programmable limit switches (pls) - steven …stevenengineering.com/tech_support/pdfs/65prog.pdf ·...

Programmable Limit Switch, "The Solid-State Programmable Cam Switch" . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-2

Stand alone PLS:

Touch•PLS, Touchscreen PLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-7

M1020 PLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-13

M1050 PLS Series — M1050, M1050A, M1051, M1051-R10, M1052, & M1053 . . . . . . . . . . . . . . . . . . . . . . . . . . .D-16

M1151 The Incredibly Small PLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-21

M1250 Mini•PLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-24

M1450 Mini•PLS with Advanced Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-24

M1500 Pc•PLS combination PLC and PLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-32

M1750 PLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-35

M1350 Mini•Cam Rotary Cam Switch — Optical Noncontacting Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-40

M1920 PLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-43

PLC/PC Backplane Mounted PLS:

M8250 Series PLS BusModules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-47

PC (ISA-Bus) PLS BusModule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-50

SECTION D — PROGRAMMABLE LIMIT SWITCHES (PLS)

PROGRAMMABLE LIMIT SWITCHES (PLS)

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Many machines used in automated manufacturing environ-ments in the early 1970's had rotary cam switches or limitswitches to sense machine position and used hard-wired relaycontrol panels to control machine operation. Even the smallestchange in machine control logic required extensive work tomodify the relay control panel. New control development wasvery inefficient since each control logic required custom-builthardware. Further, adjusting a machine's cam settings for anew set-up required many hours or even days of machinedown-time.

The mid 70's saw the development of new controls to solvethese problems. Programmable Logic Controllers (PLCs) weredeveloped to replace the relay control panels and AVGAutomation invented an electronic Programmable Limit

Switch (PLS) to replace the mechanical, cam tripped, limitswitches. The PLS consists of an absolute-position transducer,mounted in place of the rotary cam limit switch, and pro-grammable electronics mounted in the control panel. With theadvent of the PLS, cam settings can be altered in minutesinstead of hours. Also, cam settings can be optimized by fine-tuning while a machine is in operation.

The PLS and PLC combination has been so successfullyemployed in factory automation that it is now standard formany kinds of machines. The PLS, because of its speed andaccuracy, controls high-speed machine operations with preci-sion and can provide the PLC accurate timing, position, orRPM data. The PLC controls slower machine functions andprovides overall machine control.

A HISTORICAL PERSPECTIVE

PROGRAMMABLE LIMIT SWITCH"THE SOLID-STATE PROGRAMMABLE CAM SWITCH"

800-TEC-ENGRwww.avg.netD-2 Programmable Limit Switches

Since the mid to late 70's, autom0ation control users havedesired to combine the PLS and the PLC into one control.Interfacing absolute-position encoders/resolvers directly toPLCs has been widely attempted with limited success. The twoobstacles to using PLCs for the PLS function are:

1. Synchronization of rapidly changing position data to theinput scan of a PLC.

2. Slow scan time of a PLC.

The lack of synchronization may result in misreading of theposition information occasionally. AVG Automation solvedsynchronization problems for PLC users by inventing the PC-Handshake module in 1978. An external PC-HandshakeModule, however, negated the concept of "one control box".

Even though PLCs have been getting faster and faster, it isinconceivable for a PLC to be able to handle the desired posi-tion transducer data rates. For example, even a 5-ms scan timeallows a top speed of only 33 rpm for 1° resolution.

In the early 1980's the state of the art in machine control wasa combination of a PLS for high-speed response and ease ofset-up and a PLC for control logic and intelligent networking.

It was in the beginning of 1987 when the MacroPLS fromAVG Automation with its revolutionary system architectureand technology made the industry's desire for "one controlbox" a reality. The MacroPLS is the first PLS with ladder logicand a math instruction set. With direct high-speed resolverinterface and 3K of relay ladder logic repeatable to 100 µs, theMacroPLS was a giant leap into the future.

Principle of OperationA PLS system consists of a position transducer mounted on amachine's drive shaft and a programmable unit mounted inthe machine control panel. In AVG Automation's case, theposition transducer is a resolver, which produces analog signalsproportional to the shaft position. The position signals areconverted to digital format by an internal ratiometric trackingconverter in the programmable unit, displayed on the frontpanel and compared to the dwell setpoints programmed intothe PLS. When the process cycle reaches these setpoints, out-puts are turned ON or OFF, to start or stop desired functionsduring the cycle.

The cam limits or dwells are programmed into the PLS bythumbwheel settings or simple keyboard entries right from thecontrol panel. No more climbing to the top of the press tomake cam adjustments which were not only tedious but alsovery time consuming. Furthermore, with the PLSs, the fine-tuning can be done on the fly.

PLSs today offer many advanced features such as zero offsetadjustment, dynamic zeroing and programmable rate offset.Zero offset feature allows the operation an easy way of aligningresolver zero to the machine zero. Dynamic zeroing and ModZallows modification of the zero reference for selected channelsindependent of the actual resolver position. Programmable rateoffset, ROF, allows automatic adjustment of set points to com-pensate for machine speed variations.

The AVG Automation microprocessor-based PLSs uses apatented DMA technique employing look-up tables to achievethe fastest machine operation in the industry: 20,000 setpointsin 85 µs.

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Position Transducers:1. ResolverA resolver is a passive position transducer. It works on theprinciple of a rotary transformer and consists of one rotorwinding and two stator windings located 90° apart. The rotorwinding is excited with a voltage Vr. As the shaft rotates, theoutput voltage of the stator windings varies as the sine andcosine of the shaft angle.

The ratio of the secondary stator voltages:Note that the angle Ø is no longer a function of the inducedabsolute Vr, but rather the ratio of Vs1 and Vs2. Therefore,variations in the rotor voltage Vr, frequency and temperatureare no longer factors in ratiometric output signal Vs1/Vs2. Thisresults in a highly accurate and repeatable resolver decoder.

2. Ultrasonic Linear TransducerAn Ultrasonic Linear Transducer provides a means of accurate-ly measuring linear distance ultrasonically with a minimum ofmechanical linkages and extra hardware. There are no movingparts and consequently no wear.

An ultrasonic linear transducer consists of an interface controlmodule, a transducer rod and a "doughnut-shaped" magnet.An electrical interrogation pulse, generated in the interfacecontrol module, starts the leading edge of the pulse-widthmodulation signal. This pulse creates a magnetic field aroundthe conducting element housed inside a magnetorestrictivetube called waveguide. The waveguide, in turn, is enclosed inthe nonmagnetic stainless steel tube. The magnetic field fromthe "doughnut-shaped" permanent magnet, mechanically rep-resentative of machine position, reacts with this generated fieldproducing a mechanical force at right angles to the conductingelement. This force causes a twist (torsional strain) whichslightly twists the waveguide tube. The twist in the tube pro-duces a torsion wave that is transmitted along the waveguide.The time delay from the interrogating pulse until the travel-ling torsion wave produces a signal in the sensing coil is adirect measurement of the linear position of the "doughnut"magnet. The precise time interval is then converted to digitalposition inside a linear decoder or a linear PLS.

Magnetic fields normally generated by 60 or 400 Hz equip-ment will not affect the operation because these frequencieswill be rejected by the narrow bandwidth detection used.

Normally, the transducer beam is fixed and the "doughnut"magnet moves with the moving part of the machine. However,the two can be reversed if desired. The relative displacementbetween the magnet and rod provides the linear position.


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Advantages of AVG Automation PLSs over Competitive PLSs

Features AVG Automation PLSs Other PLSs

1. Number of outputsUp to 80 outputs in 6" x 4" x 6".

Field-expandable to 560 outputs byadding slave units

6-48 outputs; factory ordered; large overall size

2. Setpoints per channel80 to no limit on 3-digit models;

4- and 6-digit models have 21 setpoints per channel

Only 1 setpoint per channel on mostmodels; some models offer limited

multiple setpoints, such as 12 setpoints per 6 channels

3. Response timeFastest PLS in the market; patentedDMA technique allows processing

20,000 setpoints in 85 µs

Scan time of a few ms; Some claim µsscan time but in reality operate as time-

based rather than position-based

4. Fine-tuning in motion Yes; adjust setpoints in full motionFor most of PLSs machine shutdown

required to change setpoints

5. Autozero offsetYes, allows quick, automatic

matching of machine zero withresolver zero

Amount of offset required for machinezero alignment needs calculation

6. Write protect on memory Yes None

7. Slave unitsConnected to high-noise-immune

resolver inputConnected to the noise-susceptible BCD

output from the master PLS.

8. Position output for

external devices

Field add-on modules for analog orBCD, Binary, or Gray code; built-in PC-

handshake

Must be factory ordered; limited to BCDoutput only; no PC-handshake.

9. Tach outputField add-on module for analog or

digital tachNone

10. Broken resolver wire

detector

Built-in or field add-on accessorydepending on model

Not available on most models; Some units have factory ordered option

11. Optically isolated

outputs

Plug-in modules or a separatechassis

Separate chassis only

12. Portable program

modules

Portable EEPROM memory modulesallow a preprogrammed module

library for multiple program selectionNone

13. Resolver connectionsAbuse-proof resolver connections;

short- circuit-proofNot short-circuit-proof

14. Keyboard

programmable and remote

PLS program selection

Up to 100 programs of160 dual-limits-per-channel. May be remotelyselected by PLCs, computers,

or BCD switches

Some models offer maximum of programs of a very limited number of

setpoints. Not necessarily PLC-selectable

Advanages of AVG Automation PLS over Competitive PLSs:


Advantages of a PLS over Mechanical Limit Switches

Feature Mechanical Switches Programmable Limit switch (PLS)

1. Accuracy 5° at best; degrades with time0.1° repeatable to arc minutes;

does not degrade with time

2. Setup Very cumbersome and time consuming

Very simple and accurate limit settings with keypad or thumbwheel switches

3. Accessibility Often mounted in inaccessiblelocations

Mounted on control panel or in control room

4. Speed100 rpm max; above this speed contacts bounce

and accuracy is lostUp to 1800 rpm with 1° resolution

5. Life ExpectancyConstant cycling and wear on

cams as well as switch contactsreduce operational life

Very reliable; Resolver shaft is the only moving part

6. Dwell Range Minimum 3° to 5° dwell settings Dwell settings as low as 0.10°

7. Need for Adjustment Often requires adjustmentbecause of mechanical wear

Once set never needs adjustment

8. Adjustment during machine operation

Not possible; must stop machine to adjust cams

Setpoints can be fine-tuned with machine in operation

9. Position display No display availableDigital shaft position display is extremelyuseful for set-up and service personnel

10. Speed Compensation Not availableWith varying speed, limits advance

automatically by preprogrammed amount

11. Mod-Z: Modification Zero Not available

With an external signal, position referencefor a group of PLS output channels is reset

to zero while other channels maintainmachine position reference

12. Output Options Only electromechanical switchesOptions of EM relays, solid-state

AC or DC relays or logic level outputscompatible with PLCs

13. Cost Low initial costHigher initial cost, but lower operational

cost due to less down-time and increasedproductivity. Can pay for itself in days

14. Field ExpandableNot possible; must use a

new model for higher number of outputs

Modular construction; easily field-expandable

by adding more modules

15. Program security NoneKey-switch lock out against

unauthorized program tampering

16. Speed display Not available Built in tachometer displays shaft RPM

17. Motion Detector Not availableBuilt in motion detector monitors machime

over or under speed problems

Advanages of a PLS over Mechanical Limit Swithces:

Touch•PLS is a traditional PLS that's been combined with atouchscreen-based Graphical Operator Interface. No longer doyou have to contend with LEDs, switches, pushbuttons, andkeypads. Touch•PLS graphically depicts your application,while providing machine settings and status and productiondata. All programming and fine-tuning of the PLS settingsoccurs in a Windows-type environment. While the unit comeswith predesigned screens, AVG Automation's µWIN softwaremakes it easy to create or customize screens to suit your partic-ular application.

One size fits all!You don't need separate PLS and PLC operator interfaceswhen you use Touch•PLS because it does double duty; servingas a PLS interface/control as well as an operator interface tothe PLC. There's no need to clutter up your machine's opera-tor panel with several different displays when Touch•PLS doesit all! It reduces panel space, which also reduces installationcosts and hardware costs.

Touch•PLS Principle of OperationThe Touch•PLS, as shown in the block diagram, uses twoprocessors, one for the PLS and the other to manage, display,and communicate to the PLC. The PLS processor reads itsposition signals from the resolver mounted on the machine'sshaft. It controls position-based outputs independent of theinterface processor, providing fast repeatable outputs. The PLSprocessor and the interface processor share information using a1,024-register shared memory. The dynamic information, suchas position, RPM, and output status, is available to the inter-face processor for display through registers.

The interface processor also shares data with the connectedPLC through a second set of 1,024 registers. This arrangementmakes it easy to display data from both the PLC and PLS onone screen. In addition, 32 registers (16 in each direction) areused to exchange time-critical information between the PLSand PLC through the interface processor. These registers canbe used to send position, RPM, and output status informationto the PLC.

TOUCH•PLS

TOUCH•PLS— TOUCHSCREEN PLSA NEW HORIZON IN PROGRAMMABLE LIMIT SWITCHES

Touchscreen PLS and Graphical Operator Interfacein One Unit

Five Screen Sizes Available: 5" Color,6" Monochrome, 8" Color, 9" Monochrome EL,and 10" Color

Most-Advanced PLS with Leading- and Trailing-Edge Speed Compensation

PLS Settings and Machine Data Totally Integratedwith Your PLC

Programmable Graphical Interface to Over 30Models of PLCs

Dynamic zeroing upon external command

32 PLS Programs

8 levels of security

Brake-wear Monitor

Built-in Motion Detector and Tachometer

Angle ON/Angle OFF and Angle/ON/Time OFF

Broken wire detection

Short-Circuit-Proof Resolver

Self Diagnostics

Optically Isolated Inputs & Outputs

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Rugged, Reliable Resolver for PositionTransducerThe Touch•PLS uses a resolver as a position transducer. Unlikeincremental encoders, the resolver, along with its noise-immune ratiometric converter, always gives true machine posi-tion—even if the machine moved during a power outage. Theresolver, due to its construction, is immune to temperatureand humidity extremes and mechanical shocks and vibrations.

Short-Circuit-Proof ResolverThe Touch•PLS uses AVG Automation's standard short-cir-cuit-proof resolver circuit. Thus, in case of an accidental shortin the resolver wiring, costly damage to the PLS resolverdecoder and the resulting downtime is avoided.

Broken-Wire DetectionThe Touch•PLS features a broken resolver-wire detector tosupervise the resolver input signal. The broken-wire detectorwill signal the fault output if the resolver is missing any signals.

FEATURES:

Highest Processing SpeedTouch•PLS uses AVG Automation's patented DMA technique,which converts the resolver's analog output signal to a digitalform, then compares all the setpoints, and activates all the out-puts in less than a millisecond. The high-speed ratiometricresolver-to-digital converter and the microscan time guaranteesperfect machine operation at speeds up to 1,800 RPM.

Multiple Program StorageThe Touch•PLS can internally store 32 independent programsfor different jobs. With a pre-programmed Touch•PLS for dif-ferent product runs, the product change over is as simple as

pressing a button on a touch screen to select the program cor-responding to the job. Remote selection of PLS programs mayalso be accomplished by a PLC.

Leading- and Trailing-Edge SpeedCompensationTouch•PLS features a Speed Compensation (Rate Offset) tocompensate for speed variations. The Rate Offset, individuallyprogrammable for each channel, is used to advance the PLSsettings as a function of the machine speed

Pulse ProgrammingTouch•PLS can be fine-tuned while your machine is running.Either or both of the ON and OFF Setpoints can be incre-mented or decremented, or a fixed dwell can be incrementedor decremented, as needed.

Angle ON/Time OFFTouch•PLS can be programmed to have its outputs turned ONat an angle and turned OFF after a programmed time by touch-ing the screen. For example, Channel 12 can be turned ON atan angle of 100° and stay ON for a period of 2.45 seconds.

