter stainless 8 steel rod. The transducer is connected to an interface box, which is mounted a few feet away. The linear PLS can be mounted up to 1000 ft (304.8 m) away in a safe control room environment. In addition, a calibration provision eliminates the need to physically match the decoder to the rod, a prob- lem encountered in earlier controls. The maximum TRUE position ranges up to 108,000 counts but it can be offset to 524,287. ModZ function for up to two cam modules is provided. Tach or speed compensation is not available. Instead, the M1450-LTO provides a direction signal that is on for increasing position and off for decreasing position. Back Panel Mount Chassis The M1250 and Power Relay ... and without window with M1250 and Power Relay Output Chassis shown in a NEMA Output Chassis 12 (IP52) enclosure with window 800-TEC-ENGR Programmable Limit Switches D-28 www.avg.net M1250, M1450, AND M1451 MINI•PLS SPECIFICATIONS Input Power: 105-135 VAC, 50/60 Hz, 35 W exclusive of load INPUT/OUTPUT: (220 or 240 VAC option) Program Enable: Operating Temperature: -10 °F to +130 °F (-23 °C to +55 °C) Contact closure to user power supply common (V ); or a s- Resolution and Scale Factor: (See specification table) solid-state switch 0.8 V @ 10 mA. Resolution and scale factor are defined as follows: ModZ Input: All models except M1450-LTO: Resolution is defined to be Contact closure to customer Power supply V ; or 10-28 V s+ equal to the counts-per-revolution of the resolver. The scale logic input factor is defined as the desired resolution (counts/rev) minus Logic FALSE: 4 VDC @ 1 mA one. Logic TRUE: 10 VDC @ 10 mA to 28 VDC @ 30 mA Model M1450-LTO: Resolution is defined to be equal to the Number of ModZ Channels: See specification table counts-per-inch of travel of the linear transducer. The scale Motion Detector Output: (NOT applicable to M1450-LTO) factor in this case is defined to be equal to the desired NPN sinking: 30 VDC max. @ 100 mA resolution. Direction output: (Applicable ONLY to M1450-LTO) Offset: (NOT applicable to M1450-M10) Energizes on application of power and when transducer Programmable 0 to full scale position is increasing in value. De-energizes when transducer M1450-LTO: Offsettable to 524,287 position is decreasing in value and then remains de- Preset: (Applicable ONLY in case of M1450-M10) energized until transducer position increases again. Preset number range: 0 to 999,999 Output: NPN (sinking), 30 VDC max. @ 100 mA (referenced Preset number entry: From keypad or remote to customer power supply). Remote preset input: Contact closure to Vs+ (10-28 VDC) Rate Offset: (Also see the specification table) Remote Power Relay Outputs: Programmable, 0 to full revolution (caution: entering too- For Cam and Motion outputs requiring higher current much rate offset may result in more than one revolution ratings, a separate Remote Power Relay chassis AVG offset for higher speeds.) Automation part number, ASY-RLYCH-xxxx, can be used. The Rate Offset Resolution: Programmable in tenths of scale relay chassis is connected to an N type of cam module using factor units per ten RPM. a prewired cable. Motion Detector Limits: (NOT applicable to M1450-LTO) Relay Chassis Input Power: 120 VAC 50/60 Hz. LOW setpoint: Up to 1899 RPM (max.) Number of outputs: 8 or 16 cam outputs plus one motion HIGH setpoint: Up to 1900 RPM (max.) output. Number of programmable channels: Cam Module required: N-type 40 (5 output modules with 8 channels each) Cable: Prewired, available with DB 15 connector on one or Slave Systems: both ends. Up to 7 M1250/M1450/M1451s may be slaved to one master unit, giving additional 7 x 40 channels (total 320) using the RELAYS: same position transducer (The slave shares the position Relay chassis is available for electromagnetic or solid-state relays. transducer with the master) Electromagnetic relays: Decimal Point on Display: KSD-012DC-10A: 120 VAC @ 10 A, SPST, Form C contacts In Models M1450-400, M1450-M10, M1450-D64, M1450-D128 KSD-A12DC-10A: 120 VAC @ 10A, SPST, Form A contacts a decimal point may be placed arbitrarily after any digit. This Solid-State AC relay: decimal point is just for the convenience of display, and does KSS-120AC-3 AMP: 24-280 VAC @ 0.2-3 A, zero cross-over not affect the data. switching Triac output relay, optically isolated For M1450-LTO, the decimal point is fixed after the 3rd digit. Solid State DC relays: Decimal point is not available in M1250-010, M1450-300, or KSS-60 VDC-3 AMP: 9-60 VDC @ 3 A, optically isolated M1450-MROF. KSS-200 VDC-1 AMP: >0-200 VDC @ 1 A, optically isolated 800-TEC-ENGR Programmable Limit Switches D-29 www.avg.net SECTION D SPECIAL OUTPUT MODULES: .25 Digital Position/Tach Output Modules: Digital output format: BCD .75 1.00 Digital output Interface: TTL, PNP (sourcing) transistor or NPN (sinking) transistor, characteristics same as those of logic level cam output modules. (See 5.00 3.50 5.50 3.50 table) Module Update Rate: Background task, RPM dependent (consult factory) .75 PC Synch Circuit and Data Transfer Command: (Optional) 6.25 0 0.203 7.25 .25 0-24 Volt logic input (edge-triggered i.e., data transfer 6.75 (4 PLCS) on both rising- and falling-edges) Logic LOW: 0-0.8 V @ 3.2 mA Logic HIGH: >2.4 V @ 0.4 mA Timings: Data latches between 30-100 µs after data .875 transfer edge .437 Tach Full Scale Range: 0-1000 RPM Analog Position/Tach Output Module: (Available for M1250-010, M1450-300 and M1450-MROF only) 5.90 .875 Ref. 3.344 Output: 4-20 mA (sourcing or sinking) or 0-10 VDC 1.672 Position or Tach: DIP switch selectable Position/RPM Range for Max. Output: DIP switch selectable 1/4-28 .281 Ref. Serial Communication Modules: 6.25 UNF2-B 7.25 (Available for M1450 300 only) RS-232C, and RS-422A 7 Holes SPECIFICATION TABLES: Number of Scan Time (microseconds) dual set Resolution Number of ModZ Channels with Model # points per per turn Channels Rate Offsets Number of Cam Modules channel 1 2 3 4 5 (ON/OFF) M1250-010 17-1000 57 64 71 78 85 Resolution ÷2 None None Slots 1-4; 32 channels Slots 1-5; M1450-300 17-1000 160 200 240 280 301 Resolution ÷2 in groups of 8 40 channels in groups of 8 Slots 1-4; 32 channels Slots 1-5; M1450-400 10-4096 1300 1700 2100 2400 2700 21 in groups of 8 40 channels in groups of 8 Slots 1-2; 16 channels individually M1450-MROF 17-1000 200 400 430 460 490 Resolution ÷2 None Slots 3-5; 24 channels in groups of 8 Slots 1-3; 24 channels Slots 1-5; M1450-M10 10-4096 1700 2100 2400 2700 3100 21 in a groups of 8 40 channels in groups of 8 Slot 1; 8 channels in a Slots 1-5; M1450-D64 10-4096 1300 1700 2100 2400 2700 21 group 40 channels in groups of 8 Slot 1; 8 channels in a Slots 1-5; M1450-D128 10-4096 1300 1700 2100 2400 2700 21 group 40 channels in groups of 8 M1450-LTO 17-1000 3500 3500 3500 3500 3500 21 Slot 1-2; 16 channels None Slots 1-2; 16 channels individually