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Toledo Transducers PLS-601 User Manual

Programmable limit switch system
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Toledo Transducers
PLS-601
Programmable Limit Switch System
User's Manual
Rev. 1

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Summary of Contents for Toledo Transducers PLS-601

  • Page 1 Toledo Transducers PLS-601 Programmable Limit Switch System User's Manual Rev. 1...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS 1.0 SCOPE................................3 2.0 PROGRAMMABLE LIMIT SWITCH FUNCTIONAL DESCRIPTION.......3 3.0 PLS-601 SYSTEM COMPONENTS....................4 3.1 TRANSDUCER............................4 3.2 PLS-601 CONTROL UNIT (SPECS).....................5 3.2.1 ENCLOSURE............................5 3.2.2 FRONT PANEL USER INTERFACE....................5 3.2.4 AC/DC POWER SYSTEM ........................8 3.2.5 INTERFACE CONNECTORS......................8 3.3 TRANSDUCER/CONTROL UNIT INTERFACE CABLE...............9 3.4 PLS-601 OUTPUT BOARDS........................10...
  • Page 3 PLS-601 User's Manual TABLE OF CONTENTS - continured 5.0 PLS-601 MODEL 11 ..........................38 5.1 ELECTRONIC GEARBOX........................38 5.2 ‘MEMORY FULL’ CONDITION ......................38 5.3 SELECTING THE NUMBER OF TURNS (MASTER MODE) ............38 5.4 USING THE STANDARD FUNCTIONS (PROGRAM/DISPLAY) ..........39 5.4.1 POWER ON..............................39 5.4.2 POS/TACH...............................39...

  • Page 4: Scope

    The purpose of this User's Manual is to describe the operation, installation and programming of the Toledo Transducer's PLS-601 Programmable Limit Switch. It is strongly recommended that this User's Manual be read entirely before placing the PLS-601 into operation. Failure to follow the instructions given in this User's Manual may void your PLS-601 warranty.

  • Page 5: Pls-601 System Components

    PLS-601 User's Manual 3.0 PLS-601 SYSTEM COMPONENTS The PLS-601 is a state-of-the-art, microprocessor based programmable limit switch that allows a user to easily program single or multiple LOBES for a maximum of 16 independent circuits (CHANNELS). In addition, the PLS-601 provides the user with TACHOMETER and MOTION DETECT functions.

  • Page 6: Pls-601 Control Unit (Specs)

    3.2.2 PLS-601 FRONT PANEL USER INTERFACE The PLS-601 front panel has been designed for ease of use. The front panel utilizes a 16 digit alphanumeric display, an operating mode selection keyswitch, a positive tactile feel keypad, and various LED status indicators.
  • Page 7 Function/Data Keys: The FUNCTION key is used to select whether the ten dual-purpose function/data keys are to be used to select one of the PLS-601 functions, or to enter numerical data. By FUNCTION pressing the function key, the associated function LED will either turn on to indicate function entry mode, or turn off to indicate data entry mode.
  • Page 8 The COPY function allows the user to copy the stored program data from one channel to COPY another, one program to another, or from one PLS-601 control unit to another. In data entry mode, this is the number 6 key.

  • Page 9: Ac/Dc Power System

    DETECT output. The MD LED is active whenever the resolver shaft speed value (RPM) falls within the programmed MOTION DETECT window. The MOTION DETECT output is brought out to the twenty pin male connector that is located on the bottom of the PLS-601 Control Unit. 3.2.4 AC/DC POWER SYSTEM The AC POWER PLUG offers a safe, convenient method of providing AC power to the CONTROL UNIT - eliminating the need to connect individual power wires.

  • Page 10: Transducer/Control Unit Interface Cable

    PLS-601 User's Manual 3.3 TRANSDUCER/CONTROL UNIT INTERFACE CABLE The CONTROL UNIT is interfaced to the TRANSDUCER via a custom made transducer interface cable. This cable consist of three individually shielded pairs, that has an eight pin female plug-connector on one end, and a seven pin female MS-type connector on the other end.

  • Page 11: Pls-601 Output Boards

    D16. Up to four solid state relay boards, each with sixteen output relays can be attached to the PLS-601 control unit. Each board must be assigned to one of four output groups designated as A, B, C, or D. This is done by installing the two channel group jumpers in the proper positions on the relay board (see "Channel Group Jumpers"...
  • Page 12 P101B of the first (or previous) relay output board to P101A of the next relay output board. Up to four solid state relay output boards can be connected to the PLS-601 Control Unit by this interface method.
  • Page 13 (see Channel Group Jumpers in Figure 3.4.2). The relay board must be configured to match the PLS-601 output group that will drive it. Output Group A will drive relay output board A, Group B will drive relay output board B and so forth.
  • Page 14 Electromechanical Relay 16 may be used as one of the standard channel output relays, or it may be used as an indication that an error has occurred in the PLS-601 Control Unit. To enable solid state relay 16 as a standard output, connect pins 1 and 2 together of J1 (see Relay 16 Jumper in Figure 3.4.2).