Programmable Functionality: Brake and ModZTouch•PLS features a dynamic zeroing or ModZ(Modification Zero) to modify the zero reference point, inde-pendent of the actual resolver position. After the PLS receivesthe ModZ input, the resolver position is reset to zero.Touch•PLS can also perform Brake Monitoring to satisfy theOSHA requirement. This PLS can be field-programmed tohave Brake Monitoring Functionality (initiated by entering aCaution and Danger limit). If you do not select BrakeMonitoring, the user must select ModZ or the unit defaults tonormal PLS functionality. (If Brake Monitoring is selected, theunit cannot function as ModZ.)

Flexible Group AssignmentTouch•PLS's Flexible Group Assignment can be a powerfuland useful feature. When it is desirable to control several dif-ferent machines linked to the same drive shaft, output chan-nels may be grouped together into one of five independentsections. The base group is always PLS, while the other fourgroups (1-4) may be defined as PLS or ModZ type. Each PLSgroup has its own group offset, while each ModZ group has itsown ModZ inhibit zone.

Built-in Motion Detector and TachometerTouch•PLS has a built-in tachometer and motion detector.The motion detector energizes a relay when the RPM isbetween the programmed LOW and HIGH alarm values.


8-Levels of Password ProtectionTouch•PLS has a password protection feature eight levels deep.Up to eight different passwords that are user-programmablefrom the touchscreen, allow access to different screens in theTouch•PLS, providing ultimate protection and security ofmachine settings.

Touch•PLS has Choice Of 6 DisplaysTouch•PLS offers four different types of flat panel touchscreendisplays to suit any application and its budget. Except for thesize and availability of colors on the screen, all other featuresremain the same.

5" ColorThe 5" color LCD model offers 16 colors, high-contrast, 320x 240-pixel resolution, and an 8 x 6 touch-cell grid.

5" ColorThe 5" active matrix color LCD model offers 16 bright colors,high-contrast, 320 x 240-pixel resolution, and an 8 x 6 touch-cell grid.

6" MonochromeThe 6" monochrome model provides 320 x 240-pixel resolu-tion with three shades of gray and an 8 x 6 touch-cell grid.

8" ColorThe 8" color model provides 640 x 480-pixel resolution with16 colors and a 16 x12 touch-cell grid.

9" Monochrome ELThe 9" monochrome electroluminescent model provides 640 x400-pixel resolution with three shades of amber and an 16 x10 touch-cell grid.

10" ColorThe 10" color model comes with a bright 640 x 480-pixel reso-lution, 16-color, flat panel display, and 16 x 12 touch-cell grid.

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Touch•PLS-Total Integration With any PLCNetworkUntil the advent of Touch•PLS, the only way you communi-cated machine position, speed, or PLS status to your PLC net-work, was through hard-wired discrete outputs from the PLSto the PLC inputs. As far as the PLS program settings wereconcerned, they were simply not available to the PLC.Touch•PLS can communicates to more than 30 different PLCsand their networks, or through a serial connection, such as A-B DH+, A-B Remote I/O, or Profibus. The entire PLS pro-gram can be either uploaded or downloaded to the PLCthrough the same bus connection. Hard PLS outputs are alsoavailable to activate the machine solenoids directly—freeingthe PLC's CPU from this task.

Touch•PLS Eliminates the Need for a SeparateOperator Interface for Your PLCTouch•PLS is a complete Graphical Operator Interface for usewith the PLC in your system. Therefore, you do not need anoth-er OI for the PLC if you are using Touch•PLS. It can communi-cate to your PLC, even while performing PLS functions.

The OI part of Touch•PLS is more than a pushbutton replace-ment. It offers functionality not possible with other discreteoperator panels. Not only can it replace common panel compo-nents, such as pushbuttons, pilot lights, selector switches, etc.very economically, but you also have complex flexibility. WithTouch•PLS, your control panel is never obsolete. Any changescan be made in minutes on-line, off-line, or even remotely.

µWIN: The Windows-Based On-Line Softwareto Program PLC Screens and Customize PLSScreensTouch•PLS is shipped with preprogrammed screens for PLSoperation. However, with AVG Automation's µWIN software,a user can modify or customize the screens to his or her imagi-nation.

The µWIN software works with Microsoft Windows 3.11 orlater. In addition to supporting advanced features like CADdrawing capability, library support, etc., µWIN offers a toolbox of commonly used panel components. The tool box helpscreate simple operator panels quickly without drawing.

A library of several components are available on AVGAutomation's web site to save valuable drawing time.

With µWIN, the user can develop screens off- or on-line.With the off-line feature, the screens can be developed in theconvenience of your office or remotely, and then downloadedto the unit.

With the on-line programming feature, you can develop thescreens while the Touch•PLS is operating and communicatingto the PLC. This allows modifying screens without taking theTouch•PLS off line. The program development can be donethrough a modem, allowing you to change the program on aTouch•PLS virtually anywhere in the world.


The operator can't push the wrong buttonTouch•PLS panels display only the necessary controls that areneeded for a particular function, and only when they are need-ed. Thus, not only can the machine's control panel be madefar less cluttered; but, controls that are not needed at thatmoment are simply not available to the operator. This reducespossible operator confusion. And by locking out the operator'sability to touch the wrong control, using Touch•PLS mini-mizes or eliminates damage—and the resulting cost—thatcould be caused by introducing inappropriate control signalsto the machine.

Multiple Language DisplaysTouch•PLS units offer a unique multiple languages feature.Today, many production personnel do not speak English as afirst language. Companies are finding they can convey infor-mation to these operators faster, and with less confusion, whenthe display is in the operator's native language. Studies haveshown that in emergency situations, a person reacts fastest inthat person's native tongue. AVG Automation's µWIN pro-gramming software enables you to enter display messages inseveral different languages. Currently only English and Cyrilliccharacter sets are available.

This is not to say that µWIN translates English-languagephrases into those of other languages—it only recognizesstrings of ASCII characters. You can create up to 16 textstrings (memory dependent) for each object— each in a differ-ent language. (Please note the more screens and words you use,the more memory you use, and the fewer sets of text stringsper object you can create.)

To use this feature, a user will design a screen as usual, andenter text strings, where applicable, in as many languages asdesired (16 max.). You do not have to design & maintain sepa-rate screens for each language. All your operator has to do isgo to the language selection screen and select the languageyou've already programmed into the Touch•PLS. All screenswill then display their messages in the language selected.

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TOUCH•PLS SPECIFICATIONS

Power Requirements:5" Color and 6" Models: 24 VDC @ 18 W8" Color Model: 24 VDC, 24 W9"Amber EL Model: 115/230 VAC <40 VA or 24 VDC <40 VA10" Color Model: 120 VAC ±10%, 50-60 Hz, @ 1 A or

24 VDC @ 1.25 A Operating Temperature:

5" Models: 32 to 122 °F (0 to 50 °C)6" and 8" Models: 32 to 104 °F (0 to 40 °C)9" Model: 32 to 140 °F (0 to 60 °C)10" Model: 32 to 113 °F (0 to 45 °C)

Position Resolution: 1 part in 1,000 (consult factory for higher resolution)

Update Time: 1.5 msec

PROGRAMMABLE PARAMETERS:Scale Factor: Programmable from 16 to 999, common to all PLS

setupPosition Offset: Programmable to full scale factor value,

common to all PLS setupNumber of PLS ON/OFF Setpoints: 112 per PLS setupNumber of PLS Setups: 32Speed Compensation: Leading and Trailing edge,

programmable in scale factor units per 100 RPM, up to full-scale factor value. Each PLS output (channel) has its ownspeed compensation

Motion Detector: LOW and HIGH motion limits, common to allPLS setups, programmable from 0-999 RPM

Brake Monitor: Caution and Danger Limit, Stopping time 9.99sec. max.

Number of PLS outputs: 16Dynamic Zero or ModZ Input or Brake Input:

Modification Zero on the fly with an external input (edgetriggered) or brake input

Serial Communication: Via RS-485A portBroken Resolver Wire Detection: Indication for broken wire in

I/O Status

RESOLVER INTERFACE:Position Transducer: Resolver, AVG Automation Series RL100,

RL101, E7R, and E8R.Resolver Cable: CBL-10T22-CXXX or CBL-10T22-MXXXResolver Decoder: Ratiometric, tracks resolver shaft angle up to

1,800 RPM.Cable Length: 2,500 ft. max., shielded, twisted-pair.

INPUTS/OUTPUTS:Electrical Specifications:

I/O Power Input: 20 to 30 VDC @ 100 mA + user's loads

N-Channel Sinking I/OOutput Logic Levels:

Logic TRUE: MOSFET ON, 0.2 V Max. @ 100 mALogic FALSE: MOSFET OFF, 0.05 mA leakage @ 30 VMax. Current per Output: 600 mAMax. Current per Card: 2 AOutput Isolation: 1,500 V

Input Logic Levels:Logic FALSE: 6-30 VDCLogic TRUE: 0-1.5 VDC

Input Isolation: 1,500 V

P-Channel Sourcing I/OOutput Logic Levels:

Logic TRUE: MOSFET ON, 0.5 V Drop @ 100 mALogic FALSE: MOSFET OFF, 0.05 mA leakage @ 30 VMax. Current per Output: 600 mAMax. Current per Card: 2 AOutput Isolation: 1,500 V

Input Logic Levels:Logic TRUE: 6-30 VDCLogic FALSE: 0-1.5 VDCInput Isolation: 1,500 V

Display Size Resolution(pixels)

TouchCells

Shades/Colors

EnclosureRatings

Color (Active) 5" 320 x 240 8 x 6 16 NEMA 4

Color 5" 320 x 240 8 x 6 16 NEMA 4

Monochrome 6" 320 x 240 8 x 6 3 NEMA 4, 4X

Color 8" 640 x 480 16 x 12 16 NEMA 4

Amber EL 9" 640 x 400 16 x 10 3 NEMA 4X

Color (Active) 10" 640 x 480 16 x 12 16 NEMA 4X

AVG Automation, your Programmable Limit Switch (PLS)specialist, has now made it possible to simply obsolete electro-mechanical cam/limit switches! In spite of numerous limitations,such as cam bounce, limited life, and high maintenance,industrial use of electromechanical switches has continued dueto their low cost. The M1020-PLS from AVG Automation hasbroken down the last barrier…the price. It offers solid-state reli-ability at the cost of electromechanical cam switches.

Principle of OperationThe M1020-PLS consists of two parts, one being a positiontransducer (resolver) mounted on the machine shaft and theother a programmable unit mounted in the machine controlpanel. The resolver produces an analog signal proportional tothe shaft position that is converted to digital format by a ratio-metric converter inside the programmable unit. This positionis then displayed on the front of the PLS panel and comparedto the dwell setpoints programmed into it. When the processcycle reaches these setpoints, outputs are enabled or disabled,resulting in starting or stopping desired functions during thecycle.

Programmable Zero OffsetThe M1020-PLS allows for quick initial setup, while matching"machine zero" to "resolver zero" or compensating formachine-wear-induced speed changes. After the resolver is

mounted on the machine shaft, simply align the machine to amechanical zero reference and enter the required offset num-ber to read zero.

Programmable Limit SettingsThe "ON/OFF" setpoints for each output can be programmedsimply by the touch of a key from the front panel. The AVGAutomation patented key sequence in the M1020-PLS isincredibly simple and easy to use.

Fine-Tuning in MotionAn additional advantage of the M1020-PLS is that you canfine-tune your limit settings while the machine is running.This increase in machine productivity pays for the PLS withinmonths.

Programmable Production Rate IndicatorIn the "TACH" mode, the M1020-PLS displays the machineshaft speed in RPM. However, in this mode, a production ratefactor can be programmed to display parts manufactured perminute.

Key selects the function to be programmed, whilethe display shows each function's current values.

Key selects the parameter to be programmed, whilethe location of the decimal points indicates whichparameter is selected.

M1020-PLS

M1020 PROGRAMMABLE LIMIT SWITCHTHE SIMPLE, LOW-COST REPLACEMENT FOR CAM/LIMIT SWITCHES

Programmable Limit Switch (PLS) at the cost ofcam/limit switches

Detachable operator interface for program security

Increased machine productivity

Programmable production rate counters

Fine tuning in motion

Programmable zero offset

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Keys adjust the parameter value,while the display indicates all current parameter values.

Key selects the next programmed setpoint for the display.

MODULAR, EASY TO SERVICE

Low MaintenanceUnlike an electromechanical limit switch that requires periodicmaintenance and often at places that are hard to reach, theM1020-PLS requires no maintenance and has no mechanicalcams/contacts to wear out. In addition, the plug-in outputrelays are easily field replaceable.

Detachable operator interface for ProgramSecurity and Cost SavingsOnce the setpoints are programmed using the front-panel-pro-gramming interface, you can detach it from the main unit,making the program inaccessible to any unauthorized person-nel. While this feature makes the M1020-PLS tamper-proof, italso saves you money by using the same programmer to pro-gram various other AVG Automation PLSs in your plant.

Program Enable InputThe M1020-PLS allows another level of security against unau-thorized programming changes. In addition to the detachableprogrammer, you need a contact closure at the back of theM1020 to enable programming.

Rugged, Reliable for Hostile EnvironmentsThe M1020-PLS combines the ruggedness of a brushlessresolver and the reliability of an advanced solid-state control.The rugged, heavy-duty, NEMA 13 (IP54)-rated resolver canbe mounted on a machine shaft in hostile environments, suchas mechanical shock, vibration, extreme humidity and temper-ature changes, oil mist, coolant sprays, solvents, etc., and theprogrammable control unit, M1020-PLS, can be mounted upto 2,500 ft. away in a control panel The splash-proof, oil-tightfront plate permits the unit to be installed directly on themachine itself, if so required. The ratiometric converter usedin the M1020-PLS assures high noise immunity and short-cir-cuit-proof resolver wiring.

Fully Absolute PositionUnlike some other attempts to replace cam switches withincremental encoders, and/or counter modules in a PLC, theM1020-PLS maintains one crucial feature of cam switches…itis totally absolute.

The M1020-PLS will give you reliable limit settings, irrespectiveof power outages, machine movement during a power outage, aswell as during severe electrical noise!

A PLS AT THE COST OF CAM/LIMITSWITCHES ($500)*An innovative design and AVG Automation's fully automated100,000 sq.ft. manufacturing facility with the latest in state-of-the-art surface-mount equipment, have now made it possi-ble to provide you with a programmable electronic cam/limitswitch at the cost of electromechanical cam/limit switches. Atless than $500.00 for eight cam outputs, the M1020-PLSoffers all the advantages of a solid-state programmable devicewith the same degree of product reliability as any other AVGAutotech PLS, and yet at no penalty cost.

* OEM Quantities


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M1020 PLS SPECIFICATIONS

GENERAL:Power Requirements: AC Power: 105-135 VAC, 60Hz, 45WOperating Temperature: -10 °F to +130 °F (-23 °C to +55 °C)System Resolution: 10 BitsScale Factor: Fixed, 359Offset: Programmable, 0 to 359Scan Time: Setpoint Dependant (430 µs max.)Position Signal: AVG Automation's Series RL100, E7R, E8R, or

RL101 resolversCable Length Between Resolver and M1020: 2500 ft. (762 m)

shieldedResolver-to-Digital Decoder Tracking Speed: 380 RPM with 1°

Resolution

CONTROL INPUT:Program Enable:

Needs to be tied to common (common pin is provided) toenable programming. Programming is disabled if this input isleft open.

