Chapter 1
Contents
1. With a rotary encoder the leading and lagging signal is determined by which direction the shaft is turning This is how quadrature counting is able to sense direction have not shown the optional use of the Z output signal connected to INZ of the HSC that comes standard on most quadrature encoders The use of this input option will be discussed when we cover resetting the counter externally and the automatic home search feature Output Control A typical application for the D4 HSC might be that of having a quadrature type shaft encoder connected to your motor with the HSC counting and accumulating the pulses from the encoder as the motor rotates The HSC knows which way the motor shaft is turning because it knows which of the two signals being received is leading and lagging You can write ladder logic to change either the motor s speed or direction We ll show you how to do that a little later The D4 HSC provides output signals that can be used to change speed or direction Usually these signals are connected to an electronic drive or motor controller rather than the motor itself Some motors are smart with built in logic circuitry for initiating speed and direction changes In these exceptional cases the HSC can be connected directly to the motor to initiate the changes We leave it up to you to specify the motor control and thus dictate the load s2. encounter Appendices m although PLCDirect does not provide encoders or motor A Introduction to Motor drives we have included a brief overview explaining some of Drives and Shaft Encoders the more common encoders and electronic drives that may be used with the D4 HSC High Speed Counter Introduction to Motor this includes the X and Y data type assignment chart and an B Drives and Shaft Encoders address map for the seven shared memory parameters Other Resources You can also check our online resources for the latest product support information e Internet the address of our Web site is http www plcdirect com e Bulletin Board Service BBS call 770 844 4209 The note pad icon in the left hand margin indicates the paragraph to its immediate right will be a special note The exclamation mark icon in the left hand margin indicates the paragraph to its immediate right will be a warning or caution These are very important because the information may help you prevent serious personal injury or equipment damage la OL_ ms HSC Features etting Started babe is a High Speed Counter Who Needs a High Speed Counter Types of Counting Standard Counting Literally high speed counters count fast The D4 HSC high speed counter has one channel for counting pulses from sensors encoders switches and so on at rates up to 100 kHz
3. Rating or Requirement 405 CPU Firmware Requirements Any PLCDirect CPU or other vendor s 405 CPU Version 1 6 or later Slot for Installation Can be installed in any CPU or expansion base Cannot be installed in a remote base Maximum No HSC s per CPU 8 No of I O points required Consumes 16 X inputs and 32 Y outputs Intelligence Source Has its own microprocessor operates asynchronously to the DL405 CPU Internal Power Consumption 300 mA maximum at 5VDC Field Wiring Connector Removable terminal type Count Signal Level 4 75VDC to 30VDC less than 10mA Maximum Count Speed 100 kHz 50 duty cycle Minimum Input Pulse Width for Counting 5 us either state Count Input Signal Types Standard UP DOWN or quadrature phase differential Count Range 8 388 608 to 8 388 607 Count Direction UP or DOWN software selectable or hardwired CPU Scan Time Increase per HSC in base 4 2 to 5 5 ms Getting Started Counting Inputs INA INB INZ Rating or Requirement Input Voltage Range 4 75VDC to 30VDC Maximum Input Current 10 mA ON Voltage 4 75VDC ON Current 5mA OFF Voltage 2 0VDC OFF Current 1 6mA OFF to ON Delay 1 2us at 5VDC 0 8us at 12VDC 0 5us at 24VDC ON to OFF Delay 1 0us at 5VDC 1 2us at 12VDC 2 5us at 24VDC Control Inputs LD LATCH RST CINH RUN LS1 LS2