  • Page 15: Using The Pls-601

    4.1.2 MOUNTING THE CONTROL UNIT The PLS-601 Control Unit is designed to be mounted in a NEMA type enclosure, which is suitable for the ambient environment. The enclosure must protect the Control Unit from contamination caused by water, oil, dust, or corrosive gases. The Control Unit should not be subjected to excessive amount of mechanical shock or vibration.

  • Page 16: Mounting The Relay Boards

    4.1.5 INSTALLING THE AC POWER CORD An AC Power Cord is provided with each PLS-601 Control Unit. The female end of the Power Cord should be inserted into the male AC Power Plug located on the side of the Control Unit enclosure.

  • Page 17: Pls-601 Programming

    • END programming sequence For each of the PLS-601 functions, a BLINKING digit on the display indicates the position of the cursor at which data may be entered. Once programmed, the user may quickly and easily instruct the unit to operate under the control of any one of the four separate programs. Figure 4.2.1 depicts the front panel of the PLS-601 control unit.

  • Page 18: Change Program Number

    PLS-601 User's Manual 4.2.1 PLS-601 CHANGE PROGRAM NUMBER Once the power to the PLS-601 has been applied, one of the four programs must be selected by entering the desired program number (PROG). To accomplish this task, make sure the MODE switch is in the ‘PROGRAM’...

  • Page 19: Set

    PLS-601 User's Manual 4.2.3 SET Function The SET function is used to enter LOBE data into the PLS-601’s memory. The SET function will allow single or multiple LOBE data to be entered on any or all of the 64 available channels. A total of 3808 LOBES (238 LOBES per channel group per program) may be entered.
  • Page 20 TO field. For example, if the ‘FROM’ field is specified as 300 and the TO field is set to 060, the channel output will turn on at 300, remain on through zero, and turn off at 060. The PLS-601 will not allow data entry into the FROM or TO fields if the value is greater than the SCALE FACTOR value.
  • Page 21 FROM and TO fields, than data has been previously entered for the LOBE that is displayed. Select: FUNCTION: Terminates the SET function and returns the user to FUNCTION select mode where anyone of the PLS-601 functions can be selected. Document #11696 Page - 20...
  • Page 22 PLS-601 User's Manual 4.2.3 SET Function - Continued MODIFYING EXISTING CHANNEL LOBE DATA Display: CH A01 F 2 3 - T 3 4 5 (Highlighted character indicates blinking character that can be changed) Select: DATA 0 - 9 The numerical value of the selected DATA KEY is displayed in the present cursor position.

  • Page 23: Offset

    An AUTO ZERO function is implemented via the CLEAR key that will automatically calculate the offset required to zero the current resolver shaft position. Using this function will electrically set the position of the resolver to 000 within the position field (P) on the PLS-601 front panel display.

  • Page 24: Scale Factor

    OFFSET mode will terminates the OFFSET function and returns the user to FUNCTION select mode where any one of the PLS-601 other functions can be selected. 4.2.5 SCALE The SCALE FACTOR is the number of increments that the CONTROL UNIT divides one complete Transducer shaft rotation into.

  • Page 25: Motion Detect

    Pressing the FUNCTION key at any time while in SCALE mode will terminates the SCALE function and returns the user to FUNCTION select mode where any one of the PLS-601 other functions can be selected. 4.2.6 MOTION MOTION WINDOW Motion allows the user to set a window for shaft speed, and receive an indication that the shaft speed falls within the window via the MD (Motion Detect) LED and Motion Detect output (See section 3.2.5).
  • Page 26 Pressing the FUNCTION key at any time while in MOTION mode will terminate the MOTION function and returns the user to FUNCTION select mode where any one of the PLS-601 other functions can be selected. Document #11696 Page - 25...

  • Page 27: Teach

    Selects the displayed CHANNEL GROUP and CHANNEL NUMBER for entry of LOBE DATA. Select: FUNCTION: Terminates the TEACH function and returns the user to FUNCTION select mode where any one of the PLS-601 functions can be selected. Document #11696 Page - 26...
  • Page 28 Selects the displayed CHANNEL GROUP and CHANNEL NUMBER for entry of LOBE DATA. Select: FUNCTION: Terminates the SET function and returns the user to FUNCTION select mode where anyone of the PLS-601 functions can be selected. Document #11696 Page - 27...
  • Page 29 FROM and TO fields, than data has been previously entered for the LOBE that is displayed. Select: FUNCTION: Terminates the TEACH function and returns the user to FUNCTION select mode where any one of the PLS-601 functions can be selected. Document #11696 Page - 28...
  • Page 30 FROM and TO fields, than data has been previously entered for the LOBE that is displayed. Select: FUNCTION: Terminates the TEACH function and returns the user to FUNCTION select mode where any one of the PLS-601 functions can be selected. Document #11696 Page - 29...