Types of Outputs:8 PLS outputs, activated according to the user-enteredsetpoints (1 setpoint per channel). The available output typesare:Electromechanical SPST relay:

10 A, resistive, continuous @ 120 VACSolid-state relays:1. AC output: 120 VAC @ 3 A

ON time: < 3 ms after zero crossOFF time: At zero crossLeakage: 2.1 mA @ 120 VAC

2. DC output: Up to 60 VDC @ 3 AON time: 5 µsOFF time: 35 µsLeakage: 0.29 mA @ 15 VDC

3. DC output: Up to 200 VDC @ 1 AON time: 15 µsOFF time: 100 µsLeakage: < 0.01 mA @ 30 VDC

Panel Cutout

AVG Automation's PLS and Mini-PLS families have continu-ally set the standard for speed, precision, reliability, and prod-uct features in the Programmable Limit Switch (PLS) market-place. While retaining the key features and high-standards ofother AVG Automation products, the M1050 combines 10power outputs, fault detection and indication, eight user-defined PLS programs, and simple, easy-to-learn program-ming, in one compact unit with a NEMA 12 front panel. Inaddition, each of the eight PLS programs supports up to 80ON/OFF setpoint pairs for 8-channel units, or 160 for 16-channel units, which may be used in any combination pereight output channels. Included is a fault output which indi-cates on the display the source of the fault for fast, easy trou-bleshooting and a motion detector which energizes when theresolver is rotating between the HIGH and LOW user-pro-grammed limits.

Simultaneous display of related parametersfor easy understandingIn the normal operating mode, the large, 0.56" (14.2 mm)numerical display indicate the selected PLS program number,the selected channel number, and the current resolver RPMand position. When programming PLS setpoints, the displayshows the program number, selected channel number, and theselected ON and OFF setpoints.

In all modes, bright easy-to-read bar graph displays the TRUEoutput status of all eight or 16 PLS outputs, as well as thefault relay status, the motion output status, and the externalprogram select enable input status.

M1050-PLS

M1050 PLSTHE HIGH-PERFORMANCE SELF-CONTAINEDPROGRAMMABLE LIMIT SWITCH

Includes Power Output Relays in the Same Chassis

Eight PLS Outputs, Motion Output, and FaultOutput in compact chassis. No external power relaychassis or customer power supply needed. (Selectedmodels do not use relay rack, except for expansiongreater than 8 outputs.)

Eight PLS programs can be remotely or keyboardselected to simplify job changeover

Built-in speed compensation for all PLS outputs

All inputs and outputs fully isolated

Built-in self diagnostics

Simple creative keyboard

Setpoints-per-program– 8-channel units—80– 16-channel units—160

Programmable resolution from 17-1000 divisions-per-revolution

Simultaneous display of program number, channelnumber, ON and OFF setpoints, and output status

Rugged, reliable, resolver as position transducer,can be mounted upto 2500 ft (762 m) away

Patented and keys for fine-tuning, even withmachine in full motion

High-speed operation, 100 µs scan time

Built-in tachometer and Motion Detector

Brake Monitor Option


Powerful, Easy-to-Learn, Human-MachineInterfaceAVG Automation's human factors engineering has made itpossible to program all PLS functions with only five frontpanel keys and a smart front panel display:

Key selects the function to be programmed, whilethe display shows each function's current values

Key selects the parameter to be programmed, whilethe location of the decimal point indicates whichparameter is selected

Keys adjust the parameter value,while the display indicates all current parameter values

Key selects the next programmed setpoint for the display

With these five self-explanatory programming keys, program-ming the M1050 is extremely simple. No long complex keysequences to remember.

Patented and Keys for Fine-Tuning in MotionAll programmed values, except Scale Factor and the PLS pro-gram number, can be adjusted with the machine running,making fine-tuning of job parameters easy. Two fully isolatedsupervisory inputs prevent accidental or unauthorized programchanges.

High-Speed OperationThe M1050 PLS can operate upto 1800 RPM while maintain-ing a timing accuracy of less than 100 µs.

Multiple ProgramStorage Makes JobChangeover EasyThe M1050 PLS can store up toeight independent, user-definedPLS programs for differentmachine setups. The M1050 iseasily configured to accept eitherfront panel or external PLC-compatible input to select a program.

Built-In Speed Compensation for All PLSOutputsThe M1050 PLS features a rate offset to compensate for speedvariations. This rate offset represents a positive number thatvaries linearly with RPM. The rate offset is added to theresolver position and is used to advance the PLS settings as afunction of the machine speed. In M1050, the rate offset canbe programmed in Scale Factor units per 10 or 100 rpm,depending on model, up to full Scale Factor value.

Built-In Tachometer and Motion DetectorThe built-in tachometer and motion detector are accurate to 1rpm and are updated over 68 times per second to provide fast,accurate indication and detection of rotary motion. Themotion detector is programmed to energize a power relay out-put when the machine's RPM falls between the low or under-speed limit and the high or over-speed limit. The motiondetector output status is always indicated on the front panel.

Built-In Fault DetectorThe fault output is normally energized when the M1050 PLSis operating properly and the resolver wiring is intact. If aninternal M1050 fault is detected, or the power fails, or one ormore of the resolver wires is broken or disconnected, the faultoutput will de-energize. Under fault conditions all PLS out-puts and the motion output will de-energize.

Brake Monitor OptionThe M1050 Brake Monitor measures the time it takes to bringa rotating machine shaft to a full stop. If the shaft fails to stopwithin specified safety limits, Caution or Danger outputs areturned OFF. If the shaft stops safely in time, the Safe outputturns ON.

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Motionand FaultIndicators

ProgramNumber

Channel Number

“On” Setpoint

“Off” Setpoint

StatusIndicators

5-ButtonKeypad

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Rugged, Reliable Resolver as PositionTransducerThe M1050 combines the ruggedness of a brushless resolverand reliability of an advanced solid-state control. The rugged,heavy-duty NEMA 13 (IP54) resolver can be mounted on amachine shaft in any hostile environment, such as mechanicalshock, vibration, extreme humidity and temperature changes,oil mists, coolants, solvents, etc. And the programmable con-trol unit, M1050, can be mounted up to 2500 ft. away in acontrol panel. The splash proof, oil-tight front plate permitsthe unit to be installed directly on the machine itself, ifrequired. The ratiometric converter assures high-tracking speedof 1800 RPM and high-noise-immunity.

Fully Isolated Inputs and OutputsAll M1050 inputs and outputs are fully isolated from userpower sources to provide outstanding electrical noiseimmunity in harsh industrialenvironments.

APPLICATIONSPECIFIC SOFTWAREFOR DIFFERENTINDUSTRIES

The M1050 Series of Programmable Limit Switches, is themost versatile family of PLSs on the market. In addition to thestandard 8-channel PLS (M1050A) and 16-channel PLS(M1051), AVG Automation offers industry-specific PLS mod-els that have unique features customized for that industry.

M1050A: Eight built-in power outputs, Brake Monitor orModZ, individual speed compensation, built-inmotion detector and Tach, Pulse programming,supervisory controls, eight programs with externalprogram selection.

M1051: Eight built-in power outputs, eight NPN (sink-ing) outputs, Brake Monitor or ModZ, built-inmotion detector and Tach, eight programs withexternal program selection, individual speed com-pensation for PLS outputs with four channels hav-ing 16 speed compensation zones, five PLSs inone unit with flexible group assignment, Angle-ON/Time-OFF, Pulse programming, supervisorycontrols, and an RS-422A/RS-485A port for serialcommunication.

M1051-R10:

Standard M1051, 16-channel PLS with socketsfor electromechanical relays. Both, NO/NC con-tacts are available.

M1052: "Glue Gun Control" PLS—In addition to per-forming normal PLS functions, the M1052 has abuilt-in Glue Gun Control. It has channels 1-5controlled by three Enable Inputs and a FirstCycle Reset Input. This allows ProgrammableEnabling or Disabling of up to five glue gunsbased on three external inputs detected during aprogrammable window as well as resolver speed.Thus, a packaging machine equipped with aM1052 PLS can handle a variety of differentpackages on the same line. The M1052 PLS alsohas 16 programs as well as program duplication.The program selection is either from front panelor external digital input. It also has an optional 4-20 mA programmable Analog tach or eight addi-tional NPN sinking outputs. The M1052 PLS hasthe capability of having different speed compensa-tion values for leading and trailing edges of PLSoutputs. Other standard features of the M1052PLS include: built-in motion detector and tach,pulse programming, and supervisory controls.

M1053: "Registration Control" PLS—In addition to per-forming normal PLS functions, the M1053 PLShas a built-in registration control. Channels 15and 16 provide programmable pulses (proportion-al to error signal) that advance or retard the drivemotor to remain synchronized with a registrationmark on the package enclosure. This mark isdetected by an external sensor and fed into theM1053 PLS. Other features of this PLS include:programmable reference position; programmableLOW and HIGH correction limits, programma-ble pulse width in ms; programmable frequency ofregistration outputs; individual channel speedcompensation, built-in motion detector and tach,pulse programming and supervisory controls.

CUSTOMISED VERSION TO MEETYOUR APPLICATION:AVG Automation is continuously developing new software fordifferent industries. For further information regarding qualify-ing applications, call the factory.


M1050 SERIES PLS SPECIFICATIONS

Power Requirements: 105-135 VAC, 50/60 Hz, 20 W or220-260 VAC, 50/60 Hz, 20 W (option)

Operating Temperature: -10 °F to +130 °F(-23 °C to +55 °C)

PROGRAMMING:Number of PLS Programs:

M1050A, M1051, M1053: Eight selectable from keyboardor externally via three program-selected inputs (PS0-PS2).M1050-M10: 60 programs with 8 channel outputs or 30programs with 16 channel outputs M1052: 16 selectable from keyboard or externally via 5program selected inputs (PS0-PS3 and EP)

PLS Setpoints:M1050-M10: 256 per PLS program for 60 total programs or512 per PLS program for 30 total programs.M1050A: 80 per PLS Program, 640 total, 80 setpoints in aprogram can be assigned to the eight PLS outputs in anymanner.M1051, M1053: 160 per PLS program, 1280 total.M1052: 120 per PLS program, (60 for channels 1-8 and 60for channels 9-16) 1920 total.

Scale Factor:M1050A, M1051, M1052, M1053: Programmable from 16to 999, common to all PLS programs (resolution 17 to 1000counts/turn).M1050-M10: Programmable from 2.56" (65.0 mm) to 40.00"(1016 mm) per resolver revolution. Maximum machine travel= 16 x scale factor. Scale factor is common to all PLSprograms.

Offset:M1050A, M1051, M1052, M1053: Programmable from 0to Scale Factor Value, common to all PLS programs.M1050-M10: Programmable from 0 to 16 x Scale FactorValue, common to all PLS programs.

Speed Compensation:M1050A: Programmable in Scale Factor units-per-100 rpm,up to full Scale Factor value.M1051: Programmable in Scale Factor Units-per-100 rpm,up to full scale factor value. Each PLS channel has its ownspeed compensation. 16 speed compensation zones forchannels 1-4.M1052: Programmable leading and lagging speedcompensation for channels 1-5. Each speed compensation isprogrammable in increments of 1 ms.M1053: Programmable in Scale Factor units-per-10 rpm, upto full Scale Factor value ÷10. Each of the first 8 PLS channels(1-8) has its own speed compensation.

Motion Detector Setpoints: Two, one LOW and one HIGH,common to all PLS programs. Programmable from 0 to 999rpm.

Registration Pulse Width Resolution:M1053: 14.7 ms

Low Motion Enable:M1052: Low Motion Enable, common to channels 1-5associated with enable inputs EN1, EN2, EN3. Programmablefrom 0 to 999

New Cycle Position:M1052: Programmable from 0 to scale factor value.Common to channels 1-5 associated with enable inputs EN1,EN2, EN3.

Optional Brake Wear Monitor Limits: M1050A and M1051,Two, one Caution and one Danger. Programmable from 0 to9.99 seconds

RESOLVER INTERFACE:Position transducer: Single-Turn Resolver, AVG Automation

Series RL100, E7R, E8R, RL101, or equivalent.Cable Length between Resolver and M1050 Series: 2500 ft

(762 m) max., shieldedResolver Cable: AVG Automation CBL-10T22-XXXMaximum Resolver Shaft Speed: 3600 RPMResolver Decoder: Ratiometric, tracks resolver shaft angle to

1800 RPM

CONTROL INPUTS:Electrical specifications: (All Inputs)

Optical Isolation: 1500 VInput impedance: 1800 ΩLogic levels:

TRUE: 1 to 28 VDC sourcingFALSE: 0 to 0.8 VDC

Enable EN1, EN2, EN3:M1052: TRUE enables selected channel (1 to 5).

Program Enable (PE): When TRUE, enables Programming, and(if EP input is also TRUE) External Program Number Select

Program Enable 2 (PE2):M1051: When TRUE, enables setpoint and setup(scale factor, offset, program number, etc.)

Output Enable (OE): When TRUE, PLS Channel outputsenabled,(Both, Fault and Motion always enabled)

Fault Check Enable (FCE): When TRUE, disables PLS andMotion Detector Outputs whenever Resolver Broken WireFault or M1050-M10, M1051 internal fault occurs.

Registration Control (RC):M1053: On FALSE to TRUE transition, the resolver position iscaptured and used for error calculations.

Operator Pushbuttons (PB1 and PB2):M1053: On FALSE to TRUE transitions, PB1 increments ref.,retarding the timing of the motor while PB2 decrements ref.,advancing the timing of the motor.

First Cycle Inputs (FCI) and Enable Inputs (EN1-EN3):M1052: Channels 1 to 5 can be individually associated witheither of the enable inputs EN1 to EN3. This association isuser programmable from the keypad. Any channel 1 to 5with an enable (EN1-EN3) programmed into it is alsocontrolled by the first cycle input and the programmed newcycle position.

Brake Input (BI): When TRUE, starts Brake Monitor Operation.(For details, consult factory.)

Supervisory (SUP):M1050-M10: When TRUE, all programming modes enabled.When FALSE: only default, program number change, andsetpoint modes enabled.

Modified Zero (ModZ):M1050A, M1051, M1050-M10, M1053: On FALSE toTRUE transition, the resolver position is captured and used tozero the position for that cycle.

All ON:M1050-M10: When TRUE, all output channels areenergized. When FALSE, outputs are normal PLS control.

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SCAN TIME:Scan time varies with speed compensation programming.

Models M1050A, M1051: 100-500 µsModels M1052, M1053: 500-1500 µs.

OUTPUTS:Unregulated Voltage Out (VO): Current Limited, unregulated

12 VDC for use with M1050-M10, M1051 inputs ONLY. Not forexternal sensor power.

Fault Output: Detects resolver broken wire and M1050-M10,M1051, M1052, M1053 internal faultsElectromechanical relay (Form C) output; 10 A resistive max.@ 120 VACWithout Fault: Relay remains energizedWith Fault: Relay de-energized

Motion Output: EM relay (Form C) output; 10 A resistive max. @120 VAC. Relay energized whenever resolver RPM is withinprogrammed motion low- and high-limits

Number of PLS Outputs:M1050-M10: 1-8 Normal PLS in 60 total programconfiguration. 1-16 Normal PLS in 30 total programconfiguration.M1050A: 8M1051, M1052: 16M1053: Channels 1-14 are normal PLS. Channel 15 is theretarding registration output. Channel 16 is the advancingregistration output.

Types of Outputs:

Electromechanical SPDT Relay:(SAC-M1051-R10) basic unit)10 A resistive continuous @ 120 VAC

Solid-State Relay: (SAC-M1050-8Sx basic unit)1. AC output: 120 VAC @ 3 A;

ON time: <3 ms after zero cross;OFF time: At zero cross;Leakage: 2.1 mA @ 120 VAC

2. DC output: Up to 60 VDC @ 3 A;ON time: 5 µs; OFF time: 35 µs;Leakage: 0.29 mA @ 15 VDC

3. DC output: Up to 200 VDC @ 1 A;ON time: 15 µs;OFF time: 100 µs;Leakage: <0.01 mA @ 30 VDC


The PAK•PLS family, since its introduction to the market, hasset new standards for speed, precision and reliability. Whileretaining the key features of the PAK•PLS family, the M1151features an incredibly small size and a simple man-machineinterface. Now, AVG Automation has expanded the functionsof the M1151 to serve the specialized needs of the industrialcontrol marketplace.

