WARRANTY 1. Electro Cam Corp. warrants that for a period of twelve (12) months from the date of shipment to the original purchaser, its new product to be free from defects in material and workmanship and that the product conforms to applicable drawings and specifications approved by the Manufac- turer.
Mechanical Cam Switches Mechanical Cams The PS-6244 Programmable Limit Switch electronically simulates mechanical cam switches. A cam switch consists of a roller limit switch whose arm rides on a cam as shown in Figure 1. The cam shaft is driven by a machine at a 1:1 ratio, so that the cam switch turns on and off at specific positions in the machine cycle.
Programmable Limit Switches Figure 2—PS-6244-24-N16M09 Programmable Limit Switch and Quadrature Encoder Typical Quadrature Encoder (BEI H25D shown) Controller PS-6400 Keypad/Display PS-6244 Description Controller & Keypad PS-6244 Series Programmable Limit Switches consist of two main components: the controller and the keypad/display. The controller houses the microprocessor, associat- ed circuitry, and all of the I/O circuits.
Basic Terminology The following terms will be used throughout this manual to explain PS-6244 installation, programming and operation: Outputs (channels) An “output,” or “output channel,” refers to an external circuit that the PS-6244 controls based on encoder position or speed. Outputs can be one of two types: Switching outputs turn circuits on or off.
PS-6244. Serial Communication Using Electro Cam Corp.’s PLuSNET software for IBM-PC compatible computers, the PS-6244’s programs can be saved to a disk file or loaded from a disk file to the PS- 6244.
The controller body mounts on a DIN rail as shown in Figure 4. Keypad/Display Mount the keypad/display to a panel using the four studs on the back of the keyboard. Enclosures are available from Electro Cam if an appropriate mounting location does not exist. DIP Switches For convenience, set the DIP switches on the side of the controller and keypad to their proper positions before mounting the units in a panel.
Controller Input Wiring Input Terminals Hardware inputs can be used to select a program of setpoints, disable keypads, accept sensor signals, or clear the shift register. The 16 inputs on the PS-6244 are arranged on two terminal strips, TB 1 and TB 3, as shown in Figure 7. Each input is optically isolated and can be powered from an external DC power source or the Auxiliary Power terminals located on TB 2.
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Controller Input Wiring (cont’d) Figure 7—Controller Input Wiring (See Figures 5 & 6 for Terminal Block Locations) Sourcing Devices Sinking Devices (+VDC is being switched) (DC common is being switched) Term. Function Channel Enable 9-13 Program Select Shift Register Clear Keypad Disable Shift Register Input Input Wiring Guidelines...
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Programs 1 through 31 can be selected using binary input. A value larger than 31 will select Program 31. Gray Code Select Table Input Input Electro Cam 8-position Gray Code selector switches are Term: 13 12 11 10 9 Term: 13 12 11 10 available as accessories for PLuS controls.
Output Wiring Output Types The outputs available depend on the PS-6244 Model: Output Model Model Type 6244-24-M17 6244-24-X16M09 Transistor None Outputs 1-16 AC/DC/RR Modules Only Outputs 1-15 Outputs 17-23 AC/DC/RR or Analog Modules Output 16 Output 24 Analog Modules Only Output 17 Output 25 The load device to be driven must match the output type.
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Output Wiring (cont’d) Figure 9—Wiring for Output Modules PS-6244-24-M17 PS-6244-24-X16M09 - - - AC Output DC Output Sourcing • When other switching devices are in series or parallel with the AC output Sinking module, connect a varistor (MOV) across the terminals to prevent module damage from inductive voltage spikes.
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Output Wiring (cont’d) Figure 10—Wiring for Sinking Transistor Outputs (See Figure 6 for Terminal Block Locations) Model PS-6244-24-N16M09 Please Note: • Outputs are rated at 30 VDC, 50 mA. • Transistor outputs should not be used to switch inductive devices such as solenoids or relays.
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Output Wiring (cont’d) Figure 11—Wiring for Sourcing Transistor Outputs (See Figure 6 for Terminal Block Locations) Model PS-6244-24-P16M09 Please Note: • Outputs are rated at 30 VDC, 50 mA. • Transistor outputs should not be used to switch inductive devices such as solenoids or relays. •...