M1451-010 17-1000 450 800 855 870 905 Resolution ÷2 Slot 1-2; 16 channels Slots 3-5; 24 channels in groups of 8 800-TEC-ENGR Programmable Limit Switches D-30 www.avg.net Cam Output Modules Logic Level Power Output Type PNP Source NPN Sink TTL * AC DC Transistor Transistor ASY-M1250-08TI ASY-M1250-08PI ASYM1250-08NI Part Number ASYM1450-08AC ASY-M1450-08DC ASY-M1250-08TD ASY-M1250-08PD ASY-M1250-08ND Number of Outputs per 8 8 8 8 8 Module 2 VDC @ 15 mA Transistor ON Transistor ON 2.4 V @ 3 mA 1 A max. per channel 1 A max. per channel Logic TRUE 1.7 V drop 1.1 V drop (20 µA leakage Max. 4 A per module Max. 4 A per module @ 100 mA @ 100 mA when Tristated) 0.35 VDC @ 24 mA Transistor OFF Transistor OFF (0.4 mA max. 0.2 mA 0.1 mA 30 mA 0.1 mA Logic FALSE leakage when leakage leakage max. per output max. per output Tristated) @ 50 VDC @ 50 VDC Rated Voltage 5 VDC 50 VDC 50 VDC 105-135 VAC, 60 Hz 10-28 VDC Turn ON 12 ms Turn ON 30-50 ms Response Time < 1µs 12 µs 12 µs Turn OFF 25 ms Turn OFF 15-40 ms Electrical Isolation 2500 V between control circuit and output circuit * Note: MUX or Tristating Input = Low active, TTL level (i.e., Logic TRUE: 0-0.8 V; Logic FALSE: 2-5 VDC) Position Transducers PLS Model Transducers Cable M1250-010 Single-Turn resolver Overall foil shielded cable M1450-300 such as AVG Automation's such as AVG Automation's M1450-400 RL100, E7R, E8R, RL101, CBL-10T22-xxxx or M1450-MROF or equivalent. equivalent. M1450-M10 Max. tracking speed: 1800 rpm Max.: 2500 ft. Multi-turn resolver such as Overall foil shielded cable M1450-D64 AVG Automation's RL210 such as AVG Automation's M1450-D128 or equivalent. CBL-10T22-xxxx Max. tracking speed: 1800 rpm Max.: 2500 ft. Ultrasonic linear transducer Overall foil shielded cable such as AVG Automation's such as AVG Automation's M1450-LTO LT140, or equivalent. CBL-IB140-Mxxxx Update rate: Max.: 1000 ft. 3 ms for up to 100 800-TEC-ENGR Programmable Limit Switches D-31 www.avg.net SECTION D M1500 PC•PLS FIRST PLS WITH MULTI-PROCESSOR ARCHITECTURE uCompact 7.25" x 5.5" x 6.7" package with 20 inputs, 20 outputs uHigh-speed response of PLS in µs range uFine-tune capability of PLS uMultiple program selection for quick product change-over uStandard relay ladder logic programming for PLC functions u80 timers, 46 counters, and 2K relay ladder code uProgrammable by IBM-compatible PC M1500 PC•PLS M 1500 Pc•PLS is a powerful combination of PLS and PLC The PLC microprocessor accepts 16 external inputs and 10 functions in one, compact package. M1500 is the most cost- internal inputs from the PLS, and performs programmed logic effective and panel space saving solution for machines requir- to control a total of 16 outputs. Twelve are normal PLC relay ing fast position-based control with logic capability. outputs, whereas other four may be used to logically AND the four direct PLS outputs. The PLC microprocessor supports The Pc•PLS senses the status of the inputs and turns the out- most commonly used relay, timer, and counter instructions. puts ON and OFF according to the program supplied by the user. The instruction set offers relay ladder logic as well as Another microprocessor takes care of the operator interface. It timer and counter instructions. The PLS has features and pro- controls the display and keypad, and exchanges information gramming similar to AVG Automation's popular M1051. A with the PLS and PLC processors. Unlike most PLCs, the Resolver is used as a position transducer. Multiple programs, operator interface is integrated with the unit, thus allowing speed compensation, and ModZ capabilities are only some of monitoring of PLC variables, such as bit status and the advanced features supported by the Pc•PLS. timer/counter values, and helps in debugging the program by Forcing the I/O ON or OFF. The machine can be fine-tuned The Pc•PLS, with its 3 processors, allows distributed process- while running using the operator interface. ing of logically independent tasks. The shaft position is sensed by a robust resolver mounted on the machine shaft. The Ultra Fast Pc•PLS's microprocessor gets its position information from a The logical division of distributed processing allows each of noise-immune, ratiometric resolver decoder. The Pc•PLS's the three microprocessors to process its information at best microprocessor then controls PLS outputs, based on the pro- possible efficiency, resulting in a very fast throughput. For very grammed position limits, with µs repeatability. Additionally, it precise position-based outputs, the PLS microprocessor pro- provides Motion and Fault relay outputs. The Pc•PLS provides vides highly repeatable, six 480 µs outputs. The PLC uses a 16 PLS outputs. Ten of the 16 outputs are fed to PLC proces- high-performance, 16-bit microcontroller to execute relay lad- sor internally for inputting machine timing/angle information. der logic at an average of 6 µs/instruction. The unit supports The other six are high-speed, direct, PLS outputs. relay ladder code of up to 2K words. The PLS inside the Pc•PLS is the most advanced AVG Automation PLS model, M1051, and offers features like mul- Rugged, Reliable Absolute Position Resolver tislope, automatic speed compensation, angle ON-time OFF, The Pc•PLS uses a resolver as the position transducer. Unlike, pulse programming, ModZ (dynamic zeroing), multiple pro- incremental encoders, the resolver, along with its noise- grams, multiple groups, brake monitor, etc. immune ratiometric converter, always gives true machine posi- 800-TEC-ENGR Programmable Limit Switches D-32 www.avg.net tion, even if the machine moved during power outage. The I/O Status at Your Fingertips for Easy Setup resolver, due to its construction, is immune to temperature and Diagnostics and humidity extremes and to mechanical shocks and vibra- The interface shows the status of 8 bits, simultaneously. These tions. The short-circuit-proof resolver input circuit allows the bits include PLC input, PLC output, PLC memory (or inter- Pc•PLS to tolerate accidental shorts in resolver wiring. The nal), or PLS outputs. Pc•PLS also has built-in broken resolver wire detection. Convenient I/O Forcing for Program Simple, Easy to Program and Fine-Tune Debugging The unit's simple operator interface, using a bright-red LED The forcing of inputs/outputs, an extremely powerful debug display, makes programming, fine-tuning, debugging, and and diagnostic feature, allows all actual I/Os from the PLC to monitoring of the machine a breeze. be individually and selectively, forced ON or OFF. This helps in the debugging of a PLC program without actually wiring Simple 6-Key Keypad the unit, as well as debugging hardware wiring without pro- The operator interface has a key to switch between PLS and gramming the unit. PLC, and AVG Automation's very popular 6-key keypad to perform the programming and