Smallest PLSThe state-of-the-art design of the M1151, utilizing surfacemount technology, makes it possible to package a full-functionPLS in a 1.8" H x 3.6" W x 5.7" D cabinet. With 16-Outputsin this compact size, the M1151 is the smallest PLS availableon the market. The space saving housing (6.5 sq.in. panelspace) allows a M1151 retrofit to crowded control panels.

Simple Creative KeyboardThe creative engineering from AVG Automation has made itpossible to program all the PLS functions utilizing only fiveprogramming keys. With these five self-explanatory program-ming keys, the M1151 is extremely simple to program—nocomplex key sequence needs to be remembered nor do youneed to carry any note cards.

Patented and Keys to adjust Offset andspeed compensations as well as Setpoints,even in full motion.Resolver alignment to machine zero as well as fine-tuning the machinein motion is accomplished through our patented and keyswhich increment or decrement the machine offset or the setpoints.

Simultaneous Display of Channel Number, Onand Off SetpointsThe large 0.4 ", very-bright LED display provides good visibil-ity up to 30 feet in plant environments. The user-friendlyfront panel simultaneously displays the correlated parameterssuch as channel number, ON and OFF setpoints or programnumber, angle, and rpm allowing a simple and easy-to-under-stand man-machine interface (MMI).

Individual Channel Speed CompensationRelays and solenoids, because of their mechanical nature, haveinherent fixed delays when activating, varying from 10 ms to 30ms. A relay with a 10 ms turn on delay will cause as much as a55° shift in operation at 600 rpm. Each channel may be pro-grammed with individual speed-dependent advances to compen-sate for fixed delays attributed to relays and solenoids. Speed com-pensation is fully adjustable from 0 to 35.9° advance per 10 rpm.

THE M1151 PAK•PLS

M1151 PAK•PLSTHE INCREDIBLY VERSATILE PLS FAMILY

Smallest Programmable Limit Switch (PLS); 8 or 16-Outputs in 1.8" x 3.6" x 5.7" housing with NEMA 12faceplate

Individual Speed Compensation for each PLSoutput channel

Four or Eight PLS programs reduce changeover time

Simultaneous display of channel number, ON andOFF setpoints

Simultaneous display of machine speed andposition

Optically isolated outputs and inputs enhancesystem reliability

Self-diagnostics help in system troubleshootingand maintenance

Optional Shift Register PLS Channels

Optional Brake Monitor

Optional Dynamic Zeroing ModZ Model

Simple creative keyboard

Rugged, reliable resolver as position transducer

Patented and keys to adjust offset andsetpoints in full motion

High-speed operation, 120 µs (8-channel), 200 µs(16-channel) scan time

Built-in tachometer and motion detector

Analog or Position velocity output options

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High-Speed Operation, 120 µs Scan TimeThe M1151 PAK•PLS can operate up to 1,800 rpm. The 8-channel unit maintains a repeat accuracy of 120 µs while the16-channel unit has 200 µs scan time.

Multiple Program Storage Reduces Down-Time at Job ChangeoversThe M1151 PAK•PLS can internally store four or eight independ-ent programs for different jobs. With a preprogrammed M1151for different product runs, the product changeover is as simple aspressing the MODE and Inc/Dec keys to select the program corre-sponding to the job. Remote selection of PLS programs may beaccomplished by a PLC or an external selector switch.

Built-in Tachometer and Motion DetectorThe built-in tachometer displays the shaft speed in rpm simul-taneously with the position display. Additionally, the built-inmotion detector continuously monitors shaft speed and allowsthe programming of HIGH and LOW rpm limits for themotion output. The motion detector status is indicated on thefront-panel by an indicator LED.

Optically Isolated Inputs and OutputsOptically isolated inputs and outputs are standard to provideenhanced noise immunity and ensure operational integrity ofthe M1151 PAK•PLS in harsh industrial environments.

Internal DiagnosticsThe M1151 PAK•PLS has built in circuitry, which continuallymonitors the operation of the unit. If any of the six resolverwires break or short together, the Broken Wire Detect circuitrywill cause a fault condition. A fail-safe fault output is providedwhich is energized ONLY if the resolver cable is intact, thecustomer power supply is present, the line voltage is withinspecifications, and the processor is not in reset. The fault out-put will de-energize if the M1151 detects any of these faults.

Dynamic Zeroing ModZThe M1151 PAK•PLS features optional dynamic zeroing orModZ (MODification Zero) to modify the zero reference pointfor selected channels independent of actual resolver position.Upon receiving an external signal, the resolver position for theselected ModZ channels is reset to zero. Thereafter, the positionis incremented as the resolver rotates and outputs are turnedON or OFF at the programmed limit settings. The ModZ fea-ture is ideal for gluing applications, where the glue gun must beactivated at certain positions after detection of an upcomingproduct. Four ModZ channels, any of which can be used as anormal channel, are included in the M1151 ModZ option.

Brake MonitorThe optional M1151 Brake Monitor automatically measuresthe time in ms from an input brake signal until the resolvershaft stops rotating. This stopping time is then compared tothe programmed Warning Time and Danger Time and theappropriate Safe, Caution, or Danger output is energized as aresult. The M1151 Brake Monitor is normally applied as anindication control on metal stamping presses. The brake wearmonitor uses three PLS channels.

Shift RegisterWith the Shift Register option, the four shift register channelscan be thought of as programmable position delays. The ShiftRegister length (Turns Delay) can be programmed from 1.00to 50.00 revolutions of the input shaft. There are two shiftregister modes. The Mode 1 Shift Register emulates a normalelectronic shift register circuit with a programmable length. Toprogram a shift register channel for Mode 1 operation, pro-gram a single dwell whose From setpoint is greater than the Tosetpoint. The Mode 1 dwell never actually executes; it is a sig-nal for Mode 1 operation. In Mode 1, the input patternappears at the output after the input shaft has rotated the pro-grammed Turns Delay revolutions.

The Mode 0 Shift Register acts as a multi-turn ModZ. Mode 0can also be programmed with a Turns Delay from 1.00 revolu-tions to 50.00 revolutions. After a FALSE-to-TRUE input tran-sition, the entire pattern programmed into the Shift Registerchannel appears at the channel output after the input shaft hasrotated the Turns Delay number of revolutions. The M1151Shift Register model features battery backup of the shift registermemory to retain shift register position during power down.

The shift register memory may be cleared either from the key-board or from an external input. The additional output chan-nels are programmed as normal PLS outputs.

Front Panel Selectable Analog Output:Position or TachomenterWith the analol option, analog options are front panel selec-table, retrieving the user from ordering specific analog outputformat or setting DIP swithches. Moreover, if the applicationrequirements change, they can be easily accommodated bykeying in the appropriate information.

The M1151 unit can provide either position or tachometer inthe analog form. The following ranges are available and frontpanel selectable:

1. 0 to 10V 5. -2.5 to 2.5V2. -10 to +10V 6. 4 to 20 mA sourcing3. 0 to 5V 7. 4 to 20 mA sinking4. -5 to + 5V


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M1151 PAK•PLS SPECIFICATIONS

Power Requrirements:AC: 105-135 VAC, 50/60 Hz, 8 W exclusive of load (optional220 VAC)DC: 11 to 28 VDC, 100 mA. (exclusive of load)

Operating Temperature: -10 °F to +130 °F (-23 °C to +55 °C)System Resolution: 12 bitsScale Factor: Programmable, 16 to 999Offset: Programmable, 0 to full revolution.Scan Time for Complete System Execution: (All models: Add 13

msec for each channel nonzero speed compensation setting.)Standard M1151: (All speed compensations 0)8-Output units: 120 µs16-Output units: 200 µsM1151 Brake Monitor Option:8-Output units: 135 µs16-Output units: 215 µsIf Brake Time measurement is active, add 42 µs to normal scantime.M1151 ModZ Option:8-Output units: 185 µs16-Output units: 265 µsFor each inactive ModZ channel, add 7 µs to above scan time.For each active ModZ channel, add 17 µs to above scan time.M1151 Shift Register Option:8-Output units: 210 µs16-Output units: 290 µsFor each Mode 0 Shift Register channel, add 78 µs to above scantime. For each Mode 1 Shift Register channel, add 162 µs toabove scan time.

Position Signal: AVG Automation's Series RL100, E7R, E8R, orRL101 Resolvers

Cable Length between Resolver and M1151: 2,500 ft (762 m),shielded

Resolver Cable: AVG Automation's, CBL-10T22-xxxxMaximum Resolver Shaft Speed: 3,600 rpmResolver-to-Digital Decoder Tracking Speed: 1,800 rpm

OUTPUTS:Types Of Outputs:P: PNP Source Transistor:

Logic TRUE: Transistor ON, 1.7 V Drop @100 mALogic FALSE: Transistor OFF, 0.2 mA Leakage @ 50 V

N: NPN Sink Transistor:Logic TRUE: Transistor ON, 1.1 V Max. @100 mALogic FALSE: Transistor OFF, 0.1 mA Leakage @ 50 V

Number of PLS Outputs: Seven or 15 plus one motiondetector output

Number of ON/OFF Setpoints per channel:Channel 1: One dual-setpointAll other channels: Counts per revolution ÷ 2

Motion Detector:Low Setpoint: Up to 998-rpm max.High Setpoint: Up to 999-rpm max.Output: P- or N-type, (same as PLS outputs)Note: Motion, fault and direction outputs will be the same asthe PLS outputs ordered.

Optical Isolation: 1500 Vrms standard on all I/O (except resolverand analog velocity signals)

Remote Power Relay Outputs:For Cam and Motion outputs requiring higher currentratings, a separate Remote Power Relay chassis AVGAutomation's part number, ASY-RLYCH-xxxx, can be used. Therelay chassis is connected to a unit having N-type outputsusing a prewired cable.

Relay Chassis Input Power: 120 VAC, 50/60 Hz.Cable: Prewired with DB15 connector on both ends.Relays: Relay chassis is available for EM or solid-state relays.Number of Outputs: 7 or 15 cam outputs plus 1 motion, 1

direction, and 1 fault.Unit Required: N typeElectromagnetic relays:

(KSD-120C-10A): 120 VAC @ 10 A, SPST, Form C(KSD-A120C-10A): 120 VAC @10 A, SPST, Form A

Solid State AC relay:(KSS-120AC-3AMP):24 280 VAC @ 0.23 A, zero cross-over switching Triac outputrelay, optically isolated

Solid State DC relays:KSS-60VDC-3AMP: 960 VDC @ 3 A, optically isolatedKSS-200VDC-1A: 0-200 VDC @ 1 A, optically isolated

INPUTS:Program Enable, Output Enable, External Program Select,ModZ, Shift Register, & Brake Monitor Inputs:

For P-type units:Enable or TRUE: 11.0 to 28.0 VDC @ 13.5 mA max. or tied toTerminal 9 on the terminal block. (Terminal 9 is internallywired to Vs+ for P-type of units)Disable or FALSE: 2.0 VDC @ 0.2 mA max. or open circuit

For N-type units:Enable or TRUE: 1.0 VDC @ -3.0 mA max. or tie to Terminal 9on the terminal Block (Terminal 9 is internally wired to Vs- forN-type of units)Disable or FALSE: 3.8V DC to 28 VDC Max @ -0.2 mA max. oropen circuit.

The MINI•PLS, models M1250, M1450 and M1451, are thefastest and most versatile PLS family in the market. We call itMini because of the small compact size, but it is big in per-formance.

In fact, MINI•PLS is three controls in one: ProgrammableLimit Switch, Tachometer, and Motion Detector. The power-ful microprocessor and the revolutionary design makeMINI•PLS an extremely compact, fast and versatile solid-statereplacement of electromechanical cam switches.

The high accuracy, reliability, operating speed and convenienceof operation assure greater efficiencies in manufacturing, help-ing to increase production and reduce cost.

Principal of OperationThe MINI•PLS consists of two parts, one being a positiontransducer mounted on the machine and the other a program-mable unit mounted in the machine control panel. The posi-tion transducer in this case can be a resolver or an ultrasoniclinear transducer, which produces a rotary or linear position

signal. This position signal is converted to digital format in theprogrammable unit, displayed on the front panel and comparedto the dwell setpoints programmed into the PLS. When processcycle reaches these setpoints, outputs are enabled or disabled,starting or stopping desired functions during the cycle.

ABSOLUTE ENCODER

Absolute Positioning With ProgrammableScale FactorThe resolver as well as the ultrasonic linear transducer provideabsolute positioning, that is, the MINI•PLS always givesTRUE position even upon machine movement after poweroutage. Further, a programmable scale factor up to 4,095 (res-olution of 4,096 per turn) is provided to meet the requiredsystem resolution or for direct readout in engineering units.For linear transducer systems the resolution is predefined as1,000 counts-per-inch.

THE MINI•PLS

M1250, M1450, ANDM1451 MINI•PLS™

40 Channels in 6.25" x 4.5" x 7.25" compactenclosure

57-85 µs scan time assures high repeatability(M1250)

Programmable Rate Offset (ROF) for automaticspeed compensation (M1450)

Dynamic Zeroing—ModZ—to modify the zeropoint for selected channels (M1450)

EEPROM transportable plug-in output modulesmake maintenance easy

Optically isolated power or logic outputs

Rugged reliable resolver or ultrasonic lineartransducer input

Patented + and - keys allow fine-tuning thesetpoints in motion

Built-in tachometer and motion detector

Programmable scale factor; resolution up to 4,096counts-per-turn

Auto-Zero for zero offset

Optional broken-wire detector

Optional serial RS-232C or RS-422A communication

Multi-Turn available

Brake Monitor option (M1451)


Keyboard ProgrammingThe MINI•PLS is fully front panel programmable with con-venient tactile keyboard and yet secure against any unautho-rized program changes. Opening of an external user providedkeyswitch inhibits any program changes on the front panel.

RUGGED AND RELIABLE

Single or Multi-turn Resolver or UltrasonicLinear Transducer InputThe MINI•PLS combines the ruggedness of a brushlessresolver or noncontacting ultrasonic linear transducer and thereliability of an advanced solid-state control. The rugged,heavy-duty NEMA 13 (IP54) single- or multi-turn resolvercan be mounted on a machine in any hostile environment;such as mechanical shock, vibrations, extreme humidity andtemperature changes, oil mists, coolants, solvents etc. The pro-grammable control unit can be mounted up to 2500 feet(1000 feet for linear transducer) away in a control panel. Thesplash-proof oil-tight front plate permits the unit to beinstalled directly on the machine itself, if so required. Theratiometric converter assures high tracking speed of 1800 rpmand high noise immunity.

Modular, Easy to ServiceModular 40 Channels in 6.25" x 4.5" x 7.25" compact enclo-sure. The ultra-modern technology used by Autotech has madeit possible to house 40 channels in such a small space savingenclosure. The system flexibility is further enhanced by themodular construction. The unit can be expanded up to 40channels using five modules of eight channels each. A cammodule with desired logic level or power outputs or a separatechassis with plug-in power relay outputs can be selected tomatch the application. Parallel BCD position and tach outputmodules can be inserted in slots 4 or 5. This modular conceptalso permits an easy adoption in field to the future technologi-cal developments by simply adding new modules to the samebasic unit.

EEROM TRANSPORTABLE MODULES

No Batteries, Nonvolatile EEROM MemoryThe scale factor, offset, dwell, and motion detector setpointsare all stored in nonvolatile EEROM memory as they areentered by the user. The information is retained indefinitelyafter power loss or machine shutdown, eliminating need forback-up batteries and related hazards.

Program Stored in Transportable Plug-inModulesThe program setpoints are stored directly in the cam modulesin nonvolatile EEROM memory. The information is retainedwithout power, even when the modules are taken away fromthe MINI•PLS. This unique feature of program storage in thecam module permits programming of various modules for dif-ferent jobs or spares, reducing downtime and eliminatingeventual errors due to hurried reprogramming at job changes.Also, the cam modules can be programmed at a central place,such as corporate headquarters, and distributed to variousplant locations.

