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M4040/41 user`s manual - Sea
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1. Online Channel Set point Programming using the same set point programming commands and menus used with the off line channel programming the user can alter channel set points in the M4040 41 module directly using an RS 232 cable which connects the M4040 41 module to COMI of the IBM PC or compatible running PLSdev This allows machine timing to be altered while in operation PLS Configuration the configuration of the M4040 41 is set using PLSdev This includes defining the number of PLS timing channels in the module scale factor remote display strobe time brake wear compensation enable and parameter setting CH17 speed window enable and parameter setting Download Channels to PLS this allows channels edited in off line mode or previously uploaded channels to be downloaded to the M4040 41 module This feature allows quick replacement of an M4040 41 module by eliminating the need to reprogram the channel set points by hand Upload Channels from PLS uploads channel set points and configuration parameters from the M4040 41 module to disk files Print outs the set points of all channels as well as the PLS configuration can be printed out to provide hard copy documentation PLS Hardware Confidence test Allows the execution of hardware tests imbedded in the module to verify the proper operation of the M4040 41 This is the same test used by the factory to verify the module at completion of manufacturing M4040 M4041 User s Manua
2. 88XX where XX is the fault code The individual faults are discussed below 8807 INVALID SCALE FACTOR This fault is displayed when the scale factor is greater than 512 or less than 2 To reset the fault download the user channel program through PLSdev This downloads the configuration file which contains the scale factor as specified by the user 8808 INVALID OFFSET This fault is displayed any time the offset is greater than or equal to the scale factor To reset the fault set the offset to less than the scale factor by downloading the user channel program or by setting the offset in the on line mode of PLSdev 8809 TIMING CHANNEL OUTPUT SHORT CIRCUIT This fault is displayed anytime any one of the timing channel outputs detects a short circuit current greater than 500mA MP even if only momentarily Once the short circuit condition is removed the fault can be reset by toggling the RPM POSITION toggle switch on the front of the M4040 41 M4040 M4041 User s Manual SYSTEMS Electronics Group 29 SECTION 5 FAULT CODES This Page Intentionally Left Blank M4040 M4041 User s Manual SYSTEMS Electronics Group 30 SECTION 6 HARDWARE CONFIDENCE TEST The hardware confidence test allows the entire M4040 41 hardware to be verified for proper operation The test is resident in all M4040 41s and is initiated through PLSdev The hardware confidence test is the same test used at the factory to initially test the production M4040 4
3. If the speed is above this threshold CH17 is off The two thresholds above define a window such that if the speed is between or equal to the low and high thresholds CH17 is on If the speed is below the low or above the high threshold CH17 is off Both thresholds are defined in RPM If the CH17 speed window is disabled CH17 will function as a standard timing channel M4040 M4041 User s Manual SYSTEMS Electronics Group 17 SECTION 2 PROGRAMMING 2 4 CHANNEL SET POINT PROGRAMMING COMMANDS Three channel set point programming commands are available through PLSdev These are single set point programming set point fine tune and the pulse train programming command The single set point command allows the user to simply type in the complete set point both on and off parameters at the currently selected set point The fine tune command allows the user to either increment or decrement by one the on or off set point parameter of the currently selected set point The pulse train programming command allows the user to program the entire channel with a pulse train of a fixed on and off duration through out 2 4 1 SINGLE SET POINT PROGRAMMING COMMAND The single set point command is used to enter unique set points in a channel when that channel is not programmed as a pulse train PULSE TRAIN NO Note When the channel is programmed as a pulse train the single set point command cannot be used to modify individual
4. sc 7 5 sc RTS 4 CTS 5 DSR 6 DTR 20 M4040 M4041 User s Manual DB25 com1 to PROG Port Cable SYSTEMS Electronics Group APPENDIX A RS 232 PINOUTS CABLES This Page Intentionally Left Blank M4040 M4041 User s Manual SYSTEMS Electronics Group APPENDIX B FIELD WIRING CONNECTOR PINOUTS RESOLVER 222 ee MO Uu N O UN OU amp UN 10000000000000000 an 10 30VDC TIMING CHANNEL DUTPUTS 100mAMP 32EA SOU i N O 000000000001 REMOTE RPM POSITION DISPLAY 4 DIGIT BCD DISPLAY RPM SELECT INPUT REMOTE ENABLE INPUT POWER INPUT 24VDC La RET CHAN OUT M4041 32 CHANNEL PLS SOURCING Maj SYSTEMS ELECTRONICS GROUP M4041 32 CHANNEL PLS MODULE M4040 M4041 User s Manual SYSTEMS Electronics Group B 1
5. Depressed Set point Field 0 0 Enter lt CR gt 000 ___ 0 000 0__ lt gt 000 000 2 4 2 FINE TUNE SET POINT COMMAND The fine tune set point command allows the user to increment or decrement by one the on or off parameter of an already existing set point The fine tune command is executed by selecting F6 Fine Tune from the channel edit menu When this is done the fine tune menu is displayed This menu contains the following commands F1 On Set Point This is used to select the on parameter of the set point When selected the cursor will move to the least significant digit of the on parameter F2 Off Set Point This is used to select the off parameter of the set point When selected the cursor will move to the least significant digit of the off parameter M4040 M4041 User s Manual SYSTEMS Electronics Group 19 SECTION 2 PROGRAMMING F3 Inc This command increments the selected parameter either on or off whichever was selected with the On Set Point or Off Set Point commands by one F4 Dec This command decrements the selected parameter either on or off whichever was selected with the On Set Point or Off Set Point commands by one The fine tune command is primarily used in on line mode to fine tune set points while the machine is in operation 2 4 3 PULSE TRAIN COMMAND The pulse train command is used to program a channel with a fixed on and off duratio
6. The actual offset which may not equal the entered position will be displayed in the offset field and the M4040 41 will then display zero as the position M4040 M4041 User s Manual SYSTEMS Electronics Group 15 SECTION 2 PROGRAMMING 2 3 PLS CONFIGURATION The PLS configuration is used to define the following PLS parameters in the M4040 41 number of PLS channels scale factor remote display strobe time 1100 brake wear compensation parameters and CH17 speed window parameters The parameters are all set through the Edit PLS Configuration menu selection 2 3 1 NUMBER OF PLS CHANNELS This is the number of PLS timing channels available in the specific module being configured The number of channels should be set as follows for M4040 set number of channels 16 for M4041 set number of channels 32 2 3 2 SCALE FACTOR The scale factor is the desired number of divisions per revolution This is programmable from 2 to 512 For 360 degrees per revolution the scale factor should be set to 360 2 3 3 REMOTE DISPLAY STROBE TIME The remote display strobe time is the time that the strobe outputs on the remote display connector are activated to strobe the respective digits for the remote display The number entered between 1 and 255 1s a preset for a timer with a 2 5msec time base and represents the time the strobe output is on See section 4 for more details on the remote display output M4040 M4041 User s Manua
