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1. 31 16 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Santee 8 3 Data 1 Position Data 0 to Ful ns L Data 2 Tachometer Data TA Dataf3 Circular Offset 0 to Full NE I Data 4 Stap Time 34 to 65 410 milliseconds Data 5 Brake Applied Position 0 to Full 1 Assuming a Linear Offset of zero When the Linear Offset value is not zero the Position Data will range from Linear Offset to Linear Offset Full Scale Count 1 In this case the maximum position value is 32 767 Figure 4 9 Input Data Words ModErr Word 0 Bit 0 Module Error TransFIt Word 0 Bit 1 Transducer Fault Brakeln Word 0 Bit 12 Brake Input State Set to 1 when Brake Input 1s active Brake is active when it is not receiving power Vel 0 Word 0 Bit 13 Velocity at Zero ACK Word 0 Bit 15 Acknowledge Bit Set when a new message is received via a Message Instruction The remainder of this chapter gives the specification of equipment that should be used with the 1241 This includes specifications on transducer cabling transducers and resolvers Transducer Cable Specification The cable specified for use with the 1241 depends on the total length of the run gt For runs under 100 feet 30 meters AMCI specifies Belden 9873 or an exact equivalent Quabbin 6155 is an acceptable alternative gt For runs over 100 feet AMCI speci
2. 29 Apply Power 16 CTLR x Specifications 29 Cae a New Project 16 Transducer Specifications 30 Configure the 1241 s Slot 16 Connector Pinout 30 20 Gear Drive Plymouth Ind Park Terryville CT 06786 3 eS Tel 860 585 1254 Fax 860 584 1973 http www amci com Chapter 5 General Installation Chapter 9 SAMPLE PROGRAM Guidelines About the Program 49 Background MC 31 Message Instruction Configurations 49 Surge EMI Suppression 31 Setup Data Message 49 Surge Suppression DC Outputs 32 Apply Preset Message 49 Surge Suppression AC Outputs 33 Clear Transducer Fault Message 49 Grounding 34 Program Listing esee 50 WIDE RN 34 51 Power Supply Wattage and Filtering 35 Extended Error Codes _ 51 Chapter 6 Installing the 1241 Installing the Module 37 Transducer Cable Installation 37 CTL x Wiring Diagram 38 CTLR x Wiring Diagram 38 Transducer Installation 39 Transducer Outline Drawings 39 Transducer Mounting
3. 39 Autotech Transducers 39 Brake Input Wiring eessse 39 Input Connector 39 Connector Wiring 40 Chapter 7 RSLogix 5000 Configuration A Word About Message Instructions 41 Open Your Project 41 Configure the 1241 s Slot 41 Add a Controller Tag For Each Message Instruction 42 Add Controller Tags for the 1241 Data 42 Add Message Instructions to Ladder Logl6 2 nndis 43 Configure the Message Instruction 44 Chapter 8 DATA FORMAT Input Data 45 I Data 0 Bit Descriptions 45 Setup Data Message Format 46 Bit Descriptions 46 Apply Preset Message Format 47 Bit Description 47 Clear Transducer Fault Message Format 47 4 ADVANCED MICRO CONTROLS INC ABOUT THIS MANUAL Read this chapter to learn how to navigate through the manual and familiarize yourself with the conventions used in it The last section of this chapter highlights the manual s remaining chapters and their targeted audiences Audience This manual explains the set up installation and operation of AMCI s 1241 Resolver Interface Module for the Rockwell Automation ControlLogix PLC platform It is written for the enginee
4. A Word About Message Instructions Message Instructions are used to program the 1241 instead of the output words assigned to the module AMCI decided on this because the Message Instruction has built in hand shaking and error codes so you don t have to create this with your ladder logic The Message Instruction also has Extended Error Codes which the 1241 uses to tell the processor when there is an error in the data sent to it Extended Error Codes are given in the Error Checking section of the Sample Program chapter starting on page 51 STEP 1 Open Your Project Once you ve started RSLogix 5000 open and existing project or create a new one STEP 2 Configure the 1241 s Slot 2 1 Right click on the O Configuration branch in the open project tree window and select New Module 2 2 Select 1756 MODULE as the module type The description field will change to Generic 1756 Module 2 3 Click OK The Module Properties window will open and it will look similar to figure 7 1 below 7 1755MUDLEE 1 1 1755 MULULE Denen 1736 Module Pant Local Connection Parameters Hame m input E E 124r Desciplior 1 Bp ms 0 m Ic Slat 7 _ eee ee a o Figure 7 1 Module Properties Window Enter the following data into the page gt Name Your choice but it must begin with a letter gt Description Your choice
5. IFC Add a Message Instruction Returns Policy IFC Controller Tag eee 16 24 Hour Technical Support Number IFC Add a Message Instruction Data Tag 16 We Want Your Feedback IFC Create a send Tag xus reveren 17 Add Ladder Logic sss 17 About This Manual x Download the Program and Adel sees D 5 18 Navigating this 5 Monitor Your Data Values 18 Manual Conventions 5 Preset the Data Value 18 Trademarks and Other Legal Stuff 6 What s Going On 18 Revision Record 6 z Revision History 6 Chap s Specifications Wher 6 Speciation Sheet 19 Functionality Overview 20 Chapter 1 Introduction to the 1241 Stop Time Monitoring 21 OVETVICW 7 Hardware Specifications 22 Module Description 7 Status LED s 22 Status intres 8 Transducer Input Connector 22 Stop Time Monitoring 8 Brake Input Connector 23 Compatible Transducers 9 Module Parameters
6. Emu Code Extended Eny Code Timed Out Enor Eno Test x ce _ Figure 7 4 Message Instruction Configuration 6 2 Enter the following data into the fields gt Service Type gt Service Code Class gt Instance gt Attribute gt Source Element gt Source Length gt Destination Custom 4 4 For Setup Data block 200 For a Apply Preset command block 204 For a Clear Fault command block 205 0 The name of the tag that holds the data to be sent to the 1241 with this instruc tion This tag must exist before the Message instruction can be configured For a Setup Data block 10 For a Apply Preset command block 2 For a Clear Fault command block 2 Leave Blank 6 3 Click on the Communications tab in the Message Configuration window You must then set the path parameter to point to the 1241 module All of the remaining parameters including everything under the Tag tab can be left at their defaults Click on OK to close the window The only thing left to do is initialize the tags that contain the programming data The format of this data along with the format of the position and tachometer data produced by the 1241 is the subject of the next chapter 44 ADVANCED MICRO CONTROLS INC CHAPTER 8 DATA FORMAT Input Data Input data is the status position tachometer and stop time information produced by the 1241 Assuming
7. Two axis stepper indexer With features similar to the 3202 module this unit allows you to place the indexer where you need it thereby sim NXIF2C ControlNet plifying wiring on large installations The ControlNet interface also makes it easy to use the NX1F2C in PLC 5 and SLC500 systems Four axis stepper indexer With features similar to the 3202 module this unit allows you to place the indexer where you need it thereby sim NAIC ControlNet plifying wiring on large installations The ControlNet interface also makes 1t easy to use the NX1F4C in PLC 5 and SLC500 systems Stepper Drive Indexer Combination with integrated ControlNet inter face Programmable over ControlNet or an RS 232 485 port this microstepping drive is designed for size 23 through 42 motors and fea SD17098IC ControlNet tures RMS current control a 170Vdc output bus and up to 9 8A of motor current Designed to save the cost of a separate indexer module for applications that are already using ControlNet the indexer supports blended move profiles as well as velocity mode programming Table 1 2 Other ControlLogix Products ADVANCED MICRO CONTROLS INC INTRODUCTION E EH Other AMCI Products AMCI has been serving the industrial automation sector since 1985 and we have a broad range of other prod ucts used throughout the market gt DURACODERS Absolute Analog or Incremental encoders that replace the fragile glass disk and sen sitive optics
8. gt Comm Format Data DINT gt Slot Location of 1241 module gt Connection Parameters Assembly Instance w o 195 Configuration 1 0 20 Gear Drive Plymouth Ind Park Terryville CT 06786 41 Tel 860 585 1254 Fax 860 584 1973 http www amci com WA RSLOGIX 5000 CONFIGURATION STEP 2 Configure the 1241 s Slot continued 2 4 Click on Next gt to go to the Connection page Set the RPI Rate Packet Interval Time to the desired value The minimum value for the 1241 is 0 4 milliseconds 2 5 The other pages in the Module Properties window are not used be the 1241 so click on Finish gt gt The 1241 will now appear in the project tree under the I O Configuration branch Three data tags that appear in the Controller Tags window are also created gt Local X C Data 0 X slot number Configuration data is not used by 1241 gt Local X I Data 5 X slot number Six Input double integer words Contains Status Position Tachometer and Stop Time data from 1241 The words are numbered 0 to 5 gt Local X O Data 0 X slot number Output data is not used by 1241 You can view that data that is in these tags in the Controller Tags window If this window in not presently open in your project click on Logic in the menu bar and then click on Monitor Tags STEP 3 Add a Controller Tag For Each Message Instruction Before adding an RSLogix 5000 Message Instruction to your ladder logic i
9. m 40E ADVANCED ll micRo CONTROLS INC Manual 940 0C011 1241 Resolver Interface Module M AUT S A N OMPASS AMERICAS PARTNER GENERAL INFORMATION Important User Information The products and application data described in this manual are useful in a wide variety of different applica tions Therefore the user and others responsible for applying these products described herein are responsible for determining the acceptability for each application While efforts have been made to provide accurate information within this manual AMCI assumes no responsibility for the application or the completeness of the information contained herein UNDER NO CIRCUMSTANCES WILL ADVANCED MICRO CONTROLS INC BE RESPONSIBLE OR LIABLE FOR ANY DAMAGES OR LOSSES INCLUDING INDIRECT OR CONSEQUENTIAL DAM AGES OR LOSSES ARISING FROM THE USE OF ANY INFORMATION CONTAINED WITHIN THIS MANUAL OR THE USE OF ANY PRODUCTS OR SERVICES REFERENCED HEREIN No patent liability is assumed by AMCI with respect to use of information circuits equipment or software described in this manual The information contained within this manual is subject to change without notice This manual is copyright 2002 by Advanced Micro Controls Inc You may reproduce this manual in whole or in part for your personnal use provided that this copyright notice is included You may distribute copies of this complete manual in electronic format provided that they
10. o o c m N Cc c ja m N m et g 3 E oO a an n Cc e ge H25 FE 0 375 NEMA 4 size 25 end connector H25 FIE 0 375 1 EMA 4 size 25 end connector Bolt in replace ent for Namco C amp A HT 11B transducers H25 FS EMA 4 size 25 side connector H25 FL 0 375 4 size 25 integral 15 foot 3 meter cable H25 SE 0 375 EMA 4 size 25 end connector 25 55 0 375 4 size 25 side connector H25 SL EMA 4 size 25 integral 15 foot 3 meter cable MR 4 Bo RL100 transducers Also has HT 20 bolt pattern 1 NPT HT 400 0 625 Front thread for conduit connection Internal terminal strip for resolver connections HT 400 1E 0 625 Same as HT 400 with an AMCI MS connector Z S Z E Z 1 1 1 1 1 instead of a conduit connection 20 0 625 9 HT 20 with internal 1 gear ratio 20 1 0 625 single turn resolvers single MS connec Redundant single turn resolvers Bolt in replace HTT 400 1 0 625 Front 1 ment for Autotech RL220 transducers Dual AMCI MS connectors Available gear ratios are 2 1 2 5 1 2 77 1 3 1 4 1 4 8 1 5 1 6 1 7 1 8 1 9 1 10 1 12 1 13 1 15 1 16 1 18 1 20 1 24 1 36 1 40 1 50 1 60 1 64 1 100 1 105 1 150 1 180 1 250 1 and 256 1 Additional gear ratios may be available Check our website www amci com for an up to date listing This package contain tw
11. 585 1254 with the model number and serial number if applicable along with a description of the problem A RMA number will be issued Equipment must be shipped to with transportation charges prepaid Title and risk of loss or damage remains with the customer until shipment is received by AMCI 24 Hour Technical Support Number 24 Hour technical support is available on this product For technical support call 860 583 7271 Your call will be answered by the factory during regular business hours Monday through Friday 8AM 5PM EST During non business hours an automated system will ask you to enter the telephone number you can be reached at Please remember to include your area code The system will page one of two engineers on call Please have your product model number and a description of the problem ready before you call We Want Your Feedback Manuals at AMCI are constantly evolving entities Your questions and comments on this manual are both welcomed and necessary if this manual is to be improved Please direct all comments to Technical Docu mentation AMCI 20 Gear Drive Terryville CT 06786 or fax us at 860 584 1973 You can also e mail your questions and comments to techsupport amci com ADVANCED MICRO CONTROLS INC __ ___ TABLE OF CONTENTS General Information Chapter 3 System Checkout Important User Information IFC continued Standard Warranty
12. Each of these controlling tags must have a data type of Message 5 3 Define tags that contain the setup data to be written to the 1241 All tags must have a data type of Integer The Setup Data is five words long The Apply Preset and Clear Transducer Fault data are one word long STEP 6 Add Ladder Logic to Program the 1241 6 1 Enter the ladder logic to control the 1241 A sample ladder logic segment can be found in chapter 9 SAMPLE PROGRAM starting on page 49 STEP 7 Verify and Fine Tune Your System The steps that you ll have to take depends on your system However verify that you can program the module and if the Transducer Fault Latch is enabled clear transducer faults Also cycle the machine to verify that the position remains correct Remember that a resolver is an absolute device that does not gain or lose counts If the position appears to drift as you run the machine the most probable cause is a loose coupler somewhere in the machine 14 ADVANCED MICRO CONTROLS INC 0 SYSTEM CHECKOUT This chapter is for new users that want to bench test the 1241 to become familiar with its features Because it assumes you re bench testing the module installation practices such as grounding and surge suppression are not covered This chapter also assumes you have a grasp of the fun damentals of configuring and programing a ControlLogix system Needed Equipment The following equipment is needed to walk through th