Variety of Plug-In Output ModulesThe plug-in cam modules are optically isolated and are avail-able with TTL, PNP or NPN type of logic level outputs. Thesub D connector style on these modules with preassembledcable assembly eliminates all field wiring and the related even-tual wiring errors. Power cam modules are also available withAC (120 VAC @ 1 A) or DC (10-28 VDC @ 1 A) ratings.Optional electromechanical relays (10 A) and solid-state AC (3A) or DC (3 A) relays are mounted on a separate chassis. Allthese relays are plug-in type for easy field replacement. Thesolid-state relays are optically isolated. Optional parallel BCDposition and tach output modules with built-in PC-handshakeas well as analog position/tach output modules are available forremote readouts or control devices.

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Versatile OffsetAn extremely versatile full-scale programmable offset elimi-nates all calculations on the part of the operator, while match-ing resolver zero to machine zero or while compensating formachine wear and speed changes. After the resolver is mount-ed on the machine shaft, all you have to do is align themachine to a mechanical zero reference, e.g., Top Dead Centeron a press, and Auto-Zero the MINI•PLS. The resolver offsetwill automatically be calculated and programmed, so that theposition display reads zero. If required, a machine offset otherthan zero can be programmed by direct numerical entry. Toobtain a precise machine operation, the offset can also be fine-tuned in motion by using + and - keys.

Multiple Setpoints (up to 500) On EachChannelAll the 40 channels of MINI•PLS can be programmed formultiple setpoints without any restrictions. Depending uponthe scale factor selected, up to 500 dual setpoints can be pro-grammed on each of the 40 channels. Just like an electro-mechanical cam switch, the dwell setpoints on MINI•PLS canbe programmed through zero, e.g., on at 350 ° and off at 10 °.

Built-In TachometerIn addition to the normal PLS function as described above,the MINI•PLS has a built-in tachometer. By pressing theTACH key, the unit goes in tachometer mode and the displayshows shaft speed in RPM. When used with computer con-trols, optional analog or digital BCD Tach output modulescan be inserted in slots 4 or 5 to provide shaft speed informa-tion to variable speed drives.

Built-In Motion DetectorIn tachometer mode, a motion detection window with lowand high preset points can be programmed. Direct entry oflow and high limits together with independent fine-tuning ofeach limit permits quick programming and in-motion adjust-ments. The motion detector status is indicated on front panelby an indication light and an NPN open collector output isavailable at the main terminal block, without occupying any ofthe cam output circuits. In case a remote power relay chassis isused an independent motion detector relay is provided on therelay chassis.

Optional Broken Wire DetectorThe MINI•PLS offers an optional broken wire detector tosupervise the resolver-input signal. The broken wire detectorwill signal the missing resolver input, which can occur from aloose connection or defective cable.

Program Duplication at the Touch of a ButtonWhen various modules need to be programmed identical, useof program duplication key saves time and avoids errors bymaking fast copies of the original program. Just enter theORIGIN slot number, select the COPY slot, press the DUPkey, and the program is copied on the corresponding cammodule.

Write ProtectPNP and NPN type of Cam Modules are shipped with a fac-tory wired jumper, which enables the modules to receive anyprogram. If Write Protection of the program is required afterthe machine is adequately set up, cutting the jumper will dis-able module programming. This feature is especially usefulwhen some of the cam settings should not be accessible to theunauthorized personnel and, once adjusted, need not bechanged frequently. Installing the jumper back into place willenable the module for programming changes, if so required.

Multiple Program SelectionThe multiple program selection capability of MINI•PLSmakes set-up changes for different jobs just as simple as turn-ing a rotary selector switch. Several cam modules can be pre-programmed and wired in parallel. Using an external selectorswitch, a program corresponding to the job to be performedcan be selected simply by turning the knob. When TTL-typeCam Modules are used, multiple program selection is simplyachieved by using a multiplexing input at terminal 4 of theCam Module.

ULTRA-FAST

Operation at 1800 RPM (M1250), Adjustablein MotionThe high speed ratiometric resolver-to-digital converter andthe micro-scan time of 57-85 µs (M1250) guarantee perfectmachine operation at speeds of up to 1800 RPM. InMINI•PLS, all the program variables are active in the memoryimmediately as they are entered by the user. This feature per-mits program changes and fine-tuning with machine in fullmotion at 1800 RPM. The + and - keys are especially useful tofine-tune the machine control for maximum productivity.

Revolutionary Design Yields Ultra High SpeedsThe MINI•PLS converts the resolver signal to digital format,compares all the setpoints on all the 40 channels and activatesall the outputs in a maximum of 85 µs. This is at least twoorders of magnitude faster than programmable controllers andat least one order of magnitude faster than any PLS currentlyon the market. With one 8-channel module plugged-in, thescan time will be 57 µs.


INTELLIGENT COMMUNICATION

Parallel or serial linkParallel BCD output modules with built-in PC-handshake foreasy interface to programmable controllers or remote displaysis available and can be inserted in slots 4 or 5. The TTL-,PNP-, or NPN-types of BCD outputs allow more flexibilityfor interface to external devices.

The MINI•PLS Model M1450-300 has been designed toaccommodate special modules such as, serial link RS-422A orRS-232C, etc.

Consult factory for availability of special modules.

M1450 MINI•PLS ADVANCED FEATURES

Programmable Rate Offset, ROF, for AutomaticSpeed CompensationThe M1450 MINI•PLS features a rate offset to compensatefor speed variations. This rate offset represents a positive num-ber that varies linearly with RPM. This number is added tothe resolver position and is used to advance the PLS settings asa function of the machine speed. Depending upon the selectedmodel, you can program a single rate offset value for a groupof 8 channels on a cam module or different rate offset valuesfor up to 16 individual channels.

Dynamic Zeroing, ModZThe M1450 MINI•PLS features dynamic zeroing or ModZ(Modification Zero) to modify the zero reference point forselected group of channels independent of the actual resolverposition. Upon receiving an external signal, the resolver posi-tion for the selected ModZ channels is reset to zero. Thereafterthe position is incremented as the resolver rotates forward andoutputs are turned on and off at the programmed limit set-tings. This feature is ideal for gluing applications, where theglue-gun must be activated at a certain position after thedetection of an upcoming product. Depending upon theselected model, you can operate up to 4 ModZ cam modulesor 32 outputs.

VARIETY OF MODELS TO MEET YOURAPPLICATION NEEDS

Single-Turn Rotary PLS Models• SAC-M1250-010

• SAC-M1450-300

• SAC-M1450-MROF

• SAC-M1450-400

The model M1250 is the basic MINI•PLS, whereas all theabove M1450 models are the advanced versions of the single-turn rotary PLS. The single turn MINI•PLS is an absoluteposition programmable limit switch that uses a resolver asinput and has built-in tachometer and motion detector.

The model M1250 offers an ultra fast response time of 57 µs.The M1450 Models offer rate offset (ROF) and dynamic zero-ing (ModZ) as standard features. Serial communication RS-232C or RS-422A is provided on the model M1450-300. Themodel M1450-MROF features programmable multiple rateoffsets (up to 19), while the model M1450-400 is a high reso-lution PLS (up to 4096 counts-per-revolution)

Linear PLS with Single-Turn ResolverModel SAC-M1450-M10

This is a semiabsolute position programmable limit switch thatuses a single-resolver as input and has a maximum resolutionof 4096 counts-per-revolution. This model is a multi-turn unitthat keeps track of number of revolutions and accumulates itsposition as the resolver shaft rotates. The maximum read out is999,999. The position is retained on loss of power providedthe resolver shaft is not rotated more than 180 degrees whilepower is off. A preset input is provided to enter a preset num-ber into the memory as a reference position. The ModZ trig-ger and ModZ enable inputs allow ModZ functions for up tothree cam modules. Speed compensation is also provided forall cam modules installed.

Single-Turn Rotary PLC with Brake WearMonitorModel SAC-M1451-010

Model M1451-010 PLS is an absolute position resolver whichaccepts input from a single-turn Resolver. It combines a PLS,tach, and motion detector and features a built-in broken-wiredetector. It also has MODZ, speed compensation and brake-wear monitoring capability. At 1800 RPM the micro-scan timeis rated 450-905 µs.

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Linear PLS with Multi-turn (Dual) ResolverModels SAC-M1450-D64, SAC-M1450-D128

The multi-turn (dual) resolver MINI•PLS models D64 andD128 resolve the position of a rotary shaft up to 4096 counts-per-turn. These systems, utilizing dual resolvers with built-inprecision gear train, are fully absolute and keep track of theshaft position as well as number of turns, regardless of powerfailure, up to 64 and 128 turns respectively.

Linear PLS with Ultrasonic TransducerModel SAC-M1450-LTO

The linear MINI•PLS, model LTO, decodes the linear move-ment with 0.001" resolution and up to 108" of travel. Thisunit utilizes an ultrasonic transducer to monitor the linearposition of a machine by the movement of a 1.3" (33.02 mm)diameter magnet ring over a 3/8" (9.53 mm) diameter stainlesssteel rod. The transducer is connected to an interface box,which is mounted a few feet away. The linear PLS can bemounted up to 1000 ft (304.8 m) away in a safe control roomenvironment. In addition, a calibration provision eliminatesthe need to physically match the decoder to the rod, a prob-lem encountered in earlier controls.

The maximum TRUE position ranges up to 108,000 countsbut it can be offset to 524,287. ModZ function for up to twocam modules is provided. Tach or speed compensation is notavailable. Instead, the M1450-LTO provides a direction signalthat is on for increasing position and off for decreasing position.

Choice of Front-Panel, Back-Panel, or NEMA 12(IP52) Enclosure MountingThe basic MINI•PLS unit with its sealed front plate isdesigned for front panel mounting. It has T- (5 V, TTL), P-,or N-type (50 V DC @ 100 mA) outputs for light loads or PCinterface. For higher voltages and currents, Power CamModules or remote power output chassis are available. TheMINI•PLS can also be purchased in a back panel mount ver-sion with built-in power relay output chassis. This back panelmodel can be mounted either inside the user control panel orin a NEMA 12 (IP52) enclosure available from AVGAutomation.


Back Panel Mount Chassiswith M1250 and Power RelayOutput Chassis

... and without windowThe M1250 and Power RelayOutput Chassis shown in a NEMA12 (IP52) enclosure with window

M1250, M1450, AND M1451 MINI•PLS SPECIFICATIONS

Input Power: 105-135 VAC, 50/60 Hz, 35 W exclusive of load(220 or 240 VAC option)

Operating Temperature: -10 °F to +130 °F (-23 °C to +55 °C)Resolution and Scale Factor: (See specification table)

Resolution and scale factor are defined as follows:All models except M1450-LTO: Resolution is defined to beequal to the counts-per-revolution of the resolver. The scalefactor is defined as the desired resolution (counts/rev) minusone.Model M1450-LTO: Resolution is defined to be equal to thecounts-per-inch of travel of the linear transducer. The scalefactor in this case is defined to be equal to the desiredresolution.

Offset: (NOT applicable to M1450-M10)Programmable 0 to full scaleM1450-LTO: Offsettable to 524,287

Preset: (Applicable ONLY in case of M1450-M10)Preset number range: 0 to 999,999 Preset number entry: From keypad or remoteRemote preset input: Contact closure to Vs+ (10-28 VDC)

Rate Offset: (Also see the specification table)Programmable, 0 to full revolution (caution: entering too-much rate offset may result in more than one revolutionoffset for higher speeds.)Rate Offset Resolution: Programmable in tenths of scalefactor units per ten RPM.

Motion Detector Limits: (NOT applicable to M1450-LTO)LOW setpoint: Up to 1899 RPM (max.)HIGH setpoint: Up to 1900 RPM (max.)

Number of programmable channels:40 (5 output modules with 8 channels each)

Slave Systems:Up to 7 M1250/M1450/M1451s may be slaved to one masterunit, giving additional 7 x 40 channels (total 320) using thesame position transducer (The slave shares the positiontransducer with the master)

Decimal Point on Display:In Models M1450-400, M1450-M10, M1450-D64, M1450-D128a decimal point may be placed arbitrarily after any digit. Thisdecimal point is just for the convenience of display, and doesnot affect the data.For M1450-LTO, the decimal point is fixed after the 3rd digit.Decimal point is not available in M1250-010, M1450-300, orM1450-MROF.

INPUT/OUTPUT:Program Enable:

Contact closure to user power supply common (Vs-); or asolid-state switch 0.8 V @ 10 mA.

ModZ Input:Contact closure to customer Power supply Vs+; or 10-28 Vlogic inputLogic FALSE: 4 VDC @ 1 mALogic TRUE: 10 VDC @ 10 mA to 28 VDC @ 30 mA Number of ModZ Channels: See specification table

Motion Detector Output: (NOT applicable to M1450-LTO)NPN sinking: 30 VDC max. @ 100 mA

Direction output: (Applicable ONLY to M1450-LTO)Energizes on application of power and when transducerposition is increasing in value. De-energizes when transducerposition is decreasing in value and then remains de-energized until transducer position increases again.Output: NPN (sinking), 30 VDC max. @ 100 mA (referencedto customer power supply).

Remote Power Relay Outputs:For Cam and Motion outputs requiring higher currentratings, a separate Remote Power Relay chassis AVGAutomation part number, ASY-RLYCH-xxxx, can be used. Therelay chassis is connected to an N type of cam module usinga prewired cable.Relay Chassis Input Power: 120 VAC 50/60 Hz.Number of outputs: 8 or 16 cam outputs plus one motionoutput.Cam Module required: N-typeCable: Prewired, available with DB 15 connector on one orboth ends.

RELAYS:Relay chassis is available for electromagnetic or solid-state relays.Electromagnetic relays:

KSD-012DC-10A: 120 VAC @ 10 A, SPST, Form C contactsKSD-A12DC-10A: 120 VAC @ 10A, SPST, Form A contacts

Solid-State AC relay:KSS-120AC-3 AMP: 24-280 VAC @ 0.2-3 A, zero cross-overswitching Triac output relay, optically isolated

Solid State DC relays:KSS-60 VDC-3 AMP: 9-60 VDC @ 3 A, optically isolated KSS-200 VDC-1 AMP: >0-200 VDC @ 1 A, optically isolated

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SPECIAL OUTPUT MODULES:Digital Position/Tach Output Modules:

Digital output format: BCDDigital output Interface: TTL, PNP (sourcing)transistor or NPN (sinking) transistor, characteristicssame as those of logic level cam output modules. (Seetable)Module Update Rate: Background task, RPMdependent (consult factory)PC Synch Circuit and Data Transfer Command:(Optional)0-24 Volt logic input (edge-triggered i.e., data transferon both rising- and falling-edges)

Logic LOW: 0-0.8 V @ 3.2 mALogic HIGH: >2.4 V @ 0.4 mA

Timings: Data latches between 30-100 µs after datatransfer edgeTach Full Scale Range: 0-1000 RPM

Analog Position/Tach Output Module: (Available forM1250-010, M1450-300 and M1450-MROF only)Output: 4-20 mA (sourcing or sinking) or 0-10 VDCPosition or Tach: DIP switch selectable Position/RPM Range for Max. Output: DIP switchselectable

Serial Communication Modules:(Available for M1450 300 only) RS-232C, and RS-422A


Model # Resolutionper turn

Scan Time (microseconds)Number of

dual setpoints per

channel(ON/OFF)

Number of ModZChannels

Channels with Rate OffsetsNumber of Cam Modules

1 2 3 4 5

M1250-010 17-1000 57 64 71 78 85 Resolution ÷2 None None

M1450-300 17-1000 160 200 240 280 301 Resolution ÷2Slots 1-4; 32 channels

in groups of 8Slots 1-5;

40 channels in groups of 8

M1450-400 10-4096 1300 1700 2100 2400 2700 21Slots 1-4; 32 channels

in groups of 8Slots 1-5;


M1450-MROF 17-1000 200 400 430 460 490 Resolution ÷2 None

Slots 1-2; 16 channels individually

Slots 3-5; 24 channels in groups of 8

M1450-M10 10-4096 1700 2100 2400 2700 3100 21Slots 1-3; 24 channels

in a groups of 8Slots 1-5;


M1450-D64 10-4096 1300 1700 2100 2400 2700 21Slot 1; 8 channels in a

groupSlots 1-5;


M1450-D128 10-4096 1300 1700 2100 2400 2700 21Slot 1; 8 channels in a

groupSlots 1-5;


M1450-LTO 17-1000 3500 3500 3500 3500 3500 21 Slot 1-2; 16 channels None

M1451-010 17-1000 450 800 855 870 905 Resolution ÷2 Slot 1-2; 16 channels

Slots 1-2; 16 channels individually

Slots 3-5; 24 channels in groups of 8

.25

5.50 3.50

1.00

0 0.203 (4 PLCS)

7.25

6.25

5.90

7.25

3.50

.75

.75

.25

5.00

6.256.75

3.344.875 Ref.

1.672

1/4-28 UNF2-B7 Holes

.281 Ref.