7. and improvement the manufacturer reserves the right to change the specification of the product or it s performance or the contents of the User Manual without notice Copyright 1991 Systems Engineering Associates Inc All Rights Reserved CONTENTS 1 General Description 1 1 1 Resolver Interface 1 1 2 Timing Channels 1 13 RPM Position 2 1 4 Brake Wear Compensation 2 1 5 Motion speed Output 2 1 6 Programming 3 2 Programming 5 2 1 Introduction to PLSdev 5 2 1 1 Features of PLSdev 5 2 1 2 System Requirements 6 2 1 3 Installing PLSdev 6 2 1 4 Executing PLSdev 6 22 Menus 8 2 2 1 Main Development Menu 8 2 2 2 Channel Edit Menu 12 23 PLS Configuration 16 2 3 4 Number of PLS Channels 16 2 3 2 Scale Factor 16 2 3 3 Remote Display Strobe Time 16 2 3 4 Brake Wear Compensation 17 2 3 5 17 Speed Window 17 2 4 Channel Set Point Programming Commands 18 2 4 1 Single Set Point Programming Command 18 24 2 Fine Tune Set Point Command 19 24 3 Pulse Train Command 20 3 Brake Wear Compensation 21 31 Brake Wear Compensation Parameters 21 3 2 Operation of the Brake Wear Compensation Algorithm 22 3 3 Brake Wear Compensation Example 23 4 RPM Position Output Connector 25 4 1 Description of Operation 25 4 2 Remote Display Interface 27 4 3 Interfacing with a PLC 28 5 Fault Codes 29 M4040 M4041 User s Manual SYSTEMS Electronics Group M4040 M4041 User s Manual CONTENTS 6 Hardware Confidence T
8. description of the channel edit menu and set point programming commands When editing is complete press ESC to return to the main development menu The modified channel set points will then be saved in the channel data file on disk for the selected program 2 Online Channel Set Point Programming This selection is used to edit the channel set points in an M4040 41 module directly To initiate the on line programming mode connect the COMI port on the PC running PLSdev to the CHAN port on the M4040 41 to be programmed Select 2 Online Channel Set Point Programming The channel edit menu will be invoked and the existing channel set points in the M4040 41 will be uploaded and displayed in the menu See section 2 2 2 for a description of the channel edit menu and set point programming commands Note Any changes to the channel set points made are updated immediately to the M4040 41 module This allows set point editing during machine operation if desired When editing is complete press ESC to return to the main development menu The modified channel set points will also be saved in the channel data file on disk for the selected program when existing the on line mode 3 Edit PLS Configuration This activates the PLS configuration menu See section 2 3 When PLSdev is initially invoked and the program name entered does not exist the PLS configuration menu is automatically activated This selection allows the user to modify the syste
9. digits using four outputs for the digit data and four outputs for the individual digit strobes Figure 4 1 is a timing diagram of a typical remote display update For each digit 1 s 10 s 100 s and 1000 s the digit data 1s placed on the digit outputs 1 s 2 s 4 s and 8 s and held for a data set up time The respective strobe output STRB DGTO 1 2 3 is than activated low for a data strobe time The strobe is than released and the digit data is held for a data hold time Note The digit data is always valid when the digit strobe is low this is when the digit data lines should be sampled and read in Each digit of the remote display is updated starting with the 1 s digit until all digits are updated at which time the entire process is than started over The remote display is thus updated automatically and continuously this way DIGITAL DATA 1 S X X X DIGITAL DATA 2 S X X X X X DIGITAL DATA 4 S x x x x X DIGITAL DATA 8 S x x x X X STRB DGT3 1 5 STRB DGT3 10 5 STRB DGT3 100 5 STRB DGT3 1000 5 1 2 3 11 Set up Time 2 Strobe Time 5 Hold Time Note T1 T2 T3 Strobe Time Figure 4 1 Typical Remote Display Update M4040 M4041 User s Manual SYSTEMS Electronics Group 25 SECTION 4 RPM POSITION OUTPUT CONNECTOR The two inputs on the RPM POSITION output connector are 12 30VD
10. of each timing channel output is indicated with an individual LED The timing channel outputs contain short circuit protection such that the detection of a short circuit disables the outputs with a fault code displayed on then RPM POSITION display Once the short circuit condition is removed the fault code can be reset by toggling the RPM POSITION toggle switch on the front of the M4040 41 The outputs will then resume normal operation M4040 M4041 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION 1 3 RPM POSITION DISPLAY AND OUTPUT CONNECTOR A 4 digit RPM POSITION display is built into the M4040 41 In addition an RPM POSITION output connector is also built in for remote displays or for interfacing to a PLC If no remote display is used a switch located on the front of the M4040 41 is used to select either RPM or POSITION If a remote display is used an input on the RPM POSITION output connector is used to select either RPM or POSITION See section 4 for complete details on the use of the RPM POSITION connector 1 4 BRAKE WEAR COMPENSATION The brake wear compensation algorithm can be used in conjunction with presses which incorporate a top dead center TDC or back dead center BDC stop feature With these presses a timing signal is used to declutch the press for TDC or BDC stops However as the brake wears the press will no longer stop at TDC but will instead overshoot When enabled the brake wear algorithm
11. of the M4040 41 will automatically adjust the TDC timing signal such that the press always stops at the desired stopping location regardless of brake wear The brake wear algorithm is implemented in and can be enabled or disabled by the user When disabled 1100 functions as a standard timing channel When enabled the brake wear compensation algorithm is automatically performed for TDC stops See section 3 for complete details on this feature 1 5 MOTION SPEED OUTPUT The motion output is a user enabled feature which uses the CH17 output Two user programmable parameters are used in conjunction with the motion output low speed threshold and high speed threshold When enabled as a motion output CH17 is on when the speed RPM is between the low and high speed thresholds When the speed is below the low speed threshold or above the high speed threshold CH17 is off When disabled CH17 functions as a standard timing channel M4040 M4041 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION 1 6 PROGRAMMING Configuration and timing channel programming of the M4040 41 is performed with PLSdev a DOS based programming software package which runs on any IBM PC or compatible Connection of the PC to the M4040 41 is implemented with an RS 232 cable no other hardware is required PLSdev allows the user to perform the following e Configuration of the M4040 41 including Scale factor Offset Brake wea
12. set points for each channel from the M4040 41 and saves it in the channel data file of the currently selected program Note The configuration data is not uploaded from the M4040 41 To upload the data form the M4040 41 perform the following 1 With both the PC running PLSdev and the M4040 41 powered up connect COMI on the PC to the CHAN port on the M4040 41 using the appropriate RS 232 cable 2 Select this selection from the main development menu A prompt will appear to verify whether to continue or not To abort the upload press ESC otherwise press any key to start the upload M4040 M4041 User s Manual SYSTEMS Electronics Group SECTION 2 PROGRAMMING 3 While the upload is in progress the channel number which is currently being uploaded will be displayed Once all channels are uploaded an upload complete message will be displayed along with a prompt to return to the main menu Press any key to return to the menu 4 Ifthe computer was unable to initiate the upload to the M4040 41 a message stating this will be displayed Verify the RS 232 cable connections between COMI on the computer and the CHAN port on the M4040 41 Press any key to return to the main development menu and try the upload again 6 Print Channels Both the PLS configuration data and channel set points data can be printed out through PLSdev When this selection is made a printer selection menu is displayed Select the appropriate printer to be used O