13. These words are referenced by the tag you specified as the Source Element when configuring the Message Instruction See Configure the Message Instruction on page 44 for more information on setting the instruction Instance Length and Source Element values SETUP DATA WORDS Instance 200 Source Length 10 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 g 855 8 Word 0 Full Scale Count Word 1 2 to 8 192 Default of 1 024 Preset Value ord 2 Linear Offset to Linear Offset Full Scale Count 1 Circular Offset Word 3 0 to Full Scale Count 1 Linear Offset Word 4 0 to 32 768 Full Scale Count Figure 8 2 Setup Data Format Bit Descriptions COS Change of State Interrupt Enable Bit 0 When this bit is reset the 1241 will send data to the processor at the RPI Rate Packet Interval Time specified when you configured the module When this bit is set and the position value changes the 1241 will issue an interrupt to the processor which will cause the data be read again This is typically used in programmable limit switch appli cations where the processor determines limit switch states instead of leaving this function to a ded icated module such as AMCI s 8213 AUTION you are running the transducer at high speeds setting this bit can adversely affect the response time of the processor See COS I
14. Word 0 Bit 8 Resolver Type 0 AMCI ADVANCED MICRO CONTROLS INC __ 26 SPECIFICATIONS Ed Apply Preset Message Format This programming block applies the Preset Value programmed with the Setup Data programming block caus ing the Position value to become equal to the programmed Preset Value This block is also sent with an RSLogix 5000 Message Instruction not through the single 32 bit DINT output word assigned to the module The information presented here is not explained in detail A complete format description can be found in the Apply Preset Message Format section of chapter 8 starting on page 47 APPLY PRESET Instance 204 Source Length 2 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 AplyPV Word O Figure 4 7 Apply Preset Format AplyPST Word 0 Bit 0 Apply Preset Value This bit must be set when transmitting this message Therefore the value of the word must equal 1 Clear Transducer Fault Message Format This programming block clears a latched transducer fault This block is also sent with an RSLogix 5000 Mes sage Instruction not through the single 32 bit DINT output word assigned to the module The data word is not used with this command Therefore the state of the bits is Don t Care and can be set to either zero or one The module reads the Instance value of the command and clears the
15. 2 or 3 gt When send 1 The Setup Data Message is sent to the 1241 gt When send 2 The Apply Preset Message is sent to the 1241 gt When send 3 The Clear Transducer Fault Message is sent to the 1241 When the Message Instruction finishes its Done bit gets set which resets the value of send to zero Message Instruction Configurations Setup Data Message Message Controller Tag data_program values Apply Preset Message Message Controller Tag data_preset values Tag Name amci_setup_message Service Type Custom Service Code 4C Class 4 Instance 200 Attribute 0 Source Element data_program Name of tag that contains the programming data Source Length 10 Word 0 16 000C Transducer Fault Latch is enabled Velocity Update set to 32 mS Resolver Type Count Direction and COS Interrupt set to default Word 1 360 Full Scale Count Word 2 180 Preset Value Word 3 000 Circular Offset Word 4 000 Linear Offset Tag Name amci_preset_message Service Type Custom Service Code 4C Class 4 Instance 204 Attribute 0 Source Element data_preset Name of tag that contains the Apply Preset data Source Length 2 Word 0 1 This word must always equal 1 when writing it to the 1241 Clear Transducer Fault Message Message Controller Tag data_clear values Tag Name amci_preset_message Service Type Custom Service Code 4C Class 4 Instance 205 Attribute 0 Source Element data_clear
16. 23 Other ControlLogix Products 10 Full Scale Count 23 Other AMCI Products 11 Circular Offset sss 23 Linear Offset ese 24 Chapter 2 Quick Start Preset Value 24 Get Familiar With the 1241 13 COS Interrupt Enable 24 Decide On Needed Functionality 13 Count Direction 24 Determine Parameter Values 13 Tachometer Response 25 Transducer Fault Latch 25 Install Hardware eese 13 Resolver 25 Configure Your RSLogix 5000 Software 14 25 Add Ladder Logic to Program the 1241 14 ve A BL MN 26 Verify and Fine Tune Your System 14 Re E Setup Data Message Format 26 Chapter 3 System Checkout Apply Preset Message Format 27 Needed tinent 15 Clear Transducer Fault Message Format 27 Install the Modules in the Chassis 15 Message Instruction Error Codes 27 Faking A Transducer or Input Data Format 28 Attaching Real One 15 Transducer Cable Specification 28 Attach the PC to the Processor 16 CTL x Specifications
17. Below 77364 0 250A max 5Vdc nominal 0 065A max 24Vdc nominal 0 250A max 24Vdc under short circuit conditions Environmental Conditions Operating Temperature 0 to 60 C Relative Humidity 5 to 95 w o condensation Storage Temperature 40 to 85 20 Gear Drive Plymouth Ind Park Terryville CT 06786 Tel 860 585 1254 Fax 860 584 1973 http www amci com m Fal SPECIFICATIONS Functionality Overview The functionality of the 1241 is fairly easy to outline 1 The 1241 supplies position and velocity feedback from a rotating shaft to a ControlLogix processor The position sensor is an AMCI brushless resolver gt The position value is absolute re calculated every 200 microseconds and is in no way dependent on the previous value Ifthe shaft is rotated while power is removed from the 1241 the 1241 will be able to correctly determine the position of the shaft when power is re applied gt Ifa position value is incorrectly calculated due to a transient condition such as electrical noise future position values will be correct once the transient condition ends 2 The position value can be scaled to any value between 2 and 8 192 counts per turn gt scaling of 360 implies one count per degree of transducer shaft rotation 3 The 1241 contains multiple parameters that allow you offset the position value gt These eliminate the need to mechanically align the transducer s shaft with the machi
18. Position 3 Clear Faults EQU MSG 0002 Equal Type CIP Generic EN Source A send Message Control amci clear message DN 0 ER Source B 3 1 Setup Data 2 Preset Position Set when Setup Transfer complete 3 Clear Faults amci setup message dn MOV 0003 jr Move EC Source 0 Set when Apply Preset Transfer complete amci preset message dn Dest send JLE 0 Set when Clear Error Transfer complete amci_clear_message dn End ADVANCED MICRO CONTROLS INC SAMPLE PROGRAM 9 Error Checking The Message Instruction includes the ability to communicate error messages from the 1241 when there s a problem with the data To try this out 1 Add a new control tag to your project named amci_buffer with an integer data type 2 Change the value in word 1 of the data_program tag to 10 000 This will attempt to program a Full Scale Count of 10 000 which is invalid 3 Add the following rung to your ladder logic sample program Whenever the amci_setup_message err tag equals 9 a programming data error has occured The Message Instruction completed without error but the data was bad The amci_setup_message exerr tag contains a code that defines the error in the data When an error occurs store the exerr extended error tag in a buffer tag EQU MOV Equal Move Source amci setup message err Source
19. bar that appears when you double click the rung the mnemonic is MSG If you enter the instruction this way you can also enter the name of the message con troller tag which is amcil241 presetcmd in this example Before you can use the Message Instruction you must configure it by clicking on the ellipsis button Once you click on the ellipsis button enter the following data in the Configuration tab of the window that appears gt Service Type Custom gt Service Code 4 gt Class 4 gt Instance 204 gt Attribute 0 gt Source Element amci1241 presetdata gt Source Length 2 gt Destination Leave Blank 20 Gear Drive Plymouth Ind Park Terryville CT 06786 17 Tel 860 585 1254 Fax 860 584 1973 http www amci com EH SYSTEM CHECKOUT Add Ladder Logic continued Click on the Communications tab in the Message Configuration window and set the path parameter to point to the 1241 module All of the remaining parameters including everything under the 7ag tab can be left at their defaults Click OK to close the window Download the Program and Switch to Run Mode It s beyond the scope of this manual to tell you how to accomplish this in the RSLogix 5000 software If you need help downloading the program refer to your Rockwell Automation documentation Monitor Your Data Values Once the system is up and running view the data in the Local X I Data Y tags where X is the slot number of the 12
20. if the pro cedure is not followed properly The following table shows the text formatting conventions Description Normal Font Font used throughout this manual Emphasis Font Font used the first time a new term is introduced Cross Reference When viewing the PDF version of the manual clicking on the cross reference text jumps you to referenced section 20 Gear Drive Plymouth Ind Park Terryville CT 06786 5 Tel 860 585 1254 Fax 860 584 1973 http www amci com ABOUT THIS MANUAL Trademarks and Other Legal Stuff The logo is a trademark and AMCI and DuraCoder are registered trademarks of Advanced Micro Controls Inc Allen Bradley ControlLogix RSLogix 5000 and Rockwell Software are trademarks of Rockwell Automation Adobe and Acrobat are registered trademarks of Adobe Systems Incorporated All other trademarks contained herein are the property of their respective holders This product incorporates technology which is licensed from Allen Bradley Company LLC Allen Bradley has not technically approved nor does it warrant or support this product All warranty and support for this product and its application is provided solely by Advanced Micro Controls Inc Revision Record This manual 940 0C011 is the first revision of the manual It was initially released January 22 2003 It changes the current draw specifications to reflect the changes made to the mod
21. module also has multiple inputs for homing and over travel protection AMCI also has a full line of drives and motors to complete your stepper motor system Four channel stepper indexer module for the ControlLogix backplane Featuring blended move profiles the module also has multiple inputs for homing and over travel protection AMCI also has a full line of drives and motors to complete your stepper motor system ControlLogix Resolver Interface unit Accepts 4 single resolver transducers or 2 dual resolver absolute multi turn transducers Reports position velocity Nenad ControlNet and fault diagnostic data The unit also has a Brake Input for stop time monitoring Four channel LDT interface Accepts AMCI Balluff and Temposonic NX2C4C ControlNet transducers Reports position velocity and fault diagnostics Four channel multiple magnet LDT interface Same as the NX2C4C NX2C4C 08 ControlNet except it allows up to sixteen magnets per transducer Four channel SSI interface Accepts any transducer that outputs SSI data Supports 1 to 32 bit transfers with data value programmable ControlNet from 1 to 28 bits Reports Data Value Rate of Change fault diagnos tics and raw SSI data One resolver input programmable limit switch Sixteen digital inputs NX3BIC ControlNet and sixteen solid state relay outputs Eight outputs available on board additional eight output available from an external relay board
22. nothing else Noise can radiate through the load s wiring where it can be coupled into other cables around it and the contact may eventually be damaged by high voltage inductive spikes This connection protects the contact but nothing else Noise can radiate through the load s wiring where it can be coupled into other cables or into the power supply Noise in the supply may affect any device powered by it including the Control Logix system Also if the suppressor shorts out the load will always receive power Figure 5 1 Installing Surge Suppression Devices Surge Suppression DC Outputs All inductive DC loads require a commutating or fly back diode across the load Inductive DC loads include relays solenoids and DC motors Unlike resistors diodes have a polarity and only conduct current in one direction Therefore care must be taken when installing diodes As shown in the figure below the cathode of the diode which is denoted by the white or black band on one end of the diode must be installed on the positive side of the load If you install the diode backwards it will most likely destroy itself as soon as you apply power to the load DC Load Connection Contact _ Inductive Device Power In Id n o COLORED BAND Power Return Figure 5 2 DC Output Surge Suppression The diode must be sized to handle the inductive surge of the load when it turns off gt Some devices can be ordered
