Series 1995A Gemco ® Micro-Set Programmable Limit Switch Installation & Programming Manual
1080 North Crooks Road Clawson, MI 48017-1097 Phone: (248) 435-0700 FAX: (248) 435-8120 Internet: www.ametekapt.com www.ametek.com Preface This manual is for the Installation and Maintenance of the Gemco Series 1995A Micro-Set Programmable Limit Switch. Copyright 2000 by AMETEK All Rights Reserved - Made in the U.S.A. Version 0.1 AMETEK has checked the accuracy of this manual at the time it was printed. Any comments you may have for the improvement of this manual are welcomed.
Contents Chapter 1: Introduction/Description 1 Chapter 2: Installation 3 Chapter 3: Programming 5 1.1 Programmable Features ....................................................................................................... 1 1.2 General Information ............................................................................................................. 1 1.3 Controller Features and Functions ........................................................................................ 2 2.
Chapter 6: Security Inputs 21 Chapter 7: Remote Circular Display 22 Chapter 8: Troubleshooting 23 7.1 POS/RPM On Remote Circular Display ............................................................................. 22 8.1 Preliminary Checks ............................................................................................................ 23 8.2 Transducer Excitation Voltages ........................................................................................... 23 8.
Chapter 1: Introduction/Description Chapter 1: Introduction/Description The 1995A Micro-Set is a fully self-contained, single-turn resolver-based programmable limit switch. It includes a three-digit LED display, six output relays, and one fault check relay, and it is fully programmable for the following features: 1.1: Programmable Features Scale Factor Two scale factors to choose from either 360 or 1,000. On units with P option software, the scale factor is permanently set to 360.
Chapter 1: Introduction/Description The completely self-contained unit can operate up to 30 independent outputs (six standard) based on the rotary position of the resolver. It offers an on line fault check which provides an automatic, in-process mechanism to verify that all major programmable limit switch functions are operating properly. The fault check output can be energized by activating the fault check enable input. The output is a mechanical relay with 1 N.O. and 1 N.C.
Chapter 2: Installation Chapter 2: Installation This section describes the installation and wiring of a standard 1995A Micro-Set PLS. Changes to these instructions should be made as necessary if special options and/or equipment are used. The 1995A Micro-Set should be installed in an area free of water spray, corrosive gases, flying chips or other foreign matter. The operating temperature should be between 32 and 125 degrees Fahrenheit, with less than 95% relative humidity. 2.
Chapter 2: Installation 2.2: Electrical Installation The Micro-Set is designed for use in an industrial environment and incorporates extensive transient suppression circuitry. However, the same general installation rules should be followed that are used on all microprocessor-based equipment.
Chapter 3: Programming Chapter 3: Programming 3.1: Security Input The security input is often referred to as the Run/Program input. This input is located on the 16-place terminal strip and is discussed in Chapter 4: Expansion Modules. This input prevents unauthorized changes to the programmed functions. With the unit in the Program mode, all functions of the controller can be programmed.
Chapter 3: Programming 3.4: Number of Outputs The 1995A comes programmed for six outputs, but it is expandable to 30 outputs. However, when using a Remote Circular Display, the maximum will be 24 outputs. 3.5: Selecting Number of Outputs Selection of the number of outputs should be done after the desired scale factor is entered, and before any other programming is done. See Chapter 4: Expansion Modules. A) To program the number of outputs desired, the unit must be in the Program mode, then depress .
Chapter 3: Programming 3.7: Setpoint Formula Setpoint/Programs = 1467 -2 Number of Programs x A Where: A = = = = = 5 for 6 outputs 6 for 12 outputs 7 for 18 outputs 8 for 24 outputs 9 for 30 outputs Setpoints are in whole numbers (drop decimal). Example: S.P. = 12 outputs relays with 10 programs: 1467 10 x 6 -2 = 24.45 - 2 = 22 Setpoints/Program The following table shows the relationship between the number of outputs, the number of programs, and the number of setpoints per program.
Chapter 3: Programming C) CIR# - 7 - 7 - 2 - ENT will display the total number of setpoints available for use in the currently selected active program. D) To display the active program, depress CIR# - 7 - 7 - 1 - ENT . To change programs, with the unit in the Program mode, depress (0 thru Highest Program Number) - ENT . NOTE: Program 0 is the first program. If 10 programs were previously selected using Code 770, there will be programs 0-9. 3.
Chapter 3: Programming on a scale factor corresponding to the 360-degree rotation of the resolver. Example: In the foregoing example, with a 360 scale factor, a dwell on of 0 and a dwell off of 100 would look like this: 0 100 359 The shaded area represents the area where the selected limit output relay is energized. Programmable limit switch outputs offer a unique function which normal rotating cam limits cannot, namely, the ability to turn a limit on or off more than once in a 360-degree cycle.