4. The HSC has an automatic feature that is designed to help find and return to a home position at the end of each work cycle You could of course write your own home search RLL However the D4 HSC relieves you of that task Since the algorithm associated with the automatic home search routine assumes a certain type of configuration you will have to make sure that the components and position of each meets certain specified criteria Then you activate the home search using a Y output relay The HSC takes over from there We ll show you how to do this later in this manual lt gt Work Area Boundaries 1 H Drill Head pom Encoder i f Motor Lead Screw Limit lJ Limit J HSC Switch Switch LS2 LS1 Work Piece Motor Controller IRONS Typical Home Search Setup KJ lt I lt ______J gt Power Supply How Does the HSC Work With the CPU Setup Performed The D4 HSCis an intelligent module that has its own microprocessor and memory Via Shared Memory The microprocessor operates asychronously to the DL405 CPU Its memory area is called shared memory because both the DL405 CPU and the HSC can read and write to this area In fact that s how you handle important items like telling the counter
5. 50 duty cycle It is designed to make your job simpler The HSC has its own microprocessor that asynchronously counts and accumulates the high speed pulses This means the main CPU of the DL405 is free to do the other important tasks It can simply check the accumulated count when it needs to do so If you have an application that needs to 3 Counting Inputs count pulses rapidly then you are a cae prime candidate for an HSC The HHING D4 HSC also has 4 outputs that can be 4 Outputs eru used for controlling motor speed and CW or CCW direction There is one special requirement The variable speed motors or motor drives that are used must be capable of changing speed when receiving a voltage input between 10 2 VDC and 26 4 VDC Many digital drives being offered today offer programmable input capability precisely for this sort of application encoder NOTE The motor control capability should not be confused with a pulse output capability such as used with stepper motors The D4 HSC outputs a voltage level dependent on an external power supply and does not have pulse output capability You should check the specs of your drive or motor carefully to make certain that the specifications of this module match your application requirements The D4 HSC can do standard UP and DOWN counting or it can do quadrature counting These are software selectable as two differ
6. 00 O Sy IN T OUT S OUT OU O Cc X00 X17 Y00 Y37 For mple gt Status of CW output lt Ym 3 Y3 0N for HSC RUN X Function No Xn 0 ON if current count is greater than preset Xn 1 ON if current count is equal to preset Xn 2 ON if current count is less than preset Xn 3 Latched ON if overflow occurs reset with Ym 1 Xn 4 Status of CCW output Xn 5 Status of OUT2 brake output Xn 6 Status of CW output Xn 7 Status of OUT1 deceleration output Xn 10 Status of Limit Switch 2 Xn 11 Status of Limit Switch 1 Xn 12 ON if doing a search for home position Xn 13 ON if a sampling is being conducted Xn 14 NOT USED Xn 15 ON for missing terminal block Xn 16 ON if external power supply for outputs is missing or OFF T ca i a Y Function No Ym 0 ON to reset OUT1 and OUT2 when in HSC run Ym 1 ON to reset overflow flag Xn 3 Ym 2 Rising edge of this signal copies offset value into current count Ym 3 ON for HSC run Ym 4 Used to control CCW when not in HSC RUN or Home Search Ym 5 Used to control OUT2 when not in HSC RUN or Home Search Ym 6 Used to control CW when not in HSC RUN or Home Search Ym 7 Used to control OUT1 when not in HSC RUN or Home Search ae el a ee a etting Started Putting It All Together Up to this point we have given you only
7. CNTR c INA Depending on mode chosen this is either a standard awa e VE 5 UP DOWN counter input or one of the quadrature counter inputs C lt P CW RST INA INB Depending on mode chosen this is either a standard e In UP DOWN counter input or one of the quadrature counter inputs _ OVR OTI INH LD2 INZ This input can be used to help you find home position for positioning control It can also be used as an external meansof D4 HSC resetting the counter Control Inputs LD If you want to use an offset number with your counting a rising INA edge signal at this terminal will copy the offset value into the current count NE RST A high ON signal at this terminal resets the counter to zero and it remains there until there is a transition to a low signal OFF INZ LATCH You may want to store the current count The rising edge LD of a signal at this terminal will store the current count in shared RST RAM Counting continues with no interruption LATCH C INH You may want to temporarily ignore the count inputs C INH coming in on INA and INB A high ON signal at this terminal will RUN inhibit the counting to accomplish this need Current count is suspended until a transition to a low OFF signal is seen RUN Not to be confused with RUN mode of the DL405