23. the 1241 is located in the local chassis the data is located in Local X I Data 0 5 where X is the 1241 s slot number Note that all of the data is transmitted as thirty two bit double precision integers INPUT DATA WORDS 31 16 1514131211 10 09 08 07 06 05 04 03 02 01 00 LData o 5 0 B E 981on Data AE 2 Tachometer Data Circular Offset 0 to Full Scale Count 1 0 to 8 191 max Stop Time I Data 4 34 to 65 410 milliseconds Brake Applied Position 0 to Full Scale Count 1 I Data 5 0 to 8 191 max T Assuming a Linear Offset of zero When the Linear Offset value is not zero the Position Data will range from Linear Offset to Linear Offset Full Scale Count 1 In this case the maximum position value is 32 767 Figure 8 1 Input Data Format I Data 0 Bit Descriptions ModErr TransFIt Brakeln Vel 0 Module Error Bit 0 This bit is set by the 1241 when it detects an error with its hardware If this bit is set cycle power to the module If the bit remains on the module must be replaced Refer to the Inside Front Cover for information on contacting AMCI about our repair policy Transducer Fault Bit 1 This bit is set when there is an active transducer fault or when a transient fault has been latched by the module If the Transducer Fault Latch parameter is enabled sending the Clear Transdu
24. the instruction this way you can also enter the name of the message controller tag 5 4 Before you can use the message instruction you must configure it by clicking on the ellipsis button Figure 7 3 shows two Message Instructions entered into ladder logic The Language Ele ment toolbar is docked above the ladder logic window with the Input Output tab selected Note that the first message shows a type of CIP Generic and the second shows Unconfigured Duae da A H hes 11 nse asu ssu gt 4 gt X Favorites TimeriCounter Input Output Compare MainProgram MainRoutine program ctrl MSG Type CIP Generic Message Control msg program 12 ho R preset ctrl MSG Type Unconfigured Message Control msg preset xx R Figure 7 3 Message Instructions 20 Gear Drive Plymouth Ind Park Terryville CT 06786 43 Tel 860 585 1254 Fax 860 584 1973 http www amci com WA RSLOGIX 5000 CONFIGURATION STEP 6 Configure the Message Instruction 6 1 Once you click on the ellipsis button the following window will appear mibg Nadi am Configuration Comenia Taj Message Type DI TT RENE jami Custom Source Elener deba pega Sowcelengh Bytes Sorica fac Hex Ce Tre necs 200 Alibi n Hex Enable O Ensbie aing J Sst 3 Done Done Lengit 0
25. transducer fault if possible CLEAR TRANSDUCER FAULT Instance 205 Source Length 2 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Word 0 1 0 1 0 11 01 01 01 0 1 01 01 0 1 01 01 01 0 1 0 1 0 1 0 Figure 4 8 Clear Transducer Fault Format Message Instruction Error Codes The USER_DEFINED_TAG error bit is set when there is a problem with the setup of the instruction or the data sent to the 1241 If the problem is with the data USER_DEFINED_TAG ERR equals 9 and the type of error is USR_DEFINED_TAG EXERR ERROR DESCRIPTION 1 Any reserved bits are set to 1 2 Sending the Apply Preset Value message without bit 0 being set 3 Sending the Apply Preset Value message while there is a transducer fault Full Scale Count out of its range Preset Value out of its range Circular Offset out of its range Linear Offset out of its range 20 Gear Drive Plymouth Ind Park Terryville CT 06786 27 Tel 860 585 1254 Fax 860 584 1973 http www amci com ee SPECIFICATIONS Input Data Format Input data is produced by the 1241 and is consumed by the processor Note that all data is transmitted with 32 bit double integer DINT words The information presented here is not explained in detail A complete for mat description can be found in the Input Data section of chapter 8 starting on page 45 INPUT DATA WORDS
26. trigger The stop time monitor is a monitoring feature only Any determination of the correct operation of the brake must be made by the system PLC through a user developed ladder logic program ADVANCED MICRO CONTROLS INC INTRODUCTION Compatible Transducers Table 1 1 lists the AMCI single turn transducers that are compatible with the 1241 Model Shaft Mount Turns Comments R11X J10 7 0 120 NEMA 1 size 11 resolver Leads only no connector Same as R11X J10 7 with AMCT standard single RIIX J10 7G 0 120 turn connector wired to the resolver R11X J12 7 0 188 NEMA 1 size 11 resolver Leads only no connector Same as R11X J12 7 with standard single RILX J12 7G 0 188 connector wired to the resolver 0 188 Front Side NEMA 13 R11X J12 7 transducer HT 20 0 625 Front Side EMA 4 heavy duty transducer HT 20S 0 625 Front Side HT 20C 0 625 Front Side HT 20K 0 625 Front Side HT 20L 0 625 Front Side 1 shaft w Nitrile shaft seal HT 20KS 0 625 Front Side HT 20LS 0 625 Front Side aw HT 20L with side connector ON zla 1 20 with side connector MA 4X stainless steel HT 20 w Viton shaft 1 1 1 NEMA 4X hard coat anodized HT 20 stainless steel shaft w Viton shaft seal 1 HT 20K with side connector seal and 0 5 NPT thread for conduit connection Internal terminal plug for resolver connections Z z gt A5 x lt g c o amp
27. 241 Data In addition to the controller tags defined in step three above you also need to create the tags that contain the data to be transferred to the 1241 They are defined in the same way as step three above with the following excep Select Date Type tions gt Data type is Integer LTER LO PASS TER_NOTCH gt The number of words you associate with the tag FLIP depends on what you are doing with the tag Tags INET TR used to send setup data to the module require 5 words Tags to preset the position value or clear latched transducer faults require 1 word Enter the correct value in the Dim 0 list box at the bottom of the window Figure 7 2 Data Type Window 42 ADVANCED MICRO CONTROLS INC RSLOGIX 5000 CONFIGURATION a STEP 5 Add Message Instructions to Ladder Logic The next to last step in configuring RSLogix 5000 is to add Message Instructions to you ladder logic NOTE gt The Message Instruction only transmits data when the rung makes a 0 gt 1 transition There fore you must add some type of input condition to the Message Instruction rung 5 1 Open the ladder logic window that will contain the Message Instruction 5 2 Add your input condition s 5 3 Add the Message Instruction If you are using the Language Element toolbar the Message icon is under the Input Output tab If you are entering instructions in the text bar that appears when you double click the rung the mnemonic is MSG If you enter
28. 4 4 4 4 oz in sec 6 25 X10 8 75X10 6 00X10 2 10X10 0 51X10 Weight 4 165 4 165 1 Ib 0 7 Ib 0 25 Ib Enclosure NEMA 4 or 4X NEMA 4 NEMA 4 NEMA 13 NEMA 1 Environmental All Transducers Operating Temp Shock Vibration 20 to 125 C 50 G s for 11 milliseconds 5 to 2000 Hz 20 G s Table 4 2 Single Turn Transducer Specifications Outline drawings of our transducers and full spec sheets for our most popular models are available on our website www amci com If you do not have internet access contact AMCI and we ll fax you the information Transducer Connector Pinout Figure 4 12 shows the connector pinout and internal resolver colors for all AMCI single transducers that have connectors Note that some AMCI transducers have integral cables or conduit connections For a complete listing of AMCI transducers without connectors refer to Table 1 1 Compatible Transducers on page 9 Figure 4 12 Transducer Connector Pinout 30 ADVANCED MICRO CONTROLS INC _ 707 GENERAL INSTALLATION GUIDELINES This chapter gives general information on installing electronic controls in an industrial environ ment including the importance of proper wiring grounding and surge suppression If you are responsible for installing the 1241 make sure you are familiar with these practices and follow them when installing the system This chapter is presented as a tool in the hopes of avo
29. 4 GRN s2 BLK 9 Shields CD Eels Shields SHIELDS 277 Bobo kl 2 RED A Ox an B BLK z A Connector Transducer Input Connector AMCI Part MS 20 Included with Module 2 Places BELDEN rams r 2 Places Amare Part MS 4 Phoenix MSTB1 5 8 ST 3 81 rov ne use BELDEN 9730 1803633 Figure 4 11 CTLR x Wiring Diagram The HTT 400 1 redundant resolver transducer has two separate connectors for the resolvers For this trans ducer order two CTL x cables 20 Gear Drive Plymouth Ind Park Terryville CT 06786 29 Tel 860 585 1254 Fax 860 584 1973 http www amci com Hz SPECIFICATIONS Transducer Specifications The following table contains mechanical and environmental specifications for all of AMCI s single resolver transducers that are compatible with the 1241 Table 1 1 Compatible Transducers found on page 9 gives com plete part numbers and descriptions of all compatible transducers All HT 20 x Specification All HT 20s 400 HTT 20 1 All H25 s All R11 s amp HTT 400 1 Shaft Diameter 0 625 0 625 0 375 0 188 0 120 or 0 188 Radial Shaft Loading 400 Ibs max 400 Ibs max 40 Ibs max 8 Ibs max 2 Ibs max Axial Shaft Loading 200 Ibs max 200 Ibs max 20 Ibs max 4 Ibs max 1 Ib max Starting Torque 8oz in 25 C 807 25 1 50z in 25 C 0 50z in 25 C 0 1 0z in 25 C Moment of Inertia 4
30. 41 and is the data word number The data values should be as follows Data Word Description 16 0000_3000 Status Bits Velocity at Zero and Brake Input Status bits are on 254 258 Position Data Values given assume the transducer connection is faked 0 Tachometer Data 0 Circular Offset Data 0 Stop Time Data 0 Brake Applied Position Data Table 3 1 Data Values Before Preset Preset the Data Value Change the value of the send integer tag to one This will trigger the Message Instruction to the 1241 Note that this tag resets itself in one or two scans when the Message Instruction completes Now look at the Local X I Data Y tags The values should be similar to what s below The tags that haven t change their value from the table above are omitted Data Word Description Status Bits Acknowledge Velocity at Zero and Brake Input 0 16 0000_B000 Status bits are on 1 0 Position Data The position has been preset to zero 3 767 770 Circular Offset Data Table 3 2 Data Values After Preset Wha s Going On The Message Instruction 1s configured to send down the Apply Preset command to the 1241 This is done by setting the instruction s instance to 204 its length to 2 bytes and its data tag to a value of 1 When you power up a 1241 with its factory default settings its number of counts per turn which we call the Full Scale Count is set to 1 024 With the transducer faked the module
31. 6A16S 1S Phoenix Sr 58 ST 3 81 100 30 meters use BELDEN 9730 Figure 4 10 CTL x Wiring Diagram HT 20C and HT 400 transducer are designed for conduit connections and do not have Bendix MS connectors The H25 FL and H25 SL have integral cables instead of connectors For these transducers you can order bulk cable from CTLR x Specifications CTLR x cable is used with an HTT 20 1 transducer The HTT 20 1 has two independent resolvers in one transducer package for applications that require redundant control systems If you order a CTLR x cable from that is less than 100 feet long we ship a cable that is made from Belden 9873 or equivalent If you order a CTL x that is over 100 feet we ship a cable made from Belden 9730 or equivalent One end of the CTLR x has a Bendix MS connector that mates with the HTT 20 1 transducer The other ends are pigtailed at the factory for easy connection to the MS 8P connector included with the 1241 or the MS 8 connector used by most other AMCI modules The following is a wiring diagram from a CTLR to the 1241 s MS 8P connectors CTLR x CABLE BLK N al WHT 7 S 6 S4 GRN 5 52 BLK Sela Shields JE Shields SHIELDS e 2 RED Qu Bi BLK V UO A ee BLK QD HH HG WHT 761 N Eol S
32. Name of tag that contains the Clear Fault data Source Length 2 Word 0 0 This word can be any value but a default of zero is recommended 20 Gear Drive Plymouth Ind Park Terryville CT 06786 49 Tel 860 585 1254 Fax 860 584 1973 http www amci com FI SAMPLE PROGRAM Program Listing RSLogix 5000 AMCI 1241 example MainTask MainProgram MainRoutine in file F IRSLogix 5000 Projects AMCI_1241_example ACD 1 9 2003 11 18 42 AM Page 1 Relay Ladder Logic Listing Total number of rungs 4 The SEND tag controls the data transfer to the AMCI 1241 module When this tag becomes 1 this rung transitions from false to true and the Setup Data Message is sent to the 1241 This data is 10 bytes long and contains the Setup Bits Scale Factor Preset Value Circular Offset and Linear Offset parameters The message is completely transmitted when the Done bit turns on If the Error bit turn on there was a problem with the transmission or a logical error in the data sent to the module If the problem is the data the tag amci setup message err will equal 9 and the tag amci setup message exerr will indicate the type of error 1 Setup Data 2 Preset Position 3 Clear Faults EQU MSG 0000 Equal Type CIP Generic EN Source A send Message Control amci_setup_message DN 0 ER Source B 1 The SEND tag controls the data transfer to the AMCI 1241 module When this tag beco
33. amci setup message exerr 0 0 Source B 9 Dest amci buffer 0 Figure 9 1 Error Message Buffering 4 Set your send tag equal to 1 The error tag amci setup message err will be set to 9 and the extended error tag amci setup message exerr will be set to 2 Extended Error Codes exerr Code Description Error in the first word of the Message Instruction data 1 Unused bits in Word 0 of a Setup Data Message are set See Setup Data Message Format on page 46 2 Sending an Apply Preset Message with a data word that does not equal 0001 See Apply Preset Message Format on page 47 3 Sending an Apply Preset Message while there is a transducer fault Full Scale Count outside its range of 2 to 8 192 Preset Value outside its range of Linear Offset to Linear Offset Full Scale Count 1 Circular Offset outside its range of 0 to Full Scale Count 1 Linear Offset outside its range of 0 to 32 768 Full Scale Count 20 Gear Drive Plymouth Ind Park Terryville CT 06786 51 Tel 860 585 1254 Fax 860 584 1973 http www amci com ADVANCED MICRO CONTROLS INC 20 GEAR DRIVE TERRYVILLE CT 06786 T 860 585 1254 F 860 584 1973 WWW AMC COM a LEADERS IN ADVANCED CONTROL PRODUCTS
34. ar Offset equals zero 0 to Full Scale Count 1 COS Interrupt Enable Disabled Enabled Disabled Preset Value Count Direction Positive Negative Positive Tachometer Response 120 or 32 milliseconds 120 milliseconds Transducer Fault Latch Disabled Enabled Disabled Resolver Type AMCI Autotech AMCI Table 4 1 Factory Defaults and Ranges 20 Gear Drive Plymouth Ind Park Terryville CT 06786 25 Tel 860 585 1254 Fax 860 584 1973 http www amci com SPECIFICATIONS RSLogix Message Instruction Message Instructions are used to program setup data apply a preset value and clear a transducer fault The function performed by the instruction is determined by the Instance value you specify when entering the instruction in your ladder logic This section only gives the specifications on the data you need to enter in the instruction Complete information on entering the data can be found in chapter 7 RSLOGIX 5000 CONFIGURATION starting on page 41 1 The USER_DEFINED_TAG for the Message Instruction Control must have the MESSAGE data type 2 The USER_DEFINED_TAG error bit is set when there is a problem with the setup of the instruction or the data sent to the 1241 If the problem is with the data USER_DEFINED_TAG ERR equals 9 and the type of error is USER_DEFINED_TAG EXERR 3 In the message configuration window enter the following data under the Configuration tab Service Type Cust