monitoring. PC-Compatible Programming Software— Unlimited Programs Setups on Disk for Quick Job Change-Over English-Language Prompts & Messages for The PLS in Pc•PLS can be programmed from the key pad User Convenience and/or from a PC-compatible computer having an RS-485A The unit's display shows prompts for the user to enter appro- multidrop port. The Windows-compatible software allows you priate values, and the cursor position shows which value will to look at the complete PLS program. In fact, it emulates AVG change in response to pushing the INC/DEC keys. Automation's most popular thumbwheel type of program- ming, as used in the M1750 PLS. Counter/Timer Value Display Eliminates Need for Separate Displays Modules The off-line programming allows creation of programs without Implement batch counters, parts counter, or any desired having a unit wired. The software, by supporting program counter or timer function in relay ladder logic using 80 timers storage in disk files, allows virtually unlimited number of and 46 counters supported by the Pc•PLS, then use the inter- setups saved for quick job changeover. face to view counter/timer values. The Pc•PLS uses industry-standard relay ladder logic and IBM-compatible PCs having RS-485A port for programming the PLC portion of the Pc•PLS. The menu-driven program- ming software allows program creation off line and download- ing the program to the Pc•PLS. 800-TEC-ENGR Programmable Limit Switches D-33 www.avg.net SECTION D M1500 PC•PLS SPECIFICATIONS GENERAL: Brake Wear Monitor: Activates brake danger output if the brake stopping time Power Requirements: 108-135 VAC, 50/60 Hz, 20 W exceeds programmed danger limit. Operating Temperature: Number of PLS Programs: 8, selectable from keyboard or -10 °F to +130 °F (-23 °C to +55 °C) unlimited using disk. Computer Interface: RS-485A PLS Setpoints: 160 per PLS Program, 1280 total Power Output: 12 VDC, current limited to l00 mA Scan Time: 480 µs for 16 outputs PLC SPECIFICATIONS: POSITION INPUT: Inputs: 16, all inputs optically isolated (1500 V isolation) with Transducer: Resolver, AVG Automation Series RL100, E7R, E8R, TRUE level 11-28 VDC sourcing and FALSE level <0.8 VDC. RL101 etc. Outputs: Total 16; 12 relay outputs, SPST electromechanical; 5 A, Cable Length between Resolver and Pc•PLS: 250 VAC contact rating; 4 outputs internal for logically 2500 ft (762 m) max., shielded ANDing 4 direct PLS outputs. Programming language: Relay Ladder Logic PLS SUPERVISORY INPUTS: Instruction Set: Relay type (bit type), timer, counter Input Logic Levels: Same as PLC inputs Program Size: 2K Words Program Enable (PE): Internal Relays (bits): 256 When TRUE, enables setpoint programming Timers: 80, countdown (0 sec-18 hrs) with time-base 10 ms, 100 Program Enable 2 (PE2): ms, 1 sec When TRUE, enables setpoint and setup (scale factor, offset, Counters: 46, count up or count down (0 to 65000) program number, etc.) Supervisory Inputs: Output Enable (OE): RUN: Must be TRUE for ladder execution; FALSE For relay When TRUE, PLS Channel outputs enabled, (Both Fault and ladder programming Motion always enabled) PROGRAM: Must be TRUE for ladder program change (RUN input must be FALSE). PLS OUTPUTS: Data table locations may be changed when this input is TRUE Fault Output: Fail-safe output; detects resolver broken wire and regardless of the state of the RUN input. PLS internal fault) OUTPUT ENABLE: When TRUE, PLC outputs are enabled. Motion Output: Relay energized whenever resolver RPM is Scan Time: Average 6 µs per instruction; 300 µs overhead between programmed motion limits. Number of PLS Outputs: Six PLS SPECIFICATIONS: 4 are logic-ANDed with 4 PLC outputs Scale Factor: PLS outputs have field-replaceable relays; the relays can be To program desired number of counts per turn; electromechanical or solid-state, and can be mixed and Programmable from 16 to 999, common to all PLS programs matched. (resolution 17 to 1000 counts/turn) Electromechanical Relay: SPDT Relay, 10 A, resistive, continuous Offset: @ 120 VAC To electronically align machine zero to resolver zero. Solid-State Relays: Programmable from 0 to Scale Factor Value, common to all AC Relay: 120VAC @ 3 A PLS programs ON time: < 3 ms after zero cross Speed Compensation: OFF time: At zero cross For automatic advance of the limits based on the speed of Leakage: 2.1 mA @ 120 VAC machine. Programmable in scale factor units per 100 rpm. DC Relays: Up to 60V DC @ 3 A Each channel has its own speed compensation. Channels 1-4 ON time: 5 µs have 16 speed compensation zones. OFF time: 35 µs Motion Detector: Leakage: 0.29 mA @ 15 VDC LOW and HIGH Motion Limits, common to all PLS programs. or Up to 200 VDC @ 1 A Programmable from 0 to 999 RPM ON time: 15 µs ModZ: OFF time: 100 µs For dynamic zeroing (Modification to Zero) of zero reference Leakage: <0.01 mA @30 VDC in response to external input. Any channel can be assigned up to 4 different ModZ groups 800-TEC-ENGR Programmable Limit Switches D-34 www.avg.net THE M1750 PLS THE MODULAR ELECTRONIC CAM SWITCH uA solid-state replacement of electromechanical Cam Switches uSimple, easy-to-understand thumbwheel programming uModular construction allows easy maintenance and field expansion uThumbwheel memory assures immunity to electrical noise uVariety of input and output modules to suit different applications uRugged resolver, BCD encoder, or time-base- generator as input device THE M1750 PLS AVG Automation's M1750 Programmable Limit Switch, with its modular construction and simple operator-machine inter- face, represents the easiest solid-state replacement of rotary cam switches or drum sequencers. We call it PLS unlimited, because it can do things no common electromechanical sequencer or mechanically operated cam switch can do. When compared to mechanical switches, the M1750's superior accu- racy, reliability, and convenience of operation are outstanding. Such technology assures the AVG Automation customer a greater efficiency in manufacturing, helping him to increase production and lower costs. Principal of Operation The M1750 PLS gets the shaft position data from a rotary transducer, which could be either an absolute digital encoder or a resolver. The output of a digital encoder is binary-coded- decimal (BCD), while the analog output of a resolver is con- verted to BCD by an R-to-D converter inside the PLS. The data received is processed in the buffer circuit, displayed in degrees (0-359) or counts (0-999) and compared to the pro- grammed dwell-angle setpoints. When the process cycle reach- es these setpoints, outputs are switched ON or OFF, starting or stopping desired functions. 