Chapter 3: Programming 3.9: Clear an Existing Setpoint A) Unit must be in the Program mode. B) Depress CIR# - (Output to be Cleared) - ENT . C) Depress CIR ON D) Depress the CLR SET key. Upon depression of the CLR SET the display after Step C is deleted. E) This keypad sequence must be completed once to clear an ON setpoint and a second time to clear the OFF setpoint. See Section 3.8: Setpoints or CIR OFF key until setpoint to be cleared is on the display. key, the setpoint on 3.
Chapter 3: Programming On units without Multiprogram, setpoint availability is dependent on the number of outputs enabled. 6 Outputs = 253 Setpoints Available 12 Outputs = 242 Setpoints Available 18 Outputs = 207 Setpoints Available 24 Outputs = 181 Setpoints Available 30 Outputs = 161 Setpoints Available Refer to the Section 3.5: Selecting Number of Outputs. 3.12: Electronic Offset The offset key is used to synchronize the digital display with the actual machine position.
Chapter 3: Programming Programming Reset-to-Preset Value The Reset-to-Preset Value is programmed by entering the following: A) Unit must be in the Program mode. B) The Reset-to-Preset must first be enabled before you can store any values. To accomplish this, depress CIR# - 1 - 6 - 6 - ENT - (0 or 1) - ENT . A zero (0) disables a C) function and a one (1) enables it. Once the Reset-to-Preset has been enabled, you can store a value in memory.
Chapter 3: Programming 3.15: Power-Up in a Position or RPM The 1995A can power up displaying either Position or RPM data. The power-up mode is programmed by entering the following: A) Unit must be in the Program mode. B) Depress CIR# - 1 - 6 - 3 - ENT - (0 or 1) - ENT . If a zero (0) is entered, positional data will be displayed upon power-up; if a one (1) is entered, the unit will power up displaying RPM. 3.
Chapter 3: Programming 3.17: Enable/Disable Outputs During setup, the outputs may be enabled or disabled. When outputs are selected to be disabled, the status LEDs and the relays will be OFF. The unit must be in the Program mode to disable the outputs; as soon as the unit is switched to the Run mode, the outputs will be enabled. The enable/disable feature is programmed as follows: A) Unit must be in the Program mode. B) Depress CIR# - (380 or 381) - ENT . CIR# 380 Enables the Outputs.
Chapter 3: Programming The graph above shows an example of four steps of linear offset in which the output circuits are being advanced in the first two steps, retarded between the second and third, and remaining unchanged between the third and fourth. The first step (501) is programmed to linearly advance the selected outputs by 20 degrees between 0 and 60 RPM.
Chapter 3: Programming 3.19: Programming 1995 PLS for Linear Speed A) Unit must be in the Program mode. B) Select the number of circuits that will be offset based on RPM. The affected circuits will always start with CIR# 1 and will follow in ascending sequence to the number specified. Depress: CIR# - 80 - ENT - (1 thru 6) - ENT . NOTE: LS6 cannot be programmed for Linear Speed if it is set for Motion detect. See Section 3.
Chapter 4: Expansion Modules Chapter 4: Expansion Modules The 1995A PLS provides six outputs. A 1995E Expansion Module is required for each additional six outputs desired, up to a total of 30 outputs, or four expansion modules (units with Remote Circular Displays may use only up to 24 outputs total, or three expansion modules). The circuit location of each expansion module is defined by the location of a two-pin jumper on an eight-pin block in the upper left corner of the module.
Chapter 3: Programming 3.21: Time-Based Outputs (Available Only on Option P Units) These outputs are programmed to turn on based on position and turn off based on a keypad selectable time interval. Circuits one through six can be selected for this type of operation. Circuits cannot be programmed for Linear Speed Offset and Time-Based outputs at the same time; thus the total combined number of Linear Speed Offset and Time-Based outputs cannot exceed six.
Chapter 5: Fault Check Chapter 5: Fault Check The Fault Check option provides an automatic in-process self-diagnostic mechanism to verify that all PLS functions are operating properly. The Fault Check option will detect and disable system operation in the event of any of the following problems: 1. Disconnect or severed resolver cable. 2. Open or shorted resolver signals. 3. Resolver excitation failure. 4. Resolver-to-digital converter or associated electronic failure. 5.
Chapter 5: Fault Check 5.
Chapter 6: Security Inputs Chapter 6: Security Inputs The Run/Program security inputs may be operated by an isolated contact, current sourcing, or a current sinking device, 5V DC @ 10mA. See Fig 11-3, Chapter 11: Wiring Diagrams. NOTE: The 1995 PLS cannot be programmed until the security input has been actuated by means of connections between +5V DC and Security + input and between Security - input and ground.