35. are unaltered from the version posted by Advanced Micro Controls Inc on our official website www amci com You may incorporate portions of this documents in other literature for use within the company that you own or are employed at provided that you include the notice Portions of this document copyright 2002 by Advanced Micro Controls Inc You may not alter the contents of this document or charge a fee for reproducing or distributing it Standard Warranty ADVANCED MICRO CONTROLS INC warrants that all equipment manufactured by it will be free from defects under normal use in materials and workmanship for a period of 1 year Within this warranty period AMCI shall at its option repair or replace free of charge any equipment covered by this warranty which is returned shipping charges prepaid within one year from date of invoice and which upon examina tion proves to be defective in material or workmanship and not caused by accident misuse neglect alteration improper installation or improper testing The provisions of the STANDARD WARRANTY are the sole obligations of AMCI and excludes all other warranties expressed or implied In no event shall AMCI be liable for incidental or consequential damages or for delay in performance of this warranty Returns Policy All equipment being returned to AMCI for repair or replacement regardless of warranty status must have a Return Merchandise Authorization number issued by AMCI Call 860
36. as proper installation techniques such as wiring grounding and surge suppression The chapter also contains references to the other sections in this manual where more information can be found If you don t feel you have enough information or background to complete the steps listed here always read the referenced sections before attempting to complete a step STEP 1 Get Familiar With the 1241 1 1 Chapter 4 SPECIFICATIONS chapter 7 RSLOGIX 5000 CONFIGURATION and chapter 8 DATA FORMAT contain all of the information you ll need to know to program the module 1 2 Chapter 3 SYSTEM CHECKOUT walks you through a bench test of the 1241 STEP 2 Decide On Needed Functionality 2 1 Will you use the Brake Input If you do you ll have to develop the circuit to wire into the input See the Brake Input Wiring section of chapter 6 starting on page 39 for wiring suggestions The input triggers when the input transitions from on to off If you re not using the input then there is nothing to do Don t wire anything to the input and it won t trigger STEP 3 Determine Parameter Values 3 1 The 1241 s parameters are described in the Module Parameters section of chapter 4 starting on page 23 Table 4 1 Factory Defaults and Ranges on page 25 lists the acceptable values for each parameter STEP 4 Install Hardware 4 1 The 1241 installs in the ControlLogix chassis like every other I O module 4 2 The part number of the transducer cable is CTL
37. cer Fault command message may clear the fault If the fault message remains after this command message is sent then you have an active transducer fault that you must trouble shoot before continuing Brake Input State Bit 12 This bit is set whenever the brake input is not receiving power There fore this bit will always be on if you are not using the brake input in your application The reason for this inverted behavior is that in most press applications the brake is mechanically applied when power is removed from the clutch brake assembly Therefore if the press were to loose power the brake would automatically be applied Velocity at Zero Bit 13 With a name that says it all this bit is set when the tachometer data is less than 1 RPM The state of this bit is updated at the programmed tachometer update time Acknowledge Bit Bit 15 This bit changes state when any new message is received from the pro cessor via a Message Instruction 20 Gear Drive Plymouth Ind Park Terryville CT 06786 45 Tel 860 585 1254 Fax 860 584 1973 http www amci com S DATA FORMAT Setup Data Message Format Setup data is sent to the 1241 with a Message Instruction that has an Instance of 200 As shown below Setup data consists of five single precision 16 bit integer words that are programmed into the Message Instruction as ten bytes Note that these are integers INT not double precision integers DINT like those used as input words
38. d the following two rungs of ladder logic to the MainRoutine of the project RSLogix 5000 AMCI 1241 example MainTask MainProgram MainRoutine in file F IRSLogix 5000 WProjects AMCI 1200 example ACD 5 25 2002 11 47 43 AM Page 1 Relay Ladder Logic Listing Total number of rungs 6 The SEND tag controls the data transfer to the AMCI 1241 module When this tag becomes 1 this rung transitions from false to true and the Setup Data Message is sent to the 1241 The message is completely transmitted when the Done bit turns on If the Error bit turn on there was a problem with the transmission or a logical error in the data sent to the module 1 Setup Data 2 Preset Position 3 Clear Faults EQU MSG 0000 Equal Type CIP Generic EN Source A send Message Control amc1241_presetcmd DN 0 ER Source B 1 1 Setup Data 2 Preset Position Set when Setup Transfer complete 3 Clear Faults amci1241_presetcmd dn MOV 0001 Move Source 0 Dest send 0 Figure 3 3 System Checkout Ladder Logic NOTE gt The Message Instruction only transmits data when the rung makes 0 gt 1 transition There fore you must add some type of input condition to the Message Instruction rung If you are using the Language Element toolbar to enter the Message Instruction the Message icon is under the Input Output tab If you are entering instructions in the text
39. ded to the same earth ground as the machine ground D EQUIPMENT ENCLOSURE SYSTEM ControlLogix System Mounted to Back Panel GROUNDING ELECTRODE Figure 5 3 Ground Bus System Wiring The most important aspect of wiring is determining the amount of LOW POWER CONDUIT voltage and power carried by the cable and separating low power Transducer input z cabling from high power cabling Inside of an enclosure separate the GROUND BUS two types of cabling with as much physical distance as possible and Internal to Enclosure keep the wiring neat Outside of the enclosure low and high power Pc le cabling must be run in separate conduits gt Transducer Cabling Low Power 1 Transducer signals are of low voltage and low power If you are using A B guidelines for cabling installation treat the transducer cable as a Category 2 cable Transducer cable can be installed in conduit along with other low power cabling such as communication cables and low power ac dc I O lines It cannot be installed in conduit with ac power lines or high power ac dc I O lines 2 The shield of the cable must be grounded at the 1241 only If EQUIPMENT ENCLOSURE you must splice the transducer cable it must be done ina grounded junction box When splicing treat the shield as a signal carrying conductor Do not connect the shield to earth ground at the junction box or transducer I
40. e as shown in the figure below and plug the cable into the transducer and 1241 now CTL i Connector Transducer Input Connector Part MS 16 Included with Module BELDEN 9873 Cable Ben endi a s AMCI Part MS 8P For cable lengths greater than Phoenix 1 5 8 5 3 81 100 30 meters use BELDEN 9730 18 03 63 3 m Figure 3 2 CTL x Wiring 20 Gear Drive Plymouth Ind Park Terryville CT 06786 15 Tel 860 585 1254 Fax 860 584 1973 http www amci com EH SYSTEM CHECKOUT Attach the PC to the Processor Follow Rockwell Automation literature for connecting the communication cable from the PC to the Control Logix processor Apply Power Review all power wiring and apply power to the PLC The 1241 should power up in a few seconds and the OK LED should turn on If it doesn t remove power and recheck your wiring Create a New Project If necessary create a new project in your RSLogix software for this system checkout and configure your pro cessor This step must be performed while offline Unfortunately it s beyond the scope of this manual to give details on how to create a new project and configure Rockwell Automation hardware If your RSLogix soft ware is new to you refer to Rockwell Automation literature for assistance Configure the 1241 s Slot You have to configure the 1241 s slot by specifying the data type and connection parameters used by the mod ule S
41. e system checkout gt The 1241 including the MS 8P Transducer Input Connector that shipped with the unit gt A ControlLogix processor chassis and power supply gt with programming software such a RSLogix 5000 gt Acommunication cable to connect the PC and ControlLogix processor gt Wire and assorted hand tools such as screwdrivers wire cutters and wire strippers A transducer is not absolutely needed for the system checkout but certainly can be used If you decide to use a transducer you will also need a CTL x transducer cable where x is its length in feet Install the Modules in the Chassis Follow the instructions from Rockwell Automation to attach the power supply to the chassis Install the pro cessor and 1241 into any free slots Because the 1241 is built with hardware licensed from Rockwell Auto mation it installs in the chassis like every other ControlLogix module Faking a Transducer or Attaching a Real One If you don t have an AMCI transducer and CTL x cable you can put wire jumpers on the 1241 s Transducer Input Connector as shown in figure 3 1 below After it s wired plug the connector back into the module When you power the chassis the 1241 will think that the transducer is at 90 NV 1 on BBOBOBODO pit ln oh Figure 3 1 Faking a Transducer Connection If you have a transducer and cable wire the cabl
42. e your overall scan time because the processor is forced to service the interrupts In fact do not enable this parameter if you are running at a high speed and or high resolution For example setting the Scale Factor to 1000 and running the machine at 200 RPM will cause the 1241 to raise an COS interrupt every 300 microseconds Count Direction This parameter sets the direction of transducer shaft rotation that increases the position count f the trans ducer is wired as specified in this manual and the count direction is set to positive the count will increase with clockwise rotation looking at the shaft If the count direction is set to negative the position count will increase with counter clockwise rotation gt The default Count Direction Value is positive NOTE gt It is also possible to reverse the count direction by reversing wire pairs in the transducer cable Once the machine is setup you can easily change this parameter if the position is increasing in the wrong direction 24 ADVANCED MICRO CONTROLS INC SPECIFICATIONS EN Ed Module Parameters continued Tachometer Response This parameter sets the time between tachometer updates It only affects the update time of the tachometer It does not affect the update time of the position value which is always 200 microseconds gt The default Tachometer Response is 120 milliseconds The Tachometer Response can be set to 120 or 32 milliseconds Transducer Fau
43. ested CTL X and CTLR x cables are available from AMCI They come with the anii d connector soldered and assembled on the cable and the module connections dressed and ready for ion to the 1241 s Transducer Input Connector which is included with the module Cable specifica NOTE bund under CTL x Specifications on page 29 1 Resolvers are low voltage low power devices If you are using A B guidelines for cabling installation treat the transducer cable as a Category 2 cable It can be installed in conduit along with other low power cabling such as communication cables and low power ac dc I O lines It cannot be installed in conduit with ac power lines or high power ac dc I O lines 20 Gear Drive Plymouth Ind Park Terryville CT 06786 37 Tel 860 585 1254 Fax 860 584 1973 http www amci com INSTALLING THE 1241 2 The shields of the transducer cable must be grounded at the 1241 module only Grounding is accomplished through the module The Shield pins on the Transducer Input Connector is brought to the ControlLogix chassis When installing the cable treat the shield as a signal carrying conductor Do not connect the shield to ground at any junction box or the transducer This will eliminate ground loops that could damage the module or ControlLogix system CTL x Wiring Diagram 2 CT L x CABLE Shields Shields Transducer Connector Transducer Input Connector M Par
44. eter is directly related to the Circular Offset Applying the Preset Value is accomplished by recalculating the Circular Offset For more information on the Pre set Value parameter see its section below 20 Gear Drive Plymouth Ind Park Terryville CT 06786 23 Tel 860 585 1254 Fax 860 584 1973 http www amci com ee SPECIFICATIONS Module Parameters continued Linear Offset The Linear Offset parameter changes the range of count values output by the unit and is used when the trans ducer position directly correlates to a linear measurement that does not start at zero One such example is an overhead crane Another example is a press shut height measurement For example a 1241 is used to measure a 50 00 inch span with 0 01 inch resolution 70 00 Therefore the total number of counts over the full travel is 50 00 inches 0 01 inches count 5000 counts The Full Scale Count parameter is then set to this value The 50 inches measured by the 1241 is in the range of 20 00 to 70 00 inches on the Span machine You can use the Linear Offset to force the 1241 to send the position data to the processor in the correct format instead of using the processor to add an offset once the position value is in the data tag The formula for the Linear Offset is Minimum Desired Value Resolution Linear Offset Linear Offset 20 00 i