800-TEC-ENGR Programmable Limit Switches D-35 www.avg.net SECTION D SIMPLEST ELECTRONIC CAM SWITCH RUGGED RESOLVER Easy-to-Understand Thumbwheel Reliable Under Extreme Environments Programming The M1750 PLS combines the ruggedness of a brushless The M1750 PLS combines the ease of thumbwheel program- resolver and the reliability of an advanced solid-state control. ming with the convenience of an integrated limit switch. The The rugged, heavy-duty, NEMA 13 (IP54) resolver can be thumbwheel programming is designed to duplicate the mental mounted on a machine shaft in any hostile environment, such process used in setting-up an electromechanical cam switch as mechanical shock, vibration, extreme humidity and temper- and thus permits an easy to understand operation. Just like a ature changes, oil mists, coolants, solvents, etc. The program- rotary cam switch, the M1750 PLS can be programmed mable control unit M1750 can be mounted up to 2500 ft. through zero, e.g., ON at 350° and OFF at 10°. away in a control panel. The ratiometric converter assures high-tracking-speed of 1800 RPM and high-noise-immunity. Operation at 1800 RPM, Programmable in Motion MODULAR CONSTRUCTION The high speed ratiometric tracking converter guarantees per- The entire logic is built on modules, which are independent of fect machine operation at speeds of up to 1800 RPM. All the each other. In case of a problem, just plug-in a new module. program variables are immediately active in the process, as The modules increase design flexibility to match the system to entered by the user. This feature permits fine-tuning with the your application. machine in full motion. Entire Program Visible at a Glance SOURCE MODULES The thumbwheel programmed ON and OFF setpoints for all Resolver or Encoder Input channels are visible at a glance, which permits simple operator- A standard source module with built in Resolver-to- to-machine interface. Digital converter, offset and digital display accepts resolver input and transforms the resolver signal to digi- Absolute Position, Up to 0.36° Resolution tal format for further processing in the comparator cir- The M1750 PLS operates with a resolver or an absolute digital cuit. A digital display source module interfaces to an encoder as position transducer, giving an absolute shaft posi- absolute BCD encoder and feeds this information to the tion in both cases. This means that the system always keeps comparator circuit. track of the true position, even upon machine movements after power outage. The resolver-to-digital decoder source For time-base-generator input consult the factory. modules are available with 360 or 1000 counts-per-revolution Full-Revolution Digital Offset to achieve a resolution of 1° or 0.36°. A full-revolution thumbwheel or external offset is pro- vided on decoder source modules and permits easy ULTIMATE IN RELIABILITY, alignment of machine zero with resolver zero to com- SERVICEABILITY pensate for any mechanical misalignments, machine wear or speed variations. To fine-tune the machine oper- Thumbwheels Provide Mechanical Memory ation for maximum precision, the offset can be adjusted Even with all the advancements in technology, there is no sub- with machine in full motion. The external offset entry stitute for reliability of mechanical memory provided by from a programmable controller is especially useful for thumbwheels. The thumbwheel program memory does not continuous compensation of speed changes. require any battery back-up, nor is it affected by electrical Program Control from External Programmable Controller noise or use over an extended period of time. When using resolver as input device, a special-purpose, Thumbwheel mechanical memory is not affected by external elec- external-offset resolver decoder module accepts BCD trical interference. offset signal from a programmable controller to compen- sate continuously for any speed changes. The BCD posi- Short-Circuit-Proof Resolver-PLS Connection tion data from the decoder module or from the encoder The electrical interface circuit connecting the resolver and the terminals is also available for external devices such as M1750 PLS protects against accidental shorts in the programmable controllers or remote readouts. resolver/PLS wiring. 800-TEC-ENGR Programmable Limit Switches D-36 www.avg.net LOGIC MODULES SYSTEM EXPANSION Variety of Logic Functions Field-Expandable to Match the Application A variety of output logic functions are available to provide The eight- and twelve-channel chassis are standard, but any increased system flexibility: desired number of logic modules can be inserted to meet the requirements. Also several M1750-PLS chassis can be wired in parallel to achieve a total of 48 channels for one position transducer. Dual-Preset: Allows for the settings of both ON and OFF setpoints Variety of Plug-In Output Relays for each channel. The M1750 PLS is designed to operate with electromechanical Single-Preset/Fixed One-Shot-Timer: relays (10 Amp) or open collector (100 mA @ 30 V) or solid- Upon reaching the ON setpoint, a fixed one-shot-timer state AC (3 A), DC (2 A) or AC/DC (0.35/0.5 A) output (0.1-sec.) is activated. modules. Electromechanical relays and solid-state modules, however, cannot be mixed. The solid-state modules are optical- Single-Preset/Variable One-Shot-Timer: ly isolated. All these relays are plug-in type for easy on-site Upon reaching the ON setpoint, a variable one-shot- replacement. The AC/DC relay has less than 0.1 mA leakage timer (0.1-6 sec.) is activated and the output stays ON to interface directly to a programmable controller 110 VAC during the preset time. input card. Single-Preset/Digital Timer: Upon reaching the ON setpoint the output turns ON and stays ON for a duration set by the time thumb- wheels. Time-base setting is selectable by DIP switches from 1 ms to 100 ms per count. ModZ: Upon external signal, the position reference to the mod- ule is reset to zero and the module starts counting up from this new reference, switches output ON at the ON setpoint, and switches OFF at the OFF setpoint. The cycle is repeated by resetting the counter. One M1750- PLS chassis can accommodate up to two ModZ modules with independent reset signals. This function is especial- ly useful for glue applying applications. 800-TEC-ENGR Programmable Limit Switches D-37 www.avg.net SECTION D MOUNTING Choice of Back Panel or NEMA Enclosure Mounting The standard M1750 PLS chassis can be mounted inside the customer's control panel together with other controls or inside a NEMA 12 enclosure M1700-N with a solid cover or M1700-W with a Plexiglas see through window. The see through window allows the thumbwheel setpoints to be visi- ble, while it protects the PLS inside. A locking handle on the cover assures program security. Inside the enclosure, there is a removable NEMA 1 plate covering the terminal blocks, while retaining easy access to the thumbwheels. Accessories BCD outputs from main terminal block can be wired to a remote readout like AVG Automation's RD360 display unit or RD999 display/tachometer unit. Also one bit of BCD can be wired into AVG Automation's PS111 (zero speed switch) or PS112 (over-/under-speed switch) for detecting unsafe operation. 