8. Rating or Requirement Input Voltage Range 10 2VDC 26 4VDC Maximum Input Current 10mA ON Voltage 10 2VDC ON Current 5mA LD and LATCH gt 4 8mA RST CINH RUN LS1 and LS2 OFF Voltage 4 6VDC LD and LATCH lt 5 6VDC RST CINH RUN LS1 and LS2 OFF Current 1 6mA LD and LATCH lt 2mA RST CINH RUN LS1 and LS2 OFF to ON Delay 75us at 12VDC LD and LATCH 82 5us at 12VDC RST CINH RUN LS1 and LS2 30us at 24VDC LD and LATCH 37 5us at 24VDC RST CINH RUN LS1 and LS2 ON to OFF Delay 240us at 12VDC LD and LATCH 105us at 12VDC RST CINH RUN LS1 and LS2 260us at 24VDC LD and LATCH 105us at 24VDC RST CINH RUN LS1 and LS2 annn Control Outputs CW CCW OUT1 OUT2 Rating or Requirement Output Power Source External 10 2VDC 26 4VDC 1A Output Type Open Collector Maximum Output Current 100 mA per point Output ON Voltage Drop 1 5VDC Output OFF Leakage Current 100uA Output OFF to ON Delay 22 5us at 12V DC 21us at 24VDC Output ON to OFF Delay 210us at 12VDC 270us at 24VDC Built In Protection Shut off when output driver C 175 C Recovers at 150 C Shut off when short 500mA is detected Recovers when short is removed Input pulse reaching Preset to internal signal reaching Output 1 Time Delay 110us J Overview of HSC Inputs and Outputs Q 0 pe D Counting Inputs 5 g np HIGH SPEED
9. manual is organized into the following seven chapters 7m includes a brief description of the high speed counter module common applications for high speed counters and 1 Getting Started an overview of the steps necessary to setup and operate the high speed counter shows you step by step how to install and wire the HSC Installation and Wiring Includes wiring diagrams X Understanding a must for understanding the rest of the manual It covers the 3 Operation shared memory concept the assignment of data types for p the HSC and how values are stored covers offsets and presets which are needed for many Setting Up and applications It provides the programming tools needed to Controlling the Count make full use of the counting capability It includes count inhibiting count latching and overflow flags this chapter introduces you to the HSC s four different control E outputs It shows you how HSC RUN uses your preset 5 Controlling the Outputs information and current count to trigger the outputs in an ordered format It also covers manual operation of the outputs without using HSC RUN covers two special features that have been built into the 6 Special Features HSC You will learn about sampling and home search capabilities shows you how to write programs that will provide possible 7 Applications solutions for some common applications you might
10. the very basic information about the HSC module The six chapters that follow will give you the additional information you need to make full use of the HSC There are five basic steps for using the HSC Five Steps for Using the HSC Document Install the Module and Connect the Wiring Chapter Two Document Understand How the Module Maps into the I O Points and How the Setup Information is Stored Chapter Three Document Setup the Counting and Control Input Parameters Chapter Four Document Setup the Control Outputs Chapter Five Document Setup Any Special Features Such as Home Search or Sampling Chapter Six The Next Chapter The next chapter will walk you through the installation and wiring before moving you on to Step 2
11. your preset value In this case you store parameters first in your DL405 CPU s V memory area and then you transfer them to the shared memory area Then the HSC can read and use the information The HSC microprocessor cannot read information directly from the DL405 s V memory area Likewise it cannot write information directly into the CPU s V memory area This is why the two step process is always necessary The diagram below shows you the basic concept Chapter 4 will cover the subject in depth The CPU and the HSC do not communicate directly They do so by exchanging information to and from the shared memory area via the CPU s V Memory Your ladder logic decides what information and when it is read and written between the two memory areas CPU HSC Pied EE O i o KiE gggagggEA A Shared eS Memory V Memory Getting Started Physical Characteristics amp Specifications Q 2 b O S D LED Assignments c parj D Label Function PWR 5V POWER ON C lt P CURRENT COUNT LESS THAN PRESET C P CURRENT COUNT EQUAL TO PRESET C gt P CURRENT COUNT MORE THAN PRESET OVR COUNT OVERFLOW TB LOOSE OR MISSING TERMINAL BLOCK CW CLOCKWISE OUTPUT ENERGIZED OUT2 BRAKE O