45. f your transducer cable has individually shielded pairs then ideally the shields RODE Olio nd Power ast in the cable are also kept isolated from each other in the junction box as well ControlLogix System Mounted to Back Panel Figure 5 4 Typical Enclosure ADVANCED MICRO CONTROLS INC 34 GENERAL INSTALLATION GUIDELINES Wiring continued gt Input Cabling Low Power DC amp 1 Cabling from low power DC sensors or relays typically tied to PLC input cards or the Brake Input of the 1241 must be shielded Follow the two guidelines given above for Transducer Cabling DC Input cabling and the transducer cable can be installed in the same conduit 2 Depending on local codes cabling from low power AC sensors or relays may or may not be installed with cabling from DC sensors Follow the two guidelines given above for Transducer Cabling Cabling for AC sensors must without exception be shielded gt Output Wiring High Power AC amp DC 1 Output Wiring must be kept separate from the transducer and input wiring in order to lessen the possibility of coupling transient noise into the low power cabling 2 If a conduit containing the transducer cable or input wiring must cross conduit that contains Output Wiring they must cross at right angles gt Power Supply Wiring 24Vdc 1 If you have a separate DC supply for the ControlLogix system then it is most likely a small one tha
46. fault Solid Red Module fault such as no reference Transducer voltage Input Connector STATUS Any problem with the module will cause the STATUS LED to turn on red A problem with the transducer is indicated by blinking the LED When it blinks green the transducer signals were temporarily lost but the transducer is now working This is most commonly caused by a loose connection or a burst of electrical noise If the LED blinks red the transducer is not sending back correct signals to the module Figure 4 2 Front Panel Layout The most common causes of a non clearable transducer fault are gt Broken transducer cable gt Non compatible transducer gt Improper wiring of the transducer cable gt Improper transducer cable installation gt Faulty transducer Faulty module Transducer Input Connector Figure 4 3 shows the pinont of the Transducer Input Connector The mating con nector part number MS 8P is not shown but is included with the module 3 The figure also shows the resolver signals Cabling specifications are given later S1 in this chapter in the Transducer Cable Specification section starting on page 28 S4 Wiring diagrams are given there and in Transducer Cable Installation section of S2 chapter 6 starting on page 37 Shields gt RI R2 Reference Winding Rotor Shields gt 51 53 COS Winding Stator R2 gt 2 54 SIN Winding Stator The mating connec
47. fies Belden 9730 or an exact equivalent Quabbin 8606 is an accept able alterative These cables can be used for runs under 100 feet NOTE 5 1 Total length of run refers to the distance from the transducer to the 1241 If you have four 26 foot lengths of cable that are spliced together to form a 104 foot total run then each 26 foot cable must be Belden 9730 or equivalent 2 The important characteristic when determining an acceptable equivalent is the capacitance between conductors Belden 9873 has a conductor conductor capacitance of 30 pf ft Belden 9730 has a conductor conductor capacitance of 12 5 pf ft ADVANCED MICRO CONTROLS INC 2285 SPECIFICATIONS CTL x Specifications If you order CTL x cable from AMCI that is less than 100 feet long we ship a cable that is made from Belden 9873 or equivalent If you order a CTL x that is over 100 feet we ship a cable made from Belden 9730 or equivalent One end of the CTL x has a Bendix MS connector that mates with all AMCI single turn transducers that have a connector The other end is pigtailed at the factory for easy connection to the MS 8P connector included with the 1241 The following is a wiring diagram from a CTL to the 1241 s MS 8P CT L x CABLE Transducer Connector Transducer Input Connector AMCI Part MS 16 Included with Module BELDEN 9873 Cable Bendix Part t For cable lengths greater than MS310
48. he Stop Time Monitor is typically used in press controls but can be used in any application where you need to monitor the stopping time of the resolver Some other application examples are overhead cranes and mining cars Module Description As you can see in figure 1 1 the 1241 is very simple There are two status LED s in the display and two con nectors behind the door The eight pin connector is the Transducer Input Connector and the two pin connector is the Brake Input Connector The LED above this connector is a status LED for the input AMCI purchases the case pieces backplane connector and backplane interface IC directly from Rockwell Automation under license These are the same components used by Rockwell Automation products so the 1241 is 100 mechanically and electrically compatible with the ControlLogix system 20 Gear Drive Plymouth Ind Park Terryville CT 06786 7 Tel 860 585 1254 Fax 860 584 1973 http www amci com IE ES INTRODUCTION Module Description continued Status LED s The two Status LED s allow you to quickly verify the operating status of the module E NAE The OK LED shows the state of the communications between the 1241 and back plane It s actually controlled by the A B interface IC It does not indicate the working state of the module STATUS 1 The STATUS LED shows the working state of the module Any problem with the module itself will cause this LED to turn on red A prob
49. he industrial environment and therefore require little attention However there are some general guidelines that should be observed to ensure long life gt Limit transducer shaft loading to the following maximums Radial Load Axial Load All 0 625 Shafts 100 Ibs 445 N 50 lbs 222 All 0 375 amp 10mm Shafts 30 lbs 133 N 15 Ibs 66 7 N All Other Shafts 1 Ib 4 45 N 0 5 Ib 2 22 N Table 6 1 Transducer Bearing Loads gt Minimize shaft misalignment when direct coupling shafts Even small misalignments produce large loading effects on front bearings Itis recommended that you use a flexible coupler whenever possible A flexible coupler is required for all HT 6 transducers and R11 resolvers Autotech Transducers Most single turn transducer resolvers from Autotech Controls can be made compatible with the 1241 through the use of the Resolver Type parameter An AMCI RM 3 Reference module is not required Further informa tion on using Autotech transducer can be found in the FAQ section of our website www amci com The FAQ is entitled I Use Transducer From Other Manufacturers With AMCI Controllers Brake Input Wiring If you are using the 1241 in a press control application or any application that requires you to measure the stopping time of a load once a brake is applied you can use the stop time monitor of the unit See Stop Time Monitoring on page 21 for information on how the stop time mo
50. he press coming to a stop 3 The Stop Time timer stops when the change in position value equals zero The transducer is considered stopped when there is less than 1 1 024th of a rotation made in 125 milliseconds This translates into less than one turn every 2 1 minutes Obviously it takes 125 milliseconds to determine that the position has not changed for that amount of time Therefore the Stop Time timer runs until the transducer does not move for 125 milliseconds and it then subtracts 125 milliseconds from the Stop Time value 20 Gear Drive Plymouth Ind Park Terryville CT 06786 21 Tel 860 585 1254 Fax 860 584 1973 http www amci com ee SPECIFICATIONS Hardware Specifications Status LED s The two Status LED s on the front panel allow you to quickly verify the Status operating status of the module The OK LED tells you the status of the LED s backplane communication It s actually controlled by the A B inter face IC The STATUS LED give you information on the working state of the module itself Brake LED gt OK LED Solid Green Module owned two way communication Blinking Green PLC is in Program Mode or one way communication Module only send ing data to the PLC Blinking Red No communication between module and PLC Brake Input gt STATUS LED Solid Green Module and transducer are OK Connector Blinking Green Clearable transducer fault Blinking Red Non clearable transducer
51. hoosing a supply is output filtering The better the supply s filtering the better it can absorb noise that may be induced into the power supply wiring 20 Gear Drive Plymouth Ind Park Terryville CT 06786 35 Tel 860 585 1254 Fax 860 584 1973 http www amci com y GENERAL INSTALLATION GUIDELINES Notes ADVANCED MICRO CONTROLS INC CHAPTER 6 INSTALLING THE 1241 This chapter gives installation information specific to the 1241 its transducer and its brake input The chapter assumes you are familiar with installing electronic controls in an industrial environ ment including the importance of proper wiring grounding and surge suppression If you are responsible for installing the 1241 make sure you are familiar with these practices and follow them when installing the system The previous chapter which starts on page 31 give general guidelines you should follow when installing the 1241 This chapter is not a substitute for the safety practices called out in local electrical codes or in the United States the National Electrical Code published by the National Fire Pro tection Association If any conflicts exist local and national codes must be followed t is the responsibility of the user to determine what installation practices must be followed to conform to all local and national codes Installing the Module The 1241 can be installed in any ControlLogix module slot as long as power supply requirements are me
52. iding common installation prob lems It is not a substitute for the safety practices called out in local electrical codes or in the United States the National Electrical Code published by the National Fire Protec tion Association If any conflicts exist local and national codes must be followed t is the responsibility of the user to determine what installation practices must be followed in order to conform to all local and national codes Background AMCT has extensively tested the 1241 both in the lab and in the field under a wide range of conditions to see how the unit reacts to an adverse environment This includes testing the unit after intentionally installing it incorrectly The results of our testing is the following list of areas that must be addressed when engineering your system The order of the list shows the areas that have the largest impact on system operation first 1 Surge Suppression 2 Grounding 3 Wiring 4 Power Supply Wattage and Filtering This list also shows the first areas that should be investigated if your installation experiences problems Surge EMI Suppression NOTE gt All inductive devices in the system such as motors motor starters contactors relays and sole noids must have surge suppression devices installed across their coils This includes all devices that share a power supply with the ControlLogix system have wiring in the system s enclosure or wiring that is run in the same condui
53. k of R C networks is that they are harder to correctly specify than varistors Varistors only require you to specify breakdown voltage and power dissipation ratings R C networks require you to balance the need of suppression when the contacts open against the amount of surge current the relay can tolerate when the contacts close Table 5 1 shows the trade offs you must be aware of when specifying R C networks When Contacts Close When Contacts Open Low Resistance Higher surge current through relay contacts ower transient voltage spike Positive High Capacitance to charge capacitor Negative High Resistance Lower surge current through relay contacts Low Capacitance to charge capacitor Positive Table 5 1 R C Network Trade offs In general capacitor values range from 0 1 to 1 0 uF and resistor values range from 150 to 680 ohms Higher transient voltage spike Negative The easiest way to specify a R C network is by following the recommendations of the load s manufacturer Most manufacturers have tested and specify standard R C networks and many sell networks that are designed to integrate with their products If you cannot get help from your load s manufacturer feel free to contact AMCI for assistance 20 Gear Drive Plymouth Ind Park Terryville CT 06786 33 Tel 860 585 1254 Fax 860 584 1973 http www amci com GENERAL INSTALLATION GUIDELINES Grounding Proper grounding is the single most imp
54. ke Input the 1 gt 0 transition needed to start a measurement cycle Q INPUT LED BRAKE INPUT POWER CONNECTOR SUPPLY DL Input Electrical Specs 10 24 Vdc Voltage Differential Shield Brake Input Logic 0 0 to 2Vdc AF7 Connector Logic 1 10 to 30 Vdc Input requires a minimum of 10mA to activate Figure 4 4 Brake Input Wiring Module Parameters Full Scale Count The Full Scale Count specifies the number of counts generated by the 1241 For single turn transducers such as the HT 20 s and H25 s this is the number of counts generated per turn In the case of our multi turn trans ducers such as the HT 20 x family this is the number of counts generated over the transducer s number of turns For example an HT 20 20 with a Full Scale Count of 1 000 would generate 1 000 counts over 20 turns This equals 1 000 20 50 counts per turn gt The default Full Scale Count is 1 024 gt Range 15 2 to 8 192 Setting the Full Scale Count to 360 gives 1 degree resolution Circular Offset The Circular Offset lets you change the position count without rotating the transducer shaft This offset is most commonly used to force the position to the correct count after the machine has been mechanically aligned gt The Circular Offset s default value is zero gt The Circular Offset can be programmed from zero to Full Scale Count 1 NOTE gt The Preset Value param