800-TEC-ENGR Programmable Limit Switches D-38 www.avg.net M1750 PLS SPECIFICATIONS Input Power: 105-135 VAC, 50/60 Hz, 50 W exclusive of load OUTPUTS: (Optional 220 VAC) Number of Output Channels Per Chassis: Operating Temperature: 8 or 12 standard -10 °F to 130 °F (-23 °C to 55 °C) Maximum Number of Output Channels Per Transducer: Position Transducer: Resolver, AVG Automation's series RL100, 48, (6 x 8-channel or 4 x 12-channel chassis in parallel) E7R, E8R, and RL101 or Absolute Digital Encoder, AVG Output to Secondary Chassis or other External Devices: Automation's DigiSolver part E5N-D0360-5MOMx Format: 10 or 12-line BCD, High-Logic TRUE; System Resolution: 1° or 0.36° Logic TRUE: 2.5 V drop @ 1 mA source current Resolver-to-Digital Decoder Tracking Speed: 1800 RPM Logic FALSE: 0.4 VDC @ 2.4 mA sink current. Offset: Output Inhibit: Dry contact closure between C & D will disable Offset Range: Adjustable 0 to full revolution all the outputs. Offset Entry: From front panel with thumbwheels ModZ Reset Signal: Dry contact closure or logic level low (0 to or external input 1 VDC). High-Logic: TRUE Logic FALSE: 0-1 VDC OUTPUT RATINGS: Logic TRUE: 4.5-5 VDC KDD-012DC-10SIG: 1 NO + 1 NC relay contacts rated at 10 A Format: 10- or 12-lines. (resistive) at 125 VAC Current draw: <1 mA KSS-120AC-ERI: 3 A, 120 VAC, solid-state AC module, max ON Offset Connector: Unit comes with MS3110F-14-19P. The voltage: 1.5 V; turn ON time: 150 µs (typ.); turn OFF time: 8 ms mating receptacle MS3116F-14-19S is to be wired and (typ.); leakage: 10 mA (max) supplied by customer. KSS-055DC-ERI: 2 A, 3-40 VDC, solid-state DC module, max. Maximum Cable Length from Resolver to M1750: ON voltage: 1.5 V; turn ON time: 15 µs (typ.); turn OFF time: 2500 feet shielded 100 µs (typ.); leakage: 100 mA (max.) KSS-AC/DC-ERI: Low leakage (<0.1 mA) AC/DC solid-state module, 135 VAC (rms) @ 0.35 A or 190 VDC (max) @ 0.5 A, turn ON voltage: 3 V; turn ON time: 10 µs (typ.) turn OFF time: 100 µs (typ.) leakage: 100 mA (max.) 800-TEC-ENGR Programmable Limit Switches D-39 www.avg.net SECTION D MINI•CAM M1350 THE NEW STANDARD IN ROTARY CAM SWITCHES uSolid-state replacement of electromechanical cam switches u4, 8, 12, or 16-outputs uCompact size; eight outputs in four-output housing uNoncontact switching assures operation up to 2,000 rpm without contact bounce. uOptically isolated AC or DC outputs provide noise immunity u90 VDC outputs for clutch/brake control uBuilt-in resolver for PLS interface or position/tach uPulse generating discs for counters, rate meters, or feedback multiple outputs per channel. uFully gasketed JIC Enclosure uEasy to install and set-up THE M1350 The Mini•CAM, model M1350, is an excellent substitute for the cam disc passes or interrupts the light beam through the electromechanical rotary cam limit switches. Like rotary cam photoelectric switch at appropriate shaft angles, depending switches, the Mini•CAM is used to control outputs based on upon the cam disc adjustments. The DIP switches are provid- the position of the shaft to which it is coupled. See block dia- ed to select the outputs to turn on when light is interrupted, gram below. The Mini•CAM utilizes slotted photoelectric or when light is passed. The solid-state switching, ease of set- switches and interrupting cam discs mounted on a rotating up and improved accuracy help increase the productivity of shaft. The cam discs consist of two halves that can be adjusted your machine. to create any required dwell. When Mini•CAM shaft rotates, 800-TEC-ENGR Programmable Limit Switches D-40 www.avg.net Easy to Install and Set-up COMPACT SIZE: Installation and set-up of the Mini-Cam is extremely simple. 8 Outputs in 4-Output Housing Self-locking interrupter discs determine the "dwell" settings The Mini•CAM is available in 4, 8, 12, or 16-output models and are easily adjusted using the wrench supplied with each to match a broad range of applications. The advanced design unit. An adjustable internal degree wheel can be quickly set to from AVG Automation has made it possible to double the out- match the Mini-Cam shaft position to the machine "Zero put density of a 4-output unit and consequently the eight out- Reference". The LED output status indicators are activated puts are housed in a 4-output enclosure currently available in when each output is turned ON and help in quick and accu- the market. This compact size permits installation of the rate set-up. Mini•CAM in physically tight spaces. The optional external degree wheel, part WHLM1350-010, provides position reference without opening up the cover. Non-contact Switching Assures Operation up Optional sprocket disengagement clutch, part SDC-M1350- to 2000 rpm without Contact Bounce 5 xxx, is used to disengage a sprocket from the / " (15.88 mm) 8 The mechanical limit switches of rotary cam switches are shaft for quick set up, clear a jam etc. without jogging the replaced by photoelectric and solid-state switches, while the machine. The adjustable coupling (optional), part CPL- mechanical cams riding on the mechanical limit switches are M1350-xxx, has 90 discrete locked positions and is designed replaced by adjustable Interrupter Discs. As the outputs are 5 to "phase" a / " (15.88 mm) shaft to a sprocket. See "How to 8 turned ON or OFF simply by interruption of the light beam Order" for standard sprockets and couplings. in the photoelectric switches, there is no physical contact and consequently no wear. Also the output switches being the Fully Gasketed JIC Enclosure solid-state devices there is no contact bounce as is the case of The Mini•CAM is housed in a fully gasketed, JIC, oil-tight, electromechanical rotary cam switches. This solid-state non- 5 NEMA 12 enclosure and is fitted with / " (15.88 mm) shaft. 8 contact switching allows operation at speeds up to 2000 rpm Left-hand, right-hand, or double-ended shaft extensions are assuring improved accuracy and virtually eliminating the available that provide flexibility of mounting on your machine. maintenance. For ease of mounting, the shafts are provided with standard 5 / " (15.88 mm) shaft keyways. 