12. Getting Started In This Chapter Introduction HSC Features How Does the HSC Work With the CPU Physical Characteristics amp Specifications Overview of HSC Inputs and Outputs X Input and Y Output Assignments Putting It All Together etting Started Introduction The Purpose of this Manual Who Should Read this Manual Where to Begin Supplemental Manuals Technical Assistance Thank you for purchasing the High Speed Counter ticusreepcntr module for the DL405 This manual shows you how PWR IB VE to install program and maintain the equipment It amp P ora tH ins also helps you understand the module s operating OVR OTI INH LD2 characteristics Since we constantly try to improve 2 s our product line we occasionally issue addenda eH that document new features and changes to the Le products If an addendum is included with this ae manual please read it to see which areas of the B manual or product have changed aa RST F LATCH D C INH F RUN E LS1 E LS2 vH Ge L T UGE TaS aa T C E Ifyou understand PLC systems this manual will provide all the information you need to get and keep your
13. High Speed Counter module up and running We will use examples and explanations to clarify our meaning and perhaps help you brush up on specific features used in the DL405 system This manual is not intended to be a generic PLC training manual but rather a user reference manual for the DL405 High Speed Counter Module If you are in a hurry and already understand the basics of high speed counters and basic motion control you may only want to skim this chapter and move on to Chapter 2 Installation and Wiring Be sure to keep this manual handy for reference when you run into questions If you are anew DL405 customer we suggest you read this manual completely so you can fully understand the high speed counter module s configurations and the procedures used We believe you will be pleasantly surprised with how much you can accomplish with PLCDirect products Depending on the products you have purchased there may be other manuals necessary for your application You will want to supplement this manual with any other manuals written for other products We suggest e D4 USER M the D4 405 User Manual e DA DSOFT M the DirectSOFT User Manual If you have questions that are not answered by this manual our Technical Support Team is glad to help They are available from 9 00AM until 6 00PM Eastern Time Monday through Friday at 800 633 0405 Chapters Below is a table showing a summary of contents provided within each section of this manual The
14. UT2 OUTPUT ENERGIZED CCW COUNTER CLOCKWISE OUTPUT ENERGIZED OUT1 DECELERATION OUT1 OUTPUT ENERGIZED VE EXTERNAL POWER SUPPLY FOR OUTPUTS FAILED RST SIGNAL APPLIED TO RESET INPUT External Only LTH SIGNAL APPLIED TO LATCH INPUT External Only RUN SIGNAL APPLIED TO RUN INPUT External Only INH SIGNAL APPLIED TO INHIBIT CNT INPUT External Only INA SIGNAL APPLIED TO INA INPUT INB SIGNAL APPLIED TO INB INPUT LD1 SIGNAL APPLIED TO INZ INPUT LD2 SIGNAL APPLIED TO LD INPUT HIGH SPEED CNTR LED Assignments PWR TB VE C lt P CW RST INA CP OT2 LTH INB C gt P CCW RUN LD1 OVR OT1 INH LD2 Terminal Assignments e amp INPUTA UNA I ap iNPUTB UNB eS INPUT Z LINZ W a LOAD OFFSET LD ap RESET COUNTER RST lt p LATCH COUNT LATCH ER COUNT INHIBIT GlINH S HSC RUN RUN LIMIT SWITCH 1 LS1 Cs LIMIT SWITCH 2 Ls2 D vF CLOCKWISE OUTPUT HH CW E COUNTER CLOCKWISE OUTPUT tL ccw amp DECELERATION OUTPUT H LH out D N XY BRAKING OUTPUT tL OUT B 12 24VD D Nal Set EXTERNAL POWER SUPPLY H Laat E E p S General Specification
15. a high a mH ON signal here will activate HSC RUN A low OFF signal will i de acitivate it L cw CCW L OUT1 OUTA 12 24VD LS1 or LS2 Either or both of these terminals can be connected to limit switches to help find home position or they can merely be used as discrete inputs SIO SOLOS Sl 1 1A T oP G9 9 GE Eo GP GD GA 9 Ge Control Outputs 4 CW You connect the output of this terminal to the appropriate N terminal of your motor controller for clockwise motion when current count is less than preset and HSC RUN is ON or when the output has been turned ON with RLL CCW You connect the output of this terminal to the appropriate terminal of your motor controller for counter clockwise motion when current count is more than preset and HSC RUN is ON or when the output has been turned ON with RLL OUT1 As you approach a target position you may need to trigger motor deceleration A signal from this output can do that This is used in the automatic home search algorithm also OUT2 When you reach your target current count preset you may need to activate a brake to stop the motor A signal from this output can do that Y Data Type LD RST LATCH C INH and RUN all have software equivalents bui