Keypad Wiring Number of Keypads One or two keypads may be connected to a PS-6244 controller as shown in Figure 12. See Figure 14 for possible system configurations. Programming Enable The wiring connector on the back of each keypad includes terminals to select Operator or Master level programming for that keypad.
DIP Switch Configurations DIP Switches Each keypad and controller has a DIP switch as shown in Figure 13. For convenience, set the DIP switches correctly before mounting the units in a panel. Keypad Settings The address and termination settings on the keypad DIP switch apply to the RS-485 network that connects it to the controller.
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DIP Switch Configurations (cont’d) Figure 14—DIP Switch Settings for Typical Systems One Keypad Two Keypads, Controller on End Two Keypads, Controller in Middle DIP Switch Guidelines Termination: • Termination must be “on” for devices on each end of the chain. •...
Communications Wiring DB-9F Port Serial communication to a PLC or other system host is provided through a DB-9 female connector as shown in Figures 5 & 6. This connector can be wired for RS-232 or RS- 485 communications. RS-485 RS-485 can be used for “multi-drop” networks where more than one controller could be connected to the system host.
Encoder Wiring General Information Choose a mounting location for the encoder that allows convenient mechanical con- nection of the encoder shaft to the machine. The encoder is normally driven at a 1:1 ratio to machine cycles, but this is not true in all applications. Commonly used methods for driving the encoder shaft include flexible couplings, timing belts and pulleys, chains, and sprockets.
Fuse Tester & Fuse Replacement Fuse Tester Figure 17 shows the location of a fuse test socket and LED which can be used to test TR5 style fuses. PS-6244 controllers are shipped with a spare 4A fuse mounted in the test socket.
Output Transistor Replacement Check Fuse First If all of the transistor outputs fail to work, check the 1A fuse shown in Figures 17 & 18. Also check to be sure that a 10–30 VDC power supply is connected to TB 11, Figure 6. Correct Problems Chips will most likely be damaged by one of two events: •...
Keypad Overview Figure 19—Keypad Keys and Corresponding Functions Main Screen • Shows Active Program, RPM, and Position and Group # if applicable. • Flashing cursor points to menu. • Press SEL key to enter Menu Tree (Fig. 20) and initiate programming. Cursor Keys •...
Menu Tree Figure 20—PS-6244 Menu Tree • Press SEL to move from Main Screen into Menu Tree. • Functions are listed alphabetically in Section 3 of this manual starting on page 3-4. MAIN SCREEN ESC SEL PGM: 1 RPM:1500 PASSWORD MENU<...
Initial Programming Bench Test To test the PS-6244 prior to installing it, do the following: 1. Plug output modules into the controller beginning with Position 1 on the 6244-24- M17, or Position 17 on the 6244-24-X16M09. See Figure 9. 2. Connect an encoder. See Figure 16. 3.
Analog Output Menu Path MAIN SCREEN to SETUP MENU to ANALOG OUTPUT Purpose Analog output signals are linearly proportional to the encoder RPM. Two types of ana- log output modules are available: 0-10 VDC and 4-20 mA. This function assigns Offset and High RPM values to output positions for analog mod- ules.
Analog Output (cont’d) Offset Analog Offset is the analog signal level that will be output when the encoder is at zero RPM. This allows the minimum analog signal to be greater than zero volts or 4 mA. Because the analog output module has 4096 increments (12 bits) of signal level avail- able, the offset is specified as the number of increments of signal that should be output at zero RPM.
Communications Menu Path MAIN SCREEN to CONFIG MENU to COMMUNICATIONS Purpose The Communications function sets the communications type, controller address, and baud rate for communicating with a host computer. Communications Type: RS-232 or RS-485 TYPE:485 ADR: 1< Address: 0-255 BAUD: 9600 Baud Rate: 4800, 9600, 19.2Kb, 38.4Kb Type Use SEL to toggle between RS-232 and RS-485 communications.
Default Program Menu Path MAIN SCREEN to SETUP MENU DEFAULT PROGRAM Background The PS-6244 controller can store up to 48 programs in its memory. The Default Pro- gram is the program that controls the output channels when there are no hardware input signals on terminals 9-13 of TB 1, Figure 7.