  • Page 31: Copy

    PLS-601 User's Manual 4.2.8 COPY The COPY function allows the user to copy the stored program data from one CHANNEL to another, one PROGRAM to another, or from one PLS-601 UNIT to another. SELECTING THE TYPE OF COPY Select: COPY Selects the COPY program function.
  • Page 32 Initiates the COPY for the displayed ‘FROM’ and ‘TO’ CANNELS Select: FUNCTION: Terminates the COPY function and returns the user to FUNCTION select mode where any one of the PLS-601 functions can be selected. SELECTING the CHANNEL NUMBER Select: >CURSOR Move the cursor right within the three digit ‘FROM’...
  • Page 33 Select: FUNCTION: Terminates the COPY function and returns the user to FUNCTION select mode where any one of the PLS-601 functions can be selected. CHANNEL TO CHANNEL COPY COMPLETION During the CHANNEL to CHANNEL COPY, the Control Unit will BLINK the ‘COPY’ digits one at a time to indicate that the COPY is in progress.
  • Page 34 TYPE OF COPY’ sequence may now be followed (see section 4.2.8) COPYING FROM UNIT TO UNIT In a UNIT to UNIT COPY, all the data stored in the four PLS-601 PROGRAMS is copied from one PLS-601 Control Unit to another.
  • Page 35 After the COPY has been completed, the Control Unit will display “FINISHED” on the alphanumeric display of both SEND and RECEIVE units. The “FUNCTION LED” will be lit, allowing the user to select any of the ten PLS-601 functions. NOTE: The SEND unit may display “FINISHED” even though a successful COPY has not occurred.

  • Page 36: Special Fuction - F7

    The END function is used to end data entry for the current PROGRAM, and allows selection of any one of the four PLS-601 PROGRAMS for data entry. The Transducer shaft POSITION (‘P’) and the shaft SPEED in RPM (‘R’) are displayed.

  • Page 37: Channel Status Group Selection

    PLS-601 User's Manual 4.4 CHANNEL STATUS GROUP SELECTION The Channel outputs are divided into four groups of sixteen outputs each - designated A01-A16, B01-B16, C01-C16 and D01-D16. The sixteen CHANNEL STATUS LED’s display the status of the sixteen Channel outputs in the CHANNEL STATUS GROUP indicated by the GROUP LED’s.

  • Page 38: Control Unit Microprocessor Fault

    PLS-601 User's Manual 4.5 ERROR CONDITIONS - Continued 4.5.2 CONTROL UNIT MICROPROCESSOR FAULT In the event of a microprocessor fault, the alphanumeric display and Channel outputs are frozen in the State that existed at the time of the failure. Because it is implemented in hardware, Relay 16 (with the RELAY 16 JUMPER OPTION selected) can be used to give an indication that the control unit has experienced a microprocessor fault.

  • Page 39: Pls-601 Model 11

    PLS-601 User's Manual 5.0 PLS-601 MODEL 11 The PLS-601 Model 11 features an “Electric Gearbox” function that provides multi-turn capability for the PLS-601 Model 10, using the standard PLS-TR-1 single turn resolver. 5.1 ELECTRONIC GEARBOX The ‘ELECTRONIC GEARBOX’ function allows the user to select the total NUMBER OF TURNS required for the application, which can be any number from 1 to 100.

  • Page 40: Using The Standard Functions (Program/Display)

    PLS-601 other functions can be selected. 5.4 USING THE STANDARD FUNCTIONS (PROGRAM/DISPLAY MODES) Once the NUMBER of TURNS has been selected in MASTER MODE, the ten standard PLS-601 functions can be used in the PROGRAM or DISPLAY MODES. The following sections describe the differences between the Model 10 functions as described in Section 4.2, and the Model 11...

  • Page 41: Offset

    PLS-601 User's Manual 5.4.4 OFFSET An asterisk (*) before the ‘OF’ field indicates that the displayed data must be entered into memory via the ENTER key. The INC/DEC keys enter data immediately into memory, as in the standard unit. See Section 4.2.4 for a complete description of OFFSET function...

  • Page 42: Copy

    PLS-601 User's Manual 5.4.8 COPY See Section 4.2.8 5.4.9 SPECIAL FUNCTION - F7 See Section 4.2.9 5.4.9 SPECIAL FUNCTION - F8 See Section 4.2.10 5.4.11 END See Section 4.2.11 Display: P10140 PRG1 R030 Document #11696 Page - 41...

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