13. 1s and therefore provides the same 100 hardware test as provided at the factory The test is provided to the user to verify whether the M4040 41 hardware is functional or not Not as a tool to repair M4040 41s If a fault is detected the M4040 41 should be returned to the factory for repair Any attempt to repair an M4040 41 will void the warranty 6 1 TESTS PERFORMED The following is a list of the tests performed by the hardware confidence test 1 Micro controller RAM test 2 Channel 00 07 PLS memory test 3 Channel 10 17 PLS memory test 4 Channel 20 27 PLS memory test 5 Channel 30 37 PLS memory test 6 PLS memory address access test 7 RS 232 CHAN port test Tests 1 through 6 are not optional and are always performed Test 7 is optional and may be disabled if desired All tests are automatic and require no interaction once the test is initiated Each test performs a complete check of the respective hardware area of the M4040 41 If a fault 15 detected the test is stopped and a test fault code is displayed to indicate the nature of the hardware failure 6 2 PERFORMING THE HARDWARE CONFIDENCE TEST WARNING The hardware confidence test should not be performed in an M4040 41 installed in a users control system Unpredictable output states may result while the test is being performed M4040 M4041 User s Manual SYSTEMS Electronics Group 31 SECTION 6 HARDWARE CONFIDENCE TEST 6 2 1 EQUIPMENT REQUIRED In order to pe
14. 40 41 is programmable from 2 to 512 divisions per revolution while the offset is programmable from 0 to one minus the scale factor High speed operation is attained with a resolver tracking rate greater than 6 000 RPM and a timing channel output update uncertainty of less than one microsecond to a change in angular position 1 1 RESOLVER INTERFACE The M4040 41 can be used with virtually any type of resolver which incorporates a rotor reference signal and two stator feedback signals These include resolvers manufactured by C amp A Autotech Gemco etc A dip switch accessible through an access hole on the lower left side of the module selects the desired resolver reference voltage either 1 45 VRMS or 3 70VRMS For Autotech and Gemco resolvers the reference should be set at 1 45 VRMS for C amp A at 3 70VRMS For other resolvers refer to the manufactures specifications to determine which reference should be selected See section 7 2 for details on wiring the resolver to the M4040 41 and selection of the resolver reference voltage 1 2 TIMING CHANNELS The M4040 contains 16 timing channels while the M4041 contains 32 timing channels Each timing channel can be programmed with up to 50 arbitrary on off set points or with a pulse train of fixed on and off divisions throughout the entire channel All timing channels are mapped to 10 30VDC sourcing 100milliamp outputs which can be wired to PLC inputs for machine control timing The status
15. 40 41 will automatically adjust the TDC timing signal such that the press always stops at the desired stopping location regardless of brake wear 3 1 BRAKE WEAR COMPENSATION PARAMETERS The brake wear algorithm is implemented in and can be enabled or disabled in the PLS configuration see section 2 3 4 When disabled CHOO functions as a standard timing channel When enabled the following parameters set by the user are used to implement the algorithm Desired Stop Location This is the location in degrees that the press is desired to stop at 1 e 0 degrees TDC Allowed Stopping Error This is the plus or minus allowed deviation in degrees from the desired stopping location that the press will be allowed to stop before the algorithm adjusts the timing signal to compensate for brake wear Timing Signal Width This is the width in degrees that the algorithm will program the timing signal Note The algorithm assumes the leading off to on transition of the timing signal is used to declutch the press for a TDC stop Compensation Enable Window This is a window in degrees in which is allowed to move in order to compensate for brake wear This allows the user to place a limit on the amount of compensation the M4040 41 will perform If no limit is to be placed on the compensation of enter 000 000 for the enable window In addition to the above parameters the REMOTE ENABLE
16. 41 are wired to PLC inputs while the REMOTE ENABLE input is tied high and RPM SELECT input is wired from a PLC output This allows the PLC to read either the RPM or the POSITION In this case the digit strobe time would have to be set to a time greater than or equal to the following strobe time gt PLC input filter delay time max worst case PLC scan time X 2 Setting the strobe time to the above guarantees that each digit will be read by the PLC The PLC logic would than clock in the data for each digit when the corresponding digit strobe is low Once the 1000 s digit strobe occurs the equivalent RPM or POSITION whichever is selected by the PLC can be determined from the individual digits strobed in PLC INPUTS 24VDC gt M4020 40 41 gt 0 175 1 23 2 45 B S STRB 0610 4 0610 STRB STRB 0071 5 0611 STRB STRB 0612 6 0612 STRB STRB 0013 7 DGT3 STRB RPM SEL REM EN 4 24VDC RETURN PLC OUTPUTS 24VDC E 0 RPM SEL Figure 4 3 RPM Position Output Connector Wired to PLC M4040 M4041 User s Manual SYSTEMS Electronics Group 28 SECTION 5 FAULT CODES The M4040 41 modules detect three fault states These are invalid scale factor code 07 invalid offset code 08 and timing channel output short circuit code 09 When the M4040 41 detects any one of these faults the respective fault code is displayed on the RPM POSITION display of the module in the form
17. C sourcing true high inputs labeled REMOTE ENABLE and RPM SELECT If REMOTE ENABLE is low RPM or POSITION is selected locally via the RPM POSITION toggle switch on the M4040 M4041 If REMOTE ENABLE is high POSITION is displayed when RPM SELECT is a low and RPM is displayed when RPM SELECT is a high When REMOTE ENABLE is high the strobe time of the digit strobe outputs can be user programmed from 2 5msec to 640msec in 2 5msec increments This allows the user to match the output strobe time to the device the remote output connector is interfaced to If REMOTE ENABLE is low no remote display connected the digit strobe times are in microseconds and would be ineffective in driving a remote device Thus if a remote device 15 connected to the M4040 41 REMOTE ENABLE should be high The strobe time is set in the PLS configuration see section 2 3 3 Note When REMOTE ENABLE is high the RPM POSITION toggle switch on the M4040 41 has no effect either on the remote display or built in display Note The data placed on the digit data lines is the binary equivalent of the digit number as shown in the following table Digit Binary Equivalent Number 8 s 4 s 2 s 1 s 0 0 0 0 0 1 0 0 0 1 2 0 0 1 0 3 0 0 1 1 4 0 1 0 0 5 0 1 0 1 6 0 1 1 0 7 0 1 1 1 8 1 000 9 1 00 1 blank 1 1 1 1 When interfacing with a PLC the blank digit digit data equal to all 1 s should be converted to zero by the PLC logic M4040 M4041 User s Manual SY
18. For Autotech and Gemco resolvers the reference should be set for 1 45 VRMS For C amp A resolvers the reference should be set for 3 70VRMS For other resolvers refer to the manufactures specifications to determine which reference should be selected The reference is selected via dip switches accessible through an access hole on the lower left side of the module To select the 1 45 VRMS reference set both switches down on the side that reads 1 45VRMS To select the 3 70VRMS reference set both switches up on the side that reads 3 70VRMS Note The proper reference voltage level must be selected for the specific resolver used otherwise erroneous operation may result 7 3 WIRING INPUT POWER The M4040 41 is powered with 24VDC 10 power This power is wired to the power and C common or return terminals of the RPM POSITION output connector This provides power to the internal circuitry of the M4040 41 The current required is less than 0 6 Amps Be sure to observe the proper polarity of the input power otherwise damage to the module may occur Input fusing of 1AMP or so should be provided for the input power 7 4 WIRING THE RPM POSITION OUTPUT CONNECTOR The RPM POSITION output connector is provided to drive remote RPM POSITION displays or to interface with a PLC The connector consists of eight 10 30VDC true low outputs capable of sinking 100milliamps and two 12 30VDC sourcing inputs See section 4 for examples of wiring