55. kplane programming from processor to 1241 is accomplished with RSLogix s Mes sage Instruction Data Available to Processor Transducer Position Velocity and Fault Diagnostic data Stop Time and Brake Applied Position avail able when using Stop Time Monitor Min Rate Packet Interval RPI Time 400 microseconds Can be set to higher values Position Transducer Default of AMCI brushless resolver transducer Transducer Input Isolation 1500 Vac through isolation transformers Position Resolution Programmable to 1 part in 8 192 Position Update Time 200 microseconds Tachometer Resolution and Range 1 RPM over 0 to 5 000 RPM range Stop Time Monitor On board timer measures the time between the on off transition of the module s DC Brake Input and the transducer rotation stopping Most commonly used in press applications to collect data to determine brake functionality the module measures a stopping time of 34 milliseconds to 65 410 seconds with 1 milli second resolution Programmable Parameters Full Scale Count counts per turn Preset Value Count Direction Circular Offset Linear Offset Tachometer Update Time Transducer Fault Latch Transducer Type COS Interrupt Enable Program Storage EEPROM Memory Minimum 100 000 write cycles Brake Input 10 to 30 Vdc isolated input Requires 10 mA minimum to operate DC Supply Voltage from Backplane Serial 77364 and above 0 540A max 5Vdc Serial
56. lem with the transducer is OK indicated by blinking the LED When it blinks green the transducer signals were temporarily lost but the transducer is now working This is most commonly caused Figure 1 2 Status LED s by a loose connection or a burst of electrical noise If the LED blinks red the trans ducer is not sending back correct signals to the module This can be caused by improper wiring or a faulty transducer A more in depth description of the status LED s is given in the Hardware Specifications section of chapter 4 starting on page 22 Stop Time Monitoring If you are using the 1241 in a press control application you can use the stop time monitoring feature to mea sure the stopping time of the crankshaft The stop time monitor on the unit measures the time between the on to off transition of the Brake Input and the stopping of the transducer The Stop Time Timer measures a stop ping time of 34 milliseconds to 64 140 seconds with a resolution of 1 millisecond The 1241 also captures the position at which the brake is applied and reports this information along with the stopping time when a brake cycle is completed This information is reported over the backplane until the next brake cycle finishes If you are not using the unit in a press control application or any other application that requires you to monitor the Stopping time of your machine then you can leave the Brake Input un wired and the Stop Time Monitor will never
57. lt Latch Transducer faults can be caused by improper wiring electrical noise or a damaged transducer When the module detects a transducer fault it sets an error flag in the data it transmits over the backplane By default the 1241 clears the fault message as soon as a working transducer is properly attached It s possible to latch transducer faults which forces the 1241 to send the error flag until a Clear Errors command is received from the processor If you have a situation where electrical noise is causing spurious transducer faults that you can safely ignore you can leave the Transducer Fault Latch disabled and force the 1241 to clear faults as soon as possible Note that an intermittent wiring problem may also cause spurious faults If you want to reliably capture these tran sient faults then you must enable the Transducer Fault Latch because the 1241 can detect and clear transducer faults much faster than the processor scans the module gt The default Transducer Fault Latch value is disabled Resolver Type The Resolver Type parameter makes most Autotech Controls single turn transducers compatible with the 1241 module gt The Resolver Type default value is AMCT Parameter Defaults and Ranges Parameter Default Full Scale Count 2 to 8 192 inclusive Circular Offset Full Scale Count 1 Linear Offset 0 to 32 768 Full Scale Count Linear Offset to Linear Offset Full Scale Count 1 When the Line
58. mes 2 this rung transitions from false to true and the Apply Preset Message is sent to the 1241 This data is two bytes long The message is completely transmitted when the Done bit turns on If the Error bit turn on there was a problem with the transmission or a logical error in the data sent to the module If the problem is the data the tag amci_preset_message err will equal 9 and the tag amci_preset_message exerr will indicate the type of error 1 Setup Data 2 Preset Position 3 Clear Faults EQU MSG 0001 Equal Type CIP Generic EN Source A send Message Control amci preset message DN 0 ER Source B 2 The SEND tag controls the data transfer to the AMCI 1241 module When this tag becomes 3 this rung transitions from false to true and the Clear Transducer Fault Message is sent to the 1241 The data for this message is 2 bytes long and can be any value because the 1241 only uses the Instance Value of the message The message is completely transmitted when the Done bit turns on If the Error bit turn on there was a problem with the transmission or message parameters The Clear Error command does not have any Extended Error Codes NOTE The Clear Error Command will not clear the Extended Error Codes from a different Message Instruction The only way to clear these errors is by re transmitting valid data to the 1241 with the Message Instruction that faulted 1 Setup Data 2 Preset
59. nches 100counts inch 2000 counts gt The default Linear Offset is zero 0 00 gt The Linear Offse s range is 0 to 32 768 Full Scale Count Figure 4 5 Linear Offset Example Preset Value The Preset Value parameter allows you to set the value of the position data to any count value within its range The range of the count values is Linear Offset to Linear Offset Full Scale Count 1 When the Linear Offset equals zero this translates into 0 to Full Scale Count 1 NOTE gt Programming the Preset Value does not change the position data it only sets the value that the position will change to when an Apply Preset command is initiated gt The range of the Preset Value is Linear Offset to Linear Offset Full Scale Count 1 When the Linear Offset equals zero this reduces to 0 to Full Scale Count 1 If you program a Linear Offset and leave the Preset Value at zero the 1241 will respond with an error COS Interrupt Enable The COS Change of State Interrupt Enable parameter allows the 1241 to interrupt the processor whenever the position value changes The processor should respond by reading the module s data These readings are in addition to the readings at the programmed Rate Packet Interval RPI Time This is commonly used in programmable limit switch applications when the limits are being generated by the PLC NOTE gt Even though you will decrease the update time of the 1241 you will increas
60. ne s shaft 4 The 1241 contains a Count Direction parameter that allows you to program the direction of rotation needed to increase position values 5 The velocity value is calculated as a change in position over time This time can be set to 32 or 120 milliseconds The velocity value is always scaled to revolutions per minute RPM 6 The 1241 has a Brake Input that can be used to monitor the stopping time of the transducer shaft gt This feature is typically used in press applications but is applicably to any system that must moni tor the stopping time of a load such as an overhead crane mining cart or an indexing table gt The DC input triggers a brake measurement cycle when it makes an on off transition The time from the deactivation of the input until the transducer motion stops is measured with one millisecond resolution gt The position value where the input deactivated and the stopping time are reported to the processor The stop time monitor is a monitoring feature only Any determination of the correct opera tion of the press brake must be made by the system PLC through a user developed ladder logic program _ 20 _ ADVANCED MICRO CONTROLS INC SPECIFICATIONS EN Ed Stop Time Monitoring Figure 4 1 shows how the stop time is measured The stop time monitor is a monitoring feature only Any determination of the correct operation of the brake must be made by the system PLC through a user developed ladder logic
61. nitor works If your application does not have this requirement you can disable the stop time monitor by not wiring the Brake Input Input Connector Figure 6 3 shows a simplified schematic of the Brake Input Note that the input requires 10 30 Vdc at 10 mA to operate The circuit is completely isolated so it can be wired as a sinking or sourcing input as shown in figure 6 4 on the following page Input LED GREEN INPUT LED RED BRAKE INPUT CONNECTOR hex Optocoupler Figure 6 3 Brake Input Schematic 20 Gear Drive Plymouth Ind Park Terryville CT 06786 39 Tel 860 585 1254 Fax 860 584 1973 http www amci com INSTALLING THE 1241 Brake Input Wiring continued Connector Wiring Figure 6 4 below is an example of how to wire the Brake Input The figure assumes that a relay is used to trig ger it A normally open contact is shown because an on to off 1 gt 0 transition is needed to trigger the stop time monitoring cycle In typical press control configurations power must be applied to the brake clutch before the crankshaft can rotate In this case the normally open contact is closed and power is applied to the input When power is removed from the clutch to apply the brake the contact opens and the unit sees the on to off transition needed to start the stop time monitoring cycle Shielded cable should be used to help with signal
62. nment The chapter includes general information on grounding Et INES wiring and surge suppression that is applicable to any controls installation INSTALLING THE Anyone that must install a 1241 Includes information on mount 1241 ing grounding and wiring specific to the unit RSLOGIX 5000 Anyone that must configure the RSLogix 5000 package to commu CONFIGURATION nicate with the 1241 Anyone responsible for developing the ladder logic to control the DATA FORMAT 1241 or anyone that needs to determine the meaning of the data transmitted by the 1241 SAMPLE PROGRAM ee must develop the ladder logic to read and write data to ADVANCED MICRO CONTROLS INC E INTRODUCTION TO THE 1241 Overview The 1241 is the first resolver interface module for Rockwell Auto mation s ControlLogix platform The module converts resolver signals to digital position and tachometer data that is reported over the backplane Status information is also reported The 1241 elim inates the separate resolver decoder box input card and associated wiring needed to bring resolver data into a PLC Like an absolute optical encoder a resolver is a sensor that con verts an angle into electrical signals However this is where the similarities end The resolver is an analog device that does not contain sensitive components such as optics and electronics that may be damaged by severe environmental conditions Also
63. noise immunity Treat the shield as a signal carrying conductor and ground it only at the power supply or the 1241 Do not ground the shield at any junction box or at both the power supply and unit This will help eliminate poten tial ground loops in your system Brake Clutch Relay A normally open contact is typically used In most press applications power is applied to the clutch to allow crankshaft movement A normally open contact is used to give the Brake Input the 1 gt 0 transition needed to start a measurement cycle input LED BRAKE INPUT CONNECTOR POWER 7 SUPPLY Input Electrical Specs 10 24 Vdc Voltage Differential Logic 0 0 to 2Vdc 77 Logic 1 10 to 30 Vdc Input requires a minimum of 10mA to activate Brake Input Connector Figure 6 4 Brake Input Wiring ADVANCED MICRO CONTROLS INC lt 40 gt _ 7 RSLOGIX 5000 CONFIGURATION This chapter covers how to add a 1241 to a ControlLogix project It covers how to configure the 1241 s slot how to add data and controller tags and how to add a Message Instruction to your ladder logic The next chapter covers the format of the data you will read and write to the module This chapter was written using RSLogix 5000 Standard Edition Version 10 0 0 If you are not running this version your setup may differ slightly Refer to your Rockwell Software documenta tion if you have any questions
64. nterrupt Enable on page 24 for more infor CntDir VelUdT TFLtch RType mation Count Direction Bit 1 When this bit is reset the Count Direction parameter is set to Positive clockwise increasing counts When set Count Direction is set to negative Velocity Update Time Bit 2 When this bit is reset the Velocity Update Time is set to 120 milli seconds When set the Velocity Update Time is set to 32 milliseconds Note that this only affects the tachometer response the position data always updates at 200 microseconds Transducer Fault Latch Bit 3 When this bit is reset the 1241 will clear transducer fault errors as soon as it can correctly determine position based on the resolver signals When this bit is set the 1241 will latch transducer faults when they occur and will leave the error flag set until the fault is cleared with a Clear Transducer Fault Message Instruction from the processor See Transducer Fault Latch on page 25 for more information Resolver Type Bit 8 When this bit is reset the 1241 is configured to use AMCI resolver transdu crs When set the 1241 is configured to use most resolver transducers from Autotech Controls The remaining data words contain the rest of the 1241 s parameters See Module Parameters starting on page 23 if you need a detailed description of the parameters 46 ADVANCED MICRO CONTROLS INC DATA FORMAT 8 Apply Preset Message Format The Preset Value parameter i