.875 .437

SPECIFICATION TABLES:

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Position Transducers

PLS Model Transducers Cable

M1250-010M1450-300M1450-400

M1450-MROFM1450-M10

Single-Turn resolver such as AVG Automation's

RL100, E7R, E8R, RL101, or equivalent.

Max. tracking speed: 1800 rpm

Overall foil shielded cablesuch as AVG Automation's

CBL-10T22-xxxx orequivalent.

Max.: 2500 ft.

M1450-D64M1450-D128

Multi-turn resolver such as AVG Automation's RL210

or equivalent.Max. tracking speed: 1800 rpm


CBL-10T22-xxxxMax.: 2500 ft.

M1450-LTO

Ultrasonic linear transducersuch as AVG Automation's

LT140, or equivalent.Update rate:

3 ms for up to 100


CBL-IB140-MxxxxMax.: 1000 ft.

Cam Output Modules

Output TypeLogic Level Power

TTL * PNP Source Transistor

NPN Sink Transistor AC DC

Part Number ASY-M1250-08TIASY-M1250-08TD

ASY-M1250-08PI ASY-M1250-08PD

ASYM1250-08NI ASY-M1250-08ND ASYM1450-08AC ASY-M1450-08DC

Number ofOutputs per

Module8 8 8 8 8

Logic TRUE

2 VDC @ 15 mA 2.4 V @ 3 mA

(20 µA leakage when Tristated)

Transistor ON 1.7 V drop @ 100 mA


1 A max. per channelMax. 4 A per module

1 A max. per channelMax. 4 A per module

Logic FALSE

0.35 VDC @ 24 mA (0.4 mA max. leakage when

Tristated)

Transistor OFF 0.2 mA

leakage @ 50 VDC

Transistor OFF 0.1 mA leakage

@ 50 VDC

30 mA max. per output

0.1 mA max. per output

Rated Voltage 5 VDC 50 VDC 50 VDC 105-135 VAC, 60 Hz 10-28 VDC

Response Time < 1µs 12 µs 12 µsTurn ON 12 ms Turn OFF 25 ms

Turn ON 30-50 ms Turn OFF 15-40 ms

Electrical Isolation 2500 V between control circuit and output circuit

* Note: MUX or Tristating Input = Low active, TTL level (i.e., Logic TRUE: 0-0.8 V; Logic FALSE: 2-5 VDC)

M 1500 Pc•PLS is a powerful combination of PLS and PLCfunctions in one, compact package. M1500 is the most cost-effective and panel space saving solution for machines requir-ing fast position-based control with logic capability.

The Pc•PLS senses the status of the inputs and turns the out-puts ON and OFF according to the program supplied by theuser. The instruction set offers relay ladder logic as well astimer and counter instructions. The PLS has features and pro-gramming similar to AVG Automation's popular M1051. AResolver is used as a position transducer. Multiple programs,speed compensation, and ModZ capabilities are only some ofthe advanced features supported by the Pc•PLS.

The Pc•PLS, with its 3 processors, allows distributed process-ing of logically independent tasks. The shaft position is sensedby a robust resolver mounted on the machine shaft. ThePc•PLS's microprocessor gets its position information from anoise-immune, ratiometric resolver decoder. The Pc•PLS'smicroprocessor then controls PLS outputs, based on the pro-grammed position limits, with µs repeatability. Additionally, itprovides Motion and Fault relay outputs. The Pc•PLS provides16 PLS outputs. Ten of the 16 outputs are fed to PLC proces-sor internally for inputting machine timing/angle information.The other six are high-speed, direct, PLS outputs.

The PLS inside the Pc•PLS is the most advanced AVGAutomation PLS model, M1051, and offers features like mul-tislope, automatic speed compensation, angle ON-time OFF,pulse programming, ModZ (dynamic zeroing), multiple pro-grams, multiple groups, brake monitor, etc.

The PLC microprocessor accepts 16 external inputs and 10internal inputs from the PLS, and performs programmed logicto control a total of 16 outputs. Twelve are normal PLC relayoutputs, whereas other four may be used to logically AND thefour direct PLS outputs. The PLC microprocessor supportsmost commonly used relay, timer, and counter instructions.

Another microprocessor takes care of the operator interface. Itcontrols the display and keypad, and exchanges informationwith the PLS and PLC processors. Unlike most PLCs, theoperator interface is integrated with the unit, thus allowingmonitoring of PLC variables, such as bit status andtimer/counter values, and helps in debugging the program byForcing the I/O ON or OFF. The machine can be fine-tunedwhile running using the operator interface.

Ultra FastThe logical division of distributed processing allows each ofthe three microprocessors to process its information at bestpossible efficiency, resulting in a very fast throughput. For veryprecise position-based outputs, the PLS microprocessor pro-vides highly repeatable, six 480 µs outputs. The PLC uses ahigh-performance, 16-bit microcontroller to execute relay lad-der logic at an average of 6 µs/instruction. The unit supportsrelay ladder code of up to 2K words.

Rugged, Reliable Absolute Position ResolverThe Pc•PLS uses a resolver as the position transducer. Unlike,incremental encoders, the resolver, along with its noise-immune ratiometric converter, always gives true machine posi-

M1500 PC•PLS

M1500 PC•PLSFIRST PLS WITH MULTI-PROCESSOR ARCHITECTURE

Compact 7.25" x 5.5" x 6.7" package with 20 inputs,20 outputs

High-speed response of PLS in µs range

Fine-tune capability of PLS

Multiple program selection for quick productchange-over

Standard relay ladder logic programming for PLCfunctions

80 timers, 46 counters, and 2K relay ladder code

Programmable by IBM-compatible PC


tion, even if the machine moved during power outage. Theresolver, due to its construction, is immune to temperatureand humidity extremes and to mechanical shocks and vibra-tions. The short-circuit-proof resolver input circuit allows thePc•PLS to tolerate accidental shorts in resolver wiring. ThePc•PLS also has built-in broken resolver wire detection.

Simple, Easy to Program and Fine-TuneThe unit's simple operator interface, using a bright-red LEDdisplay, makes programming, fine-tuning, debugging, andmonitoring of the machine a breeze.

Simple 6-Key KeypadThe operator interface has a key to switch between PLS andPLC, and AVG Automation's very popular 6-key keypad toperform the programming and monitoring.

English-Language Prompts & Messages forUser ConvenienceThe unit's display shows prompts for the user to enter appro-priate values, and the cursor position shows which value willchange in response to pushing the INC/DEC keys.

Counter/Timer Value Display Eliminates Needfor Separate Displays ModulesImplement batch counters, parts counter, or any desiredcounter or timer function in relay ladder logic using 80 timersand 46 counters supported by the Pc•PLS, then use the inter-face to view counter/timer values.

I/O Status at Your Fingertips for Easy Setupand DiagnosticsThe interface shows the status of 8 bits, simultaneously. Thesebits include PLC input, PLC output, PLC memory (or inter-nal), or PLS outputs.

Convenient I/O Forcing for ProgramDebuggingThe forcing of inputs/outputs, an extremely powerful debugand diagnostic feature, allows all actual I/Os from the PLC tobe individually and selectively, forced ON or OFF. This helpsin the debugging of a PLC program without actually wiringthe unit, as well as debugging hardware wiring without pro-gramming the unit.

PC-Compatible Programming Software—Unlimited Programs Setups on Disk for Quick Job Change-Over

The PLS in Pc•PLS can be programmed from the key padand/or from a PC-compatible computer having an RS-485Amultidrop port. The Windows-compatible software allows youto look at the complete PLS program. In fact, it emulates AVGAutomation's most popular thumbwheel type of program-ming, as used in the M1750 PLS.

The off-line programming allows creation of programs withouthaving a unit wired. The software, by supporting programstorage in disk files, allows virtually unlimited number ofsetups saved for quick job changeover.

The Pc•PLS uses industry-standard relay ladder logic andIBM-compatible PCs having RS-485A port for programmingthe PLC portion of the Pc•PLS. The menu-driven program-ming software allows program creation off line and download-ing the program to the Pc•PLS.

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M1500 PC•PLS SPECIFICATIONS

GENERAL:Power Requirements: 108-135 VAC, 50/60 Hz, 20 WOperating Temperature:

-10 °F to +130 °F (-23 °C to +55 °C)Computer Interface: RS-485APower Output: 12 VDC, current limited to l00 mA

PLC SPECIFICATIONS:Inputs: 16, all inputs optically isolated (1500 V isolation) with

TRUE level 11-28 VDC sourcing and FALSE level <0.8 VDC.Outputs: Total 16; 12 relay outputs, SPST electromechanical; 5 A,

250 VAC contact rating; 4 outputs internal for logicallyANDing 4 direct PLS outputs.

Programming language: Relay Ladder LogicInstruction Set: Relay type (bit type), timer, counterProgram Size: 2K WordsInternal Relays (bits): 256Timers: 80, countdown (0 sec-18 hrs) with time-base 10 ms, 100

ms, 1 secCounters: 46, count up or count down (0 to 65000) Supervisory Inputs:

RUN: Must be TRUE for ladder execution; FALSE For relayladder programmingPROGRAM: Must be TRUE for ladder program change (RUNinput must be FALSE).Data table locations may be changed when this input is TRUEregardless of the state of the RUN input.OUTPUT ENABLE: When TRUE, PLC outputs are enabled.

Scan Time: Average 6 µs per instruction; 300 µs overhead

PLS SPECIFICATIONS:Scale Factor:

To program desired number of counts per turn;Programmable from 16 to 999, common to all PLS programs(resolution 17 to 1000 counts/turn)

Offset:To electronically align machine zero to resolver zero.Programmable from 0 to Scale Factor Value, common to allPLS programs

Speed Compensation:For automatic advance of the limits based on the speed ofmachine. Programmable in scale factor units per 100 rpm.Each channel has its own speed compensation. Channels 1-4have 16 speed compensation zones.

Motion Detector:LOW and HIGH Motion Limits, common to all PLS programs.Programmable from 0 to 999 RPM

ModZ:For dynamic zeroing (Modification to Zero) of zero referencein response to external input. Any channel can be assignedup to 4 different ModZ groups

Brake Wear Monitor:Activates brake danger output if the brake stopping timeexceeds programmed danger limit.

Number of PLS Programs: 8, selectable from keyboard orunlimited using disk.

PLS Setpoints: 160 per PLS Program, 1280 totalScan Time: 480 µs for 16 outputs

POSITION INPUT:Transducer: Resolver, AVG Automation Series RL100, E7R, E8R,

RL101 etc.Cable Length between Resolver and Pc•PLS:

2500 ft (762 m) max., shielded

PLS SUPERVISORY INPUTS:Input Logic Levels: Same as PLC inputsProgram Enable (PE):

When TRUE, enables setpoint programmingProgram Enable 2 (PE2):

When TRUE, enables setpoint and setup (scale factor, offset,program number, etc.)

Output Enable (OE):When TRUE, PLS Channel outputs enabled, (Both Fault andMotion always enabled)

PLS OUTPUTS:Fault Output: Fail-safe output; detects resolver broken wire and

PLS internal fault)Motion Output: Relay energized whenever resolver RPM is

between programmed motion limits.Number of PLS Outputs: Six

4 are logic-ANDed with 4 PLC outputsPLS outputs have field-replaceable relays; the relays can beelectromechanical or solid-state, and can be mixed andmatched.

Electromechanical Relay: SPDT Relay, 10 A, resistive, continuous@ 120 VAC

Solid-State Relays:AC Relay: 120VAC @ 3 A

ON time: < 3 ms after zero crossOFF time: At zero crossLeakage: 2.1 mA @ 120 VAC

DC Relays: Up to 60V DC @ 3 AON time: 5 µsOFF time: 35 µsLeakage: 0.29 mA @ 15 VDC

or Up to 200 VDC @ 1 AON time: 15 µsOFF time: 100 µsLeakage: <0.01 mA @30 VDC


AVG Automation's M1750 Programmable Limit Switch, withits modular construction and simple operator-machine inter-face, represents the easiest solid-state replacement of rotarycam switches or drum sequencers. We call it PLS unlimited,because it can do things no common electromechanicalsequencer or mechanically operated cam switch can do. Whencompared to mechanical switches, the M1750's superior accu-racy, reliability, and convenience of operation are outstanding.Such technology assures the AVG Automation customer agreater efficiency in manufacturing, helping him to increaseproduction and lower costs.

Principal of OperationThe M1750 PLS gets the shaft position data from a rotarytransducer, which could be either an absolute digital encoderor a resolver. The output of a digital encoder is binary-coded-decimal (BCD), while the analog output of a resolver is con-verted to BCD by an R-to-D converter inside the PLS. Thedata received is processed in the buffer circuit, displayed indegrees (0-359) or counts (0-999) and compared to the pro-grammed dwell-angle setpoints. When the process cycle reach-es these setpoints, outputs are switched ON or OFF, startingor stopping desired functions.

THE M1750 PLS

THE M1750 PLSTHE MODULAR ELECTRONIC CAM SWITCH

A solid-state replacement of electromechanicalCam Switches

Simple, easy-to-understand thumbwheelprogramming

Modular construction allows easy maintenance andfield expansion

Thumbwheel memory assures immunity toelectrical noise

Variety of input and output modules to suitdifferent applications

Rugged resolver, BCD encoder, or time-base-generator as input device

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SIMPLEST ELECTRONIC CAM SWITCH

Easy-to-Understand ThumbwheelProgrammingThe M1750 PLS combines the ease of thumbwheel program-ming with the convenience of an integrated limit switch. Thethumbwheel programming is designed to duplicate the mentalprocess used in setting-up an electromechanical cam switchand thus permits an easy to understand operation. Just like arotary cam switch, the M1750 PLS can be programmedthrough zero, e.g., ON at 350° and OFF at 10°.

Operation at 1800 RPM, Programmable inMotionThe high speed ratiometric tracking converter guarantees per-fect machine operation at speeds of up to 1800 RPM. All theprogram variables are immediately active in the process, asentered by the user. This feature permits fine-tuning with themachine in full motion.

Entire Program Visible at a GlanceThe thumbwheel programmed ON and OFF setpoints for allchannels are visible at a glance, which permits simple operator-to-machine interface.

Absolute Position, Up to 0.36° ResolutionThe M1750 PLS operates with a resolver or an absolute digitalencoder as position transducer, giving an absolute shaft posi-tion in both cases. This means that the system always keepstrack of the true position, even upon machine movementsafter power outage. The resolver-to-digital decoder sourcemodules are available with 360 or 1000 counts-per-revolutionto achieve a resolution of 1° or 0.36°.