Enable Codes Menu Path MAIN SCREEN to CONFIG MENU to PGM ENABLE MENU ENABLE CODES Background The PS-6244 has three levels of programming access: Operator, Setup, and Master in order of increasing capabilities. Figure 21 lists the menu functions that can be pro- grammed under the various levels of access.
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Enable Codes (cont’d) Figure 21—Programming Access Levels for Various Menu Items Programming Level Normal Display Operator Setup Master Can Be Enabled By… Keypad Terminal Yes, E2 Yes, E1 Password Menu Item Access Password Enter Enter Enter Program Setpoints View Program Program Program Setup Menu...
Enable Options Menu Path MAIN SCREEN to CONFIG MENU to PGM ENABLE MENU to ENABLE OPTIONS Purpose The Enable Options screen controls Operator Level access to SETUP MENU program- ming as indicated in Figure 21, note 1. SETPOINTS or SETUP MENU screen. Scroll through choices with UP and Down cursor keys.
Input ANDing Menu Path MAIN SCREEN to CONFIG MENU to CHN ANDING MENU to INPUT ANDING Background Terminals 1 through 8 of TB 3, Figure 7, can accept hardware input signals from sen- sors or PLC’s. By ANDing an output channel with one of these terminals, the output channel will be “on”...
Keyboard Quantity Menu Path MAIN SCREEN to CONFIG MENU HARDWARE MENU KEYBOARD QTY Purpose The Keyboard Quantity screen shows the number of keypads the controller will com- municate with. KEYBOARD QTY: 1< Number of keyboard/display units attached to controller The controller will attempt to establish communication with as many keypads as are programmed through this screen.
Memory Tests Menu Path MAIN SCREEN to TEST MENU to MEMORY TESTS Purpose This menu selection provides three functions that allow you to clear programmed val- ues from the controller. An additional function tests the controller’s watchdog timer. Screen MEMORY TESTS FCN:----<...
Motion ANDing Menu Path MAIN SCREEN to CONFIG MENU to CHN ANDING MENU TION ANDING Purpose This function is used to tie the operation of output channels to the Motion Detection levels programmed through MOTION DETECTION. Each output channel may be ANDed with either Motion Detection level.
Motion Detection Menu Path MAIN SCREEN to SETUP MENU to MOTION DETECT Background Motion Detection establishes one or two “Motion Levels,” or speed ranges, with low and high RPM values. These two ranges are independent of each other. Using the MOTION ANDING screen, each output channel can be ANDed with either Motion Level.
Output Status Menu Path MAIN SCREEN to SETUP MENU to I/O STATUS to OUTPUT STATUS Purpose This screen shows the On/Off state of the output channels. Both Models, Outputs 1-8 12345678 OUTPUT 01001001 1-8< Output Numbers (1-8) Output On/Off Status (O=Off, 1=On) PS-6344-17, Outputs 9-17 901234567 OUTPUT 0100100AA 9-17<...
Password (Cont'd) If you enter a password that has been programmed through ENABLE CODES, the keypad will function at the corresponding programming level. If either of the programming enable terminals on the back of the keypad is active when a password is entered, the programming level will be whichever is greater. PASSWORD:--**<...
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Program Copy Menu Path MAIN SCREEN to SETUP MENU to PGM COPY Purpose Program Copy allows you to copy all of the channels and setpoints from one program to another. It is often easier to copy an existing program and modify it, than to enter a new program from scratch.
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Pulse Copy enu Path MAIN SCREEN to SETUP MENU to PULSE COPY Purpose Pulse Copy allows you to program a series, or “train” of pulses into a channel without having to enter the On and Off setpoints for each pulse. The Pulse Copy function prompts you for the beginning and ending setpoints for the pulse train;...
Pulse Copy (cont’d) Each pulse is 50 increments wide, separated from the next pulse by 50 increments. Program PULSE COPY as follows: PROGRAM:---< Program to add pulses to; Enter number, then SEL to go to next screen CHANNEL:---< Channel to add pulses to; Enter number, then SEL to go to next screen 0<...
Rate Setup (Cont'd) Press the SEL key to toggle display mode or rate. Following is a chart summarizing the relationships between encoder speed, units, and rate multiplier: Then an Units Rate Encoder Displayed Are… Is… Speed Of… As… 100 RPM 50 RPM 100 RPM 100 RPM...