19. M4040 M4041 User s Manual Systems Engineering Associates Inc 14989 West 69th Avenue Arvada Colorado 80007 U S A Telephone 303 421 0484 Fax 303 421 8108 www sea seg com 02 2004 M4040 M4041 User s Manual Copyright 1991 Systems Engineering Associates Inc All Rights Reserved WARNING To ensure the equipment described by this User Manual as well as the equipment connected to and used with it operates satisfactorily and safely all applicable local and national codes that apply to installing and operating the equipment must be followed This includes the National Electric Code in the USA and other applicable legislation regulations and codes in practice elsewhere Since codes can vary geographically and can change with time it is the user s responsibility to determine which standards and codes apply and to comply with them FAILURE TO COMPLY WITH APPLICABLE CODES AND STANDARDS CAN RESULT IN DAMAGE TO EQUIPMENT AND OR SERIOUS INJURY TO PERSONNEL Persons supervising and performing installation or maintenance must be suitably qualified and competent in these duties and should carefully study this User Manual and any other manuals referred to by it prior to installation and or operation of the equipment The contents of the User Manual are believed to be correct at the time of printing however no responsibility is assumed for inaccuracies In the interests of a commitment to a policy of continuous development
20. STEMS Electronics Group 26 SECTION 4 RPM POSITION OUTPUT CONNECTOR 4 2 REMOTE DISPLAY INTERFACE Figure 4 2 shows a Cincinnati Electro Systems 4161 4 24 BCD display wired to the M4040 41 RPM POSITION connector This would be a typical remote display application Note REMOTE ENABLE is tied high and that a switch located at the remote display is wired to the RPM SELECT input This switch allows the remote selection of either RPM or POSITION to be displayed In this example the strobe time could be set as low as 2 5msec or the required strobe time of the display M4020 40 41 DISPLAY 15 25 45 85 STRB DGTO STRB DGT1 STRB DGT2 STRB DGT3 RPM SEL REM EN 24VDC C 24VDC RETURN REMOTE SWITCH POSITION 24VDC RPM OX pp 1000 2000 4000 8000 STROBE 1000 S NOTE DISPLAY PROGRAMMED FOR D P STROBE 1 707 TRUE LOGIC LEVEL 24VDC 24VDC 2 O TRUE STROBE LEVEL RETURN GND 3 INDIVIDUAL DIGIT STROBES Figure 4 2 RPM Position Output Connector Wired to Remote Displa M4040 M4041 User s Manual SYSTEMS Electronics Group 97 SECTION 4 RPM POSITION OUTPUT CONNECTOR 4 3 INTERFACING WITH A PLC Figure 4 3 shows the M4040 41 RPM POSITION output interfaced to a typical PLC Programmable Logic Controller This is an example of how a PLC can read the RPM or POSITION from the M4040 41 The digit data and strobe outputs of the M4040
21. TRAIN Defines whether the channel is programmed as a pulse train YES or not NO The channel defaults to NO until the F5 Pulse Train command is executed Once programmed as a pulse train the channel must be cleared using the F8 Clear Chan command to reset PULSE TRAIN to NO See section 2 4 for details of the pulse train command ON On duration in degrees of the pulse train OFF Off duration in degrees of the pulse train START Starting location of the pulse train The Channel will be programmed through out with the on and off durations starting at the Start location The function key commands of the channel edit menu are defined as follows F1 Next Chan Selects the next highest numbered channel for editing When selected the channel number will increment by one and the set points and data for that channel will be displayed The PgDn key also performs the same function as the F1 Next Chan key F2 Prev Chan Selects the next lowest numbered channel for editing When selected the channel number will decrement by one and the set points and data for that channel will be displayed The PgUp key also performs the same function as the F2 Prev Chan key F3 Select Chan Used to select any channel number for editing When selected the current channel number will be cleared and the cursor will be placed in the CHANNEL field Simply type in the desired channel number in octal and press Enter lt CR gt to accept
22. The reference output excites the resolver while the reference input and two stator inputs are used to determine the absolute position of the resolver The direction of rotation is determined by the connection S1 and S3 Swapping S1 and S3 will reverse the direction of rotation for the M4000 module M4020 40 41 RESOLVER Figure 7 1 M4020 40 41 Resolver Interface Stand Alone Figure 7 2 shows two M4000 modules wired to one resolver with module Z2 slaved to module 71 reference for resolver supplied by module 1 In this case the reference output RO of module 1 is connected to the resolver and tied to the reference inputs RI of both modules while the reference output of module 2 15 not used Up to 8 modules can be slaved off one resolver this way In all cases a shielded twisted pair cable should be used to wire the resolver to the M4040 41 making sure the cable is routed free of other high voltage wiring M4040 M4041 User s Manual SYSTEMS Electronics Group 36 SECTION 7 INSTALLATION M4020 40 41 RESOLVER S3 Ml 2 SLAVE Figure 7 2 M4020 40 41 s Slaved to One Resolver M4040 M4041 User s Manual SYSTEMS Electronics Group 2472 SECTION 7 INSTALLATION 7 2 2 RESOLVER REFERENCE VOLTAGE SELECTION The resolver reference voltage of the M4000 PLS modules can be selected for either 1 45 VRMS or 3 70VRMS depending on the requirements of the resolver
23. The set points and data for that channel will then be displayed F4 Doc Chan Used to enter the channel description or name in the DESCRIPTION field This is a user definition of the channel and will be associated with the channel at all times print outs etc Up to 20 printable characters can be entered in this field Once the name is entered press Enter lt CR gt to accept M4040 M4041 User s Manual SYSTEMS Electronics Group 4 F5 F6 F7 F8 F9 SECTION 2 PROGRAMMING Pulse Train Used to program the channel as a pulse train See section 2 4 for details Fine Tune Used to fine tune increment or decrement the selected set point See section 2 4 for details Clear Set Point Clears the currently selected set point set point designated with cursor No other set points are affected by this command Clear Chan Clears all the set points in the channel Also used to clear the channel and reset the pulse train mode to no when a channel has been programmed as a pulse train Set Offset Used primarily in the on line mode to electronically zero the resolver shaft at the machine zero To set the offset locate the machine at machine zero Read the resolver shaft position from the front of the M4040 41 select F9 Set Offset and enter the position read into the offset field The actual offset number required to make this the zero position will than be calculated by PLSdev and downloaded to the M4040 41
24. annel number 00 is selected and displayed The F1 Next Chan F2 Prev Chan and F3 Select Chan commands are used to select a different channel number DESCRIPTION This field contains the user entered description or channel name which is associated with the channel number The F4 Doc Chan command is used to enter or edit this description PROG MODE This field displays the program mode either OFFLINE or ONLINE depending on whether the channel edit menu was invoked from the Offline or Online selection of the main development menu M4040 M4041 User s Manual SYSTEMS Electronics Group B1 SECTION 2 PROGRAMMING SET POINTS This a 10 row by 5 column 50 element array where the set points are entered using the various set point programming commands Note If the channel is not programmed as a pulse train PULSE TRAIN NO that up to 50 unique set points can be entered in the channel If the channel is programmed as a pulse train PULSE TRAIN YES up to the scale factor divided by two number of set points ON 1 OFF 1 can be programmed in the channel In this case only the first 50 set points would be displayed in the channel however the channel would be programmed through out with the on and off duration specified See section 2 4 for complete details on the set point programming commands If the channel is not programmed as a pulse train a large block cursor is placed in the ON field of the currently selected set p