ULTIMATE IN RELIABILITY,SERVICEABILITY

Thumbwheels Provide Mechanical MemoryEven with all the advancements in technology, there is no sub-stitute for reliability of mechanical memory provided bythumbwheels. The thumbwheel program memory does notrequire any battery back-up, nor is it affected by electricalnoise or use over an extended period of time.

Thumbwheel mechanical memory is not affected by external elec-trical interference.

Short-Circuit-Proof Resolver-PLS ConnectionThe electrical interface circuit connecting the resolver and theM1750 PLS protects against accidental shorts in theresolver/PLS wiring.

RUGGED RESOLVER

Reliable Under Extreme EnvironmentsThe M1750 PLS combines the ruggedness of a brushlessresolver and the reliability of an advanced solid-state control.The rugged, heavy-duty, NEMA 13 (IP54) resolver can bemounted on a machine shaft in any hostile environment, suchas mechanical shock, vibration, extreme humidity and temper-ature changes, oil mists, coolants, solvents, etc. The program-mable control unit M1750 can be mounted up to 2500 ft.away in a control panel. The ratiometric converter assureshigh-tracking-speed of 1800 RPM and high-noise-immunity.

MODULAR CONSTRUCTION

The entire logic is built on modules, which are independent ofeach other. In case of a problem, just plug-in a new module.The modules increase design flexibility to match the system toyour application.

SOURCE MODULES

Resolver or Encoder InputA standard source module with built in Resolver-to-Digital converter, offset and digital display acceptsresolver input and transforms the resolver signal to digi-tal format for further processing in the comparator cir-cuit. A digital display source module interfaces to anabsolute BCD encoder and feeds this information to thecomparator circuit.

For time-base-generator input consult the factory.

Full-Revolution Digital OffsetA full-revolution thumbwheel or external offset is pro-vided on decoder source modules and permits easyalignment of machine zero with resolver zero to com-pensate for any mechanical misalignments, machinewear or speed variations. To fine-tune the machine oper-ation for maximum precision, the offset can be adjustedwith machine in full motion. The external offset entryfrom a programmable controller is especially useful forcontinuous compensation of speed changes.

Program Control from External Programmable ControllerWhen using resolver as input device, a special-purpose,external-offset resolver decoder module accepts BCDoffset signal from a programmable controller to compen-sate continuously for any speed changes. The BCD posi-tion data from the decoder module or from the encoderterminals is also available for external devices such asprogrammable controllers or remote readouts.


LOGIC MODULES

Variety of Logic FunctionsA variety of output logic functions are available to provideincreased system flexibility:

Dual-Preset:Allows for the settings of both ON and OFF setpointsfor each channel.

Single-Preset/Fixed One-Shot-Timer:Upon reaching the ON setpoint, a fixed one-shot-timer(0.1-sec.) is activated.

Single-Preset/Variable One-Shot-Timer:Upon reaching the ON setpoint, a variable one-shot-timer (0.1-6 sec.) is activated and the output stays ONduring the preset time.

Single-Preset/Digital Timer:Upon reaching the ON setpoint the output turns ONand stays ON for a duration set by the time thumb-wheels. Time-base setting is selectable by DIP switchesfrom 1 ms to 100 ms per count.

ModZ:Upon external signal, the position reference to the mod-ule is reset to zero and the module starts counting upfrom this new reference, switches output ON at the ONsetpoint, and switches OFF at the OFF setpoint. Thecycle is repeated by resetting the counter. One M1750-PLS chassis can accommodate up to two ModZ moduleswith independent reset signals. This function is especial-ly useful for glue applying applications.

SYSTEM EXPANSION

Field-Expandable to Match the ApplicationThe eight- and twelve-channel chassis are standard, but anydesired number of logic modules can be inserted to meet therequirements. Also several M1750-PLS chassis can be wired inparallel to achieve a total of 48 channels for one positiontransducer.

Variety of Plug-In Output RelaysThe M1750 PLS is designed to operate with electromechanicalrelays (10 Amp) or open collector (100 mA @ 30 V) or solid-state AC (3 A), DC (2 A) or AC/DC (0.35/0.5 A) outputmodules. Electromechanical relays and solid-state modules,however, cannot be mixed. The solid-state modules are optical-ly isolated. All these relays are plug-in type for easy on-sitereplacement. The AC/DC relay has less than 0.1 mA leakageto interface directly to a programmable controller 110 VACinput card.

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MOUNTING

Choice of Back Panel or NEMA EnclosureMountingThe standard M1750 PLS chassis can be mounted inside thecustomer's control panel together with other controls or insidea NEMA 12 enclosure M1700-N with a solid cover orM1700-W with a Plexiglas see through window. The seethrough window allows the thumbwheel setpoints to be visi-ble, while it protects the PLS inside. A locking handle on thecover assures program security. Inside the enclosure, there is aremovable NEMA 1 plate covering the terminal blocks, whileretaining easy access to the thumbwheels.

AccessoriesBCD outputs from main terminal block can be wired to aremote readout like AVG Automation's RD360 display unit orRD999 display/tachometer unit. Also one bit of BCD can bewired into AVG Automation's PS111 (zero speed switch) orPS112 (over-/under-speed switch) for detecting unsafe operation.


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Input Power: 105-135 VAC, 50/60 Hz, 50 W exclusive of load(Optional 220 VAC)

Operating Temperature:-10 °F to 130 °F (-23 °C to 55 °C)

Position Transducer: Resolver, AVG Automation's series RL100,E7R, E8R, and RL101 or Absolute Digital Encoder, AVGAutomation's DigiSolver part E5N-D0360-5MOMx

System Resolution: 1° or 0.36°Resolver-to-Digital Decoder Tracking Speed: 1800 RPMOffset:

Offset Range: Adjustable 0 to full revolutionOffset Entry: From front panel with thumbwheelsor external input

High-Logic: TRUELogic FALSE: 0-1 VDCLogic TRUE: 4.5-5 VDCFormat: 10- or 12-lines.Current draw: <1 mA

Offset Connector: Unit comes with MS3110F-14-19P. Themating receptacle MS3116F-14-19S is to be wired andsupplied by customer.

Maximum Cable Length from Resolver to M1750:2500 feet shielded

OUTPUTS:Number of Output Channels Per Chassis:

8 or 12 standardMaximum Number of Output Channels Per Transducer:

48, (6 x 8-channel or 4 x 12-channel chassis in parallel)Output to Secondary Chassis or other External Devices:

Format: 10 or 12-line BCD, High-Logic TRUE;Logic TRUE: 2.5 V drop @ 1 mA source currentLogic FALSE: 0.4 VDC @ 2.4 mA sink current.

Output Inhibit: Dry contact closure between C & D will disableall the outputs.

ModZ Reset Signal: Dry contact closure or logic level low (0 to1 VDC).

OUTPUT RATINGS:KDD-012DC-10SIG: 1 NO + 1 NC relay contacts rated at 10 A

(resistive) at 125 VACKSS-120AC-ERI: 3 A, 120 VAC, solid-state AC module, max ON

voltage: 1.5 V; turn ON time: 150 µs (typ.); turn OFF time: 8 ms(typ.); leakage: 10 mA (max)

KSS-055DC-ERI: 2 A, 3-40 VDC, solid-state DC module, max.ON voltage: 1.5 V; turn ON time: 15 µs (typ.); turn OFF time:100 µs (typ.); leakage: 100 mA (max.)

KSS-AC/DC-ERI: Low leakage (<0.1 mA) AC/DC solid-statemodule, 135 VAC (rms) @ 0.35 A or 190 VDC (max) @ 0.5 A,turn ON voltage: 3 V; turn ON time: 10 µs (typ.) turn OFF time:100 µs (typ.) leakage: 100 mA (max.)

The Mini•CAM, model M1350, is an excellent substitute forelectromechanical rotary cam limit switches. Like rotary camswitches, the Mini•CAM is used to control outputs based onthe position of the shaft to which it is coupled. See block dia-gram below. The Mini•CAM utilizes slotted photoelectricswitches and interrupting cam discs mounted on a rotatingshaft. The cam discs consist of two halves that can be adjustedto create any required dwell. When Mini•CAM shaft rotates,

the cam disc passes or interrupts the light beam through thephotoelectric switch at appropriate shaft angles, dependingupon the cam disc adjustments. The DIP switches are provid-ed to select the outputs to turn on when light is interrupted,or when light is passed. The solid-state switching, ease of set-up and improved accuracy help increase the productivity ofyour machine.

THE M1350

MINI•CAM M1350THE NEW STANDARD IN ROTARY CAM SWITCHES

Solid-state replacement of electromechanical camswitches

4, 8, 12, or 16-outputs

Compact size; eight outputs in four-output housing

Noncontact switching assures operation up to2,000 rpm without contact bounce.

Optically isolated AC or DC outputs provide noiseimmunity

90 VDC outputs for clutch/brake control

Pulse generating discs for counters, rate meters, ormultiple outputs per channel.

Easy to install and set-up

Built-in resolver for PLS interface or position/tachfeedback

Fully gasketed JIC Enclosure


COMPACT SIZE:8 Outputs in 4-Output HousingThe Mini•CAM is available in 4, 8, 12, or 16-output modelsto match a broad range of applications. The advanced designfrom AVG Automation has made it possible to double the out-put density of a 4-output unit and consequently the eight out-puts are housed in a 4-output enclosure currently available inthe market. This compact size permits installation of theMini•CAM in physically tight spaces.

Non-contact Switching Assures Operation upto 2000 rpm without Contact BounceThe mechanical limit switches of rotary cam switches arereplaced by photoelectric and solid-state switches, while themechanical cams riding on the mechanical limit switches arereplaced by adjustable Interrupter Discs. As the outputs areturned ON or OFF simply by interruption of the light beamin the photoelectric switches, there is no physical contact andconsequently no wear. Also the output switches being thesolid-state devices there is no contact bounce as is the case ofelectromechanical rotary cam switches. This solid-state non-contact switching allows operation at speeds up to 2000 rpmassuring improved accuracy and virtually eliminating themaintenance.

Logic Level or Optically Isolated PowerOutputsLogic level PNP (sourcing) or NPN (sinking) plug-in outputmodules rated at l00 mA @ 50 VDC are available. When pow-ered from internal power supply, the maximum load currentrating of the power supply is limited to l00 mA on 4 or 8-out-put units or 200 mA on 12 or 16-output units. This type ofoutput represents an economical way of interfacing theMini•CAM to a PLC for additional logic capability. However,for switching higher loads directly, the optically isolated AC (1A @ 120 VAC) or DC (1 A @ 10-28 VDC or 1 A @ 90VDC) plug-in modules are available. The optical isolation israted at 2500 V between the outputs and the control circuitry,and provides for an extremely reliable operation in electricallynoisy industrial environments. AC and DC modules can bemixed to suit your application.

Built-in Resolver for PLS Interface orPosition/Tach Feedback.The built-in resolver option allows you to combine the relia-bility of hard cams and the flexibility of programmable limitswitches. The resolver can be used for position or tach feed-back or it can interface to an external programmable limitswitch (PLS). When connected to a PLS, it allows the cam set-tings for desired automation functions to be easily pro-grammed in seconds saving time at job changeovers.

Easy to Install and Set-upInstallation and set-up of the Mini-Cam is extremely simple.Self-locking interrupter discs determine the "dwell" settingsand are easily adjusted using the wrench supplied with eachunit. An adjustable internal degree wheel can be quickly set tomatch the Mini-Cam shaft position to the machine "ZeroReference". The LED output status indicators are activatedwhen each output is turned ON and help in quick and accu-rate set-up.

The optional external degree wheel, part WHLM1350-010,provides position reference without opening up the cover.Optional sprocket disengagement clutch, part SDC-M1350-xxx, is used to disengage a sprocket from the 5/8" (15.88 mm)shaft for quick set up, clear a jam etc. without jogging themachine. The adjustable coupling (optional), part CPL-M1350-xxx, has 90 discrete locked positions and is designedto "phase" a 5/8" (15.88 mm) shaft to a sprocket. See "How toOrder" for standard sprockets and couplings.

Fully Gasketed JIC EnclosureThe Mini•CAM is housed in a fully gasketed, JIC, oil-tight,NEMA 12 enclosure and is fitted with 5/8" (15.88 mm) shaft.Left-hand, right-hand, or double-ended shaft extensions areavailable that provide flexibility of mounting on your machine.For ease of mounting, the shafts are provided with standard5/8" (15.88 mm) shaft keyways.

90 VDC outputs for clutch/Brake controlThe 90 VDC plug-in modules with short-circuit-proof out-puts are available for direct clutch/brake control from theMini•CAM without going through other external relays etc.

Built-in Pulse Generating Discs For Count,Rate, or Glue StitchingThe pulse generating discs provided as factory option makeM1350 an extremely versatile rotary cam switch. With 60pulses per revolution (3° slots) as standard (consult factory forother pulse counts), these discs can be used to generate timingpulses for counters, ratemeters, motion detectors, glue stitch-ing or other applications requiring multiple setpoints perchannel. One disc takes place of a cam and must be orderedfrom the factory.

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M1350 MINI•CAM SPECIFICATIONS

Input Power:AC: 105-135 VAC, 50/60 Hz (220 VAC, 50 Hz optional)DC: 10-28 VDC (required only if sourcing a total of morethan 100 mA with PNP (sourcing) card)

Operating Temperature:-10 °F to +130 °F (-23 °C to +55 °C)

Speed: 0 to 2,000 rpmMax. Phase Shift: 1° @ 1000 rpmResolution: 1° @ 1800 rpmNumber of Outputs: 4, 8, 12, or 16

Built-in Resolver (option):Frequency: 2,250 HzInput Voltage: 1.88 VInput Current: 6 mAInput Power: 6.5 mWRotor Impedance with Stator Open Circuit Zro:180 + j256 ΩDC Resistance (Rotor): 18.3 ΩOutput Voltage (Stator): 2.63 V +5%Transformation Ratio: 1:400

Built-in pulse generating Disc:60 ppr (3° slots), Replaces cam at position 1

Output Modules

Output Types

Logic Outputs Power Outputs

PNP Source (ASY-M1350-08P)

NPN Sink (ASY-M1350-08N)

AC Output ModulesDC Output Modules (ASY-M1350-04AC)

90 VDC OutputModules

(ASY-M1350-04DC)

Number of Outputsper Module 8 8 4 4 4

Rated Voltage 50 VDC 50 VDC 105-135 VAC, 60 Hz 10-28 VDC 72-135 VDC

Logic TRUETransistor ON

1.7 V drop @ 100 mA


1 A (rms) per output max.2 A per module

short-circuit-proof

1 A per output max.2 A per module

short-circuit-proof

1 A per output max.2 A per module

short-circuit-proof

Logic FALSETransistor OFF 0.2 mA leakage

@50 VDC

Transistor OFF 0.1 mA leakage

@50 VDC

OFF Leakage Current 0.2 mA 0.1 mA 30 mA max. per output0.1 mA max. per

output0.1 mA max. per

output

Response Time 12 µs 12µsTurn ON 12 ms Turn OFF 25 ms

Turn ON 30-50 µs Turn OFF 30-50 µs

Turn ON 6-20 µs Turn OFF 15-40 µs

Electrical Isolation None None 2500 V between control circuit and output circuit

IntroductionAutotech's PLS and Mini-PLS families have continually set thestandard for speed, precision, reliability, and product featuresin the Programmable Limit Switch marketplace. While retain-ing the key features and high standards of other Autotechproducts, the M1920 combines 80 power outputs, fault detec-tion and indication, hundred user-defined PLS programs, andsimple, easy-to-learn programming in one compact unit with aNEMA 12 front panel. In addition, each of the hundred PLSprograms supports up to 20 ON/OFF setpoint pairs whichmay be used in any combination of 10 each on the low andhigh 8 channels, per PLS card. Included also are a fault out-put that indicates on the display the source of the fault forfast, easy troubleshooting and a motion detector that energizeswhen the resolver is rotating between motion limits.

Principle of OperationThe M1920 is designed for modularity and flexibility. TheUnit has 5 slots for plug-in modules.