8 Logic Level or Optically Isolated Power Outputs 90 VDC outputs for clutch/Brake control Logic level PNP (sourcing) or NPN (sinking) plug-in output The 90 VDC plug-in modules with short-circuit-proof out- modules rated at l00 mA @ 50 VDC are available. When pow- puts are available for direct clutch/brake control from the ered from internal power supply, the maximum load current Mini•CAM without going through other external relays etc. rating of the power supply is limited to l00 mA on 4 or 8-out- put units or 200 mA on 12 or 16-output units. This type of Built-in Pulse Generating Discs For Count, output represents an economical way of interfacing the Rate, or Glue Stitching Mini•CAM to a PLC for additional logic capability. However, The pulse generating discs provided as factory option make for switching higher loads directly, the optically isolated AC (1 M1350 an extremely versatile rotary cam switch. With 60 A @ 120 VAC) or DC (1 A @ 10-28 VDC or 1 A @ 90 pulses per revolution (3° slots) as standard (consult factory for VDC) plug-in modules are available. The optical isolation is other pulse counts), these discs can be used to generate timing rated at 2500 V between the outputs and the control circuitry, pulses for counters, ratemeters, motion detectors, glue stitch- and provides for an extremely reliable operation in electrically ing or other applications requiring multiple setpoints per noisy industrial environments. AC and DC modules can be channel. One disc takes place of a cam and must be ordered mixed to suit your application. from the factory. Built-in Resolver for PLS Interface or Position/Tach Feedback. The built-in resolver option allows you to combine the relia- bility of hard cams and the flexibility of programmable limit switches. The resolver can be used for position or tach feed- back or it can interface to an external programmable limit switch (PLS). When connected to a PLS, it allows the cam set- tings for desired automation functions to be easily pro- grammed in seconds saving time at job changeovers. 800-TEC-ENGR Programmable Limit Switches D-41 www.avg.net SECTION D M1350 MINI•CAM SPECIFICATIONS Input Power: Built-in Resolver (option): AC: 105-135 VAC, 50/60 Hz (220 VAC, 50 Hz optional) Frequency: 2,250 Hz DC: 10-28 VDC (required only if sourcing a total of more Input Voltage: 1.88 V than 100 mA with PNP (sourcing) card) Input Current: 6 mA Input Power: 6.5 mW Operating Temperature: Rotor Impedance with Stator Open Circuit Zro: -10 °F to +130 °F (-23 °C to +55 °C) 180 + j256 Ω Speed: 0 to 2,000 rpm DC Resistance (Rotor): 18.3 Ω Max. Phase Shift: 1° @ 1000 rpm Output Voltage (Stator): 2.63 V +5% Resolution: 1° @ 1800 rpm Transformation Ratio: 1:400 Number of Outputs: 4, 8, 12, or 16 Built-in pulse generating Disc: 60 ppr (3° slots), Replaces cam at position 1 Output Modules Logic Outputs Power Outputs 90 VDC Output Output Types PNP Source NPN Sink DC Output Modules AC Output Modules Modules (ASY-M1350-08P) (ASY-M1350-08N) (ASY-M1350-04AC) (ASY-M1350-04DC) Number of Outputs 8 8 4 4 4 per Module Rated Voltage 50 VDC 50 VDC 105-135 VAC, 60 Hz 10-28 VDC 72-135 VDC Transistor ON Transistor ON 1 A (rms) per output max. 1 A per output max. 1 A per output max. Logic TRUE 1.7 V drop 1.1 V drop 2 A per module 2 A per module 2 A per module @ 100 mA @ 100 mA short-circuit-proof short-circuit-proof short-circuit-proof Transistor OFF Transistor OFF Logic FALSE 0.2 mA leakage 0.1 mA leakage @50 VDC @50 VDC 0.1 mA max. per 0.1 mA max. per OFF Leakage Current 0.2 mA 0.1 mA 30 mA max. per output output output Turn ON 12 ms Turn ON 30-50 µs Turn ON 6-20 µs Response Time 12 µs 12µs Turn OFF 25 ms Turn OFF 30-50 µs Turn OFF 15-40 µs Electrical Isolation None None 2500 V between control circuit and output circuit 800-TEC-ENGR Programmable Limit Switches D-42 www.avg.net THE M1920 PLS A NEW LEVEL OF COMPACTNESS AND MODULARITY... YET ANOTHER MILESTONE IN “HIGHEST PROCESSING POWER AND FEATURES PER CUBIC INCH” FROM AUTOTECH uModular, 6" x 4" x 10" compact control with 5 slots for plug-in modules uPLS, Up to 80 channels (16 per module) u4 digit bright LED for position, RPM, etc. uHot Keys for quick access u2 Line, 20 Character LCD Display u100 Set-up Programs u100-280 microsec. scan time uIndividual channel speed compensation uMultiple Dwellsu2 Mod-Z per module uAngle “ON” - Time “OFF”uOptical I/O isolation uAngle “ON” - Angle “OFF”uShort-circuit proof resovler with broken wire detect and self diagnostics THE M1920 PLS Introduction Principle of Operation Autotech's PLS and Mini-PLS families have continually set the The M1920 is designed for modularity and flexibility. The standard for speed, precision, reliability, and product features Unit has 5 slots for plug-in modules. in the Programmable Limit Switch marketplace. While retain- The microprocessor in the base unit takes care of the functions ing the key features and high standards of other Autotech common to all the modules. The intelligent module have products, the M1920 combines 80 power outputs, fault detec- their own processors to perform their control functions, which tion and indication, hundred user-defined PLS programs, and allow multiprocessor architecture to achieve fast response time simple, easy-to-learn programming in one compact unit with a from the control modules. The base unit has a short circuit NEMA 12 front panel. In addition, each of the hundred PLS proof resolver input circuit which decodes resolver (coupled on programs supports up to 20 ON/OFF setpoint pairs which drive train) signals and broadcasts machine positon slots. may be used in any combination of 10 each on the low and The basic PLS card has 16 PLS outputs, based upon angle on high 8 channels, per PLS card. Included also are a fault out- & angle off. And the advanced PLS card can have the outputs put that indicates on the display the source of the fault for selected as either angle ON/angle OFF or angle ON/time OFF. fast, easy troubleshooting and a motion detector that energizes when the resolver is rotating between motion limits. 800-TEC-ENGR Programmable Limit Switches D-43 www.avg.net SECTION D 16 16 16 Outputs Outputs Outputs PLS Module PLS Module PLS Module Microprocessor Microprocessor Microprocessor 16 16 Outputs Outputs PLS Module Master PLS Module Microprocessor Microprocessor Microprocessor Resovler Input Fault Outputs: 1 Motion and 2 Brake Brake Input Intelligence of 6 Microprocessors in Unison As shown in the block diagram above, M1920 PLS has up to 6 BASIC PLS CARD: microprocessors performing 6 logically independant tasks, yet working in unison. User-friendly Interface The front mount unit has 2 line x 20 character LCD display Because of the power of 6 microprocessors, M1920 PLS can for menu driven programming and for providing maximum process all 80 PLS outputs in a mere 280 microseconds at 600 information on one screen. A 4 digit of LEDs display is pro- RPM simultaniously. vided for displaying machine position, RPM, and other com- Built-in Brake Wear Monitor for OSHA monly used parameters. The keypad provides hot keys to Compliance quickly access different modules. The keypad provides a full The M1920 PLS offers a built-in brake wear monitor in the numeric keypad for direct entry of numerical information as basic unit. The Brake Wear Monitor accepts an input from well as 5 Simple Programming Keys common to several other clutch/brake circuit and