65. o resolvers geared 1 1 with the input shaft Most commonly used in systems that man date redundant sensors AMCI can install two different size 11 resolvers in the package per customer require ments Contact AMCI for more information Table 1 1 Compatible Transducers 20 Gear Drive Plymouth Ind Park Terryville CT 06786 9 Tel 860 585 1254 Fax 860 584 1973 http www amci com IE LS INTRODUCTION Other AMCI ControlLogix Products AMCI has a growing line of products for the ControlLogix platform and the ControlNet network Table 1 2 gives a brief description of these products Additional information on these units can be found on our web site www amci com Model Number Interface Description Resolver Interface Module Similar to the 1241 in functionality the ControlLogix 1242 can be configured to accept 2 single turn transducers or 1 dual resolver absolute multi turn transducer Resolver based Programmable Limit Switch This programmable limit switch turns outputs on and off based on the resolver s position and ControlLogix speed The 8213 has 16 limit switch outputs available over the back plane and 16 available off a relay board that attaches to the module Two velocity based analog outputs are also available Two channel stepper indexer module for the ControlLogix backplane with incremental encoder position feedback Featuring blended move ControlLogix profiles and profiles based on encoder feedback the
66. oller tag type of nteger and jumps to a new controller tag name field You must set the tag type to Message With your mouse move the cursor to the Type column of the message controller tag you are creating When the field gets the program focus you will see an ellipsis button appear Press this button 4 In the window that opens scroll through the list and select Message Click on OK to close the window Add a Message Instruction Data Tag In addition to the Message Instruction controller tag you defined above you must also define the tag that con tain the data to be sent to the 1241 It s defined in the same way as the four steps above with these exceptions gt Set the tag s name to amcil241_presetdata gt Data Type is Integer gt Set the length to This value is entered in the Dim 0 box Once the tag is created set its value to 1 ADVANCED MICRO CONTROLS INC SYSTEM CHECKOUT S Create a send Tag The tags you created in the previous two steps are for an Apply Preset command You also have to create a data tag to trigger the Message Instruction in the ladder logic you ll enter below Creating the tag is the same four step process as the last two sections gt Set the tag s name to send gt Data Type is Integer gt Set the length to This value is entered in the Dim 0 box Once the tag is created leave it at its default value of zero Add Ladder Logic Ad
67. om Source Element The name of the tag that contains the data to be sent to the 1241 Service Code 4C Class 4 Attribute 0 Instance and Source Length Programming Data Instance Source Length Setup Data 200 Apply Preset 204 Clear Transducer Fault 205 Setup Data Message Format Setup Data programs the 1241 s parameters and is sent with an RSLogix 5000 Message Instruction not through the single 32 bit DINT output word assigned to the module The information presented here is not explained in detail A complete format description be found in the Setup Data Message Format section of chapter 8 starting on page 46 SETUP DATA WORDS Instance 200 Source Length 10 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 e o o VelUdT CniDir wordo TFLtch Full Scale Count Word 1 2 to 8 192 Default of 1 024 Word 2 Preset Value or Linear Offset to Linear Offset Full Scale Count 1 Circular Offset Word 3 0 to Full Scale Count 1 Linear Offset Word 4 0 to 32 768 Full Scale Count Figure 4 6 Setup Data Format COS Word 0 Bit 0 Change Of State Interrupt Enable 0 Disabled CntDir Word 0 Bit 1 Count Direction 0 Positive CW VELUdT Word 0 Bit 2 Velocity Update Time 0 120 milliseconds TFLtch Word 0 Bit 3 Transducer Fault Latch 0 Disabled RType
68. ortant consideration for a safe installation Proper grounding also ensures that unwanted electrical currents such as those induced by electromagnetic noise will be quickly shunted to ground instead of flowing through the machine AMCI strongly suggests the use of a ground bus in the enclosure that houses the 1241 As shown in figure 5 3 the ground bus becomes the central grounding point for the enclosure and its equipment Bonding wires are run from the enclosure and each piece of equipment to the ground bus and then a single grounding elec trode conductor is run directly to the system s grounding electrode Each connection must be separate so a ground bus is typically fabricated in house or by the panel shop responsible for wiring the enclosure gt All ground connections must be permanent and continuous to GROUND BUS provide a low impedance path to earth ground for induced l ka noise currents Enclosure and ALL of its Equipment gt The ControlLogix chassis must be connected to earth ground j through its mounting in the enclosure and with a grounding 6 wire connected to the grounding stud on the bottom of the ControlLogix chassis gt Any non isolated power supply attached to the ControlLogix system must be connected to the same earth ground as the chas H sis to avoid ground loops gt All isolation transformer secondary windings that are grounded to conform to local or national codes must be groun
69. program Input State is Don t Care from the end of the Debounce Time until press has stopped Debounce Time Brake Trigger Input 33 mSec APosition Measured Stop Time Brake Applied Position AP 0 Figure 4 1 Stop Time Measurement 1 The 1241 captures the Brake Applied Position and starts the Stop Time Timer when the Brake Input makes a 1 0 on off transition The Brake Applied Position is not immediately placed in the input data It is updated along with the Stop Time when the brake cycle completes a If the Brake Input returns to its normal state for sixteen milliseconds in the next thirty four the input transition is considered noise and the brake cycle is aborted The next transition on the Brake Input starts another brake cycle b If the Brake Trigger Input is not in its active state for twelve of the last sixteen milliseconds of the thirty four millisecond debounce time the input transition is considered noise and the brake cycle is aborted If the input is in its active state at the end of the thirty four milliseconds the brake cycle will begin again immediately If the input is in its normal state the brake cycle will start on the next transition 2 Once the debounce time is exceeded the state of the brake trigger is ignored until the brake cycle is complete From this point on the Stop Time timer runs until the transducer position stops changing The APosition section of the diagram shows t
70. program to calculate the offset Clear Transducer Fault Message Format A Clear Transducer Fault Message is a Message Instruction to the 1241 that has an Instance of 205 and a length of 2 bytes Note that these bytes are treated as a single integer INT This word is referenced by the tag you specified as the Source Element when configuring the Message Instruction See Configure the Message Instruction on page 44 for more information on setting the instruction Instance Length and Source Element values The data sent to the 1241 with this instruction is ignored Therefore it can be set to any value However AMCI strongly suggests setting this word to zero CLEAR TRANSDUCER FAULT Instance 205 Source Length 2 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 Word O 1 0 1 0 1 0 1 011 011 0 170 170 170 1 0 1 011 011 0 1 0 170 170 Figure 8 4 Clear Transducer Fault Data Format 20 Gear Drive Plymouth Ind Park Terryville CT 06786 47 Tel 860 585 1254 Fax 860 584 1973 http www amci com S DATA FORMAT Notes ADVANCED MICRO CONTROLS INC 48 CHAPTER 9 SAMPLE PROGRAM About the Program The ladder logic itself is very simple That s because most of the work is being done automatically by the Message Instruction The sample makes use of an integer value named send Your program or you if you re changing its value manually set the value of send to 1
71. r responsible for incorporating the 1241 into a design as well as the engineer or technician responsible for its actual installation Navigating this Manual This manual is designed to be used in both printed and on line forms Its on line form is a PDF document which requires Adobe Acrobat Reader version 4 0 to open it Bookmarks of all the chapter names section headings and sub headings are in the PDF file to help you navi gate through it The bookmarks should have appeared when you opened the file If they didn t press the F5 key on Windows platforms to bring them up Throughout this manual you will also find green text that functions as a hyperlink in HTML documents Clicking on the text will immediately jump you to the referenced section of the manual If you are reading a printed manual most links include page numbers The PDF file is password protected to prevent changes to the document You are allowed to select and copy sections for use in other documents and if you own Adobe Acrobat version 4 05 or later you are allowed to add notes and annotations Manual Conventions Three icons are used to highlight important information in the manual NOTE gt NOTES highlight important concepts decisions you must make or the implications of those decisions D CAUTION CAUTIONS tell you when equipment may be damaged if the procedure is not followed properly WARNINGS tell you when people may be hurt or equipment may be damaged
72. s not applied to the position data when it s programmed with the Setup Data Message Programming the Preset Value doesn t change the position data Changing the position data to the Preset Value requires you to send an Apply Preset Message to the 1241 An Apply Preset Message is a Message Instruction to the 1241 that has an Instance of 204 and a length of 2 bytes Note that these bytes are treated as a single integer INT This word is referenced by the tag you spec ified as the Source Element when configuring the Message Instruction See Configure the Message Instruction on page 44 for more information on setting the instruction Instance Length and Source Element values APPLY PRESET Instance 204 Source Length 2 15 14 13 12 11 10 09 08 07 06 05 04 03 02 01 00 AplyPV 0 Figure 8 3 Apply Preset Data Format Bit Description AplyPV Apply Preset Value Bit 0 This bit must always be set when you send this Message Instruction If it s not the 1241 will respond with an error Since all other bits must be zero this word must equal 1 The EEPROM is guaranteed for approximately 100 000 write cycles Therefore contin CAUTION uously presetting the position or writing new parameters to the module should be avoided If your application requires continuous presetting of the position consider using your ladder logic
73. t MS 16 Incl with Module able endix Ingen y rithi Modu e For cable lengths greater than MS3106A16S 1S Phoenix 4 MSTB1 5 8 ST 3 81 100 30 meters use BELDEN 9730 Figure 6 1 CTL x Wiring Diagram CTLR x Wiring Diagram The CTLR x is used to attach a HTT 20 1 redundant transducer to two 1241 modules The HTT 400 1 has a separate connector for each resolver and uses two standard CTL x cables CTLHR x CABLE MODULE N A 5 6 amp ao o c oQoooQooQO Transducer Transducer Input Connector Connecter BELDEN 9873 Cable 2 Places AMC Part MS 20 Included with Module 2 Places For cable jendix AMCI Part MS 8P of vuble greater than MS3106A20 27S Phoenix MSTB1 5 8 ST 3 81 100 30 meters use BELDEN 9730 18 03 633 Figure 6 2 CTLR x Wiring Diagram ADVANCED MICRO CONTROLS INC 385 INSTALLING THE 1241 Transducer Installation Transducer Outline Drawings AMCI offers a broad line of resolver based transducers for use with the 1241 module See Compatible Transducers on page 9 Outline drawings for all of these transducers and full spec sheets for our most pop ular transducers are available on our website www amci com If you do not have internet access contact AMCI and we will fax the information to you Transducer Mounting resolver based transducers are designed to operate in t
74. t The table below shows the current requirements of the modules A change was made to the power require ments starting with serial number 77364 which was shipped December 20 2002 All units shipped from AMCI after this date use the 5Vdc supply only Backplane Supply Serial 77364 Serial lt 77364 5Vdc 0 540A 2 70W 0 250A 1 25W 24V dc nominal 0A 0 065A 1 56W 24Vdc SCT condition 0A 0 250 6 00W SC Short Circuit condition This value occurs if there is a short placed across the refer ence voltage pins which are pins 1 and 2 of the eight pin Transducer Input Connector 1 Align the module s circuit board with the top and bottom card guides in the rack 2 Gently slide the module into the rack until the top and bottom latches secure the module in place To remove the module depress the top and bottom latches and slide the module out of the rack NOTE gt The ControlLogix backplane is hot swappable however Rockwell Automation discovered problem with hot swapping modules that use the 24Vdc supply All 1241 s with a serial num ber of 77364 or above can be installed and removed while power is applied to the chassis Rockwell Automation s guidelines for installing and removing modules under power must be followed to insure safe operation If you have a module with a serial number below 77364 and you need the hot swap capability contact for assistance Transducer Cable Installation Pre assembled and t
75. t s best to define the controller tag needed by the instruction The controller tag contains the bits needed to actually accomplish the data transfer 3 1 If the Controller Tags window is not already open click on Logic in the menu bar and then click on Edit Tags If the window is already open you may need to click on the Edit Tags tab at the bottom of the window 3 2 At the bottom of the controller tags table is a blank row marked by an asterisk In this row enter the name for your new message controller tag in the Tag Name column The name must begin with a letter 3 3 After you press the Enter key the program assumes a controller tag type of Integer and jumps to a new controller tag name field You must set the tag type to Message With your mouse move the cursor to the Type column of the message controller tag you are creating When the field gets the program focus you will see an ellipsis button appear Press this button 3 4 Inthe window that opens scroll through the list and select Message Click on OK to close the window It s possible for two or more Message Instructions to run concurrently Therefore each Message Instruction requires its own controller tag Repeat the steps above for each Message Instruction that will access the 1241 This could be as many as three instructions one to program the module one to apply the Preset Value and one to clear transducer faults STEP 4 Add Controller Tags for the 1