25. d with the width specified in the PLS configuration however the algorithm assumes the leading off to on transition is used to actually declutch the press M4040 M4041 User s Manual SYSTEMS Electronics Group 22 SECTION 3 BRAKE WEAR COMPENSATION 3 3 BRAKE WEAR COMPENSATION EXAMPLE In the this example the algorithm is implemented on a press which normally requires 180 degrees to stop 1 2 stroke The parameters are set as follows Brake Wear Compensation Enabled Desired Stop Location Allowed Stopping Error Timing Signal Width Compensation Enable Window yes 090 270 The following chart shows the automatic reprogramming of set point by the algorithm as a function of the actual stopping location of the press Note These are not consecutive stops but instead a sampling of stops over a period of time Actual Stop CH00 Stopping Example Set Point Location 1 180 220 003 2 180 220 005 3 180 220 007 4 173 213 359 5 173 213 016 6 157 197 000 7 157 197 010 8 147 187 001 9 147 187 054 10 093 133 003 11 093 133 011 12 090 130 008 13 090 130 032 14 090 130 035 15 090 130 311 16 139 179 352 17 147 187 358 M4040 M4041 User s Manual New Set Point 180 220 no change 180 220 no change 173 213 advanced by 7 173 213 no change 157 197 advanced by 16 157 197 no change 147 187 advanced by 10 147 187 no change 093 133 advanced by 54 093 133
26. dicating that the scale factor and or offset has not been set yet Download the configuration and channel data to the M4040 41 using the 4 Download Channels to PLS selection of PLSdev See section 2 for details on setting the configuration programming the channels and downloading the channels to the M4040 41 M4040 M4041 User s Manual SYSTEMS Electronics Group 40 Module Size Length Height Width Scale Factor Offset Number of Timing Channels M4040 M4041 Maximum Number of Set Points per Channel Arbitrary Pulse Train Resolver to Digital Converter Resolution Accuracy Tracking Rate R to D Tracking Rate M4040 41 Signal Inputs sin and cos Input Voltage nominal Input Voltage max Input Impedance typ Reference Output Output Voltage Level Output Frequency Timing Channel Outputs Output Type Output Voltage Voltage Range Vout on min Vout on max Vout off max Output Current max Short Circuit Protection Optical Isolation 128 1024 Pulses per Revolution Outputs Output Type Output Voltage Vout on min Vout on max Output Current max Short Circuit Protection M4040 M4041 User s Manual SECTION 8 SPECIFICATIONS 8 0 5 5 4 5 2to 512 O to scale factor 1 16 32 50 Scale Factor 2 12 bits 10 arc mins 1LSB 10 000 RPM 6 000 RPM 2 Vrms 8 Volts 100K ohms 1 45 Vrms or 3 70 Vrms selectable 2 500 Hz True High S
27. ered the main development menu is cleared and the cursor is placed at the Program Name prompt Enter the desired program name as was done when PLSdev was initially invoked 9 File Utilities The PLSdev program allows you to back up restore make a new directory and to copy the current program to another program name all while inside PLSdev Selecting File Utilities brings up a sub menu with the following choices 1 Back up Program This allows the current program to be backed up on a diskette in drive A Install the back up diskette in drive A and press any key when ready This copies all the files associated with the program to the root directory of the A drive Note The files will be stored at the root directory of the diskette not within a sub directory This selection provides a convenient way to back up your program 2 Restore Program This copies the current program name from the root directory of the A drive to the drive and directory specified with the current program name Install the diskette with the program on it in the A drive and press any key when ready This copies all the files associated with the program name on the A drive to the path specified with the program name Note The program files on the diskette in drive A must be at the root directory This selection along with the back up selection above provides a convenient way to copy programs from one computer to another 3 Make new directory This p
28. est 31 6 1 Tests Performed 31 6 2 Performing the Hardware Confidence Test 31 6 2 1 Equipment Required 32 6 2 2 Executing the Test 33 6 3 Interactive Interface 33 7 Installation 35 7 1 Mounting the M4040 41 35 7 2 Resolver Interface 35 7 2 1 Resolver Wiring 36 7 2 2 Resolver Reference Voltage Selection 38 7 3 Wiring Input Power 38 7 4 Wiring the RPM Position Output 38 7 5 Wiring the Timing Channel Outputs 39 7 6 Wiring the 128ppr and 1Kppr Outputs 40 7 Power Up Sequence of the M4040 41 40 8 Specifications 41 LIST OF FIGURES Figure 4 1 Typical Remote Display Update 25 Figure 4 2 RPM Position Output Connector Wired to Remote Display 27 Figure 4 3 RPM Position Output Connector Wired to PLC 28 Figure 7 1 M4020 40 41 Resolver Interface stand alone 36 Figure 7 2 M4020 40 41 s Slaved to One Resolver 37 Figure 7 3 Typical Channel Output Wiring 39 Figure 7 4 Typical 128ppr 1Kppr Output Wiring 40 APPENDICES RS 232 Pinouts Cables Appendix A Field Wiring Connector Pinouts Appendix B LATE SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION The M4040 and M4041 PLS modules are high speed programmable limit or cam switches which accept angular position information in the form of resolver format signals and convert these to digital The modules contain 16 M4040 or 32 M4041 timing channels which can be programmed on and off at user defined position set points The scale factor of the M40
29. implemented with an MM88C30 differential line driver These outputs provide fixed pulse train signals that can be used to drive digital tachometers etc The devices these outputs drive must incorporate differential inputs do not ground either output See figure 7 4 for a typical example of the 128PPR and 1KPPR output wiring M4020 40 41 DIGITAL TACH ETC 128PPR OR 1KPPR OUTPUT P DIFFERENTIAL MM88C30 INPUT FROM INTERNAL CIRCUITRY O O Figure 7 4 Typical 128ppr 1Kppr Output Wirin 7 7 POWER UP SEQUENCE OF M4040 41 Once all connectors are wired and re installed in their respective sockets apply 24VDC power to the module The power up sequence occurs as follows 1 At initial power up the module is reset for approximately half a second During this time the RPM POSITION display will show arbitrary data decimal points arbitrary digits etc The timing channel outputs may also be randomly on or off This is normal 2 Ifthe module has previously been programmed the offset value previously set will be displayed for approximately 2 to 3 seconds The module will then proceed to normal operation with the RPM POSITION display showing either the RPM or position whichever is selected 3 If the module has not been previously programmed new module it may show either the invalid scale factor fault code 8807 or invalid offset fault code 8808 on the RPM POSITION display in
30. input is used to enable the brake wear compensation The adjustment of is performed when the press is stopped RPM 0 and the REMOTE ENABLE input is high If the REMOTE ENABLE input is low when the press is stopped 1100 is not altered regardless of the stopping location This allows the algorithm to be by passed for inch and single modes as well as emergency stops M4040 M4041 User s Manual SYSTEMS Electronics Group 21 SECTION 3 BRAKE WEAR COMPENSATION 3 2 OPERATION OF THE BRAKE WEAR COMPENSATION ALGORITHM If the brake wear compensation algorithm is to be used CH00 must be used as the TDC timing signal 1100 should be wired to an input on the PLC that controls the press with this input used in conjunction with other user logic to declutch the press for TDC stops The REMOTE ENABLE input on the M4040 41 must also be controlled such that it is high when the press is stopped for TDC stops but is low when an emergency non TDC stop is activated or when in any other non TDC stop clutch mode such as inch or bar is used It is suggested that a 24VDC sourcing output from the PLC controlling the press be wired to the REMOTE ENABLE input with the appropriate PLC logic controlling this output as described above To enable the CH00 brake wear compensation answer y to the CH00 Brake Wear Compensation enable prompt in the PLS configuration see section 2 3 4 Enter the desired stopping location allowed stopping e