measures teh stopping time of the Autotech products. press after the brake is applied. If the stopping time, measured Individual Speed Compensation for the first 8 in milliseconds, exceeds programmed danger limit, fail safe PLS Outputs output is de-energized, which can be used to disable further The M1920 PLS features a rate offset to compensate for speed press operation. If the stopping time exceeds programmed cau- variations. This rate offset represents a positive number that tion limit, the caution output energizes. The brake time can be varies linearly with RPM. The rate offset is added to the displayed on the M1920 PLS’s 4 digit LED display. resolver position and is used to advance the PLS settings as a Fine-Tune in Motion function of the machine speed. In M1920, the rate offset can The PLS module is designed for your total convenience. The be programmed in scale factor units per 100 rpm up to full setpoints can be fine-tuned while the machine is in motion, scale factor value. making machine set up extremely simple. The convenient Multiple Program Storage Makes Job UP/DOWN arrow keys increment/decrement the setpoints. Changeover Easy Supervisory control inputs are provided to prevent unautho- The M1920 PLS can store up to 100 independent, user rized, and unintentional change of setpoints. defined PLS programs for different machine setups to reduce Fully Isolated Inputs and Outputs down time. Job names can be applied to the M1920 PLS pro- All M1920 inputs and outputs are fully isolated from user grams, then these names can be used through the menus to power sources to provide outstanding electrical noise immuni- select, search, rename, copy or even delete the program! This ty in harsh industrial environments. job name will reside on the display with position and RPM to ensure that's the job you're working on. 800-TEC-ENGR Programmable Limit Switches D-44 www.avg.net Built-In Fault Detector ADVANCED PLS CARD The Fault Output is normally energized when the M1920 PLS 16 PLS output based upon selectable angle on / angle off or is operating normally and the resolver wiring is intact. If an angle on /time off. All channels have their own individual internal M1920 fault is detected, or the power fails, or one or leading edge and trailing edge speed compensation for those more of the resolver wires is broken or disconnected, the Fault who like to tailor reaction time at different speeds for the on output will de-energize. Under fault conditions all PLS out- time and off time. There are also two Modification to Zero puts and the motion output will de-energize. (ModZ) inputs available. ModZ is used for dynamic zeroing the zero reference point of the resolver position upon input Built-In Tachometer and Motion Detector from your device. Upon external input signal, the resolver The motion detector is programmed to energize a power relay position is reset for the particular ModZ channel. Thereafter, output when the machine's RPM is between the motion low the position is incremented as the resolver rotates forward and and high limits. The motion detector output status is indicat- outputs are turned "on" and "off" at the programmed limit ed on the front panel. settings. This feature is ideal for gluing applications, where the glue-gun must be activated at a certain position after the detection of an upcoming product. M1920 PLS SPECIFICATIONS BASE UNIT–GENERAL: BASIC – PLS MODULE: Power Requirements: Scale Factor: Desired counts per turn minus one Programmable 120VAC± 10%, 50/60 Hz, 24VA from 16 to 4095, common to all PLS programs 240VAC± 10%, 50/60 Hz, 24VA (Resolution:17 to 4096 counts/turn) Operating Temperature: Offset: Programmable from 0 to Scale Factor Value, -10 °F to +130 °F (-23 °C to +55 °C) common to all PLS programs Position Transducer: Single turn resolver such as RL100; with Speed Compensation: Programmable for first 8 channels; CBL-10T22-Mxxx cable, 2,500 ft. max. each program has its own speed compensation Supervisory, Brake Input and Brake Reset Inputs: Scan Time: 100 to 280 Microseconds Optically isolated Digital Outputs: P or N Type (Factory ordered) TRUE: Contact closure to VS- (common) N-type units: FALSE Open circuit Logic TRUE: Transistor ON, 1.0 V @ 100 mA Logic FALSE: Transistor OFF, 0.2 mA leakage @ 50V Motion Detector: N-type transistor outputs: Use with Autotech or Low & High programmable; Motion detector output similar relay output chassis energizes when the resolver RPM is between low and high P-type units: limits. Logic TRUE: Transistor ON, 1.7 V @ 100 mA Brake Wear Monitor: Logic FALSE: Transistor OFF, .02 mA leakage @ 250V Fail Safe, Normally energized, de-energized when press P-type transistor outputs: Use with Autotech or similar relay stopping time(0-9.99 sec) exceeds programmed danger limit output chassis - 2nd caution output energized when stopping time exceeds Maximum number of Programs of Setups: 100 caution limit. PLS Setpoints: 20 per program Brake Input: Max. 10 for channels 1-8 M1920 starts brake timing when the input becomes TRUE. Max. 10 for channels 9-16 Fault Output: Number of Output Channels: 16, multiple dwells TRUE: No fault FALSE: Fault of broken wire or some other internal error. ADVANCED – PLS MODULE: (In addition to specificaitons of the Basic PLS Module) 2 Mod-Z inputs Angle “ON” – Time “OFF” 800-TEC-ENGR Programmable Limit Switches D-45 www.avg.net SECTION D M1920 PLS DIMENSIONS Measurements taken with connectors in place. 3 31/32" 3 3/16" 2 1/2" 3 9/16" Advanced PLS Basic PLS Module Module 800-TEC-ENGR Programmable Limit Switches D-46 www.avg.net M8250 SERIES PLS BUSMODULES PLUG-IN PLS MODULES FOR ALLEN BRADLEY 1771 I/O, GE FANUC 9070 AND SEIMENS TI-505 PLCS. uFully Absolute Position; No Loss of Position Under Any Situation uProgrammable scale up to 1000 uProgrammable Offset for Quick Set-Up uBright LED Position Display uPLS Output for External Devices independant of PLC scan uHighly Noise Immune Ratiometric Decoder, Ensures Optimum Performance Under Electrically Noisy Conditions uCradles for popular PLC’s BUSMODULES AVG Automation has continuously set the standard for speed, Also, users don't want to tie-up their PLC's CPU with the precision, reliability, and product features in the resolver necessity of performing all the data processing, calculation, sig- decoder and programmable limit switch (PLS) marketplaces. nal conditioning, and scaling of a resolver's input in order to implement motion control actions. In the past, to implement such functions, the user purchased a stand-alone Resolver Decoder or PLS, and connected it to the Now, users of Allen-Bradley 1771 I/O, GE Fanuc 9070 machine. With the advent of the programmable logic con- VMEbus, and Siemens TI-505 PLCs can simply plug such troller (PLC), users now want to integrate such functionality functionality directly into their PLCs—forever freeing the with their PLCs. PLC's CPU to perform other control functions. Please Note: User of Modicon PLCs may refer to our Modconnect product catalog for plug-in modules. 