76. t as wiring connected to the 1241 DC loads are typically suppressed with a flyback diode while AC loads are typically suppressed with a RC network or varistor gt RC Networks are the preferred suppressor for AC loads 20 Gear Drive Plymouth Ind Park Terryville CT 06786 31 Tel 860 585 1254 Fax 860 584 1973 http www amci com d GENERAL INSTALLATION GUIDELINES Surge EMI Suppression continued The figure below show where surge suppression devices should be placed in the circuit Acceptable Connection Contact Power In a n o Power Return Inductive Suppressor Un Acceptable Connection 1 Contact Power In n o Suppressor Power Return o Inductive Un Acceptable Connection 2 P Contact ower In n o Suppressor Power Return Inductive Un Acceptable Connection 3 Contact Power In n o Suppressor Power Return Inductive Device The acceptable connection supresses noise at its source The wiring that connects the load to the power supply and contacts will not radiate noise when the load is switched and noise will not be coupled into the power supply This connection protects the power supply and contact but allows noise to radiate through the load s wiring where it can be coupled into other cables around it including the 1241 s transducer cable This connection protects the power supply but
77. t is mounted in the enclosure with the system In this case AC power for the supply can be routed with output wiring AC power should never be routed with the transducer or input cabling 2 If you are using a system supply and it s outside the enclosure then the supply lines should be run with the output lines if local codes permit gt Other Power Wiring High Power AC amp DC 1 Power Wiring must be kept separate from the transducer and input wiring in order to lessen the possibility of coupling transient noise into the low power cabling 2 If a conduit containing the transducer cable or input wiring must cross conduit that contains Power Wiring they must cross at right angles 3 Whenever possible conduit that contains transducer or input cabling must be kept 1 foot 30 cm away from 120Vac conductors 2 feet 61 cm from 240Vac conductors and 3 feet 91 cm from 480 Vac conductors Power Supply Wattage and Filtering A properly sized power supply is vital to system operation The best guideline that we can give you is to buy the best supply your budget allows When sizing system supplies take into consideration the surge requirements of the components you are attaching to the supply Most devices draw a surge current for a brief time when they power up If your supply cannot accommodate these surge currents the output voltage may momentarily drop when a device turns on causing data errors The other thing to consider when c
78. tep 2 of Chapter 7 RSLOGIX 5000 CONFIGURATION which starts on page 41 describes how to do this in RSLogix 5000 Version 10 The instructions are straight forward so there s no need to take up space by repeating them here Add a Message Instruction Controller Tag The 1241 transmits its position tachometer and status data to the processor through the input data words assigned to the slot However it doesn t use the output data words to accept programming data This data is sent to the 1241 with Message Instructions in your ladder logic If you re not familiar with the Message Instruction refer to your Rockwell Automation literature Each Message Instruction requires a controller tag The 1241 can use up to three different Message Instruc tions one to program the module one to preset the position value and one to clear transducer faults For this system check we ll only be using one 1 If the Controller Tags window is not already open in your RSLogix software click on Logic in the menu bar and then click on Edit Tags If the window is already open you may need to click on the Edit Tags tab at the bottom of the window 2 Atthe bottom of the controller tags table is a blank row marked by an asterisk 7 In this row enter ag the name for your new message controller tag as amci1241_presetcmd in the Name column Any name can be used but it must begin with a letter 3 After you press the Enter key the program assumes a contr
79. the position resolution of a resolver is limited only by the electronics that decode its signals When attached to a 1241 module the resolver gives an absolute position value with up to thirteen bits of position resolution over a six conductor cable An absolute optical encoder would require a cable with at least fifteen wires to accom plish the same resolution A 1241 application generally falls into one of two categories gt Rotary Application The resolver position directly corre Figure 1 1 1241 Module lates to an angular position on the machine One example is monitoring a press ram As the press cycles through one turn the resolver position is used to monitor and control such functions as material feed and part blow off gt Linear Application The resolver position correlates to a physical length These applications can be either single turn or multi turn An example of a single turn application is a packaging machine where the resolver completes one turn for each product An example of a multi turn application is monitoring the position of a load on a track or ball screw In this type of application linear position is translated to rotary position through a wheel or gearing The transducer completes several rotations in order to travel the entire distance The 1241 also has a Stop Time Monitor feature This feature measure the time between a transition on the front panel Brake Input and the stopping of the transducer rotation T
80. thinks that the position is set to 90 degrees which translates to count 256 With the input wiring faked the analog inputs are slightly over driven so the module displays a count between 254 and 258 When you enable the Message Instruction the position data is set to zero by the 1241 This is accomplished by changing the Circular Offset parameter The Acknowledge Bit which is bit 15 of I Data 0 also changes state and it does this every time you write a command to the module For example if you enable the Message Instruction again by setting the send tag to one the only change you will see in the module is that the Acknowledge bit becomes zero The writer recognizes that all of the terms introduced in the last two para graphs can be a little confusing but they re all fully described in the following chapter ADVANCED MICRO CONTROLS INC CHAPTER 4 SPECIFICATIONS This chapter contains the full specifications of the 1241 Included in it are mechanical electrical and environ mental specifications of the unit as well as descriptions of the programmable parameters their defaults and range of values This chapter concludes with the specifications of other equipment used with the 1241 such transducers and cabling Module Location Any ControlLogix module slot Occupies a sin gle slot Module Type Generic 1756 Module Registers Used 32 bit DINT words Instance Qty 100 6 195 1 0 All bac
81. tor is made by Phoenix Contact Their part number is MC1 5 8 ST 3 81 with an order number of 1803633 R1 PIN 1 Figure 4 3 Transducer Input Connector 22 ADVANCED MICRO CONTROLS INC SPECIFICATIONS Hardware Specifications continued Brake Input Connector As shown in figure 4 2 on the previous page directly above the Transducer Input Connector is the two pin Brake Input Connector and its indicator LED This input is used to trigger a stop time monitoring cycle that begins when the input transitions from on to off and ends when the transducer stops rotating The mating connector AMCI part number MS 2P is not shown but it is included with the module The con nector is made by Phoenix Contact Its part number is MC1 5 2 ST 3 81 with an order number of 1803578 This 24Vdc input is on when the input voltage is between 10 and 30Vdc 5mA Either pin can be used as the common and the input can be wired a sinking or sourcing input Pin 1 is the bottom pin when the con nector is installed When 24 volts is applied to pin 1 relative to pin 2 the indicator LED turns on green When 24 volts is applied to pin 2 relative to pin 1 the indicator LED comes on red The figure below shows one way to wire to the Brake Input Connector Brake Clutch Relay A normally open contact is typically used In most press applications power is applied to the clutch to allow crankshaft movement A normally open contact is used to give the Bra
82. ule starting with serial number 77364 Starting with the serial number all 1241 s use only the 5 volt DC supply from the backplane The use of the 24Vdc supply has been eliminated This eliminates a RIUP Removal and Insertion Under Power problem that Rockwell Automation has discovered with all ControlLogix modules that use the 24Vdc back plane supply This revision also changes the sample program in chapter 9 of this manual Revision History 940 0C011 1 22 2003 RIUP and Sample Program changes 940 0C010 7 17 2002 Initial Release Where To Go From Here This manual contains information that 1s of interest to everyone from engineers to operators The table below gives a brief description of each chapter s contents to help you find the information you need to do your job Chapier Title Intended Audience Anyone new to the 1241 This chapter gives a basic overview of Den uid TO the features available on the unit typical applications and comple mentary equipment Anyone already experienced in installing or using similar products QUICK START and wants generalized information to get up and running quickly SYSTEM CHECKOUT A bench test procedure to help you get familiar with the 1241 Anyone that needs detailed information on the 1241 including elec SPECIFICATIONS trical specifications and an explanation of its programmable parameters GENERAL Anyone new to installing electronic controls in an industrial envi ro
83. with an industrial resolver The size 25 DuraCoders are drop in replacements for similar sized optical encoders gt STEPPER MOTION Our line of stepper products that includes motors drives and indexers Stepper motor systems offer low cost motion control for many packaging machines gt PLC PLUG IN MODULES AMCI offers a broad range of PLC plug in modules for most major PLC brands including Rockwell Automation s SLC500 and 1771 I O GE Fanuc 90 70 and 90 30 and Mod icon Quantum Modules include resolver LDT and SSI interfaces programmable limit switches and registration control modules gt RESOLVER TRANSDUCERS AMCTis the only company in the market place to manufacturer its own resolvers Not only do we make the resolvers for our own products we also produce resolvers with dif ferent electrical specifications for other position feedback applications such as servo control For additional information on these items and the rest of our product lines browse through our website www amcei com or contact AMCI or your local AMCI distributor 20 Gear Drive Plymouth Ind Park Terryville CT 06786 11 Tel 860 585 1254 Fax 860 584 1973 http www amci com E INTRODUCTION Notes 12 ADVANCED MICRO CONTROLS INC _______ QUICK START This chapter was written to help an experienced user get the 1241 up and running quickly It assumes you have a solid understanding of programming a ControlLogix system as well
84. with built in fly back diodes the device manufacturer will offer sup pressors designed specifically for the device These types of devices are strongly recommended g des ADVANCED MICRO CONTROLS INC GENERAL INSTALLATION GUIDELINES Wiring continued Surge Suppression AC Outputs If you are switching AC loads with hard contacts such as mechanical relays solenoids or contactors then you must install a suppression network on the load switched by the relay The two most common suppressors for AC loads are varistors and R C networks gt AMCI strongly suggests R C networks for all AC applications A varistor is a solid state device that turns on and conducts when the voltage across its terminals exceeds its rated value Herein lies the problem with using a varistor as an AC suppressor The voltage problem must be generated before the varistor responds In our testing we have found that hard contacts will still arc when a varistor is placed across the AC load This arcing is due to the fact that the breakdown voltage of the air between the contacts when they first open can be less than the rated voltage of the varistor If the instanta neous AC voltage applied to the contacts is above the breakdown voltage of air but less than the rated voltage of the varistor the contacts will arc On the other hand an R C network acts as a low pass filter instantaneously dampening fast transients when they occur The main drawbac
85. x where x is its length in feet Note that it s a low power cable and must not be routed with high power AC or DC cabling Chapter 5 GENERAL INSTALLATION GUIDELINES which starts on page 31 contains information on installing the cable The figure below shows how to wire the CTL to the 1241 s included transducer input connector CTL x CABLE BLK Transducer Connector Transducer Input Connector AMCI Part MS 16 Included with Module BELDEN 9873 Cable Bendix AMCI Part MS 8P For cable lengths greater than MS3106A16S 1S Phoenix MSTB1 5 8 ST 3 81 100 30 meters use BELDEN 9730 18 03 633 Figure 2 1 CTL x Wiring Diagram 20 Gear Drive Plymouth Ind Park Terryville CT 06786 13 Tel 860 585 1254 Fax 860 584 1973 http www amci com EA QUICK START STEP 5 Configure Your RSLogix 5000 Software 5 1 Enter the following information when configuring the 1241 s slot Name Your choice but it must begin with a letter Description Your choice Comm Format Data DINT Slot Location of 1241 module Connection Parameters VVVVV Assembly Instance Size Table 2 1 Slot Configuration Values Configuration O6 gt RPI Time The Rate Packet Interval Time cannot be set less than 0 4 milliseconds 5 2 Define tags to control the Message Instructions that you ll use to setup the module Depending on your system you will need up to three Message Instruction tags

Manual - Advanced Micro Controls Inc

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