The microprocessor in the base unit takes care of the functionscommon to all the modules. The intelligent module havetheir own processors to perform their control functions, whichallow multiprocessor architecture to achieve fast response timefrom the control modules. The base unit has a short circuitproof resolver input circuit which decodes resolver (coupled ondrive train) signals and broadcasts machine positon slots.

The basic PLS card has 16 PLS outputs, based upon angle on& angle off. And the advanced PLS card can have the outputsselected as either angle ON/angle OFF or angle ON/time OFF.

THE M1920 PLS

THE M1920 PLSA NEW LEVEL OF COMPACTNESS AND MODULARITY...YET ANOTHER MILESTONE IN “HIGHEST PROCESSING POWER ANDFEATURES PER CUBIC INCH” FROM AUTOTECH

Modular, 6" x 4" x 10" compact control with 5 slotsfor plug-in modules

PLS, Up to 80 channels (16 per module)

4 digit bright LED for position, RPM, etc.

Hot Keys for quick access

2 Line, 20 Character LCD Display

100 Set-up Programs

100-280 microsec. scan time

Individual channel speed compensation

Multiple Dwells

Angle “ON” - Time “OFF”

Angle “ON” - Angle “OFF”

2 Mod-Z per module

Optical I/O isolation

Short-circuit proof resovler with broken wire detectand self diagnostics

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BASIC PLS CARD:

User-friendly InterfaceThe front mount unit has 2 line x 20 character LCD displayfor menu driven programming and for providing maximuminformation on one screen. A 4 digit of LEDs display is pro-vided for displaying machine position, RPM, and other com-monly used parameters. The keypad provides hot keys toquickly access different modules. The keypad provides a fullnumeric keypad for direct entry of numerical information aswell as 5 Simple Programming Keys common to several otherAutotech products.

Individual Speed Compensation for the first 8PLS OutputsThe M1920 PLS features a rate offset to compensate for speedvariations. This rate offset represents a positive number thatvaries linearly with RPM. The rate offset is added to theresolver position and is used to advance the PLS settings as afunction of the machine speed. In M1920, the rate offset canbe programmed in scale factor units per 100 rpm up to fullscale factor value.

Multiple Program Storage Makes JobChangeover EasyThe M1920 PLS can store up to 100 independent, userdefined PLS programs for different machine setups to reducedown time. Job names can be applied to the M1920 PLS pro-grams, then these names can be used through the menus toselect, search, rename, copy or even delete the program! Thisjob name will reside on the display with position and RPM toensure that's the job you're working on.

Intelligence of 6 Microprocessors in UnisonAs shown in the block diagram above, M1920 PLS has up to 6microprocessors performing 6 logically independant tasks, yetworking in unison.

Because of the power of 6 microprocessors, M1920 PLS canprocess all 80 PLS outputs in a mere 280 microseconds at 600RPM simultaniously.

Built-in Brake Wear Monitor for OSHAComplianceThe M1920 PLS offers a built-in brake wear monitor in thebasic unit. The Brake Wear Monitor accepts an input fromclutch/brake circuit and measures teh stopping time of thepress after the brake is applied. If the stopping time, measuredin milliseconds, exceeds programmed danger limit, fail safeoutput is de-energized, which can be used to disable furtherpress operation. If the stopping time exceeds programmed cau-tion limit, the caution output energizes. The brake time can bedisplayed on the M1920 PLS’s 4 digit LED display.

Fine-Tune in MotionThe PLS module is designed for your total convenience. Thesetpoints can be fine-tuned while the machine is in motion,making machine set up extremely simple. The convenientUP/DOWN arrow keys increment/decrement the setpoints.Supervisory control inputs are provided to prevent unautho-rized, and unintentional change of setpoints.

Fully Isolated Inputs and OutputsAll M1920 inputs and outputs are fully isolated from userpower sources to provide outstanding electrical noise immuni-ty in harsh industrial environments.


PLS ModuleMicroprocessor



MasterMicroprocessor



16Outputs

Brake Input

Resovler Input Fault Outputs:1 Motion and 2 Brake

16Outputs

16Outputs

16Outputs

16Outputs

Built-In Fault DetectorThe Fault Output is normally energized when the M1920 PLSis operating normally and the resolver wiring is intact. If aninternal M1920 fault is detected, or the power fails, or one ormore of the resolver wires is broken or disconnected, the Faultoutput will de-energize. Under fault conditions all PLS out-puts and the motion output will de-energize.

Built-In Tachometer and Motion DetectorThe motion detector is programmed to energize a power relayoutput when the machine's RPM is between the motion lowand high limits. The motion detector output status is indicat-ed on the front panel.

ADVANCED PLS CARD

16 PLS output based upon selectable angle on / angle off orangle on /time off. All channels have their own individualleading edge and trailing edge speed compensation for thosewho like to tailor reaction time at different speeds for the ontime and off time. There are also two Modification to Zero(ModZ) inputs available. ModZ is used for dynamic zeroingthe zero reference point of the resolver position upon inputfrom your device. Upon external input signal, the resolverposition is reset for the particular ModZ channel. Thereafter,the position is incremented as the resolver rotates forward andoutputs are turned "on" and "off" at the programmed limitsettings. This feature is ideal for gluing applications, wherethe glue-gun must be activated at a certain position after thedetection of an upcoming product.

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BASE UNIT–GENERAL:Power Requirements:

120VAC± 10%, 50/60 Hz, 24VA240VAC± 10%, 50/60 Hz, 24VA


Position Transducer: Single turn resolver such as RL100; withCBL-10T22-Mxxx cable, 2,500 ft. max.

Supervisory, Brake Input and Brake Reset Inputs:Optically isolated

TRUE: Contact closure to VS- (common)FALSE Open circuit

Motion Detector:Low & High programmable; Motion detector outputenergizes when the resolver RPM is between low and highlimits.

Brake Wear Monitor:Fail Safe, Normally energized, de-energized when pressstopping time(0-9.99 sec) exceeds programmed danger limit- 2nd caution output energized when stopping time exceedscaution limit.

Brake Input:M1920 starts brake timing when the input becomes TRUE.

Fault Output:TRUE: No faultFALSE: Fault of broken wire or some other internal error.

BASIC – PLS MODULE:Scale Factor: Desired counts per turn minus one Programmable

from 16 to 4095, common to all PLS programs (Resolution:17 to 4096 counts/turn)

Offset: Programmable from 0 to Scale Factor Value,common to all PLS programs

Speed Compensation: Programmable for first 8 channels;each program has its own speed compensation

Scan Time: 100 to 280 MicrosecondsDigital Outputs: P or N Type (Factory ordered)

N-type units:Logic TRUE: Transistor ON, 1.0 V @ 100 mALogic FALSE: Transistor OFF, 0.2 mA leakage @ 50VN-type transistor outputs: Use with Autotech or similar relay output chassisP-type units:Logic TRUE: Transistor ON, 1.7 V @ 100 mALogic FALSE: Transistor OFF, .02 mA leakage @ 250VP-type transistor outputs: Use with Autotech or similar relayoutput chassis

Maximum number of Programs of Setups: 100PLS Setpoints: 20 per program

Max. 10 for channels 1-8Max. 10 for channels 9-16

Number of Output Channels: 16, multiple dwells

ADVANCED – PLS MODULE:(In addition to specificaitons of the Basic PLS Module)2 Mod-Z inputsAngle “ON” – Time “OFF”


M1920 PLS DIMENSIONS

Basic PLS

3 3/16"

2 1/2" 3 9/16"

3 31/32"

Advanced PLS

Measurements taken with connectors in place.

Module Module

AVG Automation has continuously set the standard for speed,precision, reliability, and product features in the resolverdecoder and programmable limit switch (PLS) marketplaces.

In the past, to implement such functions, the user purchased astand-alone Resolver Decoder or PLS, and connected it to themachine. With the advent of the programmable logic con-troller (PLC), users now want to integrate such functionalitywith their PLCs.

Also, users don't want to tie-up their PLC's CPU with thenecessity of performing all the data processing, calculation, sig-nal conditioning, and scaling of a resolver's input in order toimplement motion control actions.

Now, users of Allen-Bradley 1771 I/O, GE Fanuc 9070VMEbus, and Siemens TI-505 PLCs can simply plug suchfunctionality directly into their PLCs—forever freeing thePLC's CPU to perform other control functions.

Please Note: User of Modicon PLCs may refer to our Modconnectproduct catalog for plug-in modules.

BUSMODULES

M8250 SERIES PLS BUSMODULESPLUG-IN PLS MODULES FOR ALLEN BRADLEY 1771 I/O, GE FANUC 9070 AND SEIMENS TI-505 PLCS.

Fully Absolute Position; No Loss of Position UnderAny Situation

Programmable scale up to 1000

Programmable Offset for Quick Set-Up

Bright LED Position Display

PLS Output for External Devices independant of PLC scan

Highly Noise Immune Ratiometric Decoder, EnsuresOptimum Performance Under Electrically NoisyConditions

Cradles for popular PLC’s

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PLS FUNCTION MODULES

The M8251-010 and M8251-F10 PLS Modules combine 16outputs; fault detection and indication; 8 user-defined PLSsetups; and simple, easy-to-learn programming in one compactmodule that easily plug directly into a slot of the PLC.

If the user programs the setpoints for each channel using thefront panel keys, each of the eight PLS setups supports up to160 ON/OFF setpoint pairs that may be used in any combi-nation of 80 each of the LOW and HIGH eight channels.When the programming is accomplished via the PLC back-plane, there are only 112 ON/OFF setpoint pairs available.These may be used in any combination of 56 each on theLOW and HIGH eight channels. Also included are a faultoutput and a motion detector that energize when the resolveris rotating between motion limits.

Long, complex key sequences are a thing of the past. With thefive self-explanatory programming keys, programming the PLSis extremely simple. Most programmed values can be adjustedwith the machine running, making fine-tuning of job parame-ters easy. To avoid unauthorized setpoint and setup changes,setting the Program Enable (PE) FALSE prevents tampering.

The PLS can store up to 8 independent, user-defined PLSsetups for different jobs. The unit can accept either a front-panel entered, PLC backplane command, or a serial link inputcommand to select a particular, stored setup.

Features include:

Fully isolated I/O

Electronic Offset Aligns PLS Zero to Machine Zero

Loads PLS Setups from the Backplane or PC

Broken Resolver Wire Detection

Position, RPM, and Output Status Available to Backplane

Output Update Time Independent of PLC Scan Time

16 Individually Programmable PLS Outputs

RS-485A Multidrop Serial Link

Programmable Under-/Over-Speed Limits for MotionControl

Independent Speed Compensation Available for Each PLSOutput

Brake Monitor, Tach, and ModZ


PROG

CHAN

RPM / ON

POS / OFF

INC

DEC Recall

MODE

VS-

VS+

BCD-

BCD+

MZ4

MZ3

MZ2

MZ1

SE

PE

OE

S1

S2

S3

S4

R2

R1

RXD-

RXD+

CTS-

CTS+

COM

1

2

3

4

5

6

7

8

9

10

11P1 P2

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M8251 SERIES SPECIFICATIONS

ASY-M8251-010, ASY-M8251-F10 PLS ModulesPower Requirements:

Rack: 5 VDC @ 650 mACustomer: >24 VDC @ 100 mA


PROGRAMMING:Number of PLS Setups: 8 GroupsPLS Setpoints:

Front Panel: 160 per PLS setup (80 per group of 8 outputs)Backplane: 112 per PLS setup (56 per group of 8 outputs)

Scale Factor: Programmable from 16-999, common to all PLSsetups (resolution 17 to 1000 counts-per-turn)

Offset: Programmable from 0 to scale factor value, common toall PLS setups

Speed Compensation: Programmable in scale factor units-per-100 rpm, up to full scale factor value. Each PLS channel hasits own speed compensation.

Motion Detector: LOW and HIGH Motion Limits, common to allPLS setups. Programmable from 0-1999 RPM.

Update Time: (Maximum Speed with 1° Resolution)Module: Time Speed (RPM)ASY-M8251-010: 1.6 ms 100ASY-M8251-F10: 0.8 ms 200

RESOLVER INTERFACE:Position Transducer: Single-Turn Resolver, AVG Automation

series RL100, RL101, E7R, E8R, or equivalentResolver Cable: CBL-10T22-xxx

Where xxx = length in ft, 010, 020, 050, and 50 ft. increments,e.g., 100, 150, 200 ft., etc. (3.05, 6.1, 15.24 and 15.24 mincrements, e.g., 30.48, 45.72, 60.96 m, etc.) Overall foilshielded, twisted pair

Cable Length between Resolver and M8251: 2500 ft. (762 m),max.

Maximum Resolver Shaft Speed: 2000 RPM

CONTROL INPUTS:Electrical Specifications: (All Inputs)

Optical Isolation: 2500 VInput Impedance: 7500 Ω

Logic Levels:TRUE: 20-30 VDC; 3 mA @ 24 VDCFALSE: 0-2 VDC, or open circuit

Program Enable (PE): When TRUE, enables setpointprogramming

Supervisor Enable (SE): When TRUE enables setpoint andsetup (scale factor, offset, program number, etc.)

Output Enable (OE): When TRUE, PLS channel outputs enabled(both Fault and Motion always enabled)

ModZ and Brake Inputs:MZ1/BI = ModZ input 1 or Brake Input;MZ2/BC = ModZ input 1 or Brake Clear;MZ3 = ModZ Input 3MZ4 = ModZ Input 4

OUTPUTS:An output module is required for connection to field devices.Consult AVG Automation's M8250 Sourcing or M8250 SinkingOutput Module Manual (part MAN-M8250-POUT and MAN-8250-NOUT, respective).

Fault Output: Normally energized; de-energizes if brokenresolver wire or M8251 internal fault is detected.

Motion Output: Output is energized whenever resolver RPM isbetween upper and lower programmed motion limits.

Number of PLS Outputs: 16


With the increasing use of industrial PCs (IPCs) for machinecontrol, has come a need for PLS, resolver decoder, shut-height, die protection, and tonnage functions. Now, AVGAutomation brings these functions to the industrial IBM PC(or equivalent) platform. Covering 2 ISA slots in width, userscan now take advantage of these proven technologies on theirIPCs.

AVG Automation's C-Bus is a series of function and outputmodules. This offers the user flexibility by allowing them tocustomize their plug-in cards by mixing and matching thefunction module and output module to meet their applica-tion's unique requirements.

PLS:A programmable limit switch (PLS) is an electronic switchthat duplicates the functions of either a rotary cam switch orlimit switches actuated by linear machine movement. A com-plete PLS consists of a solid-state programmable PLS moduleand position transducer.

PLS features include: PLS outputs are typically updated in 1.5 ms

The output update time is independent of the controller'sscan time

16 individually programmable PLS outputs; 8 discrete and8 through backplane

Full optical isolation

Up to 600 mA per output, 2 A total per module

Leading/Trailing edge speed compensation

ModZ (modification zero)

Brake Monitor

Stores 8 user PLS setups

Angle ON/Time OFF outputs

C-BUS ISA CRADLE

PC(ISA-BUS) PLS BUSMODULEBRING MACHINE CONTROL FUNCTIONS TO YOUR IBM PC, OR EQUIVALENT

8-bit ISA bus interface

Cradle covers 2 ISA slots

Cradle supports 2 C-bus slot connections (functionmodule and I/O card)

All function and I/O module field connections arevia 37-pin female sub D connector

C-BUS ISA CRADLE SPECIFICATIONS

ISA bus Interface: 8 bit, 4k byte window at a switch selectableaddress between A0000 to FF000

ISA slots: 2Cradle: 2 C-Bus slot connections (function module and I/O card)

Connections: All function and I/O module field connections arethrough a 37-pin female sub D connector

Dimensions: <13.345" long and <4.2" high

programmable limit switches (pls) - steven …stevenengineering.com/tech_support/pdfs/65prog.pdf ·...

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