Chapter 7: Remote Circular Display Chapter 7: Remote Circular Display The Remote Circular Display (1995-1446) is ideal for mechanical stamping presses and shears. Either position or RPM can be displayed on the large 3/4 LED digital display. A 360° bar graph will increment in 10° intervals showing the angle of the resolver. The remote circular display gets its RS422 synchronous signal from the four-place terminal strip located on the back of the 1995 programmer.
Chapter 8: Troubleshooting Chapter 8: Troubleshooting The following procedures are intended to aid in isolating system malfunctions to field replaceable modules. These modules include the 1995 programmer, output relays, remote circular display, transducer, and all interconnecting cables. Once isolated, the defective module should be replaced and returned to the factory for repair. NOTE: Field repair beyond this level is not recommended. 8.
Chapter 8: Troubleshooting 8.3: Electrical Noise and Power Quality Consideration The 1995 PLS is designed for use in an industrial environment and incorporates extensive transient suppression circuitry. However, the same general installation rules should be followed that apply to all microprocessor-based equipment.
Chapter 8: Troubleshooting If the resolver cable must be run through a terminal strip, it must be mounted in a small enclosure with no other wiring. The shields of the incoming and outgoing cable must be tied together and isolated from ground. Special purpose contact inputs all operate by connecting the input pin on the 1995 PLS to a power or GND terminal (depending on method wired per Fig. 11-3; Chapter 11: Wiring Diagrams) on the 1995 PLS through a remote contact or solid-state switch.
Chapter 9: Specifications Chapter 9: Specifications 9.1: 1995 Micro-Set PLS Programmer Resolution Scale Factor Scan Time Temperature Range Operating Voltage -12 Bit (4096) -360 or 1,000 -Standard 285 µseconds -32°F to 125°F (Operating) -0°F to 150°F (Storage) -110/120V AC 50/60 Hz 300 mA INPUTS Transducer -Resolver accurate to ±3 arc minutes provides resolution of 1 part in 4096, 2800 RPM maximum speed. Logic -Fault check and security 5V DC at 10mA.
Chapter 9: Specifications 9.4: DC Solid-State (Single Pole, Normally Open) Maximum Load Load Voltage Range Leakage Current On State Voltage Drop Surge Current Min. Operational Current Operate Time Reset Time -2 Amp DC -5 to 60V DC -2 mA Maximum -1.5V Maximum -5A (1 Sec. Maximum) -50 mA -0.5ms Maximum -2 ms Maximum 9.5: 1995E Output Expansion Module Operating Voltage Temperature Range Outputs -110/120V AC 50/60 Hz 100 mA -32°F to 125°F (Operating) 0°F to 150°F (Storage) -Same as Programmer 9.
Chapter 10: Troubleshooting Guide Chapter 10: Troubleshooting Guide SYM PTOM POSSIBLE CAUSES Display Shows: EEE Incorrect programming sequence or unit is not in the program mode. Review Chapter 6: Security Inputs for Run/Program information. Display Shows: EE0 EE1 EE2 EE3 EE4 Unit has detected a fault. Review Chapters 5: Fault Check and 8: Troubleshooting. Display Shows: PPP Loss of initialization. Loss of initialization indicates a severe power fluctuation or electrical noise.
Chapter 10: Troubleshooting Guide SYM PTOM POSSIBLE CAUSES System operates properly but exhibits a random momentary loss of all outputs. Random momentary loss of all power to the system. A loss of power for as short a duration as 50 milliseconds will cause the system to shut down. When power is reapplied, the system can take several seconds to reinitialize itself. During this time period, all outputs are disabled.
Chapter 10: Troubleshooting Guide SYM PTOM POSSIBLE CAUSES Expansion module relays will not fire. Check jumpers on expansion modules for correct position placement. Refer to Chapter 4: Expansion Module. Refer to Fig. 11- 2, (Chapter 11: Wiring Diagrams) for correct wiring of expansion modules. Fault check relay not enabled. The fault check relay will only be enabled when the fault check input is wired per Fig. 11- 3 (Chapter 11: Wiring Diagrams).
Chapter 11: Wiring Diagrams Chapter 11: Wiring Diagrams Fig 11-1 Wiring Diagram Drawing E0177100 Installation and Maintenance Manual 31
Chapter 11: Wiring Diagrams Fig 11-2 Wiring Diagram Drawing E0204400 32 Installation and Maintenance Manual
Chapter 11: Wiring Diagrams Fig 11-3 Wiring Diagram Drawing E0198200 Installation and Maintenance Manual 33
1080 N. Crooks Road l Clawson, MI 48017 800-635-0289 l 248-435-0700 l Fax 248-435-8120 www.ametekapt.com l www.ametek.com 875A 01/03.