31. l SYSTEMS Electronics Group 16 SECTION 2 PROGRAMMING 2 3 4 BRAKE WEAR COMPENSATION If the brake wear compensation algorithm available is to be used it must be enabled in the PLS configuration If enabled the following additional parameters must be set DESIRED STOPPING LOCATION The desired stopping location in degrees of the press when a normal top dead center or back dead center stop is performed ALLOWED STOPPING ERROR The amount of deviation in degrees from the desired stopping location that is allowed before the brake wear compensation algorithm modifies the timing CH00 TIMING SIGNAL WIDTH The width in degrees that the compensation algorithm will program the set point when it is modified COMPENSATION ENABLE WINDOW The window in which the brake wear algorithm will be allowed to move the 1100 set point for brake wear compensation See section 3 for more details on the brake wear compensation algorithm and the use of the above parameters If the brake wear compensation is disabled 1100 will function as a standard timing channel and the brake wear parameters above will be ignored 2 3 5 CH17 SPEED WINDOW If CH17 is to be used as a speed window it must be enabled in the PLS configuration If enabled the following additional parameters must be set LOW SPEED THRESHOLD If the speed is below this threshold CH17 is off HIGH SPEED THRESHOLD
32. l SYSTEMS Electronics Group SECTION 2 PROGRAMMING PLSdev is provided as a stand alone program or with the SYSdev shell To install or execute PLSdev from the SY Sdev shell refer to the SYSdev Programming Manual for details To install or execute PLSdev as stand alone program refer to the following sections 2 1 2 SYSTEM REQUIREMENTS PLSdev will run on any IBM PC or compatible with the following minimum system requirements 1 DOS 3 1 or greater 2 512K or more RAM 3 Hard disk not required but recommended 4 One 3 5 or 5 25 diskette drive 5 COMI RS 232 port 2 1 3 INSTALLING PLSdev PLSdev consists of one executable file PLSdev exe To install PLSdev simply install the PLSdev disk in the A or B floppy drive and PLSdev exe and S4040T exe to the desired directory on the hard drive 2 1 4 EXECUTING PLSdev To execute PLSdev switch to the directory on the hard drive that PLSdev was installed and type gt PLSdev program lt CR gt where program is the path and name of the PLS channel program to be edited The format of program should be drive directory name where drive the drive letter of the drive your channel program will be stored on directory the user or working directory where your program will be stored name your user program name without any extension M4040 M4041 User s Manual SYSTEMS Electronics Group SECTION 2 PROGRAMMING Note For the user program name two
33. m configuration at any time M4040 M4041 User s Manual SYSTEMS Electronics Group SECTION 2 PROGRAMMING 4 Download Channels to PLS This selection downloads both the PLS configuration and channel data files for the selected program to the M4040 41 module To download the data to the M4040 41 perform the following Note Each channel is cleared prior to downloading the set points for that channel thus machine operation should be ceased prior to initiating the download 1 With both the PC running PLSdev and the M4040 41 powered up connect COMI on the PC to the CHAN port on the M4040 41 using the appropriate RS 232 cable 2 Select this selection from the main development menu A prompt will appear to verify whether to continue or not To abort the download press ESC otherwise press any key to start the download 3 While the download is in progress the channel number which is currently being downloaded will be displayed Once all channels are downloaded a dump complete message will be displayed along with a prompt to return to the main menu Press any key to return to the menu 4 If the computer was unable to initiate the download to the M4040 41 a message stating this will be displayed Verify the RS 232 cable connections between COMI on the computer and the CHAN port on the M4040 41 Press any key to return to the main development menu and try the download again 5 Upload Channels from PLS This selection uploads the
34. n through out the entire channel in one simple command To program a channel with a pulse train perform the following 1 Select F5 Pulse Train from the channel edit menu 2 The cursor is located in the ON field of the channel edit menu Enter the on duration in degrees and press Enter lt CR gt 3 The cursor is located in the OFF field of the channel edit menu Enter the off duration in degrees and press Enter lt CR gt 4 The cursor is now located in the START field Enter the location that the pulse train will be initially started at in degrees and press Enter lt CR gt 5 The entire channel will be programmed with the on and off duration through out the entire channel starting at the start location The first 50 set points or less will be displayed in the set point array Note The set point cursor will not be displayed since the single set point and fine tune commands are not valid if the channel is programmed as a pulse train M4040 M4041 User s Manual SYSTEMS Electronics Group 20 SECTION 3 BRAKE WEAR COMPENSATION The brake wear compensation algorithm can be used in conjunction with presses which incorporate a top dead center TDC or back dead center BDC stop feature With these presses a timing signal is used to declutch the press for TDC or BDC stops However as the brake wears the press will no longer stop at TDC but will instead overshoot When enabled the brake wear algorithm of the M40
35. nce this is done the print outs selection menu is displayed The selections are 1 Print PLS Channel Set points This selection prints the set points for all the channels For each channel the following is printed CHANNEL number DESCRIPTION users documentation PULSE TRAIN yes no ON OFF START SET POINTS ON OFF qm etc The above is the set points data for the respective channel as entered through the channel edit menu 2 Print PLS Configuration This selection prints the configuration parameters as entered in the PLS configuration menu 3 Enter PLS Program Title This selection allows the user to enter a title for the program This title is printed at the top of each page of both the PLS Channel Set points print out and the PLS Configuration print out The title can be up to 60 characters long and can be composed of any printable characters When entry of the title is complete press Enter lt CR gt to save the title If the title or changes to the title are not to be saved press ESC M4040 M4041 User s Manual SYSTEMS Electronics Group 10 SECTION 2 PROGRAMMING T PLS Hardware Confidence Test This selection is used to invoke the hardware confidence test of the M4040 41 See section 6 for complete description of the test 8 Select PLS Program Select PLS program is used to change to a different existing PLS program or to create a new program once PLSdev has been invoked When the selection is ent