800-TEC-ENGR Programmable Limit Switches D-47 www.avg.net SECTION D Features include: PLS FUNCTION MODULES pFully isolated I/O The M8251-010 and M8251-F10 PLS Modules combine 16 pElectronic Offset Aligns PLS Zero to Machine Zero outputs; fault detection and indication; 8 user-defined PLS setups; and simple, easy-to-learn programming in one compactpLoads PLS Setups from the Backplane or PC module that easily plug directly into a slot of the PLC. pBroken Resolver Wire Detection If the user programs the setpoints for each channel using the pPosition, RPM, and Output Status Available to Backplane front panel keys, each of the eight PLS setups supports up to pOutput Update Time Independent of PLC Scan Time 160 ON/OFF setpoint pairs that may be used in any combi- nation of 80 each of the LOW and HIGH eight channels.p16 Individually Programmable PLS Outputs When the programming is accomplished via the PLC back- pRS-485A Multidrop Serial Link plane, there are only 112 ON/OFF setpoint pairs available. pProgrammable Under-/Over-Speed Limits for Motion These may be used in any combination of 56 each on the Control LOW and HIGH eight channels. Also included are a fault pIndependent Speed Compensation Available for Each PLS output and a motion detector that energize when the resolver Output is rotating between motion limits. pBrake Monitor, Tach, and ModZ Long, complex key sequences are a thing of the past. With the five self-explanatory programming keys, programming the PLS is extremely simple. Most programmed values can be adjusted with the machine running, making fine-tuning of job parame- ters easy. To avoid unauthorized setpoint and setup changes, setting the Program Enable (PE) FALSE prevents tampering. The PLS can store up to 8 independent, user-defined PLS PROG setups for different jobs. The unit can accept either a front- panel entered, PLC backplane command, or a serial link input CHAN command to select a particular, stored setup. RPM / ON POS / OFF INC Recall DEC MODE VS- 1 S1 VS+ 2 S2 BCD- 3 S3 BCD+ 4 S4 MZ4 5 R2 MZ3 6 R1 MZ2 7 RXD- MZ1 8 RXD+ SE 9 CTS- PE 10 CTS+ OE 11 COM P1 P2 800-TEC-ENGR Programmable Limit Switches D-48 www.avg.net M8251 SERIES SPECIFICATIONS ASY-M8251-010, ASY-M8251-F10 PLS Modules CONTROL INPUTS: Power Requirements: Electrical Specifications: (All Inputs) Rack: 5 VDC @ 650 mA Optical Isolation: 2500 V Customer: >24 VDC @ 100 mA Input Impedance: 7500 Ω Operating Temperature: Logic Levels: -10 °F to +130 °F (-23 °C to +55 °C) TRUE: 20-30 VDC; 3 mA @ 24 VDC FALSE: 0-2 VDC, or open circuit PROGRAMMING: Program Enable (PE): When TRUE, enables setpoint Number of PLS Setups: 8 Groups programming PLS Setpoints: Supervisor Enable (SE): When TRUE enables setpoint and Front Panel: 160 per PLS setup (80 per group of 8 outputs) setup (scale factor, offset, program number, etc.) Backplane: 112 per PLS setup (56 per group of 8 outputs) Output Enable (OE): When TRUE, PLS channel outputs enabled Scale Factor: Programmable from 16-999, common to all PLS (both Fault and Motion always enabled) setups (resolution 17 to 1000 counts-per-turn) ModZ and Brake Inputs: Offset: Programmable from 0 to scale factor value, common to MZ1/BI = ModZ input 1 or Brake Input; all PLS setups MZ2/BC = ModZ input 1 or Brake Clear; Speed Compensation: Programmable in scale factor units-per- MZ3 = ModZ Input 3 100 rpm, up to full scale factor value. Each PLS channel has MZ4 = ModZ Input 4 its own speed compensation. OUTPUTS: Motion Detector: LOW and HIGH Motion Limits, common to all An output module is required for connection to field devices. PLS setups. Programmable from 0-1999 RPM. Consult AVG Automation's M8250 Sourcing or M8250 Sinking Update Time: (Maximum Speed with 1° Resolution) Output Module Manual (part MAN-M8250-POUT and MAN- Module: Time Speed (RPM) 8250-NOUT, respective). ASY-M8251-010: 1.6 ms 100 Fault Output: Normally energized; de-energizes if broken ASY-M8251-F10: 0.8 ms 200 resolver wire or M8251 internal fault is detected. RESOLVER INTERFACE: Motion Output: Output is energized whenever resolver RPM is Position Transducer: Single-Turn Resolver, AVG Automation between upper and lower programmed motion limits. series RL100, RL101, E7R, E8R, or equivalent Number of PLS Outputs: 16 Resolver Cable: CBL-10T22-xxx Where xxx = length in ft, 010, 020, 050, and 50 ft. increments, e.g., 100, 150, 200 ft., etc. (3.05, 6.1, 15.24 and 15.24 m increments, e.g., 30.48, 45.72, 60.96 m, etc.) Overall foil shielded, twisted pair Cable Length between Resolver and M8251: 2500 ft. (762 m), max. Maximum Resolver Shaft Speed: 2000 RPM 800-TEC-ENGR Programmable Limit Switches D-49 www.avg.net SECTION D PC(ISA-BUS) PLS BUSMODULE BRING MACHINE CONTROL FUNCTIONS TO YOUR IBM PC, OR EQUIVALENT u8-bit ISA bus interface uCradle covers 2 ISA slots uCradle supports 2 C-bus slot connections (function module and I/O card) uAll function and I/O module field connections are via 37-pin female sub D connector C-BUS ISA CRADLE With the increasing use of industrial PCs (IPCs) for machine PLS features include: control, has come a need for PLS, resolver decoder, shut-pPLS outputs are typically updated in 1.5 ms height, die protection, and tonnage functions. Now, AVG pThe output update time is independent of the controller's Automation brings these functions to the industrial IBM PC scan time (or equivalent) platform. Covering 2 ISA slots in width, users p16 individually programmable PLS outputs; 8 discrete and can now take advantage of these proven technologies on their 8 through backplane IPCs. pFull optical isolation AVG Automation's C-Bus is a series of function and output modules. This offers the user flexibility by allowing them topUp to 600 mA per output, 2 A total per module customize their plug-in cards by mixing and matching the pLeading/Trailing edge speed compensation function module and output module to meet their applica- pModZ (modification zero) tion's unique requirements. pBrake Monitor PLS: pStores 8 user PLS setups A programmable limit switch (PLS) is an electronic switch pAngle ON/Time OFF outputs that duplicates the functions of either a rotary cam switch or limit switches actuated by linear machine movement. A com- plete PLS consists of a solid-state programmable PLS module and position transducer. C-BUS ISA CRADLE SPECIFICATIONS ISA bus Interface: 8 bit, 4k byte window at a switch selectable Connections: All function and I/O module field connections are address between A0000 to FF000 through a 37-pin female sub D connector ISA slots: 2 Dimensions: <13.345" long and <4.2" high Cradle: 2 C-Bus slot connections (function module and I/O card) 800-TEC-ENGR Programmable Limit Switches D-50 www.avg.net