16. ent modes With standard counting you can use the Standarda Coun ng two counting input signals INA and Using Two Inputs INB of the D4 HSC One input is used for counting UP and the other used for counting DOWN You can t use both inputs for the same direction of counting One Channel Encoders UP NA lt q INB qc F e DWN You could be using only one of the inputs Standard Counting if desired In this case the other input Using One Input terminal should be left unwired You control the direction of counting by the manner in which you set a certain bit in your control program shown later One Channel Encoder UP or DWN INA a INB Unused Quadrature Counting With quadrature counting you must use both signals INA and INB Both input terminals are connected to the same field device capable of outputting two square wave signals each being offset 90 degrees Quadrature counting is often preferred to standard counting because it can sense direction Quadrature inputs are also more noise immune With quadrature counting the direction UP or DOWN counting is determined by whether the signal being received at INA leads or lags the signal received at INB The D4 HSC looks at the signals coming in and compares them It then determines which is leading and which is lagging NOTE We Quadrature Counting
17. ide ofthe application Make sure you check the specs of your motor or motor controller and that you are sure they match up with the specs of D4 HSC before making any connections Pulse Signals In INB CW is the clockwise signal out put It is just Drive one of four possible outputs Level Signal Out gt A Output Control sites 4 Encoder e etting Started Sampling Home Search The HSC can also do sampling over time That is you can use simple ladder logic instructions to indicate the time period for a sampling When you invoke the sampling feature of the HSC it will keep track of the counted pulses for the time period you have specified and store the total for later RLL retrieval This is a great feature for determining frequency of incoming pulses It s as simple as specifying a time base say 3 seconds and then counting the pulses for that period If the HSC sees 6000 pulses during that time span then you know that you have an incoming pulse rate of 2 kHz 6000 3 2000 There are many other uses for the sampling feature frequency counting is just one example Many applications require a known starting position for a given work cycle called home point This is the point to which the moving piece of apparatus doing the work i e welder drill saw glue gun etc is returned at the end of each work cycle
18. lt in to the logic Equivalents for of the D4 HSC These are Y data types that are discussed on the next page Thus Some Functions you have your choice of either triggering these control inputs externally or accomplishing essentially the same task internally from within your RLL They have been shaded to make them easy to spot NOTE Use external inputs if immediate responses are needed When a function is activated through RLL Y outputs in this case the function will not activate until the I O update has been performed This delay is dependent on your CPU s scanning speed and the size of your program X Input and Y Output Assignments There are certain X s and Y s reserved by the D4 HSC By convention we will be referring to these assignments as Xn z and Ym z where n and m are offset values based on which slot of the CPU base you have placed your HSC The letter z will be some octal number that maps the X or Y to a specific input or output function For example if you have the HSC in slot 0 and are using automatic addressing then m and n will both be equal to zero In such case the data type assignments would be as shown below All of this is explained in great detail in Chapter 4 You will also at that time be given a complete table of the X and Y assignments In this example we have placed the HSC in slot O of the CPU base This simplifies X and Y identification because X s and Y s both start at
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