Setpoint Use Menu Path MAIN SCREEN to SETUP MENU to SYSTEM INFO SETPOINT Purpose This function displays the total number of setpoint On/Off pairs, or “pulses” available for programming, and the number of pulses that have been programmed. Screen TOTAL: 1200 Total number of pulses available for programming USED: 64 Number of pulses programmed into all channels...
Setpoints (cont’d) Adding a Pulse You may add a new pulse to a channel by pressing the SEL key when the cursor points to either the On or the Off setpoint. CH:1 EDG ON:---< OF:--- Enter ON setpoint, then ENT or right cursor to OF. Enter OFF setpoint, then press ENT.
Shift Register ANDing Menu Path MAIN SCREEN to CONFIG MENU to CHN ANDING MENU SHFT REG ANDING Background The shift register is a form of electronic memory that sets a “bit” in the zero count of the register when a signal is applied to Terminal 16, Fig. 7. Afterwards, each time the en- coder passes the point programmed through SHIFT POSITION, the register “shifts”...
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Shift Register ANDing (cont’d) Shift Position The point in the encoder revolution at which the register shifts data is programmed through SHIFT POSITION. When programming Shift Position and the On/Off setpoints for a channel, remember the following: Don’t Place the Shift Position at the Start of a Pulse When a pulse starts at the Shift Position, as shown here, the pulse will be enabled as soon as Shift...
Shift Register ANDing (cont’d) Edge Sensitivity of Channel 91 Window (Channel 91 programmed “on” at 650, “off” at 750 in this example; Shift Position = 0) Shift Shift Shift Shift Position Position Position Position CHN 91 CHN 91 CHN 91 CHN 91 Terminal 16 Terminal 16...
Speed Compensation Menu Path MAIN SCREEN to SETUP MENU to SPEED COMP Background Some devices such as hydraulic cylinders and glue guns require a fixed amount of time to perform their function. As a machine speeds up, these devices need to be actuated earlier in the cycle in order to complete their action at the required time.
Toggle RPM Menu Path MAIN SCREEN to CONFIG MENU to DISPLAY MENU TOGGLE RPM Purpose Toggle RPM is the encoder speed at which the Position display on the Main Screen will disappear. At speeds below the Toggle RPM the Position display will be visible; at speeds above the Toggle RPM the Position will not be shown.
Controller Diagnostics CAUTION The controller cannot be repaired in the field. If a unit fails, do not disassemble it. Return it to the factory for replacement. Status LED The red Status LED on the controller, Figures 5 & 6, blinks in various patterns to indi- cate the controller status.
Keypad Diagnostics CAUTION The keypad cannot be repaired in the field. If a unit fails, do not disassemble it. Return it to the factory for replacement. Keypad Fault LED If the Fault LED on the keypad lights, turn the controller off and back on. If the keypad Fault LED does not go off, the keypad microprocessor has malfunctioned.
Encoder Troubleshooting Encoder Type The encoder used with the PS-6244 controller is an incremental quadrature encoder. The encoder sends three signals to the controller: A, B, and Z, as shown below in Figure 23. Failure Symptoms Most encoder failures or wiring problems will affect the POS (position) display. Some of the possible symptoms are listed below: Pins 1, 2, 3, 5, 9: Failure Before Startup...
General Troubleshooting The controller and keypad cannot be repaired in the field. If a unit fails, do not disassemble it. Return it to the factory for replacement. Problem Possible Solution Controller & keypad dead. 1. Check main fuse shown in Figs. 5 & 6. 2.
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General Troubleshooting (cont’d) Analog output not working. 1. Check that ANALOG QTY and ANALOG OUTPUT are programmed correctly. 2. Check that analog output module is located in the correct module position. See Fig- ure 5 or 6. 3. Check correct wiring of analog output. 4.
Introduction To Speed Compensation What Is It? “Speed compensation” refers to the ability of the PS-6244 controller to automatically advance or retard setpoints in any output channel depending on the speed of the ma- chine. Speed compensation allows devices with fixed response times, such as glue guns, to perform their functions with high accuracy over a wide range of machine speeds.