36. no change 090 130 fully advanced 090 130 fully advanced 090 130 fully advanced 090 130 fully advanced 139 179 retarded by 49 147 187 retarded by 8 147 187 no change SYSTEMS Electronics Group 2203 SECTION 3 BRAKE WEAR COMPENSATION In all cases above normal TDC stops were performed with the REMOTE ENABLE input high Note In the above chart when the stopping location was within the allowed error 5 degrees or less no change was made in the set point Also not that once the set point was set to 90 130 that no further compensation occurred even though the press still stopped outside the allowed error This is because the compensation window was set at 90 270 degrees The algorithm only programs the set point within the compensation window If no limit on the amount of compensation 18 desired simply set the compensation window to 000 000 This allows to be reprogrammed anywhere M4040 M4041 User s Manual SYSTEMS Electronics Group 24 SECTION 4 RPM POSITION OUTPUT CONNECTOR In addition to the four digit RPM POSITION display built into the M4040 41 an RPM POSITION output connector is provided to drive a remote RPM POSITION display or for interfacing to a PLC allowing the PLC to read the RPM or POSITION 4 1 DESCRIPTION OF OPERATION The connector contains eight outputs and two inputs The eight outputs are 24VDC sinking true low outputs which multiplex the data for the four
37. ocket Install the connectors by firmly seated the connector to the socket observing the proper polarity of the connector Refer to appendix B for the pin outs of the various connectors on the M4040 41 7 1 MOUNTING THE M4040 41 The M4040 and M4041 modules were designed for back panel mounting The modules should be mounted using 2ea 8 32 screws and lock washers A lugged earth ground wire should be installed on one of the mounting screws to insure that the M4040 41 is grounded 7 2 RESOLVER INTERFACE The M4040 M4041 PLS modules can be used with virtually any type of resolver which incorporates a rotor reference signal and two stator feedback signals These include resolvers manufactured by C amp A Autotech Gemco etc A dip switch accessible through an access hole on the left side of the module selects the desired resolver reference voltage either 1 45 VRMS or 3 70VRMS Separate resolver reference input and output connections are provided on the resolver interface connector This allows The M4000 PLS modules to be slaved to other M4000 PLS modules or to other manufactures programmable limit switches off one resolver M4040 M4041 User s Manual SYSTEMS Electronics Group 35 SECTION 7 INSTALLATION 7 2 1 RESOLVER WIRING Figure 7 1 shows the typical wiring to a generic resolver for stand alone operation M4000 PLS provides reference voltage for resolver Note The reference output RO is tied to the reference input RI
38. oint to be edited This cursor can be moved to any set point number using the cursor arrow left right up and down keys Whichever set point the block cursor is located at is the set point that the various set point programming commands will operate on If the channel is programmed as a pulse train the cursor will not be display at all The only commands which are valid once a channel is programmed as a pulse train are the F5 Pulse Train and F8 Clear Chan commands Thus the cursor is not used to select set points since the commands that operate on individual set points are not valid If no set point is programmed at a given set point number the field is displayedas Otherwise as an example the set point will be displayed as 020 040 where 020 is the lo location the channel turns on and 040 is where the channel turns off for the given set point SCALE FACTOR This is the scale factor as entered in the PLS configuration Note The scale factor cannot be changed from the channel edit menu but is displayed only for reference MESSAGE This is field which displays various status messages informing the user of invalid commands i e invalid set point operations in process 1 e loading file etc OFFSET The current resolver offset of the selected program This is entered using the F10 Set Offset command M4040 M4041 User s Manual SYSTEMS Electronics Group 13 SECTION 2 PROGRAMMING PULSE
39. ourcing 10 to 30 VDC Vcc 2 00 volts Vcc 0 20 volts 1 5 volts 100 milliamps Yes 1500 Vrms Differential Line Driver MM88C30 10 50 volts 12 75 volts 50 milliamps No SYSTEMS Electronics Group 4 SECTION 8 SPECIFICATIONS RPM POSITION Outputs Output Type Output Voltage Vout on max Vout off min Output Current max Optical Isolation REMOTE ENABLE and RPM SELECT Inputs Input Type Input Voltage Vin on min Vin on max Vin off max Input Current max Optical Isolation Power Requirements Supply Voltage Supply Current Temperature Ranges Storage Operating Relative Humidity M4040 M4041 User s Manual True Low Sinking 24VDC 1 50 volts 20 volts 50 milliamps 1500 Vrms True High Sourcing 12 volts 30 volts 5 volts 10 milliamps at Vin 30 volts 1500 Vrms 24VDC 10 0 60 Amps max 0 to 60 degrees C 0 to 60 degrees C 5 to 95 non condensing 42 SYSTEMS Electronics Group APPENDIX A RS 232 PINOUTS CABLES 1 NOT USED 2 RXD RECEIVE DATA IN 6 1 3 TXD TRANSMIT DATA OUT 7 2 4 NOT USED a 3 5 SG SIGNAL GROUND 9 4 6 NOT USED 5 7 NOT USED 8 NOT USED 9 NOT USED PROG CHAN Port Pin Out DB9 FEMALE DB9 FEMALE COMPUTER INTERFACE PROG PORT 2 2 Rx TXD 3 3 sc 5 5 sc RTS 7 CTS 8 DSR 6 DTR 4 DB9 com1 to PROG Port Cable DB25 MALE DB9 FEMALE COMPUTER INTERFACE PROG PORT ue 2 2 e RXD 3 3 TXD
40. r compensation enable parameter programming Motion output enable parameter programming e Onand Off line timing channel programming including arbitrary set point programming pulse train channel programming timing channel fine tune e Channel set points download to M4040 41 e Channel set points upload from M4040 41 e Configuration and Channel set point print outs e M4040 41 Hardware Confidence test See section 2 for details on the programming commands and PLSdev features M4040 M4041 User s Manual SYSTEMS Electronics Group SECTION 1 GENERAL DESCRIPTION This Page Intentionally Left Blank M4040 M4041 User s Manual SYSTEMS Electronics Group SECTION 2 PROGRAMMING 2 1 INTRODUCTION TO PLSdev PLSdev is a DOS based software package used to configure and program the timing channels of the M4040 41 PLS modules An RS 232 cable connected to COMI of the IBM PC or compatible running PLSdev is used to interface with the M4040 41 module for on line programming program upload download etc No other additional hardware is required 2 1 1 FEATURES OF PLSdev PLSdev incorporates the following features 1 2 3 4 5 6 7 Offline Channel Set point Programming set points for each channel can be entered with easy to use set point programming commands and saved on disk for download to the M4040 41 at a latter time This allows the channel programming to be implemented without having an M4040 41 present
41. rform the M4040 41 hardware confidence test the following is required 1 IBM PC or compatible with PLSdev installed 2 RS 232 interface cable to connect COMI on the PC to CHAN port on the M4040 41 3 24VDC power supply to power M4040 41 4 M4040 41 to be tested 6 2 2 EXECUTING THE TEST To execute the test perform the following steps 1 Power up the M4040 41 to be tested 2 Power up PC and enter PLSdev Enter any user program name to proceed to the PLSdev Main Development Menu 3 Connect Interface cable to COMI on PC and CHAN port on M4040 41 4 Select PLS Hardware Confidence Test A prompt will be displayed verifying to proceed with the test Note Proceeding with the test will clear all set points and configuration data from the M4040 41 The user channel program will have to be re downloaded to the M4040 41 once the test is complete Press ESC to abort the test any other key to proceed 5 Select Perform Test from the Test Functions Menu to start the test Once the test 15 initiated all tests enabled will be executed repeatedly starting with testl thru the last enabled test until any key is depressed M4040 M4041 User s Manual SYSTEMS Electronics Group 332 SECTION 6 HARDWARE CONFIDENCE TEST If no faults are detected the tests will continue to execute repeatedly displaying test passed messages after the successful completion of each test If a fault does occur the test will stop and display