Standard Speed Comp (cont’d) Calculation (cont’d) In the previous example, the gluing system requires 15 msec from the time the gun is energized to the time the glue hits the carton. At 100 RPM, the transducer will rotate 0.6°/msec. Therefore, in the 15 msec response time, the transducer will rotate (15 msec x 0.6°), or 9°.
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Standard Speed Comp (cont'd) Response Time Suppose that in the previous example, the response time was unknown. Unknown To set up the machine, jog a carton through the machine and set the glue gun ON and OFF setpoints as described earlier. Then, estimate a response time and enter it into the controller using the SPEED COMP function described in Section 3.
Leading Trailing Speed Comp Leading/Trailing In the previous example, the response time of the glue gun was the same whether turning on or turning off. While this applies to many systems, some devices have differ- ent on/off response times. For these devices, PS-6244 controllers with the “-L” option (Leading/Trailing Edge) provide the ability to program different speed compensation values for the leading and trailing edges of the pulse driving the device.
Leading/Trailing Speed Comp (cont’d) Figure 27—Example for Calculating Leading and Trailing Edge Glue On Glue Off Difference 1st Line Speed: 73° 156° 83° 2nd Line Speed: 49° 144° 95° Note that the length of the pulse is 83° at 200 RPM, and 95° at 680 RPM. This means that the leading and trailing edges require different speed compensation values.
Speed Comp Guidelines Device Placement For speed compensation to work most effectively, the device being controlled by the output channel should be located on the machine in a position where the product is moving past the device at a constant speed. See Figure 29 below for an example. In the case of a glue gun, if the gun is ON when the speed is changing, the glue distribution may be inconsistent from carton to carton at varying machine speeds.
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To use PLµSNet II, a serial communications cable is required to connect the PLµS controller to an IBM compatible personal computer. This cable can be purchased from Electro Cam Corp., or it can be built by the customer using the wiring information shown in the PLµS Programming and Installation Manual.
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PLuSNET II Program (cont’d) Sample ASCII Program Copied from PS-6244 Using PLuSNET II 2: 6244 ;Model 3: 197 ;Firmware revision 4: 24 ;Output quantity 5: 5,1 ;Option: -H; High resolution NOTE: Some functions may be listed on printout 5: 7,1 ;Option: -A;...
PS-6244-24-N16M09 Controller Specs Electrical Input Voltage 20 - 30 VDC. Keypad/display is powered from controller. Input Current 500 mA maximum (control only) Power Consumption: 35 VA Permanent Memory: EEPROM (no battery required) Accessory Power Out: 20 - 30 VDC, 250 mA Max (same source and voltage as input power) Safety Compliance: Listed to UL 508 industrial control equipment, file E151636 Environment...
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SLIMLINE Output Module Specifications AC Outputs Part # EC-OAC240-3 Output Voltage: 24 to 280 VAC Output Current: 3 Amps cont. up to 113° F 2 Amps cont. @ 158° F 1 Cycle Surge: 80 Amps peak Turn On Time: Random (Not 0 Cross) Turn Off Time: 0 Cross (max time: 1/2 cycle) Off State Leakage:...
Index Entries in ALL CAPS are programming functions which are arranged alphabetically in Section 3. bsolute Offset ............3-15 actory Defaults ............A-3 Access Codes, Entering .......... 3-16 Fault LED, Keypad ............ 4-2 Access Codes, Programming ........3-8 Function 7000 ............3-13 Access Levels .........
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Index (cont’d) Entries in ALL CAPS are programming functions which are arranged alphabetically in Section 3. Output Modules, General .......... 2-8 Setpoints, Clearing ......... 3-13, 3-23 Output Modules, Specifications ......... A-2 Setpoints, Defined ............. 1-7 Output Modules, Wiring ..........2-9 Setpoints, Deleting ..........
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PLuS 6244 Setpoint Record Date: PLuS Program #:_______ Description: ________________________________________________________ ANDed With… Motion Shift Speed Input # Level # Count Comp Other Comments (multiple pulses, etc.) ____ ____ ____ ____ ______ __________________________________ ____ ____ ____ ____ ______ __________________________________ ____ ____ ____ ____ ______...
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800-228-5487 (U.S.A. and Canada) • Web Site: www.electrocam.com • email: ecam@electrocam.com PRINTED IN U.S.A 257 4/99...