42. rovides a way to make a new user program directory while inside PLSdev Enter the drive and directory name following the MS DOS conventions of directory names M4040 M4041 User s Manual SYSTEMS Electronics Group 11 SECTION 2 PROGRAMMING 4 Copy program to another program name This provides a way to copy the current program name to any disk and directory while also allowing the user to copy to a different program name Enter the drive directory and new program name using the MS DOS conventions for directory and file names Do not enter an extension with the program name This copies all the files associated with the program to the different directory and program name This selection can be used to copy the current name to another drive and directory when the program name entered is the same as the current program name This is also used to copy the program to a new program name For instance when one program is similar to another completed program simply copy the old program to the new program name and edit as required 2 2 2 CHANNEL EDIT MENU This menu is invoked for both off line and on line programming and provides a mechanism to enter and edit the set points for the channels The menu contains both information fields and function key commands The information fields are defined as follows CHANNEL This is the number in octal of the currently selected and displayed channel When the channel edit menu is initially invoked ch
43. rror timing signal width and compensation enable window Initially must also be programmed with a TDC timing signal This set point is used to stop the press after the brake wear compensation is enabled for the first time Note The press may or may not stop at the desired location the first time the brake wear compensation is enabled If the press does not stop within the allowed stopping error of the desired stopping location the algorithm will automatically advance or retard the timing set point by the difference between the actual and desired stopping location At the next TDC stop the press should than stop at the desired location Also CH00 will only be advanced or retarded within the compensation enable window and no further If the set point is advanced to the leading edge of the enable window it will not be advanced any further thus no further compensation for brake wear will occur In normal operation the algorithm verifies that the press always stops within the allowed error of the desired stopping location for all TDC stops REMOTE ENABLE high when press reaches zero speed As brake wear occurs over time the press will overshoot the desired stopping location Once it stops past the allowed error the algorithm calculates the difference and re programs the set point advancing it by this difference The press will than stop at the desired location again The set point is programme
44. set points in the channel To program a single set point locate the set point cursor large block cursor at the set point to be modified the large cursor will always be located in the on parameter of the set point Enter the set point as follows 1 Type in on parameter in degrees cursor will change to the small data entry cursor 2 Press Enter lt CR gt or to enter the on parameter 3 Type in off parameter in degrees 4 Press Enter lt CR gt to enter the off parameter 5 The cursor will change back to the large set point cursor and automatically advance to the on parameter of the next set point The set point has now been entered 6 Ifan invalid set point number is entered a message stating this will be displayed in the message field of the channel edit menu Re enter a proper set point value or press ESC to abort the set point entry Note The set point values entered must be less than the scale factor Set points are also not allowed to overlap any existing set points already entered in the channel M4040 M4041 User s Manual SYSTEMS Electronics Group 18 SECTION 2 PROGRAMMING Example 1 The following key sequence enters the set point 020 040 at set point number 1 Key Depressed Set point Field 2 2 0 20 020 4 020 4 0 020 40 Enter lt CR gt 020 040 Example 2 The following example programs the entire channel on by specifying both the on and off parameters to 000 Key
45. the following Fault Code XX test fault code and description Address of fault memory address or I O address where fault occurred Actual data at fault data actually obtained at address of fault Expected data at fault data that should have been obtained at address of fault Diagnostics test number for factory use only Once a fault occurs exit back to the Main Test Menu and re initiate the test to reset the fault code Once testing is complete exit back the Main Development Menu The user channel program will now have to be re downloaded to the M4040 41 6 3 INTERACTIVE INTERFACE The interactive interface menu contains selections to read the fault code same as displayed when a fault is detected perform diagnostics routines for use by the factory only and to read and write via the RS 232 ports to any address in the M4040 41 In general all these selections are for factory use and are of little significance to the user M4040 M4041 User s Manual SYSTEMS Electronics Group 33 SECTION 6 HARDWARE CONFIDENCE TEST This Page Intentionally Left Blank M4040 M4041 User s Manual SYSTEMS Electronics Group 34 SECTION 7 INSTALLATION The following sections provide information on mounting and wiring the M4040 41 as well as a description of the power up sequence Note All wiring is implemented with removable field wiring connectors The connectors are removed by gently pulling the connectors from the s
46. this connector M4040 M4041 User s Manual SYSTEMS Electronics Group 38 SECTION 7 INSTALLATION 7 5 WIRING TIMING CHANNEL OUTPUTS The timing channel outputs are 10 30VDC true high outputs capable of sourcing 100milliamps of current The outputs were designed to drive PLC inputs or other low current devices and are not capable of driving solenoids The timing channel outputs contain short circuit protection such that if the output current exceeds 500milliamps all outputs within the eight channel group are disabled protecting the output Power for the timing channel outputs is wired to the power and C common or return terminals on the Timing channel output connector Be sure to observe the proper polarity of the power and C wiring otherwise damage to the module may occur Note The timing channels are optically isolated thus the 10 30VDC power applied to the timing channel outputs does not have to be commoned with the 24VDC input power described above Figure 7 3 shows the typical timing channel output wiring M4020 40 41 CHANNEL OUTPUT TO OTHER CIRCUITS S 10 30VDC PLE TO INTERNAL OUTPUT aub NPUT 0 17 S Vcr TO OTHER CIRCUITS lt E Q RETURN Figure 7 3 Typical Channel Output Wirin M4040 M4041 User s Manual SYSTEMS Electronics Group 39 SECTION 7 INSTALLATION 7 6 WIRING THE 128PPR AND 1KPPR OUTPUTS The 128 and 1K pulse per revolution outputs are
47. user program files are actually created by PLSdev one that contains the PLS configuration data for the program another which contains the channel set point data for the program These are the files that are used to edit download and upload to and from the M4040 41 module Thus when referencing the program through PLSdev no extension should ever be typed in If no program name is entered when PLSdev is invoked the program name will be prompted for by PLSdev before the program proceeds to the main menu Enter the program name as outlined above to proceed M4040 M4041 User s Manual SYSTEMS Electronics Group SECTION 2 PROGRAMMING 2 2 MENUS The following sections are a description of the various PLSdev menus In general the PgUp PgDn Home End and cursor left right up and down keys all function as defined 2 2 1 MAIN DEVELOPMENT MENU 1 Offline Channel Set Point Programming This selection is used to edit the channel set points off line while not connected to an M4040 41 module All changes made to the channel set points are saved in the channel data file for the selected program The channel set points can then be downloaded to an M4040 41 module using the Download Channels to PLS selection To initiate the off line programming mode select Offline Channel Set Point Programming This invokes the channel edit menu and loads the existing channel set points from the channel data file on disk See section 2 2 2 for a
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